Low density coring material

Patent metadata

Field	Value
Publication number	US-2017058084-A1
Application number	US-201615349064-A
Country	US
Kind code	A1
Filing date	Nov 11, 2016
Priority date	Aug 10, 2010
Publication date	Mar 2, 2017
Grant date	—

Abstract

A low density coring material is described. In one embodiment, the low density coring material consists essentially of: about 40 to about 80 wt % resin; 0 to about 50 wt % monomer; 0 to about 5 wt % dispersion aid; 0 to about 5 wt % accelerator; about 3 to about 7 wt % microspheres; and about 1 to about 5 wt % catalyst; wherein a density of the cured coring material is less than about 5.0 lbs/gal. Composites made using the low density coring material and methods of making composites are also described.

First claim

What is claimed is:

1 . A process for making a composition for a low density coring material comprising:
providing one or more resins, a monomer, and a dispersion aid; performing a first mixing of the one or more resins, the monomer, and the dispersion aid with a mixer to form a resin mixture; adding one or more accelerators into the resin mixture; performing a second mixing of the added one or more accelerators and the resin mixture;
adding microspheres to the mixture of the one or more accelerators and the resin mixture while performing a third mixing; and
performing a fourth mixing and filtering the composition through a mesh to yield the low density coring material, the coring material having a cured state and an uncured state, the viscosity of the coring material in the uncured state is in a range of from 7,000 to 13,000 cps, wherein a density of the cured coring material is less than about 5.0 lbs/gal, a layer of low density coring material having a wet thickness from 15 to 40 mils per pass.

2 . The process of claim 1 wherein said one or more resins are present from 40 to 80 wt % of the composition.

3 . The process of claim 1 wherein said one or more resins is a polyester resin.

4 . The process of claim 1 wherein said monomer is present from 0 to 50 wt % of the composition.

5 . The process of claim 1 wherein said monomer is a styrene monomer.

6 . The process of claim 1 wherein the dispersion aid is present from 0 to 50 wt % of the composition.

7 . The process of claim 1 wherein the first mixing further comprises by initially mixing at low speed of about 20 rpm with a helix blade, and then mixing at high speed of 1100-1200 revolutions per minute (rpm) using a high shear blade.

8 . The process of claim 1 wherein said one or more accelerators comprise at least one of dimethyl-p-toluidine (DMPT), dimethylaniline (DMA), 1,3-dimethylamylamine (DMAA), cobalt octoate, potassium octoate, copper napthanate and quaternary ammonium salts.

9 . The process of claim 1 wherein said one or more accelerators are present from 0 to 5 wt % of the composition.

10 . The process of claim 1 wherein the second mixing further comprises mixing the accelerators are with the resin mixture for about 5 minutes with a helix blade at low speed of 30 rpm and with a high shear blade at high speed of from 1200 to 1300 rpm.

11 . The process of claim 1 wherein the third mixing further comprises mixing with a helix blade at at a low speed of from 2 to 3 rpm.

12 . The process of claim 1 wherein the microspheres are glass or plastic.

13 . The process of claim 1 wherein the microspheres are 3 to 7 wt % of the composition.

14 . The process of claim 1 wherein the fourth mixing further comprises mixing with a helix blade at about 20 rpm and no shear for about 30 minutes.

15 . The process of claim 15 wherein the density of a layer of the cured coring material is in a range of from 2.8 to 4.0 lbs/gal.

Assignees

• Illinois Tool Works

Inventors

• Adams Robert Mark
• Lake Randall
• Schaefer Louis Paul
• Twardowska Helena
• Kruchten Brian

Classifications

• B32B37/15

  with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state · CPC title

• B32B2264/101

  Glass · CPC title

• B32B5/16

  characterised by features of a layer formed of particles, e.g. chips, powder {or granules (layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02)} · CPC title

• C08J3/22 Primary

  using masterbatch techniques · CPC title

• B32B17/068

  of particles · CPC title