US 11,833,799 B2
Method of manufacturing a sheet-like composite part with improved compression strength
Burak Baser, Aarburg (CH)
Assigned to Mitsubishi Chemical Advanced Materials NV, Tielt (BE)
Appl. No. 17/284,665
Filed by MITSUBISHI CHEMICAL ADVANCED MATERIALS NV, Tielt (BE)
PCT Filed Oct. 10, 2019, PCT No. PCT/EP2019/077546
§ 371(c)(1), (2) Date Apr. 12, 2021,
PCT Pub. No. WO2020/074677, PCT Pub. Date Apr. 16, 2020.
Claims priority of application No. 18199755 (EP), filed on Oct. 10, 2018.
Prior Publication US 2021/0354436 A1, Nov. 18, 2021
Int. Cl. E04C 2/32 (2006.01); B32B 38/00 (2006.01); B32B 7/09 (2019.01); B32B 3/28 (2006.01); B32B 5/02 (2006.01); B32B 5/12 (2006.01); B32B 37/10 (2006.01); B32B 37/20 (2006.01)
CPC B32B 38/00 (2013.01) [B32B 3/28 (2013.01); B32B 5/022 (2013.01); B32B 5/024 (2013.01); B32B 5/12 (2013.01); B32B 7/09 (2019.01); B32B 37/10 (2013.01); B32B 37/20 (2013.01); E04C 2/322 (2013.01); B32B 38/1883 (2013.01); B32B 2038/008 (2013.01); B32B 2250/03 (2013.01); B32B 2250/40 (2013.01); B32B 2262/02 (2013.01); B32B 2307/718 (2013.01); Y10T 428/24694 (2015.01); Y10T 428/24711 (2015.01); Y10T 428/24727 (2015.01)] 12 Claims
OG exemplary drawing
 
1. A method of manufacturing a sheet-like composite part, comprising the following process steps:
a) providing a substantially planar sandwich arrangement (A, B, A′) comprising a core layer (B) sandwiched between a pair of skin layers (A, A′), a first face of the core layer being adjacent and substantially parallel to a first one (A) of said skin layers and a second face of the core layer being adjacent and substantially parallel to the other one (A″) of said skin layers, the skin layers (A, A′) each comprising a skin thermoplastic and optionally reinforcement fibers, the core layer (B) comprising a fleece material made of fleece thermoplastic fibers and reinforcement fibers, wherein said fleece material is prepared with the fleece thermoplastic fibers and the reinforcement fibers in an airlaying or carding process,
b) heating to melt the skin layers and pressing the sandwich arrangement (A,B,A′) followed by cooling, thereby obtaining the sheet-like composite part,
wherein
the core layer (B) is a Z-oriented core layer having the reinforcement fibers predominantly oriented in an orientation direction (Z) perpendicular to the first and second faces, and wherein the core layer (B) comprises a stacked plurality of continuously folded arrangements of said fleece material.