Fabric-faced thermoplastic composite panel
OwnerDilip K. Tailor, Mark F. Lang +2inventors
InventorsDilip K. Tailor, Mark F. Lang, Paul S. Hruska, Kevin J. McConnell
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Abstract
Polymer matrix composite materials containing a thermoplastic composite core bonded integrally with a fabric layer are provided. The fabric layer has a greater elasticity than the core, so that the fabric layer can conform smoothly to the core during thermoforming. This improvement has been demonstrated to improve aesthetic appearance and nearly eliminate wrinkling and distortion of the fabric layer when compared to conventional composite materials.
Claims23
A polymer matrix composite material suitable for thermoforming to form a molded article, comprising a fiber-reinforced thermoplastic composite core and fabric layer integrally bonded to said core, said fabric layer having greater elasticity than said core, so that said fabric layer can conform smoothly to said core during thermoforming.
A polymer matrix composite material for thermoforming to form a molded article, comprising:
- a thermoplastic composite core comprising at least two laminated thermoplastic layers, including unidirectional fibers having a first and second orientation;
- and
- a woven fabric layer bonded to said core by a resinous adhesive, said woven fabric layer being more elastic than said core so that upon thermoforming, said fabric layer conforms smoothly to said core without wrinkling.
A polymer matrix composite material suitable for thermoforming to form a molded article, comprising a thermoplastic composite core comprising a plurality of laminated thermoplastic sheets thermomolded together, each of said sheets comprising unidirectional fibers oriented in substantially a single direction, said sheets layered to provide a plurality of orientations to said fibers in said composite material;
- and a woven fabric having an aesthetic pattern bonded to said core by a thermoplastic resin or resinous adhesive, said woven fabric having at least about 5% greater elasticity than said core so that upon thermoforming, said woven fabric layer conforms smoothly to said core without wrinkling or distorting.
A method of manufacturing a thermomoldable, polymer matrix composite, comprising:
- providing a fiber-reinforced laminated thermoplastic composite core having a first surface thereon;
- and
- adhering a fabric layer having a greater elasticity than said core to said first surface, said composite containing at least 10 vol. % fibers, and said fabric layer conforming smoothly to said core during thermoforming without substantial wrinkling or distorting.
Dependencies are inferred from the claim text.