Plastic and nonmetallic article shaping or treating: processes – Mechanical shaping or molding to form or reform shaped article – To produce composite – plural part or multilayered article
Patent
1980-09-17
1986-01-07
Derrington, James
Plastic and nonmetallic article shaping or treating: processes
Mechanical shaping or molding to form or reform shaped article
To produce composite, plural part or multilayered article
156190, 156196, 156197, 156224, 156249, 264225, 264257, 264258, 264339, 428116, 428117, 428118, B32B 3104
Patent
active
045633215
ABSTRACT:
A method of producing a unitary curved structure having a honeycomb core by coating a mold with gel, applying a layer of reinforced fiberglass plastic to the gel to receive, after partial curing, a light layer of chopped glass fibers (about 3/4 ounces/sq. ft.) and a mixture of catalyzed resin and chopped fiber strand. The resulting surface may be rolled to remove bubbles and oversprayed with catalyzed resin. A Raw Kraft paper honeycomb is placed into the wet laminate and completely covered with wax paper weighted with sand bags to approximately 10 pounds per square foot to press the honeycomb into place and seal same. The resin is absorbed in and climbs the honeycomb walls, and heat and styrene gas are liberated into the cells. The bags and wax paper are removed after partial cure, excess styrene fumes are blown away, and the honeycomb is lightly oversprayed with a catalyzed resin. A layer (3/4 ounce of fibrous glass mat containing catalyzed resin) is carefully rolled over the top of the honeycomb core, the mat being sufficiently porous so that trapped styrene gas escapes from the honeycomb cells. After the styrene gas is completely vented, an outer skin of further fiberglass mat is applied, fully saturated with catalyzed resin, to seal the porous mat and allowed to cure. The result is a bondless unitary curved resin structure having parallel outer resin surfaces reinforced by fiberglass, and a honeycomb core of the same resin reinforced by paper.
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Albright Penrose Lucas
Derrington James
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