Stock material or miscellaneous articles – Hollow or container type article – Polymer or resin containing
Reexamination Certificate
1999-06-18
2001-07-10
Dawson, Robert (Department: 1712)
Stock material or miscellaneous articles
Hollow or container type article
Polymer or resin containing
C264S257000, C428S036800
Reexamination Certificate
active
06258422
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to the field of fiber reinforced composite materials produced by molding a thermosetting resin, such as an epoxy resin or polyester resin, which is reinforced with fibers, such as carbon fibers, aramid fibers (Kevlar), glass fibers, and others, and also to rubber vulcanization type, fiber reinforced composite materials, in which a rubber material is vulcanized to improve certain properties of such materials.
One object of the present invention is to provide a thermosetting resin based, fiber reinforced composite material which retains important characteristics found in such fiber reinforced composite materials, such as light weight, high strength and high rigidity, but which also has improved qualities not available at a satisfactory level in such conventional materials: chemical resistance, oil resistance, being airtight or waterproof, certain sealing properties, electrical insulating properties, vibration damping properties, etc. With such improved functions, materials according to the present invention can thereby overcome disadvantages associated with conventional fiber reinforced composite materials, such as restrictions on use, the structural shortcomings of the various products to which fiber reinforced composite materials are applied, being uneconomical, and so on.
A further object of the present invention is to provide a thermosetting resin-based, rubber vulcanization type, fiber reinforced composite material in which a rubber material is vulcanized in the thermosetting step of the molding stage for the thermosetting resin, in order to impart the various improved functions described above to the resulting composite material.
Conventionally, fiber reinforced composite materials, produced by reinforcing a thermosetting resin with fibers, have excellent characteristics, such as being light in weight, high in strength and high in rigidity, and thus are currently widely used as aircraft and automobile parts and materials.
However, since a fiber reinforced composite material is insufficiently strong in connection with concentrated loads and is inferior in its capacity to dampen vibrations, a separate reinforcing member is additionally provided in the composite material, for example, where such a concentrated load is applied. In the case of material subject to vibrations, conventionally, special measures are required to prevent the transmission of such vibrations, by using, for example, a vibration insulator
6
as shown in FIG.
1
B. In
FIG. 1
, the fiber reinforced composite material is indicated at
1
.
In the case of fiber reinforced composite materials using carbon fibers, the carbon fibers are good electrical conductors and, therefore, it may become necessary to take special precautions when such materials are used with electric wiring or used as electrical insulation, in order to prevent electrical leakage. For example, where a container
8
for an electric board
7
is formed using a carbon fiber reinforced composite material as shown in
FIG. 2B
, an insulating plate
9
interposed between the bottom of the container
8
and the electric board
7
is required.
Also, conventional fiber reinforced composite materials are inferior with regard to other qualities, such as chemical resistance, oil resistance, and being airtight or waterproof, and certain sealing properties.
Accordingly, for products requiring such functions, special measures must be taken. For example, as shown in
FIG. 3B
, a separate sealant
12
must be affixed to the sliding portion of a fiber reinforced composite material
11
where a member
10
, such as a pipe, is inserted.
OUTLINE OF THE INVENTION
The present invention provides a thermosetting resin based, rubber vulcanization type, fiber reinforced composite material using a thermosetting resin, such as epoxy resin or polyester resin, reinforced with fibers, such as carbon fibers, aramid fibers or glass fibers. In the thermosetting step of the molding stage for the thermosetting resin, a rubber material is integrally vulcanized with the thermosetting resin during the molding of the fiber reinforced composite material. This is done in order to add improved qualities to the resulting material, such as chemical resistance, oil resistance, being airtight or waterproof, certain sealing properties and the capacity for electrical insulation and the capacity to dampen vibrations.
Sheet materials composed of a thermosetting resin reinforced with carbon fibers, such as aramid or glass fibers, are molded, and, prior to the thermosetting of the sheet materials, an unvulcanized nitrile rubber sheet is molded together with the sheet materials into the desired shape. Thereafter, the sheet materials and rubber sheet, combined in the molding step, are heated together to approximately 150° C., thereby simultaneously accomplishing the setting step for the thermosetting resin and the vulcanizing step for the rubber material.
The thermosetting resin based, rubber vulcanization type, fiber reinforced composite material according to the present invention retains the beneficial characteristics of fiber reinforced composite materials, such as being light in weight, high in strength and high in rigidity, but adds or improves the qualities described above. Thus, the fiber reinforced composite material according to the present invention has wide applications and uses. This is because the advantageous of conventional materials are retained in the present invention, but various disadvantages associated such conventional fiber reinforced composite materials can be reduced or eliminated.
REFERENCES:
patent: 05301972 (1993-11-01), None
patent: 5-301972 (1993-11-01), None
Aylward D.
Dawson Robert
Dellett and Walters
Tokyo R&D Co., Ltd.
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