CN100584878C - Gel coated reinforced composite - Google Patents
Gel coated reinforced composite Download PDFInfo
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- CN100584878C CN100584878C CN200580016348A CN200580016348A CN100584878C CN 100584878 C CN100584878 C CN 100584878C CN 200580016348 A CN200580016348 A CN 200580016348A CN 200580016348 A CN200580016348 A CN 200580016348A CN 100584878 C CN100584878 C CN 100584878C
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- Prior art keywords
- matrix
- gel coat
- substrate tablet
- fiber
- moulding
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- 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
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
- B29C37/0028—In-mould coating, e.g. by introducing the coating material into the mould after forming the article
- B29C37/0032—In-mould coating, e.g. by introducing the coating material into the mould after forming the article the coating being applied upon the mould surface before introducing the moulding compound, e.g. applying a gelcoat
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- 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
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/10—Interconnection of layers at least one layer having inter-reactive properties
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- 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
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- 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
- B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
- B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
- B29C37/0028—In-mould coating, e.g. by introducing the coating material into the mould after forming the article
- B29C2037/0042—In-mould coating, e.g. by introducing the coating material into the mould after forming the article the coating being applied in solid sheet form, e.g. as meltable sheet
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- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
A method of forming a gel coated article, the method comprises thermoforming a reinforced thermoplastic substrate sheet into a desired shape wherein the resulting desired shape having a residual void content at least at the surface thereof. The desired shape is molded together with a gel coating material to form a adherent bond between said gel coating material and the desired shape wherein said gel coating material permeates into the desired shape and is cured to form a mechanical bond therewith.
Description
Background technology
Comprising matrix makes common preference use aathermoset resin system as matrix with the market economy factor of beautifying composite structure of beautifying (aesthetic) upper layer.Lower starting material and tooling cost are the factors that thermosetting material is selected in the support of often use.But, use thermosetting material can produce volatile organic compounds (VOC) discharging, and produce the long cycle usually.
For example, the method of making a kind of frequent use of structural aesthetic parts comprises the method in a kind of two steps, wherein use the traditional hot forming method to form thermoplastic surface's layer, thermosetting material is injection molding or is injected in this upper layer back and in-situ solidifying has the bilayer structure that strengthens lower floor and thermoplastic surface's layer with generation.A lot of thermoset systems and method are used to produce described enhancing lower floor.These comprise, for example, erupt glass filament reinforced plastics (FRP), resin transfer moulding, vacuum injection and various enhancing froth in situ technology.
The United States Patent (USP) 4356230 of authorizing people such as Emanuel has been described a kind of in molded operating period with coating is transferred to the method for matrix at the setting up period of moulding part from die surface.Authorize the United States Patent (USP) 4742121 of Toman and described gel coat formulations, it applies by spraying usually.
Ideally, be the matrix material that a kind of plural gel of preparation applies, it has rigidity and low CTE that a lot of structure applications need.Ideally, be to make the goods that adhesive gel applies by the method that produces low VOC discharging with short period.Other ideal quality is that the gel coat as aesthetic layer has great surface quality, excellent mechanical adhesion and wrinkling and component defect reaches minimum degree.
Summary of the invention
An embodiment that forms the method for gel-coated article comprises the shape that the enhanced thermoplastic substrate sheet is thermoformed into expectation.In one embodiment, described shape has the initial vesicular structure that extends internally from surface area.It is desirable to, described goods obtained vesicular structure at least before the cured thermoset gel coat material is with the mechanical bond that realizes gel coat and goods.It is desirable to described vesicular structure is enough to allow described gel coat material to penetrate into surf zone at least.The shape of described expectation is molded with the adhesive bond between the shape that forms described gel coat material and described expectation with described gel coat material.Described gel coat material penetrate into the shape of described expectation and solidify with its formation mechanical bond.According to an embodiment, fibre-reinforced material can be the light fibre reinforced plastic material that porosity is enough to allow to apply by this forming matrix vacuum.According to another embodiment, fiber reinforced material can be the densification material, can have low porous surface structure when it begins or not have the porous surface structure, but will obtain the porous surface structure in formation or molding process.Typically, this type of porous surface structure or surfaceness can obtain by the setting-out (lofting) that is included in the fiber in the substrate material.The matrix of described moulding and contiguous gel coat material are molded together to form the adhesive bond between gel coat material and the forming matrix.According to an embodiment, described enhancing thermoplastic substrate sheet has the porosity that is enough to allow to apply by it vacuum.According to an embodiment, using gas pressure reduction forms described forming matrix.
Another embodiment that forms the method for layered article comprises the temperature of heating substrate tablet to the fiber setting-out that is enough to allow substrate tablet; Substrate tablet is placed on the auxiliary pressure cell of film; Described substrate tablet is shifted onto on the mould to form forming matrix; Contiguous forming matrix is placed gel coat material and molded described gel coat material and forming matrix to form adhesive bond.Another embodiment comprises uses matching tool to be used for moulding.
From following detailed, accompanying drawing and claim, those skilled in the art will be familiar with and understand above-mentioned and other feature.
The accompanying drawing summary
Referring now to accompanying drawing,, they are exemplary embodiments, and wherein identical key element is used identical numbering.
Fig. 1 is the sectional view of the plastic reinforced article of exemplary gel coating.
Fig. 2 is the side cross-sectional view with matching tool of exemplary matrix that will thermoforming.
Fig. 2 A, right-hand component is the side cross-sectional view with film assisted vacuum/press device of exemplary matrix that will thermoforming.
Fig. 3 is the molding-system with the gel coat material that is used to be molded into forming matrix.
Detailed Description Of The Invention
Disclosed by the invention is the method that is used to prepare the layered article of gel coating, and described goods have the matrix that has perforate (open-celled) structure.Be noted that as used herein term " perforate " has its common connotation, set up the fluid connection from a surface to the apparent surface thereby describe to be communicated with the adjacent bores fluid.Term " thermoforming " and various derivative form thereof have their common connotations, the method that is generally used for describing the heating sheet material in this article and is shaped to ideal form.Thermoforming process and instrument are at DuBois and Pribble " Plastics MoldEngineering Handbook ", and the 15th edition, 1995, the 468-498 pages or leaves have a detailed description.
Term " layer " is to be used for herein for convenience, comprises having erose material and sheet material and film.Should further be pointed out that, term " first ", " second " or the like are not represented any order, quantity or importance in this article, but be used for a key element and another key element are made a distinction, and term " " and " a kind of " do not represent the logarithm quantitative limitation in this article, but there is at least one its described object in expression.In addition, all scopes disclosed herein all be comprise end points and be that combinative (" the highest about 25 weight % (wt%); it is desirable to the about 20wt% of about 5wt%-; that better is the about 15wt% of about 10wt%-, " this scope for example just comprises all intermediate values of end points and this scope, for example, " the about 25wt% of about 5wt%-, the about 15wt% of about 5wt%-, " or the like.)。
Method disclosed herein is particularly useful for preparing and comprises the goods that are positioned over the gel coat material on the fibre-reinforced thermoformable matrix with perforate.
Described substrate material comprises thermoplastic material.Exemplary thermoplastic material comprises polypropylene, polycarbonate (PC), polyester, polyetherimide (PEI), poly (arylene ether) or the like, and the combination that comprises at least a aforementioned thermoplastic material, for example PC/PET blend.Can use linearity or branched aromatic polycarbonate.In one embodiment, can use the unitary polycarbonate that comprises derived from one or more following materials: 2,2-two (4-hydroxy phenyl) propane (" dihydroxyphenyl propane "), two (2-hydroxy phenyl) methane, 1,1-two (4-hydroxy phenyl)-3,3, the 5-trimethyl-cyclohexane, the Fluorenone bis-phenol, 1,1-two (4-hydroxy phenyl) ethane, 2, the 6-dihydroxy naphthlene, two (3,5-diethyl-4-hydroxy phenyl) sulfone, 2,2-two (3,5-two bromo-4-hydroxy phenyls) propane, 4,4 '-dihydroxydiphenyl ether, spirobindene bis-phenol (spiro biindane bisphenol) or the like.Suitable thermoplastic polyester comprises, for example, poly-(dicarboxylic acid alkylidene group diester), for example poly-(ethylene glycol terephthalate) (PET), poly terephthalic acid 1,4-fourth diester) (PBT), poly-(trimethylene diester) (PTT), poly-(naphthalic acid second diester) (PEN), poly-(naphthalic acid fourth diester) (PBN), poly-(terephthalic acid cyclohexanedimethanoester ester), poly-(terephthalic acid cyclohexanedimethanoester ester-altogether-ethylene glycol terephthalate) (PETA) and poly-(1,4-cyclohexane dicarboxylic acid 1,4 cyclohexane dimethanol ester) (PCCD); Poly-(aromatic hydrocarbons dicarboxylic acid alkylidene group diester); With the combination that contains at least a aforementioned polyester.
In an exemplary, gel coat 10 comprises painted promoted in advance (prepromoted) resin, and it is sprayable typically.With for example cinnamic mixture of unsaturated aromatic monomer in use unsaturated polyester can be used to make the cross-linked polymer that superoxide causes.Unsaturated polyester can be from the condensation prepared of unsaturated acid or acid anhydrides and polyvalent alcohol.Employed modal unsaturated acid is maleic anhydride or fumaric acid.For improved hydrolytic resistance, can use the vinyl ester that forms from the reaction of aromatic series polyepoxide and unsaturated monocarboxylic acid.Be described in other system in the United States Patent (USP) 4742121 of authorizing Toman, comprise urethane polyesters with various side chain degrees of unsaturation, isocyanate-functional the acrylic acid or the like system, have the graft copolymerization objects system of acrylic backbone and Synolac chain and based on the vinyl ester of aromatic series poly-epoxide resin.Described patent has been described has a plurality of acrylate resins that are connected to the C-C degree of unsaturation on the polymer chain.The description of the gel coat resins that provides in the 1-10 hurdle of United States Patent (USP) 4742121 is incorporated herein by reference.Other gel coat systems can be based on epoxy polymer.
The plastic material of matrix comprises enough binding abilities so that enough structural integrities to be provided to matrix, so that it can thermoforming.For example, thus described matrix can comprise fiber and the described matrix of thermoplastic material can be placed in the thermoforming system and be thermoformed.In another exemplary, described matrix can comprise fiber, thermosetting material and reagent, and wherein said reagent makes the structure of matrix keep the form (for example sheet material) of expectation thereby described matrix can be placed in the thermoforming system and be thermoformed.
Thereby the fiber that is used for matrix is selected to form fibre-reinforced plastics, and optional formation has the fiber reinforced plastic materials of perforate.Fiber type, size, quantity or the like can change with the plastic material that is used to prepare matrix.In exemplary, described fiber is selected to give matrix desired volume of voids.For mould replicability (mold replication) that obtains expecting and the volume of voids of expecting, described fiber can setting-out (lofting) (for example can expand in the z-direction when heating).Exemplary fiber types comprises, but be limited to, glass fibre (for example, E-glass (" electrical glass ", borosilicate glass for example), S-glass (" structural glass ", for example magnesium oxide/aluminum oxide/silicate glass), or the like), inorganic fibre (mineral fibers), polymer fiber, natural fiber or the like, and the combination that comprises at least a aforementioned fibers.Randomly, described Fibre diameter (width) can be about 6 microns-Yue 25 microns.Randomly, staple length can be about 2 millimeters (mm)-Yue 75mm.
The described fibre-reinforced plastic material of described matrix comprises the plastic material of sufficient amount and fiber so that desired structural integrity and volume of voids to be provided to matrix.For example, described fibre-reinforced plastics substrate can contain the plastic material of 25 weight % (the wt%)-Yue 75wt% that have an appointment, particularly can use the about 65wt% of about 35wt%-, more especially can use the plastic material of the about 60wt% of about 40wt%-.With the plastic material while, can use about 25wt%-75wt% fiber, the about 65wt% of particularly about 35wt%-, the about 60wt% fiber of more especially about 40wt%-.Described weight percentage is based on the gross weight of fibre reinforced plastics matrix.
The example of suitable commercially available substrate material includes, but not limited to
With
Glass Mat Thermoplastics (GMT), it can be from AZDEL, Inc., Shelby, NC obtains, and has various matrixes, includes but not limited to, and polypropylene, polycarbonate are (for example, from General Electric Company's
), polyester is (for example, from General Electric Company's
), polyetherimide (General Electric Company for example
), poly (arylene ether) (polyphenylene ether for example; From General Electric Company's
Resin), polystyrene, polymeric amide and/or contain the combination of at least a aforementioned substrates.
For example, described matrix can be made (for example, as United States Patent (USP) 3938782 according to Wiggins Teape method; 3947315; 4166090; 4257754; With 5215627 in discussed like that).For example, for according to Wiggins Teape method or similar approach preparation pad (mat), fiber, thermoplastic material and any additives are measured and disperse into to be equipped with in the mixing tank of impeller to form mixture.Described mixture is pumped into head box (head-box) by distributing manifold.Described head box is positioned on the mesh screen part (wire section) of machine of papermaking type.Use vacuum, the screen cloth of dispersed mixture by moving produces fibrous wet network uniformly.Described wet network by moisture eliminator to reduce moisture content, if use thermoplastics to make described molten thermoplastic material so.Also non-woven lax fabric layer (non-wovenscrim layer) can be connected to the one or both sides of described network, with the easy processing that increases described matrix (for example, so that the structural integrity with thermosetting material to be provided to matrix).Described matrix can and be cut into (cutting) desired size by tensioning roller then.
The method according to this invention, described matrix is thermoformed into the shape of the shape that corresponds essentially to desired end article.Generally speaking, thermoforming comprises sequentially or side by side heats and formed material that wherein said material is initiated with sheet-form and is formed as the shape of expectation on mould.In case the shape that obtains expecting, the goods of moulding just are cooled to its solidification value or below the second-order transition temperature.Generally speaking, can use any thermoforming process, as long as described method can be made forming matrix, the porosity of wherein said forming matrix is enough to make vacuum to produce traction action by this matrix, and for example porosity is more than or equal to about 5 volume %.For example, suitable thermoforming process includes, but not limited to mechanical-moulded (for example matching tool moulding), the auxiliary pressure/vacuum forming of film, has auxiliary pressure/vacuum forming of film that helps plug or the like.
In the matching tool forming method of the described matrix of moulding, heat the sufficiently long time of matrix so that described matrix reaches softening temperature (it also can be called mold temperature) in enough temperature, thereby described matrix can be by the shape of Physical Processing (being machine-shaping) for expectation.Be noted that described matrix can heat in every way, for example in radiant heat moulding baking oven (it can comprise top and/or end well heater).Described matrix is placed between male mould forming instrument and the female mould forming instrument then.Being enough to matrix-forming is that desired shape also keeps porosity under the effect of the pressure of aforementioned range simultaneously, with the female mould forming instrument physics takes place mutually by the described formpiston of block (placing the periphery of U.S.'s instrument) and contacts.Suitable pressure will depend on concrete substrate composition, and those skilled in the art just can easily determine without the over-drastic experiment.But, should be noted that and avoid the pressure that overuses, thereby, cause the porosity deficiency of matrix because this may make some or all bore closures of matrix make porosity be lower than expected value.
With reference now to Fig. 2,, it provides the sectional view of the instrument moulding of coupling.Usually use anchor clamps that the substrate tablet 50 of heating is remained in position with respect to male mould forming instrument 52 and female mould forming instrument 54.It should be noted that described male mould forming instrument and described female mould forming tool configuration are mutual " coupling ", promptly complement each other.Described male mould forming instrument and female mould forming instrument can be chosen wantonly and contain a plurality of holes respectively.Block (pad) is arranged in the periphery of male mould forming instrument and female mould forming instrument, is used for determining the thickness of forming matrix.Described block is positioned at the forming area outside.Male tool and former instrument are made of the material compatible with substrate material.For example, described instrument can be made of the material that is not limited to following material: the tooling resin of aluminium, steel, Resins, epoxy, silicon rubber, filling, or the like.
In moulding process, described matrix is heated to be enough to allow thermoforming and be heated to the temperature that is enough to allow the fiber setting-out in the matrix ideally.For example, the temperature of about 450 (about 232 ℃)-Yue 700 (about 371 ℃), more especially, the temperature of about 550 (about 288 ℃)-Yue 650 (about 343 ℃) is suitable for thermoforming glass fibre enhanced polycarbonate substrates sheet.Thereby touch the matrix that block comes the moulding heating by between male tool and former instrument, producing relative movement then.Male tool and former instrument (substrate tablet is arranged between them) are put together cause described substrate tablet generation and the formpiston shape the same with the former instrument.Can cool off described matrix then to form forming matrix.Use about 5 normal atmosphere (about 101kPa)-Yue 10 normal atmosphere (about 1013kPa), the pressure of about more especially 1 normal atmosphere (about 101kPa)-Yue 5 normal atmosphere (507kPa) comes moulding
Matrix.
In the auxiliary vacuum/pressurized forming method of film, the matrix of heating is placed facing to pressure cell 58.Apply vacuum and pressure simultaneously to matrix.More specifically, vacuum is by the shaping jig tractive, positive pressure be applied to film 56 near the relative side of that side of shaping jig.The direction of vacuum and pressure schematically shows by arrow in Fig. 3.By the vacuum that mould applies the sheet material tractive is advanced/to (being called later on) mould.Suitable pressure (positive and negative) will depend on concrete matrix, and those skilled in the art just can easily determine without undo experimentation.In addition, as mentioned above, avoid over-drastic pressure,, cause the porosity deficiency of matrix because it may close some or all holes.
Fig. 3 schematically shows the auxiliary vacuum/pressurized thermoforming process of a kind of film.The matrix 24 of heating is placed between pressure cell 22 and the shaping jig 20.Described shaping jig is shown as the male mould forming instrument, but shaping jig can be male mould forming instrument or female mould forming instrument.Shaping jig comprises the hole, thereby can apply vacuum by shaping jig.Can use anchor clamps so that matrix phase is remained in position for pressure cell and shaping jig.A kind of film, more specifically, a kind of impermeable membrane 26 is deployed in above the opening of pressure cell.As discussed above, the first surface of described matrix contacts with shaping jig generation physics by vacuum (by the shaping jig tractive), and second surface contacts with film generation physics.Apply pressure on the film from the film side.Because matrix is the fibre-reinforced thermoplastic material with perforate of porosity more than or equal to about 5 volume % as previously mentioned, so vacuum directly produces traction action by matrix.So, described film is used to shift matrix onto on the shaping jig (that is, vacuum is by matrix generation traction action, with film and therefore with substrate toward tool, because push film to instrument from the malleation of pressure cell).In other words, vacuum can not see through described film tractive.More definite says, vacuum is towards shaping jig tractive film, and the pressure that is applied to film is pushed film to shaping jig.In case described matrix reaches on the shaping jig, just it is cooled off with the described forming matrix of moulding.
For example, if
Be matrix, can apply about 0.5 normal atmosphere-Yue 8 atmospheric pressure matrix is pushed to shaping jig 20 to film, traction action takes place by shaping jig 30 in vacuum simultaneously.More specifically, can apply the pressure of about 1 normal atmosphere (about 101kPa)-Yue 3 normal atmosphere (about 304kPa) to described film.
Provide above-mentioned thermoforming process just to be used for illustration purpose.It should be understood that described matrix can be by any thermoforming process moulding, the molded matrix that wherein obtains has the porosity that can apply vacuum by matrix.
After the described matrix of thermoforming prepared forming matrix, described forming matrix can be chosen wantonly and rebuild to reach the net shape of desired goods substantially.Described trimming can be carried out before being positioned over gel coat on the forming matrix follow-up.Described repair method can comprise that for example, the laser trimming is sprayed water and rebuild, trim press trimming or the like, and the combination that comprises at least a preceding method.
Enhancing resin material to described thermoforming carries out molded to form the structure combination between described strongthener and described gel coat.Preferably, penetrate into the open-celled structure that strengthens resin material by gel coating and form the adhesive bond that strengthens between resin and the gel coat, thereby form the integral layer stampings.The laminated product of described thermoforming is trimmed into the thick shape of end article at least.This shape through trimming is alignd with mould or is placed in the cavity of mould then.Uncured or slight solidified gel coat material is introduced into or guides to the other parts of mould cavity.When gel coat material flows to described enhancing resin material, close described mould, solidify described gel coat material to combine with described enhancing resin material.Be to keep A level surface ideally so that glass read through and other surface imperfection minimize.The interface comprises gel coat material and strengthens resin material.Open mould and take out structure unit.Mould typically by the metal with high thermal conductivity for example aluminium make.Be used for mould that gel coat uses and can be based on polyester, because solidification process does not need high temperature.
The structural articles that uses material disclosed herein and method to form can comprise that any wherein laminated plastics goods may advantageous use.For example, goods include but not limited to, the outside and the intraware of aircraft, motor vehicle (for example car, truck, motorcycle etc.).For example, various assemblies comprise, but be not limited to coaming plate (rockerpanels), vertical panel (vertical panels), horizontal panel (horizontal panels), splash pan (fenders), top liner (head liners), door or the like under panel, azimuth card (quarter panels), the car door.
Advantageously, method of the present invention is compared with the method for using thermosetting material, has simplified the manufacturing of ornament, structural part and panel.In various embodiments, can use the efficient higher to implement the preparation of these parts at single shaping position (single forming station) than prior art.At present, use the method for thermoforming to need independent non-thermoforming step that matrix or lower floor are placed on the shape layer (for example, the moulding gel coat), for example by spraying, injecting or the like.But, make and can apply vacuum another layer is pulled to the matrix on the matrix thereby have enough volume of voids by forming matrix by use, make and also can use thermoforming to apply described gel coat.Because the matrix of described moulding can go up moulding at formpiston (male mold) or former (female mold), so succeeding layer (example gel coating) can be the aesthetic layer that is applied to described forming matrix outside surface.
Described method has reduced the type of the equipment that is used to make these sandwich-like products, and can reduce formation time and simplify the layered article manufacturing processed.In addition, when this thermoforming process does not use thermosetting material, compare,, the VOC discharging is greatly reduced even without eliminating the VOC discharging with other method of using thermosetting material.The low relatively pressure that uses in described method makes that also tooling cost is relatively low.At last, the porousness of following matrix structure helps to be reduced in the heat-elastic stress that occurs when connecting upper layer.
Embodiment is not limited to this method, and a kind of method that is used to make the final structure structural aesthetic parts comprises by pressure, matched mold, vacuum or the moulding of vacuum bag method from Azdel Inc.'s
Sheet material.By control pressure, in matrix, kept certain porosity.This matrix material premolding thing is placed in the instrument of coupling then, and wherein the thermoset gel coating has been applied on one or two of two and half parts of described instrument.Close this instrument then, and in the time of the gel coat solidified, apply the pressure of 1-500psi.Because the porousness of matrix so there be the infiltration of tangible gel coat by matrix, makes to produce significant mechanical bond between described layer.
More specifically, described goods are made up of the gel coat 10 on enhanced porous thermoplastic matrix 14,16.Because the porousness of described thermoplastic matrix and the method that is used to make described goods, the violent blending of gel coat and matrix produces the intensive mechanical bond.Described system can not carried out " balance " at the described structure back side with film or gel coat 12 yet.
Fig. 1 shows the sectional view of multilayer material system.The typical thickness of surface layer 10 and bottom 12 gel coats that exist on demand is 0.025-2.5mm, more specifically 0.25mm-1mm.The typical thickness that porous strengthens thermoplastic matrix 14,16 is 1-10mm, more specifically 2-5mm.The quantity, finish size and the processing condition that depend on the gel coat that is applied, described gel coat can flood the thickness of the 1-100% that enters porous thermoplastic matrix material 14.
Comprise glass fibre and
Resin and
Polycarbonate resin blends
Sheet is heated to 450-700 °F in the thermoforming baking oven, and transfers to molded, uses the instrument or the pressure molding technique of coupling to make described forming materials at described molded.Apply the malleation of 1-500psi, apply the vacuum of 0-14.7psi.Fig. 2 shows matching tool technology and pressure molding technique.
Take out from described instrument then
Resin premolding thing also cooled off before the stage at gel coating.Because described material and processing condition, described premolding thing has kept certain porosity.Gel coat is by among one or two of two and half parts of spirt matching tool, and the size of wherein said matching tool is corresponding with described premolding thing.Described premolding thing is transferred to described instrument, close described instrument and apply the pressure of 1-250psi.Gel coat is solidified under pressure will be removed up to final parts.Fig. 3 has shown the gel coating method.
Though invention has been described for reference example embodiment, one skilled in the art will appreciate that not departing from scope of the present invention just can carry out various changes and can be equal to replacement to key element of the present invention.In addition, do not depart from essential scope of the present invention, can much change so that certain conditions or material adapt to instruction of the present invention.Therefore, the invention is not restricted to the present invention includes all embodiments that fall in the appended claim scope as implementing the disclosed specific embodiments of best imagination of the present invention.
Claims (13)
1. the method for the goods of a moulding gel coating, described method comprises:
Fibre-reinforced thermoplastic substrate sheet is shaped to the shape of expectation, to obtain the matrix of moulding;
The surf zone of described intended shape is contacted with the thermoset gel coating material;
The shape and the gel coat material of described expectation are molded together to form adhesive bond between the shape of described gel coat material and described expectation, wherein said gel coat material penetrate into the porous zone adjacent with the described surf zone of the shape of described expectation with its formation mechanical bond, described porous zone comprises the residual porosity rate or comes from the porosity of fiber setting-out.
2. the process of claim 1 wherein described moldedly partly carry out and one of described mould part contains described gel coat material by closing molding.
3. the process of claim 1 wherein that the Fibre diameter of described fiber is 6 microns-25 microns, staple length is 2mm-75mm.
4. the process of claim 1 wherein that described gel coat material is that thermoset resin material and described gel coat material are at molded curing during.
5. the process of claim 1 wherein that the matrix of described moulding is the fibre-reinforced plastic material with perforate.
6. the process of claim 1 wherein that described substrate tablet comprises:
The 25wt%-75wt% plastic material;
The 25wt%-75wt% fiber; With
Wherein wt percentage ratio is based on the gross weight of described substrate tablet.
7. the method for claim 6, wherein said substrate tablet comprises:
The 35wt%-65wt% plastic material; With
The 35wt%-65wt% fiber.
8. the method for claim 6, wherein said plastic material is selected from polycarbonate, polypropylene, polyester, polyetherimide, polyphenylene ether, polystyrene, polymeric amide and contains the combination of at least a previous materials.
9. the process of claim 1 wherein to use and have the auxiliary vacuum pressure forming method of the film that helps plug thermoforming substrate tablet.
10. the process of claim 1 wherein to use and have the auxiliary vacuum pressure forming method of the film that helps plug thermoforming substrate tablet.
11. the process of claim 1 wherein that the thermoforming substrate tablet comprises that further the described matrix of heating is to the temperature that is enough to allow the fiber setting-out.
12. the method for claim 11, wherein said temperature are 232 ℃-371 ℃.
13. the process of claim 1 wherein that substrate tablet further comprises is placed on the lip-deep non-woven lax fabric of substrate tablet.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US57321404P | 2004-05-21 | 2004-05-21 | |
| US60/573,214 | 2004-05-21 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1976981A CN1976981A (en) | 2007-06-06 |
| CN100584878C true CN100584878C (en) | 2010-01-27 |
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ID=36678037
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN200580016348A Expired - Fee Related CN100584878C (en) | 2004-05-21 | 2005-05-16 | Gel coated reinforced composite |
Country Status (7)
| Country | Link |
|---|---|
| EP (1) | EP1753808A2 (en) |
| JP (1) | JP2008500209A (en) |
| KR (1) | KR101213356B1 (en) |
| CN (1) | CN100584878C (en) |
| AU (1) | AU2005324509A1 (en) |
| SG (1) | SG155175A1 (en) |
| WO (1) | WO2006076026A2 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR101336224B1 (en) * | 2012-11-13 | 2013-12-05 | 주식회사 엑시아머티리얼스 | Method of bonding multilayer structure |
| US11692078B2 (en) * | 2017-03-13 | 2023-07-04 | Basf Se | Coated fiber and method |
| EP3720514B1 (en) | 2017-12-04 | 2022-04-13 | Tepha, Inc. | Vacuum membrane thermoformed poly-4-hydroxybutyrate medical implants |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4356230A (en) * | 1980-07-10 | 1982-10-26 | International Telephone And Telegraph Corporation | Molded plastic product having a plastic substrate containing a filler and an in-mold plastic coating firmly bonded thereon and a process for its manufacture |
| US4329194A (en) * | 1980-08-18 | 1982-05-11 | Composite Technology, Inc. | Method for constructing fiberglass articles |
| US4742121A (en) * | 1985-04-29 | 1988-05-03 | The Glidden Company | Acrylate resin gel coat composition |
| WO2003070834A1 (en) * | 2002-02-19 | 2003-08-28 | Verdant Technologies | Sprayable low volatility in-mold gel coat compositions |
-
2005
- 2005-05-16 SG SG200905139-2A patent/SG155175A1/en unknown
- 2005-05-16 EP EP05856719A patent/EP1753808A2/en not_active Withdrawn
- 2005-05-16 WO PCT/US2005/017139 patent/WO2006076026A2/en not_active Application Discontinuation
- 2005-05-16 CN CN200580016348A patent/CN100584878C/en not_active Expired - Fee Related
- 2005-05-16 AU AU2005324509A patent/AU2005324509A1/en not_active Abandoned
- 2005-05-16 JP JP2007527346A patent/JP2008500209A/en not_active Withdrawn
-
2006
- 2006-11-20 KR KR1020067024254A patent/KR101213356B1/en not_active IP Right Cessation
Also Published As
| Publication number | Publication date |
|---|---|
| WO2006076026A2 (en) | 2006-07-20 |
| AU2005324509A1 (en) | 2006-07-20 |
| WO2006076026A3 (en) | 2006-10-05 |
| EP1753808A2 (en) | 2007-02-21 |
| CN1976981A (en) | 2007-06-06 |
| JP2008500209A (en) | 2008-01-10 |
| SG155175A1 (en) | 2009-09-30 |
| KR101213356B1 (en) | 2012-12-17 |
| KR20070024532A (en) | 2007-03-02 |
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