DK177789B1 - Composite laminate, a method of manufacturing a composite laminate and an insulation panel - Google Patents

Composite laminate, a method of manufacturing a composite laminate and an insulation panel Download PDF

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Publication number
DK177789B1
DK177789B1 DK201270794A DKPA201270794A DK177789B1 DK 177789 B1 DK177789 B1 DK 177789B1 DK 201270794 A DK201270794 A DK 201270794A DK PA201270794 A DKPA201270794 A DK PA201270794A DK 177789 B1 DK177789 B1 DK 177789B1
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DK
Denmark
Prior art keywords
layer
composite laminate
insulation
matrix material
core layer
Prior art date
Application number
DK201270794A
Other languages
Danish (da)
Inventor
Nielsen Bose
Original Assignee
Litebau As
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Litebau As filed Critical Litebau As
Priority to DK201270794A priority Critical patent/DK177789B1/en
Priority to PCT/DK2013/050439 priority patent/WO2014094786A1/en
Priority to EP13864007.3A priority patent/EP2941511A4/en
Application granted granted Critical
Publication of DK177789B1 publication Critical patent/DK177789B1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/246—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0021—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
    • 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
    • B32B27/065—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 foam
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/243—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 one at least of the material being insulating
    • 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
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
    • B29K2995/0015—Insulating
    • 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
    • B32B2038/0052—Other operations not otherwise provided for
    • B32B2038/0076—Curing, vulcanising, cross-linking
    • 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on 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
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0221—Vinyl resin
    • B32B2266/0228—Aromatic vinyl resin, e.g. styrenic (co)polymers
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • 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
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • 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
    • B32B2607/00—Walls, panels

Abstract

Composite laminate (1) comprising; a first and a second fibre reinforced layer (3, 5), the first and second fibre reinforced layer (3, 5) comprising first and second fibres respectively and a first and a second ma- trix material respectively; and a core layer (7) disposed between the first and the second fibre reinforced layer (3, 5), the core layer (7) comprising a barrier layer (11) including filler material embedded in a core layer matrix material, wherein the core layer is co-cured with the first and the sec- ond fibre reinforced layer, wherein the composite laminate comprise a protective coating (9) applied over the first fibre reinforced layer (3), and wherein the protective coat- ing (9)is a gelcoat, a method of manufacturing a composite laminate 1 and an insulation panel (100).

Description

i DK 177789 B1
Composite laminate, a method of manufacturing a composite laminate and an insulation panel
Field of the Invention 5 The present invention relates to a composite laminate and a method of manufacturing a composite laminate
Moreover the present invention relates to an insulation panel for building insulation. Background of the Invention 10 Composite laminates consisting of fibres embedded in a matrix are susceptible to damage resulting from impacts. The impact damage usually takes the form of delamination and cracks propagating radially from the impact centre (star). Upon an impact with enough energy to cause permanent damage to the composite laminate the composite laminate would need to be repaired and the damaged area replaced by a new composite 15 laminate covering the damaged area.
A repair may cause a permanent reduction in the strength for the composite laminate. Therefore it is desired to limit the extent of the damaged area as much as possible in order to maintain as much strength as possible and to reduce the cost of repairing the 20 composite laminate.
Heating of buildings is subject to increasing cost due to the diminishing of nonrenewable energy sources and the limited availability of renewable energy sources. Therefore it is desirable to reduce the heating requirement of buildings to decrease the 25 cost and to better utilize the energy sources available.
One way of better utilizing the energy sources is to reduce the exchange of heat from the inside of a building towards the outside of the building. This can be done by improving the insulation performance of the building either by improving the efficiency of 30 the insulation material or increasing the thickness of the insulation.
2 DK 177789 B1
The efficiency of the insulation material is the so called lambda value (thermal conductivity) that is a measure of its ability to prevent passage of heat at a particular thickness in defined conditions. As the lambda value decreases a lesser thickness of the insulation is required to achieve the same insulation performance.
5
Increasing the thickness of the insulation can be done by increasing the wall or roof thickness.
In new buildings the wall or roof thickness can be increased when the building is 10 planned without affecting the gross floor area of the building. However, in existing buildings there are two options of increasing the wall or roof thickness. This can be done either by adding insulation to the inside or the outside of the building. In relation to walls latter option is preferred as the first option will reduce the gross floor area. In relation to roofs the preferred option is dependent on the construction of the building.
15
Therefore it is desired to provide a means of adding insulation to a building.
This can be done by attaching a foam insulation layer to the wall or roof and covering the insulation layer with a suitable covering material, for example fibre reinforced com-20 posites. However, it is a problem with such a covering that it is very time consuming to establish and that it is susceptible to impact damage.
Object of the Invention
An object of the present invention is therefore to provide a composite laminate and an insulation panel with improved tolerance to impacts.
25 Description of the Invention
According to the present invention, this is achieved by a composite laminate comprising; a first and a second fibre reinforced layer, the first and second fibre reinforced layer comprising first and second fibres respectively and a first and a second matrix material 30 respectively; and a core layer disposed between the first and the second fibre reinforced layer, the core layer comprising a barrier layer including a filler material embedded in a core layer ma- 3 DK 177789 B1 trix material, wherein the core layer is co-cured with the first and the second fibre reinforced layer, wherein the composite laminate comprise a protective coating applied over the first fibre reinforced layer, and wherein the protective coating is a gelcoat.
5 Furthermore, according to the present invention, this is achieved by a method of manufacturing a composite laminate comprising the steps; a. preparing a mould surface by applying a release agent, b. establishing a protective coating by preparing and applying a layer of gelcoat to the mould surface, 10 c. establishing a first fibre reinforced layer by preparing and applying a layer of first fibres and a first matrix material, d. establishing a core layer by preparing and applying a barrier layer including a mixture of filler material and a core layer matrix material, e. establishing a second fibre reinforced layer by preparing and applying a layer of sec- 15 ond fibres and a second matrix material, f. curing the composite laminate, and g. removing the composite laminate from the mould.
Moreover, according to the present invention, this is achieved by an insulation panel 20 comprising a composite laminate according to any of the claims 3-7, wherein the insulation layer is completely encapsulated by the first and the second fibre reinforced layer and the barrier layer.
Surprisingly the inventor has found that by adding the core layer comprising a barrier 25 layer including filler material embedded in the core layer matrix material between the first and the second fibre reinforced layer the permanent damage upon an impact is significantly reduced compared to the permanent damage caused to a composite laminate without the core layer by an impact with the same energy level.
30 The impact is applied to the protective coating side of the composite laminate.
The extent of the damaged area on a composite laminate according to the invention is significantly reduced.
4 DK 177789 B1
The composite laminate is less prone to crack initiation and subsequent propagation and does not easily develop stars. It is believed that this effect contribute to reducing the extent of the damaged area that would otherwise have a larger extend due to cracks 5 moving rapidly through the fibre reinforced material, as this is usually a brittle material.
The effect of significantly reducing the damage upon impact in the composite laminate according to the invention is utilized in the insulation panel to provide improved insulation performance to a wall or a roof while ensuring that damages due to impact is sig-10 nificantly reduced.
The first and the second fibres may be selected among woven or non-woven carbon fibres, glass fibres, polymer fibres, for example polyaramid fibres, or a combination of said fibres.
15
Carbon fibres provide a high strength and stiffness, but at a high cost.
Glass fibres provide a high strength and stiffness albeit lower than the strength and stiffness of carbon fibres, but at a comparably lower cost.
20
Polyaramid fibres provide high toughness as they have an inherent resistance to impact damage. However, polyaramid fibres cost much more than carbon fibres.
The failure mechanism of polyaramid fibres are different to that of both carbon and 25 glass fibres. When polyaramid fibres break, they do not fail by brittle cracking, as do fibreglass and carbon fibres. Polyaramid fibres fail by a series of small fibril failures, where these failures absorb much energy and, therefore result in very high toughness.
The first and the second fibres may have an identical composition or a dissimilar com-30 position depending on the actual application.
The first and the second matrix materials are described later.
5 DK 177789 B1
The filler material is described later.
The protective coating is a gelcoat that is applied to the surface of the first fibre reinforced layer that faces away from the core layer. The composite laminate is oriented in 5 a way such that the side having the protective coating is facing the exterior side and the side most prone to impacts.
When repairing a damaged area of the composite laminate, the damaged materiel is removed and replaced with new material. A finishing layer of gelcoat is applied to 10 cover the repair. The use of gelcoat allows for a virtually invisible repair.
When performing the method according to the invention the individual layers are applied in a wet lay up process. Curing of the layer is initiated but only to a point where the layer is still able to become integrated with a subsequent layer and achieve a com-15 pletebond.
A commercially available resin system can be used. The manufacturer will provide instructions for use that allows the skilled person to achieve a complete bond between the individual layers.
20
In the insulation panel according to the invention the panel is oriented with the side, having the protective coating, facing the exterior. The barrier layer is disposed across the entire area of the insulation panel, such that the first fibre reinforced layer is completely supported by the barrier layer. Thus, the ability of the composite laminate ac-25 cording to the invention to reduce the effect of an impact is utilized in an insulation panel according to the invention by decreasing the extent of a damaged area compared to a damaged area on an insulation panel with a composite laminate without the barrier layer.
30 Therefore the insulation panel has improved tolerance to impacts.
6 DK 177789 B1
In an embodiment the panel is attached to the outside of an exterior wall of a building or the exterior side of a roof to increase the effectiveness of the insulation and to reduce the lambda value of the wall or roof.
5 It is a significant advantage of the insulation panel according to the invention that it can be used to refurbish an exterior wall or roof that would otherwise be in need of replastering, painting or otherwise being maintained. In contrast to the mentioned methods the refurbishment by applying insulation panels to an exterior wall or roof can be applied independently of external temperature conditions and even during rain.
10
In an embodiment the insulation panel is attached to an interior wall or roof of a building to increase the effectiveness of the insulation and to reduce the lambda value of the wall.
15 The insulation in this case can also be used to refurbish an existing wall in a simple manner.
In an embodiment the insulation panel is replacing the entire wall construction of the building.
20
In this manner a significant improvement of the insulation effectiveness can be achieved.
In an alternative embodiment the composite laminate according to the invention is ap-25 plied directly to an exterior/interior wall or roof of a building to refurbish the building wall and to increase the impact resistance.
The impact resistance of the composite laminate according to the invention inhibits crack growth and thereby prevents water ingress that would subsequently cause further 30 damage to the composite laminate.
DK 177789 B1 7
Water inside the insulation panel may potentially damage the panel during the winter, where the water may freeze. During freezing the water will expand and thereby potentially cause damage to the insulation panel.
5 According to a further embodiment, the composite laminate according to the invention is peculiar in that, the filler material is selected among microspheres, cenospheres, mineral filler, or a combination of said materials.
In an embodiment of the composite laminate according to the invention the filler mate-10 rial is microspheres.
Microspheres are small particles with diameters in the micrometer range. Microspheres can be manufactured from a variety of natural and synthetic materials. Microspheres can be solid or hollow.
15
Solid microspheres are used when the density of the barrier layer must be high.
Hollow microspheres are used when the density of the barrier layer must be low.
20 In an embodiment of the composite laminate according to the invention the filler material is cenospheres.
Cenospheres included within the barrier layer are light weight, inert, hollow spheres made largely of silica and alumina and filled with air or inert gas. Cenospheres are typi-25 cally produced as a byproduct (fly ash) of coal combustion at thermal power plants.
The cenospheres can be separated from fly ash by electrostatic and floatation methods.
Cenospheres are commercially available for example under the tradename “Fillite” by Fillite (part of Omya UK Ltd.).
The cenospheres are mixed into the core layer matrix material. The mixture is applied to the composite laminate thereafter to form the barrier layer. The co-curing of the 30 8 DK 177789 B1 core layer with the first and second fibre reinforced layer ensures a complete bond between the layers of the composite laminate.
The cenospheres have good insulation proporties. Therefore the barrier layer provides 5 some thermal insulation.
In an embodiment of the composite laminate according to the invention the filler material is a mineral filler.
10 Mineral fillers include but are not limited to dolomite fillers and granite fillers.
Mineral fillers are used where the density of the barrier layer can be high.
According to a further embodiment, the composite laminate according to the invention 15 is peculiar in that, the core layer comprises an insulation layer, the insulation layer comprising a rigid foam material, wherein the insulation layer is disposed between the barrier layer and the second fibre reinforced layer.
It is herewith achieved that the lambda value of the composite laminate is further re-20 duced. Thus, the insulation efficiency of the composite laminate is increased.
In an embodiment of the invention, the foam material is an open cell foam. The open cell foam has good sound insulation properties and is cost effective.
25 In an embodiment of the invention, the foam material is a closed cell foam. The closed cell foam is non-porous and not moisture-penetrable. Thereby it provides a semipermeable vapour barrier. Moreover, closed cell foam have better thermal insulation properties than open cell foam.
30 The foam material may be selected among; expanded polystyrene, polyurethane, poly-isocyanurate or other suitable expanded polymers.
9 DK 177789 B1
According to a further embodiment, the composite laminate according to the invention is peculiar in that, the thickness of the barrier layer is between 1 mm to 3 mm, preferably 1 mm to 2 mm.
5 It has been found that the above range provide optimal impact tolerance for a composite laminate. Although increasing the thickness of the barrier layer beyond the range above does increase the strength of the composite laminate, the effect in relation to containment of cracks is not significantly improved. Containment of cracks is important in relation to preventing water ingress that will increase the damage upon an impact.
10
According to a further embodiment, the composite laminate according to the invention is peculiar in that, the thickness of the protective coating is between 300 pm and 800 pm, preferably 400 pm.
15 It has been found that the above range provide a sufficient water barrier. Therefore it is not cost effective to increase the thickness of the protective layer beyond the above range.
The above range also allow for the application of a surface texture to the mould.
20
In an embodiment of the invention the surface texture resembles that of a roughly planed wooden board.
The above embodiment can be combined with the insulation panel.
25
It is thus achieved that the insulation panel can be used on buildings with existing wall cladding of wooden boards without significantly changing the appearance of the building.
30 According to a further embodiment, the composite laminate according to the invention is peculiar in that, the thickness of the insulation layer is 10 mm to 300 mm.
10 DK 177789 B1 A good compromise between cost, insulation properties and building appearance in the area of building openings and conformance to eaves and other protruding features is achieved with the above range.
5 According to a further embodiment, the composite laminate according to the invention is peculiar in that, the first matrix material, the second matrix material and the core layer matrix material is selected among epoxies, polyesters, vinylesters, phenolics, thermoplastics, thermosets, polyurethanes, glues, cements, matrix material binders, and combinations thereof.
10
The selecting of matrix material depends on the application. The skilled person will be able to select an optimal matrix material for a given application.
According to a further embodiment, the composite laminate according to the invention 15 is peculiar in that, the filler material content in the barrier layer range from 40% to 80%, preferably 44% to 76% more preferably 44% by weight of the barrier layer.
It is herewith achieved that the shrinkage of the barrier layer is acceptable. Shrinkage of the barrier layer causes the composite laminate to warp.
20 In an embodiment, the composite laminate according to the invention is peculiar in that the filler material are cenospheres, and that the cenosphere content in the barrier layer range from 40% to 80%, preferably 44% to 76% more preferably 44% by weight of the barrier layer.
25 According to a further embodiment, the method according to the invention is peculiar in that, the following step is performed between step d. and e.; dl. establishing an insulation layer by preparing and applying a rigid foam material over the core layer.
30 It is herewith achieved that the insulation properties are improved.
11 DK 177789 B1
Description of the Drawing
The invention will be explained in more detail below with reference to the accompanying drawing, where: 5 Fig. 1 shows a cross-section of a composite laminate in a first embodiment according to the invention,
Fig. 2 shows a cross-section of a composite laminate in a second embodiment according to the invention,
Fig. 3 shows a cross-section of an insulation panel in a first embodiment according 10 to the invention,
Fig. 4 illustrates the attachment of the insulation panel to an exterior wall, and Fig. 5 illustrates the exterior wall now clad with insulation panels.
Detailed Description of the Invention 15 In the explanation of the figures, identical or corresponding elements will be provided with the same designations in different figures. Therefore, no explanation of all details will be given in connection with each single figure/embodiment.
Fig. 1 shows a cross-section of a composite laminate 1 in a first embodiment according 20 to the invention.
The composite laminate 1 comprise a first fibre reinforced layer 3 and a second fibre reinforced layer 5 and a core layer 7 disposed between said first fibre reinforced layer 3 and a second fibre reinforced layer 5. The composite laminate 1 further comprise a 25 protective coating 9 in the form of a gelcoat layer applied over the first fibre reinforced layer 3
The first fibre reinforced layer 3 is composed of first fibres and a first matrix material.
30 The first fibres may be in the form of a cloth of a woven or non-woven material. Alternatively the first fibres may be applied by spraying. The first fibres are wetted by the 12 DK 177789 B1 first matrix material, such that the first fibres become embedded in the first matrix material.
The second fibres may be in the form of a cloth of a woven or non-woven material.
5 Alternatively the second fibres may be applied by spraying. The second fibres are wetted by the second matrix material, such that the second fibres become embedded in the second matrix material.
The core layer 7 comprises a barrier layer 11. The barrier layer 11 is composed of a mixture of cenospheres and a core layer matrix material.
10
The composite laminate 1 can be produced by first preparing a mould surface by applying a release agent to the mould surface.
The protective coating 9 is applied to the mould surface and allowed to set or in other 15 terms to become surface dry.
Then the first matrix material is prepared, for example in the case of a 2-component resin system by mixing the resin with the hardener in a prescribed ratio. The first fibres and the first matrix material are applied onto the mould over the protective layer 9. Air 20 bubbles are removed by a roll that also ensures an even distribution of the first matrix material. The first fibre reinforced layer 3 is then allowed to set or become surface dry.
The barrier layer 11 is prepared by mixing the cenospheres with the core layer matrix material in a prescribed ratio. The mixture is applied and distributed in an even layer 25 over the first fibre reinforced layer 3 to establish the barrier layer 11 of the core layer 7.
The barrier layer 11 is allowed to set or become surface dry.
Then the second matrix material is prepared, for example in the case of a 2-component resin system by mixing the resin with the hardener in a prescribed ratio. The second 30 fibres and the second matrix material are applied onto the mould over the core layer 7.
Air bubbles are removed by a roll that also ensures an even distribution of the second matrix material. The second fibre reinforced layer 5 is then allowed to set or become surface dry.
13 DK 177789 B1
The composite laminate 1 is then cured at the prescribed temperature for the matrix materials used.
5 After curing the composite laminate 1 is removed from the mould and are ready to use.
Fig. 2 shows a cross-section of a composite laminate 1 in a second embodiment according to the invention.
10 The second embodiment differs from the first embodiment in that the core layer 7 further comprises an insulation layer 13. The insulation layer 13 is a rigid foam material that is located between the barrier layer 11 and the second fibre reinforced layer 5.
Fig. 3 shows a cross-section of an insulation panel 100 in a first embodiment according 15 to the invention.
The wall insulation panel 100 comprises a composite laminate according to the second embodiment shown in fig. 2. The insulation layer 13 is completely encapsulated by the first fibre reinforced layer 3 and the second fibre reinforced layer 5 and the barrier layer 20 11. This ensures that the insulation layer 13 is sufficiently protected from impact dam age and water ingress.
Fig. 4 illustrates the attachment of the insulation panels 100 to an exterior wall 102 that requires refurbishment and increased insulation performance.
25
The insulation panels 100 are applied in a side-by-side overlapping configuration.
Fig. 5 illustrates the exterior wall 102 now clad with insulation panels 100.
30 The insulation panels 100 have been adapted to the shape of the exterior wall 102.

Claims (11)

14 DK 177789 B114 DK 177789 B1 1. Kompositlaminat omfattende: - et første og et andet fiberforstærket lag, hvor det første og andet fiberforstærkede lag 5 omfatter henholdsvis første og andre fibre og henholdsvis et første og et andet matrix- materiale, og - et kemelag placeret mellem det første og andet fiberforstærkede lag, hvilket kemelag omfatter et barrierelag, der omfatter et fyldmateriale indlejret i et kernelagsmatrixmate-riale, hvori kemelaget er samhærdet med de første og andre fiberforstærkede lag, hvori 10 kompositlaminatet omfatter et beskyttende overtræk påført det første fiberforstærkede lag, og hvori det beskyttende overtræk er en gelcoat.A composite laminate comprising: - a first and a second fiber-reinforced layer, wherein the first and second fiber-reinforced layers 5 comprise first and second fibers, and a first and second matrix material, respectively, and - a core layer located between the first and second fiber-reinforced layers. a core layer comprising a barrier layer comprising a filler material embedded in a core layer matrix material, wherein the core layer is cured with the first and second fiber reinforced layers, wherein the composite laminate comprises a protective coating applied to the first fiber reinforced layer and wherein the protective coating is and gelcoat. 2. Kompositlaminat ifølge krav 1, hvori fyldmaterialet er valgt blandt mikrosfærer, ce-no sfærer, mineralsk fyldmateriale eller en kombination af disse materialer.A composite laminate according to claim 1, wherein the filler material is selected from microspheres, ce-no spheres, mineral filler material or a combination of these materials. 3. Kompositlaminat ifølge krav 1 eller 2, hvori kemelaget omfatter et isolationslag, hvilket isolationslag omfatter et stift skummateriale, hvori isolationslaget er placeret mellem barrierelaget og det andet fiberforstærkede lag.A composite laminate according to claim 1 or 2, wherein the core layer comprises an insulation layer, said insulation layer comprising a rigid foam material, wherein the insulation layer is located between the barrier layer and the second fiber reinforced layer. 4. Kompositlaminat ifølge et af krav 1-3, hvori tykkelsen af barrierelaget er mellem 1 og 3 mm, fortrinsvis 1 og 2 mm.A composite laminate according to any one of claims 1-3, wherein the thickness of the barrier layer is between 1 and 3 mm, preferably 1 and 2 mm. 5. Kompositmateriale ifølge ethvert af de foregående krav, hvori tykkelsen af det beskyttende overtræk er mellem 300 pm og 800 pm, fortrinsvis 400 pm. 25A composite material according to any one of the preceding claims, wherein the thickness of the protective coating is between 300 µm and 800 µm, preferably 400 µm. 25 6. Kompositmateriale ifølge ethvert af de foregående krav, hvori tykkelsen af isolationslaget er 10 mm til 300 mm.A composite material according to any one of the preceding claims, wherein the thickness of the insulation layer is 10 mm to 300 mm. 7. Kompositmateriale ifølge ethvert af de foregående krav, hvori det første matrixmate-30 riale, det andet matrixmateriale og kernelagmatrixmaterialet er valgt blandt epoxyer, polyestre, vinylestre, fenoler, termoplast, termohærdende plast, polyuretaner, lim, cement, matrixmaterialebindere og kombinationer deraf. 15 DK 177789 B1Composite material according to any of the preceding claims, wherein the first matrix material, the second matrix material and the core layer matrix material are selected from epoxies, polyesters, vinyl esters, phenols, thermoplastics, thermosetting plastics, polyurethanes, adhesives, cement, matrix material binders and combinations thereof. 15 DK 177789 B1 8. Kompositmateriale ifølge ethvert af de foregående krav, hvori fyldmaterialeindholdet i barrierelaget er i området 40 til 80 vægt-%, fortrinsvis 44 til 76 vægt-%, mere foretrukket 44 vægt-% af barrierelaget. 5Composite material according to any one of the preceding claims, wherein the filler content of the barrier layer is in the range of 40 to 80% by weight, preferably 44 to 76% by weight, more preferably 44% by weight of the barrier layer. 5 9. Fremgangsmåde til fremstilling af et kompositlaminat, omfattende trinene: a. tilberedning af en formoverflade ved påføring af et slipmiddel, b. etablering af et beskyttende overtræk ved tilberedning og påføring af gelcoat på formoverfladen, 10 c. etablering af et første fiberforstærket lag ved tilberedning og påføring af et lag første fibre og et første matrixmateriale, d. etablering af et kernelag ved fremstilling og påføring af et barrierelag omfattende en blanding af fyldmateriale og et kernelagmatrixmateriale, e. etablering af et andet fiberforstærket lag ved tilberedning og påføring af et lag 15 andre fibre og et andet matrixmateriale, f. hærdning af kompositlaminatet, og g. udtagning af kompositlaminatet fra formen.A method of preparing a composite laminate comprising the steps of: a. Preparing a mold surface by applying a release agent, b. Establishing a protective coating by preparing and applying gelcoat to the mold surface, 10 c. Establishing a first fiber-reinforced layer by preparing and applying a layer of first fiber and a first matrix material, d. establishing a core layer by making and applying a barrier layer comprising a mixture of filler material and a core layer matrix material, e. establishing a second fiber-reinforced layer by preparing and applying a layer 15 other fibers and another matrix material, for curing the composite laminate, and g. Removing the composite laminate from the mold. 10. Fremgangsmåde til fremstilling af et kompositlaminat ifølge krav 9, hvori det føl-20 gende trin udføres mellem trinene f. og g.: fl. etablering af et isolationslag ved tilberedning og påføring af et stift skummateriale over kernelaget.A process for preparing a composite laminate according to claim 9, wherein the following step is performed between steps f and g: fl. establishing an insulation layer by preparing and applying a rigid foam material over the core layer. 11. Isolationspanel omfattende et kompositlaminat ifølge ethvert af krav 3-8, hvori 25 isolationslaget er fuldstændigt indkapslet af det første og det andet fiberforstærkede lag og barrierelaget.An insulation panel comprising a composite laminate according to any one of claims 3-8, wherein the insulation layer is completely encapsulated by the first and second fiber reinforced layers and the barrier layer.
DK201270794A 2012-12-18 2012-12-18 Composite laminate, a method of manufacturing a composite laminate and an insulation panel DK177789B1 (en)

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DK201270794A DK177789B1 (en) 2012-12-18 2012-12-18 Composite laminate, a method of manufacturing a composite laminate and an insulation panel
PCT/DK2013/050439 WO2014094786A1 (en) 2012-12-18 2013-12-18 Composite laminate, a method of manufacturing a composite laminate and an insulation panel
EP13864007.3A EP2941511A4 (en) 2012-12-18 2013-12-18 Composite laminate, a method of manufacturing a composite laminate and an insulation panel

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US4025686A (en) * 1975-06-26 1977-05-24 Owens-Corning Fiberglas Corporation Molded composite article and method for making the article
IT1097228B (en) * 1978-07-13 1985-08-26 Pantec Srl PREFABRICATED SELF-SUPPORTING PANELS AND RELATED MANUFACTURING PROCEDURE
US4446177A (en) * 1982-03-12 1984-05-01 Munoz George L Reinforced plastic product
US4933131A (en) * 1987-12-29 1990-06-12 Sundstrand Corporation Method of fabricating composite structures
JPH0410925A (en) * 1990-04-27 1992-01-16 Daikyo Inc Laminated molding of thermosetting resin
JP3067283B2 (en) * 1991-07-10 2000-07-17 松下電器産業株式会社 Patterned molded body with a laminated structure
US6235367B1 (en) * 1998-12-31 2001-05-22 Robert D. Holmes Composite material for construction and method of making same
JP3282615B2 (en) * 1999-10-01 2002-05-20 ニチハ株式会社 Particle board and manufacturing method thereof
GB0020355D0 (en) * 2000-08-18 2000-10-04 Coniston Holdings Ltd Moulding methods
AU2006317505A1 (en) * 2005-11-28 2007-05-31 Australian National University Panel having a chemical resistant work surface
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