Reinforced Composite Materials for Use in the Manufacture Moulds and the Use of Such Moulds
First Claim
Patent Images
1. A method for producing a composite mould, comprising:
- i) forming a substrate;
ii) applying a fibre reinforced structural laminate to the substrate, wherein said fibre reinforced structural laminate comprises;
a) a first plurality of reinforcing fibres; and
b) a first curable resin mixture, comprising a first curable resin and optionally a wetting agent;
iii) applying a syntactic foam moulding product to the fibre reinforced structural laminate, wherein said syntactic foam moulding product comprises;
a) a plurality of treated reinforcing microfibres;
b) a second curable resin mixture, comprising a second curable resin, and optional thixatropes and plastic spheres/hemispheres; and
c) a coupling agent;
iv) optionally applying a tooling gel coat to the surface of said syntactic foam moulding product for the manufacture of moulds that require a high gloss surface finish; and
v) curing said composite mould;
wherein;
i) optionally applying a foam sealer product to the substrate prior to applying the structural laminate, wherein the optional foam sealer product comprises;
a) a plurality of treated reinforcing microfibres and/or Mica flakes;
b) a foam sealer; and
c) a coupling agent; and
ii) the method of producing the composite mould is inclusive or exclusive of making and/or using a plug or composite plug.
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Abstract
The present disclosure relates to the preparation of composite moulds and methods of preparing the same, wherein the composite moulds may be prepared exclusive or inclusive of a plug. Certain composites comprise a substrate, a structural laminate, and a syntactic foam moulding product.
23 Citations
20 Claims
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1. A method for producing a composite mould, comprising:
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i) forming a substrate; ii) applying a fibre reinforced structural laminate to the substrate, wherein said fibre reinforced structural laminate comprises; a) a first plurality of reinforcing fibres; and b) a first curable resin mixture, comprising a first curable resin and optionally a wetting agent; iii) applying a syntactic foam moulding product to the fibre reinforced structural laminate, wherein said syntactic foam moulding product comprises; a) a plurality of treated reinforcing microfibres; b) a second curable resin mixture, comprising a second curable resin, and optional thixatropes and plastic spheres/hemispheres; and c) a coupling agent; iv) optionally applying a tooling gel coat to the surface of said syntactic foam moulding product for the manufacture of moulds that require a high gloss surface finish; and v) curing said composite mould; wherein; i) optionally applying a foam sealer product to the substrate prior to applying the structural laminate, wherein the optional foam sealer product comprises; a) a plurality of treated reinforcing microfibres and/or Mica flakes; b) a foam sealer; and c) a coupling agent; and ii) the method of producing the composite mould is inclusive or exclusive of making and/or using a plug or composite plug. - View Dependent Claims (3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16)
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2. (canceled)
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17. A syntactic foam moulding product, comprising:
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i) a plurality of treated reinforcing microfibres; ii) a curable resin mixture, comprising a curable resin, and optionally, thixatropes, and plastic spheres/hemispheres; and iii) a coupling agent. - View Dependent Claims (18, 19, 20)
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Specification