US2011159757A1PendingUtilityA1

Custom-Moldable Composite Material

35
Individually held — no corporate assignee on recordPriority: Jun 29, 2009Filed: Jun 29, 2010Published: Jun 30, 2011
Est. expiryJun 29, 2029(~2.9 yrs left)· nominal 20-yr term from priority
Inventors:Jeffrey D. Percival
B29C 70/22D03D 15/593B29C 2035/0827Y10T442/10Y10T442/30Y10T442/3301B29C 70/885
35
PatentIndex Score
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Cited by
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References
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Claims

Abstract

A custom-moldable ultraviolet (UV) light curable composite material includes a piece of woven fabric having opposite first and second surfaces, a plurality of spaced wires woven into the piece of woven fabric in a crisscross pattern, an ultraviolet light curable resin permeating the fabric and wires, and dry, moldable, protective film layers that are removably attached to the opposite first and second surfaces of the piece of woven fabric. The plurality of wires woven into the piece of fabric allow the fabric to be molded into a desired configuration where the wires hold the fabric in the molded configuration. Exposing the molded fabric to ultraviolet light cures the resin and completes the fabrication of the composite in the molded configuration.

Claims

exact text as granted — not AI-modified
1 . A moldable composite material comprising:
 a piece of woven fabric having opposite first and second surfaces, the piece of woven fabric being permeated with an ultraviolet light-curable resin;   a first dry, moldable, protective layer of film removably attached to the first surface of the piece of woven fabric; and,   a second dry, moldable, protective layer of film removably attached to the second surface of the piece of woven fabric.   
     
     
         2 . The moldable composite material of  claim 1 , further comprising:
 the first protective layer of film being peelable away from the woven fabric first surface to expose the first surface; and,   the second protective layer of film being peelable away from the woven fabric second surface to expose the second surface.   
     
     
         3 . The moldable composite material of  claim 2 , further comprising:
 a first ultraviolet light shielding layer of film removably attached to the first protective layer of film; and,   a second ultraviolet light shielding layer of film removably attached to the second protective layer of film.   
     
     
         4 . The moldable composite material of  claim 2 , further comprising:
 the piece of woven fabric being completely sandwiched and enclosed between the first and second layers of film.   
     
     
         5 . The moldable composite material of  claim 1 , further comprising:
 a plurality of spaced wires woven into the piece of woven fabric.   
     
     
         6 . The moldable composite material of  claim 5 , further comprising:
 the plurality of wires being malleable wires.   
     
     
         7 . The moldable composite material of  claim 5 , further comprising:
 the plurality of wires being woven into the piece of woven fabric in a crisscross pattern.   
     
     
         8 . The moldable composite material of  claim 1 , further comprising:
 the piece of woven fabric being fiberglass cloth.   
     
     
         9 . The moldable composite material of  claim 1 , further comprising:
 the piece of woven fabric having a twill weave.   
     
     
         10 . A moldable composite material comprising:
 a piece of woven fabric having opposite first and second surfaces;   a plurality of spaced wires woven into the piece of woven fabric;   a curable substance impregnating the pieces of woven fabric, the curable substance curing on exposure to a curing agent;   a first dry film layer removably attached to the first surface of the piece of woven fabric; and, a second dry film layer removably attached to the second surface of the piece of woven fabric.   
     
     
         11 . The moldable composite material of  claim 10 , further comprising:
 the curable substance being an ultraviolet light curable substance and the curing agent being ultraviolet light.   
     
     
         12 . The moldable composite material of  claim 11 , further comprising:
 the first dry film layer and the second dry film layer being constructed of ultraviolet light transparent materials.   
     
     
         13 . The moldable composite material of  claim 11 , further comprising:
 a first ultraviolet light shielding film layer removably attached to the first dry film layer; and,   a second ultraviolet light shielding film layer removably attached to the second dry film layer.   
     
     
         14 . The moldable composite material of  claim 12 , further comprising:
 the first dry film layer and the second dry film layer being peelable away from the respective first and second surfaces of the piece of woven fabric.   
     
     
         15 . The moldable composite material of  claim 10 , further comprising:
 the plurality of wires being malleable wires.   
     
     
         16 . The moldable composite material of  claim 15 , further comprising:
 the plurality of wires being crisscrossed.   
     
     
         17 . The moldable composite material of  claim 10 , further comprising:
 the piece of woven fabric having a twill weave.   
     
     
         18 . The moldable composite material of  claim 10 , further comprising:
 the piece of woven fabric being fiberglass cloth.   
     
     
         19 . The moldable composite material of  claim 10 , further comprising:
 the piece of woven fabric having an elongate length with opposite first and second ends and having a rolled-up configuration around the first end.   
     
     
         20 . A moldable composite material comprising:
 a flexible mesh material having opposite first and second surfaces;   a plurality of regularly spaced malleable wires interwoven into the mesh material;   a curable substance permeating the mesh material and the interwoven wires, the curable substance curing upon exposure of the curable substance to a curing agent;   a first dry film layer removably attached to the first surface of the mesh material; and,   a second dry film layer removably attached to the second surface of the mesh material.   
     
     
         21 . The moldable composite material of  claim 20 , further comprising:
 the curable substance being an ultraviolet light curable substance and the curing agent being ultraviolet light.   
     
     
         22 . The moldable composite material of  claim 21 , further comprising:
 the curable substance being a resin.   
     
     
         23 . The moldable composite material of  claim 21 , further comprising:
 the plurality of wires interwoven into the mesh material being crisscrossed.   
     
     
         24 . The moldable composite material of  claim 21 , further comprising:
 the mesh material having a longitudinal length and a lateral width; and,   the plurality of wires interwoven into the mesh material being longitudinally and laterally oriented.   
     
     
         25 . The moldable composite material of  claim 21 , further comprising:
 the first dry film layer having ultraviolet light transparent properties; and,   the second dry film layer having ultraviolet light transparent properties.   
     
     
         26 . The moldable composite material of  claim 25 , further comprising:
 a first ultraviolet light shielding film layer removably attached to the first dry film layer; and,   a second ultraviolet light shielding film layer removably attached to the second dry film layer.   
     
     
         27 . The moldable composite material of  claim 25 , further comprising:
 the first dry film layer being peelable away from the first surface of the mesh material; and,   the second dry film layer being peelable away from the second surface of the mesh material.   
     
     
         28 . The moldable composite material of  claim 20 , further comprising:
 the mesh material being a woven fabric.   
     
     
         29 . The moldable composite material of  claim 20 , further comprising:
 the mesh material being fiberglass cloth.   
     
     
         30 . A moldable composite material comprising:
 a flexible material of interwoven warp and fill yarns, the material having opposite first and second surfaces defined by the opposite sides of the interwoven warp and fill yarns;   a plurality of regularly spaced, longitudinally and laterally oriented malleable wires interwoven in a crisscross pattern into the warp and fill yarns of the material;   an ultraviolet light curable resin permeating the interwoven warp and fill yarns of the material and the plurality of wires interwoven into the warp and fill yarns of the material;   a first dry, ultraviolet light transparent film removably attached to the first surface of the material, the first film being peelable from the first surface; and,   a second dry, ultraviolet light transparent film removably attached to the second surface of the material, the second film being peelable from the second surface.   
     
     
         31 . The moldable composite material of  claim 30 , further comprising:
 a first ultraviolet light shielding film removably attached to the first dry, ultraviolet light transparent film; and,   a second ultraviolet light shielding film removably attached to the second dry, ultraviolet light transparent film.

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