Stock material or miscellaneous articles – Composite – Of metal
Patent
1995-12-21
1998-09-29
Sellers, Robert E.
Stock material or miscellaneous articles
Composite
Of metal
294033, 310 43, 310208, 525 49, 525415, 525425, 525438, 525440, 525442, 525443, B32B 1508
Patent
active
058144129
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
The present invention relates to a thermosetting composition with superior strength and heat resistance, readily decomposed, a molding compound containing the composition, a molded structure using the molding compound, and a method for decomposing the composition, the molding compound, and the molded structure.
BACKGROUND ART
Conventionally, thermosetting resins have been widely utilized for industrial materials. The volume of production of the thermosetting resins has increased at a rate of several percent per annum since 1985, and reached about 2,000,000 tons during the full year of 1990. Examples of the thermosetting resins include an epoxy resin, a phenol resin, a polyurethane resin, an unsaturated polyester resin, a urea resin, a melamine resin, and a polyimide resin. Such thermosetting resins mostly find their application in composite materials containing a filler, such as fiber reinforced plastics (FRP). For example, about 80% of produced unsaturated polyester resins have been used as FRP. In addition to glass fibers, examples of fillers contained in the composite materials include inorganic materials such as calcium carbonate, talc, and silica, and organic materials such as pulp and wood. Since the thermosetting resins are readily reinforced by being composited with a filler or the like, they have widely been used for consumer products or for industrial products such as materials for molding, multilayer plates, adhesives, and coatings.
When being cured, the thermosetting resins have a three-dimensional cross-linked structure and generally assume an insoluble and infusible solid form, so that they are difficult to be decomposed for disposal. Thus, the thermosetting resins have conventionally been junked because of their difficulty in reproduction and recycling.
However, in recent years, waste problems have received heightened attention, and the decomposition and reproduction of waste resins have been recognized as serious problems. Such problems are also important with respect to the thermosetting resins. For example, fiber reinforced unsaturated polyesters have been used a lot for producing large products such as a fishing boat, a tank, and housing equipment, causing serious problems of decomposition and recycling of waste. This necessitates technical development for minimizing the volume of waste thermosetting resins and recycling thereof. As a result, the technique for thermally decomposing the waste thermosetting resins into raw materials has been studied. However, the thermosetting resins are technically difficult to be decomposed for disposal, because of their properties such as hardness, strength, heat resistance, frame resistance, and chemical resistance. Furthermore, the thermosetting resins are mostly used as structural materials because of their outstanding strength; for example, they are used for molding compounds for motors. In this case, the resulting waste thermosetting resins may include other materials such as metal. Such materials as metal are more expensive than the thermosetting resins. As is understood from this fact, there arises a serious problem that less expensive waste resins have prevented the expensive materials such as metal from being reproduced or recycled. Thus, waste problems with respect to the thermosetting resins cannot be dissolved by using conventionally available resins or by using conventional methods for decomposing for disposal.
On the other hand, in recent years, molded structures obtained by integrally molding a molding compound made of a thermosetting resin, such as molded motors, molded transformers, and IC packages have been used in consumer, industrial, and paperwork equipment, and the like. Hereinafter, an example of the molded motor will be described. Such molded motors have outstanding properties in terms of noise, damping, insulation, and maintenance, and their compact size facilitates the automation thereof. Because of these properties, the demand for molded motors has rapidly increased.
Conventionally used molded stators of mo
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Onishi Hiroshi
Terada Takahiko
Matsushita Electric - Industrial Co., Ltd.
Sellers Robert E.
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