Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Patent
1996-10-09
1998-06-02
Stemmer, Daniel
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
138125, 15624413, 1563096, B29C 7052, B29B 1510
Patent
active
057593230
DESCRIPTION:
BRIEF SUMMARY
The subject matter of this invention concerns a process for the manufacture of a product, especially of a pipe or hose, made of a fiber-reinforced composite material.
A number of processes for the manufacture of products made of fiber-reinforced composite materials are known. In the hand lay-up process, the final product is manufactured by manually positioning resin and glass-fiber mats or glass-fiber fabrics in a wooden, synthetic, or metal mold. Due to the high manual labor cost, this process is generally suitable only for the production of single parts or a small number of pieces. The only smooth surface of the final products that are manufactured by means of the hand lay-up process is the surface that faces the mold.
Rotationally symmetrical molded articles, such as pipes and containers, are frequently produced by means of filament process. In this process, a winding machine is used to wind textile glass mats, fabrics or rovings and resin around a metal mandrel. Again, this process produces an optimally smooth surface only on the inside surfaces of the wound components. This filament winding process is also labor-intensive, which means that the cost of producing the finished products is high.
For large lots, hot press molding of prepregs (SMC) or compression molding materials (BMC) is known. In this process, coating blanks of thickened mixtures of resin, glass, and fillers are positioned in heated surface-hardened steel molds and cured at an elevated temperature (approximately 120.degree. C. -150.degree. C.) under pressure. Due to the batchwise operation, hot press molding entails relatively high labor costs.
To produce large-area components made of a fiber-reinforced composite material, the injection process can be used. In this process, the precisely cut-to-size reinforcing material is positioned in a mold, the upper surface of which is covered by a countermold. The mold that contains the reinforcing material is subsequently evacuated; next, resin is introduced, in most cases to the deepest point of the mold, and sucked through the laminate up to the rim. Again, this process is carried out in batches and entails relatively high labor costs.
A continuous process that can be suitably used for the production of fiber-reinforced synthetics is the so-called pultrusion process. In pultrusion, the reinforcing material that is saturated with resin is continuously pulled through a heated die with the desired sectional shape, which die sets the final shape of and cures the product. This process, however, has a number of drawbacks: The matrix material, in most cases a resin, must be liquid so that the reinforcing material can be-saturated with it. Thus, the selection of the matrix material is restricted to certain liquefiable resins. As a rule, the resins that are used as the matrix material are liquefied with a solvent that is released during the curing process and which is detrimental to the environment. Furthermore, the application of the matrix material, which takes place by saturating the reinforcing material with the matrix material, leads to a nonhomogeneous distribution on the reinforcing material, as a result of which the properties of the final product vary. The speed of the pultrusion process is limited by the ability of the matrix material to penetrate the reinforcing material and by the viscosity of the matrix material. In addition, the pultrusion rate is limited by the forces that are exerted on the matrix material during the heating and molding process since excessively high tensile forces would destroy the structure of the reinforcing material and of the matrix material.
In all processes mentioned above, a thermally curable material, in most cases a synthetic resin, is used as the matrix material.
To process glass-fiber reinforced thermoplastics, the well-known injection molding process can be used. The starting material is a granular material with enclosed short glass fibers. The granules are dissolved by heat and an extruder is used to press the material into the injection mold desired. This p
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De Meyer Willy
Van Hoey Marc
Wagner Dieter
Moyer Terry T.
Robertson James M.
Stemmer Daniel
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