Low density fiber-reinforced plastic composites

Low density fiber-reinforced plastic composites

Open-cell composition and method of making same Walles, W.E. (The Dow Chemical Company, Midland, MI, USA) US Pat 4 647 498 (3 March 1987) An open-cell...

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Open-cell composition and method of making same Walles, W.E. (The Dow Chemical Company, Midland, MI, USA) US Pat 4 647 498 (3 March 1987) An open-cell network of 99-33 weight % of a microfibrous, inert inorganic oxide (silicon, aluminium ortitanium)is strengthened by acoating of 1-70 weight % of a polymer (vinyl homopolymers, copolymers of polystyrene). The composition contains 30-99% open cells by volume. Cellulose fibres for cement reinforcement Blackie, M.S. and Poynton, D.J. (Courtaulds plc, London, UK) US Pat 4 647 505 (3 March 1987) In this process, fibres are first dispersed in an aqueous medium which causes them to swell and are impregnated with a titanium and/or zirconium chelate compound under conditions which minimize hydrolysis of the chelate. Following mechanical extraction of the impregnated fibres and drying, reaction between the chelate compound(s) and hydroxyl groups on the cellulose fibres are effected to form cross-links on the surface and throughout the body of the fibres. The resulting product contains up to about 1% by weight of titanium and/or zirconium, based on the dry weight of the fibres. Structural panels Parker, J.A. et al (Administrator of the National Aeronautics and Space Administration, Washington, DC, USA ) US Pat 4 64 7 615 (3 March 1987) In the title structural panels, 0.5-5 parts by weight of reinforcing fibres are dispersed in one part by weight of a cured copolymeric resin comprising bismaleimide and a 5-vinyl-2-stilbazole of a given formula. Composite flexbeam for a rotary wing aircraft Fradenburgh, E.A., Kiely, E.F. and Miller, G.G. (United Technologies Corporation, Hartford, CT, USA) US Pat 4 638 800 (10 March 1987) The fibre-reinforced epoxy fiexbeam has torsionally stiff, thick inboard and outboard end portions, reinforced with doublers, each of which tapers down to a torsionally soft, thin, medial web portion.The product is used for mounting a variable pitch blade to a rotatable hub, Molded bow limb Johnston, R. (Precision Shooting Equipment Company, Tuscon, AZ, USA) US Pat 4 649 889 (17 March 1987) I n the article which has varying thicknesses along its length and varying widths transferse of its length so that it has a substantially uniform crosssection, the glass fibre strands are essentially longitudinal in the central portion of the body and closely conform to the skin adjacent to the skin. Filament wound interlaminate tubular attachment Policelli. F.J. (Hercules Incorporated, Wilmington, DE, USA) US Pat 4 649 960 (17 March 1987) The detailed winding configuration is given of end sections in a filament wound tube to which load-bearing coupling shells can be attached for joining similar tubes. Joint for truss structures of fiber composite material Seuster, W. (Dornier System GmbH, Friedrichshafen, FRG) US Pat 4 650 361 (17March 1987) A joint connection for attachment of reflector panels to a truss support structure comprised of bars is described. Both the bars and reflector panels are composed of FRP or metal. Composite sole for a shoe (Hannibal, A.J., Fairview. PA, USA) USPat 4 651

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445 (24 March 1987) The sole ofth e shoe is formed of plies of fibres oriented at _+40° to +90 ° to the longitudinal axis in a resilient matrix material. The fibres have a modulus of elasticity of about 7 G P a along their long axis, whereas that for the matrix is less than 0.7 GPa.

Vehicle bumper Loren, N.S. and Gordon, W.E. (Michael Ladney, Grosse Pointe Shores, MI, USA) US Pat 4 652 031 (24 March 1987) An impact-receiving fascia is bonded to a resilient, compressible plastic foam formed in situ via an integral skin on the foam.

MATERIALS Scrim reinforced, cloth-like composite laminate and a method of making Manning, J.H. and Dunkerly Ill, C.A. (The James River Corporation, Rich mond, VA, USA) US Pat 4 634 621 (6January 1987) A scrim coated with thermoplastic binder is inserted between two non-woven layers formed of cellulosic fibres bound with latex adhesive. The laminate is then heated without pressing to yield the title product. Flexible circuit laminate and method of making the same Gazit, S. and Fleischer, C.A. (Rogers Corporation, Rogers, CT, USA) US Pat 4 634 631 (t January 1987) A layer of polyimide film is coated with a glassrein forced fluoropolymer adhesive film in which the glass fibres are short and non-continuous, and has a conductive sheet disposed on at least a portion of the adhesive film. Electromagnetic interference-shielding, flameretardant ABS resin composition Kamiyo, S. and Yoshihiro, M. (Mitsubishi Rayon Co Ltd, Tokyo, Japan) US Pat 4 636 356 (13 January 1987) The ABS resin contains 5 to 20 weight % of stainless steel fibres (o faverage diameter 3 to 5 ~m and average fibre length of 3 to 50 ram) and 4 to 30 weight % of glass fibres (of aspect ratio at least 50 and an average diameter of 5 lain). Composite fiber reinforced molded structure for dimple control Harris, C.E. and Tolley, R.K. (The Boeing Company, Seattle, WA, USA) US Pat 4 636 422 (13January 1987) The structure comprises an outer member of fabric in uncured resin including a precured resinimpregnated fabric embedded therein, both fabrics containing high modulus and high strength fibres, and an internal stiffener formed integrally with the outside membercomprisinghigh modulus and strength fibres in an uncured resin. Curable epoxy resin compositions Wang, D.W., Courter, J.L. and Kohli, D.K. (American Cyanamid Company, Stamford, CT. USA) US Pat 4 636 535 (13January 1987) The structure of an amine-containing curing agent for an epoxy composition comprising a heat-curable epoxy resin and non-siliceous reinforcing filaments is given. Ncoalkoxy titanate in high density mica laminates Sklarski, D.J. (Essex Group Inc, Fort Wayne, IN, USA) US Pat 4 637 852 (20January 1987) Mica composite laminates are formed by curing

under heat and pressure a stack of mica papers impregnated with 5-14 weight % of a polysiloxane binder containing about 1-4 weight % of a neoalkoxy titanate and about 0.5-2 weight % of a naphthenate.

Scrim reinforced, flat cloth-like composite laminate and a method of making Manning, J.H. and Sorensen, W.P. (The James River Corporation, Richmond, VA, USA) USPat 4 637 949 (20January 1987) The laminates are prepared similarly to those in US Pat 4 634 621 (6 January 1987), except th at tension is maintained on the scrim and the nonwoven layers during heating. Advanced titanium composite Sastry, S.M., O'Neal, J.E. and Peng, T.C. (McDonnell Douglas Corporation, St Louis, MO, USA) US Pat 4 639 281 (27January 1987) Fibrous dispersoids are formedin situ in a rapidly solidified titanium matrix during the annealing of a titanium alloy, the dispersoids serving to increase the strength of the alloy, Ceramic-metal composites Ainsworth, J.H. and Shepler, R.E. (Chromalloy American Corporation, Dallas, TX, USA) US Pat 4 639 388 (27January 1987) The composite structure comprises a layer of heat-resistant, chemically bonded ceramic mechanically attached to a metal substrate which contains reinforcing elements. Fiber reinforced thremoplastic material Binnersley, E.K. and Krueger, W.H. (E.I. Du Pont de Nemours and C o m p a n y Inc, Wilmington, DE, USA) US Pat 4 640 861 (3 February 1987) About 50-60 volume % of thermoplastic-coated fibre bundles are arranged in a thermoplastic matrix to form a composite in which the uniformity of reinforcement distribution in the matrix, as measured by the ratio of the mean mass length between fibre bundles parallel to that perpendicular to the consolidation direction, is from 0.5 to 1.0. Preservative treated composite wood product Knudson, R.M. and Ehrenfellner, H. (MacMillan Bloedel Limited, Vancouver, Canada) US Pat 4 643 860 (17 February 1987) Molten slack wax is applied to wood particles of moisture content below 10%, the wood particles are then sprayed with an ammonical copper arsenate solution and blended with an adhesive resin. The resulting mixture is formed into a mat, and then heated and compressed to yield the product. Epoxy-glass integrated circuit package having bonding pads in a stepped cavity McNeal, N.E., Nagy, R.A. and Norell, R.A. (Burroughs Corporation, Detroit, MI, USA) US Pat 4 643 935 (17 February 1987) Thin layers of glass fibre-reinforced epoxy resin are stacked and laminated together by means of adhesive interlayers. The stack has a stepped cavity which exposes the flat surface of an internal FRP layer to which are bonded wire pads. Low density fiber-reinforced plastic composites Shaw, K.M. et al (The Dow Chemical Company, Midland, MI, USA) US Pat 4 643 940 (17 February 1987) Prepared by an aqueous slurry process and expanded by heat in thickness to a void content of 20-90 volume %, this composite comprises a thermoplastic resin matrix and 10-50

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weight % randomly oriented fibres of average length 3.18-25.4 mm and aspect ratio of > 40. Curable epoxy resin compositions Kohli, D.K. and Fisher, M.M. (American Cyanamid Company, Stamford, CT, USA) US Pat 4 645 803 (24 February 1987) The structure of an amine-containing curing agent is given which is used in a fibre/epoxy resin composition that is said to exhibit improved interlaminar toughness, compression strength and short beam shear strength under dry, wet and hot/wet conditions when cured. Boride aluminia composite Debely, P.E. (ELTECH Systems Corporation, Boca Raton, FL, USA) US Pat 4 647 405 (3 March 1987) A reaction sintered ceramic composite is described in which bulky agglomerates of alumina of random shapes and dimensions are contained in a Group IVa metal diboride which has a fibrous, electrically conductive structure. Puncture resistant laminate LeGrand, D.G. and Olszewski, W.V. (General Electric Company, Pittsfield, MA, USA) US Pat 4 467 493 (3 March 1987) The structure of the laminate is given as: a front thermoplastic lamina facing the direction of impact of thickness 2.54-6.35 mm; a back polycarbonat¢ lamina of thickness 0.76-5.59 mm; an internal lamina of glass of thickness 2.54-6.35 mm disposed between the front and back laminae; and adhesive interlayers to bond the laminae together. Electromagnetic reflection body Kanayama, T. et al (Bridgestone Corporation, Tokyo, Japan) US Pat 4 647 495 (3 March 1987) The title product has an electromagnetic reflecting member, comprising a woven fabric made from a blended yarn of metallic filament and organic or inorganic fibre, and fiber-reinforced resin joined to it to form one rigid piece. Use of fibrous mat-faced gypsum board in exterior finishing systems for buildings Lehnert, C.W. and Randall, B.G. (GeorgiaPacific Corporation, Atlanta, GA, USA) US Pat 4 647 496 (3 March 1987) Adhesively bonded to the inner surface of an insulation material is a glass mat-faced gypsum support surface, while the external surface of the insulation material is overlaid with an exterior finishing material. High temperature refractory of MgCr~O+ matrix and unstabilized ZrO 2 particles Singh, J.P., James, J.J. and Picciolo, J.J. (United States Department of Energy, Washington, DC, USA) US Pat 4 647 547 (3 March 1987) About 5-30 weight % of unstabilized ZIO~ particles of average size 0.6--5/tm are dispersed in a matrix of MgCr204. Fiber-reinforced materials Fischer, J. et al (BASF Aktiengesellschaft, FRG) US Pat 4 649 080 (10 March 1987) From 30 to 85 volume % of oriented reinforcing fibres are contained in an aromatic polyether resin which carries reactive sulphur groups. The matrix is cross-linked via the sulphur groups so that the FRP material has a Tg of > 100°C and is virtually insoluble in low-boiling chlorohydrocarbons.

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Thermally bonded fibrous product Hill, C.A. (The Babcock & Wilcox Company, New Orleans, LA, USA) US Pat 4 650 775 (17 March 1987) Aluminosilicate fibres, silica powder and boron nitride powder are sintered at > 1285°C to produce a material having high thermal insulating value, high modulus of rupture and low density. Glass fiber-reinforced oxymethylene polymer molding compositions having mechanical properties enhanced by amino-formaldehyde resin coupling agents Auerbach, A.B. and McKie, D.B. (Celanese Corporation, New York, NY, USA) US Pat 4 652 594 (24 March 1987) Amino-formaldehyde coupling agent is used to increase the adhesion between reinforcing glass fibres and an oxymethylene polymer matrix.

PROCESSES Method of producing fiber-reinforced composite body Yamaguchi, F. et al (Honda Giken Kogyo Kabushiki Kaisha, Tokyo, Japan) US Pat 4 633 931 (6 January 1987) Molten metal is introduced into the cavity of a casting mould containing shaped, fibrous material, and then subject to a primary pressure to cause the metal to semi-solidify. Hydrostatic pressure greater in magnitude than the primary pressure is applied to the semi-solid metal while a secondary pressure also greater than the primary pressure is additionally and simultaneously applied locally to the fibre shaped article to integrate the components. Method of molding fiber reinforced composite wheel McDougall, M.K. (The Budd Company, Troy, MI, USA) US Pat 4 636 344 (13 January 1987) In this process for producing a wheel having a rim and disc, a disc charge with radially outwardly extending fibre segments is formed in a mould along with an annular rim charge which comprises radial, distinct layers in which alternate layers contain transverse fibres and the innermost and outermost layers contain parallel fibres. Compression moulding is used to join the parts. Method for the preparation of a laminate Ueno, S. et al (Shin-Etsu Chemical Co Ltd, Otemachi, Japan) US Pat 4 637 851 (20 January 1987) Sheets of aromatic polyamide fabrics are exposed to a low temperature plasma before they are impregnated with polyimide or epoxy resin, stacked, and cured under heat and pressure. Method and apparatus for impregnating fiber strands Wilkinson, R.E. and Epel, J.N. (The Budd Company, Troy, MI, USA) US Pat 4 643 126 (17 February 1987) Fibre stands are passed through a container containing recirculating resin where the fibres are spread apart and impregnated uniformly with resin while minimizing air entrapment and bending of the fibres. Fastening of a leaf spring of composite material Mounier-Poulat, F., Beaupellet, J. and Gardier, P. (Renault Vehicules Industriels, Lyons,

France) US Pat 4 643 406 (17 February 1987) An FRP leaf spring is fixed to a suspension elementvia metal shoes attachedtothe suspension, with rubber pieces and steel sheets placed between the leaf spring and shoes to prevent damage to the springs as the shoes are clamped. PAGE 55 Process for making reinforced sealing gaskets Martini, G. (Tako SpA, Turin, Italy) US Pat 4 643 863 (17 February 1987) A wirelike reinforcing element is placed in on a support sheet containing an outline of the gasket to be made, and a thread of high viscosity, curable material is dispensed through a nozzle over the reinforcement. Bis-maleimide resin systems and structural composites prepared therefrom Boyd, J.D. and Shimp, D.A+(BASFCorporation, Wyandotte, MI, USA) USA Pat 4 644 039 (17 February 1987) Elevated temperature cure of a bis-maleimide resin system for use as a matrix for structural composites is accelerated by a catalyst comprising an organophosphine, organophosphonium salts or complexes thereof. Materialin sheet form, convertible in to a finished product by moulding-stamping or heat-shaping, comprising reinforcing fibers and a thermoplastics resin in powder form, and process for preparing said material Vallee, A. and Cortinchi, H. (Arjomari-Prioux, Paris, France) US Pat 4 645 565 (24 February 1987) To a mixture consisting of about 80--40 weight % thermoplastic powder (of particle size up to 500 lam) and about 20-60 weight % fibres of the same average length (mineral, metallic or synthetic organic fibres) is added about 5 to 25 weight % of the basic mixture ofa polypropylene pulp, about 5-30 weight % of a latex binder/PVA fibre mixture and about 0.2-10 weight % of a flocculating agent. The homogeneous, flocculated mixture is then dewatered on a wire screen and dried. Process for the extrusion of composite structural members Heggenstaller, A. and Spies, X. (Anton Heggenstaller, Unterbernbach, FRG) US Pat 4 645 631 (24 February 1987) In this process, peg-like wooden chips are oriented parallel to the extrusion axis of a mixture by precompression, and the outer layers of the mixture are precompressed with a reduced precompression ratio so that the particles in such layers have increased lateral spacing. Process for pre-resinating cellulose fibers for cellulose composite structures Mtangi, S.A. and Fishman, D.H. (United Technologies Automotive Trim Inc, Dearborn, MI, USA) US Pat 4 647 324 (3 March 1987) High strength and structural integrity is claimed for articles produced by moulding a resin-containing cellulose fibre web in which dry resincoated cellulose fibres are first formed by feeding cellulose material in a dry resin-containing airstream and comminuting the coated fibres. Method of manufacturing a shape from a composite material Port, R. (Aerotex Hochleistungsfaser GmbH, Willich, FRG) US Pat 4 647 326 (3 March 1987) Parallel reinforcing fibres impregnated with resin are laid up in laminations on a positive mould and at least one layer of a cellular core, rigid foam material in the form of a helix is embedded in a neutral zone of the laminations while they are being built up.

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