Fiber composite component and a process for the production thereof

Patent metadata

Field	Value
Publication number	US-9808969-B2
Application number	US-201113817300-A
Country	US
Kind code	B2
Filing date	Aug 12, 2011
Priority date	Aug 16, 2010
Publication date	Nov 7, 2017
Grant date	Nov 7, 2017

Abstract

The present invention relates to sheet-form fiber composite components which are obtainable by impregnating fibers with a reactive resin mixture comprising polyisocyanates, polyepoxides, polyols and optionally additives, and to a process for the production thereof.

First claim

The invention claimed is:

1. A sheet-form fibre composite component prepared by the vacuum-assisted resin transfer moulding process, for use in the production of rotor blades of wind turbines, comprising a fibre layer impregnated with polyurethane, wherein the polyurethane is obtainable from a reaction mixture comprising
A) one or more polyisocyanates;
B) one or more polyether polyols comprising an addition product of propylene oxide on a di-functional or poly-functional starter molecule, the polyether polyol(s) comprising at least 80% secondary OH groups;
C) one or more polyepoxides; and
D) optionally additives,
wherein the reaction mixture has a viscosity at 35° C. of from 50 to 250 mPa and a ratio of the number of NCO groups to the number of OH groups of component B) of from 1.3:1 to 10:1 and a ratio of the number of NCO groups to the number of epoxide groups of component C) of from 1.1:1 to 10:1, and
wherein the one or more polyisocyanates consists of mixtures of diphenylmethane diisocyanate and polyphenylenepolymethylene polyisocyanate with a monomer content of from 70 to 95 wt. % in the polyisocyanate component of A) based on the total weight of the polyisocyanate components.

2. The sheet-form fibre composite component of claim 1 , wherein one or more gelcoat layers are present on one side of the polyurethane-containing fibre layer.

3. The sheet-form fibre composite component of claim 2 , wherein a spacer layer is present on the side of the polyurethane-containing fibre layer that is remote from the gelcoat layer, which spacer layer is followed by a further polyurethane-containing fibre layer.

4. The sheet-form fibre composite component of claim 1 , wherein a spacer layer is present on one side of the polyurethane-containing fibre layer, which spacer layer is followed by a further polyurethane-containing fibre layer.

5. A process for producing the sheet-form fibre composite component of claim 1 by the vacuum-assisted resin transfer moulding process, comprising
a) preparing a mixture of
A) one or more polyisocyanate;
B) one or more polyether polyols comprising an addition product of propylene oxide on a di-functional or poly-functional starter molecule, the polyether polyol(s) comprising at least 80% secondary OH groups;
C) one or more polyepoxides; and
D) optionally additives,
wherein the mixture has a viscosity at 35° C. of from 50 to 250 mPa and a ratio of the number of NCO groups to the number of OH groups of component B) of from 1.3:1 to 10:1 and a ratio of the number of NCO groups to the number of epoxide groups of component C) of from 1.1:1 to 10:1, and wherein the one or more polyisocyanates consists of mixtures of diphenylmethane diisocyanate and polyphenylenepolymethylene polyisocyanate with a monomer content of from 70 to 95 wt. % in the polyisocyanate component of A) based on the total weight of the polyisocyanate components;

b) laying a fibre material in a mould half;
c) introducing the mixture prepared in step a) into the fibre material of step b) to produce an impregnated fibre material; and
d) curing the impregnated fibre material at a temperature of from 20 to 120° C.

6. The process of claim 5 , wherein step d) is performed at a temperature of from 70 to 90° C.

7. The process of claim 5 , wherein before step b), b′) one or more gelcoat layers are introduced into the mould half.

8. The process of claim 5 , wherein after step b) and before step c) a spacer material layer and then a fibre material layer are introduced into the mould half.

9. A rotor blade for wind turbines, a bodywork component for motor vehicles, an aircraft, a building, a road, or a structure which is subjected to high stress comprising the sheet-form fibre composite component of claim 1 .

Assignees

• Lindner Stefan
• Franken Klaus
• Passmann Dirk
• Nordmann Peter
• Covestro Deutschland Ag

Inventors

• Lindner Stefan
• Franken Klaus
• Passmann Dirk
• Nordmann Peter

Classifications

• C08G18/4829

  Polyethers containing at least three hydroxy groups (C08G18/4833 - C08G18/5096 take precedence) · CPC title

• C08G18/58

  Epoxy resins {(C08G18/42, C08G18/48 take precedence; reaction products of epoxy resins with at least equivalent amounts of compounds containing active hydrogen C08G18/6407, with at least equivalent amounts of amines C08G18/6415; polymeric products of isocyanates or isothiocyanates with epoxy compounds having no active hydrogen C08G18/003)} · CPC title

• B29C45/0001 Primary

  characterised by the choice of material · CPC title

• C08G18/4045 Primary

  Mixtures of compounds of group C08G18/58 with other macromolecular compounds · CPC title

• C08J5/24

  Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs · CPC title