GB2195952A - Composite sheet material - Google Patents

Composite sheet material Download PDF

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Publication number
GB2195952A
GB2195952A GB08720235A GB8720235A GB2195952A GB 2195952 A GB2195952 A GB 2195952A GB 08720235 A GB08720235 A GB 08720235A GB 8720235 A GB8720235 A GB 8720235A GB 2195952 A GB2195952 A GB 2195952A
Authority
GB
United Kingdom
Prior art keywords
fabric
sheet material
composite sheet
skin portions
core portion
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Withdrawn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
GB08720235A
Other versions
GB8720235D0 (en
Inventor
Derek Simon Richard Ness
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.)
Gurit UK Ltd
Original Assignee
Gurit UK Ltd
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
Priority claimed from GB868621393A external-priority patent/GB8621393D0/en
Application filed by Gurit UK Ltd filed Critical Gurit UK Ltd
Priority to GB08720235A priority Critical patent/GB2195952A/en
Publication of GB8720235D0 publication Critical patent/GB8720235D0/en
Publication of GB2195952A publication Critical patent/GB2195952A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • B32B5/26—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 also being fibrous or filamentary
    • 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
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • 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
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • 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
    • B32B5/026—Knitted 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 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
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • 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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—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
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • 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
    • B32B2262/0246—Acrylic resin 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
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—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
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
    • B32B2305/186—Knitted fabrics
    • 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
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • 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
    • B32B2377/00—Polyamides

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

Composite sheet material 10 comprises two hard but flexible skin portions 11, a core portion 13, and, between the core portion 13 and each of the skin portions 11, a rigid bonding agent 15. The core portion 13 is composed of an otherwise limp knitted cellular fabric impregnated with resin subsequently cured to give the fabric a fixed or stable surface geometry and a resistance to compression in its direction of thickness. The skin portions 11 are of a resin with fibre reinforcement. <IMAGE>

Description

SPECIFICATION Composite sheet material BACKGROUND TO THE INVENTION ' This invention relates to composite sheet material.
SUMMARIES OF THE INVENTION According to one aspect of the invention, a core portion for sandwiching between two skin portions, so as to form a composite sheet material comprises an otherwise limp fabric having a distribution of holes extending throughout the area of the fabric, the fabric being given stability by a hardened resin impregnant and a substantial resistance to compression in the direction of thickness of the fabric.
According to another aspect of the invention, a composite sheet material comprises two skin portions, and, sandwiched between the said skin portions, a core portion composed of an otherwise limp fabric having a distribution of holes extending throughout the area of the fabric, the fabric being given stability by a hardened resin impregnant, and a substantial resistance to compression in the direction of thickness of the fabric, and, between the core portion and each of the said skin portions, a substantially rigid bonding agent providing an areally distributed bond between the core portion and each of the skin portions.
Preferably the said fabric is a cellular fabric, that is to say, the distribution of holes therein are formed during and as a characteristic of the process of fabrication of the fabric.
Preferably, the skin portions are each composed of a reinforced structural resin. Preferably, the structural resin of the skin portions is a fibre reinforced resin.
Preferably, the bonding agent is a hardened resin impregnant uniting the resin material of the core portion and the resin material of the skin portions.
The bonding agent may be thermoplastic or thermosetting in nature.
Preferably, the resin material of the core portion, the resin material of the skin portions and the resin material of the bonding agent are of the same composition. However, differing resin compositions may be used.
Preferably, the fabric component of the core portion is a knitted fabric. It may however be a woven fabric or a felt. It follows that where the fabric is a cellular fabric, the fabric is given the distribution of holes as a part of and as a characteristic of the knitting, weaving or felting process, as the case may be.
The fabric of the core portion may, advantageously, comprise man-made i.e. synthetic fibres. Preferably, such man-made fibres are of a polyester, polyamide or acrylic material.
The fibre reinforcement material of the skin portions, on the other hand preferably comprise glass aramid or carbon fibres or a mixture comprising a combination of glass, aramid or carbon fibres.
Preferably, also, resin of the core portion and the skin portions is an epoxy; but it may be a polyester, vinylester phenolic resin or any other suitable thermoplastic or thermosetting material.
The invention also comprises an artefact manufactured of the composite sheet material.
BRIEF DESCRIPTION OF THE DRA WINGS Figure 1 depicts, in plan, the form of a typical cellular fabric used to form part of the core portion of the composite sheet material, Figure 2 depicts, in section, the core and skin portions prior to their bonding to form the sheet material, and Figure 3 depicts, in section, the sheet material with the sheet and core portions bonded together.
DETAILED DESCRIPTION OF THE PREFERREO EMBODIMENT As best shown in Figure 3, the composite sheet material 10 comprises two hard though intrinsically flexible skin portions 11, a core portion 13, and, between the core portion 13 and each of the skin portions 11, a rigid bonding agent 15.
The core portion 13 is composed of an otherwise limp knitted cellular fabric 17 and a hardened structural resin impregnant giving the fabric 17 a fixed or stable surface geometry and a resistance to compression in its direction of thickness, dependant on the rigidity of the chosen resin system.
With reference to Figures 1 and 2, the cells of the cellular knitted fabric 17 are defined by the strands 19 thereof, and, as shown, the cells comprise a distribution of diamond shaped holes 20 extending throughout the area of the fabric 17.
The fabric 1 7 is knitted in a polyester fibre.
Other fibre materials may be employed; but whilst natural or artificial fibres derived from naturally occurring materials may be employed, man-made synthetic fibres are to be preferred, being chosen for their superior mechanical properties. In particular polyamide material may be used.
The fibrous strands 19 of the limp fabric 17 are impregnated with a liquid resin and the impregnated fabric 17 is stiffened by curing of the resin. The resultant core portion 13 is an open structure substantially defined by the configuration of the cellular fabric 17, thefibrous knitted strands 19 thereof serving to reinforce the hardened epoxy impregnant.
The core portion 13 may have a certain flexibility. It is nevertheless, areally topologically stable, the knitted fibres maintaining a substantially invariant geometrical relationship to one another throughout the entire area of the fabric.
The skin portions 11 are of a resin reinforced by glass, aramid or carbon fibres, or, alternatively, a mixture thereof.
In this example, the bonding agent 15 is a resin of the same composition as that incorporated in the core and skin portions 13, 11.
However, differing resin may be used if desired. During or after curing a bond is formed by the resin bonding agent 15 between the core and skin portions.
In the process of forming the composite sheet 10, the sheet may be made in the form of a non-flat sheet. In particular, the sheet may have curvature in three dimensions. To make a sheet 10, or an artefact incorporating the material, an epoxy resin layer incorporating glass aramid and carbon fibre reinforcement is impregnated with a liquid resin and laminated on a work surface so as to form one of the skin portions 11. Thereafter the knitted cellular fabric 17, impregnated with uncured liquid resin, is laid upon the reinforced resin layer (11),the impregnated fabric 17 uniting with re- sin of the layer (11) at bridging points between the layer and the fibrous strands 19 of the fabric 17. A second layer of resin, reinforced in the same manner as the first, is applied over the epoxy impregnated fabric 17 so as to form the other of the skin portions 11.As before, the epoxy resins of the impregnated fabric 17 and of the second resin layer (11) unite at bridging points between the layer and the fibrous strands of the fabric.
The whole is then left to cure. Heat may be applied to accelerate the curing process.
The composite sheet material 10 produced by the process described above has good structural strength, the reinforced core portion 13 carrying the shear stresses between the skin portions 11.
Whilst one embodiment of the invention has been described others are possible.
Thus, whilst the cellular fabric 17 has been described as a knitted fabric, other cellular fabrics might be employed. Woven or even felted cellular fabrics may be used.
In the foregoing description it is implicit that the cells of the fabric 17 are open cells and this may indeed be the case. A composite sheet material 10 so constructed has the virtue of being relatively light as well as possessing significant structural strength. The cells may, however, be filled, or partially filled, with resin or other material, according to the result required. This may be readily effected by the operator using conventional laminating practices.
Composite sheet materials as described and in accordance with the invention have merit not only in their strength in relation to their lightness, but also in the ready availability of the materials of which they are composed. In particular, the fabrics which may be employed as reinforcement in the core portion 13 may be commonplace and cheap as a result of their extensive use in other applications. By employing such readily available fabrics expensive manufacturing processes may be avoided in the core construction. The end result is a composite sheet material with good mechanical properties and inherently economical in production.
Another advantage derived from use of a knitted or woven fabric 17 is that the threedimensional fibrous structure thereof provides good bearing and shear strength for attachments secured by through bolts or by rivets.
Whilst in the foregoing description attention has been directed to certain features and combinations of features, the invention also comprises any other novel subject matter, or any other combination incorporating novel subject matter, being novel subject matter hereinbefore disclosed.

Claims (12)

1 . A composite sheet material comprising two skin portions, and, sandwiched between the said skin portions, a core portion composed of an otherwise limp fabric having a distribution of holes extending throughout the area of the fabric, the fabric being given stability by a hardened resin impregnant and a substantial resistance to compression in the direction of thickness of the fabric, and, between the core portion and each of the said skin portions, a substantially rigid bonding agent providing an areally distributed bond between the core portion and each of the skin portions.
2. Composite sheet material as claimed in Claim wherein the fabric is a cellular fabric.
3. Composite sheet material as claimed in Claim 2, wherein the fabric is a knitted fabric.
4. Composite sheet material as claimed in Claim 2 or 3, wherein the fabric comprises synthetic fibres.
5. Composite sheet material as claimed in Claim 4, wherein the synthetic fibres are of the group consisting of polyester, polyamide and acrylic material.
6. Composite sheet material as claimed in any one of Claims 1 to 5, wherein the skin portions each comprise a fibre reinforced resin.
7. Composite sheet material as claimed in any one of Claims 1 to 6, wherein the fabric impregnating resin is of the group consisting of epoxy, polyester, vinylester and phenolic resin materials.
8. Composite sheet material as claimed in Claim 6, wherein the fibre reinforced resin is of the group consisting of glass aramid and carbon fibre material, and epoxy, polyester, vinylester and phenolic resin material.
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9. An artefact manufactured of composite sheet material, as claimed in any one of Claims 1 to 8.
10. A core portion for sandwiching between two skin portions, substantially as hereinbefore described with reference to the accompanying drawings.
11. Composite sheet material, substantially as hereinbefore described with reference to the accompanying drawings.
12. A core portion for sandwiching between two skin portions, so as to form a composite sheet material compromising an otherwise limp fabric having a distributuion of holes extending throughout the area of the fabric, the fabric being given stability by a hardened resin impregnant and a substantial resistance to compression in the direction of thickness of the fabric.
GB08720235A 1986-09-04 1987-08-27 Composite sheet material Withdrawn GB2195952A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB08720235A GB2195952A (en) 1986-09-04 1987-08-27 Composite sheet material

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB868621393A GB8621393D0 (en) 1986-09-04 1986-09-04 Composite sheet material
GB08720235A GB2195952A (en) 1986-09-04 1987-08-27 Composite sheet material

Publications (2)

Publication Number Publication Date
GB8720235D0 GB8720235D0 (en) 1987-10-07
GB2195952A true GB2195952A (en) 1988-04-20

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
GB08720235A Withdrawn GB2195952A (en) 1986-09-04 1987-08-27 Composite sheet material

Country Status (1)

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1574041A (en) * 1976-01-30 1980-09-03 Asahi Chemical Ind Composite fabric and method for producing the same
GB2053997A (en) * 1979-07-14 1981-02-11 Ver Schmirgel & Maschf Treated polyester fabric for use in flexible abrasives
GB2057968A (en) * 1979-09-11 1981-04-08 Scott Bader Co Preimpregnated materials and methods of making and using them
GB2063155A (en) * 1979-11-12 1981-06-03 Lignotock Verfahrenstech A fibre mat for producing mouldings
GB2126526A (en) * 1982-09-03 1984-03-28 T & N Materials Res Ltd Heat-resistant laminate
GB2128547A (en) * 1982-10-12 1984-05-02 Perry Blouse Manufacturing Co Laminate component part for a garment
GB2147850A (en) * 1983-10-12 1985-05-22 Secr Defence "Fibre-reinforced thermoplastic laminate
EP0142906A1 (en) * 1983-08-25 1985-05-29 The Secretary of State for Defence in Her Britannic Majesty's Government of the United Kingdom of Great Britain and Composite materials

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1574041A (en) * 1976-01-30 1980-09-03 Asahi Chemical Ind Composite fabric and method for producing the same
GB2053997A (en) * 1979-07-14 1981-02-11 Ver Schmirgel & Maschf Treated polyester fabric for use in flexible abrasives
GB2057968A (en) * 1979-09-11 1981-04-08 Scott Bader Co Preimpregnated materials and methods of making and using them
GB2063155A (en) * 1979-11-12 1981-06-03 Lignotock Verfahrenstech A fibre mat for producing mouldings
GB2126526A (en) * 1982-09-03 1984-03-28 T & N Materials Res Ltd Heat-resistant laminate
GB2128547A (en) * 1982-10-12 1984-05-02 Perry Blouse Manufacturing Co Laminate component part for a garment
EP0142906A1 (en) * 1983-08-25 1985-05-29 The Secretary of State for Defence in Her Britannic Majesty's Government of the United Kingdom of Great Britain and Composite materials
GB2147850A (en) * 1983-10-12 1985-05-22 Secr Defence "Fibre-reinforced thermoplastic laminate

Also Published As

Publication number Publication date
GB8720235D0 (en) 1987-10-07

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