Polymer foams including functionalized carbon nanotubesg
US-2022049064-A1 · Feb 17, 2022 · US
Polymer-graphene energy absorbing composite structures and methods of manufacture
US11858239B2 · US · B2
| Field | Value |
|---|---|
| Publication number | US-11858239-B2 |
| Application number | US-202117481732-A |
| Country | US |
| Kind code | B2 |
| Filing date | Sep 22, 2021 |
| Priority date | Sep 22, 2021 |
| Publication date | Jan 2, 2024 |
| Grant date | Jan 2, 2024 |
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Abstract
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A composite structure includes a foam core formed from a first polymer and between about 0.5 wt. % and about 2.5 wt. % graphene. The foam core has an average pore size between about 25 μm and about 75 μm, and a cell density between about 4×106 cells/mm2 and about 6×106 cells/mm2. Also, an overmolded skin formed from a second polymer and between about 0.25 wt. % and about 5.0 wt. % graphene is disposed on the foam core. A method of manufacturing a composite structure includes injection molding a foam core from a first polymer containing between about 0.25 wt. % and about 5.0 wt. % graphene, and injection molding an overmolded skin from a second polymer containing graphene between about 0.25 wt. % and about 5.0 wt. % graphene.
First claim
Opening claim text (preview).
What is claimed is: 1. A component comprising: a composite structure comprising a closed cell foam core, and an overmolded skin disposed on the closed cell foam core, wherein the closed cell foam core comprises a first polymer-graphene material with between about 0.5 wt. % and about 1.0 wt. % 2D graphene, an average pore size between about 25 μm and about 75 μm, and a cross-section pore density between about 4×10 6 cells/mm 2 and about 6×10 6 cells/mm 2 , wherein the overmolded skin comprises a second polymer-graphene material with between about 0.5 wt. % and about 1.0 wt. % 2D graphene, and wherein the closed cell foam core weighs at least 5% less than a solid core formed from the first polymer and the composite structure exhibits an increase in energy absorption of at least 50% compared to a closed cell foam core formed from the first polymer without graphene. 2. The component according to claim 1 , wherein the first polymer and the second polymer are the same polymer. 3. The component according to claim 1 , wherein the first polymer and the second polymer are polypropylene. 4. The component according to claim 1 , wherein the energy absorption increase is at least 75%. 5. The component according to claim 1 , wherein the first polymer-graphene material and the second polymer-graphene material comprises at least one of polypropylene, polyethylene, polystyrene, polycarbonate, polyvinyl chloride, polylactic acid, polycarbonate, polyurethane, polybutylene terephthalate, polyamide 6, and polyamide 66. 6. A method of manufacturing a component, the method comprising: injection molding a closed cell foam core from a first polymer-graphene material with between about 0.5 wt. % and about 1.0 wt. % 2D graphene, wherein the closed cell foam core comprises an average pore size between about 25 μm and about 75 μm, and a cross-section pore density between about 4×10 6 cells/mm 2 and about 6×10 6 cells/mm 2 ; and injection molding an overmolded skin on the closed cell foam core to form a composite structure, wherein the overmolded skin is formed from a second polymer-graphene material with between about 0.5 wt. % and about 1.0 wt. % 2D graphene, and wherein the closed cell foam core weighs at least 5% less than a solid core formed from the first polymer and the composite structure exhibits an increase in energy absorption of at least 50% compared to a closed cell foam core formed from the first polymer without graphene. 7. The method according to claim 6 , wherein the injection molding of the foam core comprises supercritical fluid injection molding of the foam core.
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Classifications
- B32B27/065Primary
of foam · CPC title
characterised by the choice of material · CPC title
characterised by features of a layer {of} foamed material · CPC title
characterised by the use of special additives · CPC title
comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} · CPC title
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- What does patent US11858239B2 cover?
- A composite structure includes a foam core formed from a first polymer and between about 0.5 wt. % and about 2.5 wt. % graphene. The foam core has an average pore size between about 25 μm and about 75 μm, and a cell density between about 4×106 cells/mm2 and about 6×106 cells/mm2. Also, an overmolded skin formed from a second polymer and between about 0.25 wt. % and about 5.0 wt. % graphene is d…
- Who is the assignee on this patent?
- Aisin Technical Ct America Inc
- What technology area does this patent fall under?
- Primary CPC classification B32B27/065. Mapped technology areas include Operations & Transport.
- When was this patent published?
- Publication date Tue Jan 02 2024 00:00:00 GMT+0000 (Coordinated Universal Time) (B2). Legal status and post-grant events are not shown on this page.
- What related patents are in patentsdb?
- We list 6 related publications on this page (citations in our corpus or others sharing the same primary CPC).