GB2352249A - Glass fibre prepreg manufacture - Google Patents

Glass fibre prepreg manufacture Download PDF

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Publication number
GB2352249A
GB2352249A GB9916954A GB9916954A GB2352249A GB 2352249 A GB2352249 A GB 2352249A GB 9916954 A GB9916954 A GB 9916954A GB 9916954 A GB9916954 A GB 9916954A GB 2352249 A GB2352249 A GB 2352249A
Authority
GB
United Kingdom
Prior art keywords
wetting agent
weave
preg
glass fibre
polymer
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
Application number
GB9916954A
Other versions
GB2352249B (en
GB9916954D0 (en
Inventor
Kerry Emmett Arthur Kirwan
Gordon Frederick Smith
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.)
MG Rover Group Ltd
Original Assignee
MG Rover Group 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
Application filed by MG Rover Group Ltd filed Critical MG Rover Group Ltd
Priority to GB9916954A priority Critical patent/GB2352249B/en
Publication of GB9916954D0 publication Critical patent/GB9916954D0/en
Publication of GB2352249A publication Critical patent/GB2352249A/en
Application granted granted Critical
Publication of GB2352249B publication Critical patent/GB2352249B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/12—Bonding of a preformed macromolecular material to the same or other solid material such as metal, glass, leather, e.g. using adhesives
    • 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
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
    • 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
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
    • B29B15/125—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex by dipping
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/12—General methods of coating; Devices therefor
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/24—Coatings containing organic materials
    • C03C25/26—Macromolecular compounds or prepolymers
    • C03C25/28—Macromolecular compounds or prepolymers obtained by reactions involving only carbon-to-carbon unsaturated bonds
    • C03C25/285—Acrylic resins
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
    • C03C25/10—Coating
    • C03C25/48—Coating with two or more coatings having different compositions
    • C03C25/50—Coatings containing organic materials only
    • 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
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/07—Parts immersed or impregnated 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
    • 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
    • B32B2333/00—Polymers of unsaturated acids or derivatives thereof
    • B32B2333/04—Polymers of esters
    • B32B2333/08—Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
    • 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
    • B32B2369/00—Polycarbonates
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2369/00—Characterised by the use of polycarbonates; Derivatives of polycarbonates

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Geochemistry & Mineralogy (AREA)
  • General Chemical & Material Sciences (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Reinforced Plastic Materials (AREA)

Abstract

A method of manufacture of a glass fibre pre-preg for use in a polymer glazing application is disclosed. A glass fibre weave 32 is provided and a wetting agent 36 is introduced over the weave. The weave and the wetting agent are heated and cyclically loaded to produce the pre-preg. This method has as an advantage that the cyclic loading creates a relative movement between the fibres of the glass weave 32 and the wetting agent 36, thereby increasing the wetting of the fibres 32 by the wetting agent 36. The glass fibre (6) may be placed on a first layer (4) of an encapsulating film e.g. acrylic and a second layer (10) of an encapsulating film e.g. acrylic may be provided on the wetting agent (8) to form a sandwich before heating and cyclical loading. The wetting agent may be thermoset. Alternatively a polymer such as polycarbonate may be back injected against the pre-peg (22) in a mould (20) in which the heat from the polymer of the be used to cure the thermoset polymer of the wetting agent.

Description

2352249 Manufacturing Method The present invention relates to polymer
glazing, and in particular to the use of polycarbonate as a polymer glazing material.
There are a number of problems associated with the use of polycarbonate as a glazing material. In particular a lack of inherent stiffness is seen as a major inhibitor to the widespread introduction of polymer glazing. The introduction of glass fibres into a surface of a polycarbonate component will increase the structural rigidity of the component. However, this is typically at the expense of transparency or clarity of the polycarbonate component thus produced. This is believed to be due to incomplete wetting between the glass fibres and the polycarbonate.
It is known to manufacture a laminate by individually drawing flourophosphate glass fibres onto a cylinder, the cylinder first being provided with a poly(chlorotrifluoroethylene) (PCTFE) film coating, the fibres thus forming an even distribution of parallel fibres on the PCTFE film. A series of laminates may then be hot pressed together to form a composite material. This process results in a composite component having good optical properties.
However, as will be appreciated, such a process is extremely time consuming and is not cost effective. As a result it is believed to have no current application in a commercial mass production process.
The present invention has as an advantage that it eliminates, or at least reduces the impact of, the problems noted above.
According to a first aspect of the present invention a of a glass fibre pre-preg for use in a polymer glazing application comprises the steps of providing a glass fibre weave, providing a wetting agent over the weave, heating and cyclically loading the weave and the wetting agent to produce the pre-preg.
This has the advantage that the cyclic loading creates a relative movement between the material of the glass weave and the wetting agent, thereby increasing the wetting of the fibres by the wetting agent.
Conveniently, the method may further comprise the steps of providing a first layer of an encapsulating film onto which the glass fibre is placed, and providing a second layer of an encapsulating film over the wetting agent to form a sandwich, before heating and cyclically loading to produce the pre-preg or laminate.
The wetting agent may take the form of a polymeric resin or powder.
Acco9rding to a second aspect of the present invention a method of manufacture of a glazing component comprises the steps of providing a glass pre-preg manufactured in accordance with the first aspect of the invention and back injecting a polymer against the prepreg to form the component.
Preferably, the fibre weave is arranged at an outer surface of the component where most mechanical benefit will be realised.
The invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
Figure I shows a schematic side view of the elements required for the manufacture of a pre-preg in accordance with the first aspect of the present invention; Figure 2 shows a side section of an apparatus suitable for use in the second aspect of the present invention; and Figure 3 shows a schematic view of an alternative manner of manufacture of a pre-preg in accordance with the first aspect of the present invention.
3 - Referring first to Figure I there may be seen a schematic view of the elements required for a first method of manufacture of a pre-preg in accordance with the first aspect of the present invention.
A portion of a first lower platen 2 of a hot press tool is shown at the bottom of Figure 1.
A first layer 4 of an encapsulating film is laid up on the lower platen 2. The first layer 4 of encapsulating film is of any suitable material, conveniently an acrylic material. The first layer 4 of encapsulating filin is of a suitable thickness, typically 100 microns.
A glass fibre weave 6 is then laid up over the first layer 4 of the encapsulating film.
A wetting agent 8 is then spread over the glass fibre weave 6. The wetting agent 8 is of a similar refractive index to the glass fibres of the weave 6. Typically, the wetting agent 8 is clear. The wetting agent 8 is of any suitable material, conveniently a thermoset material. The wetting agent may take the form of a polymeric resin or powder. When the wetting agent is in the form of a powder, the powder is such that it will liquefy in the hot press.
A second layer 10 of the encapsulating film of similar size and dimensions to the first layer 4 is placed over the top to form a sandwich. An upper platen 12 of the hot press tool is shown at the top of Figure 1. It will be understood that the upper and lower platens 2,12 of the hot press tool may form a mould cavity therebetween to receive the elements of the sandwich.
Alternatively, the components of the sandwich may be assembled away from the hot press and the sandwich brought to the hot press.
The temperature of the hot press tool is sufficient to induce the wetting agent 8 to flow. 'Me hot press is conveniently heated to about 200 degrees Centigrade. The sandwich in the hot press tool is subjected to several cyclic loadings by the upper and lower platens 2,12 of the hot press tool. The cyclic loadings stimulates relative movement of the wetting agent and the glass fibres of the weave 6 resulting in increased wetting of the glass fibres of the weave 6 by the wetting agent 8.
After the cyclic loadings, the pre-preg thus formed is removed. Ile prepreg is transparent.
The time taken to produce such a pre-preg is a matter of minutes. Further improvements in the process time can be obtained by evacuating a mould cavity in the hot press tool prior to cyclic loading.
Referring now to Figure 2, a diagrammatic cross-section through a two part mould 20 with a glass pre-preg 22 in position ready for injection of a liquid polymer material is shown.
The mould 20 comprises a first mould part 24 and a second mould part 26. A mould cavity 28 is defined between the first mould part 24 and the second mould part 26. The first mould pan 24 is formed with an injection passage or sprue 30 through which a liquid polymer material can be injected from an injection moulding machine (not shown).
In use, the glass pre-preg 22 manufactured as described previously is located in the mould cavity 28. The mould is closed by bringing together the first and second mould parts 24,26. A liquid polymer is then back injected into the mould cavity 28 behind the pre preg 22. The liquid polymer is allowed to cool to form the component, and the mould 20 opened to allow the component to be removed.
The liquid polymer is preferably a polycarbonate. The heat from the back injected polymer can be used to cure the thermoset polymer of the wetting agent 8.
A glazing component produced in this manner has been found to have a three fold increase in flexural modulus as compared to a similar component manufactured from polycarbonate alone.
Referring to Figure 3, a schematic view of the elements required for an alternative method of manufacture of a pre-preg in accordance with the first aspect of the present invention.
The apparatus of Figure 2 can be seen to comprise a first roller 30 on which is mounted a roll of continuous glass fibre mat or weave 32, a container or bath 34 containing a liquid wetting agent 36, an oven 38 and a collecting -roller 40.
The glass fibre weave 32 is taken from the first roller 30 and fed into the bath of liquid wetting agent. As in the first embodiment, the wetting agent may comprises any suitable material.
Within the liquid wetting agent are located a first pair of rollers 42 and a second pair 44 of rollers. The glass fibre weave is drawn through the first pair of rollers and the second pair of rollers. The rollers act to expel any air present within the glass fibre weave and promote relative motion between the fibres and the liquid wetting agent.
The glass fibre weave is then drawn through the oven 38, such as an infrared oven, and then onto the collecting roll 40. Preferably this process is conducted in a near vacuum or low pressure environment since this enhances the wetting of the fibres of the weave 32 by the wetting agent 36.

Claims (2)

  1. -6CLAIMS
    A method of manufacture of a glass fibre pre-preg for use in a polymer glazing application comprises the steps of providing a glass fibre weave, providing a wetting agent over the weave, heating and cyclically loading the weave and the wetting agent to produce the pre-preg.
  2. 2. A method according to claim 1, characterised in that the method ftirther comprises the steps of providing a first layer of an encapsulating film onto which the glass fibre is placed, and providing a second layer of an encapsulating film over the wetting agent to form a sandwich, before heating and cyclically loading to produce the pre- preg or laminate.
    3 A method according to claim 2, characterised in that the first layer or second layer or both are formed of an acrylic material.
    4 A method according to any previous claim, characterised in that the wetting agent is a thermoset material.
    A method of manufacture of a glass fibre pre-preg for use in a polymer glazing application substantially as described herein with reference to and as illustrated in Figure I or Figure 3 of the accompanying drawings.
    6 A method of manufacture of a glazing component comprises the steps of providing a glass pre-preg manufactured in accordance with the first aspect of the invention and back injecting a polymer against the pre-preg to form the component.
    7 A method according to claim 6, characterised in that the fibre weave is arranged at an outer surface of the component.
    8 A method according to claim 6 or claim 7, characterised in that the liquid polymer is a polycarbonate.
    9 A method of manufacture of a glazing component substantially as described herein with reference to and as illustrated in Figures I or 3 and Figure 2 of the accompanying drawings.
    I I
GB9916954A 1999-07-21 1999-07-21 A method of manufacture of a glass fibre pre-preg for use in a polymer glazing application Expired - Fee Related GB2352249B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB9916954A GB2352249B (en) 1999-07-21 1999-07-21 A method of manufacture of a glass fibre pre-preg for use in a polymer glazing application

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9916954A GB2352249B (en) 1999-07-21 1999-07-21 A method of manufacture of a glass fibre pre-preg for use in a polymer glazing application

Publications (3)

Publication Number Publication Date
GB9916954D0 GB9916954D0 (en) 1999-09-22
GB2352249A true GB2352249A (en) 2001-01-24
GB2352249B GB2352249B (en) 2004-04-14

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106113317A (en) * 2016-07-28 2016-11-16 黄河科技学院 A kind of continuous carbon fibre melt impregnation thermoplastic polymer prepreg tape prepares mould

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0223061A2 (en) * 1985-10-23 1987-05-27 International Business Machines Corporation Process for the production of prepreg sheets

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS54141852A (en) * 1978-04-27 1979-11-05 Nhk Spring Co Ltd Manufacture of frp leaf spring
JPS6090757A (en) * 1983-10-24 1985-05-21 新神戸電機株式会社 Manufacture of laminated board
AT396240B (en) * 1990-06-13 1993-07-26 Isovolta PREPREG PROCESS FOR ITS PRODUCTION AND USE

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0223061A2 (en) * 1985-10-23 1987-05-27 International Business Machines Corporation Process for the production of prepreg sheets

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106113317A (en) * 2016-07-28 2016-11-16 黄河科技学院 A kind of continuous carbon fibre melt impregnation thermoplastic polymer prepreg tape prepares mould

Also Published As

Publication number Publication date
GB2352249B (en) 2004-04-14
GB9916954D0 (en) 1999-09-22

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732E Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977)
732E Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977)
PCNP Patent ceased through non-payment of renewal fee

Effective date: 20060721