| JP2001049134 | BIODEGRADABLE RESIN AND COMPOSITE SHEET USING THE SAME |
| WO/1999/023370 | COMPOSITE MAT |
| JP04278335 | MANUFACTURE OF LIGHTWEIGHT COMPOSITE MOLDED ARTICLE |
BOEREN, Michael (Sollevelden 72, Putte, B-2580, BE)
| Claims .
1. Method for manufacturing a laminate construction (1), characterised in that it comprises at least the steps of supplying a core plate (2), of supplying two prefabricated films (5,6), one on each opposite side (3,4) of the core (2) whereby each film (5,6) comprises at least a basalt fibre layer (7) which is provided with a layer of thermoplastic material (8,9) on it least one side, and the step of mutually connecting the above-mentioned core plate (2) to the prefabricated films (5,6) at a raised temperature and increased pressure.
2. Method according to claim 1, characterised in that the basalt fibre layer (7) of the first film (5) and/or of the second film (6) is provided with a layer of thermoplastic material (8,9) on either side, which layers adhere to each other through the openings between the basalt fibres, such that a matrix of thermoplastic material is created which comprises the basalt fibres .
3. Method according to claim 1 or 2, characterised in that the first film (5) is provided with perforations (10).
4. Method according to claim 1 or 2, characterised in that the second film (6) is provided with a fleece (15) .
5. Method according to claim 1 or 2, characterised in that the first film (5) is provided with a binder course (H) .
6. Method according to claim 1 or 2, characterised in that the second film (6) is provided with a fleece (15) on one side and with a binder course (12) on the other side.
7. Method according to claim 4, characterised in that between the layer of thermoplastic material (8,9) and the fleece (15) is provided a barrier layer (13) .
8. Method according to claim 7, characterised in that between the layer of thermoplastic material (8,9) and the barrier layer (13) is provided a binder course (12) .
9. Method according to claim 7, characterised in that between the barrier layer (13) and the fleece (15) is provided a binder course (14) .
10. Method for manufacturing a car roof, characterised in that it comprises at least the steps of supplying a core plate (2), supplying two prefabricated films (5,6), one on each opposite side (3,4) of the core (2) whereby each film (5,6) comprises at least a basalt fibre layer (7) which is provided with a layer of thermoplastic material (8,9) on at least one side, and the step of mutually connecting the above-mentioned core plate (2) to the prefabricated films (5,6) at a raised temperature and increased pressure, which thus results in a laminate construction (1) , partly cooling the laminate construction (1), cutting the laminate construction (1) into pieces (32), either or not before the laminate construction (1) is preheated, providing a piece of laminate construction (32) in the mould (28), providing a piece of lining (33) in the mould (28), mutually connecting the piece of laminate construction (32) and the piece of lining (33) and transforming the whole into a car roof (23) .
11. Method according to claim 10, characterised in that the laminate construction (1) is cut into pieces (32) while the mould parts are being closed.
12. Method according to claim 10 or 11, characterised in that, after the above-mentioned pieces (32,33) have been connected and transformed, the car roof (23) is finished further by trimming the edges, possibly by means of the mould parts which are provided with knives on their contours to this end. |
Method for manufacturing a laminate construction.
The present invention concerns a method for manufacturing a laminate construction, in particular a laminate construction for car roofs.
Car roofs are usually made of a laminate construction which is cast in a mould.
A known type of laminate construction for a car roof consists of a fleece onto which is successively provided a first outer layer of thermoplastic binding material, a first basalt fibre layer, a first inner layer of thermoplastic binding material, a core made for example of polyurethane, a second inner layer of thermoplastic binding material, a second basalt fibre layer, a second outer layer of thermoplastic binding material, and on the latter a binder course and a lining.
The inner layers refer to the layers which are provided on the core, whereas the outer layers refer to the layers which are provided on the other side of the basalt fibre layer and which are in other words removed from the core.
According to a known method, such a laminate construction is manufactured by providing a fleece and on top of that a first outer layer of thermoplastic binding material. Next, basalt fibres are scattered on the above-mentioned layer of
thermoplastic binding material.
On the basalt fibre layer is then provided a first inner layer of thermoplastic binding material and on top of that is provided the core.
In a similar manner, also the other side of the core is provided with a second inner layer of thermoplastic binding material, followed by a second basalt fibre layer, and further a second outer layer of thermoplastic binding material, and on top of that a binder course and a lining.
The above-mentioned basalt fibres are obtained by each time cutting a piece from a wound bundle of basalt fibres, having for example a thousand fibres per bundle, at the required length.
In order to manufacture a car roof, the above-described laminate construction is provided in a moulding die in another process.
A permanent challenge when developing laminates for car roofs consists in limiting the weight and in minimizing the use of expensive materials. Naturally, also much attention is paid to the environmental impact of such a car roof. It is clear that also much attention is paid to lowering the energy consumption and to lowering the manpower required during the production.
In that sense, the invention aims to improve the above- described method for manufacturing a laminate construction and to that end compri ses at least the steps of supplying a core plate , supplying two prefabricated films , one on each opposite side of the core, whereby each film comprises at least a basalt fibre layer which is provided at least on one side with a layer of thermoplastic material, and of mutually connecting the aforesaid core plate to the prefabricated films at a raised temperature and raised pressure .
The advantage obtained in comparison with the known method i s that the device i s cons iderably s impler , which o f f ers the po s s ibi l ity t o l ink other operat i ons to the method according to the invention .
Moreover, the prefabricated basalt fibre-reinforced film can be made lighter and having a higher quality, -since a separate process can be specially adjusted, among others thanks to the use of better unbundled fibres .
Indeed, the basalt fibres in the known and described laminate construction and the car roof made of the latter are still strongly bundled, even after cutting the fibres at the desired length and scattering them. Due to the remaining bundling, the fibres are not optimally used .
On the other hand, a prefabricated basalt fibre-reinforced film may be provided with additional layers having extra functionalities . Pre-manufacturing such films makes it possible to obtain a high-quality end product .
The present invention also concerns a method for manufacturing a car roof which, apart from applying the above-described method for manufacturing a laminate construction, comprises at least the steps of partly cooling the thus obtained laminate construction, subsequently heating this laminate construction and putting it in a mould, providing a lining in the mould and mutually connecting and transforming the above- mentioned layers in the mould.
A major advantage is that the laminate construction is only partly cooled and is immediately thereafter heated in one and the same process, which guarantees a considerable energy saving in comparison to the process whereby the laminate construction is entirely cooled first and is heated in a second process.
Moreover, the car roofs can thus be made with considerably less manpower in comparison to the method whereby car roofs are manufactured in two separate processes.
In order to better explain the characteristics of the present invention, the following preferred embodiments of a laminate construction for car roofs according to the invention, and a method for manufacturing such laminates and such car roofs are given as an example only, without being limitative in any way, with reference to the accompanying drawings, in which:
figures 1 to 3 schematically represent the
v a r i a n t e mb o d i m e n t s o f a laminate construction for car roofs , seen as sections ; figure 4 represents a device for manufacturing a laminate construction; figure 5 represents a device for manufacturing a car roof .
Figure 1 represents a laminate construction 1 which, in this simple embodiment, consists of a core plate 2 made of polyurethane having a first side 3 and an opposite second side 4 , whereby both sides are provided with a film, a first film 5 and a second film 6 respectively.
In this simple embodiment, the first film 5 and the second film 6 are identical and they consist in particular of a basalt fibre layer 7 provided with a layer of thermoplastic material 8 on one side .
The basalt fibre layer 7 in this embodiment consists of loose basalt fibres and is largely permeated with the thermoplastic material 8.
The basalt fibres have a length of for example 8 to 10 mm, and they have a section diameter of some 18 micrometer . The basalt fibres are to a large degree unbundled .
Figure 2 represents another preferred embodiment of such a laminate construction 1 .
This laminate construction 1 is also based on a core plate 2 made of polyurethane onto which a first film 5 is provided on
a first side 3, which in this embodiment consists of a basalt fibre layer 7 which is provided with a layer of thermoplastic material on both sides, an inner layer 8 and an outer layer 9. Further, the first film 5 is provided with perforations 10.
The basalt fibre layer 2, which has the shape of a basalt fibre mat in this case, is permeated with the thermoplastic material, in this case polyethylene, and both layers 8 and 9 of thermoplastic material adhere through the openings between the basalt fibres, such that together they form a matrix surrounding the basalt fibres.
The second film 6 in this preferred embodiment in a similar manner consists of a basalt fibre layer 7 provided on both sides with a layer of thermoplastic material, an inner layer 8 and an outer layer 9.
Figure 3 is an embodiment of another preferred laminate construction 1.
This laminate construction 1 mainly corresponds to the laminate construction 1, as discussed above and represented in figure 2, but it is different in that the first film 5 is provided with a first binder course 11 on its outer layer 9, and in that the second film 6 is provided with a second binder course 12 on its outer layer 9, onto which are provided a barrier layer 13, a third binder course 14 and a fleece 15.
The binder courses 11, 12 and 14 consist for example of
modified polyethylene, the barrier layer 13 consists for example of polyamide, and the fleece 15 consists for example of polyester viscose.
The working of the laminate construction 1 and the functions of the different layers in a car roof are as follows.
The laminate construction 1 according to figure 1 is extremely simple and both films 5 and 6 first of all serve as a reinforcement of the core plate 2. This laminate construction 1 may be used for example as a semi-finished product which is completed and/or finished as a car roof in a later process.
In the laminate construction 1 according to figure 2, the perforations 10 are designed to improve the sound-insulating qualities of such a laminate construction 1, which is particularly important for the application in the interiors of vehicles .
The laminate construction 1 according to figure 3 is provided with a first binder course 11 which possibly serves to improve or speed up the adhesion of for example a lining which can be provided on top of it.
The barrier layer 13 prevents an air or gas stream being created through the laminate construction 1. This prevents pollution, for example by cigarette smoke.
The fleece 15 forms a screen or a damping buffer and thus prevents an annoying noise which does occur when there is no
fleece 15 due to the rubbing or vibrating contact between the outer layer 9 of thermoplastic material of the film 5 and the coachwork of the car. The fleece 15 moreover increases the deformability of the laminate construction 1, as a result of which a more complex geometry can be realised.
The binder courses 12 and 14 are provided to make the barrier layer 13 adhere to the adjacent layers 6 and 15.
The method for manufacturing such a laminate construction 1 according to the invention can be realised by means of a device 16, as is schematically represented in figure 4.
The given device 16 shows how such a laminate construction 1, as represented in figure 2, can be manufactured, but in a slightly different manner as the outer layer 9 of the second film 6 is additionally provided with a fleece 15, for example made of polyester viscose.
The core plate 2 is supplied in a central and horizontal manner in this case, and a first bobbin 17 is moreover provided on which is wound a prefabricated fibre- reinforced film 5.
Between the first bobbin 17 and the core plate 2 is also provided a perforation cylinder 18.
On the bottom side of the core plate 2 is provided a second bobbin 19 on which is wound a prefabricated
fibre-reinforced film 6.
Along the latter is provided a third bobbin 20 on which the above-mentioned fleece 15 is wound.
The device 16 is further provided with a lamination device 21, in the direction Z in which the core plate 2 progresses, which mutually connects the above- mentioned core plate to the prefabricated films at a raised temperature and an increased pressure.
The above-mentioned laminate construction 1 can thus be manufactured by supplying a core plate 2 and by providing it with a prefabricated fibre-reinforced film 5 on a first side, which is unwound from the bobbin 17 here.
The film 5 in this case consists of a basalt fibre layer 7 which is provided with a layer of thermoplastic material on both sides.
Said film 5 is perforated in this case by putting it against the perforation cylinder 18 after it has been unwound from the bobbin 17 and before the film 5 has been provided against the core plate 2. Naturally, the film 5 may also be perforated during a preceding, separate process.
Against the other side of the core plate 2 is provided a second film 6 which is unwound from the second bobbin 19.
Against the latter is provided a fleece 15 in this embodiment, which is unwound from the third bobbin 20.
Next, the method consists in mutually connecting the above-mentioned layers, i.e. the core plate 2, the first film 5 on the upper side of the core plate 2, the second film 6 on the lower side of the core plate 2 and the fleece 15 which is provided against the second film 6, at a raised temperature and increased pressure, which is obtained in this case by feeding the layers through a lamination device 21 and possibly cooling them in the end, which promotes the detachment. The thus obtained laminate construction 1 can then be cut up if desired.
Figure 5 schematically represents a second device 22, this time for making car roofs 23 on the basis of a laminate construction 1 as discussed above.
This device 22 comprises the device 16, as is represented in figure 4, and it is additionally provided with means 24 to dissipate the heat, in particular on the output side 25 of the lamination device 21 and possibly integrated in the lamination device 21.
Further, in the direction Z in which the core plate 2 progresses, the device 22 is provided with first knives 26, heating means 27 and a mould 28.
Behind the mould 28, seen in the supply direction Z, is situated a fourth bobbin 29 on which is wound what is called a decorative layer or lining 30.
Between the fourth bobbin 29 and the mould 28 are provided
second knives 31.
The method for manufacturing a car roof 23 according to the invention, making use of the above-described device 22, corresponds to the above-described method for manufacturing a laminate construction 1, from the start up to the mutual connection of the different layers of the laminate construction 1 in the lamination device 21.
In order to facilitate the detachment of the thus obtained laminate construction 1 from the lamination device 21, the thus obtained laminate construction 1 is partly cooled with the means 24 for heat dissipation, provided on the output side 25 of the lamination device 21.
Immediately thereafter, and before feeding the laminate construction 1 into the mould 28, it is preheated by guiding it along the heating means 27.
In this embodiment, the laminate construction 1 is cut into pieces 32 by the knives 26, after said preheating, as required in order to produce the car roofs 23.
A thus obtained piece 32 is fed into the mould 28.
On the opposite side of the mould 28, the lining 30 is unwound from the fourth bobbin 29, and subsequently cut in appropriate pieces 33 by the second knives 31, and the thus obtained piece of lining 30 is fed into the mould 28 to be connected to
the piece 32 and to be transformed together into a car roof 23.
If necessary, the car roof 23 can be finished further by trimming the edges . If need be, this processing can be carried out by means of the mould parts which must then be provided with knives on their contours to that end . The car roof 23 is preferably taken out of the mould 28 via one of the free sides .
It is clear that the devices 16 and 22 are only given by way of illustration of the method according to the invention for manufacturing a laminate construction 1 according to the invention and for manufacturing a car roof 23 according to the invention respectively, and that the simplest method for manufacturing such a laminate construction for car roofs mainly consists in supplying a core plate 2 , in supplying two prefabricated films 5 and
6 which compri s e a basalt fibre layer 7 and which are provided with a layer of thermoplastic material 8 or 9 on at least one side, and in mutually connecting the above- mentioned core plate 2 to the prefabricated films 5 and 6 at a raised temperature and increased pressure.
The simplest method for manufacturing a car roof 23 according to the invention mainly comprises the same steps as the above-described method for manufacturing a laminate construction 1 and moreover comprises at least the steps of partially cooling the thus obtained laminate construction 1, of cutting the laminate construction 1 into pieces 32 before or after the heating of the laminate
construction 1, and of providing a piece of laminate construction 32 into a mould 28 , of providing a piece of lining 33 in the mould 28 and of mutually connecting and transforming the above-mentioned pieces 32 and 33 in the mould 28.
Cutting the laminate construction 1 into pieces 32 can be done before or after heating the laminate construction 1 and possibly while closing the mould parts which must then be provided with knives on their contours to that end which are not identical to the knives for the possible finishing of the car roofs 23.
As far as the fibre-reinforced films 5 and 6 are concerned, it is clear that they can be made in different ways and may have different compositions .
In order to manufacture such a film 5 or 6, a prefabricated basalt fibre mat 35 forming the basalt fibre layer 7 can be taken as a basis, for example .
Such a basalt fibre mat can be made for example by solving basalt fibres in water and by providing this solution on a conveyor belt which is provided with an underpressure at the bottom, such that the water is extracted from it , and whereby, during the drying process , a binding agent is added, such that a paperlike layer is obtained .
Natural ly, such a mat can also be obtained in other ways , for example by mutually braiding the wirel ike fibres , such that a fabric is obtained .
A first layer of thermoplastic material 8, for example polyethylene or polypropylene, is provided on the mat for example by means of an extrusion device.
If necessary, a prefabricated film 6 can be provided with a fleece 15 which is unwound for example from a bobbin while the film 6 is being manufactured and which is provided on the layer of thermoplastic material 8.
The whole is fed for example between a rubber pressure roller and a metal cooling roller, such that the basalt fibre mat is largely permeated by the polyethylene or polypropylene, and such that, simultaneously, the fleece 15 is laminated onto the layer of thermoplastic material 8.
If the basalt fibre layer 7 is provided with a layer of thermoplastic material on either side, the semifinished film, as described above, will be subsequently turned by means of return pulleys and fed with the non-finished side up into a second extrusion device, in this case operating for example in various manners, and it will be provided with a layer of thermoplastic material 9 there and possibly with one or several binder courses 12 and/or 14 and possibly with a barrier layer 13 according to what is called the co-extrusion technique .
The semi-finished film 5 or 6 is fed between a rubber pressure roller and a metal cooling roller in a manner which is similar to that of the first extrusion device.
The thus obtained basalt fibre-reinforced film 5 or 6 can possibly be guided along a perforation cylinder to be finally wound on a bobbin.
More details related to other possible constructions of such films 5 or 6 and which are related to the method for manufacturing them are described in Belgian patent application BE 2004/0519.
It is clear that the binder courses 11 , 12 and 14 can be made of modified polyethylene, or for example also of ethylene vinyl acetate, ethylene acrylic acid, co-polyester or co-polyamide .
The fleece 15 can be made for example of polyester viscose, polyester cellulose, paper or the like .
The layer of thermoplastic material 8 and/or 9, or the thermoplastic matrix formed therewith, can possibly be coloured.
The present invention is by no means restricted to the above-described method for manufacturing a laminate construction or to the above-described method for manufacturing a car roof out of a laminate construction; on the contrary, such a method can be made according to different variants while still remaining within the scope of the invention .
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