CA1083939A - Process for the manufacture of laminates - Google Patents
Process for the manufacture of laminatesInfo
- Publication number
- CA1083939A CA1083939A CA293,223A CA293223A CA1083939A CA 1083939 A CA1083939 A CA 1083939A CA 293223 A CA293223 A CA 293223A CA 1083939 A CA1083939 A CA 1083939A
- Authority
- CA
- Canada
- Prior art keywords
- ply
- resin
- plies
- base
- laminates
- 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.)
- Expired
Links
Classifications
-
- 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
- B32B38/08—Impregnating
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63C—SKATES; SKIS; ROLLER SKATES; DESIGN OR LAYOUT OF COURTS, RINKS OR THE LIKE
- A63C5/00—Skis or snowboards
- A63C5/12—Making thereof; Selection of particular materials
- A63C5/124—Selection of particular materials for the upper ski surface
-
- 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
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is 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
- 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
- B32B2305/07—Parts immersed or impregnated in a matrix
- B32B2305/076—Prepregs
-
- 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
- B32B2398/00—Unspecified macromolecular compounds
- B32B2398/10—Thermosetting resins
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Laminated Bodies (AREA)
- Reinforced Plastic Materials (AREA)
- Glass Compositions (AREA)
- Sampling And Sample Adjustment (AREA)
Abstract
Abstract of Disclosure Process for the manufacture of laminates from a synthetic resin impregnated, fiber-reinforced base ply and absorbent outer plies, in which the absorbent outer ply or plies are pressed onto the base ply, which consists of at least two fiber reinforced plies in procured form, of which plies the upper one, being in contact whith the ab-sorbent material contains 40 - 70% of the resin, the flow of said resin being between 10% and 60%, while the lower one contains 20 - 40% of the resin, the flow of said resin being between 1 and 9% measured at 5 kp/cm2 and 150°C, whereby the absorbent material is completely impregnated by the resin available from the upper ply of the base ply and all plies are joined to one another and fully cured.
The laminates are especially useful as a ski component.
The laminates are especially useful as a ski component.
Description
~03839~
Process for ~he manufacture oP laminates ~.
The present invention relates to a process ~or the manuPac~ure o laminates from a syn~hetic resin-impregna~ed base ply and one or two absorben~ outer plies~
In.our copending application Ser.No. 263.3~6, ~iled october 14, 1976~ a process or ~he manufacture o~
laminates ~or ski componen-~s, especially those or Porming ~he upper or lower outer ply, which consi~ o~ a ~iber~rein-Porced base ply ~ a thermose~tin~ synthetic resin, which ~-has been obtained by polymeriæat~on or polyaddi~ion, and at least one outer ply based on absorbent material, the plies being joined to one another unde~ pressure, and whilst curing the the~mosetting ~ynthetic resin is described and claimed in which process at least one ply o the absorbent mater~al is pressed onto the base ply, which is in a precured form, ~nd which contains 40 - 70% oP a thermo~etting synthetic resing the low o~ the said resin ~ the said base ply being between 10 % and 60 %~ measured under a pressure of 5 kp/cm2 at ~50~C~ over a period o~ 10 minutes, and the ply or plies oP
th~ absorbent materia} are completely impregnated by the resin available rom the base ply, and ~ll plies are joined to one another and Pully cured.
In the case oP thicker ~nd mul~i-ply b~se plies this leads to increasin~ losses oP resin~ since the resin i5 squeeæed out "
It has now been Pound that~ when multi-ply base p1ies are used for the manufacture oP la~inates, the losses o~ resin can be greatly redueed iP only those plies of the multi ply base material, on Y~hich the absorben~ materials rests directly, are provided with the high resin con~ent and the large resin ~low, but the plies o~ ~he base ply which ~ie underneath are not provided therewith.
The subject o~ ~he present invention is, thus, in a process ~or the manuacture o~ l~minates ~or ski components, which laminates con~ist essentially of a iber-rein~orced base ply o~ a thermosetting synthetic resin, obtained by polymeri-satlon or polyadd~tion and at least one ou~er ply based on anabsorbent material~ ~he plies being joined to one another under pressuxe while curing the resin in a combined pre~sing and curing step, the impro~ement ~hich comprises, in said combined pressing and curing step, pressing at least one ply o$ the absorbent material onto the base ply~ which base.ply c0~5ists o~ at least two ~iber reinorced plies in precured ~or~n~ o~ which plies the upper one, which lies directly under the ab~orbent ma-terial contains 40 - 70~ o~ the resin, the ~low o said resin in ~aid ply ~eing be~ween 10/~ and 60% and the lower one or ones ~ :
contai~ 20 - 40% o~ the resin, the flow o$ said resin in ~aid lower ply or plie~ being between 1% and 9%, said ~low being measured under a pressure o~ 5 kp/cm~ at 150C over a per:iod o~ 1~ minutes, ~hereby the ply or plies o the absorben~ ma-terial become completely impre~na~d by ~he res~n available ~rom the upper ply o ~he base ply, and all the plies are joined to one another and Eully cured to orm a lamina~e havin~
smooth ou~er sur~ace.
Woven fabrics, leeces or other fibrous products~ which form the outer plies o the base ply, are impregnated with the requisite amount o~ synthetic resin so that, on pressing in com-bination with the outer ply, su~ficient a~ailable resin is
Process for ~he manufacture oP laminates ~.
The present invention relates to a process ~or the manuPac~ure o laminates from a syn~hetic resin-impregna~ed base ply and one or two absorben~ outer plies~
In.our copending application Ser.No. 263.3~6, ~iled october 14, 1976~ a process or ~he manufacture o~
laminates ~or ski componen-~s, especially those or Porming ~he upper or lower outer ply, which consi~ o~ a ~iber~rein-Porced base ply ~ a thermose~tin~ synthetic resin, which ~-has been obtained by polymeriæat~on or polyaddi~ion, and at least one outer ply based on absorbent material, the plies being joined to one another unde~ pressure, and whilst curing the the~mosetting ~ynthetic resin is described and claimed in which process at least one ply o the absorbent mater~al is pressed onto the base ply, which is in a precured form, ~nd which contains 40 - 70% oP a thermo~etting synthetic resing the low o~ the said resin ~ the said base ply being between 10 % and 60 %~ measured under a pressure of 5 kp/cm2 at ~50~C~ over a period o~ 10 minutes, and the ply or plies oP
th~ absorbent materia} are completely impregnated by the resin available rom the base ply, and ~ll plies are joined to one another and Pully cured.
In the case oP thicker ~nd mul~i-ply b~se plies this leads to increasin~ losses oP resin~ since the resin i5 squeeæed out "
It has now been Pound that~ when multi-ply base p1ies are used for the manufacture oP la~inates, the losses o~ resin can be greatly redueed iP only those plies of the multi ply base material, on Y~hich the absorben~ materials rests directly, are provided with the high resin con~ent and the large resin ~low, but the plies o~ ~he base ply which ~ie underneath are not provided therewith.
The subject o~ ~he present invention is, thus, in a process ~or the manuacture o~ l~minates ~or ski components, which laminates con~ist essentially of a iber-rein~orced base ply o~ a thermosetting synthetic resin, obtained by polymeri-satlon or polyadd~tion and at least one ou~er ply based on anabsorbent material~ ~he plies being joined to one another under pressuxe while curing the resin in a combined pre~sing and curing step, the impro~ement ~hich comprises, in said combined pressing and curing step, pressing at least one ply o$ the absorbent material onto the base ply~ which base.ply c0~5ists o~ at least two ~iber reinorced plies in precured ~or~n~ o~ which plies the upper one, which lies directly under the ab~orbent ma-terial contains 40 - 70~ o~ the resin, the ~low o said resin in ~aid ply ~eing be~ween 10/~ and 60% and the lower one or ones ~ :
contai~ 20 - 40% o~ the resin, the flow o$ said resin in ~aid lower ply or plie~ being between 1% and 9%, said ~low being measured under a pressure o~ 5 kp/cm~ at 150C over a per:iod o~ 1~ minutes, ~hereby the ply or plies o the absorben~ ma-terial become completely impre~na~d by ~he res~n available ~rom the upper ply o ~he base ply, and all the plies are joined to one another and Eully cured to orm a lamina~e havin~
smooth ou~er sur~ace.
Woven fabrics, leeces or other fibrous products~ which form the outer plies o the base ply, are impregnated with the requisite amount o~ synthetic resin so that, on pressing in com-bination with the outer ply, su~ficient a~ailable resin is
- 2 -~083939 present to impregnate the outer ply completely and to form a surface film thereon. In general, 40 - 50/0 of resin suffice for this purpose. The amount used depends on the "flow" of the particular resin. This flow must be at least 10% under pressing conditions of 5 kp/cm2 at 150C, with 10 minutes duration, in order to achieve the effect according to the invention.
Pressing is c'arried out under conventional conditions for the manufacture of laminates of this type. For example, it is possible to apply a pressure of about 5 - 15 kp/cm2 at 120 - 160C. `~
The choice of the ratio of resln component to fibrous ' material in the external ply of the base ply is intended to ensure that on pressing sufficient resin is available to impreg-nate the outer ply completely and to form a perfect layer of resin on the surface. The thickness and absorbency of the outer ply as well as the fluidity of the resin are important in achieving the object of the invention. By using decorative webs of paper, fleeces or similar materials, or using colored 20 resins, any desired surface effects can be achieved. ' The individual plies of the base ply consist predomi-nantly of glass fibers but these can also be replaced entirely or p~lally by carbon fibres and can be constructed similar to woven fabrics, knitted fabrics, fleeces or the like, The outer ply consists, above all, of paper, absorbent fleeces made from cellulose, cotton or glass, and also a mixed fleece.
Thermosetting synthetic resins, obtained by polymeri-zation or polyaddition, which should be mentioned are, above all,'epoxide resins and unsaturated polyester resins, especially .. , _ .. . . _ lL083939 those which are modified with diallyl phthalate.
The thermosetting resins used can have a differen-t chemical structure which can also result in differen-t flow prop-erties of the individual plies, for example by braking -the flow of the base ply and/or assisting that of the outer ply. For example, this effect is already achieved if, with the same type of resin, different curing systems are employed, but it is, of ~ ;
course, also possible to vary the nature of the resin itself, for example by using an unsaturated polyester resin for the base ply and an epoxide resin for the outer ply, or vice versa~
The advantage of the present invention is that only one ïmpregnating process is required, even for the manufacture of thicker laminates, without an uncontrolled effusion of resin occurring during pressing. The surface of the laminate here becomes so smooth and perfect -that grinding it, in order to glue a covering film onto it, is superfluous.
Example 1:
The base ply, a unidirectional glass fiber fabric weighing 500 g/m2 as ply l, is impr~g~ated with about 35% of an epoxide resin (prepreg), the resin being formulated to give a flow of l - 3%. As ply 2, a glass fabric is impregnated with about 50% of an epoxide resin, the resin being formul~ted to give a flow of lO - 15%. The two prepregs are pressed together with an absorbent, colored a-cellulose paper, weigh-ing 80 g/m2, at about 140C and 5 kp/cm2 in such a way that the ~-cellulose paper is bonded to the ply 2 and the latter is bonded to the ply lo The laminate taken out of the press after it has cooled down again consists of an about 0.85 mm _ 4 -`
33~
, thick GRP ply and an about 0.15 mm thick outer ply.
Example 2:
A unidirectional glass fiber fabric weighing 520 g/m2 is impregnated with an epoxide resin based on the diglycidyl ether of bisphenol A and diaminodiphenylme-thane as a curing agent in such a way that a prepreg with a resin conten-t of 35% and a flow of 3% results. A second unidirectional glass fiber fabric weighing 520 g/m2 is impregnated with an epoxide ~-resin which is based on the diglycidyl ether of bisphenol A
and which is reacted with dicyandiamide as a curing agent and dimethylbenzylamine as an accelerator. The resin is formu-lated to give a content of 45/0 in the prepreg and a flow of 15%.
The two plies are now pressed together with a colored a-cellulose paper, weighing 160 g, at about 150~ and 5 kp/cm2 coritact pressure in such a way that the a-cellulose paper is pressed together with the second prepreg which is richer in resin and more fluid, and the latter is pressed together with `
the prepreg which is lower in resin and less fluid. The laminate taken out of the press consists of an about 0.8 mm thick GRP ply and a 0.2 mm thick outer ply.
, ... ...
Pressing is c'arried out under conventional conditions for the manufacture of laminates of this type. For example, it is possible to apply a pressure of about 5 - 15 kp/cm2 at 120 - 160C. `~
The choice of the ratio of resln component to fibrous ' material in the external ply of the base ply is intended to ensure that on pressing sufficient resin is available to impreg-nate the outer ply completely and to form a perfect layer of resin on the surface. The thickness and absorbency of the outer ply as well as the fluidity of the resin are important in achieving the object of the invention. By using decorative webs of paper, fleeces or similar materials, or using colored 20 resins, any desired surface effects can be achieved. ' The individual plies of the base ply consist predomi-nantly of glass fibers but these can also be replaced entirely or p~lally by carbon fibres and can be constructed similar to woven fabrics, knitted fabrics, fleeces or the like, The outer ply consists, above all, of paper, absorbent fleeces made from cellulose, cotton or glass, and also a mixed fleece.
Thermosetting synthetic resins, obtained by polymeri-zation or polyaddition, which should be mentioned are, above all,'epoxide resins and unsaturated polyester resins, especially .. , _ .. . . _ lL083939 those which are modified with diallyl phthalate.
The thermosetting resins used can have a differen-t chemical structure which can also result in differen-t flow prop-erties of the individual plies, for example by braking -the flow of the base ply and/or assisting that of the outer ply. For example, this effect is already achieved if, with the same type of resin, different curing systems are employed, but it is, of ~ ;
course, also possible to vary the nature of the resin itself, for example by using an unsaturated polyester resin for the base ply and an epoxide resin for the outer ply, or vice versa~
The advantage of the present invention is that only one ïmpregnating process is required, even for the manufacture of thicker laminates, without an uncontrolled effusion of resin occurring during pressing. The surface of the laminate here becomes so smooth and perfect -that grinding it, in order to glue a covering film onto it, is superfluous.
Example 1:
The base ply, a unidirectional glass fiber fabric weighing 500 g/m2 as ply l, is impr~g~ated with about 35% of an epoxide resin (prepreg), the resin being formulated to give a flow of l - 3%. As ply 2, a glass fabric is impregnated with about 50% of an epoxide resin, the resin being formul~ted to give a flow of lO - 15%. The two prepregs are pressed together with an absorbent, colored a-cellulose paper, weigh-ing 80 g/m2, at about 140C and 5 kp/cm2 in such a way that the ~-cellulose paper is bonded to the ply 2 and the latter is bonded to the ply lo The laminate taken out of the press after it has cooled down again consists of an about 0.85 mm _ 4 -`
33~
, thick GRP ply and an about 0.15 mm thick outer ply.
Example 2:
A unidirectional glass fiber fabric weighing 520 g/m2 is impregnated with an epoxide resin based on the diglycidyl ether of bisphenol A and diaminodiphenylme-thane as a curing agent in such a way that a prepreg with a resin conten-t of 35% and a flow of 3% results. A second unidirectional glass fiber fabric weighing 520 g/m2 is impregnated with an epoxide ~-resin which is based on the diglycidyl ether of bisphenol A
and which is reacted with dicyandiamide as a curing agent and dimethylbenzylamine as an accelerator. The resin is formu-lated to give a content of 45/0 in the prepreg and a flow of 15%.
The two plies are now pressed together with a colored a-cellulose paper, weighing 160 g, at about 150~ and 5 kp/cm2 coritact pressure in such a way that the a-cellulose paper is pressed together with the second prepreg which is richer in resin and more fluid, and the latter is pressed together with `
the prepreg which is lower in resin and less fluid. The laminate taken out of the press consists of an about 0.8 mm thick GRP ply and a 0.2 mm thick outer ply.
, ... ...
Claims (4)
1. In a process for the manufacture of laminates for ski components, which laminates consist essentially of a fiber-reinforced base ply of a thermosetting synthetic resin obtained by polymerization or polyaddition, and at least one outer ply based on an absorbent material, the plies being joined to one another under pressure while curing the resin in a combined pressing and curing step, the improvement which comprises, in said combined pressing and curing step, pressing at least one ply of the absorbent material onto the base ply, which base ply consists of at least two fiber reinforced plies in precured form, of which plies the upper one, which lies directly under the absorbent material contains 40 - 70 % of the resin, the flow of said resin in said ply being between 10% and 60% and the lower one or ones contain 20 - 40% of the resin, the flow of said resin in said lower ply or plies being between 1% and 9% said flow being measured under a pressure of 5 kp/cm2 at 150°C over a period of 10 minutes, whereby the ply or plies of the absorbent material become completely impregnated by the resin available from the upper ply of the base ply, and all the plies are joined to one another and fully cured to form a laminate having a smooth outer surface.
2. A process according to claim 1, characterized in that said process is applied to the manufacture of laminates for forming the upper or lower outer ply of a ski.
3. A process according to claim 1, characterized in that the pressure employed in joining the plies to one another is 5 - 15 kp/cm2.
4. A process according to claim 1, characterized in that one ply or some of the plies of the base ply are impreg-nated with a resin of a chemical composition which is different from that of the other plies of the base ply.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DEP2659011.4 | 1976-12-27 | ||
| DE19762659011 DE2659011A1 (en) | 1976-12-27 | 1976-12-27 | METHOD FOR MANUFACTURING LAMINATE |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1083939A true CA1083939A (en) | 1980-08-19 |
Family
ID=5996745
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA293,223A Expired CA1083939A (en) | 1976-12-27 | 1977-12-16 | Process for the manufacture of laminates |
Country Status (8)
| Country | Link |
|---|---|
| JP (1) | JPS5382873A (en) |
| CA (1) | CA1083939A (en) |
| CH (1) | CH609910A5 (en) |
| DE (1) | DE2659011A1 (en) |
| FI (1) | FI773362A (en) |
| FR (1) | FR2375038A2 (en) |
| NO (1) | NO773998L (en) |
| SE (1) | SE7714360L (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6375788B1 (en) * | 1996-07-16 | 2002-04-23 | Premark Rwp Holdings, Inc. | Method of coating melamine resin on laminating paper |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB453648A (en) * | 1935-02-14 | 1936-09-14 | George Crawford Tyce | Improvements in or relating to the manufacture of decorative fibrous sheet material and plaster board |
| GB1079835A (en) * | 1963-10-11 | 1967-08-16 | De La Rue Thomas & Co Ltd | Improvements in or relating to the printing of plastics articles |
| CH512626A (en) * | 1969-07-07 | 1971-09-15 | Ciba Geigy Ag | Process for the production of prepregs |
| BE793637A (en) * | 1972-01-14 | 1973-05-02 | Cartiere Ambrogio Binda Spa | PROCESS FOR THE CONTINUOUS MANUFACTURING OF MULTI-LAYER DECORATIVE MATERIAL |
-
1976
- 1976-12-27 DE DE19762659011 patent/DE2659011A1/en not_active Withdrawn
-
1977
- 1977-11-09 FI FI773362A patent/FI773362A/en not_active Application Discontinuation
- 1977-11-22 NO NO773998A patent/NO773998L/en unknown
- 1977-12-02 FR FR7736296A patent/FR2375038A2/en active Granted
- 1977-12-16 SE SE7714360A patent/SE7714360L/en unknown
- 1977-12-16 CA CA293,223A patent/CA1083939A/en not_active Expired
- 1977-12-27 JP JP15674177A patent/JPS5382873A/en active Pending
- 1977-12-27 CH CH1604977A patent/CH609910A5/en not_active IP Right Cessation
Also Published As
| Publication number | Publication date |
|---|---|
| FR2375038A2 (en) | 1978-07-21 |
| FR2375038B2 (en) | 1981-08-07 |
| DE2659011A1 (en) | 1978-07-06 |
| SE7714360L (en) | 1978-06-28 |
| FI773362A (en) | 1978-06-28 |
| NO773998L (en) | 1978-06-28 |
| JPS5382873A (en) | 1978-07-21 |
| CH609910A5 (en) | 1979-03-30 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |