System and method of making a layered, reinforced composite
A system and method of making a layered, reinforced composite having an as-cured “Class A” surface. A mold ( 20 ) with a surface ( 200 ) having a predetermined degree of finish is heated to a temperature consistent with “in-molding coating” techniques applied to polyurethane-like matrix materials. The mold surface is coated with a first formulation to create an unreinforced topcoat ( 22 ) of the eventually cured composite. A second formulation is applied atop the topcoat to create an unreinforced barrier layer ( 23 ). A third formulation, comprising polymeric matrix material and reinforcements, is applied atop the barrier layer to create a reinforced layer ( 24 ). The combined topcoat, barrier layer, and reinforced layer making up an uncured preform are allowed to cure. The result is a reinforced composite with an as-cured “Class A” surface ( 210 ).
1 . A method of making a fiber-reinforced composite having an as-cured Class A surface, the method comprising:
a. providing a mold having a mold surface having a predetermined degree of finish; the degree of finish such that a mating surface of a cured polymer-based material fabricated in the mold would exhibit a Class A quality;
b. coating the mold surface with a first formulation to create an unreinforced barrier layer of the composite;
c. applying a second formulation atop the barrier layer to create a reinforced layer, the second formulation comprising polymeric matrix forming material and fibers, so as to create an, as yet, uncured composite preform; and
d. allowing the preform to cure so as to make a fiber-reinforced composite having an as-cured Class A surface.
2 . A method according to claim 1 including the step of heating the mold to a temperature of between approximately 37 degrees Celsius and approximately 94 degrees Celsius.
3 . A method according to claim 2 wherein the first and second formulations comprise polyurethane.
4 . A method according to claim 3 wherein the first and second formulations comprise aromatic polyurethane.
5 . A method according to claim 2 wherein the fibers comprise fiberglass.
6 . A method according to claim 2 wherein the unreinforced barrier layer has a thickness between approximately 0.005 inches and approximately 0.250 inches.
7 . A method according to claim 6 wherein the unreinforced barrier layer has a thickness of at least approximately 0.030 inches.
8 . A method according to claim 2 , further comprising:
a. closing the mold after applying the second formulation; and
b. applying pressure to the closed mold and its contents to shape and to assist in curing the composite preform.
9 . A fiber-reinforced composite made according to claim 2 .
10 . A fiber-reinforced composite made according to claim 3 .
11 . A fiber-reinforced composite made according to claim 5 .
12 . A fiber-reinforced composite made according to claim 6 .
13 . A fiber-reinforced composite made according to claim 7 .
14 . A fiber-reinforced composite made according to claim 8 .
15 . A method of making a reinforced composite having an as-cured Class A surface, the method comprising:
a. providing a mold having a mold surface having a predetermined degree of finish; the degree of finish such that a mating surface of a cured polymer-based material fabricated in the mold would exhibit a Class A quality;
b. coating the mold surface with a first formulation to create an unreinforced topcoat of the composite;
c. applying a second formulation atop the topcoat to create an unreinforced barrier layer;
d. applying a third formulation atop the barrier layer to create a reinforced layer, the third formulation comprising polymeric matrix forming material and fibers, so as to create an, as yet, uncured composite preform; and
e. allowing the preform to cure so as to make a fiber-reinforced composite having an as-cured Class A surface.
16 . A method according to claim 15 including the step of heating the mold to a temperature of between approximately 37 degrees Celsius and approximately 94 degrees Celsius.
17 . A fiber-reinforced composite made according to claim 15 .
18 . A method according to claim 15 wherein the topcoat has a thickness between approximately 0.0005 inches and approximately 0.005 inches.
19 . A method according to claim 15 wherein the topcoat comprises a plurality of layers.
20 . A method according to claim 19 wherein the second layer is colored.
21 . A method according to claim 15 , further comprising:
a. closing the mold after applying the third formulation; and
b. applying pressure to the closed mold and its contents to shape and to assist in curing the composite preform.
22 . A method according to claim 15 wherein the topcoat comprises a solvent based, two component precursor of aliphatic polyurethane.