Modified Surfacer Coat for Improving Non-Uniform Composite Surfaces
A surfacer coat ( 300, 300 ′) includes a resin material ( 302 ), a plurality of first particles ( 306, 306 ′), and a plurality of second particles ( 308, 308 ′). The plurality of first particles ( 306, 306 ′) and the plurality of second particles ( 308, 308 ′) are uniformly distributed through the resin material ( 302 ). Each first particle ( 306, 306 ′) is of a preselected shape and of a size ranging from about 5 microns to about 10 microns, and each second particle ( 308, 308 ′) is of a preselected shape and of a size ranging from about 40 microns to about 50 microns.
1 . A surfacer coat, comprising:
a resin material;
a plurality of first particles, each first particle having a preselected shape and a size ranging from about 5 microns to about 10 microns, the plurality of first particles uniformly distributed through the resin material; and
a plurality of second particles, each second particle having a preselected shape and a size ranging from about 40 microns to about 50 microns, the plurality of second particles uniformly distributed through the resin material.
2 . The surfacer coat of claim 1 , wherein a weight of the plurality of first particles is approximately 30 percent to 35 percent of a combined weight of the plurality of first particles and the plurality of second particles.
3 . The surfacer coat of claim 1 , wherein a weight of the plurality of second particles is approximately 65 percent to 70 percent of a combined weight of the plurality of first particles and the plurality of second particles.
4 . The surfacer coat of claim 1 , wherein at least about 20 percent of a volume of the surfacer coat results from a combined volume of the plurality of first particles and the plurality of second particles.
5 . The surfacer coat of claim 1 , wherein the first particles and the second particles further comprise a urethane material.
6 . The surfacer coat of claim 1 , wherein the first particles and the second particles are non-shrinking.
7 . The surfacer coat of claim 1 , wherein the resin material is a thermoset material.
8 . The surfacer coat of claim 1 , wherein the resin material further comprises a polycarbonate polyol urethane isocyanate resin.
9 . The surfacer coat of claim 1 , wherein the first particles and the second particles have a substantially spherical shape.
10 . The surfacer coat of claim 1 , wherein the first particles and the second particles have a substantially elliptical shape.
11 . The surfacer coat of claim 1 , wherein the first particles and the second particles have an irregular shape.
12 . A structure, comprising:
at least one layer of composite material;
at least one layer of primer disposed on an outer surface of the composite material, the primer including a first resin material; and
at least one layer of surfacer coat disposed on an outer surface of the primer, the surfacer coat having a thickness of about at least 50 microns, the surfacer coat including:
a second resin material;
a plurality of first particles, each first particle having a preselected shape and a size ranging from about 5 microns to about 10 microns; and
a plurality of second particles, each second particle having a preselected shape and a size ranging from about 40 microns to about 50 microns, the first particles and the second particles uniformly distributed through the second resin material.
13 . The structure of claim 12 , wherein the first resin material is the same as the second resin material.
14 . The structure of claim 12 , wherein the first resin material and the second resin material are thermoset materials.
15 . The structure of claim 12 , wherein the first resin material and the second resin material further comprise a polycarbonate polyol urethane isocyanate resin.
16 . The structure of claim 12 , further comprising a topcoat disposed on an outer surface of the surfacer coat.
17 . The structure of claim 12 , wherein the thickness of the surfacer coat ranges from about 50 microns to about 178 microns.
18 . The structure of claim 12 , wherein the surfacer coat further comprises a layer of colors tinted surfacer coat and a layer of un-tinted surfacer coat.
19 . The structure of claim 12 , wherein the first particles and the second particles further comprise a urethane material.
20 . The structure of claim 12 , wherein a weight of the plurality of first particles is about equal to 30 percent to 35 percent of a combined weight of the plurality of first particles and the plurality of second particles.
21 . The structure of claim 12 , wherein a weight of the plurality of second particles is about equal to 65 percent to 70 percent of a combined weight of the plurality of first particles and the plurality of second particles.
22 . The structure of claim 12 , wherein at least about 20 percent of a volume of the surfacer coat results from a combined volume of the plurality of first particles and the plurality of second particles.
23 . The structure of claim 12 , wherein the structure is an aircraft element.
24 . The structure of claim 12 , wherein the structure is a boat element.
25 . The surfacer coat of claim 12 , wherein the first particles and the second particles have a substantially spherical shape.
26 . The surfacer coat of claim 12 , wherein the first particles and the second particles have a substantially elliptical shape.
27 . The surfacer coat of claim 12 , wherein the first particles and the second particles have an irregular shape.
28 . A method of preparing an outer surface of a composite structure for receipt of a topcoat, comprising:
disposing at least one layer of primer on the outer surface of the composite structure, the primer having a first resin material;
disposing at least one layer of surfacer coat on an outer surface of the primer, the surfacer coat including a second resin material, a plurality of first particles having a preselected shape, and a plurality of second particles having a preselected shape, the first particles and the second particles uniformly distributed through the second resin material; and
curing the surfacer coat.
29 . The method of claim 25 , wherein curing is selected from the group consisting of: drying, ultraviolet radiation exposure, heating, exposure to high pressure, and combinations thereof.
30 . The method of claim 25 , wherein the first resin material is the same as the second resin material.
31 . The method of claim 25 , wherein the first resin material and the second resin material are thermoset materials.
32 . The method of claim 25 , wherein the first particles and the second particles further comprise a urethane material.
33 . The method of claim 25 , wherein the composite structure is a preexisting composite structure.
34 . The method of claim 28 , wherein the first particles and the second particles may be redistributed within the second resin material by mechanical shaking the surfacer coat.
35 . The method of claim 28 , wherein a uniform distribution of the first particles and the second particles in the second resin material maybe maintained by mechanically stirring the surfacer coat.