COMPOSITE PRODUCT WITH SHIELDING AGAINST ELECTROMAGNETIC INTERFERENCE AND METHOD FOR MANUFACTURING THE SAME

Abstract

The present disclosure relates to a composite product that preferably provides electromagnetic interference (EMI) shielding of a housing and a method of making the same, and more particularly relates to an automotive product for an electric vehicle, and more particularly to a battery housing for the electric vehicle.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 380,897, filed October 25, 2023, the entire disclosure of which is incorporated herein by reference. AREA

[0002] The present disclosure relates to a composite product providing electromagnetic interference (EMI) shielding of a housing and a method of manufacturing the same, and more particularly relates to an automotive product for an electric vehicle, and more particularly to a battery housing for the electric vehicle. BACKGROUND

[0003] The increasing number of electric vehicles and the use of relatively large and heavy batteries has led to the need for newer types of battery enclosures. The goal of such enclosures is to meet the necessary EMI shielding requirements while simultaneously addressing the generation of fire, smoke, and toxic fumes, which can occur, particularly as a result of an accident. The battery enclosures must also desirably have a relatively lightweight design that simultaneously meets the necessary structural requirements to enclose and support a battery within the vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The following detailed description may be better understood by reference to the accompanying figures, which are provided for illustrative purposes and should not be construed as limiting aspects of the disclosure. Fig. 1 is a perspective cross-sectional view of a mold and a sheet material in a first position; Fig. 2 is a side cross-sectional view of the mold and sheet material of Fig. 1; Fig. 3 is an enlarged side cross-sectional view of the mold and sheet material of Fig. 2; Fig. 4 is a perspective cross-sectional view of the mold and sheet material of Fig. 1 in a different position; Fig. Figure 5 is a side cross-sectional view of the mold and sheet material of Fig. 4; Fig. Figure 6 is an enlarged side cross-sectional view of the mold and sheet material of Fig. 5; Fig. Figure 7 is a perspective cross-sectional view of the mold and sheet material of Fig. 1 in a different position; Fig. Figure 8 is a side cross-sectional view of the mold and sheet material of Fig. 7; Fig. Figure 9 is an enlarged side cross-sectional view of the mold and sheet material of Fig. 8; Fig. 10 is a perspective cross-sectional view of the mold and sheet material of Fig. 1 in a different position; Fig. 11 is an enlarged perspective cross-sectional view of the mold and sheet material of Fig. 10; Fig. 12 is a side cross-sectional view of the mold and sheet material of Fig. 10; Fig. 13 is an enlarged side cross-sectional view of the mold and sheet material of Fig. 12; Fig. 14 is a perspective cross-sectional view of the mold and sheet material of Fig. 1 in the position of Fig. 10, wherein a polymer composition partially fills a mold cavity of the mold; Fig. Figure 15 is a side cross-sectional view of the mold, sheet material, and polymer composition of Fig. 14; Fig. Figure 16 is an enlarged side cross-sectional view of the mold, sheet material, and polymer composition of Fig. 15; Fig. 17 is a perspective cross-sectional view of the mold and sheet material of Fig. 1 in the position of Fig. 10, wherein the polymer composition completely fills the mold cavity of the mold; Fig. Figure 18 is a side cross-sectional view of the mold, sheet material, and polymer composition of Fig. 17; Fig. Figure 19 is an enlarged side cross-sectional view of the mold, sheet material, and polymer composition of Fig. 18; Fig. 20 is a perspective cross-sectional view of the mold cavity side of the mold of Fig. 1, showing a retention mechanism in an extended position; Fig. 21 is an enlarged perspective cross-sectional view of a portion of the retention mechanism of Fig. 20 in the extended position; Fig. 22 is an enlarged side cross-sectional view of another portion of the retention mechanism of Fig. 20 in the extended position; Fig. 23 is an enlarged perspective cross-sectional view of the retention mechanism portion of Fig. 22; Fig. 24 is a perspective cross-sectional view of the mold cavity side of the mold of Fig. 1; Fig. 25 is an enlarged perspective cross-sectional view of a portion of the retention mechanism of Fig. 21 in the retracted position; Fig. 26 is a side cross-sectional view of another forming tool and sheet material in a first position; Fig. Figure 27 is a side cross-sectional view of the mold and sheet material of Fig. 26 in a different position; Fig. Figure 28 is an enlarged side cross-sectional view of the mold and sheet material of Fig. 27; Fig. 29 is a perspective cross-sectional view of another mold and sheet material in a first position; Fig. 30 is a side cross-sectional view of the mold and sheet material of Fig. 29; Fig. 31 is a side cross-sectional view of the mold and sheet material of Fig. 29 in another position, with a batch of polymer composition prior to compression moulding; Fig. 32 is a side cross-sectional view of the mold, sheet material, and batch of Fig. 31 in another position, wherein the charge of the polymer composition completely fills the mold cavity of the mold; Fig. 33 is an enlarged side cross-sectional view of the mold, sheet material, and polymer composition of Fig. 32; Fig. 34 is a side cross-sectional view of the mold, sheet material, and polymer composition of Fig. 32 in another position; Fig. 35 is a perspective cross-sectional view of the mold, sheet material, and polymer composition of Fig. 34; and Fig. 36 is an enlarged perspective cross-sectional view of the mold, sheet material, and polymer composition of Fig. 35. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0005] It should be understood that the present disclosure is not limited in its application to the structural details and arrangement of components set forth in the following description or illustrated in the drawings. The embodiments herein may be implemented in other forms and may be practiced or carried out in various ways. It is further understood that the phraseology and terminology used herein is for the purpose of description and should not be considered limiting.

[0006] Electric vehicle (EV) batteries generate electromagnetic interference (EMI) that can be harmful to the vehicle's electronic systems / components, and can also be susceptible to electromagnetic interference from other sources that can damage the batteries. The present disclosure provides a composite article (which may also be referred to herein as a part), preferably an enclosure within a vehicle, such as an EV battery enclosure, preferably formed from a polymer composition (e.g., thermoplastic or thermoset composition) with a molded-in sheet material, preferably in the form of at least one sheet, and more preferably at least one metal mesh, that provides an EMI shield / shield (electromagnetic interference shield / shield) sufficient for battery applications.For example, the sheet and / or the composite product comprising the sheet can provide a shielding effect of at least 20 decibels of reduction over a range of 30 MHz to 1.5 GHz, measured according to ASTM D-4935-18. More preferably, the sheet can provide a shielding effect of at least 30 decibels of reduction over a range of 30 MHz to 1.5 GHz, measured according to ASTM D-4935-18. Most preferably, the sheet can provide a shielding effect of at least 40 decibels of reduction over a range of 30 MHz to 1.5 GHz, measured according to ASTM D-4935-18. In addition, the sheet can provide, for example, a shielding effect of at least 20 decibels of reduction over a range of 9 kHz to 15.9 MHz and at least 50 decibels of reduction over a range of 16 MHz to 18 GHz, measured according to IEEE 299-2006.

[0007] The formed composite product comprising the sheet preferably has a thickness in the range of 1.0 mm to 6.0 mm, most preferably 2.5 mm to 5.0 mm, including all individual values ​​and increments contained in this range. Accordingly, the formed composite product may, for example, have a thickness of 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2.0 mm, 2.1 mm, 2.2 mm, 2.3 mm, 2.4 mm, 2.5 mm, 2.6 mm, 2.7 mm, 2.8 mm, 2.9 mm, 3.0 mm, 3.1 mm, 3.2 mm, 3.3 mm, 3.4 mm, 3.5 mm, 3.6 mm, 3.7 mm, 3.8 mm, 3.9 mm, 4.0 mm, 4.1 mm, 4.2 mm, 4.3 mm, 4.4 mm, 4.5 mm, 4.6 mm, 4.7 mm, 4.8 mm, 4.9 mm, 5.0 mm, 5.1 mm, 5.2 mm, 5.3 mm, 5.4 mm, 5.5 mm, 5.6 mm, 5.7 mm, 5.8 mm, 5.9 mm or 6.0 mm. As will be discussed in more detail herein, in the formed composite product, all or a majority of the sheet is now selectively located on one side of that product.

[0008] The flat material, and in particular the at least one sheet or the at least one metal mesh, preferably has a thickness of 0.01 mm to 0.50 mm, including all individual values ​​and increments within this range, when present in the composite product. Accordingly, the at least one sheet, which may be in the form of a metal mesh, may, for example, have a thickness of 0.01 mm, 0.02 mm, 0.03 mm, 0.04 mm, 0.05 mm, 0.06 mm, 0.07 mm, 0.08 mm, 0.09 mm, 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, or 0.50 mm. The sheet, and in particular the metal mesh, may be made of steel, aluminum, copper, nickel, iron, or metal alloys. In particular, the sheet, and in particular the metal mesh, may consist essentially of metal.The sheet, and in particular the metal mesh, may be coated with another metal (for example, a metal plating such as silver plating, copper plating, or nickel plating) or a polymer composition or a corrosion-resistant coating. The sheet, and in particular the metal mesh, may also be coated with a flame retardant, such as an intumescent flame retardant. The metal mesh itself may preferably be in the form of a woven or non-woven mesh. The metal mesh may preferably have a mesh size in the range of 40 mesh / inch to 300 mesh / inch, including all values ​​and increments within this range.More specific examples include an aluminum mesh with an adhesive, such as a fiberglass adhesive; an aluminum mesh with a polyester / polyethylene film coating; and a multi-layer sheet comprising a fabric layer (for example, a non-metallic fabric layer) and a metal layer.

[0009] The polymer composition may preferably contain one or more additives, such as graphite, graphene, metal whiskers, carbon black, or a metal oxide, such as iron oxide. It is also contemplated that the polymer composition may contain ferrites, which preferably include iron oxide (Fe2O3), magnesium ferrite (MgFe2O4), or zinc ferrite (Zn x Fe 3-xO4, for example ZnFe2O4) or magnesium zinc ferrite (MgZnFe2O4). The polymer composition may also preferably contain one or more flame retardants, preferably an intumescent flame retardant, and in particular a non-halogenated intumescent flame retardant (IFR), as well as glass fillers, such as glass fibers. Such IFRs preferably contain an acid source, a carbonaceous charring agent, and a foaming agent. The acid source may be one of phosphoric acid, sulfuric acid, and boric acid. The carbonizing source may include pentaerythritol, sorbitol, mannitol, dextrins, starch, phenol-formaldehyde resins, and char-forming polymers. The foaming source is typically nitrogen-containing compounds such as urea, urea-formaldehyde resin, melamine, dicyandiamide, and polyamides. Flame retardants preferably include those listed in US Publication No.2019 / 0264002 entitled Flame Retardant Propylene Composition.

[0010] The polymer composition may preferably also contain one or more foaming agents, including a physical foaming agent or chemical foaming agent, to reduce the density of the final product.

[0011] It is also contemplated to use, instead of the sheet mentioned above, one or more polymer composite mats already containing metal (e.g., a sheet, a metal mesh, metal particles dispersed in a polymer composition) and / or other additives to similarly provide EMI shielding. The one or more polymer composite mats containing metal and providing EMI shielding preferably have a thickness of 0.05 mm to 0.50 mm, inclusive of all individual values ​​and increments included within this range, if present in the composite product. More preferably, the polymer composite mat containing metal and providing EMI shielding has a thickness of 0.50 mm to 1.5 mm, inclusive of all individual values ​​and increments included within this range.The one or more metal-containing polymer composite mats can be formed, for example, by extrusion of metal particles (discontinuous phase) arranged in a polymer matrix (continuous phase).

[0012] The use of at least one metal-containing polymer composite mat and / or the composite product itself comprising at least one metal-containing polymer composite mat is also contemplated to provide a shielding effect of at least 20 decibels of reduction over a range of 30 MHz to 1.5 GHz, as measured according to ASTM D-4935-18. More preferably, the metal-containing polymer composite mats can provide a shielding effect of at least 30 decibels of reduction over a range of 30 MHz to 1.5 GHz, as measured according to ASTM D-4935-18. Most preferably, the sheet can provide a shielding effect of at least 40 decibels of reduction over a range of 30 MHz to 1.5 GHz, as measured according to ASTM D-4935-18.In addition, the sheet can, for example, provide a shielding effect of at least 20 decibels of reduction over a range of 9 kHz to 15.9 MHz and at least 50 decibels of reduction over a range of 16 MHz to 18 GHz, measured according to IEEE 299-2006.

[0013] Additives that can be used in such polymer composite mats to similarly enhance EMI shielding include, but are not limited to, graphene, graphite, metal whiskers, carbon black, or a metal oxide such as iron oxide. A ferrite can also be incorporated. The resulting product comprising the polymer composite mat, the sheet metal, and in particular the metal mesh, or other additives to similarly provide EMI shielding can have a thickness in the range of 2.0 mm to 7.0 mm, including all individual values ​​and increments within this range.

[0014] In this text, it is considered that the formed product comprising the polymer composite mat is a relatively lightweight product compared to the use of sheet metal per se. The formed product comprising the polymer composite mat preferably also contains flammability protection, particularly to delay direct contact of the vehicle occupants with the flames.

[0015] As indicated above, non-halogenated intumescent flame retardants and / or carbon fibers / fillers are preferably added to the polymer composition to allow the formation of a protective char layer. The content of such non-halogenated intumescent flame retardants is preferably in the range of 20.0 wt.% to 50.0 wt.%, inclusive of all individual values ​​and increments within this range. That is, such preferred intumescent flame retardants can contribute to delaying the thermal impact of flame contact. The formed article of the present text can also realize the benefit of thermal insulation and preferably eliminate the need for a separately formed thermal blanket to improve the insulation of, for example, a battery casing.

[0016] Additionally, as a result of the formation / shaping process described in more detail herein, the sheet material may be disposed on the B-side / face of the product, i.e., the side / face that then contacts or faces another component, such as the battery within a battery casing. This means that the sheet material may be selectively disposed further toward the B-side / face of the product than toward the A-side / face. Preferably, the majority of the sheet material, or 60% or more of the sheet material, may be selectively disposed further toward the B-side / face of the product than toward the A-side / face. Accordingly, 60% (most) to 100% (all) of the sheet material may be selectively disposed further toward the B-side / face of the product than toward the A-side / face, including all individual values ​​and increments within this range.As a result, the product preferably has an electrically conductive surface (e.g., an electrically insulated mesh) on the B-side / surface, while the A-side / surface remains electrically non-conductive. It is understood that the A-side / surface of the product can be understood as a first, or outer, side / surface, and the B-side / surface of the product can be understood as a second, or inner, side / surface. This selective arrangement of the sheet material, and in particular the sheet, then improves the safety (e.g., electrical insulation) of the EV battery enclosure.

[0017] It should be understood that the present disclosure alternatively contemplates that the sheet material may also be disposed on the A-side of the product, rather than being limited to the B-side of the product, which also provides EMI shielding. That is, the sheet material may be selectively located farther toward the A-side / face of the product than toward the B-side / face. Preferably, the majority of the sheet material, or 60% or more of the sheet material, may be selectively located farther toward the B-side / face of the product than toward the B-side / face. Accordingly, 60% (most) to 100% (all) of the sheet material may be selectively located farther toward the A-side / face of the product than toward the B-side / face, including all individual values ​​and increments within this range.

[0018] During the manufacture of the product, a thermoplastic injection mold may be used to process the polymer composition, which is now preferably also configured to provide position and tension control of the sheet material within the mold cavity. Therefore, in the broad context of the present invention, injection molding, injection-compression molding, compression molding, or thermoforming may be used.

[0019] The position and tension control of the sheet material can preferably be accomplished during the closing of the mold and during the injection of the polymer composition into the mold cavity. The position and tension control can preferably be provided by a holding mechanism (e.g., a clamping mechanism) that holds, clamps, or otherwise restrains the sheet material, preferably around an entire circumference of the sheet material. It can also be accomplished through the use of robotic grippers. In particular, by holding or clamping the sheet material, preferably outside the mold cavity, such clamping ensures relatively unrestricted movement of the sheet material within the mold cavity during the injection of the polymer composition.The sheet material is stretched and formed by the flow and downward pressure of the polymer composition to the contour of the A-side / surface or the B-side / surface of the mold (depending on what is desired).

[0020] The controlled holding / clamping of the sheet also serves to manage the integrity of the sheet. Specifically, tearing, ripping, buckling, folding, or other damage to the sheet throughout the product during mold closing and during injection of the polymer composition into the mold cavity are to be reduced and / or prevented. Accordingly, the sheet is tensioned in a manner that restrains the sheet, but preferably also allows a certain degree of release or slippage from the selected tension so that the sheet can be drawn into the mold cavity.In this regard, the sheet material is preferably held / clamped to create a relatively flat and flush mounting flange surface at the parting line of the injection mold—particularly without gaps that could otherwise cause EMI leakage and compromise shielding performance—to maintain continuity and grounding of the cover-base interface for the EV enclosure.

[0021] In other preferred embodiments, the planar sheet material, alone as a sheet or as a metal-containing polymer composite mat (which provides EMI shielding), may be pre-formed into a three-dimensional shape, such as by thermoforming, including either negative pressure (vacuum) forming or positive pressure forming, before being placed into the injection mold, injection mold-compression mold, or compression mold tool.

[0022] We now turn to the Fig. 1-3, where a longitudinal cross-sectional view of a mold 100 is shown, particularly an injection mold for injecting a polymer composition when the mold is in a fully closed state, or which may also be used as an injection mold to inject the polymer composition when the mold is in an open (i.e., not fully closed) state at the beginning of the molding process to form an article of manufacture according to the present disclosure. As shown, the mold 100 may be located in a molding press 10 and arranged such that a horizontal parting line is located between the mold halves, i.e., the mold core side 120 and the mold cavity side 140.

[0023] As shown, the mold 100 includes a mold core side 120 (which may also be referred to as a core half or first half) having a core-side molding surface 122, and a mold cavity side 140 (which may also be referred to as a cavity half or second half) having a cavity-side molding surface 142. The core-side molding surface 122 and the cavity-side molding surface 142 are disposed on opposite sides of the mold that face each other and define a mold cavity 180 therebetween.

[0024] As shown, the mold cavity side 140 may further include at least one injection port 150 through which a molten thermoplastic composition may be injected from the injection unit 20 (e.g., a reciprocating screw injection unit) and received within the mold cavity 180. As also shown, the mold cavity side 140 further includes a spring-loaded retaining mechanism (sheet retention mechanism) 160 comprising a clamping ring 162 shown as a closed loop, the operation of which will be explained in more detail below.

[0025] As through Fig. As shown in Figures 1-3, a relatively planar sheet material 200 is disposed between the mold core side 120 and the mold cavity side 140, and in particular between the core-side mold surface 122 and the cavity-side mold surface 142. This sheet material can particularly preferably be a planar sheet, and in particular the metal mesh. As shown, the planar sheet material 200 is not yet in contact with the mold core side 120 or the mold cavity side 140.

[0026] As through Fig. 3 (as well as in alternative views in Fig. 20-25), the retention mechanism 160 comprises a self-contained clamping ring 162 that is attached to the cavity-side mold block 146 using threaded fasteners 164, particularly collar threaded screws, that are screwed into the cavity-side mold block 146. As shown, the retention mechanism 160 further comprises a biasing element 170, preferably a helical compression spring, disposed adjacent the threaded fastener 164 (additional views in FIGS. Fig. 20-25). In operation, the clamping ring 162 is biased / urged into or toward an extended position by the compression spring 170, as shown. In some views, the threaded fasteners 164 and a biasing member 170 are not shown to reduce complexity and increase clarity.

[0027] As through Fig. As shown in Figures 1-3, a relatively planar sheet material 200, which may particularly preferably be a sheet metal, and in particular the metal mesh, is disposed between the mold core side 120 and the mold cavity side 140, and in particular between the core-side molding surface 122 and the cavity-side molding surface 142. As shown, the sheet material 200 has a first side 210 and a second side 220 (opposite the first side 210) and is completely planar.

[0028] We now turn to the Fig. 4-6. The mold 100 has been partially closed such that the first side 210 of the sheet 200, which still has a relatively planar shape, is now in contact with the clamping ring 162, and the second side 220 of the sheet 200 is now in contact with the core-side mold surface 122. As shown, the clamping ring 162 is still in the extended position.

[0029] We now turn to the Fig. 7-9. The mold 100 has been further closed such that the sheet 200 has been drawn and deformed into a three-dimensional shape / form, particularly as a result of forming over the core-side forming surface 122. As shown, the first side 210 of the sheet 200 is still in contact with the clamping ring 162, and the second side 220 of the sheet 200 is still in contact with the core-side forming surface 122. In addition, the second side 220 of the sheet 200 is now also in contact with the core-side run-out surface 124. Thus, the sheet 200 is now initially clamped between the clamping ring 162 and the core-side run-out surface 124, particularly due to a clamping force provided by the partial retraction of the clamping ring 162 and the concomitant compression of the spring 170.

[0030] We now turn to the Fig. 10-12, where the mold 100 is now fully closed. As shown, the sheet material 200 is further clamped between the clamping ring 162 and the core-side run-out surface 124, particularly with a greater clamping force due to the complete retraction of the clamping ring 162 and the concomitant further compression of the spring 170.

[0031] As shown, the second side 220 of the sheet 200 is still in contact with the core-side mold surface 122. However, in addition, the first side 210 of the sheet 200 may now be in contact with the cavity-side mold surface 142 at some locations.

[0032] We now turn Fig. 13, which shows a further enlarged view of the mold 100. In an alternative embodiment, the sheet material 200 may particularly preferably have a plurality of through-openings 230, which may be referred to as stress / strain relief slots, to allow the sheet material 200 to be more efficiently drawn into the mold cavity 180 during three-dimensional forming and injection molding. Furthermore, the cavity-side run-out surface 144 between the mold cavity 180 and the clamping ring 162 may preferably be configured to make no contact (for example, by 0.050 mm or less) with the first side 210 of the sheet material 200 to allow the sheet material 200 to be more effectively drawn into the mold cavity 180 during three-dimensional forming and injection molding.

[0033] We now turn Fig. 14-19, Fig. 14-16 and Fig. 17-19, which illustrate advancing a molten polymer composition 250 flowing through the mold cavity 180 while the mold 100 is fully closed. As shown, the sheet material 200 is further deformed as a result of the flow of the polymer composition 250 and the associated molding pressures (such as clamping force and holding pressure), particularly away from contact with the cavity-side mold surface 142. Fig. 17-19 show the fully formed product 300. As can be seen, the sheet material 200 is now preferably disposed on one side of the polymer composition 250 and the product 300. In particular, the product 300 has an A-side / face 302 and a B-side / face 304, with the sheet material 200 disposed on the B-side / face 304.

[0034] Continuing with the above, the sheet material 200 is now selectively directed toward a side of the manufactured article 300, namely, the side of the article 300 remote from the injection location of the polymer composition 250, such as remote from or opposite the injection port 150. More specifically, 60% or more of the sheet material 200 is now selectively directed toward a side of the manufactured article 300, namely, the side of the article 300 generally remote from or opposite the injection port 150 where the polymer composition 250 is introduced into the mold cavity 180. Such flow of the polymer composition 250 under pressure causes the sheet material 200 to move to another side of the mold 100.

[0035] We now turn Fig. 20-25, where the mold cavity side 140 is shown with additional views of the spring-loaded retention mechanism 160. In particular, Fig. 20-23 the spring-loaded retaining mechanism 160 in the extended position, without the flat material 200 in Fig. 20 and Fig. 21 and with the flat material in Fig. 22 and Fig. 23. As shown, the shank 166 of the shoulder screw 164 extends through a counterbore 168 in the clamping ring 162, while the spring 170 is disposed in a cylindrical recess 148 in the cavity-side mold block 146 and a cylindrical recess 172 in the clamping ring 162. Fig. 24 and Fig. 25 show the spring-loaded retention mechanism 160 in the retracted position. It should be understood that the shoulder screw 164 and spring 170 are shown in only two locations for clarity, and that additional shoulder screws 164 and springs 170 are arranged along the circumference of the clamping ring 162 to provide evenly distributed loading and alignment.

[0036] With reference to Fig. 26-28, in other variations, the mold core side 120 may include the injection port 150 through which the molten thermoplastic composition 250 may be injected from the injection unit 20 and received within the mold cavity 180. As also shown, the mold core side 120 may further include the retention mechanism 160, which includes a clamping ring 162, the operation of which was further explained above. Similar to the mold 100 above, however, the mold 100 is arranged such that the mold cavity side 140 overlies the mold core side 120.

[0037] If that in Fig. 26-28 is arranged in the molding press 10 such that the parting line between the mold core side 120 and the mold cavity side 140 is horizontal, the sheet material 200 can be supported by the retention mechanism 160 (against gravity) before the mold is closed, thanks to the placement of the retention mechanism 160 on the mold core side 120. Furthermore, the polymer composition 250 can be introduced through the injection port 150 before the sheet material 200 is deformed by closing the mold 150, or otherwise deformed by closing the mold 100, but before the mold 100 is completely (fully) closed.In the manner set forth above, the molten polymer composition 250 may spread in the form of a disk on the core-side mold surface 122 before the mold 150 is fully closed, which may allow filling of the mold cavity 180 at lower pressures.

[0038] While the injection port 150 and the retention mechanism 160 are disclosed as being located on either the mold core side 120 or the mold cavity side 140, it should be understood that the injection port 150 and the retention mechanism 160 may alternatively be located on opposite sides of the mold 100. For example, the injection port 150 may be located on the mold core side 120, and the retention mechanism 160 may be located on the mold cavity side 140, or the injection port 150 may be located on the mold cavity side 140, and the retention mechanism may be located on the mold core side 120.

[0039] Thus, the product 300 in the case of the mold 100 of the Fig. 26-28 similarly have an A-side / surface 302 and a B-side / surface 304, but the sheet material 200 is arranged on the A-side / surface 302.

[0040] With reference to Fig. 29-36, in other variations, the mold 100 need not include the injection port 150. As shown, the mold 100 may be a compression mold instead of an injection mold. In other variations, however, the mold 100 may include the injection port 150 and may then be referred to as an injection mold compression mold.

[0041] As in Fig. 29-36, the mold 100 is still provided with a horizontal parting line, but the mold 100 is now arranged so that the mold core side 120 lies above the mold cavity side 140. The mold 100 now has a stepped parting line, which may also be referred to as a stepped run-out region 110.

[0042] As shown, the run-out region 110 of the mold cavity side 140 may be divided into run-out surface sections 144a, 144b, and 144c. The run-out surface section 144a extends horizontally from the peripheral edge of the mold cavity 180 and the molded article 300 outward to the vertical run-out surface section 144b. The vertical run-out surface section 144b extends vertically between the horizontal run-out surface sections 144a and 144c. The horizontal run-out surface section 114 extends from the vertical run-out surface section 144b to the outer edge of the mold 100. The vertical transition between the horizontal run-out surface sections 144a and 144c may be referred to as a stepped transition.

[0043] As shown, the outermost perimeter of the run-out region 110 of the mold cavity side 140 includes an annular shoulder 112 defined by a vertical run-out surface portion 144b and a horizontal run-out surface portion 144c. Furthermore, as shown, the clamp ring 162 of the mold core side 120 has a clamp ring surface 174 (also part of the run-out surface 124) that clamps the sheet material 200 between the clamp ring 162 of the mold core side 120 and the horizontal run-out surface portion 144a of the mold cavity side 140.

[0044] As through the Fig. 29 and Fig. As shown in Figure 30, the sheet material 200 may first be disposed in a planar configuration between the mold core side 120 and the mold cavity side 140. The sheet material 200 may be supported by the annular shoulder 112 of the mold cavity side 140 while the retention mechanism 160 is in the retracted position.

[0045] After that, in Fig. 31, the retention mechanism 160 can be extended to clamp / tension the sheet material 200, and a charge of the polymer composition 250 can then be introduced into the open mold 100, in particular by an extrusion unit 30 (for example, an extruder with a stationary screw) that is movable into and out of the space between the mold core side 120 and the mold cavity side 140. The mold 100 is then closed, as in Fig. 32 and Fig. 33 to press-mold the polymer composition 250, and the product 300 is then removed from the mold as shown in the Fig. 34-36 shown.

[0046] As has now become apparent, the present disclosure relates to a method of manufacturing a composite product, comprising: providing a sheet of material, providing a mold having a first side having a location for injecting a polymer composition and a second side remote from the first side, positioning the sheet of material in the mold, and introducing the polymer composition into the mold and forming the composite product, the composite product having a respective first side proximate the location for injecting the polymer composition and a second side remote from the location for injecting the polymer composition.A major portion of the sheet material is located further toward the second side of the product, which is located away from the point of injection of the polymer composition, than the first side of the product.

[0047] Additionally, as will further become apparent, the present disclosure relates to a method of manufacturing a composite article, comprising: providing a polymer composite mat having an additive for reinforcing EMI shielding; providing a mold having a first side having a location for injecting a polymer composition and a second side remote from the first side; positioning the polymer composite mat in the mold; and introducing the polymer composition into the mold and manufacturing the composite article, wherein the composite article has a corresponding first side proximate the location for injecting the polymer composition and a second side remote from the location for injecting the polymer composition.A major portion of the polymer composite mat is located further toward the second side of the composite product, which is remote from the location for injecting the polymer composition, than the first side of the product.

[0048] It is further understood that the present disclosure, in product form, relates to a composite article comprising a first side and a second side, wherein the first side of the composite article is the side of the article where a polymer composition has been injected, and the second side of the article is the side of the article remote from the location of injection of the polymer composition. The composite article comprises a sheet, wherein a majority of the sheet is located farther toward a second side of the composite article than a first side of the composite article.

[0049] Furthermore, it is also contemplated herein to provide a method for producing a composite product, comprising providing a sheet of material, and providing a mold having a first side open for introducing a polymer composition and a second side remote from the first side. Such a mold may preferably be a compression mold. With the mold open, the sheet of material may then be selectively positioned within the mold and placed under tension. This may then be followed by introducing the polymer composition into the mold. The polymer composition may comprise thermoplastic or thermosetting compositions. The polymer composition may also preferably be a charge of a polymer composition that may be provided from an extruder.After closing the mold, the composite product can then be formed, wherein the composite product has a corresponding first side proximate the first side of the mold, which opens to introduce a polymer composition, and a second side remote from or opposite the first side. A major portion of the sheet material can now be located further toward the second side of the product than the first side of the product.

[0050] Although specific embodiments of the present invention have been described, it should be understood that various changes, adaptations, and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims. The scope of the invention, therefore, should not be determined from the description set forth above, but rather should be determined from the appended claims together with the full scope of equivalents. Furthermore, it should be understood that the appended claims do not necessarily represent the broadest scope of the invention that the applicant is entitled to claim, or the only forms in which the invention may be claimed, nor do they necessarily imply that all recited features are necessary. List of reference symbols 10 molding press 20 injection unit 30 Extrusion unit 100 mold tools 110 Run-off region 112 annular shoulder 120 mold core side 122 core-side molding surface 124 core-side run-out area 126 core-side mold block 140 Mold cavity side 142 cavity-side mold surface 144 cavity-side outlet surface (also 144a, 144b, 144c) 146 cavity-side mold block 148 cylindrical recess 150 injection port 160 (spring-loaded) retention mechanism 162 (self-contained) clamping ring 164 threaded fasteners 166 shaft 168 reduction 170 Preload element (compression spring) 172 cylindrical recess 174 clamping ring surface 180 mold cavity 200 flat material 210 first flat material side 220 second flat material side 230 through holes in the flat material 250 Polymer composition 300 products / parts 302 A-side / area of ​​the product 304 B-side / surface of the product QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 380,897

[0001]

Claims

[1] A method for producing a composite product, comprising: Providing at least one sheet, optionally in the form of a metal mesh grid, providing EMI shielding; Providing a mold having a mold cavity disposed between a first side of the mold and a second side of the mold, and having at least one injection port disposed on the first side of the mold for injecting a polymer composition into the mold cavity; Positioning the sheet in the die cavity between the first side of the die and the second side of the die; Introducing the polymer composition into the mold cavity and molding the article, wherein the article has a first side of the article and a second side of the article formed by the first side of the mold and the second side of the mold, respectively; and wherein a major part of the sheet is located further towards the second side of the product than towards the first side of the product. [2] The method of claim 1, wherein the first side of the mold is a mold cavity side of the mold and the second side of the mold is a mold core side of the mold. [3] The method of claim 1, wherein the first side of the mold is a mold core side of the mold and the second side of the mold is a mold cavity side of the mold. [4] The method according to claim 1, wherein the sheet has a thickness in the range of 0.01 mm to 0.5 mm. [5] The method of claim 1, wherein the sheet comprises one or more metal layers. [6] The method of claim 1, wherein the product has a thickness in the range of 1.0 mm to 6.0 mm. [7] The method of claim 1, wherein the sheet is in the form of a metal mesh having a mesh size in the range of 40 mesh / inch to 300 mesh / inch. [8] A method according to claim 1, wherein the sheet is placed under tension by the forming tool. [9] A method according to claim 1, wherein the sheet is selected from steel, aluminum, copper, nickel, iron or metal alloys. [10] The process according to claim 1, wherein the polymer composition contains one or more of the following additives: graphite, graphene, metal whiskers, glass, carbon black, metal oxide, a foaming agent, a ferrite and / or a flame retardant. [11] The method of claim 10, wherein the flame retardant comprises an intumescent flame retardant. [12] The method of claim 11, wherein the intumescent flame retardant comprises a non-halogenated flame retardant. [13] The process of claim 12, wherein the non-halogenated flame retardant is present in an amount ranging from 20.0 wt% to 50.0 wt%. [14] The method of claim 1, wherein the major portion comprises 60% or more of the sheet located further toward the second side of the product than toward the first side of the product. [15] A method of manufacturing a composite product, comprising: Providing at least one polymer composite mat with EMI shielding; and Providing a mold having a mold cavity disposed between a first side of the mold and a second side of the mold, and having at least one injection port disposed on the first side of the mold for injecting a polymer composition into the mold cavity; Positioning the polymer composite mat in the mold cavity between the first side of the mold and the second side of the mold; Introducing the polymer composition into the mold cavity and molding the article, wherein the article has a first side of the article and a second side of the article formed by the first side of the mold and the second side of the mold, respectively; and wherein a major portion of the polymer composite mat is located further toward the second side of the product than the first side of the product. [16] The method of claim 15, wherein the first side of the mold is a mold cavity side of the mold and the second side of the mold is a mold core side of the mold. [17] The method of claim 15, wherein the first side of the mold is a mold core side of the mold and the second side of the mold is a mold cavity side of the mold. [18] The method of claim 15, wherein the EMI shielding polymer composite mat has a thickness in the range of 0.50 mm to 5.0 mm. [19] The method of claim 15, wherein the polymer composite mat comprises a sheet, optionally in the form of a metal mesh. [20] The method of claim 15, wherein the polymer composite mat contains one or more of the following additives: graphene, graphite, metal whiskers, glass, carbon black and a metal oxide. [21] The method of claim 15, wherein the polymer composition contains graphite, graphene, metal whiskers, glass, carbon black, metal oxide, a foaming agent, a ferrite and / or a flame retardant. [22] The method of claim 15, wherein the major portion comprises 60% or more of the polymer composite mat that is located further toward the second side of the article than the first side of the article. [23] Composite product comprising: a first side of the article and a second side of the article, the first side of the article being a side of the article where a polymer composition has been injected, and the second side of the article being a side of the article opposite the first side of the article and separated from the first side of the article by a thickness of the article; wherein the product comprises at least one sheet, optionally in the form of a metal mesh, providing EMI shielding; and wherein a major part of the at least one sheet is located further towards the second side of the product than the first side of the product. [24] The product of claim 23, wherein the product is at least a portion of a battery casing. [25] A method of manufacturing a composite product, comprising: Providing an open mold, the mold having a mold cavity disposed between a first side of the mold and a second side of the mold; Positioning a sheet, optionally in the form of a metal mesh providing EMI shielding, in the open mold; Introducing a polymer composition into the open mold, wherein the polymer composition is disposed between the first side of the mold and the metal mesh; Closing the mold and molding the polymer composition; Forming the product, wherein the product has a first side of the product and a second side of the product formed by the first side of the mold and the second side of the mold, respectively; and wherein a major part of the sheet is located further towards the second side of the product than the first side of the product.

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