Fiber-bound engineered materials formed using foundation scrims
US-2024415230-A1 · Dec 19, 2024 · US
US9770844B2 · US · B2
| Field | Value |
|---|---|
| Publication number | US-9770844-B2 |
| Application number | US-201314433903-A |
| Country | US |
| Kind code | B2 |
| Filing date | Sep 17, 2013 |
| Priority date | Sep 19, 2012 |
| Publication date | Sep 26, 2017 |
| Grant date | Sep 26, 2017 |
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A molding material comprising a fibrous reinforcement layer and a curable resin matrix. The fibrous reinforcement layer comprises a non-woven fabric comprising a single layer of unidirectional tows arranged at an angle greater than 0° in relation to the lengthwise direction of the fabric and a support structure for maintaining the arrangement of the tows.
Opening claim text (preview).
The invention claimed is: 1. A two layer molding material having a lengthwise direction, said two layer molding material comprising: a first layer of dry unidirectional fibers wherein said dry unidirectional fibers are oriented in a direction that is from −30° to −45 with respect to said lengthwise direction, said first layer of dry unidirectional fibers being held together with stitching yarns that extend in said lengthwise direction; a second layer of resin impregnated unidirectional fibers wherein said resin impregnated unidirectional fibers axe oriented in a direction that is from +30° to +45 with respect to said lengthwise direction, said second layer of impregnated unidirectional fibers being held together with stitching yarns that also extend in said lengthwise direction; and a curable resin that impregnates said second layer of resin impregnated unidirectional fibers to form a resin matrix therein. 2. A molding material according to claim 1 wherein said dry unidirectional fibers are oriented in a −30° direction with respect to said lengthwise direction and wherein said resin impregnated unidirectional fibers are oriented in a +30° direction with respect to said lengthwise direction. 3. A molding material according to claim 1 wherein said dry unidirectional fibers are oriented in a −45° direction with respect to said lengthwise direction and wherein said resin impregnated unidirectional fibers are oriented in a +45° direction with respect to said lengthwise direction. 4. A molding material according to claim 1 wherein said dry unidirectional fiber and said resin impregnated unidirectional fibers are glass fibers. 5. A molding material according to claim 2 wherein said dry unidirectional fiber and said resin impregnated unidirectional fibers are glass fibers. 6. A molding material according to claim 3 wherein said dry unidirectional fiber and said resin impregnated unidirectional fibers are glass fibers. 7. A molding material according to claim 1 wherein said curable resin comprises an epoxy resin. 8. A molding material according to claim 2 wherein said curable resin comprises an epoxy resin. 9. A molding material according to claim 3 wherein said curable resin comprises an epoxy resin. 10. A molding material according to claim 4 wherein said curable resin comprises an epoxy resin. 11. A molding material according to claim 5 wherein said curable resin comprises an epoxy resin. 12. A molding material according to claim 6 wherein said curable resin comprises an epoxy resin. 13. A molding material according to claim 1 wherein said stitching yarn comprises fibers selected from the group consisting of polyamide fibers and polyethersulfone fibers. 14. A molding material according to claim 2 wherein said stitching yarn comprises fibers selected from the group consisting of polyamide fibers and polyethersulfone fibers. 15. A molding material according to claim 3 wherein said stitching yarn comprises fibers selected from the group consisting of polyamide fibers and polyethersulfone fibers. 16. A molding material according to claim 4 wherein said stitching yarn comprises fibers selected from the group consisting of polyamide fibers and polyethersulfone fibers. 17. A molding material according to claim 7 wherein said stitching yarn comprises fibers selected from the group consisting of polyamide fibers and polyethersulfone fibers.
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