WO1992005216A1 - Materiaux et procedes de modelage - Google Patents

Materiaux et procedes de modelage Download PDF

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Publication number
WO1992005216A1
WO1992005216A1 PCT/GB1991/001600 GB9101600W WO9205216A1 WO 1992005216 A1 WO1992005216 A1 WO 1992005216A1 GB 9101600 W GB9101600 W GB 9101600W WO 9205216 A1 WO9205216 A1 WO 9205216A1
Authority
WO
WIPO (PCT)
Prior art keywords
thermoplastic
filler
modelling
materials
resin
Prior art date
Application number
PCT/GB1991/001600
Other languages
English (en)
Inventor
Roger Mark Sloman
Original Assignee
Advanced Composites 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 Advanced Composites Group Ltd. filed Critical Advanced Composites Group Ltd.
Publication of WO1992005216A1 publication Critical patent/WO1992005216A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/22—Expanded, porous or hollow particles
    • C08K7/24—Expanded, porous or hollow particles inorganic
    • C08K7/28—Glass
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/01—Use of inorganic substances as compounding ingredients characterized by their specific function
    • C08K3/013—Fillers, pigments or reinforcing additives

Definitions

  • This invention relates to synthetic modelling blocks, and materials for forming them.
  • the model may be manufactured from metal, graphite, wood, plaster, synthetic resins, plastics and other suitable materials.
  • Wood is still often used due to low cost, ease of working and availability, but it suffers from inherent drawbacks, and is gradually being replaced by other, synthetic products.
  • Wood can swell or shrink due to temperature and humidity variations and can be too soft for processes where pressure is used such as in an autoclave.
  • the grained nature of the material can lead to differential expansion and shrinkage, leading to warpage.
  • thermosetting resins such as epoxide or polyurethane resins filled with various materials.
  • thermosetting resins Whilst these materials are homogeneous with reduced thermal expansion coefficients, and higher temperature performance capability, and are as suitable as wood for being shaped and smoothed, production of the material can be problematic, and the final characteristics of the material are still not ideal for some applications.
  • the production process involves the use of matrix resins which rely on a heat-producing chemical reaction to harden, i.e. they are thermosetting resins.
  • This factor also limits the size of the block that may be produced, especially in terms of the thickness of material, due to the poor heat transfer characteristics of these materials.
  • the maximum temperature at which standard synthetic modelling block materials, currently available, may be utilised is about 120°C, and may have a limit of only 60 - 100°C, depending on the use conditions and requirements.
  • the material softens and distorts.
  • the material In order to achieve this maximum operating temperature, the material must be 'post cured' , that is, subjected to elevated temperatures for a period of time. This process is time and energy consumptive, further increasing production costs.
  • a typical production process would be to mix the various components under vacuum and cast into metal moulds. After low temperature hardening the cast blocks would be de oulded and post cured. The blocks would then be machined to size if necessary.
  • An alternative process is to extrude the material as a thick paste or dough, cut the extrudate into blocks, and subsequently apply heat to cure the material.
  • the thermal expansion coefficient is higher than desired for many applications, usually being in the range 25 to 40 x 10 " per D C, and often rising rapidly above 60 - 100 D C as the glass transition temperatures of the resins used are exceeded.
  • the term 'advanced composite materials' covers a wide range of materials used in many applications where high levels of structural performance are required, usually combined with high, consistent quality, such as aerospace, defence, sports, medical and industrial equipment. In most cases the desired properties are high specific strength, and/or high specific modulus, although other secondary properties such as corrosion resistance, fatigue resistance, impact energy absorption, or X-Ray transparency can lead to the selection of advanced composites.
  • the materials consist of a combination of strong and/or stiff reinforcing fibres in a matrix of some kind, usually a thermosetting resin or thermoplastic polymer, although metal and ceramic matrices are also used.
  • prepreg' has different meanings in different countries and in different market sectors, and there is not yet any agreed standard definition.
  • the term referring to a combination of resin and fibres processed to give an easily handled, storeable sheet material containing all the ingredients necessary for complete cure which can then be laid into a mould and formed to a required shape, normally by a combination of heat and pressure.
  • the term is derived from an abbreviation of the word ' preimpregnation' , this term describing the process by which the resin matrix is impregnated into the fibrous material some time before the resulting sheet material is laid into the mould and further processed to produce the required shape.
  • preimpregnation is usually carried out by specialist materials production companies, who then supply the prepreg to end users such as aircraft component producers.
  • the long time delay between material production and use to make components usually demands that the prepreg has to be relatively stable during transport, storage and handling at ambient temperature.
  • the prepreg resin is formulated so that it does not cure significantly until relatively high temperatures, usually in the 120° - 180°C range.
  • thermosetting resin matrices are usually formulated and processed to give a resin viscosity which results in the material having a level of tack and drape which gives the most convenient handleability during layup in the mould. This is known as the B-stage. Usually this means sufficient tack and drape to allow the prepreg to form to the shape of the mould, and then stick to the mould surface. Ideally, resin should not transfer to the fingers when the prepreg is touched.
  • the term 'prepreg' refers primarily to the latter type, i.e. a thermosetting matrix prepreg with tack, drape and cure properties appropriate to the use of the material for the production of advanced composite moulds or tools from the synthetic modelling materials described in this specification. Prepregs made using high temperature thermoplastic polymer matrices, metal, or ceramic matrices would not be suitable for use with these materials.
  • U.K. Patent No. 2108038 identifies the state of the art in 1981, and the invention of a new technique using prepreg materials curing at low temperatures, rather than using the then conventional wet-layup technique or normal (above 100°C) temperature cure prepregs to produce an advanced composite mould or tool.
  • thermo expansion coefficient of the modelling block is matched with the prepreg material and the processing conditions used during manufacture of an advanced composite tool or mould. 9. Capable of a more rapid production technique than conventional materials.
  • the invention relates to materials and methods of producing materials that can be utilised to manufacture master models, with some or all of the improved properties identified above.
  • the invention provides a modelling material for use in the manufacture of models for pattern making, tooling and the like, the material comprising a resin matrix and filler material in the matrix, wherein the resin matrix comprises a thermoplastic material.
  • the thermoplastic material may be polysulphone, polyethersulphone, phenoxy, polyaryletherketone, or another thermoplastic material, or combinations thereof.
  • the filler may be glass spheres, hollow glass spheres, phenolic microballoons, cenospheres, perlite, or any lightweight or mineral material, either natural or synthetic, or combinations thereof.
  • thermoplastic resin may be between 5 and 95 percent by weight.
  • proportion of filler may be between 5 and 95 percent by weight.
  • the method of production may be to predisperse or predissolve the themoplastic in solvent, from an intimate mix of thermoplastic and solvent, and subsequently to remove solvent by the application of heat and/or pressure and/or vacuum.
  • the method of production may comprise forming an intimate mixture of solid thermoplastic and particulate filler and producing a solid block by the application of heat and/or pressure and/or vacuum.
  • the method of production may comprise coating particulate filler with thermoplastic by electrostatic, solution coating or mechanical means, following which the coated material is consolidated into a block by the application of heat and/or pressure and/or vacuum.
  • the material may be consolidated in a press or autoclave, either restrained or unrestrained.
  • the production of the material may be controlled to determine the porosity of the finished product.
  • the formulation is based on the combination of a primarily thermoplastic resin matrix and suitable solid materials. These may be combined in varying proportions to produce a number of materials ranging from impervious solid to porous block. In a modification of the basic type of formulation a mixture of thermoplastic and thermosetting resins can be used to provide different characteristics.
  • a porous block may be advantageous for producing tools and moulds for use in a vacuum forming process, or in the manufacture of advanced composite mould tools.
  • thermoplastic resins are as follows:-
  • thermoplastic material may be used singly, or combinations may be used if desired.
  • the matrix may be a combination of thermoplastic and thermosetting resins such as epoxies,
  • the solid content of the material may be, for example:-
  • thermoplastic resin it is possible to dissolve or disperse the thermoplastic resin in a suitable solvent system to produce a liquid. This is mixed with the filler system to form a homogeneous mix.
  • Heat, vacuum and/or pressure may be applied to the mix to produce a solid block.
  • Finely ground or micronised thermoplastic in powder form is blended with the filler system to produce an intimate mixture of powders.
  • the mixture is subjected to heat and pressure to form a solid block.
  • thermoplastic/solvent blend is coated onto the surface of the individual particles by means of a pan coater or similar.
  • the particles are dried and consolidated by heat and/or pressure to form a block.
  • the finely divided thermoplastic powder is sprayed or similarly combined with hot or electrostatically charged filler to form a coherent surface coating.
  • the coated particles are then consolidated by heat and pressure.
  • Suitable processes for applying heat, vacuum and pressure are hydraulic, electric or manual presses and autoclaves.
  • methods of generating heat in the material to melt the resin and cause it to flow, and thereby allow the material to be consolidated properly under the applied pressure are ultrasonic stimulation, and microwave heating.
  • the polymer and methylene chloride are mixed until dissolved and the Metaspheres 50 added. Methylene chloride is removed by evaporation until the remaining material has a dough like consistency. The mix is placed in a suitable mould in a press, press-clave, or autoclave.
  • Suitable methods of removing solvent are employed, such as vacuum extraction.
  • the solvent may be recovered for recycling.
  • the mixture is heated for 2 hrs at 120°C, the pressure released and the block allowed to cool.
  • the resultant product has a softening point of 145°C as measured by Thermomechanical Analysis and a coefficient of thermal expansion of 12 x 10 " per °C which is linear over the temperature range 20 - 140°C.
  • the block is easily workable by hand or machine tools and capable of being sanded smooth.
  • This material has been found to possess most or all of the desired properties listed above, to a sufficient degree to make the material particularly suitable for use in vacuum forming tooling, as a pattern for the manufacture of advanced composite moulds and tooling from prepreg materials, or as a mould for the manufacture of components from prepreg materials.
  • Different grades of the material can be made to exhibit different porosities appropriate to different end-use requirements.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

Matériau de modelage s'utilisant dans la fabrication de modèles servant à réaliser des maquettes, des outillages ou similaire. Le matériau comprend une matrice de résine et un matériau de charge intégré à la matrice; ladite matrice de résine comprend un matériau thermoplastique tel qu'un polysulfate, un sulfure de polyéther, phénoxy, polyaryléther, polyéthylène, polypropylène, polystyrène, polysulfate, polyétherimide, polyéthosulfate, ou sulfure de polyphényle ou une combinaison desdits constituants.
PCT/GB1991/001600 1990-09-21 1991-09-18 Materiaux et procedes de modelage WO1992005216A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9020649.1 1990-09-21
GB909020649A GB9020649D0 (en) 1990-09-21 1990-09-21 Modelling materials and processes

Publications (1)

Publication Number Publication Date
WO1992005216A1 true WO1992005216A1 (fr) 1992-04-02

Family

ID=10682574

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB1991/001600 WO1992005216A1 (fr) 1990-09-21 1991-09-18 Materiaux et procedes de modelage

Country Status (3)

Country Link
AU (1) AU8535591A (fr)
GB (1) GB9020649D0 (fr)
WO (1) WO1992005216A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0626433A1 (fr) * 1993-05-26 1994-11-30 Fibre Glass-Evercoat Company, Inc. Composition de charge pulvérisable
US6060540A (en) * 1998-02-13 2000-05-09 Landec Corporation Modeling pastes
US6355196B1 (en) 1998-03-16 2002-03-12 Vantico Inc. Process for producing direct tooling mold and method for using the same
DE102004002560A1 (de) * 2004-01-17 2005-08-18 Knauf Perlite Gmbh Formkörper

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3920602A (en) * 1974-08-12 1975-11-18 Celanese Corp Thermoplastic nylon molding resins
GB2000786A (en) * 1977-07-06 1979-01-17 Tba Industrial Products Ltd Moulding composition comprising rubber modified polymers
EP0016988A1 (fr) * 1979-03-17 1980-10-15 Bayer Ag Pâtes de silicones thixotropiques et leur utilisation pour former des empreintes de dents et de muqueuses
US4403048A (en) * 1980-08-08 1983-09-06 T C Manufacturing Company Corrosion-resistant coating composition containing hollow microballoons
SU1125371A1 (ru) * 1983-06-29 1984-11-23 Всесоюзный Ордена Трудового Красного Знамени Научно-Исследовательский Институт Горной Геомеханики И Маркшейдерского Дела Состав дл изготовлени моделей из эквивалентного материала
EP0380303A1 (fr) * 1989-01-23 1990-08-01 Sumitomo Chemical Company, Limited Composition de résine de polysulfone aromatique
DE4008980A1 (de) * 1990-03-21 1991-09-26 Staedtler Fa J S Plastische masse zum kneten, modellieren, basteln und dekorieren sowie verfahren zu deren herstellung

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3920602A (en) * 1974-08-12 1975-11-18 Celanese Corp Thermoplastic nylon molding resins
GB2000786A (en) * 1977-07-06 1979-01-17 Tba Industrial Products Ltd Moulding composition comprising rubber modified polymers
EP0016988A1 (fr) * 1979-03-17 1980-10-15 Bayer Ag Pâtes de silicones thixotropiques et leur utilisation pour former des empreintes de dents et de muqueuses
US4403048A (en) * 1980-08-08 1983-09-06 T C Manufacturing Company Corrosion-resistant coating composition containing hollow microballoons
SU1125371A1 (ru) * 1983-06-29 1984-11-23 Всесоюзный Ордена Трудового Красного Знамени Научно-Исследовательский Институт Горной Геомеханики И Маркшейдерского Дела Состав дл изготовлени моделей из эквивалентного материала
EP0380303A1 (fr) * 1989-01-23 1990-08-01 Sumitomo Chemical Company, Limited Composition de résine de polysulfone aromatique
DE4008980A1 (de) * 1990-03-21 1991-09-26 Staedtler Fa J S Plastische masse zum kneten, modellieren, basteln und dekorieren sowie verfahren zu deren herstellung

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
WORLD PATENTS INDEX LATEST ,Week 8524, Derwent Publications Ltd., London, GB; AN 85-145037 :& SU,A,1 125 371 (MINE GEOMECH SURVEY) 23 November 1984 see abstract *
WORLD PATENTS INDEX LATEST .Week 9117, Derwent Publications Ltd., London, GB; AN 91-119839 :& HU,A,54 723 (MATRAALJAI ALLAMI) 28 March 1991 see abstract *

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0626433A1 (fr) * 1993-05-26 1994-11-30 Fibre Glass-Evercoat Company, Inc. Composition de charge pulvérisable
US6060540A (en) * 1998-02-13 2000-05-09 Landec Corporation Modeling pastes
US6355196B1 (en) 1998-03-16 2002-03-12 Vantico Inc. Process for producing direct tooling mold and method for using the same
DE102004002560A1 (de) * 2004-01-17 2005-08-18 Knauf Perlite Gmbh Formkörper
DE102004002560B4 (de) * 2004-01-17 2007-02-08 Lkt Gmbh Formkörper

Also Published As

Publication number Publication date
GB9020649D0 (en) 1990-10-31
AU8535591A (en) 1992-04-15

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