Note: Descriptions are shown in the official language in which they were submitted.
A
-- 1 -- LFM--7336 & 7341
.
LAMINATED COMPOSITES
The present invention relates to laminated
composites and more particularly to laminated composites
which are useful as partitions, walls, decorative
surfaces, and the like.
Hack no of t he Invention
The construction of laminated sheet materials
has received extensive study by industry. In paretic-
ular, materials have bee sought which are light in
weight have good appearance, are rugged and durable
and are fireproof or fire-resistant. The latter I-
attributes in particular, have received special
attention. Interior surfaces in buildings, aircraft,
automobiles, and the like, are often made of organic
materials When such materials are exposed to heat or
fire, toxic fumes are given off and, in many instances,
these fumes lead to asphyxiation or result in severe
lung damage to those persons who are exposed to the
fumes Accordingly, industry has spent a substantial
amount of time and effort in attempting to develop
products which will have all of the aforementioned
attributes, yet which will give off no toxic fumes when
subjected to f ire.
The Prior Art
A number of references are found in the prior
art which deal with ways in which fire-resistant
products can be produced. For example, Us So Patent No.
go 3,~i3~,
- 2 - LO 7336 & 73-~1
2,744,589 discloses wall panel units which comprise an
insulated panel whereby the core is doubly insulated.
The insulating materials are indicated to be rock-wool
materials and gypsum sheet. Similarly, US S. Patent No.
3,466,222 discloses a combination of materials which by
themselves would be unsuitable for use as fire retardants;
however, in combination, they are capable of forming
laminated materials which are stated to be fire-resistant.
Recently, U. So Patent No. 4l375,516 disclosed
rigid, water-resistant phosphate ceramic materials and
processes for preparing them. Both foamed and unframed
materials can be produced according to procedures set
forth in this patent, and the products which have been
produced are remarkably suitable for use as wall boards,
ceiling boards, and the like. Further, these products
are fire-resistant because they can be produced as
totally or primarily inorganic compositions.
Nevertheless, the products produced as indicated in the
reference are not entirely satisfactory for all uses
because they are rigid in nature. That is, rather than
bending under stress, the boards tend to break.
Accordingly, one objective of the present
invention is to provide inorganic boards which can be
flexible in nature, ye which are strong and durable.
I Another objective of the present invention is
to provide fire-resistant boards which are in tumescent
when subjected to heat or fire, and which produce little
or no smoke and fumes.
Another objective of the present invention is
to provide inorganic laminates which are flexible even
though they are constructed using materials that are
disclosed in the art as being suitable Jo provide rigid
products.
These and other advantages of the present
invention will become apparent from the detailed
description of preferred embodiments which follow.
Summary of the Invention
The present invention relates to laminated
~22~
- 3 LF~I-7336 & 7341
materials which are constructed using layers of
reinforcing and/or non-reinforcing materials in
combination with layers of a composition which is known
in the art to provide water-resistant phosphate ceramic
materials. In a preferred embodiment, the products are
fire-resistant and in tumescent when exposed to heat or
direct flame, and they produce little or no smoke.
Nevertheless, these products are Tao durable and
suitable to provide a decorative and pleasing
lo appearance.
Detailed Description of the Preferred Embodiment
In one embodiment, the present invention
relates to a bonded composite structure comprising at
least one layer of at least one type of layer material,
each said layer of layer material being bonded to
contiguous layers of layer material by a water-resistant
phosphate bonding material obtained from the reaction of
a composition comprising a metal oxide, calcium silicate
and phosphoric acid.
In a second embodiment, the present invention
relates to a fire-resistant bonded composite comprising
a plurality of layers of at least one type of layer
material, and a plurality of layer of a water-resistant
phosphate bonding material obtained from the reaction of
a composition comprising a metal oxide, calcium silicate
and phosphoric acid, each said layer of layer material
being bonded to contiguous layers of layer material by
said bonding material, said bonded composite being
capable of exhibiting in tumescent properties when
exposed to flame and/or heat.
In a third embodiment, the present invention
relates to a process for forming a bonded composite
structure, said process comprising the steps of preparing
a layered composition comprising at least one layer of a
phosphate bonding composition comprising a metal oxide,
calcium silicate and phosphoric acid said composition
being suitable to provide a water-resistant phosphate
bonding material, and at least one layer of at least
I
- Lo 7336 h 73~1
one type of layer material, said composite being
arranged such that contiguous layers of said layer
material are in contact with intervening layers of said
bonding composition, and curing said layered compost-
lion, optionally by subjecting it to heat and/orpress~reO
The unique characteristics of the products
which may be produced according to the present invention
are attributable in significant part to the use of a
phosphate bonding composition which is suitable to
provide a water-resistant phosphate ceramic material.
Such materials are presently taught in the art to be
suitable to provide rigid foamed and unframed phosphate
ceramic products. Surprisingly, however, it has been
discovered that when such compositions are applied as
relatively thin bonding layers, they are useful to
provide laminated structures which are highly flexible.
Examples of compositions which are suitable to achieve
this result include those disclosed in Us So Patent No.
4,375,516. That patent disclosed that compositions
comprising calcium silicate, phosphoric acid and a metal
oxide selected from the group consisting of aluminum
oxide, magnesium oxide calcium oxide and zinc oxide, and
the hydrates thereof, could be reacted to provide water-
resistant phosphate materials, however, it has now been discovered that other metal oxides can also provide
water-resis~ant phosphate materials. Accordingly, the
present invention contemplates all compositions
comprising a metal oxide, calcium silicate and
phosphoric acid, provided that these compositions react
to provide a water-resistant material.
These compositions are coated, preferably in
relatively thin layers on the order of c_ 1-20 miss
thick, onto the surface of a layer material which may be
a reinforcing or a non-reinforcing material. The
compositions may be applied at normal consistency, or
they may be applied as mechanically frothed foams
Herr very thin coatings are desired or where lighter-
5 - Lo 7336 7341
weight laminates are desired, the latter technique is
preferred because the foam may be applied at a thickness
of cay 1 mill after which the thickness is reduced to a
thinner dimension as the foam collapses. As yet another
alternative, the bonding composition may be applied in a
discontinuous manner to portions of the layer materiel.
Accordingly, the term "layer" of bonding material is
intended to encompass applications in which this
material is deposited in a uniform and also a non-uniform
manner.
After applying the bonding composition, the
coated material may then be allowed to cure, or it may
be covered with a second layer of the same or a
different layer material and then allowed to cure.
Curing may be achieved under ambient conditions:
however, where more dens products are desired, curing
may be effecter under pressure. In addition, heat may
also be applied during curing to accelerate the curing
process.
A variety of materials may be used to provide
laminates as disclosed herein For example, raft
paper, paper towel, cheese cloth, woven and non-woven
class mats, woven and non-woven synthetic materials such
as polyester, nylon, and the like chopped fibers of
various materials, mineral wool, wire mesh and other
well-known materials may be used alone or in combination
as layer materials. In addition, non-reinforcing
materials such as Simmons materials and the like
may also be used although, in most instances, these will
I lead to products which are rigid in character.
Particularly effective reinforcing materials
for use in combination with the phosphate bonding
materials disclosed herein are materials which are
disclosed in cop ending Canadian application Serial No.
476,051, and also in U. S. Patent No. 4,239,519
and patents related thereto. These references,
when considered collectively, disclose a class of
I 6 - LF~1-7336 & 7341
material which is referred to herein as synthetic mica"
materials. In essence, they are non-asbestos papers or
sheets which are derived from silicate gels by cation
exchange reactions Materials of this type are known to
be relatively unaffected by high temperatures, yet they
tend to have good flexibility.
Laminated structures comprising layers of the
phosphate bonding materials and synthetic mica sheets
have shown remarkable characteristics. For example,
lo whey such composites were exposed to direct flame, they
have not only been shown to be fire-resistant and
relatively smoke-free, but they have also demonstrated
in tumescent properties. That is, the exposure of one
surface of the structure to direct flame has been
lo observed to cause an apparent internal delamination of
the structure, resulting in the production of air
spaces. Such air spaces haze been shown to be
insulative in nature, and dramatic heat differentials
have been noted between two sides of a structure tested
in this manner, For example, although one side of a
relatively thin structure on the order of 0~06 in. in
thickness was exposed to direct flame at a temperature
of about 2050F for l minute internal swelling occurred
and the temperature on the opposite side of the
structure was less than 600F.
This phenomenon is not restricted to laminates
constructed using synthetic mica materials. For
example, laminates comprising raft paper also exhibit
in tumescent properties, and large temperature different
trials have been noted for these laminates when tested as
described above The reason why delamination occurs is
not clearly understood, although it is believed to be
associated at least in part with water contained within
the structure.
In addition to in tumescent laminates, heat
conducting laminates can also be produced by including
wire screen as one of the Lowry. Laminates of this
type have been quite effective in conducting heat away
Jo I
Ye 7 - LF~7336 & 7341
.
from the point of application; thus, these materials can
be useful as heat-conducting gaskets, and the like.
The thickness of the laminates produced
according to the present invention can be highly
variable At the desire of the artisan, structure
thickness may be varied from very thin (e.g., 0.03 in
to very thick (e.g., 0.5 in. or more). Laminated
structures have been produced comprising as few as one
layer of one reinforcing material and one layer of
phosphate bonding material, or as many as 37 layers of
reinforcing layers and 36 layers of phosphate bonding
material. This illustration, however, is not intended
to limit the number of layers which could be included in
a laminate. Furthermore, therm is no necessity to
restrict the reinforcing materials used in making the
laminated structure to a single type, and combinations
of reinforcing materials may be used to advantage.
The advantages ox the present invention will
become more apparent by reference to the following
examples which are intended by way of illustration, and
no itationO
EXAMPLES
Example 1
A phosphate bonding material was prepared from
the following ingredients
Weight
Components (grams)
AYE 15.0
Moo 8.0
30 Talc 16.0
75% H3P04
~53~0% Pros) 105.0
H3BO3 4.0
Couch 100.0
35 HO 18.0
.
A phosphate bonding material was produced by preparing a
reaction solution comprising the phosphoric acid, the
LO
- 8 - LF~-7336 & isle
aluminum oxide, and the water After clear solution
was obtained, and while the solution was still hot, the
boric acid was added and the mixture was stirred until
it again became clear. The reaction solution was cooled
to 4~C. and a mixture of the dry components was added.
Each of five two-ply layers of Reich hold
Modiglass ~.5X-SM scrip measuring 3 in. x 12 in. was
rapidly provided with Molly draw downs of the above
formula. the five layers were immediately stacked and
pressed together for 25 second under 556 psi pressure in
a press heated to 250 F. The resulting sheet was
strong and water resistant, yet flexible.
The MOW of the laminate, measured essentially
according to ASTM D-1037, was 2,100 psi; the IRE value
was calculated to be 621 ski; and the NBS fire rating
was 0 for smoldering and 2 for flaming, measured
essentially according to ASTM E-662-79.
Example 2
The process as set forth in Example 1 was
repeated, except that the press was equipped on one face
with an embossing plate The resulting sample picked up
the very fine details of the embossing plate.
Example 3
A Emil draw down of a phosphate bonding
material having the formula set forth in Example 1 was
made onto each of ten separate sheets of raft paper
having dimensions of 12 in. x 12 in x 00012 in. The
ten sheets were immediately stacked together and pressed
for 1 minute under 560 psi pressure in a press heated at
200~ Fox The resulting sample was strong and flexible,
although it was not as flexible as the glass reinforced
structure set forth it Example 1. Its MOW value,
measured as described in Example 1, was 4~500 Sue
The bonded composite structure was cut into 4
in. x 4 in. pieces and two of the pieces were selected
at random for testing. Each piece was placed
horizontally on a ring stand and a thermocouple was
placed at a location on the bottom surface where the
I
- 9 - Lo 7336 7341
point of the blue propane flame was to be applied. A
second thermocouple was placed on the top surface of the
laminate directly above the first thermocouple. When
the flame was applied, the temperatures at both
5 thermocouples were recorded with time. Sample PA
increased in thickness from 0.085 in. to 0.199 in. when
heated for 7 minutes. At the end of that time period,
the thermocouple on the flame side of the face measured
a temperature of 1893~F whereas the temperature on the
top side was measured to be 622. 5F~ Sample 3B was
heated for 6 minutes and showed an increase in thickness
from 0.085 in. to 0.166 in., and temperature readings of
1844F and 713~F on the flame side and top side,
respectively, were recorded
Example 4
A phosphate bonding material as set forth in
Example 1 was prepared, except that it comprised 50% by
weight of colored No. 17 silica granules from Ottawa
Silica Company. This was achieved by mixing the
granules with the dry components and then preparing the
phosphate bonding material. The filled bonding material
was drawn down in a Molly layer onto one sheet of
Johns-Manville glass paper and, at the same time, Molly
draw downs were also prepared on three separate 3-ply
sheets of the Modiglass scrip described in Example 1.
The three Modiglass layers were stacked on top of one
another and the Johns-Manville lass paper was placed on
the top of the stack with the ~ranule-filled bonding
material facing up The stacked material was then
pressed under 556 psi pressure at ~20 Y. for two
minutes to give a flexible sheet with good scratch
resistance.
Example 5
The procedure as set forth in Example 4 was
repeated except what the press was equipped on one face
with an embossing plate. The resulting product
exhibited fine detail from the embossing plate.
-I - 10 - LF~I 7336 7341
Example 6
A phosphate bonding material was prepared
comprising the following components:
Weight
5 Components (grams)
.
AYE 18.0
Moo 8.0
Talc 16.0
75% H3PO4
(53.0% Pus 108.0
H3BO3 4
Couch 100,0
HO 18.0
The reaction solution was prepared by mixing the
phosphoric acid, the water, and the aluminum trihydrate
and stirring until a clear solution was obtained. The
boric acid was added to the resulting warm solution and
stirred After this solution had become clear, the
reaction solution was chilled to about 35 39 I.
To the 148 grams of cold liquid was added,
with vigorous stirring, the 124 grams of dry components
which had been mixed to provide a uniform material. The
resulting mixture was stirred until it had become
homogeneous, and it juicy then placed in an ice bath to
prolong the liquid consistency; it to delay the
interaction of the components. The pot life of this
material could be varied from about 30 seconds to about
7 minutes, depending on the capability of controlling
the exothermic reaction temperature in the ice bath.
A synthetic mica sheet was prepared from the
following components essentially as described in the
aforementioned cop ending application
Weight
Component (grams
35 Magnesium fl~lorhectorite 100.0
Bleached redwood cellulose
1/8" DE glass fibers 5.0
LF;1-7336 & 73~1
I
weight
Component (grams
Palomino P flocculating agent 0.075
Hydra id 777 flocculating agent 0.037
5 Water Jo
The bleached redwood cellulose was dispersed in water by
means of a hydropulper and was refined in a Jordan
Refiner until a consistency of 500 Canadian Freeness)
was obtained. The refined pulp was transferred to a
large, open-head tank and was slurries with the glass
fibers. After charging the required amount of water
into the tank to get a consistency of 1.3% solids, the
magnesium fluorhectorite floe was added and the mixture
was stirred until it was homogeneous. The Palomino P and
Hydra id 777 were then added and the composition was
immediately flowed onto the forming screen of a
Fourdrinier machine. After removing most of the water,
the mat was subjected to vacuum it a series of vacuum
presses. Residual water was then removed by passing the
synthetic mica mat over a heated drum.
A thin coating of the above phosphate bonding
material (It was brushed at an approximate thickness of
10 miss onto the surface of a synthetic mica sheet (S).
A piece of microlith glass sheet (G), designated S~20/1
from Glaswerk Sculler GmbH, was immediately placed in
the bonding material and saturated, and a second
synthetic mica sheet was placed on top of the glass
layer. The assembled materials were placed in a press
between glass surfaces and pressed under 250 psi
pressure for five minutes at 170 F. After pressing was
complete, the pressed composite was conditioned at 170F
for several additional minutes to remove water, giving a
product which was strong and flexible.
It is noted that, due to the porous nature of
the glass sheet the bonding Muriel did not have to be
applied on both sidles of the glass sheet. The bonding
material was capable of passing through (saturating) the
glass layer under pressure such that both continuous
92 - 12 - LF~-7336 & 7341
layers of synthetic mica could be bonded to the glass
through a single application of bonding material. In
this, and the following examples, the saturation is
indicated by (GO) or JIG). Accordingly, the structure
of this example had the luminary order SAGAS.
Example 7
A process similar to what of Example 6 was
repeated except that glass sheets constituted the
exterior layers and the composite material had the
structure (GI)S(IG). The glass sheets were bonded with
the phosphate bonding material to the single internal
layer of synthetic mica sheet by placing the composite
in a press that was equipped with shallowly patterned
embossing plates The plates provided a fine texture in5 a desired design to the surface of the laminate.
example 8
The procedure of Example 7 was repeated,
except that the composite material was placed between a
foamed silicone rubber pad and male or female metal
molds bearing a design. This resulted in the production
of molded products with deeply embossed images.
Example 9
A series of laminates was prepared essentially
as described in Example 6, each sample containing sun-
Thetis mica, phosphate bonding material, and, optionally glass sheet. As in Example I the phosphate binder sat-
rated the glass sheet such that, when included internally
in a laminated structure, the binder served to bond con-
togas layers of synthetic mica even though the binder
may have been applied to only one face of the glass sheet,
or to only one of toe contiguous synthetic mica sheets.
Modulus of rupture (MOW) values were
determined according to ASTM D-1037 whereas modulus of
elasticity MOE values were calculated by standard
mathematical means from the MOW values. The structures
of each laminate are indicated, top to bottom. Unless
otherwise indicated, the bonding material was applied in
Molly draw downy and SO ~0~1 glass sheet was used.
-- 13 -LF:!;-7336 E 73!~1
Sample Structure MOR(psi) ~OE(ksi)
PA SOUSES 1448 164
9BS¦IG~S(IG)S(IG3S 1568 175
9C*S(IG~S(IG)S(IG)S 1682 211
9D~GI)SIIG)S(IG)S~IG)S~IG~ 3449 576
*I applied as a Molly draw down
The results for these samples show a marked increase in
strength when the laminate is faced with the glass
sheet.
10 Sample Structure MOR~psi) Mecca)
9E(Gl)SISISIS(IG) 3214 58~
9F*~(GI)SISISIS(IG) 3906 568
9G(GI3SISIS(IG) 3247 610
9HtGI)SIS~IG) 3500 582
15 **ASH 50/1 glass sheet used in place of SO 20/1
glass sheet.
These results, when compared to the values obtained for
sample ED, suggest that the facing scrip sheets
contribute substantially more to the strength of the
laminate than do the internal glass sheets.
I ISIS 1713 323
9J S~IG~S(IG)S 2320 385
OK IS(IG)SIIG~SI 2355 471
These data are provided for comparison.
Example It
This example will illustrate the results when
various samples were heaved with a propane torch as
described in Example 3. The results are indicated below
for laminates having various components and structural
arrangements.
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- 14 - LF~:-7336 & 7341
Heating caused noticeable changes to the
laminates, and these changes became more pronounced as
the number of layers increased. For example, when heat
was applied to a single synthetic mica sheet, only a
small expansion of the sheet was seen. However, when
two or more synthetic mica and phosphate bonding layers
(with or without glass reinforcing) were utilized,
blistering became more pronounced. The effect with the
thicker samples, as shown below, was to provide good
insulative effects. The table indicates the increase in
thickness which was induced in each sample by the
heating.
Samples were constructed of layers of SO 20/1
glass sheet and/or synthetic mica bonded together with
phosphate bonding material substantially as described in
Example 9. The resulting laminates were unembossed.
They were designated as Samples lo through lo and the
"Structure" column lists the luminary sequence from top
to bottom.
_ Thickness Change (inch)
Sample Structure Initial Final Increase
lo S 0~027 0.038 0.011
lob IS 0.034 0.125 0.091
lOC(GI)S(IG) 0.037 0.130 0.093
25 lo ISIS 0.055 0.150 0.095
lOE(GI)S~GI)S(IG) 0.063 0.173 0.110
lOFISISISI 0~073 0.194 0.121
log (GI)S(GI)SIS(IG) 0.085 0.210 00125
lo (GI)S(~I)S(GI)S 0.084 0.250 0.166
Temperature differentials were as follows measured at
the indicated time intervals. Measurements were made by
subtracting the temperature at the top-side thermocouple
(To) from the flame-side thermocouple ifs) to obtain the
differential (D).
I% 9 - 15 - LF.~:-7336 h 7341
Temperatures OF as Indicated
Time Intervals (seconds
Sample Location 15 30 60 120 130
lo Us 2163 21802196 - -
To 1017 10901107
D 1146 10901089
lob Us 2195 22222239
To 855 10321024
D 1340 11901215
lo Us 2275 23292314 2291 2304
To 454 10641064 1074 1068
D 1821 12541254 1217 1236
.
lo Us 1862 19972016 2038 2059
To 183 344 794 866 869
D 1679 16531222 1172 1190
lye Us 1897 20422043 2072 2079
To 160 237 5S2 736 756
D 1737 18051491 1336 1323
lo Us 2060 21062162 2192 2175
To 179 199 365 714 726
D 1881 19071797 1478 1449
log Us 2182 22192216 2253 2262
To 169 182 281 658 687
D 2013 20371935 1595 1575
lo Us 2051 20292073 2149 2166
To 158 176 221 584 622
D 1893 18531852 1565 1504
~2~9~94 - 16 - LF~;-7336 h &341
These results illustrate that heating causes the lam-
notes to swell, thereby exhibiting in tumescent
properties.
Example 11
The procedure as set forth in Example 6 was
repeated using synthetic mica, Sculler 20/1 glass
scrims Burlington #1653 Lyon (16x8) glass scrip
(abbreviated By and/or galvanized iron wire window
screen (W) having 14 strands v. 17 strands per square
inch. The following samples were prepared:
Sample Structure
lea SKIS
lob IS
llC SAGAS
15llD (GI)S(IG)
lye SAABS
elf SWISS
The products were tested for tensile strength and also
for flexibility. Tensile strengths were determined
essentially according to ASTM F-152 using Type 1
specimen sizes on an Instron tensile tester at 1 inhuman
crosshead speed and a chart speed OX 1 inhuman; however,
the samples were not preconditioned, The samples were
cut in a l/2-inch dumbbell shape, with the exception of
sample elf which was cut in a l-in. dumbbell shape. The
following results were obtained:
Sample Results
Lobs.@ break psi
lea 24.7(1 5)1030 ~106)
30llB 11.6(2.4)777 (282)
llC 30.0(3.7)1~80 ~240)
lid 24.5(1.8)1210 (180)
lye 45.1(2.3)1880 (180)
elf 146(11) 5830 (170
I
- 17 - LF~1-7336 & 73~11
the valves reported are an average of three
measurements, with the numbers in parentheses being the
difference between the highest and lowest numbers
recorded for each set.
Flexibility was determined essentially
according to ASTM F-147, commonly referred to as a
"mandrel bend testily' Samples lulled failed the test
using a l-in. mandrel; sample elf passed using a l-in.
mandrel; and sample lye passed using a inn. mandrel.
lo None of the samples was preconditioned.
Example 12
This example will illustrate the heat conduct
live results which can be obtained by including a metal
screen in a laminate. Laminate C, having the structure
lo JUICES, was prepared in the usual manner, except that
thermocouples were incorporated into the structure by
placing them on the upper surface of the upper synthetic
mica sheet They were then cured in place by applying
the upper (GO) layers The thermocouples were located
at measured distances from the point of flame
application either in the wire direction (WE) or
diagonally across the mesh (oblique), as follows:
Thermocouple Location Distance
.
TO flame application point
25 TO oblique 2"
TO 3obl pique 4 "
TO oblique 5"
TO oblique 6"
TO 6 WE 41.
Laminate C was prepared using galvanized iron
wire as described in Example if whereas Laminate B was
prepared to contain comparable copper wire. Laminate A,
which contained no wire, was prepared as a control. The
following temperatures were recorded.
I Fuji 18 LF~-7336 7341
Temperatures Recorded
Time
(Min.)
TO 1 TO 2 TO 3
_
A _ C A B C A B C_
0 8080 I I 80 78 81 80 7g
3 19891892 1~1116~ 191 210 99 101 96
10 19201865 1919161 219 255 100 108 10~
15 18611877 1871~00 237 261 102 110 111
TO 4 TO 5 TO 6
A B C A B C A B C
-
0 8181 79 81 81 79 81 80 78
3 9495 89 90 92 86 1~6 156 14~
9599 96 91 I 91 11~ 163 168
15 15 96100 98 92 95 93 121 172 169
These results indicate that a laminated screen
will assist in dissipating the heat from the point of
application, and thaw copper wire will dissipate the
heat more efficiently than will galvanized iron wire.
I In addition, by comparing the results for TC5 and TC6,
it is seen thaw heat is more efficiently conducted in a
wire direction as opposed to an oblique direction.
Example 13
This example will illustrate the preparation
of a sample which is not cured under heat and pressure.
A Molly coating of the bonding composition described in
Example 1 (about 125g) was applied to a 12 in. x 12 in.
piece of 2.5X-SM Modiglass scrims and a second piece of
scrip was placed on top of the coating. The layered
material was briefly compressed to drive the bonding
composition into the respective scrip layers and the
composite was allowed to cure under ambient conditions.
Curing was effected in about 5 minute
Example 14
This example will illustrate the application
of a foamed bonding composition to a layer ox scrims
I
19 - LFM-7336 73~1
The bonding composition was prepared as described in
Example 1 and mixed for about I seconds. To the mixed
material (268g) was added 10.19 t3.8%) of Millifoam
surfactant from Onyx Chemical Co. and the foam was
produced by mechanically mixing with an air stirrer for
40 seconds. A Molly coating was applied to both
surfaces of a 12 in. x 12 in. piece of 7.5X-SM Modiglass
scrims the total application by weight being about 82g.
The coated scrip was pressed fox 25 seconds at 180F to
give a cured sheet.
The present invention is not restricted solely
to the descriptions and illustrations provided above,
but encompasses all modifications envisaged by the
following claims
