PLASTIC LAMINATED STRUCTURE AND METHOD FOR PRODUCING THE SAME

• US 20200130320A1
• Filed: 10/28/2019
• Published: 04/30/2020
• Est. Priority Date: 10/26/2018
• Status: Abandoned Application

• Current Assignee: Morita Giken Inc.
• Original Assignee: Morita Giken Inc.
• Inventors: SEI, Keisuke
• Application Number:
  US16/665,099
• Publication Number:
  US 20200130320A1
• Time in Patent Office: Days
• CPC Class Codes: B29C 53/26 parallel with direction of feed
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 65/26 Hot fluid
• CPC Class Codes: B29C 66/112 Single lapped joints
• CPC Class Codes: B29C 66/131 Single flanged joints, i.e. one of the parts to be joined being rigid and flanged in the joint area
• CPC Class Codes: B29C 66/232 said joint lines being multiple and parallel, i.e. the joint being formed by several parallel joint lines
• CPC Class Codes: B29C 66/3022 said melt initiators being integral with at least one of the parts to be joined
• CPC Class Codes: B29C 66/30321 making use of protrusions belonging to at least one of the parts to be joined
• CPC Class Codes: B29C 66/3034 making use of additional elements, e.g. meshes
• CPC Class Codes: B29C 66/5326 said single elements being substantially flat
• CPC Class Codes: B29C 66/53461 joining substantially flat covers and/or substantially flat bottoms to open ends of container bodies
• CPC Class Codes: B29C 66/53462 joining substantially flat covers and substantially flat bottoms to open ends of container bodies
• CPC Class Codes: B29C 66/721 Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/7212 characterised by the composition of the fibres
• CPC Class Codes: B29C 66/73921 characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/81427 comprising a single ridge, e.g. for making a weakening line; comprising a single tooth
• CPC Class Codes: B29C 66/81435 comprising several parallel ridges, e.g. for crimping comprising a single ridge B29C66/81427
• CPC Class Codes: B29C 66/81811 of the welding jaws
• CPC Class Codes: B29C 66/8322 Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29C 66/8432 Machines for making separate joints at the same time mounted in parallel or in series
• CPC Class Codes: B29C 69/00 : Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore B29C48/001 takes precedence
• CPC Class Codes: B29C 70/465 : and impregnating by melting a solid material, e.g. sheets, powders of fibres
• CPC Class Codes: B29D 24/008 : the structure having hollow ridges, ribs or cores
• CPC Class Codes: B29D 99/0014 : provided with ridges or ribs, e.g. joined ribs
• CPC Class Codes: B29K 2307/04 : Carbon
• CPC Class Codes: B29L 2024/003 : comprising corrugated cores
• CPC Class Codes: B32B 2250/05 : 5 or more layers
• CPC Class Codes: B32B 2250/40 : Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2255/10 : on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/28 : Multiple coating on one surface
• CPC Class Codes: B32B 2262/106 : Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2305/076 : Prepregs
• CPC Class Codes: B32B 2307/538 : Roughness
• CPC Class Codes: B32B 27/08 : of synthetic resin
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/308 : comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/365 : comprising polycarbonates
• CPC Class Codes: B32B 27/42 : comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 3/28 : characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 3/30 : characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 37/0076 : characterised in that the layers are not bonded on the totality of their surfaces
• CPC Class Codes: B32B 37/10 : characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
• CPC Class Codes: B32B 7/04 : Interconnection of layers
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties

Abstract

A plastic laminated structure includes a plate member of plate-shaped fiber-reinforced plastic and a core member of trapezoidal-wave-shaped fiber-reinforced plastic. The plate member includes a thermoplastic resin and reinforcing fibers embedded in the thermoplastic resin. The core member is thermally bonded to the plate member, and includes a thermoplastic resin and reinforcing fibers that is embedded in the thermoplastic resin. A part of or the entire area of a main surface of the plate member includes smooth and rough surfaces. The rough surface has larger roughness than the smooth surface. The smooth and rough surfaces are alternately arranged in stripes.

Claims

1. A plastic laminated structure comprising:

a plate member of plate-shaped fiber-reinforced plastic that includes a thermoplastic resin and reinforcing fibers embedded in the thermoplastic resin; and

a core member of trapezoidal-wave-shaped fiber-reinforced plastic that is thermally bonded to the plate member, and includes a thermoplastic resin and reinforcing fibers embedded in the thermoplastic resin,

wherein a part of or the entire area of a main surface of the plate member includes smooth and rough surfaces, and first asperities are formed on the rough surface on the main surface side, and

wherein the smooth and rough surfaces are alternately arranged in stripes.

2. The plastic laminated structure according to claim 1, wherein the smooth surface has second asperities, and the difference between first asperities is greater than the second asperities.

8. The plastic laminated structure according to claim 1,

wherein the trapezoidal wave shape of the core member is formed by alternately arranging slant-face portions and bonding portions so that parallel grooves are arranged at a predetermined pitch alternately on the both sides of the core member, and

wherein the bonding portions have a width within the range not smaller than 20% and not greater than 100% of the thickness of the plastic laminated structure.

9. The plastic laminated structure according to claim 1, wherein the plastic laminated structure has a thickness not smaller than 0.8 mm.

3. A plastic laminated structure comprising:

a plate member of plate-shaped fiber-reinforced plastic that includes a thermoplastic resin and reinforcing fibers embedded in the thermoplastic resin; and

a core member of trapezoidal-wave-shaped fiber-reinforced plastic that is thermally bonded to the plate member, and includes a thermoplastic resin and reinforcing fibers embedded in the thermoplastic resin,

wherein a part of or the entire area of a main surface of the plate member includes smooth and rough surfaces, and the rough surface has larger roughness than the smooth surface, and

wherein the smooth and rough surfaces are alternately arranged in stripes.

4. The plastic laminated structure according to claim 3, wherein the rough surface of the plate member is formed by the reinforcing fibers which are embedded in the thermoplastic resin.

5. The plastic laminated structure according to claim 3, wherein the rough surface of the plate member is formed by the reinforcing fibers that are embedded in the thermoplastic resin and protrudes from a surface of the thermoplastic resin.

6. The plastic laminated structure according to claim 3,

wherein the trapezoidal wave shape of the core member is formed by alternately arranging slant portions and bonded portions so that parallel grooves are arranged at a predetermined pitch alternately on the both sides of the core member, and

wherein a bonded part that is formed by thermally bonding the bonded portion of the core member onto a back surface of the plate member serves as the smooth surface, and a non-bonded part onto which the core member is not thermally bonded serves as the rough surface.

7. The plastic laminated structure according to claim 3,

wherein the trapezoidal wave shape of the core member is formed by alternately arranging slant portions and bonded portions so that parallel grooves are arranged at a predetermined pitch alternately on the both sides of the core member, and

wherein a bonded part that is formed by thermally bonding the bonding portions of the core member onto a back surface of the plate member serves as the rough surface, and a non-bonded part onto which the core member is not thermally bonded serves as the smooth surface.

10. The plastic laminated structure according to claim 3, wherein a surface treatment layer is formed on the main surface of the plate member.

11. The plastic laminated structure according to claim 10, wherein the surface treatment layer is a coating.

12. The plastic laminated structure according to claim 11, wherein the surface treatment layer is a coating of laminated structure that includes a primer and a finishing coating material laminated on the primer.

13. The plastic laminated structure according to claim 3, wherein the plate member is thermally bonded to one side of the core member.

14. The plastic laminated structure according to claim 3, wherein the plate members are thermally bonded to the both sides of the core member.

15. The plastic laminated structure according to claim 3, wherein the fiber-reinforced plastic of the plate member and the core member includes carbon fibers as the reinforcing fibers embedded in the thermoplastic resin.

16. The plastic laminated structure according to claim 3, wherein the thermoplastic resin of the fiber-reinforced plastic is selected from the group consisting of nylon, polycarbonate, acrylic resin, PET, PP, PPS, HTPE, phenoxy resin, and polyvinyl chloride.

17. A method for producing a plastic laminated structure including a plate member of plate-shaped fiber-reinforced plastic that includes a thermoplastic resin and reinforcing fibers embedded in the thermoplastic resin;

and a core member of trapezoidal-wave-shaped fiber-reinforced plastic that is thermally bonded to the plate member, and is formed of a thermoplastic resin and reinforcing fibers embedded in the thermoplastic resin, the core member including slant portions and bonded portions that are arranged alternately whereby forming parallel grooves that are alternately arranged on the both sides,

wherein the method comprising;

placing the core member on the plate member;

inserting press protrusions into their corresponding parallel grooves of the core member; and

bonding the bonded portions of the core member to the plate member by pressing the bonded portions of the core member by the press protrusions whereby bonding the bonded portions of the core member to the plate member.

18. The method for producing a plastic laminated structure according to claim 17, wherein the bonded portions of the core member are bonded to the plate member by thermally melting the thermoplastic resin of the plate member and the core member in the bonding step.

19. The method for producing a plastic laminated structure according to claim 17, wherein the bonded portions of the core member are bonded to the plate member by an adhesive in the bonding step.

20. The method for producing a plastic laminated structure according to claim 19, wherein a both thermosetting and thermoplastic material that is liquid or paste in its uncured state and becomes a thermoplastic material after cured is used as said adhesive.