CA2089310A1 - Method of making a pre-impregnated composite material - Google Patents
Method of making a pre-impregnated composite materialInfo
- Publication number
- CA2089310A1 CA2089310A1 CA002089310A CA2089310A CA2089310A1 CA 2089310 A1 CA2089310 A1 CA 2089310A1 CA 002089310 A CA002089310 A CA 002089310A CA 2089310 A CA2089310 A CA 2089310A CA 2089310 A1 CA2089310 A1 CA 2089310A1
- Authority
- CA
- Canada
- Prior art keywords
- resin bath
- resin
- roll
- impregnated
- dicyandiamide
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
- B29B15/10—Coating or impregnating independently of the moulding or shaping step
- B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
- B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
- B29B15/127—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex by spraying
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
- B32B19/04—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material
- B32B19/045—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
- B32B19/08—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica comprising asbestos
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
- B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only
- B32B37/203—One or more of the layers being plastic
- B32B37/206—Laminating a continuous layer between two continuous plastic layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/10—Thermosetting resins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0809—Fabrics
- B29K2105/0845—Woven fabrics
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
- B29K2309/12—Asbestos
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/021—Fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/08—Reinforcements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
- B32B2315/12—Asbestos
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2398/00—Unspecified macromolecular compounds
- B32B2398/10—Thermosetting resins
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Reinforced Plastic Materials (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
The disclosure describes a method of making a pre-impregnated composite material of asbestos fibre weaving that comprises the steps of passing a bidirectionally woven asbestos fabric in a resin bath formed between a pair of impregnating rollers to form an impregnated sheet. Both faces of the latter is covered with a film of plastic material to form a laminated sheet which is then wound onto a roller. This laminated roll is left to mature and is then refrigerated prior to being used for subsequent moulding.
The disclosure describes a method of making a pre-impregnated composite material of asbestos fibre weaving that comprises the steps of passing a bidirectionally woven asbestos fabric in a resin bath formed between a pair of impregnating rollers to form an impregnated sheet. Both faces of the latter is covered with a film of plastic material to form a laminated sheet which is then wound onto a roller. This laminated roll is left to mature and is then refrigerated prior to being used for subsequent moulding.
Description
208931~
FIELD OF THE INVENTION
The present invention pertains to a method of making a pre-impregnated composite material of asbestos fibre weaving.
! 5 BACRGROUND OF THE INVENTION
For sometime now, asbestos fibres have been used as reinforcements in various plastic resins to form a material, called "composite". Whether it be in the form of brake linings, pipes or covering panels, asbestos fibres have, in most cases, been used in the form of short fibres. With the use of mixers, the asbestos fibres have been dispersed and encapsulated using an adhesive or a resinous matrix. This technology, which is more or less known, is characterized by hazardous environmental conditions and it has therefore become necessary to evaluate a more modern technology with improved results, whether it be at the level of mechanical resistance or at the level of environmental conditions of handling.
i 20 OBJECT8 OF THE INVENTION
An object of the present invention therefore concerns the use of a composite in the shape of a pre-impregnated material which is essentially constituted of a weaving of asbestos fibres, the mechanical performances of which after moulding or shaping are clearly superior . ..
.~,..... .
,i, ,~,.~';' ' 2~89310 to the materials which are constituted of short fibres isotropically dispersed in accordance with the previous method. A pre-impregnated material, commonly known as 3 "prepreg", is constituted of an assembly of reinforcing fibres impregnated with a resinous matrix or adhesive, which is maintained in a non-polymerization state or sub-~ polymerization state prior to being moulded. The fibres 3 are in the shape of continuous strands and woven according to different geometries, such as unidirectional, biaxial or angular.
The pre-impregnated material is maintained in a maturing chamber and then is refrigerated until its use for the next stage, i.e. moulding. The orientation of the fibres in the weaving enables to obtain mechanical properties which vary in accordance with the laminating pattern, and the selection of plastic resin ensures the chemical resistance of the part.
~, . .
Therefore, the preparation of asbestos fibres in the form "prepreg" enables moulders to have access to the potential of performance of such a fibre without having to be subjected to the inconveniences of air contamination and the inherent risks of the previously known technology of mixing and moulding asbestos fibres.
Also, this new technology enables moulders to obtain a material which has improved mechanical, chemical and thermal properties.
.,~,' ' . ~
, i','..~, :'. ' ~, ' ' , 208~3~(~
The present invention therefore relates to a method of making a pre-impregnated composite material of asbestos fibre weaving which comprises the steps of passing a bidirectionally woven asbestos fabric in a resin bath formed between a pair of impregnating rollers to form an impregnated sheet, both faces of which are then covered with a film of plastic material to form a lamination which is then wound onto a roller.
10The roll of laminated fabric is matured and refrigerated until it is later used for moulding.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter.
15It should be understood, however, that this detailed description, while indicating preferred embodiments of the invention, is given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those ~
20skilled in the art. -Figure 1 is a schematic side representation of an apparatus for carrying out the method of the present invention; and .~ , .... .
:
~,,."
:
Figure 2 is a schematic front view of the apparatus shown in figure 1.
A first step in the making of an asbestos woven fabric consists in mixing chrysotile fibres of various lengths with organic or synthetic fibres. In a second step, this mixture is introduced in the form of a sandwich in a mixer and it is conveyed to the hopper of a card. The material is then carded in an apparatus having an arrangement of cylinders rotating at varying speeds. These cylinders are covered with many short brushes perpendicular to the axis of the cylinders; this operation removes impurities and brushes off unwanted fibres. The mixture is then separated into bands of various dimensions, called rovings, which are then either wound separately or together with two, three or four strands. A third step in the making of asbestos fabric is the spinning operation during which the rovings pass through a loom which transforms them by torsion into a thread which is resistant to traction. This resistance is also augmented by the addition of a further thread which may be metallic, synthetic or organic. These twisted threads, called strands, are wound and shipped to clients where they are woven. During weaving, the strands are placed on a loom where the cloth is formed by the interweaving of two types of strands: the warp which extends along the length of the cloth, and the weft which 2089~10 traverses the width of the cloth. This cloth is finally vaporized with an adhesive of phenolic resin.
Thereafter, the resin is polymerized at high temperature and the cloth is wound.
The present invention is concerned with a method of making a pre-impregnated composite material that includes such asbestos fibre fabric. Referring to figure 1, it comprises the step of passing the bidirectionally woven asbestos fabric 10 taken from roll 12 in a resin bath 14 formed between a pair of i impregnating rollers 16 and 18. The bath contains a plastic resin, such as polyester, vinylester, phenolic, etc., catalysts and other additives. The impregnated fabric 10' thus obtained is covered on both faces thereof with a plastic film 20, 22 mounted on transverse rotatable supports 21 and 23 respectively and is simultaneously wound to form a roll 24 supported on transverse support 25.
Thereafter, the roll of impregnated sheet is stored at ambient temperature for maturing, that is until the viscosity of the resin is sufficiently high to enable - it to be properly handled. It is thereafter refrigerated ~ in order to increase its shell life and until it is s1 wished to utilize it in a moulding operation. The shell life of the prepreg is about three to six months.
~' 208~310 One type of resin which can be used is a liquid unsaturated polyester of the isophtalic type which is diluted in a styrene monomer. This resin is classified among those which are thermosetting and is largely utilized in cases where corrosion resistance is required.
Another resin is a liquid vinylester which also forms part of the thermosetting resin family. This resin is obtained from an epoxy made from bisphenol A to which an elastomer is added to obtain a flexibilized vinylester resin offering excellent adhesive properties.
Another resin among thermosetting resins is an epoxide having excellent electrical properties which is also made of bisphenol A and epichlorohydrin.
Another semi-solid thermosetting resin is novalac epoxide which combines, in a molecule, the thermal stability of a phenolic resin with the reactivity and the versatility of epoxy resin. This resin offers good chemical resistance at high temperatures.
Another resin is phenolic resin which is a phenol formaldehyde copolymer in liquid form. This thermosetting resin forms part of the resol family which has a ratio of formol-to-phenol higher than one. This resin has high fire resistance and low smoke emission properties.
~" ` 2089310 , The resin bath may also include catalysts.
.
Perkadox 16 (trade name) may be used; it i5 a solid catalyst in powder form of the peroxide family. It is used as a curing agent for unsaturated polyester ~ 5 resins and vinylester resins.
¦ Another catalyst is DEH 40, which i5 a f commercial name for a solid hardener in powder form and which is used during moulding operations at high temperature using epoxy resins (DEH 40 is a dicyandiamide accelerated with 2-methylimidazole).
Another catalyst is BF3MEA which is a solid hardener in the shape of flakes which is used for moulding at high temperature using epoxy resin~. Its chemical denomination is boron trifluoride monomethyl amine.
f Certain phenolic resins have a catalytic system which is very particular, in that they do not necessitate a catalyst to polymerize during moulding at high temperature. This is due to their ratio of formol-to-phenol being higher than one.
The resin bath used with the present invention may also contain solvents, such as Dowanol PM which is a commercial name given to propylene glycol monomethyl . ~
208~310 ether; it is used as a solvent for dissolving the catalyst DEH 40. Also used as a solvent, is dimethylformamide which is used to dissolve DEH 40.
The resin bath may also contain additives such as Aerosil (trade name), MgO, MgOH, CaO, Ca OH, talc and hollow glass balls. Aerosil is a powder of fine particles of silicium dioxide; it is a thixotropic agent which prevents drainage of the resin on a vertical wall.
Magnesium oxide, such as Maglite D (trade name), is highly reactive; it is a thickening agent used to increase the viscosity of the resin at ambient temperature. Talc is an inert material, in powder form, forming part of the family of silicates; it has high chemical resistance and is used to thicken the resin and reduce the cost of materials. Finally, hollow glass balls are used as reinforcing elements, mainly to reduce the density of the molded parts.
Referring to figures 1 and 2, once the resin is mixed, it is fed from a container 29 to a distribution system that includes pipe lines 26 and 28 connected to a pair of parallel conduit systems 30 and 32 equipped with a series of nozzles 34, 36.
Although the invention has been described above with respect with one specific form, it will be evident to a person skilled in the art that it may be modified ~: . : , , -2~9310 _ 9 _ and refined in various ways. It is therefore wished to ~ , have it understood that the present invention should not be limited in scope, except by the terms of the following claims.
FIELD OF THE INVENTION
The present invention pertains to a method of making a pre-impregnated composite material of asbestos fibre weaving.
! 5 BACRGROUND OF THE INVENTION
For sometime now, asbestos fibres have been used as reinforcements in various plastic resins to form a material, called "composite". Whether it be in the form of brake linings, pipes or covering panels, asbestos fibres have, in most cases, been used in the form of short fibres. With the use of mixers, the asbestos fibres have been dispersed and encapsulated using an adhesive or a resinous matrix. This technology, which is more or less known, is characterized by hazardous environmental conditions and it has therefore become necessary to evaluate a more modern technology with improved results, whether it be at the level of mechanical resistance or at the level of environmental conditions of handling.
i 20 OBJECT8 OF THE INVENTION
An object of the present invention therefore concerns the use of a composite in the shape of a pre-impregnated material which is essentially constituted of a weaving of asbestos fibres, the mechanical performances of which after moulding or shaping are clearly superior . ..
.~,..... .
,i, ,~,.~';' ' 2~89310 to the materials which are constituted of short fibres isotropically dispersed in accordance with the previous method. A pre-impregnated material, commonly known as 3 "prepreg", is constituted of an assembly of reinforcing fibres impregnated with a resinous matrix or adhesive, which is maintained in a non-polymerization state or sub-~ polymerization state prior to being moulded. The fibres 3 are in the shape of continuous strands and woven according to different geometries, such as unidirectional, biaxial or angular.
The pre-impregnated material is maintained in a maturing chamber and then is refrigerated until its use for the next stage, i.e. moulding. The orientation of the fibres in the weaving enables to obtain mechanical properties which vary in accordance with the laminating pattern, and the selection of plastic resin ensures the chemical resistance of the part.
~, . .
Therefore, the preparation of asbestos fibres in the form "prepreg" enables moulders to have access to the potential of performance of such a fibre without having to be subjected to the inconveniences of air contamination and the inherent risks of the previously known technology of mixing and moulding asbestos fibres.
Also, this new technology enables moulders to obtain a material which has improved mechanical, chemical and thermal properties.
.,~,' ' . ~
, i','..~, :'. ' ~, ' ' , 208~3~(~
The present invention therefore relates to a method of making a pre-impregnated composite material of asbestos fibre weaving which comprises the steps of passing a bidirectionally woven asbestos fabric in a resin bath formed between a pair of impregnating rollers to form an impregnated sheet, both faces of which are then covered with a film of plastic material to form a lamination which is then wound onto a roller.
10The roll of laminated fabric is matured and refrigerated until it is later used for moulding.
Other objects and further scope of applicability of the present invention will become apparent from the detailed description given hereinafter.
15It should be understood, however, that this detailed description, while indicating preferred embodiments of the invention, is given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those ~
20skilled in the art. -Figure 1 is a schematic side representation of an apparatus for carrying out the method of the present invention; and .~ , .... .
:
~,,."
:
Figure 2 is a schematic front view of the apparatus shown in figure 1.
A first step in the making of an asbestos woven fabric consists in mixing chrysotile fibres of various lengths with organic or synthetic fibres. In a second step, this mixture is introduced in the form of a sandwich in a mixer and it is conveyed to the hopper of a card. The material is then carded in an apparatus having an arrangement of cylinders rotating at varying speeds. These cylinders are covered with many short brushes perpendicular to the axis of the cylinders; this operation removes impurities and brushes off unwanted fibres. The mixture is then separated into bands of various dimensions, called rovings, which are then either wound separately or together with two, three or four strands. A third step in the making of asbestos fabric is the spinning operation during which the rovings pass through a loom which transforms them by torsion into a thread which is resistant to traction. This resistance is also augmented by the addition of a further thread which may be metallic, synthetic or organic. These twisted threads, called strands, are wound and shipped to clients where they are woven. During weaving, the strands are placed on a loom where the cloth is formed by the interweaving of two types of strands: the warp which extends along the length of the cloth, and the weft which 2089~10 traverses the width of the cloth. This cloth is finally vaporized with an adhesive of phenolic resin.
Thereafter, the resin is polymerized at high temperature and the cloth is wound.
The present invention is concerned with a method of making a pre-impregnated composite material that includes such asbestos fibre fabric. Referring to figure 1, it comprises the step of passing the bidirectionally woven asbestos fabric 10 taken from roll 12 in a resin bath 14 formed between a pair of i impregnating rollers 16 and 18. The bath contains a plastic resin, such as polyester, vinylester, phenolic, etc., catalysts and other additives. The impregnated fabric 10' thus obtained is covered on both faces thereof with a plastic film 20, 22 mounted on transverse rotatable supports 21 and 23 respectively and is simultaneously wound to form a roll 24 supported on transverse support 25.
Thereafter, the roll of impregnated sheet is stored at ambient temperature for maturing, that is until the viscosity of the resin is sufficiently high to enable - it to be properly handled. It is thereafter refrigerated ~ in order to increase its shell life and until it is s1 wished to utilize it in a moulding operation. The shell life of the prepreg is about three to six months.
~' 208~310 One type of resin which can be used is a liquid unsaturated polyester of the isophtalic type which is diluted in a styrene monomer. This resin is classified among those which are thermosetting and is largely utilized in cases where corrosion resistance is required.
Another resin is a liquid vinylester which also forms part of the thermosetting resin family. This resin is obtained from an epoxy made from bisphenol A to which an elastomer is added to obtain a flexibilized vinylester resin offering excellent adhesive properties.
Another resin among thermosetting resins is an epoxide having excellent electrical properties which is also made of bisphenol A and epichlorohydrin.
Another semi-solid thermosetting resin is novalac epoxide which combines, in a molecule, the thermal stability of a phenolic resin with the reactivity and the versatility of epoxy resin. This resin offers good chemical resistance at high temperatures.
Another resin is phenolic resin which is a phenol formaldehyde copolymer in liquid form. This thermosetting resin forms part of the resol family which has a ratio of formol-to-phenol higher than one. This resin has high fire resistance and low smoke emission properties.
~" ` 2089310 , The resin bath may also include catalysts.
.
Perkadox 16 (trade name) may be used; it i5 a solid catalyst in powder form of the peroxide family. It is used as a curing agent for unsaturated polyester ~ 5 resins and vinylester resins.
¦ Another catalyst is DEH 40, which i5 a f commercial name for a solid hardener in powder form and which is used during moulding operations at high temperature using epoxy resins (DEH 40 is a dicyandiamide accelerated with 2-methylimidazole).
Another catalyst is BF3MEA which is a solid hardener in the shape of flakes which is used for moulding at high temperature using epoxy resin~. Its chemical denomination is boron trifluoride monomethyl amine.
f Certain phenolic resins have a catalytic system which is very particular, in that they do not necessitate a catalyst to polymerize during moulding at high temperature. This is due to their ratio of formol-to-phenol being higher than one.
The resin bath used with the present invention may also contain solvents, such as Dowanol PM which is a commercial name given to propylene glycol monomethyl . ~
208~310 ether; it is used as a solvent for dissolving the catalyst DEH 40. Also used as a solvent, is dimethylformamide which is used to dissolve DEH 40.
The resin bath may also contain additives such as Aerosil (trade name), MgO, MgOH, CaO, Ca OH, talc and hollow glass balls. Aerosil is a powder of fine particles of silicium dioxide; it is a thixotropic agent which prevents drainage of the resin on a vertical wall.
Magnesium oxide, such as Maglite D (trade name), is highly reactive; it is a thickening agent used to increase the viscosity of the resin at ambient temperature. Talc is an inert material, in powder form, forming part of the family of silicates; it has high chemical resistance and is used to thicken the resin and reduce the cost of materials. Finally, hollow glass balls are used as reinforcing elements, mainly to reduce the density of the molded parts.
Referring to figures 1 and 2, once the resin is mixed, it is fed from a container 29 to a distribution system that includes pipe lines 26 and 28 connected to a pair of parallel conduit systems 30 and 32 equipped with a series of nozzles 34, 36.
Although the invention has been described above with respect with one specific form, it will be evident to a person skilled in the art that it may be modified ~: . : , , -2~9310 _ 9 _ and refined in various ways. It is therefore wished to ~ , have it understood that the present invention should not be limited in scope, except by the terms of the following claims.
Claims (19)
1. A method of making a pre-impregnated composite material of asbestos fibre weaving comprising the steps of:
passing a bidirectionally woven asbestos fabric in a resin bath formed between a pair of impregnating rollers to form an impregnated sheet;
covering both faces of said impregnated sheet with a film of plastic material to form a three layer laminated sheet; and winding said laminated sheet to form a roll.
passing a bidirectionally woven asbestos fabric in a resin bath formed between a pair of impregnating rollers to form an impregnated sheet;
covering both faces of said impregnated sheet with a film of plastic material to form a three layer laminated sheet; and winding said laminated sheet to form a roll.
2. A method as defined in claim 1, wherein said covering and said winding steps are carried out simultaneously.
3. A method as defined in claim 1 or claim 2, further comprising the step of maturing the wound laminated sheet at ambient temperature until the resin has a given viscosity for proper handling.
4. A method as defined in claim 3, further comprising wrapping said roll in aluminized paper and sealing the wrapped roll in a plastic container.
5. A method as defined in claim 4, wherein said plastic container is stored horizontally.
6. A method as defined in claim 4 or claim 5, further comprising the step of refrigerating said roll.
7. A method as defined in claim 6, wherein said refrigerating step lasts from about three to six months.
8. A method as defined in claim 1, wherein said resin bath contains a liquid unsaturated polyester.
9. A method as defined in claim 1, wherein said resin bath contains a liquid vinyl ester.
10. A method as defined in claim 1, wherein said resin bath contains a liquid thermosetting epoxy made from bisphenol A.
11. A method as defined in claim 1, wherein said resin bath contains a liquid phenol formaldehyde copolymer.
12. A method as defined in claim 1, wherein said resin bath contains semi-solid thermosetting epoxy novalak.
13. A method as defined in claim 8 or 9, wherein said resin bath further contains a solid catalyst.
14. A method as defined in claim 13, wherein said catalyst is a peroxide.
15. A method as defined in claim 10 or claim 12, wherein said resin bath further contains a solid catalyst consisting of a dicyandiamide.
16. A method as defined in claim 10 or claim 12, wherein said resin bath further contains a solid catalyst consisting of boron trifluoride monomethyl amine.
17. A method as defined in claim 15, wherein said resin bath further contains a solvent to dissolve said dicyandiamide.
18. A method as defined in claim 15, wherein said resin bath further contains a solvent consisting of dimethylformamide to dissolve said dicyandiamide.
19. A method as defined in claim 1, wherein said resin bath contains an additive taken from the group including aerosil, magnesium oxide, talc and hollow glass balls.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002089310A CA2089310A1 (en) | 1993-02-11 | 1993-02-11 | Method of making a pre-impregnated composite material |
| AU59671/94A AU5967194A (en) | 1993-02-11 | 1994-01-31 | Method of making a pre-impregnated composite material |
| PCT/CA1994/000045 WO1994017999A1 (en) | 1993-02-11 | 1994-01-31 | Method of making a pre-impregnated composite material |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002089310A CA2089310A1 (en) | 1993-02-11 | 1993-02-11 | Method of making a pre-impregnated composite material |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2089310A1 true CA2089310A1 (en) | 1994-08-12 |
Family
ID=4151141
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002089310A Abandoned CA2089310A1 (en) | 1993-02-11 | 1993-02-11 | Method of making a pre-impregnated composite material |
Country Status (3)
| Country | Link |
|---|---|
| AU (1) | AU5967194A (en) |
| CA (1) | CA2089310A1 (en) |
| WO (1) | WO1994017999A1 (en) |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2727028B1 (en) * | 1994-11-21 | 1997-01-24 | Salomon Sa | METHOD FOR MANUFACTURING A GLUE SKI COMPRISING A WET REINFORCEMENT REINFORCEMENT STAGE |
| HU9800200D0 (en) * | 1998-02-03 | 1998-03-30 | Kecskemethy | Method for producing of thermosetting resin prepreg system |
| MXPA03002155A (en) * | 2000-09-13 | 2004-12-13 | David Fuel Cell Components S L | Method for manufacturing composite materials. |
| SE522503C2 (en) | 2002-06-24 | 2004-02-10 | Tetra Laval Holdings & Finance | Method and apparatus for manufacturing a web-shaped packaging laminate |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1402733A (en) * | 1972-11-14 | 1975-08-13 | Nitto Boseki Co Ltd | Process for producing shaped articles of fibre reinforced plastics |
| NL7404517A (en) * | 1973-04-09 | 1974-10-11 | ||
| US4207282A (en) * | 1978-06-01 | 1980-06-10 | Armco Inc. | Method for molding reinforced polymeric articles |
| JPS5698136A (en) * | 1980-01-08 | 1981-08-07 | Kanegafuchi Chem Ind Co Ltd | Continuous manufacture of laminated substance |
| AT395432B (en) * | 1990-06-13 | 1992-12-28 | Isovolta | MAT IMPREGNATED WITH PLASTIC AND METHOD FOR THE PRODUCTION THEREOF AND THEIR USE |
-
1993
- 1993-02-11 CA CA002089310A patent/CA2089310A1/en not_active Abandoned
-
1994
- 1994-01-31 AU AU59671/94A patent/AU5967194A/en not_active Abandoned
- 1994-01-31 WO PCT/CA1994/000045 patent/WO1994017999A1/en active Application Filing
Also Published As
| Publication number | Publication date |
|---|---|
| AU5967194A (en) | 1994-08-29 |
| WO1994017999A1 (en) | 1994-08-18 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |