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Abrasion resistant composite material and process for making the same
mide or combinations thereof and coated with 3-12 wt%, based on the weight of the fibre, carboxyl-terminated, oil-free alkyd resin and 0.5-2 wt% vinyl chloride copolymer with a glass transition temperature greater than 60°C. The resin is the reaction product of at least one aliphatic glycol containing 2-12 carbon atoms with a combination of aromatic di- or tri-functional carboxylic acids and optionally an unsaturated aliphatic carboxylic acid, said resin having a degree of esterification below the gel point of the resin. Chemical preparation of zirconiumaluminium-magnesium oxide composites Henslee, W.W. and Witkowski, T.S. (The Dow Chemical Company, Midland, MI, USA) US Pat 4 880 757 (14 November 1989) A sinterable precursor powder consists of at least one decomposable salt of a metal or metals which form spinel structures on calcination, a zirconium compound selected from a salt capable of being converted on heating to zirconium oxide or a fine zirconium oxide powder. The powder is intimately admixed in a liquid medium and can be converted to zirconia-spinel ceramic composites. Mica and glass reinforced polyketone polymers George, E.R. (Shell Oil Company, Houston, TX, USA) US Pat 4 880 865 (14 November 1989) A polymeric composition comprises a major amount of a linear, alternating polymer of carbon monoxide and at least one ethylenically unsaturated hydrocarbon and minor amounts of glass fibre reinforcement and mica. Fibre for reinforcing plastic composites and reinforced plastic composites therefrom Cordova, D.S., Coffin, D.R., Lazarus, S.D. and Young, S.A. (Allied-Signal Inc, Morris Township, Morris County, NJ, USA) US Pat 4 880 871 (14 November 1989) A fibre-reinforced plastic composite is formed from a resin matrix and a high tenacity, coated, reinforcing fibre selected from the group consisting of polyester, aliphatic polyamide and combinations thereof. The coating consists of an aqueous solution of a carboxyl-terminated, oil-free alkyd resin which is the reaction product of at least one aliphatic glycol containing 2 to 12 carbons with a combination of aromatic di- or trifunctional carboxylic acids and optionally an unsaturated aliphatic carboxylic acid, said resin having a degree of esterification below the gel point of the resin. Abrasion resistant composite material and process for making the same Bauman, B.D. (Air Products and Chemicals, Inc, Allentown, PA, USA) US Pat 4 880 879 (14 November 1989) An easily moulded composite product with high abrasion resistance comprises a polyurethane material with a surface tension of at least 4 mN m -1 at 20°C into which has been dispersed between 4 and 66 wt% high molecular weight polyethylene particles treated to have a surface tension of at least 4 mN m I at 2&C. Fibre reinforced composites with improved glass transition temperatures Jordan, R.C. and Portelli, G.B. (Minnesota
256
COMPOSITES. MAY 1991
Mining and Manufacturing Company, St Paul, MN, USA) US Pat 4 882 370 (21 November 1989) A fibre-reinforced composite structure with a glass transition temperature of > 150°C when cured has reinforcing fibres in a curable epoxy resin composition free of fluorenecontaining amine curing agents. This consists of one or more epoxides with more than one epoxide group per molecule of which epoxides at least 10 wt% is a 9,9-bis[4-(2,3epoxypropoxy)phenyl]fluorene, all of the fluorane epoxy present being free of ortho substitution. An effective amount of a curing agent in the resin is chosen from the group consisting of polybasic carboxylic acids and their anhydrides; aliphatic, cycloaliphatic and aromatic amines; carboxylic acid amides; and melamines. Carbon fibre cord for rubber reinforcement Ogawa, H., Kogo, Y., Takahashi, S. and Suzuki, Y. (Toho Rayon Co, Ltd and The Yokohama Rubber Co, Ltd, Tokyo, Japan) US Pat 4 883 712 (28 November 1989) A carbon fibre bundle has the cured coating thereon provided by coating and curing a resin composition comprising a mixture of 100 parts by weight of a butadieneacrylonitrile copolymer with a carboxyl group on at least both terminals of the copolymer; 5-40 parts by weight of an epoxy resin or a reaction mixture obtained therefrom; 5-50 wt% based on the total weight of the carbon fibre bundle and coating of a curing agent for the epoxy resin. In addition there is a coating of a mixture of a phenol-formalinrubber latex-type adhesive for rubber in an amount of 0.5-5 wt% based on the total weight of the carbon fibre bundle and the resin composition coated thereon. Mouldable material reinforcement fibres with hydraulic or non-hydraulic binder and manufacturing thereof Destree, X.P. and Lazzari, A.A. (Eurosteel S.A., Brussels, Belgium) US Pat 4 883 713 (28 November 1989) A fibre consists of an elongated cylindrical steel body with a head at each end. The heads are shaped conically outward at an angle of between 20° and 60° to the longitudinal axis. The heads are formed by mechanically deforming the ends of the elongated steel body. Products formed of a ceramic-glass-metal composite Singh Deo, N.N., Mahulikar, D. and Butt, S.H. (Olin Corporation, New Haven, CT, USA) US Pat 4 883 778 (28 November 1989) A composite is claimed which has a 15-50 vol% glass matrix with 5-45 vol% metallic particles dispersed therein. The metal particles are selected from the group consisting of AI, Cu, Fe, Ag, Au, stainless steel and alloys thereof. The balance consists of a dispersion of ceramic particles which are selected from the group consisting of A1203, SiC, BeO, TiO 2, ZrO2, MgO, AIN, Si3N4, BN and mixtures thereof. Heat resisting low expansion zirconyl phosphate-zircon composite Watanabe, K. and Ohashi, T. (NGK Insulators, Ltd, Nagoya, Japan) US Pat 4 883 781 (28 November 1989) A microcracked composite has zirconyl phosphate as the main crystalline phase and zircon
as the secondary crystalline phase. The body has a chemical composition of 58.2-65.4 wt% ZrO2, 17.4--37.1 wt% P205 and 1.5-19 wt% SiO2. It has a thermal expansion coefficient of not more than 3 x 1 0 ~ C -1 between room temperature and 1400°C; a melting point of not less than 1600~C; and a self-weight softening percentage of not more than 0.1%.
PROCESSES Method of making a mortar binder and product Filbert, N.V. (Stevensville, MD, USA) US Pat4875 938 (24 October l989) A method for making a cementitious binder for use in mortars is described. The process consists of heating marine shell material to about 1250-1290°C, allowing this material to cool and then mixing it with water (1 part of water to about 5 of shell material by volume). The mixture heats up and on cooling again forms a white powder which can be used as a binder in mortars. Process for dry fibre winding and impregnating of projectiles Horton, J. (Murdock, Inc, Compton, CA, USA) US Pat 4 876 050 (24 October 1989) A projectile is wound with dry fibres from the group consisting of glass, polyester, carbon, aramids, carbon-aramid hybrids, aramidglass hybrids, aramid, glass-carbon hybrids, carbon-glass hybrids and combinations thereof. The wound portion of the projectile is placed in a mould; a vacuum is applied and then a resin is pressure injected. The resin is cured to the gel stage by raising the temperature of the mould and the cure is completed outside the mould. Process for preparing carbon fibres in gas phase growth Arakawa, K. and Ohsaki, T. (Nikkiso Co, Ltd, Tokyo, Japan) US Pat 4 876 078 (24 October 1989) A gas mixture consisting of at least one carbon compound, at least one inorganic transition metal compound gas and at least one carrier gas is subjected to a temperature of 600-1300°C in reactor for inducing growth of carbon fibres without using any substrate. Process of making a resin-composite panel Wolf, J.M. (Midwest Acoust-A-Fiber, Inc, Ostrander, OH, USA) US Pat 4 877 476 (31 October 1989) A method of making an air conditioning frame having an insulated article thereon is given. A resin-impregnated, partially cured fibreglass batt is coated with a compatible resin onto which a porous, non-woven polymeric sheet is applied. The whole article is cured so that polymeric sheet melts to form a non-porous coating on the surface of the cured article. The coated side is bonded with an adhesive to the air conditioning frame. Moulding of composite plastics products Wilson, K.A. and Kliene, R.I. (The Victaulic Company plc, Hitchin and Tecron Industries Limited, Pavenham, UK) US Pat 4 877 562 (31 October 1989) A cross-linkable polymer and a catalyst are rotomoulded under conditions insufficient to cause significant cross-linking of the polymer so that it remains thermoplastic in nature.
256
COMPOSITES. MAY 1991
Mining and Manufacturing Company, St Paul, MN, USA) US Pat 4 882 370 (21 November 1989) A fibre-reinforced composite structure with a glass transition temperature of > 150°C when cured has reinforcing fibres in a curable epoxy resin composition free of fluorenecontaining amine curing agents. This consists of one or more epoxides with more than one epoxide group per molecule of which epoxides at least 10 wt% is a 9,9-bis[4-(2,3epoxypropoxy)phenyl]fluorene, all of the fluorane epoxy present being free of ortho substitution. An effective amount of a curing agent in the resin is chosen from the group consisting of polybasic carboxylic acids and their anhydrides; aliphatic, cycloaliphatic and aromatic amines; carboxylic acid amides; and melamines. Carbon fibre cord for rubber reinforcement Ogawa, H., Kogo, Y., Takahashi, S. and Suzuki, Y. (Toho Rayon Co, Ltd and The Yokohama Rubber Co, Ltd, Tokyo, Japan) US Pat 4 883 712 (28 November 1989) A carbon fibre bundle has the cured coating thereon provided by coating and curing a resin composition comprising a mixture of 100 parts by weight of a butadieneacrylonitrile copolymer with a carboxyl group on at least both terminals of the copolymer; 5-40 parts by weight of an epoxy resin or a reaction mixture obtained therefrom; 5-50 wt% based on the total weight of the carbon fibre bundle and coating of a curing agent for the epoxy resin. In addition there is a coating of a mixture of a phenol-formalinrubber latex-type adhesive for rubber in an amount of 0.5-5 wt% based on the total weight of the carbon fibre bundle and the resin composition coated thereon. Mouldable material reinforcement fibres with hydraulic or non-hydraulic binder and manufacturing thereof Destree, X.P. and Lazzari, A.A. (Eurosteel S.A., Brussels, Belgium) US Pat 4 883 713 (28 November 1989) A fibre consists of an elongated cylindrical steel body with a head at each end. The heads are shaped conically outward at an angle of between 20° and 60° to the longitudinal axis. The heads are formed by mechanically deforming the ends of the elongated steel body. Products formed of a ceramic-glass-metal composite Singh Deo, N.N., Mahulikar, D. and Butt, S.H. (Olin Corporation, New Haven, CT, USA) US Pat 4 883 778 (28 November 1989) A composite is claimed which has a 15-50 vol% glass matrix with 5-45 vol% metallic particles dispersed therein. The metal particles are selected from the group consisting of AI, Cu, Fe, Ag, Au, stainless steel and alloys thereof. The balance consists of a dispersion of ceramic particles which are selected from the group consisting of A1203, SiC, BeO, TiO 2, ZrO2, MgO, AIN, Si3N4, BN and mixtures thereof. Heat resisting low expansion zirconyl phosphate-zircon composite Watanabe, K. and Ohashi, T. (NGK Insulators, Ltd, Nagoya, Japan) US Pat 4 883 781 (28 November 1989) A microcracked composite has zirconyl phosphate as the main crystalline phase and zircon
as the secondary crystalline phase. The body has a chemical composition of 58.2-65.4 wt% ZrO2, 17.4--37.1 wt% P205 and 1.5-19 wt% SiO2. It has a thermal expansion coefficient of not more than 3 x 1 0 ~ C -1 between room temperature and 1400°C; a melting point of not less than 1600~C; and a self-weight softening percentage of not more than 0.1%.
PROCESSES Method of making a mortar binder and product Filbert, N.V. (Stevensville, MD, USA) US Pat4875 938 (24 October l989) A method for making a cementitious binder for use in mortars is described. The process consists of heating marine shell material to about 1250-1290°C, allowing this material to cool and then mixing it with water (1 part of water to about 5 of shell material by volume). The mixture heats up and on cooling again forms a white powder which can be used as a binder in mortars. Process for dry fibre winding and impregnating of projectiles Horton, J. (Murdock, Inc, Compton, CA, USA) US Pat 4 876 050 (24 October 1989) A projectile is wound with dry fibres from the group consisting of glass, polyester, carbon, aramids, carbon-aramid hybrids, aramidglass hybrids, aramid, glass-carbon hybrids, carbon-glass hybrids and combinations thereof. The wound portion of the projectile is placed in a mould; a vacuum is applied and then a resin is pressure injected. The resin is cured to the gel stage by raising the temperature of the mould and the cure is completed outside the mould. Process for preparing carbon fibres in gas phase growth Arakawa, K. and Ohsaki, T. (Nikkiso Co, Ltd, Tokyo, Japan) US Pat 4 876 078 (24 October 1989) A gas mixture consisting of at least one carbon compound, at least one inorganic transition metal compound gas and at least one carrier gas is subjected to a temperature of 600-1300°C in reactor for inducing growth of carbon fibres without using any substrate. Process of making a resin-composite panel Wolf, J.M. (Midwest Acoust-A-Fiber, Inc, Ostrander, OH, USA) US Pat 4 877 476 (31 October 1989) A method of making an air conditioning frame having an insulated article thereon is given. A resin-impregnated, partially cured fibreglass batt is coated with a compatible resin onto which a porous, non-woven polymeric sheet is applied. The whole article is cured so that polymeric sheet melts to form a non-porous coating on the surface of the cured article. The coated side is bonded with an adhesive to the air conditioning frame. Moulding of composite plastics products Wilson, K.A. and Kliene, R.I. (The Victaulic Company plc, Hitchin and Tecron Industries Limited, Pavenham, UK) US Pat 4 877 562 (31 October 1989) A cross-linkable polymer and a catalyst are rotomoulded under conditions insufficient to cause significant cross-linking of the polymer so that it remains thermoplastic in nature.