Sheet molding compound with cores

Abstract

A component made of at least one thermoformable material, having a first layer made of a first material, a second layer made of a second material, and a third layer made of the first material. The three layers form a sheet, which is formed to various shapes, depending upon the part that is to be created. The sheet may be formed to produce the bumper of an automobile, a door panel for an automobile, a flotation device, such as a pontoon for a pontoon boat, or the like. The first and third layers are SMC, and the second layer, or “core,” is disposed between the first and third layers, allowing the strength of the first and third layers to be used more efficiently, compared to a sheet having only the first and third layers, and no core.

1 . An automotive component made of at least one thermoformable material, comprising:
 a first structural layer made of a first material;   a spatial support layer made of a second material; and   a third structural layer made of said first material, said spatial support layer being disposed between said first structural layer and said third structural layer;   wherein said first structural layer, said spatial layer, and said third structural layer are placed into a mold, and said mold his heated such that said first structural layer and said third structural layer are chemically bonded to said spatial support layer.   
     
     
         2 . The automotive component made of at least one thermoformable material of  claim 1 , each of said first structural layer and said third structural layer further comprising a thermoformable, pre-impregnated sheet molding compound (SMC). 
     
     
         3 . The automotive component made of at least one thermoformable material of  claim 2 , wherein said thermoformable, preimpregnated SMC further comprises a thermoset material, a polymer resin, inert fillers, a fiber reinforcement, catalysts, pigments and stabilizers, release agents, thickeners, and combinations thereof. 
     
     
         4 . The automotive component made of at least one thermoformable material of  claim 1 , each of said first structural layer and said third structural layer further comprising a pre-impregnated material. 
     
     
         5 . The automotive component made of at least one thermoformable material of  claim 4 , said pre-impregnated material being one selected from the group consisting of Glass Mat Thermoplastic (GMT) material, Kevlar, E-Glass, a carbon fiber material, a composite fiber material, and combinations thereof. 
     
     
         6 . The automotive component made of at least one thermoformable material of  claim 1 , wherein said spatial support layer is made of a material which is one selected from the group consisting of polyester, polypropylene, polyurethane, polyvinylchloride (PVC), styrene acrylonitrile resin (SAN), and combinations thereof. 
     
     
         7 . The automotive component made of at least one thermoformable material of  claim 1 , wherein said first structural layer and said third structural layer are substantially the same thickness. 
     
     
         8 . The automotive component made of at least one thermoformable material of  claim 1 , wherein said first structural layer and said third structural layer are of different thicknesses. 
     
     
         9 . The automotive component made of at least one thermoformable material of  claim 1 , wherein said spatial support layer is of a greater thickness compared to said first structural layer and said third structural layer. 
     
     
         10 - 15 . (canceled) 
     
     
         16 . A wind blade made of at least one thermoformable material, comprising:
 a top structural layer made of a sheet molding compound;   a middle support layer made of a polymer material, said middle support layer having a first side and a second side; and   a bottom structural layer made of said sheet molding compound;   wherein said top structural layer is bonded to first side of middle support layer, and said bottom structural layer is bonded to said second side of said middle support layer, forming a sheet.   
     
     
         17 . The wind blade made of at least one thermoformable material of  claim 16 , wherein said polymer is one selected from the group consisting of polyester, polypropylene, polyurethane, polyvinylchloride (PVC), styrene acrylonitrile resin (SAN), and combinations thereof. 
     
     
         18 . The wind blade made of at least one thermoformable material of  claim 16 , wherein said sheet molding compound further comprises a thermoset material, a polymer resin, inert fillers, a fiber reinforcement, catalysts, pigments and stabilizers, release agents, thickeners, and combinations thereof. 
     
     
         19 . The wind blade made of at least one thermoformable material of  claim 16 , wherein said top structural layer and said bottom structural layer are of a first thickness. 
     
     
         20 . The wind blade made of at least one thermoformable material of  claim 19 , wherein said first thickness is generally from about 1.0 millimeters to about 5.0 millimeters, typically about 1.0 millimeters to about 2.0 millimeters, and preferably about 1.3 millimeters to about 1.7 millimeters. 
     
     
         21 . The wind blade made of at least one thermoformable material of  claim 16 , wherein said middle support layer is of a thickness which is generally from about 1.0 millimeters to about 50.8 millimeters, typically about 1.0 millimeters to about 25.4 millimeters, and preferably about 1.0 millimeters to about 5.0 millimeters. 
     
     
         22 . The wind blade made of at least one thermoformable material of  claim 16 , wherein said sheet is placed into a mold and cured to bond said top structural layer to said middle support layer, and to bond said bottom structural layer to said middle support layer. 
     
     
         23 . The wind blade made of at least one thermoformable material of  claim 22 , wherein said sheet is cured at a temperature of generally in the range of about 200° Fahrenheit to about 400° Fahrenheit, typically in the range of about 250° Fahrenheit to about 350° Fahrenheit, and preferably in the range of about 280° Fahrenheit to about 320° Fahrenheit.