Folded core having a high compression modulus and articles...

B - Operations – Transporting – 31 – D

Patent

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Details

B31D 3/00 (2006.01) D21H 13/26 (2006.01) E04C 2/24 (2006.01)

Patent

CA 2730906

This invention is directed to a folded tessellated core structure having a high compression modulus. The core structure comprises a nonwoven sheet and a cured resin in an amount such that the weight of cured resin as a percentage of combined weight of cured resin and nonwoven sheet is at least 50 percent, The nonwoven sheet further comprises fibers having a modulus of at least 200 grams per denier (180 grams per dtex) and a tenacity of at least 10 grams per denier (9 grams per dtex) wherein, prior to impregnating with the resin, the nonwoven sheet has an apparent density calculated from the equation Dp = K x ((dr x (100 -- %r)/%r)/(1 + dr/ds x (100 - %r)/%r), where Dp is the apparent density of the sheet before impregnation, dr is the density of cured resin, ds is the density of solid material in the sheet before impregnation, %r is the cured resin content in the final core structure in weight %, K is a number with a value from 1.0 to 1.5, Further, the Gurley porosity of the nonwoven sheet before impregnation with the resin is no greater than 30 seconds per 100 milliliters. The invention is also directed to composite structures incorporating such folded core.

L'invention concerne une structure de noyau réduit en mosaïque plié qui présente un module de compression élevé. La structure de noyau comporte une feuille non tissée et une résine durcie en une quantité telle que le poids de résine durcie en tant que pourcentage du poids combiné de la  résine durcie et de la feuille non tissée est au moins de 50 %. La feuille non tissée comporte de plus des fibres ayant un module d'au moins 200 g par denier (180 g par dtex) et une ténacité d'au moins 10 g par denier (9 g par dtex), avant d'être imprégnée de résine, la feuille non tissée ayant une densité apparente calculée à partir de l'équation Dp = K × ((dr × (100 - %r)/%r)/(1 + dr/ds × (100 - %r)/%r), Dp étant la densité apparente de la feuille avant limprégnation, dr étant la densité de résine durcie, ds étant la densité de matériaux solides dans la feuille avant limprégnation, %r étant la teneur en résine durcie dans la structure de moyeu final en % de poids, K étant un nombre ayant une valeur de 1,0 à 1,5. De plus, la porosité Gurley de la feuille non tissée avant dêtre imprégnée de résine n'est pas supérieure à 30 secondes par 100 millilitres. L'invention concerne également des structures composites incorporant un tel noyau plié.

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