GB2109743A - Pre-finished laminate - Google Patents
Pre-finished laminate Download PDFInfo
- Publication number
- GB2109743A GB2109743A GB08129293A GB8129293A GB2109743A GB 2109743 A GB2109743 A GB 2109743A GB 08129293 A GB08129293 A GB 08129293A GB 8129293 A GB8129293 A GB 8129293A GB 2109743 A GB2109743 A GB 2109743A
- Authority
- GB
- United Kingdom
- Prior art keywords
- laminate
- finish
- fibre
- construction
- reinforced plastic
- 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.)
- Granted
Links
- 239000000463 material Substances 0.000 claims abstract description 14
- 238000000034 method Methods 0.000 claims abstract description 12
- 229920002430 Fibre-reinforced plastic Polymers 0.000 claims abstract description 10
- 238000010276 construction Methods 0.000 claims abstract description 10
- 239000011151 fibre-reinforced plastic Substances 0.000 claims abstract description 10
- 239000002648 laminated material Substances 0.000 claims abstract description 7
- 239000002131 composite material Substances 0.000 claims 1
- 239000000470 constituent Substances 0.000 claims 1
- 239000002184 metal Substances 0.000 abstract description 4
- 238000007730 finishing process Methods 0.000 abstract description 2
- 239000012467 final product Substances 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 16
- 229920005989 resin Polymers 0.000 description 7
- 239000011347 resin Substances 0.000 description 7
- 238000003475 lamination Methods 0.000 description 6
- 239000002023 wood Substances 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000012790 adhesive layer Substances 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 239000006260 foam Substances 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004840 adhesive resin Substances 0.000 description 1
- 229920006223 adhesive resin Polymers 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 210000003298 dental enamel Anatomy 0.000 description 1
- 238000011031 large-scale manufacturing process Methods 0.000 description 1
- 239000004005 microsphere Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 239000000454 talc Substances 0.000 description 1
- 229910052623 talc Inorganic materials 0.000 description 1
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
- B29C70/302—Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination
-
- 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
- B29C70/06—Fibrous reinforcements only
- B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
- B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPINGÂ
- B63B5/00—Hulls characterised by their construction of non-metallic material
- B63B5/24—Hulls characterised by their construction of non-metallic material made predominantly of plastics
-
- 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
- B29K2995/0037—Other properties
- B29K2995/0072—Roughness, e.g. anti-slip
- B29K2995/0073—Roughness, e.g. anti-slip smooth
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3067—Ships
- B29L2031/307—Hulls
-
- 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
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Composite Materials (AREA)
- Combustion & Propulsion (AREA)
- Ocean & Marine Engineering (AREA)
- Laminated Bodies (AREA)
Abstract
This invention refers to a laminated material and associated method of construction for use, for example in small boat construction, in which the main structure is a fibre- reinforced plastic 3, 6, in which one surface of the laminate is smooth, and the final product is of substantially homogeneous material. Thus no subsequent finishing process is necessary except at joints and edges. The laminate may be assembled on a flat surface, e.g. of metal provided with a release coat. <IMAGE>
Description
SPECIFICATION
Pre-finished laminate
In small boat building, for pleasure craft or a workboat, there are in general, two main methods of construction in fibre-reinforced plastic material.
For large-scale production purposes, a mould is prepared on which successive layers of material are built up to produce a component of the final craft, separate components subsequently being assembled to form the whole craft. The finish of the mould, against which the first layer to be applied forms the outer skin, being such that when the component is removed from the mould, the outer surface does not need addition81 finish to be separately applied.
An alternative constructional method used predominantly in a case where one only craft will be produced from the design, is to build up the structure from the inside outwards, by successive layers, the final layer thus becoming the outer skin of'the craft. This final layer will carry on its surface the imperfections of the previous layers, and of the fibre reinforcing element used. In this case, the finish of the outer skin must be provided subsequently by successive applications of 'filler' material, rubbed down to an acceptable surface, which is then finally covered by the outer enamel or 'gel-coat'.
This subsequent application of a smooth surface finish is necessarily labour-intensive and thus an expensive process, but the method of construction has the advantage that an expensive mould is not required. In general the surface finish obtained will be inferior to that obtained (at much greater cost) by use of a mould.
In either method of construction, one or more of the laminations may be of wood, particularly in the thicker sections, whilst in the case of the second method, a sub-structure of wood may be built up, needing the final application of a strengthening and finishing skin of laminations of fibre-reinforced plastic.
It is the object of this invention to propose a basic laminated material from which the structure of the craft may be built, using the second of the methods described, in which the outer surface is itself provided with a high class smooth finish, comparable with that provided by build-up using a mould, and not requiring any additional finishing process, except in local areas where there are joins between the sheets of laminate. Where a completely homogeneous material is desired, the basic laminate will be provided with adequate thickness or reinforcement of the strength requirements of the craft hull and superstructure.
When used for construction of the structure of the craft, without other sub-structure, in this manner, the inner surfaces of the constructional laminate will thereafter be covered by one or more laminations of fibre-reinforced plastic material, extending over all joints, and serving to rigidify the structure. Bulkheads and compartment walls will then be fitted to this inner skin in conventional manner.
In a secondary object of the invention, the laminate' material is used in order merely to provide a good external finish to a structure built from fibre-reinforced plastic without use of a mould, or from wood, the external finishing laminate being flexible enough to mould generally to the configuration required, yet stiff enough not to follow the local surface imperfections of the sub-structure.
Materials which might be selected for use in the sub-surface layers of the special laminate are sheets of chopped strand glass fibre, woven rovings of glass fibres, or of carbon fibre, preprepared foam resin, or thin sheets of metal, prepared by perforation or surface treatment to ensure adhesion of the plastic bonding material.
As was previously noted, for series production of fibre-reinforced components, a mould is required, which is normally produced by the intermediate building of a male mould master (referred to as a 'plug', which conforms to the final shape of the boat or other structure, but which does not have the requisite mechanical strength required in the final article. The surface finish of this 'plug' must be of a very high order, since the mould finally produced from it will reproduce any surface defects. Provision of such high finish is time-consuming and therefore costly, and cannot be justified unless a very large production run is contemplated.The use of the pre-finished laminate according to this invention would therefore be advantageous in producing at low cost the 'plug' from which a mould could be produced economically for a small series production for which the cost of producing a 'plug' by the conventional method would be uneconomic.
In one embodiment of the invention, the special laminate will be prepared by use of a polished sheet of metal or other flat surface of adequate size and rigidity, referred to as the mould-sheet (1), which is treated with a substance referred to as a 'Release Agent', (2) which enables the final laminate to be stripped from the mould sheet retaining its surface finish, and the initial coating of resin which will ultimately become the outer skin, usually of 'gei-coat' pigmented suitably, (3) is applied thereto.
Further coats of resin, with or without fibrereinforcing layers will then be applied, each coat of resin being allowed to harden adequately as desired before application of the following layer.
For the simples type of lamination, purely required for use for providing surface finish, this layer or layers (4) will be adequate for the purpose, and the laminate will be stripped off the mould sheet after it has hardened sufficiently, and cut to the final size required. (Refer to Figure 1.)
For application to the surface to be provided with the good 'mould finish' as with surfaces of structures made by a full moulding technique, the laminate will be applied to the sub-structure (5) by use of a similar or compatible resin, loaded with a form of filler material, such as talc or plastic microspheres (6), which fill up the surface imperfections of the sub-structures and unite the laminate and sub-structure in a homogeneous mass after the adhesive layer has hardened.In applying the adhesive layer, between the laminate and the sub-structure, the laminate will be rolled outwards from its centre, or from one edge in order to secure intimate contact without inclusion of air-bubbles or cavities. (Refer to Figure 2.)
In producing the alternative form of lamination, in which the laminate possesses adequate mechanical strength for the structure, as designed, the strength is provided by a thick layer of a suitable material (7), which may be metal, foam plastic sheet or wood, which is applied to the initial surface laminate while it is still on the mould sheet, further layers of resin being applied if desired. (Refer to Figure 3.)
In the construction of a structure using this thick, substantially-reinforced laminate, the several portions of thick laminate are cut to size.
edges being mitre if necessary for the final shape required, and fixed in position using a compatible adhesive resin (8), (Refer to Figure 4), the complete assembly then being covered internally by one or more layers of fibre-reinforced plastic (9) which further rigidifies the structure. The joint area of the external surfaces are then the only areas which require to be finished to an acceptable surface finish.
In some cases it may be thought desirable, in order to provide additional strength at the joins between sheets, to leave the thicker layers of the laminations protruding somewhat outside the surface layers, as shown in Figure 5, and to make a a more substantial joint by the application of outer fillets of fibre-reinforcing material with layers of resin, (10), and accepting that these small areas will need to be provided with high surface finish subsequently, in conventional manner.
In cases where a high class interior finish is desirable, the inside surfaces of the structure may also be treated by application of a pre-finished laminate, which may well also provide the structural strength in place of other separatelyapplied layers of fibre-reinforced plastic, (11).
Having thus described the invention with reference to the embodiments described above, I claim it to be described in full in the claims following in the attached sheet:
Claims (7)
1. A composite laminate for use as a constructional material in the construction of fibre-reinforced plastic structures, such as small boats, to provide a high grade surface finish to a structure, such surface finish being inherently provided by the surface of the laminate, and being of the same character as the finish produced by the structure being built up in a mould in conventional manner.
2. A flat laminate as described in Claim 1, in which the constituents are such as to provide reasonable flexibility to allow the laminate to conform to curved pre-formed structures for the purpose of adding a high quality finish to the final surface.
3. A laminate material as described in Claim 1, built up to a predetermined shape as required by the sub-structure to which it will be applied, in order to add a high quality surface finish to the final structure.
4. A constructional laminate material as claimed in any of the preceding claims, in which one or more of the sub-laminates are of such a material as to provide adequate strength in a structure built substantially completely from such laminates, with or without additional laminates being applied over the surface of the structure.
5. A method of construction of a structure of fibre-reinforced plastic, such as a sailing dinghy or yacht, in which the main constructional material is one laminate or a number of different laminate materials as claimed in any or all of the preceding claims.
6. A method of construction of a structure of fibre-reinforced plastic, such as a small vessel, in which the male mould master, referred to as the 'plug' has been produced by the use of such laminate materials as claimed in any of the preceding claims.
7. A laminated material or constructional method substantially in accordance with any of the drawings attached to this specification.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB08129293A GB2109743B (en) | 1981-09-29 | 1981-09-29 | Pre-finished laminate |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB08129293A GB2109743B (en) | 1981-09-29 | 1981-09-29 | Pre-finished laminate |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB2109743A true GB2109743A (en) | 1983-06-08 |
| GB2109743B GB2109743B (en) | 1986-01-29 |
Family
ID=10524797
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB08129293A Expired GB2109743B (en) | 1981-09-29 | 1981-09-29 | Pre-finished laminate |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2109743B (en) |
-
1981
- 1981-09-29 GB GB08129293A patent/GB2109743B/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| GB2109743B (en) | 1986-01-29 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |