Blow molding has been utilized for a number of years to form a variety of hollow plastic parts. It has proven effective to form single layer as well as multilayer materials and, with more recent advances, has been used to form a variety of complex shapes, for instance via 3D blow molding techniques. The versatility of blow molding processes is providing a route to the formation of multi-functional, one-piece blow molded components that can reduce weight and simplify assembly of consumer goods as well as manufacturing and production devices.
Many of the applications that could benefit from the utilization of blow molded components are quite demanding, and require components that can withstand a variety of both chemical and mechanical insults. For example, components for use in transport and transportation applications should be able to provide a long life under operating conditions that include temperature fluctuations as well as movement during use. Thus, materials generally require both strength and flexibility. Moreover, materials should be resistant to and impermeable to fluids that may be encountered during use such as oil, gas, coolants, water, air, etc. that may also be heated or cooled during use.
Further, various limitations have been recognized with respect to currently known blow molding techniques. For example, current technologies allow for the formation of single or multiple layer blow molded components. The various layers and materials thereof of multiple layer components allow some tailoring such that the final component provided desired, targeted properties. However, such tailoring is limited, and the required blow molding machinery and techniques are complex, expensive, and time consuming.
According, improved composite components and methods for forming such components are desired in the art. In particular, blow molded components and methods that provide blow molded components having improved targeted properties, such as targeted, localized reinforcement, would be advantageous.
In according with one embodiment of the present disclosure, a method for forming a composite component is disclosed. The method includes inserting a continuous fiber reinforced thermoplastic tape into a molding device, and feeding a parison into the molding device. The parison includes a thermoplastic material. The method further includes blow molding the parison within the molding device such that the parison bonds with the tape, forming the composite component.
In accordance with another embodiment of the present disclosure, a composite component is disclosed. The composite component includes a blow molded inner layer comprising a thermoplastic material. The composite component further includes an outer layer bonded to the inner layer during blow molding of the inner layer. The outer layer includes a continuous fiber reinforced thermoplastic tape.
Other features and aspects of the present invention are set forth in greater detail below.
The present disclosure may be better understood with reference to the following figures:
Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.
It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present disclosure.
The present disclosure is generally directed to composite components, and methods for forming composite components. Specifically, the present disclosure is directed to the use of blow molding to form composite components. The resulting blow molding components include an inner blow molded layer. Further, such components include an outer layer that is bonded to the inner layer during the blow molding process. The outer layer provides reinforcement to the inner blow molded layer. The outer layer may be, for example, a sleeve or a patch, and may be provided at targeted, localized locations on the inner layer to provide localized reinforcement of the inner layer as required. For example, the outer layer may be located on predetermined vulnerable portions of the inner layer, such as portions of relatively higher stress during use, to provide local reinforcement of such portions. Bonding of the outer layer to the inner layer during the blow molding process is particularly advantageous, as it allows for efficient forming of the resulting composite component.
The outer layer according to the present disclosure may be formed from a continuous fiber reinforced thermoplastic tape, as shown in
As discussed, in exemplary embodiments, the various components of a composite component according to the present disclosure, such as the inner layer and the tapes 10 forming the outer layer, are formed from thermoplastic materials 14, 22. Suitable thermoplastic materials for use according to the present disclosure include, for instance, polyolefins (e.g., polypropylene, propylene-ethylene copolymers, etc.), polyesters (e.g., polybutylene terephalate (“PBT”)), polycarbonates, polyamides (e.g., PA12, Nylon™), polyether ketones (e.g., polyether ether ketone (“PEEK”)), polyetherimides, polyarylene ketones (e.g., polyphenylene diketone (“PPDK”)), liquid crystal polymers, polyarylene sulfides (e.g., polyphenylene sulfide (“PPS”), poly(biphenylene sulfide ketone), poly(phenylene sulfide diketone), poly(biphenylene sulfide), etc.), fluoropolymers (e.g., polytetrafluoroethylene-perfluoromethylvinylether polymer, perfluoro-alkoxyalkane polymer, petrafluoroethylene polymer, ethylene-tetrafluoroethylene polymer, etc.), polyacetals, polyurethanes, polycarbonates, styrenic polymers (e.g., acrylonitrile butadiene styrene (“ABS”)), polyoxymethylene (“POM”), and so forth.
Further, the thermoplastic materials 14 may include a plurality of fibers 12 embedded therein. Impregnation of a thermoplastic material with a plurality of fibers may be performed utilizing any suitable processes and/or apparatus, such as suitable impregnation and/or pultrusion processes and/or apparatus. For example, as discussed, the outer layer may be formed from a continuous fiber reinforced thermoplastic tape. Thus, continuous fibers may be embedded in the thermoplastic material, although it should be understood that long fibers may additionally be included therein. Further, as shown in
As used therein, the term “long fibers” generally refers to fibers, filaments, yarns, or rovings that are not continuous, and as opposed to “continuous fibers” which generally refer to fibers, filaments, yarns, or rovings having a length that is generally limited only by the length of a part.
The fibers 12, 24 dispersed in the thermoplastic material 14, 22 may be formed from any conventional material known in the art, such as metal fibers, glass fibers (e.g., E-glass, A-glass, C-glass, D-glass, AR-glass, R-glass, S-glass such as S1-glass or S2-glass), carbon fibers (e.g., graphite), boron fibers, ceramic fibers (e.g., alumina or silica), aramid fibers (e.g., Kevlar® marketed by E. I. DuPont de Nemours, Wilmington, Del.), synthetic organic fibers (e.g., polyamide, polyethylene, paraphenylene, terephthalamide, polyethylene terephthalate and polyphenylene sulfide), and various other natural or synthetic inorganic or organic fibrous materials known for reinforcing polymer compositions. Glass fibers, carbon fibers, and aramid fibers are particularly desirable. In exemplary embodiments, continuous fibers 12 dispersed in a resulting tape may be generally unidirectional, as shown in
Referring to
A relatively high percentage of fibers 12 may be employed in a resulting continuous fiber reinforced thermoplastic tape 10 to provide enhanced strength properties. For instance, fibers 12 typically constitute from about 25 wt. % to about 90 wt. %, in some embodiments from about 30 wt. % to about 75 wt. %, and in some embodiments, from about 35 wt. % to about 70 wt. % of the tape 10 and material thereof. Likewise, polymer(s) typically constitute from about 20 wt. % to about 75 wt. %, in some embodiments from about 25 wt. % to about 70 wt. %, and in some embodiments, from about 30 wt. % to about 65 wt. % of the tape 10. Such percentage of fibers may additionally or alternatively by measured as a volume fraction. For example, in some embodiments, a tape 10 or material thereof may have a fiber volume fraction between approximately 25% and approximately 80%, in some embodiments between approximately 30% and approximately 70%, in some embodiments between approximately 40% and approximately 60%, and in some embodiments between approximately 45% and approximately 55%.
In other embodiments, as further shown in
In exemplary embodiments, a tape 10, such as a sleeve 40 or patch 42 forming the outer layer 34, may be located on the inner layer 32 to provide local reinforcement to a predetermined vulnerable portion 44 of the inner layer 32 and composite component 30. Such predetermined vulnerable portion 44 may be a portion of the component 30 which, due to for example size or shape, has a generally increased vulnerability to stress, and thus may be considered a failure point for component 30. For example, predetermined vulnerable portions 44 are illustrated at bends in the component 30 shown in
As further shown in
The other layers, such as the outer layer 66 and the intermediate layer 64 in the embodiment shown, can be formed from any suitable materials. In some embodiments, the other layers may be formed from thermoplastic materials that are the same or different than the thermoplastic material that forms the composite component 30. In other embodiments, the other layers may be formed from thermosets, metals, ceramics, or another other suitable materials.
In other embodiments, a composite component 30 according to the present disclosure may, for example, form a component for use in the transportation field. By way of example and without limitation, automotive components of the fuel system, the HVAC system, the engine cooling system, as well as interior and exterior portions of the vehicle body can be formed according to a process that includes blow molding the composite component as discussed herein. Specific examples include struts, supports (e.g., radiator supports), grill guards, floor pans, trunk flooring, inner pillars, fuel filler necks, fuel tanks, air ducts, running board assemblies, etc.
As discussed, composite components 30 according to the present disclosure are formed by blow molding. Specifically, the inner layer 32 may be blow molded. Tapes 10 forming the outer layer 34 may be bonded to the inner layer 32 during blow molding of the inner layer 32. For example, and as shown in
One blow molding process is illustrated sequentially in
As shown in
As further shown in
As further shown in
Referring still to
As can be appreciated, a certain period of time elapses from formation of the parison 120 to clamping and moving the parison 120 into engagement with the molding device 126. During this stage of the process, the melt strength of the thermoplastic material should be high enough such that the parison 120 maintains its shape during movement. The thermoplastic material should also be capable of remaining in a semi-fluid state and not solidifying too rapidly before blow molding commences.
As shown in
Referring to FIG, 9, once the parison 120 has been moved into position, the first portion 128 and the second portion 130 of the molding device 126 move together such that the parison 120 partially extends through the mold cavity 132.
As shown in
Having separately movable top sections as shown in
Once the top sections 140 and 142 of the molding device 126 are closed as shown in
After blow molding, the finished component 30 is then removed and used as desired. In one embodiment, cool air can be injected into the molded part for solidifying the component prior to removal from the molding device 126.
Blow molding processes are not limited to robotic 3-D blow molding methodology as illustrated in
In another embodiment, 3-D suction blow molding techniques may be utilized. For example, in some embodiments, tapes 10 in the form of sleeves 40 and/or patches 42, as well as inserts 36, may be inserted in a mold device. The mold device may then be closed. A parison may then be fed into the closed mold device through a feed aperture in the mold device via suction, and blow molded therein.
In another embodiment, standard 2-D blow molding may be utilized. For example, in some embodiments, tapes 10 in the form of sleeves 40 and/or patches 42, as well as inserts 36, may be initially provided on a parison outside of the mold device. The parison may, for example, be filled with air sufficient such that the parison supports the sleeves 40 and/or patches 42 and/or inserts 36. The tapes 10 and inserts 36 may be then be inserted into the mold device with the parison as the parison is fed into the mold device. Alternatively, the tapes 10 and/or inserts 36 may be inserted into the mold device, and the parison then fed into the mold device. Blow molding may then take place.
It should be noted that when utilizing any suitable blow molding technique, such as those discussed herein, tapes 10 and inserts 36 can be provided on the parison before the parison is fed into a mold device and/or in the mold device before the parison is fed therein. When tapes 10 and/or inserts 36 are held in a mold device before the parison is provided therein, they may be held due to the mold device geometry, or through use of a vacuum, or through any other suitable device or technique.
The material forming the blow molded inner layer 32 can be constant throughout the entire component or only a portion of the component. For instance, when considering a component having a large aspect ratio (L/D>1), such as a tubular member, the inner layer 32 can be formed such that the thermoplastic material extends along a section of the inner layer 32 and an adjacent section can be formed of a different composition, for instance a different thermoplastic material, Such an inner layer 32 can be formed by, e.g., altering the material that is fed to a blow molding device during a formation process. The inner layer 32 can include an area in which the two materials are mixed that represents a border region between a first section and a second section formed of different materials. An inner layer 32 can include a single section formed of the thermoplastic material or a plurality of sections, as desired. Moreover, other sections of a component can be formed of multiple different materials. By way of example, when considering a tubular component such as a fluid conduit, both ends of the inner layer 32 can be formed of a first thermoplastic material and a center section can be formed of a less flexible second thermoplastic material, Thus, the more flexible ends can be utilized to tightly affix the component to other components of a system. Alternatively, a center section of an inner layer 32 could be formed from a more flexible thermoplastic composition, which can improve flexibility of the component in that section, making installation of the component easier.
The present disclosure thus provides blow molded composite components with advantageous reinforcement features. As discussed, an outer reinforcement layer comprising continuous fiber reinforced thermoplastic tapes 10 is bonded to an inner blow molded layer during the blow molding process. Bonding of the outer layer to the inner layer during the blow molding process is particularly advantageous, as it allows for efficient forming of the resulting composite component. Further, the present disclosure advantageously provides targeted localized reinforcement of the resulting composite components.
These and other modifications and variations to the present disclosure may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present disclosure. In addition, it should be understood the aspects of the various embodiments may be interchanged, either in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the disclosure.
The present application claims filing benefit of U.S. Provisional Patent application 61/737,979 having a filing date of Dec. 17, 2012, which is incorporated by reference herein in its entirety.
Number | Date | Country | |
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61737979 | Dec 2012 | US |