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公开(公告)号：US11091595B2
公开(公告)日：2021-08-17
申请号：US16395869
申请日：2019-04-26
Applicant: GM Global Technology Operations LLC
Inventor： Hamid G. Kia , Selina X. Zhao
Abstract: Presented are fiber-reinforced polymer (FRP) sandwich structures, methods for making/using such FRP sandwich structures, and motor vehicles with a vehicle component fabricated from a compression molded thermoset or thermoplastic FRP sandwich structure. A multidimensional composite sandwich structure includes first and second (skin) layers formed from a thermoset of thermoplastic polymer matrix, such as resin or nylon, filled with a fiber reinforcing material, such as chopped carbon fibers. A third (core) layer, which is encased between the first and second skin layers, is formed from a thermoset/thermoplastic polymer matrix filled with a fiber reinforcing material and a filler material, such as hollow glass microspheres. The first, second and third layers have respective rheological flow properties that are substantially similar such that all three layers flow in unison at a predetermined compression molding pressure. These layers may be formed from the same thermoset/thermoplastic polymer material, and include the same fiber reinforcing material.
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公开(公告)号：US10358767B2
公开(公告)日：2019-07-23
申请号：US15211814
申请日：2016-07-15
Applicant: GM Global Technology Operations LLC
Inventor： Hamid G. Kia , Nicole D. Ellison , Selina X. Zhao
Abstract: Methods and components produced from carbon fiber pre-impregnated composite precursor materials (pre-preg) having enhanced flowability and moldability are provided. Discontinuous cut regions are introduced into a pre-preg. A sheet of pre-preg may be contacted with a patterned surface having a plurality of non-contiguous staggered cutters, so that the contacting creates discontinuous cuts in the pre-preg. A plurality of staggered discontinuous cut regions are formed in the plurality of continuous carbon fibers that define a first plurality of carbon fibers having a first length and a second plurality of carbon fibers having a second distinct length. The patterned surface may be provided on a cutter device that is a roller or a plate having the non-contiguous staggered cutters formed or disposed thereon. The discontinuous cut regions that are formed in the pre-preg reduce stiffness and improve moldability/flowability when forming carbon fiber polymeric composites, while retaining high strength levels.
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3.发明申请公开(公告)号：US20190062955A1
公开(公告)日：2019-02-28
申请号：US15685157
申请日：2017-08-24
Applicant: GM Global Technology Operations LLC
Inventor： Hamid G. Kia , Selina X. Zhao
Abstract: Methods of producing a continuous carbon fiber for use in composites having enhanced moldability are provided. A continuous precursor fiber is formed that has a sheath and a core. The sheath includes a first polymer material. The core includes a second polymer material and a plurality of discrete regions distributed within the second polymer material. The discrete regions include a third polymer material. After the continuous precursor fiber is heated for carbonization and graphitization, the continuous precursor fiber forms a continuous carbon fiber having a plurality of discrete weak regions corresponding to the plurality of discrete regions in the core. Carbon fiber composites made from such modified continuous carbon fibers having enhanced moldability are also provided.
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公开(公告)号：US11331890B1
公开(公告)日：2022-05-17
申请号：US17130566
申请日：2020-12-22
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Selina X. Zhao , Xiaosong Huang
Abstract: A polymeric sandwich structure having enhanced thermal conductivity includes a first layer formed from a first polymer matrix and including a first fiber reinforcing sheet embedded within the first polymer matrix, a second layer formed from a second polymer matrix and including a second fiber reinforcing sheet embedded within the second polymer matrix, and a third layer disposed between the first and second layers, the third layer formed from a third polymer matrix having graphene nanoplatelets interspersed therein. Each of the first and second fiber reinforcing sheets is made of reinforcing fibers and includes a respective set of staggered discontinuous perforations formed therein, wherein each respective set of staggered discontinuous perforations defines a respective first plurality of reinforcing fibers having a respective first length and a respective second plurality of reinforcing fibers having a respective second length longer than the respective first length.
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公开(公告)号：US20190177893A1
公开(公告)日：2019-06-13
申请号：US15836315
申请日：2017-12-08
Applicant: GM Global Technology Operations LLC
Inventor： Hamid G. Kia , Selina X. Zhao
Abstract: An apparatus for perforating a carbon fiber substrate material comprises a support structure including a first side support and a second side support and a cylindrical anvil rotatably connected between the first side support and the second side support. The anvil is configured to move the carbon fiber substrate material in response to rotation of the anvil. The apparatus further comprises a cylindrical cutting wheel rotatably connected to the support structure between the first side support and the second side support and positioned adjacent to the anvil. The cutting wheel includes a plurality of blades projecting outward from an outer surface of the cutting wheel wherein the blades of the cutting wheel are configured to perforate the carbon fiber substrate material when the carbon fiber substrate material moves between the anvil and the cutting wheel.
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Patent Agency Ranking
公开(公告)号：US20180143164A1
公开(公告)日：2018-05-24
申请号：US15358301
申请日：2016-11-22
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Ingrid A. Rousseau , Selina X. Zhao , Hamid G. Kia
CPC classification number: G01N29/069 , G01N29/4481 , G01N2291/0289 , G01N2291/267
Abstract: An assembly includes a sensor configured to obtain a data scan of a joint. A controller is operatively connected to the sensor. The controller includes a processor and tangible, non-transitory memory on which is recorded instructions for executing a method for automated quality assessment of the joint. Execution of the instructions by the processor causes the controller to: obtain the data scan of the joint (via the sensor) and generate a first image based on the data scan. The first image is divided into a plurality of pixels having respective numeric values. The controller is programmed to identify a region of interest as the plurality of pixels from the first image with a respective numeric value greater than a threshold value (I0). The controller is programmed to assess joint quality based on a porosity factor (PF) determined at least partially from the data scan.
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公开(公告)号：US20180016740A1
公开(公告)日：2018-01-18
申请号：US15211814
申请日：2016-07-15
Applicant: GM Global Technology Operations LLC
Inventor： Hamid G. Kia , Nicole D. Ellison , Selina X. Zhao
IPC: D06M15/55 , B26D1/22 , D06H7/02 , D06M101/40
CPC classification number: D06M15/55 , B26D1/225 , B32B3/266 , C08J5/042 , C08J5/24 , D06H7/02 , D06M2101/40 , D10B2101/12 , D10B2505/02 , Y10T428/24314
Abstract: Methods and components produced from carbon fiber pre-impregnated composite precursor materials (pre-preg) having enhanced flowability and moldability are provided. Discontinuous cut regions are introduced into a pre-preg. A sheet of pre-preg may be contacted with a patterned surface having a plurality of non-contiguous staggered cutters, so that the contacting creates discontinuous cuts in the pre-preg. A plurality of staggered discontinuous cut regions are formed in the plurality of continuous carbon fibers that define a first plurality of carbon fibers having a first length and a second plurality of carbon fibers having a second distinct length. The patterned surface may be provided on a cutter device that is a roller or a plate having the non-contiguous staggered cutters formed or disposed thereon. The discontinuous cut regions that are formed in the pre-preg reduce stiffness and improve moldability/flowability when forming carbon fiber polymeric composites, while retaining high strength levels.
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公开(公告)号：US11453182B2
公开(公告)日：2022-09-27
申请号：US16703947
申请日：2019-12-05
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Selina X. Zhao , Xiaosong Huang
IPC: B29C70/46 , B29C45/14 , B29C37/00 , B29C64/147 , B29C70/30 , B32B3/26 , B32B5/02 , B32B5/26 , B32B27/12 , B32B27/20 , B29L31/30 , B29K307/04
Abstract: Methods for fabricating Class-A components (CAC) include providing a molding precursor which includes a first and second skin layer each including a fiber reinforcing material embedded in a polymer matrix, a third layer between the first and second skin layers and including a third polymer matrix and a filler material interspersed therein. The fiber reinforcing materials include a plurality of substantially aligned carbon fibers having a plurality of low strength regions staggered with respect to the second axis. The method includes disposing a molding precursor within a die, compression molding the molding precursor in the die, wherein the die includes a punch configured to contact the second skin layer, opening the die to create a gap between the punch and an outer surface of the second skin layer, and injecting a Class-A finish coat precursor into the gap to create a class-A surface layer and form the CAC.
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公开(公告)号：US11273611B2
公开(公告)日：2022-03-15
申请号：US16594288
申请日：2019-10-07
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Venkateshwar R. Aitharaju , William R. Rodgers , Selina X. Zhao
IPC: B29C70/00 , B33Y80/00 , B29B11/00 , B29B13/00 , B29C70/46 , B29C70/54 , B29B13/02 , B29B11/16 , B29B11/14 , B29L31/30
Abstract: A reinforced preform includes a sheet of reinforced material having opposed first and second edges, with each edge having a respective first connection point located therealong. The preform also includes first and second tethers, with each tether being attached at a respective first end thereof to a respective one of the first connection points and having a respective second end thereof terminating in at least one of: a respective loop tied at the respective second end, a respective knot tied at the respective second end, a respective graspable member to which the respective second end is connected, and an attachment to a respective second connection point located along a perimeter of the sheet. A method and mold for molding a reinforced preform are also disclosed.
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公开(公告)号：US20210170730A1
公开(公告)日：2021-06-10
申请号：US16703931
申请日：2019-12-05
Applicant: GM GLOBAL TECHNOLOGY OPERATIONS LLC
Inventor： Selina X. Zhao , Xiaosong Huang
Abstract: Class-A components (CAC) include a first and second skin layer each having a polymer matrix and a fiber reinforcing material embedded within the polymer matrix, a third layer disposed between the first and second skin layers and including a third polymer matrix and a filler material interspersed within the third polymer matrix, and a Class-A finish coat applied to the second skin layer. The fiber reinforcing materials include a plurality of substantially aligned carbon fibers and a plurality of low strength regions staggered throughout the carbon fibers. The CAC can be integrated with a rigid vehicle frame. The CAC can be a structural component. The CAC can be a door, a roof panel, or a hood. The CAC can include a layer of woven fibers between the Class-A finish coat and the second skin layer and a portion of the woven fibers can be visible through the Class-A surface layer.
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