Process and apparatus for forming thermosetting material

Abstract

The invention relates to a process for forming a cured, partially cured or uncured thermosetting material, comprising: an irradiation step wherein the thermosetting material is exposed to electromagnetic radiation which to a significant extent is within the near-infrared range in such a way that the temperature of the irradiated thermosetting material is brought to between 40° C. and 400° C., and a forming step wherein the irradiated thermosetting material is brought into a desired shape, whereby the forming step is executed during and/or subsequent to the irradiation step. The invention also relates to an apparatus for carrying out the said process and to a thermosetting material.

1 . Apparatus for shaping a multilayer laminate preform having at least on layer comprised of a partially cured thermosetting phenol and/or aminoplast resin, comprising:
 a) means of irradiating the multilayer laminate preform with electromagnetic radiation, whereby near infrared range with a wavelength of between 0.8 μm and 1.5 μm is at least 10% of the electromagnetic radiation, expressed in energy per surface area, that is directed at the multilayer laminate preform; and   b) means of exerting deformation force on the irradiated multilayer laminate preform.   
     
     
         2 . Apparatus according to  claim 1 , comprising means to irradiate the multilayer laminate perform with said electromagnetic radiation during the shaping of the multilayer laminate preform. 
     
     
         3 . Apparatus according to  claim 1 , wherein the intensity of the electromagnetic radiation aimed at the multilayer laminate preform can be set between 100 and 8000 kW/m 2 . 
     
     
         4 . Apparatus according to  claim 1 , comprising means to expose the multilayer laminate preform with said electromagnetic radiation from several sides. 
     
     
         5 . Apparatus according to  claim 1 , wherein means are present to terminate the irradiation step when the temperature of the multilayer laminate preform has reached the desired temperature, such termination being automated with the aid of temperature measurement on the multilayer laminate preform and a feedback circuit. 
     
     
         6 . Apparatus according to  claim 1 , wherein means are present to shape the multilayer laminate preform in 2D or 3D during the deformation step. 
     
     
         7 . Apparatus according to  claim 1 , wherein the means of exerting deformation force are means for shaping the multilayer laminate preform into the arc of a circle with a radius of at most 3 cm. 
     
     
         8 . Apparatus according to anyone of  claims 1 , comprising means to measure the deformation force as executed on the multilayer laminate perform during shaping. 
     
     
         9 . Apparatus according to  claim 8 , comprising means to adjust the amount of radiation as a function of the deformation force. 
     
     
         10 . Process for optimizing an existing apparatus for heating and/or forming a multilayer laminate preform having at least on layer comprised of a partially cured thermosetting phenol and/or aminoplast resin, characterized in that a radiation source is added which emits electromagnetic radiation which to a significant extent is within the near-infrared range.