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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 PDF

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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
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Prior art keywords
thermosetting resin
fibre web
fibres
grains
reinforcing
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Abandoned
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US10/302,487
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English (en)
Inventor
Christian Hogfors Ziebell
Per-Ola Hagstrand
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Individual
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Individual
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
    • 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
    • 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
    • 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
    • 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
    • B29C70/508—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
    • 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
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4218—Glass fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4242—Carbon fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/60—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in dry state, e.g. thermo-activatable agents in solid or molten state, and heat being applied subsequently
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H11/00—Non-woven pile fabrics
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/002—Inorganic yarns or filaments
    • D04H3/004—Glass yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/013—Regenerated cellulose series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/015—Natural yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/12—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/12—Glass fibres
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • 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.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Reinforced Plastic Materials (AREA)
  • Laminated Bodies (AREA)
US10/302,487 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 Abandoned US20030148087A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
SE0001929-9 2000-05-23
SE0001929A SE0001929L (sv) 2000-05-23 2000-05-23 Förfarande för framställning av en härdplastinnehållande fiberbana, en sådan fiberbana, och en armerad härdplastkomposit innefattande fiberbanan
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

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US20030148087A1 true US20030148087A1 (en) 2003-08-07

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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

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US (1) US20030148087A1 (sv)
AU (1) AU2001260924A1 (sv)
SE (1) SE0001929L (sv)
WO (1) WO2001090482A2 (sv)

Cited By (2)

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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

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GB2546962A (en) * 2015-12-21 2017-08-09 Hexcel Composites Ltd Apparatus and method of impregnating reinforcement material
CN108729276B (zh) * 2017-04-18 2022-04-12 上海众伟生化有限公司 麻纤维生物覆土膜及其制备方法
CN111101293A (zh) * 2019-12-25 2020-05-05 耿程辉 一种蒲公英绒纤维混纺静电聚合工艺及其聚合设备
CA3199781A1 (en) * 2020-10-30 2022-05-05 Nike Innovate C.V. Asymmetric faced composite nonwoven textile and methods of manufacturing the same

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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
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US11427687B2 (en) * 2015-07-29 2022-08-30 The Boeing Company Noodle comprised of a matrix of discontinuous filaments
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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
WO2001090482A2 (en) 2001-11-29
SE0001929L (sv) 2001-12-21
AU2001260924A1 (en) 2001-12-03
SE0001929D0 (sv) 2000-05-23
WO2001090482A3 (en) 2002-04-11

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