Patent GB-888270-A (GB)
Title: A method of making synthetic resin/metal fibre articles
Filed: 1958-08-25
Abstract: Articles having a surface layer composed of a formed, smooth, hard, uniform material are produced by (i) forming on a pattern a layer of a thermosetting epoxy resin or an unsaturated polyester resin, (ii) homogenously interspersing throughout said resin unwoven fibres or ribbons of heat-conductive metallic material, and (iii) curing said resin to a thermoset condition, said fibres or ribbons having a length between 0,8 and 13 mm. and a cross-sectional perimeter between 0,04 and 2,1 mm. and being present in an amount between 5 and 70% of the total volume of the resin and fibre or ribbon.  A series of layers may be applied in this way; applied layers may or may not be cured before further layers are applied; and an applied layer may be compacted, e.g., with an impacting gun.  If the layers are not impacted, they may be porous and may be rendered more so by the prior inclusion of blowing agents such as NaHCO3 or p-hydroxy phenylazide. The preferred method of process (ii) is to use a flocking technique as illustrated in the examples.  Furthermore, the layers may be built up on a backing material, many being listed and the following being preferred: formed or foamable polyurethane, synthetic resin bonded glass fibre, a mixture of unwoven metal fibres and an epoxy resin, and wood.  The use of the following materials under heading (i) is discussed: Epoxy resins: glycidyl ethers of polyhydric phenols (e.g. bisphenol A in the examples) hardened by 2-hydroxyethyl diethylenetriamine, a eutectic mixture of m-phenylenediamine, bisaniline F and bisphenol A, resorcinol, bisphenol A, maleic or phthalic anhydrides, ethylenediamine, diethylenetriamine, polyols, polythiols, trimethylamine, triethylamine, NaOH, KOH or BF3. Polyesters: derived from ethylene or diethylene glycol and fumaric acid or maleic anhydride with or without adipic acid or phthalic anhydride, inhibited by tertiary butyl catechol or hydroquinone, and cross-linked with styrene or diallylphthalate in the presence of azo compounds, benzoyl peroxide, tert. butyl perbenzoate or methyl ethyl ketone peroxide.  The fibres or ribbons of (ii) may be of steel, Al Cu, Ag, Ni or brass, or of plastic or glass fibre coated with Ag, Al or Cu.  Optional fillers include stainless steel flake, Fe or Al oxides, Fe, Al and silica.  Uses: A wide variety of articles, especially dies, moulds, panels and checking fixtures, may be formed.ALSO:Articles having a surface layer composed of a formed, smooth, hard, uniform material are produced by (i) forming on a pattern a layer of a thermosetting epoxy resin or an unsaturated polyester resin, (ii) homogeneously interspersing throughout said resin unwoven fibres or ribbons of heat-conductive metallic material, and (iii) curing said resin to a thermoset condition, said fibres or ribbons having a length between 0,8 and 13 mm. and a cross-sectional perimeter between 0,04 and 2,1 mm. and being present in an amount between 5 and 70% of the total volume of the resin and fibre or ribbon.  A series of layers may be applied in this way; applied layers may or may not be cured before further layers are applied; and an applied layer may be compacted, e.g. with an impacting gun.  If the layers are not impacted, they may be porous and may be rendered more so by the prior inclusion of blowing agents such as NaHCO3 or p-hydroxy phenylazide.  The preferred method of process (ii) is to use a flocking technique as illustrated in the examples. Furthermore, the layers may be built up on a backing material, many being listed and the following being preferred:- foamed or foamable polyurethane, synthetic resin bonded glass fibres, a mixture of unwoven metal fibres and an epoxy resin, and wood.  The use of the following materials under heading (i) is discussed:-Epoxy resins: glycidyl ethers of polyhydricphenols (e.g. bisphenol A in the examples) hardened by 2-hydroxyethyl diethylenetriamine, a eutectic mixture of m-phenylenediamine, bisaniline F and bisphenol A, resorcinol, bisphenol A, maleic or phthalic anhydrides, ethylenediamine, diethylenetriamine, polyols, polythiols, trimethylamine, triethylamine, NaOH, KOH or BF3.  Polyesters: derived from ethylene or diethylene glycol and fumaric acid or maleic anhydride with or without adipic acid or phthalic anhydride, inhibited by tertiary butyl catechol or hydroquinone, and cross-linked with styrene or diallylphthalate in the presence of azo compounds, benzoyl peroxide, tert. butyl perbenzoate or methyl ethyl ketone peroxide.  The fibres or ribbons of (ii) may be of steel, Al, Cu, Ag, Ni or brass, or of plastic or glass fibre coated with Ag, Al or Cu.  Optional fillers include stainless steel flake, Fe or Al oxides, Fe, Al and silica.  Uses: A wide variety of articles, especially dies, moulds, panels and checking fixtures, may be formed.ALSO:Articles having a surface layer composed of a formed, smooth, hard, uniform material are produced by (i) forming on a pattern a layer of a thermosetting epoxy resin or an unsaturated polyester resin, (ii) homogeneously interspersing throughout said resin unwoven fibres or ribbons of heat-conductive metallic material, and (iii) curing said resin to a thermoset condition, said fibres or ribbons having a length between 0,8 and 13 mm. and a cross-sectional perimeter between 0,04 and 2,1 mm. and being present in an amount between 5 and 70% of the total volume of the resin and fibre or ribbon.  A series of layers may be applied in this way; applied layers may or may not be cured before further layers are applied; and an applied layer may be compacted, e.g., with an impacting gun.  If the layers are not impacted, they may be porous and may be rendered more so by the prior inclusion of blowing agents such as NaHCO3 or p-hydroxy phenylazide.  The preferred method of process (ii) is to use a flocking technique as illustrated in the examples. Furthermore, the layers may be built up on a backing material, many being listed and the following being preferred:- foamed or foamable polyurethane, synthetic resin bonded glass fibres, a mixture of unwoven metal fibres and an epoxy resin, and wood.  The use of the following materials under heading (i) is discussed:-  Epoxy resins: glycidyl ethers of polyhydricphenols (e.g. bisphenol A in the examples) hardened by 2-hydroxyethyl diethylenetriamine a eutectic mixture of m-phenylenediamine, bisaniline F and bisphenol A, resorcinol, bisphenol A, maleic or phthalic anyhdrides, ethylenediamine, diethylenetriamine, polyols, polythiols, trimthylamine, triethylamine, NaOH, KOH or BF3.  Polyesters: derived from ethylene or diethylene glycol and fumaric acid or maleic anhydride with or without adipic acid or phthalic anhydride, inhibited by tertiary butyl catechol or hydroquinone, and cross-linked with styrene or diallylphthalate in the presence of azo compounds, benzoyl peroxide, tert. butyl perbenzoate or methyl ethyl ketone peroxide.  The fibres or ribbons of (ii) may be of steel, Al, Cu, Ag. Ni or brass, or of plastic or glass fibre coated with Ag, Al or Cu.  Optional fillers include stainless steel flake, Fe or Al oxides, Fe, Al and silica.  Uses: A wide variety of articles, especially dies, moulds, panels and checking fixtures, may be formed.