METHOD OF MAKING A SANDWICH-TYPE, COMPRESSION-MOLDED, COMPOSITE COMPONENT HAVING A CELLULOSE-BASED CORE AND IMPROVED SURFACE APPEARANCE

摘要

A method of making a sandwich-type, compression-molded, composite component having improved surface appearance is provided. Reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based core of a blank or stack of sandwich materials are heated to a softening temperature of the thermoplastics. The heated blank or stack is allowed to cool in the mold cavity until inner surfaces of the skins are bonded to top and bottom surfaces of the core by the sheets to seal core cavities. Air in the sealed cavities urges softened portions of the sheets and portions of the core inwardly towards the cavities of the core as the air in the cavities cools to inhibit debossing and improve surface appearance of a first outer surface of the blank or stack.

主权项

1. A method of making a sandwich-type, compression-molded, composite component having improved surface appearance, the method comprising:
heating a blank or stack of sandwich material including first and second reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based core positioned between the skins and between the sheets and having a large number of cavities, the skins, the sheets and the core being heated to a softening temperature of the thermoplastics; providing a compression mold including component-forming, upper and lower dies with opposing molding surfaces cooperating to define a mold cavity having a shape substantially corresponding to a desired shape of the component; placing the blank or stack on the lower die in an open position of the mold; moving the dies toward each other until the mold is in a closed position; and allowing the heated blank or stack to cool in the mold cavity in the closed position until inner surfaces of the skins are bonded to top and bottom surfaces of the core by the sheets to seal the core cavities, air in the sealed cavities urging softened portions of the sheets and portions of the core inwardly towards the cavities of the core as the air in the cavities cools to inhibit debossing and improve surface appearance of a first outer surface of the blank or stack during the step of allowing.