1454 results about "Thermoplastic composites" patented technology

A composite structural member of the invention comprises a linear member having a first end and a second end attached to each end of the linear member as an end piece or end cap structure. Covering the composite member is a thermoplastic envelope preferably adherently bonded to the composite member. The end caps or end pieces are preferably thermoplastic materials typically thermoplastic composites comprising a thermoplastic resin and a fiber. Such a member is environmentally stable, resists moisture absorption, forms strong mitered joints and can be used in the assembly of fenestration products for commercial and residential real estate.

A process and associated apparatus used to prepare a thermoplastic composite from a plurality of plies of thermoplastic resin prepregs. The prepregs are formed into a composite structure under two chambers; a rigid outer chamber (of any convenient size or shape) and a second flexible inner chamber containing a prepreg lay-up. The absolute pressures are reduced concurrently in a stepwise method in both chambers. This concurrent, stepped pressure reduction is accomplished at a rate which prevents the vacuum bag from moving far from the prepregs, and prevents wrinkles from forming in the prepregs. Pinching off the diffusion paths required for the removal of unwanted gases is eliminated. The lay-up is then heated and the absolute pressure in the outer rigid chamber is increased. This pressure constrains the flexible inner chamber during out-gassing of the thermoplastic resin, preventing wrinkles from forming in the prepregs. The absolute pressure in the outer rigid chamber is increased to atmospheric pressure or greater causing the prepregs to consolidate. A low absolute pressure is maintained in the flexible inner chamber. The temperature is then increased to the cure temperature of the resin and held for a time sufficient for the resin to cure. The resulting consolidated thermoplastic resin is substantially void free and detectable wrinkles are absent.

An improved composite structural member comprising a complex profile structural member, made of a composite comprising a polypropylene polymer and a wood fiber. The material is useful in conventional construction applications. The complex profile, in the form of an extruded thermoplastic composite member can be used in residential and commercial structures as described. Preferably, the structural member is used in the manufacture of the fenestration components such as windows and doors. Such linear members are designed with specifically configured cross-sectional shapes to form structural elements in the fenestration units. Structural elements must possess sufficient strength, thermal stability and weatherability to permit the manufacture of a structurally sound window unit that can be easily installed into a rough opening but can maintain its attractive appearance and structural integrity over the life of the window unit often twenty years or more. The structural member comprises a hollow complex cross-section with at least one structural web or one fastener web formed within the component. The exterior of the extruded component has a visible capstock layer and is shaped and adapted for installation in rough openings. The exterior also contains shape and components capable of supporting the elements of the fenestration unit such as a window, sash or movable door unit. The improved polypropylene structural members have unique advantages and can be assembled in thermoplastic weld processes.

The invention relates to reinforced composite vehicle load floors of the sandwich-type having a cellular core. In a method for making a load floor of the invention, a stack is formed that is made up of: a load-bearing upper skin made of a reinforced thermoplastics material; an upper skeletal frame structure of reinforcing slats each of which is made of a reinforced thermoplastic composite or pultrusion; a cellular core made of a thermoplastic material; a lower skeletal frame structure of reinforcing slats each of which is also made of a reinforced thermoplastic composite or pultrusion; and a bottom skin made of a reinforced thermoplastic material. Each of the frame structures of reinforcing slats has a surface area that is smaller than the surface area of each of the skins. The frame structures of reinforcing slats are positioned symmetrically about a plane formed by the cellular core against the skins.

A fiber-reinforced thermoplastic composite material having an advantageous combination of smoke generation, heat release, and mechanical property characteristics. The composite generally comprises a fiber-reinforced thermoplastic core containing discontinuous reinforcing fibers bonded together with one or more thermoplastic resins. The core material may further comprise at least one first skin material applied to a first surface of the core and/or one or more second skin material applied to a second surface of the core material. The thermoplastic core material has a maximum smoke density D_s (4 minutes) of less than 200 as measured in accordance with ASTM E662, a maximum heat release (5 minutes) of less than 65 kW/m² as measured in accordance with FAA Heat release test FAR 25.853 (a) Appendix F, Part IV (OSU 65/65), and an average total heat release (2 minutes) of less than 65 kW/m² as measured in accordance with FAA Heat release test FAR 25.853 (a) Appendix F, Part IV (OSU 65/65). The invention is useful in the manufacture of articles for aircraft, automotive, railcar, locomotive, bus, marine, aerospace and construction in which the certain advantages may be provided over other materials utilized for such applications.

The invention relates to an anti-bacterial thermoplastic composite, which comprises the following mixed components: 100 parts of thermoplastic by weight and 0.1-40 parts of composite antibacterial agent by weight, wherein the composite antibacterial agent comprises micronano inorganic/organic particles and guanidinesalt polymers which are coated on the surfaces of the micro/nano particles and/or embedded among pores and layers of the micronano particles; the weight ratio of the guanidinesalt polymers to the micro/nano particles is 1:1-1:50; and the micro/nano particles have at least a one-dimensional average size of 1nm-1000mum. The anti-bacterial thermoplastic composite is obtained by melting and mixing the components such as the thermoplastic, the composite antibacterial agent, and the like, therefore the antibacterial rate of the anti-bacterial thermoplastic composite is higher and the preparation method is simple.

A process for the manufacture of a composite article is described wherein the process comprises the steps of (i) providing on a tool (22) a fibrous material (14) having associated therewith in at least one region thereof an in-situ polymerisable non-fibrous form of a thermoplastic material; (ii) applying heat and a vacuum to said material; and additionally (iii) drawing into the fibrous material, from a source external to the tool, additional thermoplastic pre-polymer material. The process described is particularly useful for the manufacture of a large composite structure such as thermoplastic composite wind turbine blade, for example.

A lightweight fiber reinforced thermoplastic composite having an improved combination of surface roughness, flexural and shear characteristics. The composite generally comprises a fiber reinforced thermoplastic core containing reinforcing fibers bonded together with a first thermoplastic resin in which the core has a first surface and a second surface and at least one first skin applied to the first surface. The first skin comprises a plurality of fibers bonded together with a second thermoplastic resin, with the fibers in each first skin aligned in a unidirectional orientation within the first skin. The composite satisfies at least one of the conditions: an average surface roughness of the outer surface of the first skin is equal to or less than about 4.0 μm/10 mm; the flexural modulus and strength are greater than about 10,000 MPa and greater than about 180 MPa, respectively; and the shear modulus and strength are greater than about 3,000 MPa and greater than about 100 MPa, respectively. In another embodiment, a fiber reinforced thermoplastic composite comprises a fiber reinforced thermoplastic core containing reinforcing fibers bonded together with a first thermoplastic resin, the core having a density of about 0.1 gm/cc to about 2.25 gm/cc and a porosity greater than about 0% by volume. The core has a first surface and a second surface and at least one first skin applied to the first surface, each of the first skins comprising fibers bonded together with a second thermoplastic resin. The first skin comprises a thermoplastic melt impregnated continuous fiber prepreg material, or commingled fiber rovings comprising reinforcing fibers and thermoplastic fibers, with the fibers in the first skin aligned in a unidirectional orientation within the first skin.

The invention relates to a preparation method of a continuous fiber reinforced thermoplastic composite material prepreg and equipment thereof. The method comprises the following steps: (a) leading out and unfolding continuous fiber from a creel (10) to pass a tension adjusting device (20) and a static elimination device (30) in sequence, sending the fiber to a preheating oven (40) to preheat, and then passing a tension adjusting device (50); (b) leading a preheated continuous fiber band into a dual-extrusion die head set which can be opened and closed in a staggered manner to presoak; and (c) leading the presoaked continuous fiber band into a soaked rolling roll set (70) to soak, then cooling by a cooling roll-in device (80), and finally leading into a traction rolling device (90) for shaping by winding to obtain the product. Compared with the prior art, the invention significantly improve the dispersion, infiltrating property and operability of the fiber, and obtains the continuous fiber reinforced thermoplastic composite material prepreg which has uniformly dispersed and completely soaked fiber.

The invention discloses a completely degraded plant powder modified thermoplastics composite material and preparation method thereof, which consists of the components with the weight portions as follows: 100 portions of degradable thermoplastics resin, 1-400 portions of plant powder, 0.1-40 portions of dispersing agent, 0.5-60 portions of impact modifier, 0-40 portions of inorganic filler as well as 0.1-10 portions of stabilizing agent. The degraded thermoplastics resin has similar physiochemical performances with universal polyethylene and polypropylene, has excellent processing performances, and can be commixed with plant powder to prepare thermoplastics wood plastic composite materials. The obtained thermoplastics wood plastic composite materials can be completely degraded into carbon dioxide and water in natural environment under the effects of broadly existed microbes like germs, actinomycetes, etc. Compared with wood products, the composite material has the characteristics of good durability and dimensional stability, easy forming, small water absorbability, and corrosion resistance; compared with plastic, the composite material has the characteristics of low cost and high rigidity. The completely degraded plant powder modified thermoplastics composite material can be used for producing the shells of electric apparatuses like TV, sound, copier, printer, etc, and can also be applied on other workpieces used for injection.

The present invention relates to a recyclable thermoplastic composite sheet which is excellent in mechanical properties, such as bending strength, bending elastic modulus, impact strength and linear thermal expansion coefficient, and also in secondary processability, and suitable for molding into various structures, such as panels for use as building materials, and automobile parts, as well as a manufacturing method thereof and an article manufactured therefrom. The sheet comprises: a center layer of a thermoplastic composite material comprising 40% by weight of reinforcing fibers with an average length of 1-30 mm and 60% by weight of a thermoplastic resin containing an organic filler; and a continuous reinforcing fiber-impregnated prepreg layer laminated on at least one surface of the upper surface and lower surface of the center layer, the prepreg layer comprising 5-65% by weight of reinforcing fibers and 35-95% by weight of a thermoplastic resin containing a small amount of inorganic filler.

The invention belongs to polymer modification technical field and processing technology field, and discloses a flame-retardant antistatic high-strength thermoplastic composite material and its preparation method. The material comprises (by weight share) 80-100 thermoplastic resin, 50-120 reinforcing fiber, 8-18 flame retardant, 0-5 flame retardant synergistic agent, 0.5-1.8 antistatic agent, 15-30 compatibilizer, 4-10 composite antioxidants, and 0-80 other additives. The invention also discloses the thermoplastic composite material preparation method. The inventive lame-retardant antistatic high-strength thermoplastic composite material has high tension and bending strength, high impact resistance property at low and high temperature, obvious antistatic property, high flame-retardant and fire proof performance. It can reach UL-94 V-O level standard.

A fabrication method of forming curved thermoplastic composite laminate parts with tailored and varying thickness in a continuous process. Automated equipment or hand lay-up are used to collate parts or components into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. Ply consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of differing thickness from the multiple ply stacks.

A composite wood flooring system for a vehicular trailer floor comprising: a plurality of wood boards, each wood board comprising a top surface and a bottom surface opposite the top surface; and a filled thermoplastic composite layer comprising a thermoplastic polymer and a discontinuous filler, the thermoplastic layer being substantially bonded to the top surface of each wood board.

A polymeric composite comprises a polymeric resin; an electrically conductive filler; and a polycyclic aromatic compound, in an amount effect to increase the electrical conductivity of the polymeric composition relative to the same composition without the polycyclic aromatic compound. The addition of the polycyclic aromatic compound in addition to a conductive filler imparts improved electrical and mechanical properties to the compositions.

A thermoplastic pultrusion die system for pultruding a thermoplastic composite includes a first pultrusion die member with a curved, concave top surface; a second pultrusion die member with a curved, convex bottom surface; a curved die cavity gap formed between the a curved, concave top surface of the first pultrusion die member and the curved, convex bottom surface of the second pultrusion die member; a die cavity gap adjustment mechanism that imparts movement to at least one of the first pultrusion die member and the second pultrusion die member to vary the die cavity gap from closed to a specified location to open at a specified location; a pultrusion gripper mechanism having one or more grippers in series, and a computer numerical control (CNC) computer system controlling the die cavity gap adjustment mechanism.

A fabrication method of forming a thermoplastic composite laminate material with tailored and varying thickness in a continuous process. This process utilizes automated equipment or hand lay-up to collate parts or components into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. The consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of differing thickness from these multiple ply stacks.

A composite material is provided in which certain properties, or combinations of properties, are improved relative to similar comparative composite materials. The composite material generally comprises a fiber reinforced thermoplastic core that includes a thermoplastic resin and discontinuous fibers dispersed within the thermoplastic resin. The fibers are particularly subject to certain conditions, namely a content of about 15 wt. % to about 65 wt. % of the thermoplastic core, a diameter of from about 17 μm to about 22 μm, and a length of from about 17 mm to about 25 mm. By including fibers meeting these characteristics, the present invention composite material exhibits improved maximum flexural stiffness at reduced basis weight compared to a comparative composite material comprising a fiber reinforced thermoplastic core differing from the composite material only in that the fiber reinforced thermoplastic core of the comparative composite material does not contain fibers meeting the content, diameter and length conditions of the fibers in the thermoplastic core of the composite material.

The present invention is a thermoplastic composite liftgate system with reinforcements in key areas to allow the system to meet performance requirements, while lowering the tooling investment, lowering the system mass, and improving the styling flexibility. The present invention includes an inner panel and at least one bracket or reinforcement member connected to the inner panel such that when a force is applied to the bracket, the force is distributed to the inner panel.

Thermoplastic composite laminate parts with tailored and varying thickness and/or curved sections are manufactured in a continuous process. Automated equipment or hand lay-up is used to collate parts or components into a multi-layer stack. Each stack contains all plies, including ply build-up areas, tacked in the proper location to maintain orientation and location. Some or all of the plies may be continuously fed from spools of single or multiply ply material. Ply consolidation tooling contains all necessary part features and is coordinated to the customized multiple ply stacks to form a single integrated thermoplastic composite laminate potentially having areas of differing thickness from the multiple ply stacks.

A twin-sheet thermoforming process for the manufacture of vehicle headliners. In the process a first sheet and second sheet of SuperLite material are mounted onto respective frames. The frames transfer the sheets into an oven, where they are heated to a desired temperature using IR. The first sheet is combined with a cover-stock material using compression molding forming a covered first headliner part. The covered first headliner part is then transferred to a second mold station. The second sheet is heated and then transferred from the oven to the second mold station where it is vacuum-formed on the upper half mold, forming a second headliner part. The upper and lower mold halves are pressed together fusing and sealing the first and second headliner parts into a unified part. The unified part is then unloaded and trimmed as necessary forming a headliner. The SuperLite material used to form the headliner is a sheet of low pressure, thermoformable, thermoplastic composite comprised of polypropylene and long chopped glass fibers.