Articles of Composite Construction and Methods of Manufacture Thereof

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.

1 . 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. 
   
   
       2 . An article according to  claim 1  wherein the fibrous layer provides reinforcing for the composite. 
   
   
       3 . An article according to  claim 2  wherein the fibrous layer is at least partially embedded in said thermoplastic layer. 
   
   
       4 . An article according to  claim 3  wherein the fibrous layer is partially embedded in the thermoplastic layer by heat melting of the thermoplastic layer. 
   
   
       5 . An article according to  claim 4  wherein the thermoplastic layer has a smooth exposed surface and a second surface with the fibrous layer embedded therein. 
   
   
       6 . An article according to  claim 5  wherein the thermoplastic layer material is selected from the following materials polyethylene (HDPE), polypropylene (PP), polyvinylidene fluoride (PVDF), ethylene chloro tri fluoro ethylene (ECTFE). 
   
   
       7 . An article according to  claim 6  wherein thermosetting resins are, selected from a group including polyester, vinylester, epoxy and polyurethane. 
   
   
       8 . An article according to  claim 7  wherein the fibrous layer material is selected from a group including woven cloth, mat or felt. 
   
   
       9 . An article according to  claim 8  wherein the fibrous layer comprises woven cloth having alternate strands of warp and weft traversing the thickness of the cloth. 
   
   
       10 . An article according to  claim 9  wherein the thermoplastic layer material is introduced into the mould in powder form. 
   
   
       11 . An article according to  claim 10  wherein the thermoplastic layer is heat melted into the fibre layer. 
   
   
       12 . An article according to  claim 11  wherein the mould is a rotational mould. 
   
   
       13 . An article according to  claim 12  wherein the article is a hollow storage vessel. 
   
   
       14 . An article according to  claim 13  wherein the article is a hollow storage vessel for a road tanker. 
   
   
       15 . An article according to  claim 13  wherein the article is a hollow storage vessel for an aircraft wing. 
   
   
       16 . An article according to  claim 13  wherein the article is a hollow storage vessel for a rail car. 
   
   
       17 . A method of manufacture of a composite plastics element for use in formation of an article manufactured in a mould, the composite plastics element comprising 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, wherein the fibrous layer is at least partially embedded in said thermoplastics layer. 
   
   
       18 . A method according to  claim 17  wherein the at least partial embedding of the fibrous layer in the thermoplastics layer joins the thermosetting resin to the thermoplastics layer thereby forming a structural element in which the fibrous layer is at least partially embedded in the thermoplastics layer and in the thermosetting resin layer. 
   
   
       19 . A method according to  claim 18  wherein the composite is manufactured in a rotational mould. 
   
   
       20 . A method according to  claim 19  wherein the structural element is shaped according to an internal shape of the mould. 
   
   
       21 . A method according to  claim 20  wherein the article formed by the structural element is a hollow storage vessel 
   
   
       22 . A method according to  claim 21  wherein the article formed by the structural element is an aircraft fuel tank. 
   
   
       23 . A method according to  claim 22  wherein the fuel tank is an aircraft wing tank. 
   
   
       24 . A method according to  claim 23  wherein a wall of the fuel tank has a smooth thermoplastic interior and a reinforced plastics outer layer coupled to the thermoplastic by fibres of the fibrous layer interpenetrating the thermoplastics and thermosetting resin layers. 
   
   
       25 . A method according to  claim 24  wherein the fuel tank includes isotensoid shaped compartments which conform to a shape of an external cross section of the wing. 
   
   
       26 . A method according to  claim 25  wherein the tank includes compartments formed by internal walls which provide structural webs for said wing. 
   
   
       27 . A method according to  claim 26  wherein each said compartments include fuel filling connections and exit vents for vapour venting. 
   
   
       28 . A method according to  claim 27  wherein, said compartments are interconnected with hollow fasteners through said fuel and vent connections which seal each compartment into an interconnected whole tank. 
   
   
       29 . A method according to  claim 28  wherein the manufacture of said tank comprises the further step of placing structural fibres and resin between opposing walls of adjacent compartments. 
   
   
       30 . A method according to  claim 29  wherein said compartments are reinforced with load bearing elements placed between the compartments as attachment points for concentrated loads. 
   
   
       31 . A method according to  claim 30  wherein said compartments are loaded into the mould including said structural fibres and resin. 
   
   
       32 . A method according to  claim 31  comprising the further step of pressure inflating the compartments and allowing said resin to cure with catalysis and/or heat for a predetermined time. 
   
   
       33 . A method according to  claim 32  comprising the further step of, removing form said mould said completed wing tank. 
   
   
       34 . A method according to  claim 33  comprising the further step of assembling the wing tank into an aircraft. 
   
   
       35 . A method according to  claim 21  wherein the article formed by the structural element is a rail car storage vessel
 A method according to  claim 21  wherein the article formed by the structural element is a storage vessel for a road vehicle.   
   
   
       36 . A method of manufacture of a plastics composite for use in the construction of a hollow vessel manufactured in a mould, the method comprising the steps of:
 a) placing at least one layer of fibrous material in a mould in apposition to an inner surface of the mould and opposing a surface of the thermoplastics material;   b) taking a thermoplastics material   c) heating the thermoplastics material sufficient to morph from a solid to a flowable state;   d) allowing the first layer to flow at least part way through the thickness of the at least one fibrous layer;   e) allowing the first layer to cool so that at least some fibres of the at least one fibrous layer are embedded in the first layer;   f) applying a thermosetting resin to fibres of the fibrous layer not embedded in the first layer to form a second layer such that the first layer is bonded with the second layer.   
   
   
       37 . A method of manufacture of a plastics composite according to  claim 36  comprising the further step of prior to introduction of said fibrous layer into said mould, applying a primer to the fibrous layer. 
   
   
       38 . A method of manufacture of a plastics composite according to  claim 37  wherein the primer increases penetrability of the thermoplastics material into said fibres during rotation of said mould. 
   
   
       39 . A method of manufacture of a plastics composite according to  claim 38  wherein, the primer is sprayed onto said fibrous layer. 
   
   
       40 . A method of manufacture of a plastics composite according to  claim 39  wherein the primer comprises polystyrene dissolved in styrene. 
   
   
       41 . A method of manufacture of a plastics composite according to  claim 40  wherein the primer is a paste. 
   
   
       42 . A method of manufacture of a plastics composite according to  claim 41  wherein the primer is mixed with a suspension of thermoplastics powder. 
   
   
       43 . A method of manufacture of a plastics composite according to  claim 42  comprising the step of allowing the primer to fix fibres of the fibrous layer in place for engagement with flowable said heat melted thermoplastics. 
   
   
       44 . A method according to  claim 43  comprising the further step of applying at least one additional fibrous layer and thermosetting resin to the second layer. 
   
   
       45 . A method according to  claim 44  wherein, the fibrous layer is initially formed into a predetermined required shape prior to heating the thermoplastics layer. 
   
   
       46 . A method of manufacture of a plastics composite according to  claim 45  wherein the thermoplastic layer is melted around the fibrous layer causing it to flow at least part way through the thickness of the fibrous layer. 
   
   
       47 . A method of manufacture of a plastics composite according to  claim 46  comprising the further step of allowing the thermoplastics layer to cool and return to its ambient temperature properties. 
   
   
       48 . A method of manufacture of a plastics composite according to  claim 47  wherein the composite is used in the production from said mould of a fluid storage tank. 
   
   
       49 . A method of manufacture of a plastics composite according to  claim 48  wherein the composite is used in the production from said mould of a fluid storage tank for an aircraft wing. 
   
   
       50 . A method of manufacture of a plastics composite according to  claim 48  wherein the composite is used in the production from said mould of a fluid storage tank for a road vehicle. 
   
   
       51 . A method of manufacture of a plastics composite according to  claim 48  wherein the composite is used in the production from said mould of a fluid storage tank for a rail car. 
   
   
       52 . A method of manufacture of a plastics composite according to  claim 37  wherein the primer is a wetting binder solution applied to said fibrous layer and including a solvent which evaporates before closing the mould. 
   
   
       53 . A method of manufacture of a plastics composite according to  claim 52  wherein the binder is polystyrene or polymethylmethacrylate dissolved in their respective monomers styrene and methyl methacrylate as the solvent. 
   
   
       54 . A method of manufacture of a composite hollow vessel, the method comprising the steps of:
 a) taking a fibrous layer of material and placing the material into 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 first layer sufficient to morph from a solid to a flowable state;   f) allowing the first layer 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 first layer to cool so that at least some fibres of the at least one fibrous layer are embedded in the first layer;   b) removing the article from the mould.   
   
   
       55 . A method of manufacture of a composite hollow vessel according to  claim 54  comprising the further step of:
 applying a thermosetting resin to fibres of the fibrous layer not embedded in the first layer to form a second layer such that the first layer is bonded with the second layer.   
   
   
       56 . A method of manufacture of a composite hollow vessel comprising the further preliminary step of applying a release agent to the mould prior introduction of the fibrous layer. 
   
   
       57 . A mobile storage tank manufactured from a mould, the tank comprising a wall defining an internal space for holding tank contents; wherein, the wall is formed from at least two layers of plastics material and a reinforcing layer engaging each said layers, a first of said layers being a thermoplastics material and a second layer comprising a resin, wherein the reinforcing layer is interposed between said layers to form a plastics composite; and wherein the fibrous layer is pre treated with a primer comprising a wetting binder solution applied to said fibrous layer and including a solvent which evaporates before closing the mould. 
   
   
       58 . A mobile storage tank according to  claim 57  wherein the binder is polystyrene or polymethylmethacrylate dissolved in their respective monomers styrene and methyl methacrylate as the solvent. 
   
   
       59 . A hollow storage vessel 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 by joining 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. 
   
   
       60 . A vessel according to  claim 59  wherein, the fibrous layer provides reinforcing for the composite. 
   
   
       61 . A vessel according to  claim 60  wherein, the fibrous layer is at least partially embedded in said thermoplastic layer. 
   
   
       62 . A vessel according to  claim 61  wherein the fibrous layer is partially embedded in the thermoplastic layer by heat melting of the thermoplastic layer. 
   
   
       63 . A vessel according to  claim 62  wherein the thermoplastic layer has a smooth exposed surface and a second surface with the fibrous layer embedded therein. 
   
   
       64 . A vessel according to  claim 63  wherein the thermoplastic layer material is selected from the following materials polyethylene (HDPE), polypropylene (PP), polyvinylidene fluoride (PVDF), ethylene chloro tri fluoro ethylene (ECTFE). 
   
   
       65 . A vessel according to  claim 64  wherein thermosetting resins are, selected from a group including polyester, vinylester, epoxy and polyurethane. 
   
   
       66 . A vessel according to  claim 65  wherein, the fibrous layer material is selected from a group including woven cloth, mat or felt. 
   
   
       67 . A vessel according to  claim 66  wherein the vessel forms at least part of a fluid storage tank. 
   
   
       68 . A vessel according to  claim 67  wherein the storage tank is incorporated in a road transport vehicle. 
   
   
       69 . A vessel according to  claim 67  wherein the storage tank is incorporated in a rail transport vehicle. 
   
   
       70 . A vessel according to  claim 67  wherein the storage tank is incorporated in an aircraft wing road transport vehicle. 
   
   
       71 . A vessel according to  claim 59  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. 
   
   
       72 . A vessel according to  claim 71  wherein the binder is polystyrene or polymethylmethacrylate dissolved in their respective monomers styrene and methyl methacrylate as the solvent.