Reinforced composite materials for use in the manufacture moulds and the use of such moulds
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C08J-009/00
B32B-027/18
B29C-033/38
B29C-033/40
B32B-005/24
B32B-005/26
B32B-005/18
B32B-037/14
B29K-105/12
B29L-031/00
출원번호
US-0699199
(2011-05-26)
등록번호
US-9132614
(2015-09-15)
우선권정보
AU-2010902306 (2010-05-26)
국제출원번호
PCT/AU2011/000637
(2011-05-26)
§371/§102 date
20130204
(20130204)
국제공개번호
WO2011/146995
(2011-12-01)
발명자
/ 주소
Hodgson, Peter
Bystrzynski, Richard
출원인 / 주소
MIRTEQ PTY LIMITED
대리인 / 주소
Jones Day
인용정보
피인용 횟수 :
3인용 특허 :
29
초록
The present disclosure relates to the preparation of composite molds and methods of preparing the same, wherein the composite molds may be prepared exclusive or inclusive of a plug. Certain composites comprise a substrate, a structural laminate, and a syntactic foam molding product.
대표청구항▼
1. A method for producing a composite mould, comprising: i) forming a substrate;ii) applying a fibre reinforced structural laminate to the substrate, wherein said fibre reinforced structural laminate comprises: a) a first plurality of reinforcing fibres; andb) a first curable resin mixture, comprisi
1. A method for producing a composite mould, comprising: i) forming a substrate;ii) applying a fibre reinforced structural laminate to the substrate, wherein said fibre reinforced structural laminate comprises: a) a first plurality of reinforcing fibres; andb) a first curable resin mixture, comprising a first curable resin and a wetting agent, wherein the wetting agent is prepared by reacting a polyol with an organo-functional silane;iii) applying a syntactic foam moulding product to the fibre reinforced structural laminate, wherein said syntactic foam moulding product comprises: a) a plurality of treated reinforcing microfibres;b) a second curable resin mixture, comprising a second curable resin, and optionally thixatropes and plastic spheres/hemispheres; andc) a coupling agent, wherein the coupling agent is prepared by reacting a polyol with an organo-functional silane;iv) optionally applying a tooling gel coat to the surface of said syntactic foam moulding product for the manufacture of moulds that require a high gloss surface finish; andv) curing said composite mould. 2. The method of claim 1, wherein said syntactic foam moulding product adds rigidity to the produced composite mould. 3. The method of claim 1, wherein said syntactic foam moulding product is sprayable and/or machineable. 4. The method of claim 1, wherein the substrate comprises: i) a structural substrate, comprising: a solid substrate; a wooden substrate; a plywood substrate; a particle board substrate; a MDF substrate; a composite material; a structural fibre board; a polymer concrete substrate; a concrete substrate; a fibreglass substrate; a polymer composite substrate; or a plastic composite substrate;ii) a non-structural substrate, comprising: a foam substrate; a plastic foam, meshing, or fabric; a sealed polystyrene foam substrate; a polyurethane foam substrate; or a rigid plastic foam substrate;iii) a machined substrate, a CNC machined substrate, a fabricated substrate, and/or a sealed substrate; and/oriv) combinations thereof. 5. The method of claim 1, wherein the substrate is sealed with a foam sealer product. 6. The method of claim 1, wherein the foam sealer comprises: i) a sprayable and/or rollable water based sealer formulated from polyvinyl alcohol;ii) a sealer made from a low viscosity sprayable and/or rollable epoxy compound that when cured allows unsaturated polyester or vinyl ester resins to adhere to its surface; oriii) a specially formulated vinyl functional resin that does not attack a polystyrene foam surface. 7. The method of claim 1, wherein the plurality of treated reinforcing microfibres comprise: i) mineral fibres, comprising wollastonite and/or Mica;ii) glass fibres, comprising E-, S-, or C-class glass;iii) aramid fibres;iv) ceramic fibres;v) cellulose fibres; and/orvi) carbon fibres. 8. The method of claim 1, wherein the plurality of treated reinforcing microfibres are coated with a coupling agent. 9. The method of claim 1, wherein the coupling agent comprises a plurality of molecules, each having: i) a first end adapted to bond to a fibre of the plurality of reinforcing fibres; andii) a second end adapted to bond to the resin when cured. 10. The method of claim 1, wherein the first and/or second curable resin comprises a liquid curable resin. 11. The method of claim 1, wherein the first plurality of reinforcing fibres comprise an average length of between about 5 mm and 20 mm for the structural layer. 12. The method of claim 1, wherein the said first and/or second curable resin comprises an unsaturated polyester resin; a vinyl ester resin; or a blend of unsaturated polyester and vinyl ester resins. 13. The method of claim 1, wherein the polyol reacted to prepare said wetting agent comprises trimetholylpropane or pentaerythritol. 14. The method of claim 1, wherein the method further comprises applying a foam sealer product to the substrate prior to applying the structural laminate. 15. The method of claim 1, wherein the foam sealer product comprises: a) a plurality of treated reinforcing microfibres and/or Mica flakes;b) a foam sealer; andc) a coupling agent. 16. The method of claim 1, wherein the method is inclusive of making and/or using a plug or composite plug. 17. The method of claim 1, wherein the method is exclusive of making and/or using a plug or composite plug. 18. The method of claim 1, wherein said syntactic foam moulding product provides a durable and machineable moulding surface to the produced composite mould. 19. The method of claim 6, wherein the polystyrene foam surface is CCP Styroguard. 20. The method of claim 1, wherein the polyol reacted to prepare said coupling agent comprises trimetholylpropane or pentaerythritol.
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이 특허에 인용된 특허 (29)
Graham Roy R. (Lexington NC), Aqueous dispersion of glass fibers and method and composition for producing same.
Hsu Ed C. (Pittsburgh PA) Moore L. Dow (Allison Park PA) Temple Chester S. (McKees Rocks PA), Aqueous sizing composition for glass fibers and sized glass fibers for thermoplastic reinforcement.
Oda Kunio (Sakura JPX) Oda Denichi (Ichihara JPX) Fujii Yuichi (Ichihara JPX) Takagi Takeshi (Hirakata JPX), Fiber-reinforced chlorinated polyethylene composition and process for production thereof.
Matsuura Tetsuro (Narita JPX) Yamamoto Shinji (Ichihara JPX) Oda Denichi (Ichihara JPX) Matsumori Yasuo (Ichihara JPX), Fiber-reinforced rubber article and process for producing the same.
Du Pont Preston S. (Northridge CA) Freeman Janet E. (Pasadena CA) Ritter Robert E. (Palos Verdes Estates CA) Wittmann Alois (Palos Verdes CA), Fiber-reinforced syntactic foam composites and method of forming same.
Rahrig Douglas B. (Racine WI) Magistro Angelo J. (Brecksville OH) Parker Richard G. (Hudson OH), Glass fiber reinforced vinyl chloride polymer products and process for their preparation.
Brichta Corrado (Milan ITX) Tettamanzi Natale (Arenzano-Genova ITX) Rial Elio (Milan ITX), Process for imparting a better adhesion between reinforcing materials and plastic matrix and product thereby produced.
Joslyn Wallace G. (Jacksonville FL) Ulrich ; III Alfred D. (Jacksonville FL) Wilson Michael E. (Middleburg FL), Silane compositions for reinforcement of polyolefins.
Skinner, James W.; Gamble, Jimmy D.; Slocum, Robert R.; Kaczmarczyk, John M., Manhole base assembly with internal liner and method of manufacturing same.
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