Injection molded composite blank and guide

• US 10,059,078 B2
• Filed: 03/22/2013
• Issued: 08/28/2018
• Est. Priority Date: 03/23/2012
• Status: Active Grant

• Current Assignee: Cutting Dynamics, Inc.
• Original Assignee: Cutting Dynamics, Inc.
• Inventors: Carson, Jr., William V., Bielert, George, Deangelis, Rocco
• Primary Examiner(s): Vonch, Jeffrey A
• Application Number:
  US14/386,382
• Publication Number:
  US 20150050453A1
• Time in Patent Office: 1,985 Days
• Field of Search: None
• CPC Class Codes: A47C 5/12 of plastics, with or without reinforcement
• CPC Class Codes: A47C 7/40 for the back
• CPC Class Codes: B29C 2045/0008 the fibres being oriented randomly
• CPC Class Codes: B29C 2045/14319 bonding by a fusion bond
• CPC Class Codes: B29C 2045/14327 anchoring by forcing the material to pass through a hole in the article
• CPC Class Codes: B29C 2045/14868 Pretreatment of the insert, e.g. etching, cleaning
• CPC Class Codes: B29C 2045/14877 preheating or precooling the insert for non-deforming purposes
• CPC Class Codes: B29C 45/14 incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles B29C45/1671 takes precedence
• CPC Class Codes: B29C 45/14311 using means for bonding the coating to the articles B29C45/14795 takes precedence
• CPC Class Codes: B29C 45/14786 Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/34 using heated elements which remain in the joint, e.g. "verlorenes Schweisselement"
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 65/50 using adhesive tape , e.g. thermoplastic tape; using threads or the like B29C65/3444 takes precedence
• CPC Class Codes: B29C 65/5057 positioned between the surfaces to be joined B29C65/5035 takes precedence
• CPC Class Codes: B29C 65/565 involving interference fits, e.g. force-fits or press-fits B29C65/66 takes precedence
• CPC Class Codes: B29C 65/58 Snap connection
• CPC Class Codes: B29C 65/72 by combined operations or combined techniques, e.g. welding and stitching
• CPC Class Codes: B29C 66/028 Non-mechanical surface pre-treatments, i.e. by flame treatment, electric discharge treatment, plasma treatment, wave energy or particle radiation B29C65/14 takes precedence; non-mechanical surface treatment of plastics in general B29C59/08 - B29C59/16
• CPC Class Codes: B29C 66/12443 : having the tongue substantially in the middle
• CPC Class Codes: B29C 66/12449 : being asymmetric B29C66/12445 takes precedence
• CPC Class Codes: B29C 66/12461 : being rounded, i.e. U-shaped or C-shaped
• CPC Class Codes: B29C 66/12463 : being tapered
• CPC Class Codes: B29C 66/12469 : being asymmetric
• CPC Class Codes: B29C 66/126 : Tenon and mortise joints tenons and mortises for positioning purposes B29C65/7814
• CPC Class Codes: B29C 66/301 : Three-dimensional joints, i.e. the joined area being substantially non-flat B29C66/5223, B29C66/5224, B29C66/5225 take precedence
• CPC Class Codes: B29C 66/536 : Joining substantially flat single elements to hollow articles to form tubular articles
• CPC Class Codes: B29C 66/5414 : said substantially flat extra element being rigid, e.g. a plate B29C66/5416 takes precedence
• CPC Class Codes: B29C 66/547 : Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles, e.g. endless tubes
• CPC Class Codes: B29C 66/71 : characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/7212 : characterised by the composition of the fibres
• CPC Class Codes: B29C 66/72141 : Fibres of continuous length
• CPC Class Codes: B29C 66/72143 : Fibres of discontinuous lengths
• CPC Class Codes: B29C 66/7392 : characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/73921 : characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 70/06 : Fibrous reinforcements only
• CPC Class Codes: B29C 70/12 : using fibres of short length, e.g. in the form of a mat non-woven fabrics per se D04H1/00
• CPC Class Codes: B29C 70/16 : using fibres of substantial or continuous length non-woven fabrics per se D04H3/00
• CPC Class Codes: B29C 70/20 : oriented in a single direction, e.g. roofing or other parallel fibres B29C70/083, B29C70/226 take precedence
• CPC Class Codes: B29C 70/202 : arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC] B29C70/207 takes precedence
• CPC Class Codes: B29C 70/22 : oriented in at least two directions forming a two dimensional structure woven fabrics per se D03D; knitted fabrics per se D04D; braid per se D04C
• CPC Class Codes: B29C 70/74 : Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding B29C70/845 takes precedence
• CPC Class Codes: B29C 70/76 : Moulding on edges or extremities of the preformed part
• CPC Class Codes: B29K 2023/12 : PP, i.e. polypropylene
• CPC Class Codes: B29K 2055/02 : ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
• CPC Class Codes: B29K 2059/00 : Use of polyacetals , e.g. POM, i.e. polyoxymethylene or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2067/003 : PET, i.e. poylethylene terephthalate
• CPC Class Codes: B29K 2067/006 : PBT, i.e. polybutylene terephthalate
• CPC Class Codes: B29K 2069/00 : Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2071/00 : Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/02 : Polyureas
• CPC Class Codes: B29K 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/10 : Aromatic polyamides [polyaramides] or derivatives thereof
• CPC Class Codes: B29K 2079/00 : Use of polymers having nitrogen, with or without oxygen or carbon only, in the main chain , not provided for in groups B29K2061/00 - B29K2077/00, as moulding material
• CPC Class Codes: B29K 2079/08 : PI, i.e. polyimides or derivatives thereof
• CPC Class Codes: B29K 2079/085 : Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof
• CPC Class Codes: B29K 2081/04 : Polysulfides, e.g. PPS, i.e. polyphenylene sulfide or derivatives thereof
• CPC Class Codes: B29K 2081/06 : PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof
• CPC Class Codes: B29K 2101/12 : Thermoplastic materials
• CPC Class Codes: B29K 2105/0845 : Woven fabrics
• CPC Class Codes: B29K 2105/0881 : unidirectional
• CPC Class Codes: B29K 2105/089 : fabric
• CPC Class Codes: B29K 2277/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as reinforcement
• CPC Class Codes: B29K 2277/10 : Aromatic polyamides [Polyaramides] or derivatives thereof
• CPC Class Codes: B29K 2305/00 : Use of metals, their alloys or their compounds, as reinforcement
• CPC Class Codes: B29K 2307/04 : Carbon
• CPC Class Codes: B29K 2309/08 : Glass
• CPC Class Codes: B29L 2031/003 : having a profiled transverse cross-section
• CPC Class Codes: B29L 2031/008 : having a longitudinal cross-section
• CPC Class Codes: B29L 2031/3055 : Cars
• CPC Class Codes: B29L 2031/3076 : Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B29L 2031/771 : Seats
• CPC Class Codes: B32B 2250/20 : All layers being fibrous or filamentary
• CPC Class Codes: B32B 2250/24 : All layers being polymeric
• CPC Class Codes: B32B 2305/076 : Prepregs
• CPC Class Codes: B32B 2305/08 : Reinforcements
• CPC Class Codes: B32B 2305/10 : Fibres of continuous length
• CPC Class Codes: B32B 2305/18 : Fabrics, textiles
• CPC Class Codes: B32B 2305/188 : Woven fabrics
• CPC Class Codes: B32B 2305/20 : in the form of a non-woven mat
• CPC Class Codes: B32B 2305/22 : Fibres of short length
• CPC Class Codes: B32B 2310/14 : Corona, ionisation, electrical discharge, plasma treatment
• CPC Class Codes: B32B 2367/00 : Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2371/00 : Polyethers, e.g. PEEK, i.e. polyether-etherketone; PEK, i.e. polyetherketone
• CPC Class Codes: B32B 2379/00 : Other polymers having nitrogen, with or without oxygen or carbon only, in the main chain
• CPC Class Codes: B32B 2398/20 : Thermoplastics
• CPC Class Codes: B32B 2605/00 : Vehicles
• CPC Class Codes: B32B 2605/003 : Interior finishings
• CPC Class Codes: B32B 2605/18 : Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 27/281 : comprising polyimides
• CPC Class Codes: B32B 27/285 : comprising polyethers
• CPC Class Codes: B32B 27/286 : comprising polysulphones; polysulfides
• CPC Class Codes: B32B 27/288 : comprising polyketones
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 3/266 : characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 5/28 : impregnated with or embedded in a plastic substance not used
• CPC Class Codes: B60N 2/68 : Seat frames
• CPC Class Codes: Y10T 428/24182 : Inward from edge of web or sheet
• CPC Class Codes: Y10T 428/24298 : Noncircular aperture [e.g., slit, diamond, rectangular, etc.]
• CPC Class Codes: Y10T 428/24322 : Composite web or sheet
• CPC Class Codes: Y10T 428/24612 : Composite web or sheet
• CPC Class Codes: Y10T 428/24785 : including layer embodying mechanically interengaged strands, strand portions or strand-like strips [e.g., weave, knit, etc.]
• CPC Class Codes: Y10T 428/24994 : Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/249942 : Fibers are aligned substantially parallel
• CPC Class Codes: Y10T 428/24995 : Two or more layers
• CPC Class Codes: Y10T 442/20 : Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer

Abstract

This specification discloses an article of manufacture. The article of manufacture has at least one structural blank and at least one guide. The structural blank has a plurality of oriented fiber plies in a thermoplastic matrix. The guide has a plurality of random dispersed fibers in a thermoplastic matrix. The guide is affixed to the structural blank by injection molding and over molding the guide onto the structural blank. The article of manufacture can take a number of forms for use in industries such as aircraft, automobiles, motorcycles, bicycles, trains or watercraft.

Claims

1. An article of manufacture comprising a thermoplastic injection molded guide melt bonded to a thermoplastic structural blank, wherein

the thermoplastic injection molded guide comprises a guide thermoplastic matrix,

the thermoplastic structural blank has a structural blank length, a structural blank width, and a structural blank height wherein the structural blank height is less than or equal to the structural blank width and the structural blank width is less than or equal to the structural blank length, and the thermoplastic structural blank comprises;

at least one ply containing a plurality of oriented continuous fibers in a structural blank thermoplastic matrix wherein the plurality of oriented continuous fibers are selected from the group consisting of unidirectional oriented fibers and woven oriented fibers, and the at least one ply lies in a structural blank horizontal plane defined by the structural blank length and the structural blank width,

a structural blank top side corresponding to one side of the structural blank horizontal plane, and

a structural blank bottom side corresponding to the side opposite of the structural blank top side of the structural blank horizontal plane, and

the thermoplastic injection molded guide is molded to at least a portion of the structural blank top side, around the structural blank height and to at least a portion of the structural blank bottom side, and

a guide hole running through at least a portion of the guide in a plane perpendicular with the at least one ply containing a plurality of oriented continuous fibers,

wherein the guide hole is within a perimeter of the structural blank horizontal plane, the guide material does not touch an internal edge of an optional hole in the thermoplastic structural blank, and the thermoplastic injection molded guide further comprises a plurality of randomly dispersed fibers in the guide thermoplastic matrix.

2. The article of manufacture of claim 1, wherein the randomly dispersed fibers in the guide thermoplastic matrix comprise a type of fiber selected from the group consisting of carbon fiber, glass fiber, polyaramide fiber or combinations thereof.

3. The article of manufacture of claim 1, wherein the oriented continuous fibers in the structural blank thermoplastic matrix comprise a type of fiber selected from the group consisting of carbon fiber, glass fiber, polyaramide fiber or combinations thereof.

4. The article of manufacture of claim 1, wherein the amount of oriented continuous fibers in the structural blank thermoplastic matrix is between 5% and 60% by weight of the structural blank.

5. The article of manufacture of claim 1, wherein the amount of randomly dispersed fibers in the guide thermoplastic matrix is between 5% and 60% by weight of the structural blank.

6. The article of manufacture of claim 1, wherein the structural blank thermoplastic matrix comprises a thermoplastic selected from the group consisting of polyphenylene sulphide, polyetherimide, polyetheretherketone, polyetherketoneketone, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyethersulfone and combinations thereof.

7. The article of manufacture of claim 6, wherein the guide thermoplastic matrix comprises a thermoplastic selected from the group consisting of polyphenylene sulphide, polyetherimide, polyetheretherketone, polyetherketoneketone, polyethylene terephthalate, polyester, polybutylene terephthalate, polyethylene naphthalate, polyethersulfone and combinations thereof.

8. The article of manufacture of claim 7, wherein the structural blank thermoplastic matrix and the guide thermoplastic matrix comprise the same type of thermoplastic.

9. The article of manufacture of claim 7, wherein the structural blank thermoplastic matrix comprises a different thermoplastic than the guide thermoplastic matrix.

10. The article of manufacture of claim 1, wherein the article is void of an adhesive layer between the guide and the structural blank.

11. A process for producing the article of manufacture of claim 1 comprising the structural blank and the guide, said process comprising the steps of:

A) manufacturing the structural blank by laying the at least one ply of oriented fibers in a structural blank thermoplastic matrix on top of one another and heat compression molding said at least one ply to form the structural blank,

B) injection molding the guide comprising a guide thermoplastic matrix and a plurality of randomly dispersed fibers onto the structural blank wherein the guide is affixed to the structural blank by melt bonding.

12. The process of claim 11, further comprising the step of corona treating the structural blank to modify the surface area to be more bondable with the thermoplastic of the guide prior to injection molding the guide to the structural blank.

13. The process of claim 11, further comprising the step of flame treating the structural blank to modify the surface area to be more bondable with the thermoplastic of the guide prior to injection molding the guide to the structural blank.