Composite materials and method of making
A method for forming improved composite materials using a thermosetting polyester urethane hybrid resin, a closed cavity mold having an internal heat transfer mechanism used in this method, and the composite materials formed by this method having a hybrid of a carbon fiber layer and a fiberglass layer.
1. A method of making a composite material comprising the steps of:
providing at least one carbon fiber layer,
providing at least one fiberglass layer,
providing at least one polymeric flow media,
placing said layers in a closed cavity mold,
permeating said layers with a thermosetting polyester urethane hybrid resin comprising:
a polyester resin at a temperature of between 35° C. and 40° C.,
an isocyanate resin at a temperature of between 35° C. and 40° C.,
a peroxide catalyst
a promoter,
and a filler,
and curing said thermosetting polyester urethane hybrid resin at a temperature between 35° C. and 60° C. wherein the closed cavity mold controls the maximum variation in temperature within the composite material during cure to within 5° C.
2. The method of claim 1 wherein said thermosetting polyester urethane hybrid resin is injected into said polymeric flow media from three separate feeds.
3. The method of claim 2 wherein said three separate feeds comprise a first feed of a mixture of the polyester resin, a promoter, a filler, a second feed of the isocyanate resin, and a third feed of the peroxide catalyst.
4. The method of claim 3 wherein the mixture of the polyester resin, promoter, and filler is mixed in a static mixer tube prior to injection.
5. The method of claim 1 wherein said promoter is provided as a cobalt promoter.
6. The method of claim 1 wherein said filler is provided as a calcium carbonate filler.
7. A method of making a composite material comprising the steps of:
providing a preforming mold,
within said preforming mold, providing a first carbon fiber layer and a second carbon fiber layer
providing a first fiberglass layer and a second fiberglass layer juxtaposed between the first carbon fiber layer and the second carbon fiber layer,
providing a polymeric flow media juxtaposed between the first fiberglass layer and the second fiberglass layer,
holding said layers together with a polymeric binder,
removing said layers from said preforming mold and placing said layers in a closed cavity mold,
permeating said layers with a thermosetting polyester urethane hybrid resin comprising:
a polyester resin
an isocyanate resin
a peroxide catalyst
a promoter,
and a filler,
and curing said thermosetting polyester urethane hybrid resin at a temperature between 35° C. and 60° C. wherein the closed cavity mold controls the maximum variation in temperature within the composite material during cure to within 5° C.
8. The method of claim 7 wherein said a polyester resin and said isocyanate resin are at a temperature of between 35° C. and 40° C. prior to permeating said layers.
9. The method of claim 7 wherein said thermosetting polyester urethane hybrid resin is injected into said polymeric flow media from three separate feeds.
10. The method of claim 9 wherein said three separate feeds comprise a first feed of a mixture of the polyester resin, promoter, and filler, a second feed of the isocyanate resin, and a third feed of the peroxide catalyst.
11. The method of claim 10 wherein the mixture of the polyester resin, promoter, and filler is mixed in a static mixer tube prior to injection.
12. The method of claim 7 wherein said promoter is provided as a cobalt promoter.
13. The method of claim 7 wherein said filler is provided as a calcium carbonate filler.