Components Molded With Moldable Carbon Fiber And Methods of Manufacturing Thereof

• US 20180085991A1
• Filed: 09/23/2016
• Published: 03/29/2018
• Est. Priority Date: 09/23/2016
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: Kia, Hamid G., Zhao, Selina X.
• Granted Patent: US 10,427,349 B2
• Time in Patent Office: Days
• CPC Class Codes: B29B 11/12 Compression moulding
• CPC Class Codes: B29B 11/14 characterised by structure or composition
• CPC Class Codes: B29C 2049/4655 water
• CPC Class Codes: B29C 2049/4658 oil
• CPC Class Codes: B29C 2949/0715 the preform having one end closed
• CPC Class Codes: B29C 2949/079 Auxiliary parts or inserts
• CPC Class Codes: B29C 2949/3008 at neck portion
• CPC Class Codes: B29C 2949/3016 at body portion
• CPC Class Codes: B29C 43/02 of articles of definite length, i.e. discrete articles B29C35/0227 takes precedence
• CPC Class Codes: B29C 43/52 Heating or cooling
• CPC Class Codes: B29C 49/0005 characterised by the material
• CPC Class Codes: B29C 49/0685 Compression blow-moulding
• CPC Class Codes: B29C 49/0691 using sheet like material, e.g. sheet blow-moulding from joined sheets
• CPC Class Codes: B29C 49/071 Preforms or parisons characterised by their configuration, e.g. geometry, dimensions or physical properties
• CPC Class Codes: B29C 49/22 using multilayered preforms or parisons
• CPC Class Codes: B29C 49/58 Blowing means
• CPC Class Codes: B29K 2105/08 of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
• CPC Class Codes: B29K 2105/12 of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2507/04 Carbon
• CPC Class Codes: B29L 2031/7158 Bottles
• CPC Class Codes: D01F 9/145 : from pitch or distillation residues
• CPC Class Codes: D01F 9/22 : from polyacrylonitriles
• CPC Class Codes: D10B 2505/02 : Reinforcing materials; Prepregs

Abstract

In various aspects, the present disclosure provides a structural component. The structural component includes a body defining at least one hollow region. The body includes a carbon fiber composite including a plurality of substantially aligned continuous carbon fibers. The plurality of substantially aligned carbon fibers defines a major axis and a second axis perpendicular to the major axis. The plurality of substantially aligned continuous carbon fibers includes a plurality of discrete termination points staggered with respect to the second axis. Methods of making such structural components, including by blow molding and compression molding are also provided.

Claims

1. A structural component comprising:

a body defining at least one hollow region, wherein the body comprises a carbon fiber composite comprising a plurality of substantially aligned continuous carbon fibers defining a major axis and a second axis perpendicular to the major axis, wherein the plurality of substantially aligned continuous carbon fibers comprise a plurality of discrete termination points staggered with respect to the second axis.

2. The structural component of claim 1, wherein the plurality of continuous carbon fibers further comprises a first plurality of carbon fibers having a first distinct length and a second plurality of carbon fibers having a second distinct length.

3. The structural component of claim 1, wherein the plurality of continuous carbon fibers comprises one or more continuous carbon fibers having a length of greater than or equal to about 2 inches, wherein the one or more continuous carbon fibers comprise a plurality of discrete weak regions, wherein the plurality of weak regions has an ultimate tensile strength that is at least 50% less than the strength of a remainder of the continuous carbon fiber and the carbon fiber composite has an ultimate tensile strength of greater than or equal to about 500 MPa.

4. The structural component of claim 1, wherein the structural component is selected from the group consisting of:

a hood, a pillar, a panel, a structural panel, a door panel, a door component, an interior floor, a floor pan, a roof, an exterior surface, an underbody shield, a wheel component, a storage area, a glove box, a console box, a trunk, a trunk floor, a truck bed, a lamp pocket, a shock tower cap, a control arm, a suspension component, a crush can, a bumper, a structural front rail, a structural frame, a cross car beam, an undercarriage component, a drive train component, and combinations thereof.

5. A method of producing a structural component, the method comprising:

creating a molding material by placing a sheet of a first carbon precursor material between two sheets of a second carbon fiber precursor material, wherein the first carbon fiber precursor material and the second carbon fiber precursor material are distinct from one another, wherein at least one of the first carbon fiber precursor material or the second carbon fiber precursor material comprises a moldable carbon fiber precursor material comprising a plurality of substantially aligned continuous carbon fibers defining a major axis and a second axis perpendicular to the major axis, wherein the plurality of substantially aligned continuous carbon fibers comprise a plurality of discrete termination points staggered with respect to the second axis; and

compression molding the molding material to form the structural component.

6. The method of claim 5, wherein the other of the first carbon fiber precursor material and the second carbon fiber material comprises a plurality of continuous carbon fibers, the second carbon fiber precursor material having an ultimate tensile strength of greater than or equal to about 650 MPa.

7. The method of claim 5, wherein the moldable carbon fiber precursor material comprises a plurality of continuous carbon fibers and a polymer material precursor, the plurality of continuous carbon fibers having a plurality of staggered discontinuous cut regions that define a first plurality of carbon fibers having a first length and a second plurality of carbon fibers having a second distinct length.

8. The method of claim 5, wherein the moldable carbon fiber precursor material comprises one or more continuous carbon fibers having a length of greater than or equal to about 2 inches, wherein the one or more continuous carbon fibers comprise a plurality of discrete weak regions, wherein the plurality of weak regions has an ultimate tensile strength that is at least 50% less than the strength of a remainder of the continuous carbon fiber and the carbon fiber composite has an ultimate tensile strength of greater than or equal to about 500 MPa.

9. The method of claim 5, wherein a percentage flow based on surface area expansion of the moldable carbon fiber precursor is greater than or equal to about 10%.

10. A method of producing a structural component having at least one interior cavity, the method comprising:

placing a parison comprising a moldable carbon fiber precursor material disposed around a mandrel in a die, wherein the moldable carbon fiber precursor material comprises a polymer precursor and a plurality of substantially aligned continuous carbon fibers defining a major axis and a second axis perpendicular to the major axis, wherein the plurality of substantially aligned continuous carbon fibers comprise a plurality of discrete termination points staggered with respect to the second axis;

blow molding the parison to create the structural component; and

crosslinking or solidifying the polymer precursor to form the structural component.

11. The method of claim 10, wherein the moldable carbon fiber precursor material stretches by greater than or equal to about 10% with respect to an initial surface area of the moldable carbon fiber precursor material during blow molding.

12. The method of claim 11, wherein the moldable carbon fiber precursor material stretches by greater than or equal to about 200% with respect to an initial surface area of the moldable carbon fiber precursor material during blow molding.

13. The method of claim 10, further comprising wrapping the moldable carbon fiber precursor material around the mandrel so at least a portion of an outer surface of the mandrel is disposed inside the moldable carbon fiber precursor material.

14. The method of claim 10, further comprising winding a filament comprising a moldable carbon fiber coated in the polymer precursor around an outer surface of the mandrel to form the parison.

15. The method of claim 10, further comprising heating the die to a temperature greater than or equal to about 50°

C. and less than or equal to about 200°

C.

16. The method of claim 10, further comprising injecting a fluid into a cavity of the mandrel at about 120°

C. and about 7 MPa, wherein the fluid is selected from a group consisting of;

water, air, and oil.

17. The method of claim 10, wherein the mandrel comprises a polymeric material selected from the group consisting of:

polyethylene ((C₂H₄)_n), polypropylene ((C₃H₆)_n), polyethylene terephthalate (“

PET”

) ((C₁₀H₈O₄)_n), nylon, and shape memory epoxy resin.

18. The method of claim 17, wherein the mandrel comprises a shape memory epoxy resin.

19. The method of claim 18, further comprising heating the mandrel to greater than or equal to about 150°

C. and less than or equal to about 200°

C. and removing the mandrel from the structural component after blow molding.

20. The method of claim 10, wherein the structural component has an ultimate tensile strength of greater than or equal to about 500 MPa.