Canadian Patents Database / Patent 2477564 Summary

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(12) Patent: (11) CA 2477564
(54) English Title: PROCESS TO MANUFACTURE GREENER THERMOSETTING COMPOSITES OF PRE-SHAPED STRUCTURE
(54) French Title: PROCEDE POUR FABRIQUER DES COMPOSITES THERMODURCISSABLES PLUS ECOLOGIQUES A STRUCTURE PREFORMEE
(51) International Patent Classification (IPC):
  • B29C 70/48 (2006.01)
(72) Inventors (Country):
  • SAIN, MOHINI M. (Canada)
(73) Owners (Country):
  • SAIN, MOHINI M. (Canada)
(71) Applicants (Country):
  • SAIN, MOHINI M. (Canada)
(74) Agent: NA
(45) Issued: 2014-03-18
(22) Filed Date: 2004-08-23
(41) Open to Public Inspection: 2006-02-23
Examination requested: 2009-08-11
(30) Availability of licence: N/A
(30) Language of filing: English

English Abstract



A process to prepare structural composites for automotive, aerospace,
furniture and sports
goods applications whereby composites are manufactured by a modified resin
transfer
molding process with resins in liquid form either modified or unmodified were
injected
under pressure into a cavity of a pre-shaped design containing fibres in
nonwoven, loose
or mat form whereby fibres obtained mainly from natural origin but in few
cases they are
combined with synthetic fibres to a lesser extent are layered in the pre-
shaped mold in
single or multiple layers whereby the fibres. The molded products exhibit
excellent
mechanical strength and durability suitable for applications in automotive
exterior,
interior parts, aerospace parts, furniture and sports goods applications.


French Abstract

Un procédé pour préparer des composites structuraux pour des applications pour les automobiles, les aéronefs, le mobilier et les articles de sport où les composites sont fabriqués par un procédé de moulage de transfert de résine modifiée où les résines sous forme liquide, modifiées ou non modifiées, ont été injectées sous pression dans une cavité d'un modèle préformé contenant des fibres sous forme non tissée, libre ou tissée, où les fibres ont été obtenues principalement d'origine naturelle, mais peuvent aussi être combinées à des fibres synthétiques dans une moindre mesure puis mises en couche dans le moule préformé en couche simple ou multiple. Les produits moulés présentent une excellente résistance mécanique et une durabilité convenant pour des applications de pièces extérieures et intérieures d'automobile, de pièces d'aéronef et d'articles de sport.


Note: Claims are shown in the official language in which they were submitted.


CLAIMS
Claim 1: A
process to prepare structural composites for automotive, aerospace,
furniture and sports goods applications whereby composites are manufactured by

modified resin transfer molding process, whereby fibres of natural origin are
placed in
layers inside the cavity of the mold (30), wherein the moisture of fibres
first being
removed (70) by applying vacuum (40) followed by impregnating resin in liquid
form
(10) of adequate viscosity, allowing to heat the resin impregnated fibre to
solidify the
resin inside the mold to obtain product parts of required shape, size,
performance and
durability requirement.
Claim 2. A process in claim 1, wherein the drying of fibre mats are done under

controlled vacuum conditions aided by heating of the mold with hot water above
40 C.
Claim 3. A process as cited in claim 1, where in the resin system is a
thermosetting
material may comprise of Silane Modified Polyester resin, Epoxy vinyl ester
resin,
Silane modified epoxy ester resin, Acrylic resin, silane modified acrylic
resin, Soy resin,
silane modified soy resin and contains not less than 30 % by weight of the
resin
composition.
Claim 4. A process as cited in claim 1, wherein the said moldable composition
comprises
cellulosic fibres selected from pulp fibres, bast fibres, leaf fibres, and
agricultural waste
fibres such as corn, wheat and rice straw and comprises not more than 70
percentage by
weight of the said composition.
Claim 5. A process as cited in any one of claims 1,3, and 4 where in wood pulp
fibres
selected from thermomechanical pulp (TMP), kraft pulp and bleached kraft pulp
(BKP)
from hard wood or soft wood or a combination of the same.
2


Claim 6. A process as cited in any one of claims 1,4 and 5, where in the bast
fibres can
be selected from hemp, flax, jute and kenaf and / or a combination of the
same.
Claim 7. A process as cited in claim 1, where in the synthetic fibres comprise
of any
chemical artificial fibres such as polypropylene, carbon, kevlar, boron, and
glass fibres.
Claim 8. A composite product made from the process of claim 7, wherein the
inorganic
fibres can be selected from any chemical artificial fibres such as
polypropylene, carbon,
kevlar, boron, and glass fibres.
Claim 9. A composite product made from the process of any one of claims 4 to
6,
wherein the organic fibres are treated with an enzyme or chemicals.
Claim 10. A composite product made from the process of any one of claims 4 to
6,
wherein the organic fibres are treated or untreated were used in loose form or
mat form,
more specifically loose form were used in the core and mat form were used on
the surface
of the layered structure.
Claim 11. A composite product made from the process of any one of claims 4 to
7, where
in the chemicals used for treatment are from any of the following functional
chemicals
such as silanes, imides, maleimides, alkanes, alkene dimers, rosin acid and
esters, alkyl
imines.
Claim 12. A composite product made from the process of any one of claims 4 to
8, where
in the chemicals used for treatment are Microthene Powder, Polyvinyl acetate,
Polyethyleneimine, Styrene Maleic Anhydride, Styrene Maleic Imide, Alkyl
ketene
Dimer, Rosin Acid, Trimethoxy (3,3,3-trifluoropropyl) silane, (3-Glycidyloxy
propyl)
trimethoxy silane, Dimethyl (pentafluorophenyl) styryl silane, Chloro-dimethyl
(3,3,3-
trifluoropropyl) silane
3


Claim 13. A composite product made from the process of any one of claims 4 to
7, where
in the enzymes used are from any of the following category: such as endo-
glucanase,
hemicellulase.
Claim 14. A composite product made from the process of any one of claims 7-13,
where
in the said liquid resin material has been modified with silane chemicals to
enhance
mechanical properties of the resin in the presence of fibre.
Claim 15. A composite product made from the process of any one of claims 7-13,
where
in the said resin transfer molded composite materials have flexural strength
and modulus
140-250% and 300- 700% greater than that of the said resin materials and have
flexural
modulus exceeding 10GPa.
Claim 16. A composite product made from the process of any one of claims 7-14,
where
in the said composites have impact strength improved by more than 70% by using
loose
fibre in the layered design.
Claim 17. A composite product made from the process of any one of claims 1-16
can be
used for structural applications in the automotive, sports goods, furniture
and aerospace
industry.
4


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Admin Status

Title Date
(22) Filed 2004-08-23
(41) Open to Public Inspection 2006-02-23
Examination Requested 2009-08-11
Correction of Dead Application 2013-02-06
(45) Issued 2014-03-18

Maintenance Fee

Description Date Amount
Last Payment 2017-08-15 $125.00
Next Payment if small entity fee 2018-08-23 $125.00
Next Payment if standard fee 2018-08-23 $250.00

Note : If the full payment has not been received on or before the date indicated, a further fee may be required which may be one of the following

  • the reinstatement fee set out in Item 7 of Schedule II of the Patent Rules;
  • the late payment fee set out in Item 22.1 of Schedule II of the Patent Rules; or
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Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Filing $200.00 2004-08-23
Maintenance Fee - Application - New Act 2 2006-08-23 $50.00 2006-06-20
Reinstatement: Failure to Pay Application Maintenance Fees $200.00 2007-10-29
Maintenance Fee - Application - New Act 3 2007-08-23 $50.00 2007-10-29
Maintenance Fee - Application - New Act 4 2008-08-25 $50.00 2008-06-06
Maintenance Fee - Application - New Act 5 2009-08-24 $100.00 2009-08-03
Request for Examination $400.00 2009-08-11
Maintenance Fee - Application - New Act 6 2010-08-23 $100.00 2010-06-22
Maintenance Fee - Application - New Act 7 2011-08-23 $100.00 2011-06-30
Maintenance Fee - Application - New Act 8 2012-08-23 $100.00 2012-06-29
Maintenance Fee - Application - New Act 9 2013-08-23 $100.00 2013-06-17
Final $150.00 2013-12-20
Maintenance Fee - Patent - New Act 10 2014-08-25 $125.00 2014-06-09
Maintenance Fee - Patent - New Act 11 2015-08-24 $325.00 2016-08-09
Maintenance Fee - Patent - New Act 12 2016-08-23 $125.00 2016-08-09
Maintenance Fee - Patent - New Act 13 2017-08-23 $125.00 2017-08-15

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Document
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Cover Page 2006-02-03 1 30
Claims 2004-11-16 3 113
Abstract 2004-11-16 1 22
Description 2004-08-23 15 697
Drawings 2004-08-23 4 1,132
Drawings 2011-09-12 3 82
Description 2011-09-12 12 524
Claims 2011-09-12 3 104
Abstract 2011-09-12 1 24
Abstract 2013-08-15 1 25
Claims 2013-08-15 3 104
Description 2013-08-15 10 466
Drawings 2013-08-15 3 93
Cover Page 2014-02-11 1 32
Fees 2011-06-30 1 65
Correspondence 2004-11-16 4 155
Correspondence 2004-09-24 1 27
Fees 2006-06-20 3 150
Fees 2007-10-29 2 133
Fees 2008-06-06 1 63
Prosecution-Amendment 2009-06-18 1 65
Fees 2009-06-18 1 64
Prosecution-Amendment 2009-08-11 1 21
Fees 2010-06-22 1 60
Prosecution-Amendment 2011-09-12 22 848
Prosecution-Amendment 2011-03-07 4 140
Fees 2012-06-29 1 71
Prosecution-Amendment 2013-03-04 2 75
Fees 2013-06-17 1 68
Prosecution-Amendment 2013-08-15 19 746
Correspondence 2013-12-20 2 120
Fees 2014-06-09 1 69
Correspondence 2015-06-12 1 29
Fees 2015-09-04 1 68
Correspondence 2015-10-19 2 57
Correspondence 2015-10-27 1 37
Fees 2016-08-09 1 68
Fees 2016-08-09 1 54
Fees 2017-08-15 2 211