GB2151535A - Rigid light-weight components - Google Patents

Rigid light-weight components Download PDF

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Publication number
GB2151535A
GB2151535A GB08404064A GB8404064A GB2151535A GB 2151535 A GB2151535 A GB 2151535A GB 08404064 A GB08404064 A GB 08404064A GB 8404064 A GB8404064 A GB 8404064A GB 2151535 A GB2151535 A GB 2151535A
Authority
GB
United Kingdom
Prior art keywords
resin
component
coating
mixture
strength
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Withdrawn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
GB08404064A
Other versions
GB8404064D0 (en
Inventor
Ronald Mann
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.)
DYE JOHN JOSEPH
LOCKWOOD BENTINE GREGORY LOCKW
LOCKWOOD BENTINE SELWYN DEREK
Original Assignee
DYE JOHN JOSEPH
LOCKWOOD BENTINE GREGORY LOCKW
LOCKWOOD BENTINE SELWYN DEREK
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 DYE JOHN JOSEPH, LOCKWOOD BENTINE GREGORY LOCKW, LOCKWOOD BENTINE SELWYN DEREK filed Critical DYE JOHN JOSEPH
Publication of GB8404064D0 publication Critical patent/GB8404064D0/en
Publication of GB2151535A publication Critical patent/GB2151535A/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Withdrawn legal-status Critical Current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
    • B29C70/58—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres
    • B29C70/66—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising fillers only, e.g. particles, powder, beads, flakes, spheres the filler comprising hollow constituents, e.g. syntactic foam
    • 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
    • B29K2069/00—Use of PC, i.e. polycarbonates 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
    • B29K2105/16—Fillers
    • B29K2105/165—Hollow fillers, e.g. microballoons or expanded particles
    • 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
    • B29K2995/0013—Conductive
    • 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
    • B29L2009/00—Layered products

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)

Abstract

A rigid light-weight component is formed by making a core of low density plastics, and then covering this core with a metal coating. The metal coating can provide most, some or none of the strength of the finished component, and a significant part, or all, of the component strength is also derived from the plastics core. The core is formed by mixing glass micro-spheres or micro balloons with a plastics resin. The micro-spheres introduce void areas or cavities into the resin/micro-sphere mixture, to reduce the density of this mixture. The glass walls of the micro-spheres however play a significant role in increasing the strength, particularly the compressive strength of the core. The core can be coated with metal by giving it a conductive film over its surface and then electroplating the component.

Description

SPECIFICATION Rigid light-weight components Field of Invention This invention relates to a method of forming rigid light-weight components, and to such components themselves. Rigid light-weight components are often required for aerospace applications and other similar applications.
Summary of the Invention According to the present invention, there is provided a method of forming a rigid lightweight component, the method comprising the steps of mixing glass micro-spheres with a plastics resin, forming the mixture to a desired shape, allowing the resin to set and coating the resulting shape with metal.
The thickness of the metal coating can be varied. In one embodiment, the thickness can be such as to give the component the major part of its strength, with the remainder of the strength provided by the glass microspheres (or micro balloons)/plastic mix. These spheres are an internal part of the component and with the plastics resin they do provide a significant part of the strength, particularly the compressive strength, of the component. The thickness of such a metal coating is likely to be in excess of 0.25mm.
In a second embodiment, the metal coating can be just a coating which resists abrasion and which provides only a minor part of the strength of the component. The thickness of such a coating is likely to be in the range 0.05mm to 0.25mm.
In a third embodiment, the coating contributes nothing structurally, but allows for radio frequency screening or provides a conductive surface. The thickness of such a coating is likely to be in the range 1 to 125 microns.
The metal coating thickness for each of these three embodiments will vary depending on the size and shape of the component, the exact make-up of the filled resin used as the core material and the general performance requirements.
The resin may be, for example, an epoxy resin or a polyester resin.
The mixture may be formed to the desired shape in a mould which may be heated to allow the resin to set. The metal coating is preferably applied by an electroplating process. In such a process, the set resin shape is first given a conductive surface fill which can be applied by any convenient technique.
Examples of such techniques are electroless deposition, immersion silvering, spray metal painting, spray reduction silvering and spray or brush on metallic paint or graphite.
The invention also extends to a rigid lightweight component formed by the method set out above.
Example A rigid light-weight component was made using an epoxy resin system with Ciba-Geigy LY560 resin with HY560 hardener. The resin was mixed with a filler of hollow glass microspheres produced by Emerson and Cumming U.K. Limited. The resin and micro-spheres were mixed throughly using a low shear mixer to form a mixture having a smooth uniform consistency. Air trapped in the mixture was removed by allowing the mixture to stand whilst agitating it intermittently. An alternative way of removing this air would be to apply vacuum to the mixture.
The mixture was filled into a mould and was raised to the curing temperature for the time necessary for the resin to cure.
The moulded shape was then removed from the mould and a conductive film was then applied to its surface by vacuum deposition.
The conductive film was then electroplated with a layer of nickel, although other metals such as copper are quite suitable. The plating was continued until the required thickness of material has been built up to give the desired strength to the skin of the component.
The glass microspheres in the component core produce a composite component having an improved compressive strength relative to a similarly produced material in which the spherical air pockets have no reinforcing wall around them, but are simply air bubbles or gas bubbles produced in a foaming process.
1. A method of forming a rigid lightweight component, the method comprising the steps of mixing glass micro-spheres with a plastics resin, forming the mixture to a desired shape, allowing the resin to set and coating the resulting shape with metal.
2. A method as claimed in Claim 1, wherein the resin is an epoxy resin.
3. A method as claimed in Claim 1, wherein the resin is a polyester resin.
4. A method as claimed in any preceding claim, wherein the mixture is formed to its desired shape in a mould.
5. A method as claimed in any preceding claim, wherein the temperature of the mixture is raised to allow the resin to set.
6. A method as claimed in any preceding claim, wherein the set resin shape is provided with a conductive film over its surface and is then electroplated.
7. A method as claimed in claim 6, wherein the conductive film is applied by vacuum deposition.
8. A rigid light-weight component formed by the method of any one of the preceding claims.
9. A rigid light-weight component formed by the method described in the example.
10. A rigid light-weight component as claimed in Claim 8, wherein the metal coating
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (15)

**WARNING** start of CLMS field may overlap end of DESC **. SPECIFICATION Rigid light-weight components Field of Invention This invention relates to a method of forming rigid light-weight components, and to such components themselves. Rigid light-weight components are often required for aerospace applications and other similar applications. Summary of the Invention According to the present invention, there is provided a method of forming a rigid lightweight component, the method comprising the steps of mixing glass micro-spheres with a plastics resin, forming the mixture to a desired shape, allowing the resin to set and coating the resulting shape with metal. The thickness of the metal coating can be varied. In one embodiment, the thickness can be such as to give the component the major part of its strength, with the remainder of the strength provided by the glass microspheres (or micro balloons)/plastic mix. These spheres are an internal part of the component and with the plastics resin they do provide a significant part of the strength, particularly the compressive strength, of the component. The thickness of such a metal coating is likely to be in excess of 0.25mm. In a second embodiment, the metal coating can be just a coating which resists abrasion and which provides only a minor part of the strength of the component. The thickness of such a coating is likely to be in the range 0.05mm to 0.25mm. In a third embodiment, the coating contributes nothing structurally, but allows for radio frequency screening or provides a conductive surface. The thickness of such a coating is likely to be in the range 1 to 125 microns. The metal coating thickness for each of these three embodiments will vary depending on the size and shape of the component, the exact make-up of the filled resin used as the core material and the general performance requirements. The resin may be, for example, an epoxy resin or a polyester resin. The mixture may be formed to the desired shape in a mould which may be heated to allow the resin to set. The metal coating is preferably applied by an electroplating process. In such a process, the set resin shape is first given a conductive surface fill which can be applied by any convenient technique. Examples of such techniques are electroless deposition, immersion silvering, spray metal painting, spray reduction silvering and spray or brush on metallic paint or graphite. The invention also extends to a rigid lightweight component formed by the method set out above. Example A rigid light-weight component was made using an epoxy resin system with Ciba-Geigy LY560 resin with HY560 hardener. The resin was mixed with a filler of hollow glass microspheres produced by Emerson and Cumming U.K. Limited. The resin and micro-spheres were mixed throughly using a low shear mixer to form a mixture having a smooth uniform consistency. Air trapped in the mixture was removed by allowing the mixture to stand whilst agitating it intermittently. An alternative way of removing this air would be to apply vacuum to the mixture. The mixture was filled into a mould and was raised to the curing temperature for the time necessary for the resin to cure. The moulded shape was then removed from the mould and a conductive film was then applied to its surface by vacuum deposition. The conductive film was then electroplated with a layer of nickel, although other metals such as copper are quite suitable. The plating was continued until the required thickness of material has been built up to give the desired strength to the skin of the component. The glass microspheres in the component core produce a composite component having an improved compressive strength relative to a similarly produced material in which the spherical air pockets have no reinforcing wall around them, but are simply air bubbles or gas bubbles produced in a foaming process. CLAIMS
1. A method of forming a rigid lightweight component, the method comprising the steps of mixing glass micro-spheres with a plastics resin, forming the mixture to a desired shape, allowing the resin to set and coating the resulting shape with metal.
2. A method as claimed in Claim 1, wherein the resin is an epoxy resin.
3. A method as claimed in Claim 1, wherein the resin is a polyester resin.
4. A method as claimed in any preceding claim, wherein the mixture is formed to its desired shape in a mould.
5. A method as claimed in any preceding claim, wherein the temperature of the mixture is raised to allow the resin to set.
6. A method as claimed in any preceding claim, wherein the set resin shape is provided with a conductive film over its surface and is then electroplated.
7. A method as claimed in claim 6, wherein the conductive film is applied by vacuum deposition.
8. A rigid light-weight component formed by the method of any one of the preceding claims.
9. A rigid light-weight component formed by the method described in the example.
10. A rigid light-weight component as claimed in Claim 8, wherein the metal coating provides the major part of the component's strength.
11. A rigid light-weight component as claimed in Claim 10, wherein the coating thickness is 0.25mm or more.
12. A rigid light-weight component as claimed in Claim 8, wherein the metal coating provides a minor part of the component's strength.
13. A rigid light-weight component as claimed in Claim 12, wherein the coating thickness lies in the range 0.05mm to 0.25mm.
14. A rigid light-weight component as claimed in Claim 8, wherein the metal coating provides none of the component's strength.
15. A rigid light-weight component as claimed in Claim 14, wherein the coating thickeness lies in the range 1 to 125 microns.
GB08404064A 1983-12-21 1984-02-16 Rigid light-weight components Withdrawn GB2151535A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB838334047A GB8334047D0 (en) 1983-12-21 1983-12-21 Rigid lightweight components

Publications (2)

Publication Number Publication Date
GB8404064D0 GB8404064D0 (en) 1984-03-21
GB2151535A true GB2151535A (en) 1985-07-24

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GB838334047A Pending GB8334047D0 (en) 1983-12-21 1983-12-21 Rigid lightweight components
GB08404064A Withdrawn GB2151535A (en) 1983-12-21 1984-02-16 Rigid light-weight components

Family Applications Before (1)

Application Number Title Priority Date Filing Date
GB838334047A Pending GB8334047D0 (en) 1983-12-21 1983-12-21 Rigid lightweight components

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2707427A1 (en) * 1993-07-07 1995-01-13 Deutsche Forsch Luft Raumfahrt Method for producing a negative mold for reflectors of parabolic antennas Reflector obtained and press device for producing composite bodies for these reflectors.

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1070874A (en) * 1963-09-14 1967-06-07 Hamburger Flugzeugbau Gmbh Lightweight constructional elements
GB1246582A (en) * 1965-09-23 1971-09-15 Pittsburgh Corning Corp Method of making a shaped article from coated multicellular glass nodules
GB1389446A (en) * 1971-04-08 1975-04-03 Ici Ltd Abrasion resistant cellular articles
GB1483211A (en) * 1975-08-22 1977-08-17 Groombridge B Method of electro-plating a non-conductive substrate

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1070874A (en) * 1963-09-14 1967-06-07 Hamburger Flugzeugbau Gmbh Lightweight constructional elements
GB1246582A (en) * 1965-09-23 1971-09-15 Pittsburgh Corning Corp Method of making a shaped article from coated multicellular glass nodules
GB1389446A (en) * 1971-04-08 1975-04-03 Ici Ltd Abrasion resistant cellular articles
GB1483211A (en) * 1975-08-22 1977-08-17 Groombridge B Method of electro-plating a non-conductive substrate

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2707427A1 (en) * 1993-07-07 1995-01-13 Deutsche Forsch Luft Raumfahrt Method for producing a negative mold for reflectors of parabolic antennas Reflector obtained and press device for producing composite bodies for these reflectors.

Also Published As

Publication number Publication date
GB8404064D0 (en) 1984-03-21
GB8334047D0 (en) 1984-02-01

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Legal Events

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WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)