WO2012078115A1 - Composite de fibres de carbone - Google Patents

Composite de fibres de carbone Download PDF

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Publication number
WO2012078115A1
WO2012078115A1 PCT/SG2011/000430 SG2011000430W WO2012078115A1 WO 2012078115 A1 WO2012078115 A1 WO 2012078115A1 SG 2011000430 W SG2011000430 W SG 2011000430W WO 2012078115 A1 WO2012078115 A1 WO 2012078115A1
Authority
WO
WIPO (PCT)
Prior art keywords
carbon fiber
fiber layer
layer
substrate
secondary carbon
Prior art date
Application number
PCT/SG2011/000430
Other languages
English (en)
Inventor
Kim Mui Bernadette Seow
Kim Khyok Carolyn Seow
Original Assignee
Kim Mui Bernadette Seow
Kim Khyok Carolyn Seow
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 Kim Mui Bernadette Seow, Kim Khyok Carolyn Seow filed Critical Kim Mui Bernadette Seow
Priority to SG2013043435A priority Critical patent/SG191013A1/en
Publication of WO2012078115A1 publication Critical patent/WO2012078115A1/fr

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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
    • B32B5/14—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 a layer differing constitutionally or physically in different parts, e.g. denser near its faces

Definitions

  • the invention relates broadly to composite for sealing a substrate.
  • the invention further relates to a polymerizable composition for sealing a substrate and method of sealing a substrate.
  • Conduits such as pipes
  • pipes are utilized in a myriad of industries for the purpose of transporting liquid, gas, and semi-solid material. They are typically made of metal, fiberglass or plastic, have various diameters and extend various lengths. Rarely does a single piece of pipe traverse the entire distance over which the pipe extends. Rather, single pieces of pipe are joined at what are referred to as "joints".
  • the pipes are sealed at these joints by, for example, threading on the pipe itself, welding, soldering, flange with or without a gasket, Teflon tape, or sealing compounds.
  • Sealing compounds are also used when a conduit, such as a pipe, is damaged or corrodes and leaks. Leaks may occur for many reasons, for example, corrosion or physical damage. Corrosion may be caused by the environment surrounding the pipe, the chemical nature of the material the pipe is transporting, and the like.
  • a composite for sealing a substrate includes a primary carbon fiber layer having a first weave density and a secondary carbon fiber layer having a second weave density that is different from the first weave density of the primary carbon fiber layer. Both primary and secondary carbon fiber layers may be encapsulated in a polymer matrix.
  • a polymerisable composition for sealing a substrate comprising a primary carbon fiber layer having a first weave density and a secondary carbon fiber layer having a second weave density that is different from the first weave density of the primary carbon fiber layer and wherein both primary and •secondary carbon fiber layers are encapsulated in a curable resin.
  • the composite and polymerizable composition form a durable seal that is permanent, structurally sound and suitable for industrial use.
  • the composite and polymerizable composition are capable of sealing even pinhole size gaps and defects in a substrate.
  • the composite and polymerizable composition resist corrosion even in environments with high humidity and temperature.
  • the composite and polymerizable composition may be used to replace (or substitute for) a substrate, such as a conduit, by coating the entire surface.
  • a substrate such as a conduit
  • the composite and polymerizable composition provide a cost effective method of replacing the substrate.
  • the composite and polymerizable composition are also a cost effective substitute for the sealants of the prior art.
  • the composite and polymerizable composition comprises at least two different carbon fiber layers to construct an anticorrosive , durable, permanent sealant.
  • a method of sealing a substrate comprising applying a composite over the substrate to seal the substrate, the composite comprising a primary carbon fiber layer having a first weave density and a secondary carbon fiber layer having a second weave density that is different from the first weave density of the primary carbon fiber layer, and wherein both primary and secondary carbon fiber layers are encapsulated in a polymer matrix.
  • the disclosed method of sealing a substrate uses a composite comprising at least a primary and secondary carbon fiber layer encapsulated in a polymer matrix .
  • the erm "about”, in the context of concentrations of components .of the formulations, typically means +/- 5% of the stated value, more typically +/- 4% of the stated value, more typically +/- 3% of the stated value, more typically, +/- 2% of the stated value, even more typically +/- 1% of the stated value, and even more typically +/- 0.5% of the stated value.
  • weave density refers to the weight (in grams per meter squared) of a fiber layer.
  • polymer matrix means a polymer that forms a continuous phase and/or surrounds one or more materials or components.
  • sub-ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc., as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range .
  • the substrate may be composed of materials selected from the group consisting of: plastic, fiberglass, concrete, ceramic, clay, metal, glass, and the like, and combinations thereof.
  • Plastics may include, for example, polyvinyl chloride (PVC) , polybutylene (PB), acrylonitrile butadiene styrene (ABS), polyethylene (PE), polypropylene (PP) , fluoroplastics , polyacrylates , polycarbonates, polyesters, and the like, and combinations thereof.
  • Metals may include, for example, lead, copper, steel, iron, brass, aluminium, titanium, and alloys and the like, and combinations thereof.
  • the substrate is steel .
  • the primary carbon fiber layer is innermost to the substrate relative to the secondary carbon fiber layer.
  • the primary carbon fiber layer may be a plain weave carbon fiber material.
  • the primary carbon fiber layer may possess a first weave density in the range of 200g/m 2 to 400 g/m 2 .
  • the first weave density may be 200 g/m 2 .
  • the primary carbon fiber layer may have a thread count per centimetre of from five to 10 in both the warp and weft directions. In some embodiments, the thread count per centimetre may be five in both the warp and weft directions.
  • the primary carbon fiber layer may be, for example, KDL 8003 (SIGRATEX ® ) . The higher thread count of the primary carbon fiber layer may allow for better conformation to the shape of the substrate and for forming a more impermeable seal.
  • the secondary carbon fiber layer may be a plain weave carbon fiber material.
  • the secondary carbon fiber layer may have a second weave density.
  • the second weave density may be in the range of 480 g/m 2 to 960 g/m 2 .
  • the second carbon fiber layer may have a weave density of 480 g/m 2 .
  • the secondary carbon fiber layer may impart strength and durability due to the higher weight of the fiber.
  • the secondary carbon fiber layer may have thread count per centimetre in . the range of three to four in both the warp and weft directions. In some embodiments, the secondary fiber layer may have a thread count per centimetre of three in both the warp and weft directions.
  • the secondary carbon fiber layer may be, for example, KDL 8001 (SIGRATEX ® ) .
  • the secondary carbon fiber layer may be alternated with the primary carbon fiber layer and/or layered on itself, i.e., one secondary carbon fiber layer on top of another secondary carbon fiber layer.
  • the polymer matrix and/or curable resin may be selected from the group consisting of: an elastomer modified epoxy vinyl ester resin, a novolac-based epoxy vinyl ester resin, a bisphenol-A epoxy vinyl ester resin and combinations thereof.
  • the polymer matrix is a cured epoxy resin.
  • the polymerisable composition has a curable resin selected from the group consisting of: a novolac-based resin, a bisphenol-A resin, and an elastomer modified resin.
  • Examples of elastomer modified epoxy vinyl resins include EPON® (Momentive Specialty Chemicals), 20-3236 (EPOXIES), and DERAKANE ® 8084 (ASHLAND ® ) .
  • Examples of novolac-based epoxy vinyl ester resins include, for example VIPEL ® K095-AAA-00 (AOC) and DERAKANE ® 470-300 (ASHLAND ® ) .
  • Examples of bisphenol-A epoxy vinyl ester resins include, for example VIPEL ® F010 and DERAKANE ® 411-350 (ASHLAND ® ) .
  • the polymer matri and curable resin include one or more of the elastomer -modified epoxy vinyl ester resin, the novolac-based epoxy vinyl ester resin, and the bisphenol-A epoxy vinyl ester resin.
  • the polymer matrix and/or curable resin include an elastomer modified epoxy vinyl ester resin nearer (or innermost) to the substrate followed by a novolac-based epoxy vinyl ester resin.
  • the composite also includes a glass fiber.
  • the polymerizable composition further includes a glass fiber.
  • the glass fiber may be a fiberglass material selected from the group consisting of: a C-glass veil, a chopped strand mat E-glass, and the like.
  • the glass fiber in some embodiments, is innermost to the substrate relative to the primary carbon fiber layer. In some embodiments, the glass fiber is outermost to the substrate relative to the secondary carbon fiber layer.
  • the fiberglass is a C-glass veil.
  • the C-glass veil may have a weight per meter squared that is preferably from about 25 to about 55 g/m 2 , more preferably the C-glass is about 30 g/m 2 .
  • the fiberglass material is an E-glass.
  • the E-glass is a chopped strand mat. In .
  • the E-glass material may have a weight per meter squared that is preferably from about 400 to about 500 g/m 2 , more preferably the E-glass is about 450 g/m 2 . In some embodiments one or more types of glass fiber may be used.
  • the composite and polymerizable composition may comprise at least one type of a glass fiber with the two different carbon fiber layers.
  • a glass fiber with the two different carbon fiber layers.
  • layers of glass fiber material may be applied directly to the substrate before applying the carbon fiber layers thereon.
  • the carbon fiber layer does not come into direct contact with the substrate, which would result in oxidation of the substrate, but is applied to the substrate over a glass fiber material to create strength and durability.
  • the composite and/or polymerizable composition may further include putty selected from the group consisting of sealing putty, such as clay based putty, epoxy putty or a combination of these.
  • the putty includes a glass fiber, a viscosity enhancing agent, and a curable resin.
  • the putty may include, for example, a curable resin, a glass fiber, and viscosity enhancing agent.
  • the curable resin of the putty is a bisphenol-A epoxy resin.
  • glass fiber material of the putty is a fiberglass chopped strand mat E- glass.
  • the viscosity enhancing agent of the putty is silica.
  • the silica is fumed silica, such as, for example AEROSIL ® (AEROSIL) .
  • a wax may also be included in the composite and/or polymerizable composition of the disclosure.
  • the wax may be any type of wax for example, a natural wax such as animal, mineral, or vegetable wax, a synthetic wax such as a polyethylene wax, or a petroleum wax such as paraffin or microcrystalline wax and combinations of waxes.
  • the wax selected from the group consisting of: paraffin wax, polyethylene wax, and combinations of these.
  • An example wax that may be used is BOSNY WAX ® (RICHARD LONDON CHEMICAL INDUSTRIES CO., LTD. ) .
  • the applying step includes sealing and structuring.
  • the sealing step includes sealing a glass fiber to the substrate.
  • a resin may be applied to the substrate, followed by one or more layers of glass fiber and additional resin.
  • the resin is an elastomer modified epoxy vinyl ester resin.
  • the sealing layer includes both a C-glass veil glass fiber and a chopped strand mat E-glass fiber.
  • a layer of C- glass veil is applied followed by one or more layers of chopped strand mat E-glass fiber.
  • one layer of C-glass veil is applied followed by two layers of chopped strand mat E-glass fiber.
  • the structuring step may include alternating a primary carbon fiber layer and a secondary carbon fiber layer on the substrate.
  • the structuring step includes alternating layers of the primary carbon fiber layer and the secondary carbon fiber layer on the substrate.
  • the structuring step may nclude, for example one or more primary carbon fiber layer (s) and one or more secondary carbon fiber layer (s) alternately applied.
  • the structuring step includes a first primary carbon fiber layer, a first secondary carbon fiber layer, a second primary carbon layer and a second secondary carbon fiber layer.
  • the primary or secondary carbon fiber layers may be innermost relative to the substrate.
  • the structuring step further includes applying the primary carbon fiber layer innermost relative to the substrate.
  • the secondary carbon fiber layers provide both strength and durability to the seal.
  • the structuring step further includes applying at least one additional secondary carbon fiber layer as compared to the number of primary carbon fiber layers to the substrate. For example, after applying the alternating primary and secondary carbon fiber layers, one or more additional secondary carbon fiber layers may be applied.
  • the number of additional secondary carbon fiber layers applied may range from three to eleven. In embodiments, the number of additional secondary carbon fiber layers applied is four, in some embodiments six, in other embodiments eight secondary carbon fiber layers are applied.
  • the substrate to which the sealant is applied may be cleaned prior to application of the sealant.
  • the substrate may be cleaned using chemical, physical, or mechanical cleaning methods.
  • the cleaning method is sandblasting.
  • the substrate may be primed prior to sealing.
  • Priming may include applying resin, a glass fiber material, and putty.
  • priming includes applying an elastomer modified epoxy vinyl ester resin layer, a C-glass veil, and putty.
  • the sealing step may occur after priming and be followed by structuring.
  • a top coat is applied.
  • the top coat may include a resin containing a wax.
  • a glass fiber is layered on top of the final secondary carbon fiber layer.
  • the glass fiber is a C-glass veil.
  • the top coat may include a novolac-based epoxy vinyl ester resin combined with a wax .
  • the structuring step includes offsetting the layers of primary carbon fiber and secondary carbon fiber on the substrate.
  • this offset method of applying the layers is capable of providing a uniform thickness to the seal and prevent bulking or sagging of the seal.
  • maximum adhesion of the layers to the substrate and the layers to one another is achieved.
  • offsetting and lapping the layers prevents lumping or sagging of the composite at a given location.
  • the substrate is a pipe
  • the layers are offset by 30° .
  • the substrate includes a first part and a second part with a conduit extending there between. In some embodiments, the substrate is a conduit.
  • the substrate may be a conduit.
  • the conduit may be a pipe, tube, duct, channel, penstock, trough, and the like.
  • the diameter of the cylinder may be used to determine the needed thickness of the composite.
  • Fig. 1 is a plan view of a cleaned elbow joint including a primer layer
  • Fig. 2 is a plan view of the elbow joint of Fig. 1, further including a putty layer;
  • Fig. 3 is a plan view of the elbow joint of Fig. 1, further including a layer of glass fiber material;
  • Fig. 4 is a plan view of the elbow joint of Fig. 1, further including all of the layers of the composite;
  • Fig. 5 is an alternate view of a pipe showing offset /lapped application of the layers.
  • Fig. 1 depicts an elbow joint 10 of a steel pipe as a substrate.
  • the elbow joint 10 which includes two butt joints 12/14, is sandblasted and a layer of elastomer modified epoxy vinyl ester resin 16 is applied followed by a single layer of C-glass veil 18.
  • the elastomer modified epoxy vinyl ester resin 16 and C-glass veil 18 are applied to the entire elbow joint 10 including both butt joints 12/14.
  • putty 20 is then applied to the area of the substrate in need of sealing - in this case the butt joints 12/14 of the elbow joint 10.
  • An additional layer of C-glass 22 is then applied only to the areas that have received putty (Fig. 3) .
  • Fig. 4 depicts the C-glass veil 18, putty layer 20, second C-glass veil 22, two E- glass chopped strand mat 24/26, one primary carbon fiber layer 28, one secondary carbon fiber layer 30, a second primary carbon fiber layer 32, followed by seven layers of secondary carbon fiber layer material 34, and a layer of C- glass veil 36.
  • the C-glass veil 36 is covered by a top coat of resin and wax (not shown) .
  • each layer 102 of the composite surrounds the entire diameter of the pipe 100. Furthermore, each layer is. applied offset 104 from the previous layer in order to provide a consistent diameter to the substrate each layer laps the previous layer by at least 100 millimetres. Examples
  • Example 1 30" Diameter 90° Elbow with Two 30" Butt Joints
  • the elbow of the steel pipe was sand blasted with sharp edged form to remove oil, grease, rust and scale. All sand and dust were then removed from the surface of the pipe.
  • the surface profile following sand blasting was 50 ]im (determined using Press-O-Film (TESTEX) ) and surface roughness was achieved.
  • TESTEX Press-O-Film
  • a layer of DERAKANE ® 8084 (ASHLAND ® ) elastomer modified epoxy vinyl ester resin was immediately applied to the surface of the elbow of 'the steel pipe followed by one layer of C-glass veil (30 g/m 2 ) and the resin was allowed to cure for one and one-half hours.
  • DMA dimethylaniline
  • MEKP methylethylketone peroxide
  • the putty was applied to the step from the pipe surface up to the butt joint and at irregularities in the surface of the elbow joint.
  • the putty was allowed to dry, sanded, and the surface of the elbow joint was cleaned to remove dust and debris.
  • a layer of C-glass veil (30 g/m ) was layered onto the puttied areas of the elbow joint.
  • the seal was allowed to cure for 24 hours.
  • a primary carbon fiber layer (200 g/m 2 ) ;
  • a secondary carbon fiber layer (480 g/m 2 );
  • a primary carbon fiber layer (200 g/m 2 ) ;
  • a secondary carbon fiber layer (480 g/m 2 );
  • a secondary carbon fiber layer (480 g/m 2 );
  • the layers were then allowed to cure for one and one-half hours.
  • a secondary carbon fiber layer (480 g/m 2 );
  • a secondary carbon fiber layer (480 g/m 2 );
  • top coat The following components were combined to form a top coat :
  • Example 2 Tee Joint including a 24" pipe and a 36" pipe
  • a tee joint including three junctures - two between the tee joint and a 36" pipe and one between the tee joint and a 24" pipe, used for transporting sea water were repaired using the composite and method of the invention.
  • the structural layer of the juncture of the tee joint and 24" pipe was prepared as follows:
  • a primary carbon fiber layer (200 g/rn ⁇ ) ;
  • a secondary carbon fiber layer (480 g/rn ⁇ ) ;
  • a primary carbon fiber layer (200 g/m 2 ) ;
  • a secondary carbon fiber layer (480 g/m ) ;
  • a secondary carbon fiber layer (480 g/rn ⁇ ) ; a layer of DERAKANE ® 470-300 (ASHLAND ® ) novolac-based epoxy vinyl ester resin;
  • a secondary carbon fiber layer (480 g/m 2 );
  • a secondary carbon fiber layer (480 g/m 2 );
  • top coat prepared as in Example 1 was then applied to the structural layer.
  • a primary carbon fiber layer (200 g/m 2 ) ;
  • a secondary carbon fiber layer (480 g/m 2 );
  • a primary carbon fiber layer (200 g/m');
  • a secondary carbon fiber layer (480 g/m 2 ) ;
  • a secondary carbon fiber layer (480 g/m 2 );
  • a secondary carbon fiber layer (480 g/m 2 ) ;
  • a secondary carbon fiber layer (480 g/m 2 );
  • a secondary carbon fiber layer (480 g/m 2 );
  • a secondary carbon fiber layer (480 g/m 2 ) ;
  • a secondary carbon fiber layer (480 g/m 2 );
  • top coat prepared as in Example 1 was then applied to the structural layer.
  • a butt joint of an 18" pipe used for transporting sea water was repaired using the composite and method of the invention.
  • a primary carbon fiber layer (200 g/m 2 ) ;
  • a secondary carbon fiber layer (480 g/m 2 );
  • a primary carbon fiber layer (200 g/m'');
  • a secondary carbon fiber layer (480 g/m 2 ) ;
  • a secondary carbon fiber layer (480 g/m 2 );
  • a secondary carbon fiber layer (480 g/m 2 );
  • top coat prepared as in Example 1 was then applied.
  • a tee joint including three junctures - two between the tee joint and a 48" pipe and one between the tee joint and an 18" pipe, used for transporting sea water were repaired using the composite and method of the invention.
  • Example 1 The cleaning, priming, and sealing of the flange joint of the pipe were prepared as in Example 1. Structuring and top coat for the 18" pipe was as described for the 18" pipe of Example 3.
  • a primary carbon fiber layer (200 g/m 2 );
  • a secondary carbon fiber layer (480 g/m 2 );
  • a primary carbon fiber layer (200 g/m 2 ) ;
  • a secondary carbon fiber layer (480 g/m 2 ) ;
  • a secondary carbon fiber layer (480 g/m 2 );
  • a secondary carbon fiber layer (480 g/m 2 );
  • a secondary carbon fiber layer (480 g/m 2 );
  • a secondary carbon fiber layer (480 g/m 2 );
  • a secondary carbon fiber layer (480 g/m 2 ) ;
  • a secondary carbon fiber layer (480 g/m 2 );
  • top coat prepared as in Example 1 was then applied.
  • the composite of the invention is applicable to myriad substrates for sealing the substrates.
  • the composite may be used to seal leaks in a substrate, conduit joints, damaged or weakened areas of a substrate and the like.
  • the polymerizable composition of the invention is useful for sealing leaks, joints, damaged areas, and weakened areas of a substrate.
  • the method of the invention is suitable for industrial and commercial applications. Use of the method provides a sealed substrate.

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  • Laminated Bodies (AREA)
  • Reinforced Plastic Materials (AREA)
  • Inorganic Fibers (AREA)

Abstract

La présente invention concerne un composite permettant d'étanchéifier un substrat comprenant une première couche de fibres de carbone présentant une première densité de tissage et une seconde couche de fibres de carbone présentant une seconde densité de tissage qui est différente de la première densité de tissage de la première couche de fibres de carbone. Les première et seconde couches de fibres de carbone sont toutes les deux encapsulées dans une matrice polymère. L'invention concerne également une composition polymérisable et un procédé d'étanchéification d'un substrat.
PCT/SG2011/000430 2010-12-08 2011-12-08 Composite de fibres de carbone WO2012078115A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
SG2013043435A SG191013A1 (en) 2010-12-08 2011-12-08 Carbon fiber composite

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SG201009156-9 2010-12-08
SG201009156 2010-12-08

Publications (1)

Publication Number Publication Date
WO2012078115A1 true WO2012078115A1 (fr) 2012-06-14

Family

ID=46207402

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/SG2011/000430 WO2012078115A1 (fr) 2010-12-08 2011-12-08 Composite de fibres de carbone

Country Status (2)

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SG (1) SG191013A1 (fr)
WO (1) WO2012078115A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6759352B2 (en) * 2001-07-05 2004-07-06 Sony Corporation Composite carbon fiber material and method of making same
EP2100719A1 (fr) * 2008-03-12 2009-09-16 BYD Company Limited Matériau composite en fibres de carbone, produit et procédé

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6759352B2 (en) * 2001-07-05 2004-07-06 Sony Corporation Composite carbon fiber material and method of making same
EP2100719A1 (fr) * 2008-03-12 2009-09-16 BYD Company Limited Matériau composite en fibres de carbone, produit et procédé

Also Published As

Publication number Publication date
SG191013A1 (en) 2013-07-31

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