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Process for manufacturing resin-based composite material

a technology of resin-based composite materials and manufacturing processes, which is applied in the direction of chemistry apparatus and processes, domestic applications, paper/cardboard layered products, etc., can solve the problems of difficult capture of gel coating fumes and dangerous operation

Inactive Publication Date: 2005-06-16
NOBLE COMPOSITES
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

This solution reduces VOC emissions, improves safety by eliminating hazardous mold handling, and enables the production of fiberglass-reinforced sheets of any length without scrap, enhancing efficiency and safety in the manufacturing process.

Problems solved by technology

While this provides for an excellent layer of gel coating on the mold, due to the movement of the sprayer, capturing the fumes of the gel coating can be difficult.
Furthermore, as maintenance of the molds is required, the molds are moved into and out of their various positions by way of an overhead crane, which due to the size of the elongate mold, can be a dangerous operation.

Method used

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  • Process for manufacturing resin-based composite material
  • Process for manufacturing resin-based composite material
  • Process for manufacturing resin-based composite material

Examples

Experimental program
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Embodiment Construction

[0024] With reference now to FIG. 1A, a continuous molding apparatus is shown generally at 2, which includes a MYLAR sheet or film feed station 4, (MYLAR is a registered trademark of E.I. Du Pont de Nemours) which feeds MYLAR sheet onto a support track mechanism 6, which is fixed and guided by a sub-frame member 8. A spray apparatus 10 spans the width of the support track mechanism 6 and includes a spray head 12 as will be described herein. Downstream of the spray apparatus 10 is an oven 14 which is enclosed and extends for some length as depicted in FIGS. 1B and 1C. Downstream of the oven 14 is a first resin-dispensing station 16, which applies a first spray of resin through spray head 18 and a first coating of chopped fiberglass through fiberglass applicator station 20. Downstream of applicator 16 is an automatic roller mechanism 22, which will be described in greater detail herein. As shown in FIG. 1D, a second resin-dispensing station 24 is positioned downstream of the first res...

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Abstract

An apparatus for manufacturing fiberglass-reinforced sheet is shown as including a feed mechanism feeding a sheet, whereby the sheet forms the upper mold surface for the fiberglass-reinforced sheets. The fed sheet moves longitudinally through a gel coating sprayer, and through applicators to apply resin in fiberglass. An automatic roller mechanism rolls the fiberglass strands into the resin and an automatic pressure mechanism applies pressure to wooden sheets placed on top of the fiberglass strands to form continuously fed completed sheet.

Description

TECHNICAL FIELD [0001] The subject application relates to a method and apparatus for the manufacture of fiber-reinforced panels. BACKGROUND OF THE INVENTION [0002] It is commonplace in the recreational vehicle business to use glass fiber-reinforced wall panels for the exterior surface of the recreational vehicle. These wall panels vary in widths up to, and including, dimensions from 2.4 to 3 meters (8 to 10 feet), and can have a length as long as 12 meters (40 ft.) or more. While the composite material from which the panels are made provides an adequate material for the recreational vehicle side walls, the presently utilized equipment for manufacturing the composite material invariably may emit VOCs, both within the facility, as well as that which may be exhausted to atmosphere. [0003] The process of making the composite material first begins with use of an elongate mold. The mold is somewhat larger than the panels to be made, but large enough to accommodate the 3×12 meter (10×40 ft...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): B32B37/22
CPCB32B37/10B32B37/22B32B2037/243B32B2305/08Y10T156/12B32B2607/00B32B2317/16Y10T156/1722B32B2305/22
Inventor MILLER, LESTER D.
Owner NOBLE COMPOSITES