US20030148087A1 - Process of manufacturing a fibre web comprising a thermosetting resin, such a fibre web, and an reinforced the fibre web comprising a thermosetting resin composite - Google Patents
Process of manufacturing a fibre web comprising a thermosetting resin, such a fibre web, and an reinforced the fibre web comprising a thermosetting resin composite Download PDFInfo
- Publication number
- US20030148087A1 US20030148087A1 US10/302,487 US30248702A US2003148087A1 US 20030148087 A1 US20030148087 A1 US 20030148087A1 US 30248702 A US30248702 A US 30248702A US 2003148087 A1 US2003148087 A1 US 2003148087A1
- Authority
- US
- United States
- Prior art keywords
- thermosetting resin
- fibre web
- fibres
- grains
- reinforcing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 229920001187 thermosetting polymer Polymers 0.000 title claims abstract description 144
- 229920005989 resin Polymers 0.000 title claims abstract description 131
- 239000011347 resin Substances 0.000 title claims abstract description 131
- 239000000835 fiber Substances 0.000 title claims abstract description 110
- 238000000034 method Methods 0.000 title claims abstract description 54
- 239000000805 composite resin Substances 0.000 title claims abstract description 20
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 19
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 55
- 238000005304 joining Methods 0.000 claims abstract description 24
- 238000010438 heat treatment Methods 0.000 claims abstract description 6
- 238000001816 cooling Methods 0.000 claims abstract description 3
- 239000000463 material Substances 0.000 claims description 31
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 claims description 12
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 10
- 239000000945 filler Substances 0.000 claims description 9
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 8
- 229910052799 carbon Inorganic materials 0.000 claims description 8
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 claims description 8
- 229920000877 Melamine resin Polymers 0.000 claims description 7
- 239000004753 textile Substances 0.000 claims description 7
- 229920003180 amino resin Polymers 0.000 claims description 6
- 239000002184 metal Substances 0.000 claims description 6
- 229910052751 metal Inorganic materials 0.000 claims description 6
- -1 caolin Chemical compound 0.000 claims description 5
- 229920005615 natural polymer Polymers 0.000 claims description 5
- 229920006254 polymer film Polymers 0.000 claims description 5
- 239000000377 silicon dioxide Substances 0.000 claims description 5
- 235000012239 silicon dioxide Nutrition 0.000 claims description 5
- 229920001059 synthetic polymer Polymers 0.000 claims description 5
- YCMLQMDWSXFTIF-UHFFFAOYSA-N 2-methylbenzenesulfonimidic acid Chemical compound CC1=CC=CC=C1S(N)(=O)=O YCMLQMDWSXFTIF-UHFFFAOYSA-N 0.000 claims description 4
- GZVHEAJQGPRDLQ-UHFFFAOYSA-N 6-phenyl-1,3,5-triazine-2,4-diamine Chemical compound NC1=NC(N)=NC(C=2C=CC=CC=2)=N1 GZVHEAJQGPRDLQ-UHFFFAOYSA-N 0.000 claims description 4
- 229920000742 Cotton Polymers 0.000 claims description 4
- FBPFZTCFMRRESA-FSIIMWSLSA-N D-Glucitol Natural products OC[C@H](O)[C@H](O)[C@@H](O)[C@H](O)CO FBPFZTCFMRRESA-FSIIMWSLSA-N 0.000 claims description 4
- 229920000168 Microcrystalline cellulose Polymers 0.000 claims description 4
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 claims description 4
- NJYZCEFQAIUHSD-UHFFFAOYSA-N acetoguanamine Chemical compound CC1=NC(N)=NC(N)=N1 NJYZCEFQAIUHSD-UHFFFAOYSA-N 0.000 claims description 4
- 125000003277 amino group Chemical group 0.000 claims description 4
- 125000005605 benzo group Chemical group 0.000 claims description 4
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 claims description 4
- 239000000292 calcium oxide Substances 0.000 claims description 4
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 claims description 4
- 239000004202 carbamide Substances 0.000 claims description 4
- 230000005611 electricity Effects 0.000 claims description 4
- 239000011521 glass Substances 0.000 claims description 4
- 229910052500 inorganic mineral Inorganic materials 0.000 claims description 4
- 239000002923 metal particle Substances 0.000 claims description 4
- 235000019813 microcrystalline cellulose Nutrition 0.000 claims description 4
- 239000008108 microcrystalline cellulose Substances 0.000 claims description 4
- 229940016286 microcrystalline cellulose Drugs 0.000 claims description 4
- 239000011707 mineral Substances 0.000 claims description 4
- 239000004627 regenerated cellulose Substances 0.000 claims description 4
- 239000000600 sorbitol Substances 0.000 claims description 4
- 239000004014 plasticizer Substances 0.000 claims description 3
- 239000005995 Aluminium silicate Substances 0.000 claims description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 2
- 230000002745 absorbent Effects 0.000 claims description 2
- 239000002250 absorbent Substances 0.000 claims description 2
- 235000012211 aluminium silicate Nutrition 0.000 claims description 2
- 239000008240 homogeneous mixture Substances 0.000 claims description 2
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 2
- 238000005406 washing Methods 0.000 abstract description 2
- 239000012779 reinforcing material Substances 0.000 description 13
- 239000000203 mixture Substances 0.000 description 11
- 239000000047 product Substances 0.000 description 9
- 239000007788 liquid Substances 0.000 description 7
- 238000001035 drying Methods 0.000 description 6
- 239000000243 solution Substances 0.000 description 6
- 239000011230 binding agent Substances 0.000 description 5
- 239000002131 composite material Substances 0.000 description 5
- 239000006185 dispersion Substances 0.000 description 5
- 239000003365 glass fiber Substances 0.000 description 4
- 239000011159 matrix material Substances 0.000 description 4
- 238000000748 compression moulding Methods 0.000 description 3
- 229920003043 Cellulose fiber Polymers 0.000 description 2
- 229920001807 Urea-formaldehyde Polymers 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 150000002148 esters Chemical class 0.000 description 2
- IVJISJACKSSFGE-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine Chemical compound O=C.NC1=NC(N)=NC(N)=N1 IVJISJACKSSFGE-UHFFFAOYSA-N 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 239000006072 paste Substances 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- VHUUQVKOLVNVRT-UHFFFAOYSA-N Ammonium hydroxide Chemical class [NH4+].[OH-] VHUUQVKOLVNVRT-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 description 1
- 229920000297 Rayon Polymers 0.000 description 1
- 239000003677 Sheet moulding compound Substances 0.000 description 1
- 239000002253 acid Chemical class 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 239000000908 ammonium hydroxide Substances 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000004020 conductor Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- WSFSSNUMVMOOMR-UHFFFAOYSA-N formaldehyde Substances O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 210000001724 microfibril Anatomy 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 125000002924 primary amino group Chemical group [H]N([H])* 0.000 description 1
- 239000002964 rayon Substances 0.000 description 1
- 238000001175 rotational moulding Methods 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 230000008961 swelling Effects 0.000 description 1
- 238000001721 transfer moulding Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/504—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands
- B29C70/506—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands and impregnating by melting a solid material, e.g. sheet, powder, fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
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- B29C70/508—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] using rollers or pressure bands and first forming a mat composed of short fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
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- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
Definitions
- the present invention relates to a process for manufacturing a fibre web comprising a thermosetting resin.
- the invention is further related to a fibre web comprising thermosetting resin which has been obtained by means of the process, and an reinforced thermosetting containing composite which includes the fibre web comprising the thermosetting resin.
- thermosetting composite of the invention can preferably be used for sanitary products, such as washing stands, and toilet chairs, for different surfaces being subject to abrasion, for electricity conducting products, and for many medical technical products, such as devices for lengthening a leg to be implanted, and the similar. Many other applications are considered as well.
- thermosetting resins are often used as a binder or matrix material.
- thermosetting resins, often before hardening (cross linking) are present in a form of a liquid having a relatively low viscosity at room temperature, something that makes the impregnation of a reinforcing material quite simple.
- thermosetting resins such as urea-formaldehyde (UF) and melamine-formaldehyde (MF) are, however, not in liquid state at room temperature prior to hardening.
- UF urea-formaldehyde
- MF melamine-formaldehyde
- this type of thermosetting resin should be provided in the form of a solution, dispersion, or paste of thermosetting resin together with a suitable liquid, (e.g. water).
- a suitable liquid e.g. water
- thermosetting resin composite Within the field of reinforced thermosetting resin, here often called thermosetting resin composite it is previously known a number of manufacturing processes, reinforcing materials, and matrix material.
- the reinforcing material of a reinforced thermosetting resin is often fibres in the form of roving, web, mats, or non-woven material. Depending on the actual application field the reinforcing fibres may consist of natural or synthetic polymers. Examples of commonly used reinforcing fibres are glass fibres, and carbon fibres, and in some applications also cellulose fibres, such as pulp fibres, rayon or linen.
- the binding agent or matrix material in a reinforced thermosetting resin is often an unsaturated ester resin, but also epoxy, pheno- or amino resins are used.
- a number of different methods for forming details of reinforced thermosetting resin are known since earlier.
- a well known forming method is the contact method which comprises that Thermosetting resin and reinforcing material (e.g., ester resin and glass fibre material) are put in layers on a mould at room temperature, whereupon the ready resin detail, after hardening, is brought out off the mould provided with a mould release agent.
- Thermosetting resin and reinforcing material e.g., ester resin and glass fibre material
- a development of the above mentioned process using layering by hand includes that one in stead manually or by means of a robot sprays a two component thermosetting resin and reinforcing material in the form of chopped roving onto the mould.
- the hardening of the resin can be carried out under pressure by pressuring a film against a contact or spray moulded article using super pressure or vacuo, which provides for an increased strength.
- a pressure and heat in an autoclave the result can be even more improved.
- thermosetting resin Another common method for manufacturing polymer details of reinforced thermosetting resin is compression moulding.
- a preform of reinforcing material e.g., chopped roving
- thermosetting resin e.g., polyester as binder.
- the preform is brought out off the mould and is placed in a form press together with a sufficient amount of polyester, which then, during heating, is pressed into the material.
- preimpregnated mats of reinforcing material e.g., glass fibre mats
- preimpregnated press sheets can be used at compression moulding.
- the manufacture of preimpregnated reinforcing material for the manufacture of Thermosetting resin composite can be done by means of a number of “wet” methods, in which the reinforcing fibres are impregnated with a solution, dispersion or paste containing thermosetting resin.
- U.S. Pat. No. 4,906,505 describes a skin formed product comprising a mixture of amino resin-formaldehyde and fibrous material, whereby the product is characterized in that the resin mixture has a viscosity of 25 Pa.s.-15 ⁇ 10 3 Pa.s. at 120° C. in the skin formed product, and that the fibre material in the form of a pile or sheet has a strength of 0.1 MPa-20 MPa at 20° C.
- the fibre material is impregnated with the resin mixture whereupon the impregnated material is dried until the amino resin mixture obtains a viscosity which exceeds 25 Pa.s. to 15 ⁇ 10 3 Pa.s.
- an abrasion resistant, flame protected material which is manufactured by producing a compression moulding composition of a precondensate of a melamine aldehyde, silicon dioxide, aluminium trihydrate, a soap having a low solubility, ammonium hydroxide, and an acid salt catalyst.
- the composition is then applied onto the surface of a sheet of glass fibres comprising a heat hardening binder, and the composite is bound under heat and pressure to harden both binders simultaneously, and to bind the composition to the fibre layer of the sheet.
- the reinforcing material has to be added in the form of a continuous fibre sheet or fibre web.
- a such is considerably more expensive than the fibres present in the reinforcing material per se.
- the amount of reinforcing fibre and the liquid absorbing ability are defined by the actual construction of the fibre sheet or fibre web it can be hard to control the amount of reinforcing fibre of the ready material, to a desired level.
- thermosetting resin containing solutions or dispersions for the manufacture of preimpregnated reinforcing fibre webs a particular drying process is needed. Such a drying process may lead to certain problems with uneven drying or prehardening, and thereby result in a fibre web having uneven quality. Further, the drying process requires much energy and is often connected with problem of precipitations of resin in the details present in the drying step.
- thermosetting resin is applied in the form of a paste
- some of the above mentioned problems are reduced or eliminated, and makes it possible to use reinforcing fibres in the form of economically advantageous chopped roving.
- the above mentioned problems using the particular drying step will remain fully.
- a first object of the present invention is thus to obtain a method for manufacturing a fibre web containing thermosetting resin, which method eliminates all above mentioned problems.
- thermosetting resin in the form of substantially dry grains of thermosetting resin, joining the grains of thermosetting resin with the Reinforcing fibres at a joining temperature of about room temperature, then binding the fibre web by, prior to and/or under pressure, at least partly heating the grains of thermosetting resin in the fibre web to a binding temperature above the joining temperature, and by then cooling down the fibre web to room temperature.
- a second object of the present invention is to obtain a fibre web containing Thermosetting resin obtained by means of the process.
- the fibre web comprises at least Reinforcing fibres and a Thermosetting resin and is intended to be present in a reinforced Thermosetting resin composite, whereby the Thermosetting resin is present in the fibre web in the form of only partially hardened grains of Thermosetting resin.
- a third object of the present invention is to obtain a reinforced Thermosetting resin composite which comprises the fibre web containing the Thermosetting resin.
- This third object is achieved, in accordance with claim 24, by means of a reinforced Thermosetting resin composite which has been produced by forming a charge of material comprising at least a part of a fibre web containing a Thermosetting resin according to the invention and by then hardening the Thermosetting resin present in the part at a hardening temperature above room temperature.
- FIG. 1 shows a schematic side view of an arrangement suitable for utilizing a process according to a first embodiment of the invention
- FIG. 2 shows a schematic side view of a arrangement suitable for utilizing a process according to a second embodiment of the invention
- FIG. 3 shows a schematic side view of an arrangement suitable for utilizing a process according to a third, particularly preferred embodiment of the invention
- FIGS. 1 - 3 schematic side view of three different arrangements which are suitable for utilizing the different embodiments of the process according to the invention are shown. Thereby it should be noted that other arrangement than those shown in FIGS. 1 - 3 may be suitable for carrying out the process according to the invention, as well.
- the process according to the invention includes forming a fibre web 100 ; 200 ; 300 of at least reinforcing fibres 101 ; 201 ; 301 ; to bring together said fibres with a thermosetting resin 102 ; 202 ; 202 ′; 302 and to join the fibre web 100 ′; 200 ′; 300 ′ at least partly by means of the thermosetting resin after the bringing together.
- the process further includes adding the thermosetting resin in the form of a substantially dry grains 103 ; 203 ; 303 of thermosetting resin.
- the thermosetting resin is thus not in liquid state and not in a form of an emulsion or solution either at the confluence with the reinforcing fibres.
- the process of the invention further includes bringing the grains of thermosetting resin together with the reinforcing fibres 101 , 201 , 301 , at a confluence temperature T 1 at about room temperature, and to then join the fibre web by prior to and/or under a pressure p at least partly heating the grains of thermosetting resin present in the fibre we 100 ′, 200 ′, 300 ′ to a joining temperature T 2 being higher than the temperature T 1 at the confluence. Then the fibre web 100 ′, 200 ′ 300 ′ is cooled to room temperature and the thermosetting resin containing fibre web of the invention is, after an optional treatment and conversion to suitable dimensions, ready for use.
- the joining of the fibre web which takes place by means of heating the grains of thermosetting resin under pressure can advantageously be carried out in a pressing device known per se for other purposes of the type which is indicated in FIGS. 1 - 3 and which is called a dual belt press.
- a pressing device known per se for other purposes of the type which is indicated in FIGS. 1 - 3 and which is called a dual belt press.
- the fibre web is carried between two metal belts and passes together with the belt through a number of press nips whereby both the temperature T 2 and the pressure p can be carefully controlled to control the joining.
- the joining takes place in another suitable manner e.g., where the fibre web 200 is preheated to a first elevated temperature T 2 ′ in a particular preheating step using heated rolls of the similar before being heated to the proper joining temperature T 2 .
- the reinforcing fibres 101 are formed in a first step to a fibre pile 100 , of textile material or non-woven material.
- the thermosetting resin 102 is brought together with the reinforcing fibres by with bringing the grains of thermosetting resin 103 in a gas flow 104 which is led through the fibre pile 100 , textile material or non-woven material.
- Suitable techniques for producing the reinforcing material already formed and optionally bound, before the confluence in this embodiment, are well known to the one skilled in the art. It should, however, be noted that within the scope of the invention it is considered having embodiments where the fibre pile, textile material or non-woven material comprise short cut fibres, continuous fibres or combinations of these.
- the reinforcing fibres are added at least partly in the form of short cut fibres 201 .
- the thermosetting resin 202 , 202 ′ is brought together with the reinforcing fibres by forming the short cut fibres 201 to a reinforcing layer on the top of at least one provided layer of thermosetting resin 205 of the grains of thermosetting resin 203 and/or by having the short cut fibres formed into a reinforcing layer on top of which at least a layer of thermosetting resin 205 ′ of the grains of thermosetting resin 203 ′ is added.
- Short cut fibres in the dimensions desired based on different polymers are commercially available from many suppliers of fibres.
- the short cut fibres are generated in situ by cutting filaments in the form of so called roving or tow to a desired length in a device arranged therefor.
- the reinforcing fibres are added at least partly in the form of short cut fibres 301 .
- the thermosetting resin 302 is brought together with the reinforcing fibres by having the short cut fibres 301 and the grains of thermosetting resin 303 brought with a gas flow 306 to then together be formed to the fibre web 300 .
- an equipment, per se known for other purposes, for air fluidizing the fibres to form the fibre web 300 for air fluidizing the fibres to form the fibre web 300 .
- At least a part of the reinforcing fibres are added in the form of cotton fibres, linen fibres or other plant fibres.
- the reinforcing fibres are added in the form of short cut fibres and/or continuous filaments of glass, carbon, metal or mineral. It is, however, also considered possible having embodiments which utilizes other types of inorganic fibres as reinforcing fibres.
- thermosetting resin 102 , 203 , 203 ′, 303 are particularly preferably added in a form which contains amino resin where the amino groups are present as urea, melamine, or benzoguanamine.
- a plasticiser 207 can, most preferably be chosen from the group of sorbitol, caprolactane, ethylene glycol, trioxitol, toluene sulfonamide, benzo or aceto guanamine and be added to the fibre web 200 prior to joining. It is, however, also possible having other types of plasticisers.
- a filler 208 is added, which includes a micro crystalline cellulose and/or a superabsorbent to the fibre web 200 prior to the joining.
- This embodiment is particularly preferred in the case the resulting fibre web containing the thermosetting resin shall be used for reinforced thermosetting resin composite having liquid absorbing properties, e.g., in connection with implantable devices for lengthening of legs and the similar.
- a filler which most preferably includes calcium oxide, kaolin, carbon, silicon dioxide, or metal particles, to the fibre web prior to the joining. It is, however, also possible to having other types of filing agents.
- a polymer film material is added to the fibre web prior to joining.
- the fibre web containing the thermosetting resin according to the invention includes at least reinforcing fibres and a thermosetting resin and is intended to, after hardening, be present in a reinforced thermosetting resin composite.
- the thermosetting resin is present in the fibre web 100 ′′, 200 ′′, 300 ′′ in the form of only partially hardened grains of thermosetting resin.
- thermosetting resin In a first preferred embodiment of the fibre web containing the thermosetting resin according to the invention the grains of thermosetting resin are carried by the reinforcing fibres of a fibre pile 100 , textile material or non-woven material present in the fibre web 100 ′′.
- the reinforcing fibres are at least partly short cut fibres whereby a substantially homogenous mixture of grains of thermosetting resin 203 , 203 ′, 303 and the short cut fibres 201 , 301 form or are present in the fibre web 200 ′′, 300 ′′.
- At least a part of the reinforcing fibres is short cut fibres 201 , 301 and/or continuous filaments of regenerated cellulose, natural polymers or synthetic polymers.
- At least a part of the reinforcing fibres is cotton fibres, linen fibres or other plant fibres.
- At least a part of the reinforcing fibres are short cut fibres and/or continuous filaments of glass, carbon, metal or mineral.
- thermosetting resin 103 , 203 , 203 ′, 303 of the fibre web containing thermosetting resin according to the invention comprises preferably amino resins, where amino groups are provided by urea, melamine, or benzoguanamine.
- the fibre web comprises sorbitol, caprolaktan, ethylene glycol, trioxytol, toluene sulfonamide, benzo or aceto guanamine.
- fibre web 200 ′′ of the invention this comprises a microcrystalline cellulose 208 and/or a superabsorbent.
- the fibre web containing thermosetting resin comprises calcium oxide, silicon dioxide, or metal particles.
- the fibre web of the invention comprises a polymer film material which may be chosen of a suitable type for the application in mind.
- the fibre web containing thermosetting resin according to the invention is preferably utilized to manufacture a reinforced thermosetting resin composite by forming a material charge (not shown in the figures) which comprises at least a piece of the fibre web 100 ′′, 200 ′′, 300 ′′ containing the thermosetting resin and by then hardening (not shown in the figures) the thermosetting resin present in the piece at a hardening temperature above room temperature.
- the reinforced thermosetting resin composite is particularly preferably present in or is a sanitary product, an abrasive surface, an electricity conducting material, or a medical technical product as an implantable device for lengthening of a leg.
- the present invention thus facilitates inter alia the manufacture of electricity conducting thermosetting resin composite with a high content of metal, thermosetting resin composite having an aesthetically appealing and abrasive resistant surfaces to be used as abrasive surfaces or sanitary products, and thermosetting resin composite containing superabsorbent to be used as medical technical swelling bodies.
Abstract
A process for the manufacture of a fibre web containing a thermosetting resin, and a reinforced thermosetting resin composite containing the fibre web containing the thermosetting resin. The process comprises forming a fibre web of at least reinforcing fibres, bringing at least a thermosetting resin together with the reinforcing fibres, and joining the fibre web at least partly by means of said thermosetting resin. Further, the process comprises having the thermosetting resin in the form of substantially dry grains, bringing said grains of thermosetting resin together with the reinforcing fibres at a confluence temperature at about room temperature, and then joining the fibre web by prior to and/or under a pressure at least partly heating the grains of thermosetting resin present in the fibre web to a joining temperature being higher than the temperature at the confluence and then cooling the fibre web to room temperature. The reinforced thermosetting resin composite can preferably be used for sanitary products such as washing basins, toilet chairs, for different abrasive surfaces, for electrically conducting products and for medical technical products such as implantable devices for lengthening of a leg and the similar. Many other applications are considered as well.
Description
- The present invention relates to a process for manufacturing a fibre web comprising a thermosetting resin. The invention is further related to a fibre web comprising thermosetting resin which has been obtained by means of the process, and an reinforced thermosetting containing composite which includes the fibre web comprising the thermosetting resin.
- The invention will be applied within the field of reinforced thermosetting composites, and their manufacture. The thermosetting composite of the invention can preferably be used for sanitary products, such as washing stands, and toilet chairs, for different surfaces being subject to abrasion, for electricity conducting products, and for many medical technical products, such as devices for lengthening a leg to be implanted, and the similar. Many other applications are considered as well.
- At the manufacture of fibre composites thermosetting resins are often used as a binder or matrix material. One reason for this is that thermosetting resins, often before hardening (cross linking) are present in a form of a liquid having a relatively low viscosity at room temperature, something that makes the impregnation of a reinforcing material quite simple.
- Certain thermosetting resins, such as urea-formaldehyde (UF) and melamine-formaldehyde (MF) are, however, not in liquid state at room temperature prior to hardening. In order to be able to impregnate a reinforcing material using such a thermosetting resin it has thus previously been proposed that this type of thermosetting resin should be provided in the form of a solution, dispersion, or paste of thermosetting resin together with a suitable liquid, (e.g. water). The last mentioned is described in e.g., patent description of U.S. Pat. No. 4,101,475, which will be discussed more in detail in the following.
- Within the field of reinforced thermosetting resin, here often called thermosetting resin composite it is previously known a number of manufacturing processes, reinforcing materials, and matrix material.
- The reinforcing material of a reinforced thermosetting resin is often fibres in the form of roving, web, mats, or non-woven material. Depending on the actual application field the reinforcing fibres may consist of natural or synthetic polymers. Examples of commonly used reinforcing fibres are glass fibres, and carbon fibres, and in some applications also cellulose fibres, such as pulp fibres, rayon or linen.
- The binding agent or matrix material in a reinforced thermosetting resin is often an unsaturated ester resin, but also epoxy, pheno- or amino resins are used.
- A number of different methods for forming details of reinforced thermosetting resin are known since earlier. A well known forming method is the contact method which comprises that Thermosetting resin and reinforcing material (e.g., ester resin and glass fibre material) are put in layers on a mould at room temperature, whereupon the ready resin detail, after hardening, is brought out off the mould provided with a mould release agent.
- A development of the above mentioned process using layering by hand includes that one in stead manually or by means of a robot sprays a two component thermosetting resin and reinforcing material in the form of chopped roving onto the mould.
- The hardening of the resin (matrix material) can be carried out under pressure by pressuring a film against a contact or spray moulded article using super pressure or vacuo, which provides for an increased strength. By simultaneously applying a pressure and heat in an autoclave the result can be even more improved.
- Another common method for manufacturing polymer details of reinforced thermosetting resin is compression moulding. In this method, there is usually first manufactured a preform of reinforcing material, e.g., chopped roving, and a minor amount of thermosetting resin, e.g., polyester as binder. After hardening the preform is brought out off the mould and is placed in a form press together with a sufficient amount of polyester, which then, during heating, is pressed into the material. In stead of preforms, preimpregnated mats of reinforcing material, e.g., glass fibre mats, can be used (Sheet Moulding Compound) or preimpregnated press sheets can be used at compression moulding.
- Other previously known methods for manufacturing details of reinforced thermosetting resin is profile drawing, winding, centrifugal and rotational moulding, transfer moulding, and injection moulding
- Common to several of the above given methods for manufacturing reinforced thermosetting resin composite, are that they utilizes or can utilize different types of reinforcing material being preimpregnated with thermosetting resin, so called “Prepreg”.
- The manufacture of preimpregnated reinforcing material for the manufacture of Thermosetting resin composite can be done by means of a number of “wet” methods, in which the reinforcing fibres are impregnated with a solution, dispersion or paste containing thermosetting resin.
- Thus, e.g., U.S. Pat. No. 4,906,505 describes a skin formed product comprising a mixture of amino resin-formaldehyde and fibrous material, whereby the product is characterized in that the resin mixture has a viscosity of 25 Pa.s.-15×103 Pa.s. at 120° C. in the skin formed product, and that the fibre material in the form of a pile or sheet has a strength of 0.1 MPa-20 MPa at 20° C. According to U.S. Pat. No. 4,906,505 the fibre material is impregnated with the resin mixture whereupon the impregnated material is dried until the amino resin mixture obtains a viscosity which exceeds 25 Pa.s. to 15×103 Pa.s.
- Further, there has been described in the previously mentioned U.S. Pat. No. 4,101,475 an abrasion resistant, flame protected material, which is manufactured by producing a compression moulding composition of a precondensate of a melamine aldehyde, silicon dioxide, aluminium trihydrate, a soap having a low solubility, ammonium hydroxide, and an acid salt catalyst. The composition is then applied onto the surface of a sheet of glass fibres comprising a heat hardening binder, and the composite is bound under heat and pressure to harden both binders simultaneously, and to bind the composition to the fibre layer of the sheet.
- The previously known “wet” processes for the manufacture of preimpregnated reinforced fibre webs, sheets, boards or smaller sheets can, however, be connected with certain problems.
- At the impregnation methods utilizing thermosetting resin solutions or dispersions the reinforcing material has to be added in the form of a continuous fibre sheet or fibre web. A such is considerably more expensive than the fibres present in the reinforcing material per se. As the amount of reinforcing fibre and the liquid absorbing ability are defined by the actual construction of the fibre sheet or fibre web it can be hard to control the amount of reinforcing fibre of the ready material, to a desired level.
- In those cases where one wishes to add a filler together with the actual resin mixture, there is in the previously known processes utilizing thermosetting resin solutions or dispersions, depending on the density of the actual filler, a risk that the filler will precipitate or float in the resin mixture so that an uneven application is obtained. Further, problems with too a high viscosity of the resin mixture can appear at high concentrations of filler, or at the mixing-in of the filler, which functions as a viscosity improver, such as cellulose fibres, micro fibrils, super absorbents, and the similar. Furthermore, at longer storage periods ageing phenomena may occur in liquid thermosetting resin mixtures.
- When using thermosetting resin containing solutions or dispersions for the manufacture of preimpregnated reinforcing fibre webs a particular drying process is needed. Such a drying process may lead to certain problems with uneven drying or prehardening, and thereby result in a fibre web having uneven quality. Further, the drying process requires much energy and is often connected with problem of precipitations of resin in the details present in the drying step.
- Previously proposed processes for the manufacture of preimpregnated fibre materials using thermosetting resin, where the thermosetting resin is applied in the form of a paste, some of the above mentioned problems are reduced or eliminated, and makes it possible to use reinforcing fibres in the form of economically advantageous chopped roving. The above mentioned problems using the particular drying step however, will remain fully.
- A first object of the present invention is thus to obtain a method for manufacturing a fibre web containing thermosetting resin, which method eliminates all above mentioned problems.
- This first object is achieved, in accordance with claim 1, by that the method comprises shaping a fibre web of at least reinforcing fibres, joining at least one thermosetting resin with said reinforcing fibres, and binding, after joining, the fibre web at least partly by means of the thermosetting resin. The method further comprises adding the thermosetting resin in the form of substantially dry grains of thermosetting resin, joining the grains of thermosetting resin with the Reinforcing fibres at a joining temperature of about room temperature, then binding the fibre web by, prior to and/or under pressure, at least partly heating the grains of thermosetting resin in the fibre web to a binding temperature above the joining temperature, and by then cooling down the fibre web to room temperature.
- A second object of the present invention is to obtain a fibre web containing Thermosetting resin obtained by means of the process.
- This second object is obtained, in accordance with
claim 13, in that the fibre web comprises at least Reinforcing fibres and a Thermosetting resin and is intended to be present in a reinforced Thermosetting resin composite, whereby the Thermosetting resin is present in the fibre web in the form of only partially hardened grains of Thermosetting resin. - A third object of the present invention is to obtain a reinforced Thermosetting resin composite which comprises the fibre web containing the Thermosetting resin.
- This third object is achieved, in accordance with
claim 24, by means of a reinforced Thermosetting resin composite which has been produced by forming a charge of material comprising at least a part of a fibre web containing a Thermosetting resin according to the invention and by then hardening the Thermosetting resin present in the part at a hardening temperature above room temperature. - Further objects of the present invention will be apparent from the following description while the features that facilitates that these further objects are achieved, are evident from the subclaims.
- The invention will be described more in detail in the following with reference to the accompanying drawings, whereby
- FIG. 1 shows a schematic side view of an arrangement suitable for utilizing a process according to a first embodiment of the invention
- FIG. 2 shows a schematic side view of a arrangement suitable for utilizing a process according to a second embodiment of the invention
- FIG. 3 shows a schematic side view of an arrangement suitable for utilizing a process according to a third, particularly preferred embodiment of the invention
- With referenced to the accompanying FIGS.1-3 a process for manufacturing a fibre web containing Thermosetting resin according to the invention will be described more in detail in the following.
- On the accompanying FIGS.1-3 schematic side view of three different arrangements which are suitable for utilizing the different embodiments of the process according to the invention are shown. Thereby it should be noted that other arrangement than those shown in FIGS. 1-3 may be suitable for carrying out the process according to the invention, as well.
- The process according to the invention includes forming a
fibre web 100; 200; 300 of at least reinforcingfibres 101; 201; 301; to bring together said fibres with athermosetting resin 102; 202; 202′; 302 and to join thefibre web 100′; 200′; 300′ at least partly by means of the thermosetting resin after the bringing together. - According to the invention the process further includes adding the thermosetting resin in the form of a substantially
dry grains 103; 203; 303 of thermosetting resin. The thermosetting resin is thus not in liquid state and not in a form of an emulsion or solution either at the confluence with the reinforcing fibres. - The process of the invention further includes bringing the grains of thermosetting resin together with the reinforcing
fibres fibre web 100′, 200′ 300′ is cooled to room temperature and the thermosetting resin containing fibre web of the invention is, after an optional treatment and conversion to suitable dimensions, ready for use. - The joining of the fibre web which takes place by means of heating the grains of thermosetting resin under pressure can advantageously be carried out in a pressing device known per se for other purposes of the type which is indicated in FIGS.1-3 and which is called a dual belt press. In such a pressing device the fibre web is carried between two metal belts and passes together with the belt through a number of press nips whereby both the temperature T2 and the pressure p can be carefully controlled to control the joining. However, one can also consider embodiments of the process of the invention where the joining takes place in another suitable manner e.g., where the
fibre web 200 is preheated to a first elevated temperature T2′ in a particular preheating step using heated rolls of the similar before being heated to the proper joining temperature T2. - In a first preferred embodiment of the process of the invention, particularly illustrated in FIG. 1 the reinforcing
fibres 101 are formed in a first step to afibre pile 100, of textile material or non-woven material. In this embodiment thethermosetting resin 102 is brought together with the reinforcing fibres by with bringing the grains ofthermosetting resin 103 in agas flow 104 which is led through thefibre pile 100, textile material or non-woven material. Suitable techniques for producing the reinforcing material already formed and optionally bound, before the confluence in this embodiment, are well known to the one skilled in the art. It should, however, be noted that within the scope of the invention it is considered having embodiments where the fibre pile, textile material or non-woven material comprise short cut fibres, continuous fibres or combinations of these. - In a second preferred embodiment of the process according to the invention, particularly illustrated in FIG. 2, the reinforcing fibres are added at least partly in the form of
short cut fibres 201. In this embodiment thethermosetting resin short cut fibres 201 to a reinforcing layer on the top of at least one provided layer ofthermosetting resin 205 of the grains ofthermosetting resin 203 and/or by having the short cut fibres formed into a reinforcing layer on top of which at least a layer ofthermosetting resin 205′ of the grains ofthermosetting resin 203′ is added. Short cut fibres in the dimensions desired based on different polymers are commercially available from many suppliers of fibres. In the embodiment shown in FIG. 2 the short cut fibres are generated in situ by cutting filaments in the form of so called roving or tow to a desired length in a device arranged therefor. - In a third, particularly preferred embodiment of the invention, in particular illustrated in FIG. 3 the reinforcing fibres are added at least partly in the form of
short cut fibres 301. In this embodiment thethermosetting resin 302 is brought together with the reinforcing fibres by having theshort cut fibres 301 and the grains ofthermosetting resin 303 brought with agas flow 306 to then together be formed to thefibre web 300. In this embodiment an equipment, per se known for other purposes, for air fluidizing the fibres to form thefibre web 300. - In a particular embodiment of the process according to the invention at least a part of the reinforcing
fibres - In another preferred embodiment at least a part of the reinforcing fibres are added in the form of cotton fibres, linen fibres or other plant fibres.
- In an alternative embodiment of the invention the reinforcing fibres are added in the form of short cut fibres and/or continuous filaments of glass, carbon, metal or mineral. It is, however, also considered possible having embodiments which utilizes other types of inorganic fibres as reinforcing fibres.
- The abovementioned grains of
thermosetting resin - When so desired, or necessary a
plasticiser 207 can, most preferably be chosen from the group of sorbitol, caprolactane, ethylene glycol, trioxitol, toluene sulfonamide, benzo or aceto guanamine and be added to thefibre web 200 prior to joining. It is, however, also possible having other types of plasticisers. - In a particularly preferred embodiment of the process according to the invention a
filler 208 is added, which includes a micro crystalline cellulose and/or a superabsorbent to thefibre web 200 prior to the joining. This embodiment is particularly preferred in the case the resulting fibre web containing the thermosetting resin shall be used for reinforced thermosetting resin composite having liquid absorbing properties, e.g., in connection with implantable devices for lengthening of legs and the similar. - In a further alternative embodiment of the process according to the invention a filler is added which most preferably includes calcium oxide, kaolin, carbon, silicon dioxide, or metal particles, to the fibre web prior to the joining. It is, however, also possible to having other types of filing agents.
- In a preferred embodiment of the process of the invention a polymer film material is added to the fibre web prior to joining. Thereby it is possible, as well, having embodiments where the polymer film material is added to both sides of the fibre web.
- In the following, a number of different embodiments of fibre webs containing thermosetting resin according to the invention, will be described, and when possible, with reference to the different accompanying FIGS.1-3.
- The fibre web containing the thermosetting resin according to the invention includes at least reinforcing fibres and a thermosetting resin and is intended to, after hardening, be present in a reinforced thermosetting resin composite. According to the invention the thermosetting resin is present in the
fibre web 100″, 200″, 300″ in the form of only partially hardened grains of thermosetting resin. - In a first preferred embodiment of the fibre web containing the thermosetting resin according to the invention the grains of thermosetting resin are carried by the reinforcing fibres of a
fibre pile 100, textile material or non-woven material present in thefibre web 100″. - In a particularly preferred embodiment of the fibre web containing the thermosetting resin according to the invention the reinforcing fibres are at least partly short cut fibres whereby a substantially homogenous mixture of grains of
thermosetting resin short cut fibres fibre web 200″, 300″. - In another preferred embodiment at least a part of the reinforcing fibres is
short cut fibres - In a further preferred embodiment of the fibre web containing the thermosetting resin according to the invention, at least a part of the reinforcing fibres is cotton fibres, linen fibres or other plant fibres.
- In an alternative embodiment of the fibre web containing the thermosetting resin according to the invention at least a part of the reinforcing fibres are short cut fibres and/or continuous filaments of glass, carbon, metal or mineral.
- The abovementioned grains of
thermosetting resin - In another preferred embodiment of the fibre web of the invention the fibre web comprises sorbitol, caprolaktan, ethylene glycol, trioxytol, toluene sulfonamide, benzo or aceto guanamine.
- In a particularly preferred embodiment of the
fibre web 200″ of the invention this comprises amicrocrystalline cellulose 208 and/or a superabsorbent. - In a still further embodiment of the invention the fibre web containing thermosetting resin comprises calcium oxide, silicon dioxide, or metal particles.
- In another embodiment the fibre web of the invention comprises a polymer film material which may be chosen of a suitable type for the application in mind.
- The fibre web containing thermosetting resin according to the invention is preferably utilized to manufacture a reinforced thermosetting resin composite by forming a material charge (not shown in the figures) which comprises at least a piece of the
fibre web 100″, 200″, 300″ containing the thermosetting resin and by then hardening (not shown in the figures) the thermosetting resin present in the piece at a hardening temperature above room temperature. The reinforced thermosetting resin composite is particularly preferably present in or is a sanitary product, an abrasive surface, an electricity conducting material, or a medical technical product as an implantable device for lengthening of a leg. - The present invention will in no way be regarded as restricted to what has been described herein in connection with the different embodiments or to what has been shown in the accompanying figures, but the scope of the invention is defined be the accompanying claims.
- The present invention thus facilitates inter alia the manufacture of electricity conducting thermosetting resin composite with a high content of metal, thermosetting resin composite having an aesthetically appealing and abrasive resistant surfaces to be used as abrasive surfaces or sanitary products, and thermosetting resin composite containing superabsorbent to be used as medical technical swelling bodies.
Claims (25)
1. A process for the manufacture of a fibre web containing a thermosetting resin, comprising forming a fibre web (100, 200, 300) of at least reinforcing fibres (101, 201, 301), bringing at least a thermosetting resin (102, 202, 202′, 302) together with the reinforcing fibres, and joining the fibre web (100′, 200′, 300′) at least partly by means of said thermosetting resin after the confluence,
characterized in that the process comprises having the thermosetting resin in the form of substantially dry grains (103, 203, 303), bringing said grains of thermosetting resin together with the reinforcing fibres (101, 201, 301) at a confluence temperature (T1) at about room temperature, and then joining the fibre web by prior to and/or under a pressure (p) at least partly heating the grains of thermosetting resin present in the fibre web (100′, 200′, 300′) to a joining temperature (T2) being higher than the temperature (T1) at the confluence, and then cooling the fibre web (100′, 200′ 300′) to room temperature.
2. Process according to claim 1 , wherein the reinforcing fibres (101) in a first step are formed to a fibre pile (100), textile material or non-woven material,
characterized in that the thermosetting resin (102) is brought together with the reinforcing fibres by bringing the grains of thermosetting resin (103) in a gas flow (104) which is led through the fibre pile (100), textile material or non-woven material.
3. Process according to claim 1 , wherein the reinforcing fibres at least partly are added in the form of short cut fibres (201),
characterized in that the thermosetting resin (202, 202′) is brought to together with the reinforcing fibres by having the short cut fibres (201) formed to a reinforcing layer on the top of at least a spread out layer of thermosetting resin (205) of said grains (203) of thermosetting resin and/or the short cut fibres are formed to a reinforcing layer on top of which at least a thermosetting resin layer (205′) of said grains of thermosetting resin (203′) is added.
4. A process according to claim 1 , wherein the reinforcing fibres at least partly are added in the form of short cut fibres (301),
characterized in that the thermosetting resin (302) is brought together with the reinforcing fibres by having the short cut fibres (301) and the grains of thermosetting resin (303) brought with a gas flow (306) to then together being formed to a fibre web (300).
5. A process according to one or more of the preceding claims,
characterized in that at least a part of the reinforcing fibres (101, 201, 301) are added in the form of short cut fibres and/or continuous filaments of regenerated cellulose, natural polymers, or synthetic polymers.
6. A process according to one or more of the preceding claims,
characterized in that at least a part of the reinforcing fibres are added in the form of cotton fibres, linen fibres, or other plant fibres.
7. A process according to one or more of the preceding claims,
characterized in that at least a part of the reinforcing fibres are added in the form of short cut fibres and/or continuous filaments of glass, carbon, metal or mineral.
8. A process according to one or more of the preceding claims,
characterized in that the grains of thermosetting resin (103, 203, 203′, 303) are added in a form which includes amino resins, where amino groups are provided by urea, melamine, or benzo guanamine.
9. A process according to one or more of the preceding claims,
characterized in that a plasticizer (207) is selected from the group of sorbitol, caprolactane, ethylene glycol, trioxitol, toluene sulfonamide, benzo and aceto guanamine, and is added to the fibre web (200) before joining the same.
10. A process according to one or more of the preceding claims,
characterized in that a filler (208) comprising micro crystalline cellulose and/or a super absorbent is added to the fibre web (200) prior to joining the same.
11. A process according to one or more of the preceding claims,
characterized in that a filler comprising calcium oxide, caolin, carbon, silicon dioxide, or metal particles is added to the fibre web prior to joining the same.
12. A process according to one or more of the preceding claims,
characterized in that a polymer film material is added to the fibre web prior to joining the same.
13. A thermosetting resin containing fibre web, including at least reinforcing fibres and a thermosetting resin intended to, after hardening be present in a reinforced thermosetting resin composite,
characterized in that the thermosetting resin is present in the fibre web (100″, 200″, 300″) in the form only partly hardened grains of thermosetting resin.
14. A thermosetting resin containing fibre web according to claim 13 ,
characterized in that the grains of thermosetting resin are carried on the reinforcing fibres of a fibre pile (100), textile material or non-woven material of a fibre web (100″).
15. A thermosetting resin containing fibre web according to claim 13 wherein the reinforcing fibres at least partly are short cut fibres,
characterized in that a substantially homogenous mixture of grains of thermosetting resin (203, 203′, 303) and the short cut fibres (201, 301) form or are present in the fibre web (200″, 300″).
16. A thermosetting resin containing fibre web according to any of claims 13-15,
characterized in that at least a part of the reinforcing fibres are short cut fibres (201, 301) and/or continuous filaments of regenerated cellulose, natural polymers or synthetic polymers.
17. A thermosetting resin containing fibre web according to any of claims 13-16,
characterized in that at least a part of the reinforcing fibres are cotton fibres, linen fibres or other plant fibres.
18. A thermosetting resin containing fibre web according to any of claims 13-17,
characterized in that at least a part of the reinforcing fibres are short cut fibres and/or continuous filaments of glass, carbon, metal or mineral.
19. A thermosetting resin containing fibre web according to any of claims 13-18,
characterized in that the grains of thermosetting resin (103, 203, 203′ 303) includes amino resins, where the amino groups are provided by urea, melamine, or benzoguanamine.
20. A thermosetting resin containing fibre web according to any of claims 13-19,
characterized in that the fibre web includes sorbitol, caprolactane, ethylene glycol, trioxytol, toluene sulfonamide, benzo or aceto guanamine.
21. A thermosetting resin containing fibre web according to any of claims 13-20,
characterized in that the fibre web (200″) includes microcrystalline cellulose (208) and/or a superabsorbent.
22. A thermosetting resin containing fibre web according to any of claims 13-21,
characterized in that the fibre web includes calcium oxide, kaolin, carbon, silicon dioxide, or metal particles.
23. A thermosetting resin containing fibre web according to any of claims 13-22,
characterized in that the fibre web includes a polymer film material.
24. A reinforced thermosetting resin composite,
characterized in that it has been manufactured by forming a material charge which includes at least a piece of a fibre web (100″, 200″, 300″) containing thermosetting resin according to any of claims 13-23, and by then hardening the thermosetting resin present in said piece at a temperature higher than room temperature.
25. A reinforced thermosetting resin composite according to claim 24 ,
characterized in that said thermosetting resin composite is part of or is a sanitary product, an electricity conducting product, an abrasive surface, or a medical technical product.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SE0001929A SE0001929L (en) | 2000-05-23 | 2000-05-23 | Process for producing a thermosetting resin-containing fibrous web, such a fibrous web, and a reinforced thermosetting composite comprising the fibrous web |
SE0001929-9 | 2000-05-23 | ||
PCT/SE2001/001137 WO2001090482A2 (en) | 2000-05-23 | 2001-05-21 | Process for manufacturing a fibre web comprising a thermosetting resin, such a fibre web, and a reinforced fibre web comprising a thermosetting resin composite |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/SE2001/001137 Continuation WO2001090482A2 (en) | 2000-05-23 | 2001-05-21 | Process for manufacturing a fibre web comprising a thermosetting resin, such a fibre web, and a reinforced fibre web comprising a thermosetting resin composite |
Publications (1)
Publication Number | Publication Date |
---|---|
US20030148087A1 true US20030148087A1 (en) | 2003-08-07 |
Family
ID=20279809
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/302,487 Abandoned US20030148087A1 (en) | 2000-05-23 | 2002-11-22 | Process of manufacturing a fibre web comprising a thermosetting resin, such a fibre web, and an reinforced the fibre web comprising a thermosetting resin composite |
Country Status (4)
Country | Link |
---|---|
US (1) | US20030148087A1 (en) |
AU (1) | AU2001260924A1 (en) |
SE (1) | SE0001929L (en) |
WO (1) | WO2001090482A2 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11396146B2 (en) * | 2020-07-10 | 2022-07-26 | Jiangsu Qiyi Technology Co., Ltd | Method and equipment for making unidirectional continuous fiber-reinforced thermoplastic composite material |
US11427687B2 (en) * | 2015-07-29 | 2022-08-30 | The Boeing Company | Noodle comprised of a matrix of discontinuous filaments |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2546962A (en) * | 2015-12-21 | 2017-08-09 | Hexcel Composites Ltd | Apparatus and method of impregnating reinforcement material |
CN108729276B (en) * | 2017-04-18 | 2022-04-12 | 上海众伟生化有限公司 | Fibrilia biological covering film and preparation method thereof |
CN111101293A (en) * | 2019-12-25 | 2020-05-05 | 耿程辉 | Dandelion wool fiber blending electrostatic polymerization process and polymerization equipment thereof |
EP4338948A2 (en) * | 2020-10-30 | 2024-03-20 | NIKE Innovate C.V. | Asymmetric faced composite nonwoven textile and methods of manufacturing the same |
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US4011063A (en) * | 1972-04-05 | 1977-03-08 | Minnesota Mining And Manufacturing Company | Low density abrasive utilizing isocyanurate resin |
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US5804005A (en) * | 1996-05-09 | 1998-09-08 | Buck; George S. | Bonding fibrous batts with thermosetting fiber-binders of certain expoxy resins |
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BE669711A (en) * | 1964-09-21 | 1966-03-16 | ||
GB2015604B (en) * | 1978-03-02 | 1982-06-03 | Kroyer K K K | Air laying bonded fibre structures |
CA1159317A (en) * | 1979-09-12 | 1983-12-27 | George S. Buck, Jr. | Process and apparatus for contacting a powder with a fibrous web |
US4457793A (en) * | 1982-01-15 | 1984-07-03 | Fiberlok, Inc. | Method for producing a fiberous batt |
BE1004947A4 (en) * | 1991-06-13 | 1993-03-02 | Dsm Nv | Half of fiber product material and plastic, and method of making same kind products obtained by the processing of such half product. |
US6030575A (en) * | 1991-10-21 | 2000-02-29 | The Dow Chemical Company | Method for making preforms |
-
2000
- 2000-05-23 SE SE0001929A patent/SE0001929L/en unknown
-
2001
- 2001-05-21 WO PCT/SE2001/001137 patent/WO2001090482A2/en active Application Filing
- 2001-05-21 AU AU2001260924A patent/AU2001260924A1/en not_active Abandoned
-
2002
- 2002-11-22 US US10/302,487 patent/US20030148087A1/en not_active Abandoned
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US4011063A (en) * | 1972-04-05 | 1977-03-08 | Minnesota Mining And Manufacturing Company | Low density abrasive utilizing isocyanurate resin |
US4101475A (en) * | 1976-12-17 | 1978-07-28 | Owens-Corning Fiberglas Corporation | Flame resistant materials and method of making same |
US4335965A (en) * | 1978-07-07 | 1982-06-22 | Dresser Industries, Inc. | Fiber-resin blending technique |
US4319870A (en) * | 1979-08-27 | 1982-03-16 | American Can Company | Apparatus for the manufacture of fibrous webs |
US4692291A (en) * | 1980-04-14 | 1987-09-08 | Union Carbide Corporation | Molding method using fast curing fiber reinforced, low viscosity thermosetting resin |
US5272000A (en) * | 1987-05-22 | 1993-12-21 | Guardian Industries Corp. | Non-woven fibrous product containing natural fibers |
US5286553A (en) * | 1988-12-15 | 1994-02-15 | Asahi Kasei Kogyo Kabushiki Kaisha | Composite sheet for fibrous reinforcing material |
US5804005A (en) * | 1996-05-09 | 1998-09-08 | Buck; George S. | Bonding fibrous batts with thermosetting fiber-binders of certain expoxy resins |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11427687B2 (en) * | 2015-07-29 | 2022-08-30 | The Boeing Company | Noodle comprised of a matrix of discontinuous filaments |
US11396146B2 (en) * | 2020-07-10 | 2022-07-26 | Jiangsu Qiyi Technology Co., Ltd | Method and equipment for making unidirectional continuous fiber-reinforced thermoplastic composite material |
US11479000B2 (en) * | 2020-07-10 | 2022-10-25 | Jiangsu Qiyi Technology Co., Ltd | Method for making unidirectional continuous fiber-reinforced thermoplastic composite material |
Also Published As
Publication number | Publication date |
---|---|
SE0001929L (en) | 2001-12-21 |
SE0001929D0 (en) | 2000-05-23 |
WO2001090482A2 (en) | 2001-11-29 |
AU2001260924A1 (en) | 2001-12-03 |
WO2001090482A3 (en) | 2002-04-11 |
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