Title of Invention

INFUSION FABRIC FOR MOLDING LARGE COMPOSITE STRUCTURES

Abstract An infusion fabric (10), comprising: a mat (12) selected from a group consisting of continuous filament mat, direct chopped mat, direct continuous mat and combinations thereof; and a woven roving or bonded reinforcement layer (14), characterized in that said woven roving or bonded reinforcement layer includes multiple parallel tows (18, 20), wherein a first smaller tow (18) has a yield, that is larger than a yield of a second larger row (20), wherein one or more first smaller tows (18) are provided between two second large tows (20 so as to form spaced channels (21).
Full Text

INFUSION FABRIC FOR MOLDING
LARGE COMPOSITE STRUCTURES
Technical Field and Industrial Applicability of the Invention
This invention relates generally to an infusion fabric that may be molded into large
composite structures as well as to a novel continuous filament mat and a novel binder
Background of the Invention
Reinforcement fabrics made from fibrous materials formed into woven, knitted and
non-woven material, are well known in the art Yarns of glass, carbon and aramid are
typically formed into fabrics, and a plurality of layers of fabric are stacked and cut into dry
fabric kits 01 performs The preforms are then infused or impregnated with a resin binder
and cured to form a rigid composite
Typically a glass reinforced fibrous mat is preformed and then placed in a mold for
molding into a fiber-reinforced article Glass fiber-remforcement mats arc used in
situations where a desired strength is necessary, such as in truck fenders, auto chassis or
bus components and the like For example, layers of the continuous strand mat and layers
of unidirectional or multidirectional reinforcement material are fabricated separately
These layers arc individually placed in a set of preformed screens, which generally consist
of an upper screen and a lower screen The upper and lower screens arc moved together in
order to conform the layers to the shape of the preformed screens The layers are thus
shaped into what is known as a preform The preform is then placed in a mold and
injected with a suitable resinous material to make the fiber reinforced article
U S Patent Publication No 2005-0070182, published on 31 March 2005, owned
by the assignee of the present invention, discloses a crimp-free infusible reinforcement
fabnc The unidirectional fabric has small size tows spaced between large size tows The
"channels" that are formed from the small tows between the larger tows permit faster resin
infusion and increased productivity
The present invention relates to an improved infusion fabric that better optimizes
kitting, preforming, conformability to tooling, resin infusion rate, consolidation thickness,
surface aesthetics, and composite structural performance in a range of closed molding
processes including VIP, RTM and RTM Lite or VARTM processes This represents the
full range of composite closed molding processes used by marine, wind, construction,

transportation and industrial customers In addition, the present invention relates to a
novel continuous filament mat and binder useful in making that unproved infusion fabric
mat
Summary of the Invention
The infusion fabric comprises a mat selected from a group consisting of continuous
filament mat, direct chopped mat, direct continuous mat and combinations thereof along
with a woven or bonded reinforcement layer In one possible embodiment the mat and
woven roving or bonded reinforcement layer are stitched together
More specifically describing the invention, the mat is constructed from a material
selected from a group consisting of glass fibers, carbon fibers, graphite fibers, vitreous
carbon fibers, non-graphite carbon fibers, boron monolithic graphite fibers, boron
monolithic non-graphite carbon fibers, silicone, aramid fibers, ceramic fibers,
thermoplastic polymer fibers and mixtures thereof Natural fibers such as, foi example,
cotton, kenaf, sisal and jute may also be used alone or in combination with any of the
above The woven roving reinforcement layer may also be constructed from the same list
of materials
Typically the woven roving reinforcement layer has an areal weight of between
about 8 to about 60 o/Jsq yd (about 0.27 to about 2 03 kg/sq m ) Further, the woven
roving reinforcement layer is selected from a group consisting of plain, twill and satin
style The woven roving reinforcement layer can include multiple paiallcl tows at least
two tows of which have differing yields so as to foim spaced channels Typically a first
tow of the two tows has a yield A of between about 750 to about 2500 yds/lb (about
1511 9 to about 5039 7 rn/kg) and a second tow of said two lows has a yield B of between
about 52 to about 450 yds/lb (about 104 8 to about 907 2 m/kg)
In accordance with still another possible embodiment of the present invention the
infusion fabric may include a surfacing mat The mat is sandwiched between the surfacing
mat and the woven roving reinforcement layer
In accordance with one particular embodiment of the present invention, the mat of
the infusion fabric is a continuous filament mat including E-glass fibers and/or ECR-glass
fibers, a binder and a size More specifically, this continuous filament mat includes
between about 80 and about 99 weight percent glass fibers, between about 1 and about 20
weight percent binder and between about 0 01 and about 1 weight percent size on the

fiber The glass fibers are provided as glass filament bundles The glass filament bundles
include between about 20 to about 140 filaments per bundle Each filament has a mean
diameter of between about 11 to about 26 microns The bundle diameter is between about
0 127 to about 3 175 mm The loop formation ratio ranges from about 2 0 to about 8 0
The binder is a polyester or an epoxy compatible binder such as cpoxy resin and
epoxy novolak The polyester binder is ground to a particle size of between about 25 to
about 200 mm The binder also includes talc and benzoyl peroxide More specifically, the
binder includes between about 92 5 and about 99 9 weight percent polyester, between
about 0 01 and about 5 weight percent talc and between about 0 1 and about 2 5 weight
percent benzoyl peroxide
Still further, the continuous filament mat has a degree of cure expressed as acetone
extractables of between about 50 and about 100 percent More typically, the continuous
filament mat has a degree of cure expressed as acetone extractables of between about 60
and about 90 percent
In accordance with yet another aspect of the piescnt invention, a continuous
filament mat is provided The continuous filament mat comprises E-glass fibers and/or
ECR-glass fibers, a bindei and a size The continuous filament mat includes between
about 90 and about 98 weight percent E-glass or ECR-glass fibers, between about 2 and
about 10 weight percent binder and between about 0 1 and about 1 0 weight percent size
on the fiber The glass fibers are provided as glass filament bundles The glass filament
bundles include between about 20 to about 140 filaments per bundle Each filament has a
mean diameter of between about 11 and about 26 micions The bundle diameter is
between about 0 127 and about 3 175 mm The loop formation ratio ranges from about 2 0
to about S 0 The cure, measured as acetone extractables, is between about 50 and about
100 percent and more typically between about 60 and about 90 percent
In a particularly useful embodiment, the continuous filament mat includes E-glass
or ECR glass fiber bundles having between about 44 to about 50 filaments per bundle or
loop strand The bundle diameter mean is about 0 3048 mm and the langc is horn about
0 127 to about 1 27 mm The strand to mat architecture or loop formation latio is between
about 6 0 and 6 6
In accordance with still another aspect of the present invention, a binder is
provided for preparing a glass fiber mat The binder comprises between about 95 and
about 99 8 weight percent polyester, between about 0 05 and about 3 weight peicent talc

and between about 0 2 and about 2 weight percent benzoyl peroxide The polyester binder
is ground to a particle size of between about 25 to about 200 mm The polyester is based
upon ethylene glycol and fumanc acid
In the following description there is shown and described several different
embodiments of this invention, simply by way of illustration of some of the modes best
suited to carry out the invention As it will be realized, the invention is capable of other
different embodiments, and its several details arc capable of modification in various,
obvious aspects all without departing from the invention Accordingly, the diawmgs and
descriptions will be regarded as illustrative in nature and not as restrictive
Brief Description of the Drawings
The accompanying drawings incorporated in and forming a part of the
specification, illustrate several aspects of the present invention, and together with the
description serve to explain certain principles of the invention In the drawings
Fig 1 is a partially sectional perspective view of one possible embodiment of the
infusion fabric of the present invention,
Fig la is a full cross sectional view ot the infusion fabric illustrated in Fig 1,
Fig 2 is a partially sectional perspective view of another possible embodiment of
the infusion iabnc of the present invention, and
Fig 2a is a full cross sectional view of the infusion fabric illustrated in Fig 2
Reference will now be made in detail to the present preferred embodiment of the
invention, an example of which is illustrated in the accompanying drawings.
Detailed Description and Preferred Embodiments of the Invention
A first embodiment of the infusion fabric 10 of the present invention is illustrated
in Figs 1 and la As illustrated the infusion fabric 10 includes a mat 12 and a woven
roving or bonded reinforcement layer 14 Both the mat 12 and the woven loving
reinforcement layer 14 may be constructed from a material selected from a group
consisting of glass fibers, carbon fibers, graphite fibers, vitreous carbon fibers, non-
graphite carbon fibers, boron monolithic graphite fibers, boron monolithic non graphite
carbon fibers, silicone, aramid, ceramic fibers, thermoplastic polymer fibers, natural fibers
(for example, cotton, kenaf, sisal, jute) and mixtures thereot Of couisc, the mat 12 and

woven roving reinforcement layer 14 may be constructed from the same or different
materials from this list as desired
The woven roving reinforcement layer 14 has an arcal weight of between about 8
to about 60 oz/sq yd (about 0 27 to about 2 03 kg/sq m ) The woven roving
reinforcement layer 14 is selected from a group consisting of plain, twill and satm style
The woven roving or bonded reinforcement layer 14 also includes multiple parallel tows
18, 20 at least two tows of which have differing yields so as to form spaced channels 21
The first low 18 of the two tows has a yield A of between about 750 to about 2500 yds/lb
(about 1511 9 to about 5039 7 m/kg) The second tow 20 of the two tows has a yield B of
between about 52 to about 450 yds/lb (about 104 8 to about 907 2 m/kg) By placing one
or more of the smaller first tows 18 between two or more of the larger second tows 20, a
channel 21 is provided A typical woven roving reinfoi cement layer 14 includes a group
of these channels 21 that allow rapid infusion of resin across the infusion fabric 10 during
the molding process
The spacing of the tows 18, 20 is typically determined by the resm utilized in the
molding process More specifically, a more viscous resm requires a greater number of
channels per suifacc area in order to better enhance the flow of resin during the molding
process Alternatively, a less viscous resin flows more easily and requires fewer channels
per surface area In such a situation a fewer number of small tows 18 are required
between a larger number of large tows 20
The woven roving or bonded reinforcement layer 14 typically includes
unidirectional liber orientation Various methods may be utilized to maintain the primary
fibers in position in the unidirectional layer Those methods include weaving, stitching
and bonding as is known in the art In one particularly useful embodiment the layer 14 is
constructed from ciimp-free warped knitted fabric otherwise known as stitch-bonded
fabric In the illustrated embodiment, the lows 18 and 20 oi the woven roving or bonded
reinforcement layer 14 are held in place by a secondary, non-structural stitching thread 22
This may typically be a polyester thread or any other thread conventionally used in the art
The mat 12 and woven roving or bonded reinforcement layer 14 are connected
together by any appropriate means In the illustrated embodiment the connection is
completed by stitch-bonding using conventional stitch-bonding techniques and styles such
as chain, tricot, modified tncot or promal Conventional machines known in the art such
as Liba stitch-bondmg machines may be used for this purpose

As also illustrated in Figs 1 and 1 a, the infusion fabric 10 may also include a
second woven roving or bonded reinforcement layci 24 Ihe second woven roving
reinforcement layer 24 has a structure similar to the first woven roving reinfoicemcnl layer
14 that is, the second woven roving or bonded reinforcement layer includes multiple
parallel tows 26, 28 at least two tows of which have differing yields so as to form spaced
channels for resin infusion The tows 26, 28 do not have to have identical yields to the
tows 18, 20 in the first woven roving reinforcement layer 14 It should be appreciated,
however, that the tows 18, 20 of the fust woven roving reinforcement layer 14 extend in a
first direction while the tows 26, 28 ol the second woven roving reinforcement layei 24
extend in a second direction at a bias to the first direction Typically that bias is one of
approximately 90 degrees This structural arrangement adds additional strength to the
infusion fabric 10
An alternative embodiment for the infusion fabric 10 is illustrated in Figs 2 and
2a This embodiment includes a mat 12 and a woven roving or bonded reinforcement
layer 14 substantially identical to that described above with respect to the Fig 1
embodiment In addition, the infusion fabric 10 includes a surfacing mat 30 The
surfacing mat 30 is connected to the face of the mat 12 opposite the woven roving
reinforcement layer 14 so that the mat 12 is sandwiched between the surfacing mat 30 and
the woven roving reinforcement layer 14 The surfacing mat 30 is formed from a print
blocking media such as another continuous fiber mat or a veil incorporating glass fibers,
polyester fibers, natural fibers (for example, cotton, kenaf, sisal, jute), polymer particles
and binder The surfacing mat 30 may, for example, be connected to the mat 12 by spin
bonding, wet bonding, dry bonding and needle punching
As pieviously noted, the mat 12 may be a continuous filament mat For purposes
of this document, "continuous filament" is defined as a colhmated assembly of individual
fibers treated, sized or finished appropriately for wetting and adhering resin or polymer
upon composite consolidation
Also (or purposes of this document, a "continuous filament mat" is defined as a
random swirl placement of continuous bundled fibers which has orientation defined by the
loop formation ratio in the process creating a mat with planar isotropy A useful
continuous filament mat 12 is made utilizing a loop formation latio of between about 2 0
to about 8 0 and typically between about 6 0 and 6 6 (loop formation ratio is strand or
bundle speed/oscillation rate)

A continuous filament mat 12 particularly useful in the present invention also
includes E-glass and/or ECR-glass fibers, a binder and a size The glass fibers are
provided as glass filament bundles The glass filament bundles include between about 20
to about 140 filaments per bundle. Each filament has a mean diameter of between about
11 and about 26 microns. The bundle diameter is between about 0 127 and about 3 175
mm.
In a particularly useful embodiment, the mean filament diameter is between about
17 0 and about 20.0 microns. Further, there are between about 44 and about 50 filaments
per bundle or loop strand. The strand or bundle diameter mean is about 0 3048 mm and
the bundle diameter falls m an overall range of between about 0 127 to about 1.27 mm.
The strand to mat architecture or preferred loop formation ratio is between about 6.0 and
about 6 6
The binder is a polyester or an epoxy compatible binder such as a powdered epoxy
resin or an epoxy novolak. Epoxy resins include those made from epichlorohydrin and
bisphenol A. Epoxy novolaks include resins made by reaction of epichlorohydrin with a
novolak resin (phenol-formaldehyde).
In one possible embodiment that polyester binder is based upon ethylene glycol
and fumaric acid. The binder also includes talc and benzoyl peroxide. For a typical
application the binder is ground to a particle size of between about 25 to about 200 mm.
The talc is added as a crystallization enhancer. The binder is prepared by cryogemcally
grinding the crystalline polymer with a little zinc stearate to the desired particle size. The
powder is then dry blended with the benzoyl peroxide. More specifically describing the
binder, the binder includes between about 95 to about 99.8 weight percent polyester,
between about 0.05 to about 3 weight percent talc and between about 0.2 to about 2 weight
percent benzoyl peroxide.
The size utilized in the continuous filament mat 12 includes one or more
formulations incorporating water, acetic acid, silane, and a biocide Silane coupling
agents useful in the present invention include but are not limited to A-187, A-171, A-174
and A-1100 silane available from General Electric Silanes. Lubricants useful in the
present invention include but are not limited to Cirrosol 185AE and 185AN, each
manufactured and sold by ICI America and Omega 16407 Biocides useful in the present
invention include but are not limited to quaternary ammonium compounds containing

bis/tnbutyltinoxide. One such biocide is sold under the trademark Biomet 66 and is
available from Atochem.
The continuous filament mat 12 is manufactured by transporting glass filament
bundles through the binder application process on a conveyor chain A portion of the
conveyor chain is supported within an open-ended trough called a flood pan The purpose
of the flood pan is to allow sufficient slurry to accumulate and fully submerse the non-
woven web for some period of time. The slurry is fed from a reservoir located above and
toward the inlet end of the flood pan (that is, the curtain coder). The reservoir discharges
the slurry through its slot on the lowermost portion of the reservoir. The reservoir and slot
extend across the width of the floor pan. The major axes of the reservoir and slot are
oriented perpendicular to the machine direction (major axis) on the process conveyor
The slurry is discharged vertically down from the reservoir slot, in a continuous
curtain, toward the upper surface of the non-woven web of glass strands. The velocity of
the curtain of slurry is a function of the discharge velocity of the slurry from the reservoir
slot, the vertical distance between the slot and the surface of the web and the viscosity of
the slurry.
The non-woven web of glass strands and the conveyor chain are substantially
permeable to the flow of the slurry, allowing the slurry to flow easily around both the glass
strands and the conveyor chain wires and down to the impermeable flood pan. When the
vertical slurry flow from the reservoir impinges on the flat surface of the flood pan
(perpendicular to the surface of the flood pan), the flow is redirected to a horizontal flow.
The flow of slurry upon interacting with the web, conveyor chain and flood pan, is
generally redirected to flow in the same direction as the conveyor and web. The removal
rate of the slurry from the flood pan is a function of the supply rate of slurry into the flood
pan, the thickness of the conveyor chain, the drag of the chain and the slurry, the viscosity
of the slurry, depth of slurry in the flood pan and other factors. The volumetric flow of
slurry supplied by the reservoir is, by design, sufficient to ensure the web is fully
submerged as it is carried through the majority of the length of the flood pan The slurry
flows through the glass strands and leaves a binder deposit which is subsequently cured in
the oven into a bound mat structure.
In order for the continuous filament mat 12 to allow the desired resin infusion, the
glass fiber bundles must not be too large or too close together. Both these aspects affect
the openness or permeability of the mat construction for purposes of resin infusion.

Continuous filament mats 12 useful m the present invention include but are not limited to
CFM 8610, CFM 8620, CFM 8630, CFM 8635, CFM 8636 and CFM 8643, commercially
available from the assignee of the present invention
Factors influencing resin infusion for RTM, RTM lite or VIP processes follow
Darcy's law on the need to reduce resin viscosity and increase mat/fabric in-plane
permeability Continuous filament mat permeability to balance resin infusion with mold
conformabihty has been shown to improve with reduced Filamentization, proper solids and
cure of the binder. The random swirl of the mat, continuous fiber and proper sizing/binder
chemistry allow good composite mechanical and structural performance. For purposes of
this document cure is measured as acetone extractables. The continuous filament mat has
a cure of between about 50 to about 100 percent and more typically about 60 to about 90
percent as measured by acetone extractables
The various embodiments of the infusion fabric 10 of the present invention
including those illustrated in Figs. 1 and 2 are particularly useful in molding processes
where resin must move through a fabric to create a consolidated composite. One
particular process is resin transfer molding (RTM). Resin transfer molding (RTM) is a
process by which a resin is pumped at low viscosities and low pressures into a closed mold
die set containing a preform of dry fabric, that is, fabric 10 to infuse resin into the preform
and to make a fiber-reinforced composite part. The RTM process can be used to produce
at low cost composite parts that are complex in shape. These parts typically require
continuous fiber reinforcement along with inside mold line and outside mold line
controlled surfaces. The ability to include and place continuous fiber reinforcement in
large and small structures sets RTM apart from other liquid molding processes
The fabric 10 is also useful in a vacuum assisted resin transfer molding (VARTM)
system. In VARTM, the preform is covered by a flexible sheet or liner, such as fabric 10.
The flexible sheet or liner is clamped onto the mold to seal the preform in an envelope A
catalyzed matrix resin is then introduced into the envelope to wet the preform. A vacuum
is applied to the interior of the envelope via a vacuum line to collapse the flexible sheet
against the preform. The vacuum draws the resin through the preform and helps to avoid
the formation of air bubbles or voids in the finished article. The matrix resm cures while
being subjected to the vacuum The application of the vacuum draws off any fumes
produced during the cunng process. The fabric 10 of the present invention is useful in

standard vacuum infusion molding processes as well as processes where the reinforced
fabric is under vacuum
In summary, numerous benefits are provided by the fabric 10 of the present
invention The fabric 10 is characterized by excellent handling qualities, ease of use and
unsurpassed resin permeability. The faster flow rate allows for higher production and mold
turnover, while potentially decreasing cost by eliminating local resin distnbution media
Further, VOC loss to the environment is reduced In addition, laminate bulk can be built
with minimal labor and cost.
The foregoing description of the preferred embodiments of the invention has been
presented for purposes of illustration and description It is not intended to be exhaustive
or to limit the invention to the precise form disclosed. Obvious modifications or variations
are possible in light of the above teachings
The embodiments were chosen and described to provide the best illustration of the
principles of the invention and its practical application to thereby enable one of ordinary
skill in the art to utilize the invention in various embodiments and with various
modifications as are suited to the particular use contemplated. All such modifications and
variations are within the scope of the invention as determined by the appended claims
when interpreted in accordance with the breadth to which they are fairly, legally and
equitably entitled. The drawings and preferred embodiment do not and are not intended to
limit the ordinary meaning of the claims and their fair and broad interpretation m any way.

WE CLAIM:
1. An infusion fabric (10), comprising:
a mat (12) selected from a group consisting of continuous filament mat, direct
chopped mat, direct continuous mat and combinations thereof; and
a woven roving or bonded reinforcement layer (14),
characterized in that said woven roving or bonded reinforcement layer includes
multiple parallel tows (18, 20), wherein a first smaller tow (18) has a yield, that is
larger than a yield of a second larger tow (20), wherein one or more first smaller tows
(18) are provided between two second large tows (20) so as to form spaced channels
(21).
2. The infusion fabric as claimed in claim 1, wherein the mat (12) is a continuous
filament mat.
3. The infusion fabric as claimed in claim 1 or 2, wherein said mat (12) and said
woven roving reinforcement layer (14) are stitched together.

4. The infusion fabric as claimed in claims 1 or 2, wherein said mat (12) is
constructed from a material selected from a group consisting of glass fibers,
carbon fibers, graphite fibers, vitreous carbon fibers, non-graphite carbon fibers,
boron monolithic graphite fibers, boron monolithic non-graphite carbon fibers,
silicone, aramid, ceramic fibers, thermoplastic polymer fibers, natural fibers and
mixtures thereof.
5. The infusion fabric as claimed in claims 1 or 2, wherein said woven roving
reinforcement layer or bonded reinforcement layer is constructed from a material
selected from a group consisting of glass fibers, carbon fibers, graphite fibers,
vitreous carbon fibers, non-graphite carbon fibers, boron monolithic graphite
fibers, boron monolithic non-graphite carbon fibers, silicone, aramid, ceramic
fibers, thermoplastic polymer fibers, natural fibers and mixtures thereof.
6. The infusion fabric as claimed in claim 5, wherein said woven roving
reinforcement layer has an areal weight of between 0.27 to 2.03 kilograms per
square meter.
7. The infusion fabric as claimed in claim 6, wherein said woven roving
reinforcement layer is selected from a group consisting of plain, twill and satin
style.

8. The infusion fabric as claimed in claim 1, wherein a first tow (18) has a yield of
between 1511.9 to 5039.7 meters/kilograms and a second tow (20) has a yield of
between 104.8 to 907.2 meters/kilograms.
9. The infusion fabric as claimed in claim 1 or 2, further including a surfacing mat
(30).
10. The infusion fabric as claimed in claim 9, wherein said mat (12) is sandwiched
between said surfacing mat (30) and said woven roving reinforcement layer (14).
11. The infusion fabric as claimed in claim 1 or 2, wherein said continuous filament
mat (12) includes glass fibers selected from a group consisting of E-glass fibers,
ECR-glass fibers and mixtures thereof, a binder and a size.
12. The infusion fabric as claimed in claim 11, wherein said continuous filament mat
(12) includes between 90 and 98 weight percent glass fibers, between 2 and 10
weight percent binder and between 0.1 and 1 weight percent size;
13. The infusion fabric as claimed in claim 11, wherein said continuous filament mat
(12) includes between 80 and 99 weight percent glass fibers, between 1 and 20
weight percent binder and between 0.01 and 2 weight percent size.

14. The infusion fabric as claimed in claim 12 or 13, wherein said glass fibers are
provided as glass filament bundles.
15. The infusion fabric as claimed in claim 14, wherein said glass filament bundles
include between 20 and 140 glass filaments per bundle.
16. The infusion fabric as claimed in claim 15, wherein said glass filaments of said
glass filament bundles have a mean diameter of between 11 and 26 microns.
17. The infusion fabric as claimed in claim 16, wherein said glass filament bundles
have a mean diameter of 0.3048 mm and a diameter range of between 0.127 and
1.27 mm.
18. The infusion fabric of any one of claims 11 to 13, wherein said binder is selected
from a group of materials consisting of a polyester and an epoxy compatible
binder.
19. The infusion fabric as claimed in claim 18, wherein said binder is a polyester and
said polyester binder is ground to a particle size of between 25 to 200 mm.

20. The infusion fabric as claimed in claim 19, wherein said binder also includes talc.
21. The infusion fabric as claimed in claim 19, wherein said binder also includes
benzoyl peroxide.
22. The infusion fabric as claimed in claim 19, wherein said binder includes:
between 95 and 99. 8 weight percent polyester;
between 0.05 and 3 weight percent talc; and
between 0.2 and 2 weight percent benzoyl peroxide.
23. The infusion fabric as claimed in claim 11 wherein said continuous filament mat
has a loop formation ratio of between 2.0 to 8.0 and a cure of between 50 and 100
percent when measured as acetone extractables.



ABSTRACT


Title: Infusion fabric for molding large composite structures.
An infusion fabric (10), comprising: a mat (12) selected from a group consisting of
continuous filament mat, direct chopped mat, direct continuous mat and combinations
thereof; and a woven roving or bonded reinforcement layer (14), characterized in that
said woven roving or bonded reinforcement layer includes multiple parallel tows (18, 20),
wherein a first smaller tow (18) has a yield, that is larger than a yield of a second larger
row (20), wherein one or more first smaller tows (18) are provided between two second
large tows (20 so as to form spaced channels (21).

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=MZKQdZXL7uq3Aop/qOJAiQ==&loc=wDBSZCsAt7zoiVrqcFJsRw==


Patent Number 272650
Indian Patent Application Number 1162/KOLNP/2007
PG Journal Number 17/2016
Publication Date 22-Apr-2016
Grant Date 18-Apr-2016
Date of Filing 04-Apr-2007
Name of Patentee OCV INTELLECTUAL CAPITAL,LLC
Applicant Address ONE OWENS-CORNING PARKWAY TOLEDO, OH
Inventors:
# Inventor's Name Inventor's Address
1 DUNN, MATTHEW, W. 125 OAK RUN COURT, LEWISVILLE, NC 27023
2 HARTMAN, DAVID R. 2550 LANCASTER ROAD, GRANVILLE, OH 43023
PCT International Classification Number B32B 5/02
PCT International Application Number PCT/US2005/037704
PCT International Filing date 2005-10-19
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10/971,286 2004-10-22 U.S.A.