Method of manufacturing a composite part comprising a core and a skin region

EP4761901A1Pending Publication Date: 2026-06-24MITSUBISHI CHEMICAL ADVANCED MATERIALS GMBH +1
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Patent Information

Authority / Receiving Office
EP · EP
Patent Type
Applications
Current Assignee / Owner
MITSUBISHI CHEMICAL ADVANCED MATERIALS GMBH
Filing Date
2024-07-22
Publication Date
2026-06-24

AI Technical Summary

Technical Problem

Existing methods for manufacturing composite parts with a core and skin region face challenges such as delamination, limited adhesion, health and safety concerns, and high energy consumption, particularly in processes involving polyurethane foaming and slush molding.

Method used

A method involving a core element with anchoring sites, where a layer of thermoplastic polymer granules is applied and melted to form a skin region mechanically engaged with the core, using a thermoplastic fleece with reinforcement fibers and a double band press for continuous processing.

Benefits of technology

This method achieves a strong, reliable bond between the core and skin without delamination, reduces equipment complexity and energy consumption, and allows for the production of parts with structural rigidity and high-quality surface finish in a single processing step.

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    Figure EP2024070785_23012025_PF_FP_ABST
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Abstract

A method of manufacturing a composite part (2) comprising a core (4) and a skin region (6) formed of a skin polymer attached thereto, comprises the following steps: a) providing a core element (8) having a surface with at least one upper contacting region having a plurality of anchoring sites (10); b) applying onto the contacting region a layer (12) of the skin polymer in granular form, whereby skin polymer granules contact and embed the anchoring sites; c) applying a heating step whereby the skin polymer granules are molten to form a molten skin polymer matrix (18); d) applying a pressing and cooling step, whereby the skin polymer matrix solidifies to form a skin region (6) mechanically engaged into the anchoring sites of the core element forming the core.
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