Method of making a composite with a barrier layer in a closed mold process

• US 7,118,699 B2
• Filed: 08/18/2003
• Issued: 10/10/2006
• Est. Priority Date: 03/05/2001
• Status: Expired due to Term

• Current Assignee: Illinois Tool Works Inc.
• Original Assignee: Illinois Tool Works Inc.
• Inventors: Anderson, Robert Phillip, Lauersdorf, William F.
• Primary Examiner(s): Crispino, Richard
• Assistant Examiner(s): Musser, Barbara J
• Application Number:
  US10/643,048
• Publication Number:
  US 20040033347A1
• Time in Patent Office: 1,149 Days
• Field of Search: None
• US Class Current: 264/255
• CPC Class Codes: B29C 67/24 characterised by the choice of material
• CPC Class Codes: B29C 70/58 comprising fillers only , e.g. particles, powder, beads, flakes, spheres B29C70/025 takes precedence, agglomerating hollow spheres to produce synthetic foam B29C70/66; compounding ingredients per se C08K
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B63B 2231/52 Fibre reinforced plastics materials
• CPC Class Codes: B63B 2231/72 Hollow glass microspheres
• CPC Class Codes: B63B 5/24 made predominantly of plastics surf boards B63B32/57
• CPC Class Codes: C08F 283/02 on to polycarbonates or saturated polyesters C08F283/004 takes precedence
• CPC Class Codes: C08F 290/064 Polymers containing more than one epoxy group per molecule
• CPC Class Codes: C08K 3/013 Fillers, pigments or reinforcing additives
• CPC Class Codes: C08K 3/346 Clay
• CPC Class Codes: C08K 5/0025 Crosslinking or vulcanising agents; including accelerators
• CPC Class Codes: C08L 2666/18 Polyesters or polycarbonates according to C08L67/00 - C08L69/00; Derivatives thereof
• CPC Class Codes: C08L 2666/22 Macromolecular compounds not provided for in C08L2666/16 - C08L2666/20
• CPC Class Codes: C08L 63/10 Epoxy resins modified by unsaturated compounds
• CPC Class Codes: C08L 67/00 Compositions of polyesters obtained by reactions forming a carboxylic ester link in the main chain of polyester-amides C08L77/12; of polyester-imides C08L79/08; Compositions of derivatives of such polymers
• CPC Class Codes: C09D 163/10 Epoxy resins modified by unsaturated compounds
• CPC Class Codes: C09D 167/06 Unsaturated polyesters having carbon-to-carbon unsaturation
• CPC Class Codes: E04C 2/20 of plastics
• CPC Class Codes: Y10T 428/249952 At least one thermosetting synthetic polymeric material layer

Abstract

A closed mold method of making a composite having a barrier layer. The method includes providing a mold; applying and curing a layer of gel coat on an inside surface of the mold; applying and curing a layer of barrier composition over the gel coat, the barrier composition comprising: about 10 to about 50 wt % vinyl ester resin, about 15 to about 60 wt % polyester resin, 0 to about 30 wt % monomer, about 1 to about 15 m wt % thickening agent, about 0.1 to about 5 wt % accelerators, about 1 to about 25 wt % filler, and a catalyst; applying a layer of fiberglass reinforcement over the barrier composition; applying resin to the fiberglass reinforcement; closing the mold; curing the resin; and opening the mold and removing the composite, wherein the composite has an improved surface finish compared to a composite without the barrier composition made with a closed mold process. The invention also relates to the composite made by the method.

Claims

1. A closed mold method of making a composite having a barrier layer, the method comprising:

providing a mold;

applying and curing a layer of gel coat on an inside surface of the mold;

applying end curing a layer of barrier composition over the cured gel coat, the barrier composition comprising;

about 10 to about 50 wt % vinyl ester resin;

about 15 to about 60 wt % polyester resin;

0 to about 30 wt % monomer;

about 1 to about 15 wt % thickening agent;

about 0.1 to about 5 wt % accelerators;

about 1 to about 25 wt % filler; and

a catalyst;

applying a layer of fiberglass reinforcement over the cured barrier composition;

applying resin to the fiberglass reinforcement;

closing the mold;

curing the resin; and

opening the mold and removing the composite,

wherein the composite has an improved surface finish compared to a composite

made with a closed mold process without the barrier composition.

2. The method of claim 1 wherein the mold is a two piece mold, and wherein the mold is closed by moving the two pieces together.

3. The method of claim 2 further comprising applying pressure to the mold.

4. The method of claim 2 wherein the resin is applied after the mold is closed, and wherein the resin is applied under pressure.

5. The method of claim 4 wherein a vacuum is applied after the mold is closed.

6. The method of claim 1 wherein the mold is closed by sealing a vacuum bag around the mold.

7. The method of claim 6 further comprising applying a vacuum to the vacuum bag.

8. The method of claim 7 wherein the resin is applied after the vacuum is applied.

9. The method of claim 1 wherein the closed mold method is a closed mold process selected from compression molding, vacuum bag molding, vacuum infusion molding, or resin transfer molding.

10. The method of claim 1 wherein the accelerators comprise at least one material selected from dimethyl para-toluidine, diniethyl aniline, diethyl aniline, dimethyl acetalacetamide, cobalt octoate, potassium octoate, copper naplflhanate, quaternary arnmonium salts, or mixtures thereof.

11. The method of claim 1 wherein the fillers comprise a material selected from hollow spheres or microspheres, wollastonite fibers, mica, potassium aluminum silicate, calcium silicate, calcium sulfate, aluminum tribydrate, or combinations thereof.

12. The method of claim 11 wherein the hollow spheres or niicrospheres comprise a material selected from silicate glass, ceramic, plastic, or combinations thereof.

13. The method of claim 1 wherein said thickening agent is a thixotropic clay.

14. The method of claim 1 further including fumed silica.

15. The method of claim 1, wherein the catalyst is selected from methyl ethyl ketone peroxide. benzoyl peroxide, or cumyl hydroperoxide.

16. The method of claim 1, wherein the barrier composition comprises:

about 10 to about 20 wt % vinyl ester resin;

about 40 to about 60 wt % polyester resin;

about 5 to about 10 wt % monomer;

about 1 to about 15 wt % thickening agent;

0 to about 2 wt % fumed silica;

about 0.1 to about 5 wt % accelerators; and

about 1 to about 25 wt % fillers.

17. The method of claim 1, wherein the barrier composition comprises:

about 20 to about 50 wt % vinyl ester resin;

about 15 to about 40 wt % polyester resin;

about 5 to about 10 wt % monomer;

about 1 to about 15 wt % thickening agent;

0 to about 2 wt % fumed silica;

about 0.1 to about 5 wt % accelerators; and

about 1 to about 25 wt % fillers.

18. The method of claim 1, further comprising applying a second layer of fiberglass reinforcement, applying resin to the second layer of fiberglass reinforcement, and curing the resin.

19. The method of claim 1, further comprising applying and curing a second layer of barrier composition.