EP0634969A4 - Method of forming a preform using a powder binder. - Google Patents

Method of forming a preform using a powder binder.

Info

Publication number
EP0634969A4
EP0634969A4 EP93908276A EP93908276A EP0634969A4 EP 0634969 A4 EP0634969 A4 EP 0634969A4 EP 93908276 A EP93908276 A EP 93908276A EP 93908276 A EP93908276 A EP 93908276A EP 0634969 A4 EP0634969 A4 EP 0634969A4
Authority
EP
European Patent Office
Prior art keywords
preform
particles
manufacturing
binder
particulate binder
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.)
Withdrawn
Application number
EP93908276A
Other languages
German (de)
French (fr)
Other versions
EP0634969A1 (en
Inventor
Josh Kelman
Robert Hames
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Davidson Textron Inc
Original Assignee
Davidson Textron Inc
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 Davidson Textron Inc filed Critical Davidson Textron Inc
Publication of EP0634969A1 publication Critical patent/EP0634969A1/en
Publication of EP0634969A4 publication Critical patent/EP0634969A4/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/305—Spray-up of reinforcing fibres with or without matrix to form a non-coherent mat in or on a mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • 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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/08—Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder
    • 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
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25—Solid
    • B29K2105/251—Particles, powder or granules
    • 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
    • B29K2709/00—Use of inorganic materials not provided for in groups B29K2703/00 - B29K2707/00, for preformed parts, e.g. for inserts
    • B29K2709/08—Glass

Definitions

  • This invention relates generally to directed fiber preforming and, more particularly, to an improved process for forming a glass fiber preform.
  • Glass fibers have been commonly incorporated in thermoplastic molded objects and other cured plastics for added strength and durability.
  • the glass fiber is introduced in a mold where resinous plastic is then injected such that the glass fibers become imbedded into the final formed object. It has been found advantageous to form a preform of the final object out of glass fibers and place the preform into the mold.
  • the glass fibers are often chopped and blown onto a preform screen.
  • a liquid binder agent is sprayed on and allowed to cure which sets the fibers in place.
  • liquid binder coats substantially the entire chopped glass fiber which can prevent matrix resin in the molded part from fully wetting-out the fibers in the preform. This lack of penetration of the matrix resin into the fiberglass strand within the preform for the finished molded part restricts its mechanical strength and integrity.
  • What is needed is a method for adding a binder to the preform fibers that prevents substantial coating of the fibers so that the preform is more supple during handling thus improving its integrity and such that the later added matrix resin in the subsequent molding process more fully wets out the fibers of the preform.
  • chopped fibrous material such as chopped glass fibers
  • the fibers may be retained on the screen by a vacuum draw there ⁇ through.
  • a solid particulate binder material commonly referred to as a powder, is deposited onto the deposited chopped fibers.
  • the particulate binder are retained on the deposited glass fibers.
  • the particles of binder may be retained by static electrical charges on either the binder particles or glass fibers or both.
  • the binder particles can be softened while on the deposited fibers such that the fibers are adhered to the fibers independently of the electro-static charge. The softening of the binder particles also allows fibers to adhere to other fibers via the binder particles.
  • the softening of the binder particles may be by applying heat to a binder made from a thermoplastic polyester material such that upon softening it becomes tacky and sticks to the adjacent glass fibers.
  • the particles are then re-solidified to form a cured preform.
  • the preform is then removed from the preform screen.
  • Figure 1 is side elevational view of a direct fiber apparatus used in a method according to the invention
  • Figure 2 is an enlarged and schematic view of the glass fibers and particulate binder deposited onto the preform screen shown in figure 1.
  • a preform screen assembly 10 includes a mounting table 12, a foraminous preform screen 14 and. a suction fan 15.
  • the screen 14 has a plurality of holes 27 and its contour conforms to one surface of the desired preform shape.
  • the screen 14 is mounted about its periphery to the table 12 which in turn has appropriate duct work 13 for housing the suction fan 15.
  • the suction fan when actuated draws a vacuum through the screen 14.
  • a nozzle control system generally indicated as 20 is pointed toward the preform screen 14.
  • the system includes a blower nozzle 18 for deposition of blown glass fibers 19 and at least one nozzle 21 for the spraying of dry binder powder 25.
  • the glass fibers used may be chopped from a commercially available roving such as one sold under the brand name PPG-5542.
  • the fiber nozzle 18 is the distal end of a flexible tube 26 that has its other end 27 mounted onto a rigid delivery tube 28 communicating from a chop ⁇ per/blower assembly 30.
  • the tubes 26 and 28 and chop ⁇ per/blower assembly 30 are mounted on a gantry 32 that can move the nozzles left, right, up, and down relative to the screen 14.
  • the chopped glass fibers 19 from nozzle 18 are directed onto the preform screen 14.
  • the chopped glass fibers may be chopped between 1" and 4" in length depending on the application. Simultaneously or im edi- ately after the deposition of the fibers, the powder binder is blown onto the preform screen 14.
  • the binder may be Reichhold's Atlac 32-626 and can be blown by a Volstatic Coatings LTD's Solidspray-90 spray station in combination with their SPG-1351 spray gun onto the preform screen at a rate of approximately 2.14 g/s.
  • Other particulate thermoplastic polyester binders may be alternately used.
  • the particulate sizes of the powder binder may range from mesh size 35 to 200 which corre ⁇ sponds to .00122" to .0021".
  • the binder powder is retained on the glass fibers through static electrical charges.
  • the glass fibers are retained on the preform screen by the use of a vacuum draw through the screen produced by suction fan 15. As shown in figure 2, the particles and glass fibers form a porous mat 50 with many interstices 52 between the fibers and particles.
  • the amount of binder by weight is about 2-6% of the glass fibers.
  • heat is applied to the preform 40.
  • heat lamps 43 may be positioned about the preform screen 14 to direct heat onto the preform 40.
  • the screen assembly 10 may be moved on a multi-station line such that the heat is applied at a different station than the station that deposits the glass fibers.
  • the heat may be applied by heat lamps 43, heated air, or other conventional heating methods.
  • the heat softens the particles of the binder such that each particle becomes tacky and sticks to any glass fibers with which it is in contact.
  • the binder and glass fibers on the preform screen 14 are cooled such that the binder is set, i.e. cured, to form a one-piece preform 40.
  • the preform is then allowed to cool by use of chilled air or deactuation of heat lamps 43.
  • the glass fibers are not coated with binder and as such, preform release from the screen is significantly easier compared to preforms made with sprayed liquid binders. Furthermore, preform integrity is improved. The strength derived from adhesion with particles exceeds that from coated fibers touching each other.
  • coated fibers prevent matrix resin in the molded part from fully wetting-out the fibrous strands which are composed of thousands of filaments. By not coating the fibrous strands, nothing interferes with wet-out. Each fiber can be penetrated by the matrix resin to fully wet-out all the filaments in any subsequent molding process.

Abstract

A process for producing a preform (40) includes the deposition of powder binder (25) onto chopped glass fibers (19) that are on a preform screen (14). The powder binder and chopped glass fibers are then heated to soften the particles of binder and make them stick to the glass fibers to form the preform.

Description

METHOD OF FORMING A PREFORM USING A POWDER
BINDER
TECHNICAL FIELD
This invention relates generally to directed fiber preforming and, more particularly, to an improved process for forming a glass fiber preform.
BACKGROUND OF THE INVENTION
Glass fibers have been commonly incorporated in thermoplastic molded objects and other cured plastics for added strength and durability. The glass fiber is introduced in a mold where resinous plastic is then injected such that the glass fibers become imbedded into the final formed object. It has been found advantageous to form a preform of the final object out of glass fibers and place the preform into the mold. The glass fibers are often chopped and blown onto a preform screen. Immediately following the fiber placement, a liquid binder agent is sprayed on and allowed to cure which sets the fibers in place.
The use of a liquid binder coats substantially the entire chopped glass fiber which can prevent matrix resin in the molded part from fully wetting-out the fibers in the preform. This lack of penetration of the matrix resin into the fiberglass strand within the preform for the finished molded part restricts its mechanical strength and integrity.
What is needed is a method for adding a binder to the preform fibers that prevents substantial coating of the fibers so that the preform is more supple during handling thus improving its integrity and such that the later added matrix resin in the subsequent molding process more fully wets out the fibers of the preform.
SUMMARY OF THE INVENTION
In accordance with one aspect of the inven¬ tion, chopped fibrous material, such as chopped glass fibers, are deposited on a preform screen. The fibers may be retained on the screen by a vacuum draw there¬ through. A solid particulate binder material, commonly referred to as a powder, is deposited onto the deposited chopped fibers. The particulate binder are retained on the deposited glass fibers. The particles of binder may be retained by static electrical charges on either the binder particles or glass fibers or both. The binder particles can be softened while on the deposited fibers such that the fibers are adhered to the fibers independently of the electro-static charge. The softening of the binder particles also allows fibers to adhere to other fibers via the binder particles. The softening of the binder particles may be by applying heat to a binder made from a thermoplastic polyester material such that upon softening it becomes tacky and sticks to the adjacent glass fibers. The particles are then re-solidified to form a cured preform. The preform is then removed from the preform screen.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is now made to accompanying drawings in which:
Figure 1 is side elevational view of a direct fiber apparatus used in a method according to the invention; and Figure 2 is an enlarged and schematic view of the glass fibers and particulate binder deposited onto the preform screen shown in figure 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to figure 1, a preform screen assembly 10 includes a mounting table 12, a foraminous preform screen 14 and. a suction fan 15. The screen 14 has a plurality of holes 27 and its contour conforms to one surface of the desired preform shape. The screen 14 is mounted about its periphery to the table 12 which in turn has appropriate duct work 13 for housing the suction fan 15. The suction fan when actuated draws a vacuum through the screen 14. A nozzle control system generally indicated as 20 is pointed toward the preform screen 14.
The system includes a blower nozzle 18 for deposition of blown glass fibers 19 and at least one nozzle 21 for the spraying of dry binder powder 25. The glass fibers used may be chopped from a commercially available roving such as one sold under the brand name PPG-5542. The fiber nozzle 18 is the distal end of a flexible tube 26 that has its other end 27 mounted onto a rigid delivery tube 28 communicating from a chop¬ per/blower assembly 30. The tubes 26 and 28 and chop¬ per/blower assembly 30 are mounted on a gantry 32 that can move the nozzles left, right, up, and down relative to the screen 14. The chopped glass fibers 19 from nozzle 18 are directed onto the preform screen 14. The chopped glass fibers may be chopped between 1" and 4" in length depending on the application. Simultaneously or im edi- ately after the deposition of the fibers, the powder binder is blown onto the preform screen 14. The binder may be Reichhold's Atlac 32-626 and can be blown by a Volstatic Coatings LTD's Solidspray-90 spray station in combination with their SPG-1351 spray gun onto the preform screen at a rate of approximately 2.14 g/s. Other particulate thermoplastic polyester binders may be alternately used. The particulate sizes of the powder binder may range from mesh size 35 to 200 which corre¬ sponds to .00122" to .0021". The binder powder is retained on the glass fibers through static electrical charges. The glass fibers are retained on the preform screen by the use of a vacuum draw through the screen produced by suction fan 15. As shown in figure 2, the particles and glass fibers form a porous mat 50 with many interstices 52 between the fibers and particles. The amount of binder by weight is about 2-6% of the glass fibers.
After the appropriate amount of glass fiber and powder binder is applied onto the preform screen 14, heat is applied to the preform 40. In one case, heat lamps 43 may be positioned about the preform screen 14 to direct heat onto the preform 40. The screen assembly 10 may be moved on a multi-station line such that the heat is applied at a different station than the station that deposits the glass fibers. The heat may be applied by heat lamps 43, heated air, or other conventional heating methods. The heat softens the particles of the binder such that each particle becomes tacky and sticks to any glass fibers with which it is in contact. After sufficient softening, the binder and glass fibers on the preform screen 14 are cooled such that the binder is set, i.e. cured, to form a one-piece preform 40. The preform is then allowed to cool by use of chilled air or deactuation of heat lamps 43. As shown in figure 2, the glass fibers are not coated with binder and as such, preform release from the screen is significantly easier compared to preforms made with sprayed liquid binders. Furthermore, preform integrity is improved. The strength derived from adhesion with particles exceeds that from coated fibers touching each other.
Furthermore, coated fibers prevent matrix resin in the molded part from fully wetting-out the fibrous strands which are composed of thousands of filaments. By not coating the fibrous strands, nothing interferes with wet-out. Each fiber can be penetrated by the matrix resin to fully wet-out all the filaments in any subsequent molding process.
Other variations and modifications are possi- ble without departing from the scope and spirit of the invention as defined in the appended claims.

Claims

The embodiments in which an exclusive property or privilege is claimed are defined as follow.
1. A process of manufacturing a preform comprising the steps of; depositing chopped fibrous strands onto a preform base member; depositing solid particulate binder material made from solid particles onto said deposited chopped fibrous strands; softening said particles of particulate binder retained on said fibrous to adhere the chopped fibrous strands to the particles and to other fibrous strands; re-solidifying said particles such that said chopped fibrous strands adhered to said particles form a preform.
2. A process for manufacturing a preform as defined in claim 1 wherein the depositing of solid particulate binder includes using electrostatic charge on said particles to retain said particulate binder on said fibrous strands. 3. A process for manufacturing a preform as defined in claim 2 wherein said particulate binder is blown onto said fibrous strands.
4. A process for manufacturing a preform as defined claim 1 wherein said particulate binder is made from a thermoplastic polyester material.
5. A process for manufacturing a preform as defined in claim 4 wherein said softening of said particles includes heating said particulate binder.
6. A process for manufacturing a preform as defined in claim 5 wherein said fibrous strands are made from glass fibers.
7. A process for manufacturing a preform as defined in claim 1 wherein said softening of said particles includes heating said particulate binder.
8. A process for manufacturing a preform as defined in claim 1 wherein said fibrous strands are made from glass fibers.
EP93908276A 1992-04-08 1993-03-02 Method of forming a preform using a powder binder. Withdrawn EP0634969A4 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US865238 1986-05-20
US86523892A 1992-04-08 1992-04-08
PCT/US1993/001905 WO1993020994A1 (en) 1992-04-08 1993-03-02 Method of forming a preform using a powder binder

Publications (2)

Publication Number Publication Date
EP0634969A1 EP0634969A1 (en) 1995-01-25
EP0634969A4 true EP0634969A4 (en) 1995-12-06

Family

ID=25345027

Family Applications (1)

Application Number Title Priority Date Filing Date
EP93908276A Withdrawn EP0634969A4 (en) 1992-04-08 1993-03-02 Method of forming a preform using a powder binder.

Country Status (5)

Country Link
EP (1) EP0634969A4 (en)
JP (1) JPH07508227A (en)
AU (1) AU3915493A (en)
CA (1) CA2132631A1 (en)
WO (1) WO1993020994A1 (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6030575A (en) * 1991-10-21 2000-02-29 The Dow Chemical Company Method for making preforms
GB2323552B (en) * 1997-03-24 2001-12-12 Alan Roger Harper Method and apparatus for manufacture of a preform
US7910038B2 (en) 2008-11-24 2011-03-22 GM Global Technology Operations LLC Preforms and methods of making the same
DE102015200275A1 (en) 2015-01-12 2016-07-14 Hp Pelzer Holding Gmbh 3-dimensional high-strength fiber composite component and method for its production

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2686141A (en) * 1951-06-29 1954-08-10 Keyes Fibre Co Preparation of resin-bearing fibrous pulp
US2961361A (en) * 1955-05-10 1960-11-22 Fiberglas Canada Ltd Manufacture of reinforcing mats
US3063833A (en) * 1959-12-14 1962-11-13 Ingersoll Rand Co New metal alloy material and method of heat treating

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
No further relevant documents disclosed *

Also Published As

Publication number Publication date
AU3915493A (en) 1993-11-18
EP0634969A1 (en) 1995-01-25
JPH07508227A (en) 1995-09-14
CA2132631A1 (en) 1993-10-28
WO1993020994A1 (en) 1993-10-28

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