# US 2013/0156981 A1 · Articles of composite construction and methods of manufacture thereof

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- Number: US 2013/0156981 A1
- Document ID: US20130156981A1
- Status: Published application
- Kind: A1
- Application number: 13/763,076
- Filed: 2013-02-08
- Published: 2013-06-20
- Earliest claimed: 2006-02-17
- Inventors: William RODGERS
- Web page: https://patentgrep.com/patent/US20130156981A1

## CPC

- B65D 90/022: {Laminated structures (B65D90/029 takes precedence)}
- B29C 33/62: based on polymers or oligomers
- B29C 39/08: Introducing the material into the mould by centrifugal force
- B29C 39/10: incorporating preformed parts or layers, e.g. casting around inserts or for coating articles {(coating a surface by casting in general B05D1/30, B29C39/126 takes precedence)}
- B29C 39/123: {Making multilayered articles}
- B29C 39/36: Removing moulded articles
- B29C 41/20: incorporating preformed parts or layers, e.g. moulding inserts or for coating articles
- B29C 70/323: {on the inner surface of a rotating mould}
- B32B 1/00: Layered products having a non-planar shape
- B32B 7/04: Interconnection of layers
- B32B 27/00: Layered products comprising {a layer of} synthetic resin {(fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18)}
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/302: {comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers}
- B32B 27/308: {comprising acrylic (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/36: comprising polyesters
- B32B 27/38: comprising epoxy resins
- B32B 27/40: comprising polyurethanes
- B60K 15/03: Fuel tanks
- B60P 3/2205: {Constructional features}
- B62D 29/043: {Superstructures (B62D25/161 takes precedence)}
- B62D 29/046: {Combined superstructure and frame, i.e. monocoque constructions}
- B64C 3/34: Tanks constructed integrally with wings, e.g. for fuel or water
- B65D 88/12: specially adapted for transport (associated with vehicles, see the relevant subclasses of B60 - B64)
- B29C 2045/14319: {bonding by a fusion bond}
- B29L 2031/3085: {Wings}
- B29L 2031/7126: {large, e.g. for bulk storage}
- B29L 2031/7172: {Fuel tanks, jerry cans}
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/046: Synthetic resin
- B32B 2262/101: Glass fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2439/40: Closed containers
- B32B 2605/00: Vehicles
- B32B 2605/18: Aircraft
- B60K 2015/03032: {Manufacturing of fuel tanks}
- B60K 2015/03046: {made from more than one layer}
- B65D 88/128: {tank containers, i.e. containers provided with supporting devices for handling}
- Y02T 50/40: Weight reduction
- Y10T 428/1362: Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
- Y10T 428/249921: Web or sheet containing structurally defined element or component
- Y10T 428/31511: Of epoxy ether
- Y10T 428/3154: Of fluorinated addition polymer from unsaturated monomers
- Y10T 428/31544: Addition polymer is perhalogenated
- Y10T 428/31587: Hydrocarbon polymer [polyethylene, polybutadiene, etc.]
- Y10T 428/31797: Next to addition polymer from unsaturated monomers
- Y10T 442/3854: Woven fabric with a preformed polymeric film or sheet
- Y10T 442/387: Vinyl polymer or copolymer sheet or film [e.g., polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, etc.]
- Y10T 442/3878: Fluorinated olefin polymer or copolymer sheet or film [e.g., Teflon@, etc.]
- Y10T 442/3886: Olefin polymer or copolymer sheet or film [e.g., polypropylene, polyethylene, ethylene-butylene copolymer, etc.]
- Y10T 442/59: At least three layers
- B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60P: VEHICLES ADAPTED FOR LOAD TRANSPORTATION OR TO TRANSPORT, TO CARRY, OR TO COMPRISE SPECIAL LOADS OR OBJECTS (vehicles with special provisions for transporting patients or disabled persons, or their personal conveyances A61G3/00)
- B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M)
- B64C: AEROPLANES; HELICOPTERS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An article manufactured in a mould and which comprises a structural composite of plastics layers, the article having a wall defining an internal space for holding contents therein; wherein, the wall is formed from at least two layers of plastics materials; wherein a first of said layers comprises a thermoplastics material and at least a second layer comprises a thermosetting resin and a fibrous layer.

## Claims

### Claim at position 1

1-72. (canceled)

### Claim 73

A storage vessel manufactured in a rotational mould and which comprises a structural composite including a thermoplastics material and a fibrous reinforcing layer, the vessel when formed having a wall defining an internal space for holding contents therein;
the wall including said thermoplastics material and the fibrous reinforcing layer at least partially embedded in said thermoplastic material and reinforcing the composite;
wherein the vessel is manufactured in the rotational mould according to the following method steps;
a) placing the layer of fibrous material inside the mould in apposition to an inner surface of the mould;
b) placing the thermoplastics material inside the mould;
c) closing the mould and heating the mould to thereby heat the thermoplastics material sufficient to enable the thermoplastics material to morph from a non flowable state to a flowable state;
d) during rotation of the mould, allowing the heated thermoplastics material to flow at least part way through the thickness of the layer of fibrous reinforcing material so that at least some fibres of the fibrous layer are embedded in the thermoplastics material thereby forming a layer of reinforced thermoplastics material;
e) allowing the thermoplastics layer to cool; and
f) removing the composite from the rotational mould.

### Claim 74 (depends on 73)

A vessel according to claim 73 wherein the thermoplastics layer material is selected from any one of the following materials; polyethylene (HDPE), polypropylene (PP), polyvinylidene fluoride (PVDF), ethylene chloro tri fluoro ethylene (ECTFE).

### Claim 75 (depends on 74)

A vessel according to claim 74 wherein the fibrous layer material is selected from a group including woven cloth, mat or felt.

### Claim 76 (depends on 75)

A vessel according to claim 75 wherein the fibrous layer comprises woven cloth having alternate strands of warp and weft traversing the thickness of the cloth.

### Claim 77 (depends on 76)

A vessel according to claim 76 wherein the thermoplastic layer material is introduced into the mould in powder form prior to heating.

### Claim 78 (depends on 77)

A vessel according to claim 77 wherein the fibrous layer is prior to introduction into said mould pretreated with a primer wherein the primer is a wetting binder solution including a solvent which evaporates before closing the mould.

### Claim 79 (depends on 78)

A vessel according to claim 78 wherein the binder is polystyrene or polymethylmethacrylate dissolved in their respective monomers styrene and methyl methacrylate as the solvent.

### Claim 80 (depends on 79)

A vessel according to claim 79 wherein the thermoplastics material is urged into engagement with the fibre reinforcing layer under gas pressure applied inside the mould.

### Claim 81 (depends on 80)

A vessel according to claim 80 wherein the gas pressure is adjusted according to the degree of penetration of the thermoplastics material through the fibrous layer required.

### Claim 82 (depends on 81)

A vessel according to claim 81 wherein the gas pressure is applied to enable full penetration of the thermoplastics layer through the fibre reinforcing layer.

### Claim 83 (depends on 82)

A vessel according to claim 82 wherein the gas pressure is applied to enable partial penetration of the thermoplastics layer through the fibre reinforcing layer.

### Claim 84 (depends on 83)

A vessel according to claim 83 wherein a thermosetting resin is applied to fibres of the fibrous layer not embedded in the thermoplastics layer to thereby form a bond between the thermoplastics layer and the thermosetting resin.

### Claim 85 (depends on 84)

A vessel according to claim 84 wherein thermosetting resin is, selected from a group including polyester, vinylester, epoxy and polyurethane.

### Claim 86 (depends on 85)

A vessel according to claim 85 wherein the vessel forms a hollow liquid storage tank mountable on a road tanker vehicle.

### Claim 87 (depends on 85)

A vessel according to claim 85 wherein the vessel forms an aircraft fuel tank.

### Claim 88 (depends on 85)

A vessel according to claim 85 wherein the article forms a hollow storage vessel for a rail car.

### Claim 89 (depends on 78)

A vessel according to claim 78 wherein the primer applied to the fibrous layer increases the penetrability of the thermoplastics material into said fibres during rotation of said mould.

### Claim 90 (depends on 89)

A vessel according to claim 89 wherein the primer comprises polystyrene dissolved in styrene.

### Claim 91 (depends on 90)

A vessel according to claim 90 wherein the primer is mixed with a suspension of thermoplastics powder.

### Claim 92

A method of manufacture of a composite hollow vessel using a rotational mould, the method comprising the steps of:
a) taking a fibrous layer of material and placing the material against an inner surface of a mould having a predetermined internal shape;
b) forming a the fibrous layer into a shape conforming with the mould;
c) introducing a thermoplastics material into the mould and heating the material;
d) allowing the thermoplastics material to at least partially penetrate the fibrous layer;
e) heating the thermoplastics material sufficient to enable that material to morph from a solid to a flowable state;
f) allowing the thermoplastics material to flow at least part way through the thickness of the at least one fibrous layer to form a wall of an article to be formed in the mould;
g) allowing the thermoplastics material to cool so that at least some fibres of the at least one fibrous layer are embedded in the first layer; and
h) removing the article from the mould.

### Claim 93 (depends on 92)

A method of manufacture according to claim 92 wherein the thermoplastic layer is melted about the fibrous layer causing it to flow at least part way through the thickness of the fibrous layer.

### Claim 94 (depends on 93)

A method according to claim 93 wherein, the thermoplastics layer material is selected from the following materials polyethylene (HDPE), polypropylene (PP), polyvinylidene fluoride (PVDF), ethylene chloro tri fluoro ethylene (ECTFE).

### Claim 95 (depends on 94)

A method according to claim 94 wherein, the fibrous layer material is selected from a group including woven cloth, mat or felt.

### Claim 96 (depends on 95)

A method of manufacture according to claim 95 comprising the further step of applying a primer as a wetting binder solution applied to said fibrous layer and including a solvent which evaporates before closing the mould.

### Claim 97 (depends on 96)

A method of manufacture according to claim 96 wherein, the binder is polystyrene or polymethylmethacrylate dissolved in their respective monomers styrene and methyl methacrylate as the solvent.

### Claim 98 (depends on 97)

A method according to claim 97 comprising the preliminary step of applying a release agent to the mould inner surface prior introduction of the fibrous layer.

### Claim 99 (depends on 98)

A method according to claim 98 comprising the further step of urging the thermoplastics material into engagement with the fibre reinforcing layer under gas pressure applied inside the mould.

### Claim 100 (depends on 99)

A method according to claim 99 wherein the gas pressure is adjusted according to the degree of penetration of the thermoplastics material through the fibrous layer required.

### Claim 101 (depends on 100)

A method according to claim 100 wherein the gas pressure is applied to enable full penetration of the thermoplastics layer through the fibre reinforcing layer.

### Claim 102 (depends on 100)

A method according to claim 100 wherein the gas pressure is applied to enable partial penetration of the thermoplastics layer through the fibre reinforcing layer.

### Claim 103 (depends on 102)

A method according to claim 102 wherein a thermosetting resin is applied to fibres of the fibrous layer not embedded in the thermoplastics layer to thereby form a bond between the thermoplastics layer and the thermosetting resin.

### Claim 104 (depends on 103)

A method according to claim 103 wherein thermosetting resin is, selected from a group including polyester, vinylester, epoxy and polyurethane.

### Claim 105 (depends on 104)

A method according to claim 104 wherein the composite element forms a hollow storage vessel.