WO2017194939A1 - Precursor material for forming into a reinforced resin panel and method for the production thereof - Google Patents

Precursor material for forming into a reinforced resin panel and method for the production thereof Download PDF

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Publication number
WO2017194939A1
WO2017194939A1 PCT/GB2017/051300 GB2017051300W WO2017194939A1 WO 2017194939 A1 WO2017194939 A1 WO 2017194939A1 GB 2017051300 W GB2017051300 W GB 2017051300W WO 2017194939 A1 WO2017194939 A1 WO 2017194939A1
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WO
WIPO (PCT)
Prior art keywords
precursor material
material according
resin
curable resin
fibrous
Prior art date
Application number
PCT/GB2017/051300
Other languages
French (fr)
Inventor
Mike ORANGE
Humphrey Bunyan
Original Assignee
Cecence 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 Cecence Ltd filed Critical Cecence Ltd
Publication of WO2017194939A1 publication Critical patent/WO2017194939A1/en

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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
    • B32B5/22—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
    • 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
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
    • C08J5/244—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using glass fibres
    • 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
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • 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
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/081—Combinations of fibres of continuous or substantial length and short fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • 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
    • B32B27/42—Layered products comprising a layer of synthetic resin comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
    • 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
    • B32B5/30—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 formed of particles, e.g. chips, granules, powder
    • 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
    • C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
    • C08J5/249—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs characterised by the additives used in the prepolymer mixture
    • 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
    • B32B2250/20—All layers 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
    • 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
    • B32B2260/023—Two or more 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
    • 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
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    • 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
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    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B32B2262/10—Inorganic fibres
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    • 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
    • B32B2262/10—Inorganic fibres
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
    • B32B2305/188—Woven fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B32B2305/22—Fibres of short length
    • B32B2305/28—Fibres of short length in the form of a mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
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    • 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
    • B32B37/02—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by a sequence of laminating steps, e.g. by adding new layers at consecutive laminating stations
    • 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
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/08—Impregnating

Definitions

  • the present invention relates to a precursor material for the production of reinforced resin composite components and to a method for the production of the precursor material.
  • Composites of particular interest are, for example, reinforced resin composites, in which a polymeric resin matrix is reinforced by, for example, fibres, such as glass fibres. Phenolic resins are particularly preferred for use as the composite matrix, due to their good fire resistance (this is an especially important consideration in the selection of materials for mass transportation applications).
  • the present invention may provide a multi-layer precursor material for shaping into a reinforced resin panel.
  • a material may simply be cut to the desired size (if necessary) and inserted into a mould, in which it is cured in order to provide the composite component.
  • the time-consuming and complex process of building up the material layer by layer in the mould may be avoided.
  • the extent to which the technician is required to handle resin is limited and so his or her exposure to unpleasant or harmful fumes may be reduced.
  • the present invention may provide a precursor material for forming into a reinforced resin panel, the precursor material being provided by a multi-layer stack comprising two fibrous mats and a filler layer disposed therebetween, the multi-layer stack being impregnated with a curable resin, the precursor material being arranged in a folded configuration or in the form of a roll.
  • the provision of two fibrous mats having a filler layer disposed therebetween is considered to be an effective arrangement for increasing the flexural rigidity of the reinforced resin panel that is created from the precursor material: the load-carrying mats at the faces of the panel are spaced apart from the neutral axis of the panel by the filler layer, so as to increase their effectiveness in countering bending forces acting on the panel. That is, by spacing the load- carrying mats apart from each other, the moment of inertia of the panel is increased. Since the filler layer tends to be cheaper than the mats at the faces of the panel, this arrangement may also allow for the cost-effective production of panels having good flexural rigidity.
  • the stiffness of the panel may be tailored through the selection of the thicknesses of the fibrous mats and/or the thickness of the filler layer.
  • the precursor material may comprise more than two fibrous mats, each pair of adjacent fibrous mats being separated by a respective filler layer.
  • the precursor material is symmetrical about a central filler layer.
  • one or both of the fibrous mats is a woven mat.
  • Woven mats are considered to impart particularly high tensile strength to the outer surface of the panel.
  • one or both of the fibrous mats may be provided by a non-woven mat, such as a mat comprising a unidirectional fabric.
  • a unidirectional fabric is a fabric in which at least 75%, preferably at least 80%, more preferably at least 90% of the fibres are in alignment with each other.
  • one or both of the fibrous mats may be provided by a biaxial cloth that is produced by joining two unidirectional fabrics in a face-to-face configuration such that the principal axes of the unidirectional fabrics do not coincide.
  • the fibrous mat comprises inorganic fibres, which may be glass fibres and/or mineral fibres such as basalt. In other embodiments, the fibrous mat comprises organic fibres such as carbon fibre, UHMWPE fibre, or aramid.
  • the filler layer comprises particles embedded in the curable resin. In other embodiments, the filler layer comprises chopped glass strands embedded in the curable resin. In yet further embodiments, the filler layer comprises a chopped strand mat impregnated with the curable resin.
  • the curable resin is a phenolic resin.
  • the curable resin comprises a catalyst in order to accelerate the curing process.
  • the maximum dimension of the precursor material is greater than 5m, preferably greater than 10m, more preferably greater than 20m
  • the present invention may provide a method of forming a precursor material for forming into a reinforced resin panel, comprising the steps of:
  • the continuous fibrous sheets each have a maximum dimension that is greater than 50m, preferably greater than 75m, more preferably greater than 100m.
  • an additional filler layer may be deposited on the upper surface of the upper fibrous sheet, followed by the step of covering the additional filler layer with an additional fibrous sheet. Further pairs of filler layer and fibrous sheet may be laid over this
  • one or both of the fibrous sheets is a woven mat.
  • Woven mats are considered to impart particularly high tensile strength to the outer surface of the panel.
  • one or both of the fibrous mats may be provided by a non- woven mat, such as a mat comprising a unidirectional fabric.
  • a unidirectional fabric is a fabric in which at least 75%, preferably at least 80%, more preferably at least 90% of the fibres are in alignment with each other.
  • one or both of the fibrous mats may be provided by a biaxial cloth that is produced by joining two unidirectional fabrics in a face- to-face configuration such that the principal axes of the unidirectional fabrics do not coincide.
  • the fibrous sheet comprises inorganic fibres, which may be glass fibres and/or mineral fibres such as basalt. In other embodiments, the fibrous sheet comprises organic fibres such as carbon fibre, UHMWPE fibre, or aramid.
  • the filler layer comprises particles. In other embodiments, the filler layer comprises chopped glass strands. Typically, in this case, the chopped glass strands are prepared in situ by chopping strands from continuous fibre rolls and allowing the strands to fall onto the base fibrous sheet. In yet further embodiments, the filler layer comprises a chopped strand mat.
  • the multi-layer stack is heated in order to promote full and even penetration of the resin throughout the stack and/or the reduction of air bubbles in the material. This helps to increase the quality of the precursor material.
  • the precursor material is cut into shorter lengths e.g. between 5 and 25m and arranged in the form of a roll or in a folded configuration.
  • the length of cut is chosen with a view to balancing the requirement of ease of handling (which favours cutting into shorter lengths of material) with the requirement of economic viability (which favours the provision of longer lengths of material).
  • the curable resin is a phenolic resin.
  • the curable resin comprises a catalyst in order to accelerate the curing process.
  • the present invention may provide a method of creating a reinforced resin panel, comprising the step of providing a precursor material according to the first aspect of the invention, inserting at least a portion of the precursor material into a mould and curing the resin.
  • Figure 1 shows a schematic exploded perspective view of a precursor material according to an embodiment of the first aspect of the invention
  • Fig. 2 shows a schematic section view of apparatus for carrying out a method according to an example of the second aspect of the invention.
  • Figure 3 shows a schematic section view of apparatus for carrying out a method according to an example of the third aspect of the invention.
  • a precursor material for shaping into a reinforced resin panel comprises two outer woven glass layers 10,30 and a layer of chopped glass 20 disposed therebetween. All three layers of the precursor material are impregnated with a phenolic resin, which penetrates the interstices between the glass fibres.
  • a first continuous woven glass sheet is dispensed from drum 50, moving in the direction of arrow A towards drum 52.
  • the first continuous woven glass sheet provides a horizontal surface onto which chopped glass is deposited at a chopped glass deposition station 54 to form an even layer on the upper side of the woven glass sheet.
  • the chopped glass is prepared in situ by chopping strands from continuous fibre rolls and allowing the strands to fall onto the first continuous woven glass sheet.
  • a second continuous woven glass sheet is dispensed from drum 56 and laid over the chopped glass.
  • the resulting multi-layer assembly comprising outer woven glass layers and an inner layer of chopped glass passes beneath roller 58 to a resin application station 60.
  • a two-part phenolic resin containing a latent catalyst is deposited onto the upper surface of the second continuous woven glass sheet and allowed to penetrate into the multi-layer assembly.
  • the phenolic resin system may comprise
  • the resin-impregnated multi-layer assembly subsequently passes below a heater 62, which warms the resin to a temperature of around 20-40°C, thus reducing its viscosity and helping to ensure its full and even penetration into the multi-layer assembly.
  • the assembly is passed between compaction rollers 64a, b,c disposed on either side of the assembly which further assist in promoting penetration of the resin into the assembly.
  • multiple sets of compaction rollers may be provided on either side of the assembly.
  • the assembly is wound onto drum 52 and stored until required. Referring to Figure 3a, a portion of precursor material 78 is placed between internal surfaces 82,84 of mould 80.
  • the mould is then closed around the precursor material (Figure 3b) and the precursor material is cured at a temperature above 130°C (for example, about 140°C) and a pressure of about 10 bar for about 5-10 minutes, so as to provide a shaped reinforced resin panel (Figure 3c).

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Medicinal Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Composite Materials (AREA)
  • Reinforced Plastic Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

A precursor material for forming into a reinforced resin panel is described, the precursor material being provided by a multi-layer stack comprising two fibrous mats and a filler layer disposed therebetween, the multi-layer stack being impregnated with a curable resin, the precursor material being arranged in a folded configuration or in the form of a roll. A method of forming a precursor material for forming into a reinforced resin panel is also described.

Description

PRECURSOR MATERIAL FOR FORM ING INTO A REINFORCED RESIN PANEL AND METHOD FOR THE PRODUCTION THEREOF
Field of the invention
The present invention relates to a precursor material for the production of reinforced resin composite components and to a method for the production of the precursor material.
Background to the invention
In recent years, there has been a trend towards the use of composite components in place of, for example, metal components. This is largely due to the availability of low density composite components that allow significant weight savings to be achieved. This trend has been particularly evident in the field of transport, in which it is often desirable to replace e.g. metal components with composite components, thus reducing the weight of the vehicle, and the fuel costs associated with running it. For example, composite components are often used in the production of panels for mass transportation vehicles.
Composites of particular interest are, for example, reinforced resin composites, in which a polymeric resin matrix is reinforced by, for example, fibres, such as glass fibres. Phenolic resins are particularly preferred for use as the composite matrix, due to their good fire resistance (this is an especially important consideration in the selection of materials for mass transportation applications).
Typically the process of constructing panels for mass transportation vehicles requires each individual component to be built up in a mould layer by layer. This process generally has one or more of the following drawbacks:
· it is time-consuming;
• it requires a skilled technician;
• it may expose the technician to unpleasant or hazardous fumes from the resin. It is desirable to develop a process of producing reinforced resin composite materials that avoids one or more of these problems.
Summary of the invention
At its most general, the present invention may provide a multi-layer precursor material for shaping into a reinforced resin panel. Such a material may simply be cut to the desired size (if necessary) and inserted into a mould, in which it is cured in order to provide the composite component. Thus, the time-consuming and complex process of building up the material layer by layer in the mould may be avoided. Furthermore, the extent to which the technician is required to handle resin is limited and so his or her exposure to unpleasant or harmful fumes may be reduced.
Therefore, in a first aspect, the present invention may provide a precursor material for forming into a reinforced resin panel, the precursor material being provided by a multi-layer stack comprising two fibrous mats and a filler layer disposed therebetween, the multi-layer stack being impregnated with a curable resin, the precursor material being arranged in a folded configuration or in the form of a roll.
The provision of two fibrous mats having a filler layer disposed therebetween is considered to be an effective arrangement for increasing the flexural rigidity of the reinforced resin panel that is created from the precursor material: the load-carrying mats at the faces of the panel are spaced apart from the neutral axis of the panel by the filler layer, so as to increase their effectiveness in countering bending forces acting on the panel. That is, by spacing the load- carrying mats apart from each other, the moment of inertia of the panel is increased. Since the filler layer tends to be cheaper than the mats at the faces of the panel, this arrangement may also allow for the cost-effective production of panels having good flexural rigidity. The stiffness of the panel may be tailored through the selection of the thicknesses of the fibrous mats and/or the thickness of the filler layer.
In certain embodiments, the precursor material may comprise more than two fibrous mats, each pair of adjacent fibrous mats being separated by a respective filler layer. Typically, the precursor material is symmetrical about a central filler layer.
Preferably, one or both of the fibrous mats is a woven mat. Woven mats are considered to impart particularly high tensile strength to the outer surface of the panel.
In other embodiments, one or both of the fibrous mats may be provided by a non-woven mat, such as a mat comprising a unidirectional fabric. A unidirectional fabric is a fabric in which at least 75%, preferably at least 80%, more preferably at least 90% of the fibres are in alignment with each other. In certain cases, one or both of the fibrous mats may be provided by a biaxial cloth that is produced by joining two unidirectional fabrics in a face-to-face configuration such that the principal axes of the unidirectional fabrics do not coincide.
In certain embodiments, the fibrous mat comprises inorganic fibres, which may be glass fibres and/or mineral fibres such as basalt. In other embodiments, the fibrous mat comprises organic fibres such as carbon fibre, UHMWPE fibre, or aramid.
In certain embodiments, the filler layer comprises particles embedded in the curable resin. In other embodiments, the filler layer comprises chopped glass strands embedded in the curable resin. In yet further embodiments, the filler layer comprises a chopped strand mat impregnated with the curable resin.
Typically, the curable resin is a phenolic resin. Preferably, the curable resin comprises a catalyst in order to accelerate the curing process.
Typically, the maximum dimension of the precursor material is greater than 5m, preferably greater than 10m, more preferably greater than 20m
According to a second aspect, the present invention may provide a method of forming a precursor material for forming into a reinforced resin panel, comprising the steps of:
• providing a continuous base fibrous sheet and causing a filler layer to be deposited on the base fibrous sheet;
· causing a continuous upper fibrous sheet to be deposited on the filler layer, to form a multi-layer stack;
• transporting the multi-layer stack to a resin application station and applying a curable resin to the multi-layer stack such that it impregnates the multi-layer stack. The continuous fibrous sheets each have a maximum dimension that is greater than 50m, preferably greater than 75m, more preferably greater than 100m.
In certain cases, an additional filler layer may be deposited on the upper surface of the upper fibrous sheet, followed by the step of covering the additional filler layer with an additional fibrous sheet. Further pairs of filler layer and fibrous sheet may be laid over this
arrangement.
Preferably, one or both of the fibrous sheets is a woven mat. Woven mats are considered to impart particularly high tensile strength to the outer surface of the panel.
In other examples of the method, one or both of the fibrous mats may be provided by a non- woven mat, such as a mat comprising a unidirectional fabric. A unidirectional fabric is a fabric in which at least 75%, preferably at least 80%, more preferably at least 90% of the fibres are in alignment with each other. In certain cases, one or both of the fibrous mats may be provided by a biaxial cloth that is produced by joining two unidirectional fabrics in a face- to-face configuration such that the principal axes of the unidirectional fabrics do not coincide.
In certain embodiments, the fibrous sheet comprises inorganic fibres, which may be glass fibres and/or mineral fibres such as basalt. In other embodiments, the fibrous sheet comprises organic fibres such as carbon fibre, UHMWPE fibre, or aramid. In certain embodiments, the filler layer comprises particles. In other embodiments, the filler layer comprises chopped glass strands. Typically, in this case, the chopped glass strands are prepared in situ by chopping strands from continuous fibre rolls and allowing the strands to fall onto the base fibrous sheet. In yet further embodiments, the filler layer comprises a chopped strand mat.
In general, after application of the curable resin to the multi-layer stack, the multi-layer stack is heated in order to promote full and even penetration of the resin throughout the stack and/or the reduction of air bubbles in the material. This helps to increase the quality of the precursor material.
Typically, after impregnation of the multi-layer stack with the curable resin, the precursor material is cut into shorter lengths e.g. between 5 and 25m and arranged in the form of a roll or in a folded configuration. The length of cut is chosen with a view to balancing the requirement of ease of handling (which favours cutting into shorter lengths of material) with the requirement of economic viability (which favours the provision of longer lengths of material).
Typically, the curable resin is a phenolic resin. Preferably, the curable resin comprises a catalyst in order to accelerate the curing process.
In a third aspect, the present invention may provide a method of creating a reinforced resin panel, comprising the step of providing a precursor material according to the first aspect of the invention, inserting at least a portion of the precursor material into a mould and curing the resin.
Detailed description
The invention will now be described by way of example only with reference to the following Figures in which:
Figure 1 shows a schematic exploded perspective view of a precursor material according to an embodiment of the first aspect of the invention;
Fig. 2 shows a schematic section view of apparatus for carrying out a method according to an example of the second aspect of the invention. Figure 3 shows a schematic section view of apparatus for carrying out a method according to an example of the third aspect of the invention.
Referring to Figure 1 , a precursor material for shaping into a reinforced resin panel comprises two outer woven glass layers 10,30 and a layer of chopped glass 20 disposed therebetween. All three layers of the precursor material are impregnated with a phenolic resin, which penetrates the interstices between the glass fibres. Referring to Figure 2, a first continuous woven glass sheet is dispensed from drum 50, moving in the direction of arrow A towards drum 52. The first continuous woven glass sheet provides a horizontal surface onto which chopped glass is deposited at a chopped glass deposition station 54 to form an even layer on the upper side of the woven glass sheet. The chopped glass is prepared in situ by chopping strands from continuous fibre rolls and allowing the strands to fall onto the first continuous woven glass sheet.
A second continuous woven glass sheet is dispensed from drum 56 and laid over the chopped glass. The resulting multi-layer assembly comprising outer woven glass layers and an inner layer of chopped glass passes beneath roller 58 to a resin application station 60. At the resin application station, a two-part phenolic resin containing a latent catalyst is deposited onto the upper surface of the second continuous woven glass sheet and allowed to penetrate into the multi-layer assembly. The phenolic resin system may comprise
Cellobond™ resin and a Phencat™ catalyst, both supplied by Hexion.
The resin-impregnated multi-layer assembly subsequently passes below a heater 62, which warms the resin to a temperature of around 20-40°C, thus reducing its viscosity and helping to ensure its full and even penetration into the multi-layer assembly. After this, the assembly is passed between compaction rollers 64a, b,c disposed on either side of the assembly which further assist in promoting penetration of the resin into the assembly. In certain cases, multiple sets of compaction rollers may be provided on either side of the assembly. After passing between the compaction rollers, the assembly is wound onto drum 52 and stored until required. Referring to Figure 3a, a portion of precursor material 78 is placed between internal surfaces 82,84 of mould 80. The mould is then closed around the precursor material (Figure 3b) and the precursor material is cured at a temperature above 130°C (for example, about 140°C) and a pressure of about 10 bar for about 5-10 minutes, so as to provide a shaped reinforced resin panel (Figure 3c).

Claims

1. A precursor material for forming into a reinforced resin panel, the precursor material being provided by a multi-layer stack comprising two fibrous mats and a filler layer disposed therebetween, the multi-layer stack being impregnated with a curable resin, the precursor material being arranged in a folded configuration or in the form of a roll.
2. A precursor material according to claim 1 , wherein at least one of the fibrous mats is a woven mat.
3. A precursor material according to claim 1 , wherein at least one of the fibrous mats is a unidirectional fabric.
4. A precursor material according to any one of the preceding claims, wherein the
fibrous mat comprises inorganic fibres such as glass fibres or basalt fibres.
5. A precursor material according to any one of claims 1 to 3, wherein the fibrous mat comprises organic fibres such as carbon fibre, UHMWPE fibre, or aramid.
6. A precursor material according to any one of the preceding claims, wherein the filler layer comprises particles embedded in the curable resin.
7. A precursor material according to claim 6, wherein the filler layer comprises chopped fibre strands embedded in the curable resin.
8. A precursor material according to claim 7, wherein the filler layer comprises a
chopped fibre strand mat impregnated with the curable resin.
9. A precursor material according to claim 7 or claim 8, wherein the fibre strands are glass.
A precursor material according to any one of the preceding claims, wherein the maximum dimension of the precursor material is greater than 5m, preferably greater than 10m, more preferably greater than 20m.
A precursor material according to any one of the preceding claims, wherein the curable resin is a phenolic resin.
A precursor material according to any one of the preceding claims, wherein the curable resin comprises a catalyst.
13. A method of forming a precursor material for forming into a reinforced resin panel, comprising the steps of:
• providing a continuous base fibrous sheet and causing a filler layer to be deposited on the base fibrous sheet;
• causing a continuous upper fibrous sheet to be deposited on the filler layer, to form a multi-layer stack;
· transporting the multi-layer stack to a resin application station and applying a curable resin to the multi-layer stack such that the resin impregnates the multi-layer stack.
A method of creating a reinforced resin panel, comprising the step of providing a precursor material according to any one of claims 1-12, inserting at least a portion of the precursor material in a mould and curing the resin.
PCT/GB2017/051300 2016-05-12 2017-05-10 Precursor material for forming into a reinforced resin panel and method for the production thereof WO2017194939A1 (en)

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Citations (4)

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EP1055513A1 (en) * 1999-05-27 2000-11-29 Hexcel Corporation Pre-preg and panel structure
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US20130327479A1 (en) * 2011-03-03 2013-12-12 Mitsubishi Rayon Co., Ltd. Matrix resin composition, prepreg and method for producing the same, and fiber-reinforced composite material

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GB1074525A (en) * 1965-01-19 1967-07-05 Minnesota Mining & Mfg Reinforced resinous structural material
WO1998053978A1 (en) * 1997-05-30 1998-12-03 Ppg Industries Ohio, Inc. Glass fiber mats, composites reinforced with the same and methods for making the same
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Publication number Priority date Publication date Assignee Title
DE3729633A1 (en) * 1987-09-04 1989-03-16 Hoechst Ag Structural honeycomb with increased compressive strength, process for the production thereof and planiform sandwich mouldings produced therefrom
EP1055513A1 (en) * 1999-05-27 2000-11-29 Hexcel Corporation Pre-preg and panel structure
DE19949318A1 (en) * 1999-09-11 2001-03-15 Menzolit Fibron Gmbh Carbon fiber reinforced SMC for multiaxially reinforced components
US20130327479A1 (en) * 2011-03-03 2013-12-12 Mitsubishi Rayon Co., Ltd. Matrix resin composition, prepreg and method for producing the same, and fiber-reinforced composite material

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