Back to results
US 2025/0050616 A1Published application
Thermoplastic composites with improved induction heating properties
AssigneeToray Advanced Composited USA Inc.
InventorsKapil Milind INAMDAR, Saurabh Vaidya, Dickie DeWayne Howell
Life of this patent
Estimating the term…
Abstract
Described herein are thermoplastic composites and methods of making thereof. The thermoplastic composites disclosed herein can include at least one randomly-oriented carbon fiber layer in the laminate to improve induction heating efficiency of the thermoplastic composite.
Claims41
A method of producing a thermoplastic composite comprising:
- preparing a first laminate comprising:
- a first layer comprising a first plurality of unidirectional fibers and a first polymer;
- and
- a second layer comprising randomly-oriented carbon fibers and a second polymer, wherein the second layer covers at least a portion of a surface of the first layer;
- preparing a second laminate comprising:
- a third layer comprising a second plurality of unidirectional fibers and a third polymer;
- placing the first laminate in contact with the second laminate such that the second layer of the first laminate contacts the second laminate;
- inducing electrical currents in the randomly-oriented carbon fibers of the second layer via an alternating electromagnetic field, thereby generating heat in the randomly-oriented carbon fibers of the second layer;
- and
- melting and/or softening the first, second, and third polymer with the heat generated by the randomly-oriented carbon fibers, thereby welding the first laminate to the second laminate.
7 more elements
A method of producing a thermoplastic composite comprising:
- preparing a lay-up comprising:
- a first layer comprising a first plurality of unidirectional fibers and a first polymer;
- a second layer comprising a second plurality of unidirectional fibers and a second polymer;
- and
- and at least one third layer comprising randomly-oriented carbon fibers and a third polymer, wherein the at least one third layer is between the first layer and the second layer in the lay-up;
- inducing electrical currents in the randomly-oriented carbon fibers of the at least one third layer via an alternating electromagnetic field, thereby generating heat in the randomly-oriented carbon fibers of the at least one third layer;
- and
- melting and/or softening the first, second, and third polymer of the third layer with the heat generated by the randomly-oriented carbon fibers, thereby welding the at least one third layer to the first layer and the second layer.
5 more elements
A thermoplastic composite comprising:
- a first layer comprising a first plurality of unidirectional fibers and a first polymer;
- a second layer comprising a second plurality of unidirectional fibers and a second polymer;
- and
- at least one third layer comprising randomly-oriented carbon fibers and a third polymer, wherein the at least one third layer is between the first layer and the second layer and the at least one third layer is welded to the first and second layers.
1 more element
A method of producing a thermoplastic composite comprising:
- preparing a first laminate comprising:
- a first layer comprising a first woven fabric comprising a first plurality of fibers and a first polymer;
- and
- a second layer comprising randomly-oriented carbon fibers and a second polymer, wherein the second layer covers at least a portion of a surface of the first layer;
- preparing a second laminate comprising:
- a third layer comprising a second woven fabric comprising a second plurality of fibers and a third polymer;
- placing the first laminate in contact with the second laminate such that the second layer of the first laminate contacts the second laminate;
- inducing electrical currents in the randomly-oriented carbon fibers of the second layer via an alternating electromagnetic field, thereby generating heat in the randomly-oriented carbon fibers of the second layer;
- and
- melting and/or softening the first, second, and third polymer with the heat generated by the randomly-oriented carbon fibers, thereby welding the first laminate to the second laminate.
7 more elements
A method of producing a thermoplastic composite comprising:
- preparing a first laminate comprising:
- a first layer comprising a first plurality of unidirectional fibers and a first polymer;
- and
- a second layer comprising a first portion and a second portion, wherein the first portion comprises randomly-oriented carbon fibers and a second polymer and the second portion comprises a second plurality of unidirectional fibers and a third polymer;
- preparing a second laminate comprising:
- a third layer comprising a third plurality of unidirectional fibers and a fourth polymer;
- placing the first laminate in contact with the second laminate such that the second layer of the first laminate contacts the second laminate;
- inducing electrical currents in the randomly-oriented carbon fibers of the second layer via an alternating electromagnetic field, thereby generating heat in the randomly-oriented carbon fibers of the second layer;
- and
- melting and/or softening the first, second, third, and fourth polymers with the heat generated by the randomly-oriented carbon fibers, thereby welding the first laminate to the second laminate.
7 more elements
Dependencies are inferred from the claim text.