Patent Application
20220111566
The present invention relates generally to a field of chemistry: natural resins or derivatives. More specifically, the present invention is a method for achieving a one component growable resin system.
Short molecular chain resins generally have certain advantages over long molecular chain resins. For example, lower viscosity, better wetting ability of substrate in case of adhesive applications and other processing advantages. However, the short molecular chain resins also generally have some disadvantages. For example, poorer mechanical properties, less heat resistance, etc.
To overcome such disadvantages, the concept of growing the resin after it has been formed into a shape of the final product is sometimes applied.
In growable resins, the issue of how to prevent resin growth before it is formed into the shape of the final product is a key factor to its practicality(i.e., excessive premature resin growth, e.g., during storage, would render the resin unusable for its original intended purpose). For example, viscosity would be too high or molecular chain would be too long to achieve sufficient adhesion or conforming to the desired shape in a mold.
Therefore, there is a need for improved materials and processes to achieve a one component growable resin system that may overcome one or more of the above-mentioned problems and/or limitations.
This summary is provided to introduce a selection of concepts in a simplified form, that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter. Nor is this summary intended to be used to limit the claimed subject matter's scope.
According to some embodiments, one component growable resin system is disclosed. Accordingly, one component means that no significant mixing of components is required prior to use. In an instance, it may mean that a system may be already pre-mixed under normal storage conditions. In another instance, it may mean 2 components that are brought in contact with each other immediately prior to use or during use but no significant mixing of the 2 components is required. Further, materials and processes to achieve the one component growable resin system may include a growable resin that may be stable under normal storage conditions. Further, the growable resin may grow when exposed to special growth initiation conditions. Further, the special growth initiation condition may be a presence of growth initiators. Further, the growth initiators need not be homogeneously dispersed throughout the resin (i.e., once growth starts in one area in the resin, the growth may propagate to a significant distance away from starting point). Further, in some embodiment, the growth initiator may be already in an active form but brought into contact with the growable resin only after the growable resin may become solid. Further, in another embodiment, the growth initiator may be brought into contact with the growable resin while the growth initiator may be in an inactive form. Further, the growth initiator may be transformed into the active form when the resin may be desired to commence growing. Further, the active form may usually be achieved by exposing the growth initiator to special growth initiation conditions.
Both the foregoing summary and the following detailed description provide examples and are explanatory only. Accordingly, the foregoing summary and the following detailed description should not be considered to be restrictive. Further, features or variations may be provided in addition to those set forth herein. For example, embodiments may be directed to various feature combinations and sub-combinations described in the detailed description.
All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.
The present invention is a system and method for achieving a one component growable resin system. In further detail, the present invention is a process for resin growth where all substances are pre-mixed under normal storage conditions instead of requiring mixing during application or requiring pre-mixing before application. In reference to
The method of the present invention follows an overall process which achieves resin growth using a one component system. With reference to
Alternatively, Step B or C can be optional based on the situation. For example, if the quantity of initiator is in inactive form, the usable initiator portion 2 can be already premixed. The quantity of initiator can also be in active form from the beginning and brought into contact with usable resin portion 1 only just before reaction. In more detail, the usable initiator portion 2 can be premixed into a carrier film and coated onto growable resin tows. Thus, coated resin tows can be placed in a mold, and the heat and pressure in the mold causes the particles of the usable initiator portion 2 to come into closer contact with the usable resin portion 1 and start resin growth. No significant resin growth occurs before that, even if the quantity of initiator is already active, because contact of the usable initiator portion 2 with the usable resin portion 1 is minimal. In more detail, solid powder particles of the usable initiator portion 2 can be lightly touching the bulk surface of the usable resin portion 1.
The present invention can be used for molding applications. For molding applications and with reference to
Alternatively, the usable resin portion 1 can be coated with the usable initiator portion 2 rather than coating the mold assembly 3 with the usable initiator portion 2. In this case, the usable initiator portion 2 comes into contact with the usable resin portion 1 after resin processing and before the usable resin portion 1 is positioned within the mold assembly 3.
In another embodiment, the usable initiator portion 2 contacts the usable resin portion 1 during resin processing. In further detail, the quantity of growth initiator is processed into the quantity of growable resin. In this case, the quantity of growable resin and the quantity of growth initiator must be heat stable in order for the quantity of growable resin to be stable enough to withstand the processing conditions. Thus, the usable initiator portion 2 in this embodiment is integrated into the usable resin portion 1 and can be readily activated after positioning the usable resin portion 1.
In another embodiment of the present invention and with reference to
As mentioned previously, the usable resin portion 1 is activated through various methods. Step C may be executed by applying heat to the usable initiator portion 2. In this case, the usable initiator portion 2 can be, but is not limited to, K-PURE CXC-1612 or NaCure XP-357 heat-activated latent acids. The heat is enough to cause the usable initiator portion 2 to activate and not too high allowing the usable resin portion 1 to remain stable.
Alternatively, Step C may be executed by applying electromagnetic energy to the usable initiator portion 2. Electromagnetic energy can be applied via ultraviolet light or electron beam. In this case, the usable initiator portion 2 is preferably a cationic UV initiator. This would best be applied to the case where the quantity of growth initiator is processed into the quantity of growth initiator.
In another embodiment and with reference to
In another embodiment, a sheet molding compound can be prepared using multiple layers of the usable resin portion 1 in sheet form. Sheet mold methods generally use resin and chopped fiber sheets cut to a size smaller than the mold. The precut sheets are built into a charge that contains enough material to fill the mold. The mold closure compresses the compound forcing it to fill the cavity. Heat from the mold would create the special condition to initiate growth. The preforms in both cases could have reinforcements such as carbon fiber or glass fiber to further increase the mechanical properties. The preforms could also be made from a composite towpreg 4.
One potential advantage of such resins compared to growable resins like polyamide-imide (PAI) is that the growth reaction does not occur for such resins until the resin enters the mold, whereas PAI resins already start their growth reaction in the extruder used to inject it into the mold, thereby limiting the amount of time the resin can stay in the extruder without significantly impacting molding conditions. Furthermore, because the growth reaction for such resins commence at and occur very quickly (sometimes even already finished by the time the product is removed from the mold), the tendency for product dimensional distortion during the secondary growth process after it is removed from the mold is minimized versus in case of PAI resins.
Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.
The current application is a continuation-in-part (CIP) application of the Patent Cooperation Treaty (PCT) application PCT/IB2020/055758 filed on Jun. 18, 2020. The PCT application PCT/IB2020/055758 claims a priority to a U.S. Provisional Patent application Ser. No. 62/863,071 filed on Jun. 18, 2019.
| Number | Date | Country | |
|---|---|---|---|
| 62863071 | Jun 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/IB2020/055758 | Jun 2020 | US |
| Child | 17556217 | US |
