Thermosetting resin composition of a radically curable resin mixture and carbon fibre

Abstract

The invention relates to a thermosetting resin composition including a radically curable resin mixture of: a) 50-100 parts by weight of a radically curable resin that also contains a free monomer capable of copolymerising with it; b) 0-50 parts by weight of a shrink-resistant compound that can also contain an amount of copolymerisable free monomer, the total of (a) and (b) adding up to 100, and 2D-randomly distributed, discontinuous carbon fibres obtained by chopping split, continuous carbon fibre bundles to form packages of carbon filaments, which carbon bundles are provided with a sizing that is at least partially chemically bonded thereto, and with a binder whose solubility at room temperature in the copolymerisable free monomer present in the radically curable resin mixture amounts to at least 10% by weight, the weight percentage of carbon fibres relative to the resin composition being between 5 and 65% by weight, and optionally a filler also being present. The invention also relates to a process for the preparation of a thermosetting resin composition, as well as processes for the manufacture of 3D-moulded articles therefrom and to 3D-moulded articles themselves.

1 - 15 . (Canceled)  
     
     
         16 . A method of making from laminate a carbon-fiber-filled sheet molding compound having the characteristics of light weight, high stiffness and strength, the method comprising 
 providing chopped carbon fibers, a predetermined resin, a first carrier film and a second carrier film,    coating one side of one of the first and second carrier films with the predetermined resin to define a coated side of the one of the first and second carrier films,    depositing the chopped carbon fibers onto the coated side of the first carrier film,    covering the deposited carbon fibers with the second carrier film to define a compactible carbon-filled laminate, and    compacting the carbon-filled laminate to admix the resin with the carbon fibers between the films, whereby to form the carbon fiber-filled sheet molding compound.    
     
     
         17 . The method of  claim 16 , wherein the chopped carbon fibers have lengths between 5 and 100 millimeters.  
     
     
         18 . The method of  claim 16 , wherein the carbon fibers have a K value of greater 20.  
     
     
         19 . The method of  claim 16 , wherein the resin includes at most about 75% by weight of filler based on the weight of the resin.  
     
     
         20 . The method of  claim 16 , wherein individual filaments of the fibers are wetted as a result of compaction.  
     
     
         21 . The method of  claim 16 , further comprising maintaining the compacted laminate for a set time period to mature the laminate for further molding.  
     
     
         22 . The method of  claim 16 , further comprising coating one side of the other of the first and second films with the predetermined paste.  
     
     
         23 . The method of  claim 16 , wherein the step of compacting the carbon-filled laminate comprises rolling the carbon-filled laminate between hold-down rolls.  
     
     
         24 . The method of  claim 16 , wherein the first and second carrier films comprise polyethylene/polyamide.