US2012021166A1PendingUtilityA1

Recyclable Composite Plastic Panel

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Assignee: BIRRELL MICHAEL IANPriority: Jul 20, 2004Filed: Aug 12, 2011Published: Jan 26, 2012
Est. expiryJul 20, 2024(expired)· nominal 20-yr term from priority
Inventors:Michael Ian Birrell
B29C 70/46B32B 27/32B32B 27/04B32B 27/08Y10T428/24132B32B 2305/70B32B 2305/08Y10T428/24124B32B 2605/003
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Claims

Abstract

A method of producing a panel having at least one feature comprising a discontinuation in curvature of surface in the surface, the method comprising the steps of: providing a first reinforced layer of long and/or continuous parallel fibre reinforced thermoplastic of a first polymer ( 102 a, 104 a ); providing a core layer of thermoplastic with at least roughly 70% by volume of a second polymer which is compatible with the first polymer ( 106 ); providing a second reinforced layer of long or continuous parallel fibre reinforced thermoplastic of the first polymer ( 102 b, 104 b ); stacking the layers such that the reinforced layers are separated by the core layer; introducing the stack into a panel mould and heating the mould to at least the melting point of the predetermined polymer to consolidate the layers and form the panel.

Claims

exact text as granted — not AI-modified
1 . A method of producing a panel having at least one feature comprising a discontinuation in curvature of surface in the surface, the method comprising the steps of:
 providing a first reinforced layer of long and/or continuous parallel fibre reinforced thermoplastic of a first polymer;   providing a core layer of thermoplastic of a second polymer which is compatible with the first polymer;   providing a second reinforced layer of long or continuous parallel fibre reinforced thermoplastic of the first polymer;   stacking the layers such that the reinforced layers are separated by the core layer;   introducing the stack into a panel mould and heating the mould to at least the melting point of the predetermined polymer to consolidate the layers and form the panel.   
     
     
         2 . A method according to  claim 1  in which the core material has at least one of the following: i. roughly 70% by volume of the second polymer and ii. roughly an equal volume as the two reinforced layers. 
     
     
         3 . A method of producing a panel according to  claim 1  or  2  which further comprises treating the moulded panel with a flame treatment, corona discharge or a plasma gun. 
     
     
         4 . A method of producing a panel according to any preceding claim in which are the first and second polymers are the same, or substantially the same polymer. 
     
     
         5 . A method of producing a panel according to any preceding claim in which the moulding is performed in a vacuum consolidation mould or a stamp-press mould. 
     
     
         6 . A method of producing a panel according to any preceding claim in which at least a portion of the mould is heated. 
     
     
         7 . A method of producing a panel according to  claim 6  in which at least a tooling surface intended to mould a side of the panel to be painted is heated. 
     
     
         8 . A method of producing a panel according to any preceding claim which further comprises cooling at least a portion of the mould. 
     
     
         9 . A method of producing a panel according to  claim 8  in which only the tooling surface is cooled. 
     
     
         10 . A method of producing a panel according to any preceding claim which comprises providing the core layer such that it comprises approximately 50% of the depth of the panel. 
     
     
         11 . A method of producing a panel according to any preceding claim comprises providing more than two reinforced layers. 
     
     
         12 . A method of producing a panel according to  claim 11  which comprises providing two reinforced layers either side of the core layer, wherein the outermost layers incorporate fibres in a first direction and the inner reinforced layers incorporated fibres in a second direction, orthogonal to the first and the core is disposed between the inner reinforced layers. 
     
     
         13 . A method of producing a panel according to any preceding claim in which the reinforcing layer(s) to one side of the core layer are arranged to substantially mirror the reinforcing layer(s) to the other side of the core. 
     
     
         14 . A method of producing a panel according to any preceding claim which comprises providing the reinforced layer(s) with fibres lying in two orthogonal directions and/or the layer(s) additionally comprise fibres lying across the diagonal in a Quasi isotropic arrangement. 
     
     
         15 . A method of producing a panel according to  claim 14  which comprises weaving together the fibres before incorporating them into a layer. 
     
     
         16 . A method of producing a panel according to any preceding claim which comprises providing the core layer with reinforcing fibres. 
     
     
         17 . A method of producing a panel according to any preceding claim in which the core is made up of recycled material, industrial regrind or end of use recycling. 
     
     
         18 . A method of producing a panel according to any preceding claim which comprises using the panel in the manufacture of a vehicle. 
     
     
         19 . A panel formed of laminate composite material comprising a core of thermoplastic comprising a predetermined polymer by volume and cover layers comprising long fibre reinforced thermoplastic of the predetermined polymer, wherein the long fibres are oriented parallel to the surface of the cover layers and the inner layer is at least partly covered on each surface by a cover layer, wherein the layers have been consolidated in a heated mould. 
     
     
         20 . A panel according to  claim 19  in which the stack comprises at least three layers, the two outer layers comprising a long or continuous fibre reinforced thermoplastic of the common polymer and at least one inner layer comprising an unreinforced thermoplastic of the predetermined polymer. 
     
     
         21 . A panel according to  claim 19  or  20  in which the core layer comprises at least one of 70% by volume of the predetermined polymer and 50% by volume of the panel. 
     
     
         22 . A method of painting a fibre reinforced plastic panel comprising applying a first layer of primer paint which incorporates a lacquer, allowing the first layer to form a rigid coating and applying a second layer of paint. 
     
     
         23 . A method of painting a fibre reinforced plastic panel according to  claim 22  in which the plastic comprises a hybrid structure of a plurality of composite plastics materials. 
     
     
         24 . A method of painting a fibre reinforced plastic panel according to  claim 22  or  23  which further comprises providing the second layer of paint as a coloured layer. 
     
     
         25 . A method of painting a fibre reinforced plastic panel according to any of  claims 21  to  24  which further comprises providing a layer of clear gloss coat. 
     
     
         26 . A method of producing a panel substantially as described herein and as illustrated in the accompanying  FIGS. 1 to 3 . 
     
     
         27 . A panel substantially as described herein and as illustrated in the accompanying  FIGS. 1 to 3 . 
     
     
         28 . A composite plastic substantially as described herein and as illustrated in the accompanying  FIGS. 1 to 3 . 
     
     
         29 . A method of painting a fibre reinforced plastic panel substantially as described herein and as illustrated in the accompanying  FIGS. 1 to 3 .

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