Composite materials and method of making

Abstract

A method for forming improved composite materials using a thermosetting polyester urethane hybrid resin, a closed cavity mold having an internal heat transfer mechanism used in this method, and the composite materials formed by this method having a hybrid of a carbon fiber layer and a fiberglass layer.

1 . A composite material comprising:
 at least one carbon fiber layer   at least one fiberglass layer   at least one polymeric flow media,   the layers permeated with a thermosetting polyester urethane hybrid resin comprising:   a polyester resin   an isocyanate resin   a peroxide catalyst   a promoter   and a filler.   
     
     
         2 . The composite material of  claim 1  wherein said carbon fiber is a mixture of amorphous carbon and graphitic carbon. 
     
     
         3 . The composite material of  claim 1  wherein the fiberglass and graphite are chopped. 
     
     
         4 . The composite material of  claim 1  wherein the fiberglass is selected from the group S glass, E glass, C glass. 
     
     
         5 . The composite material of  claim 1  wherein said promoter is a cobalt promoter. 
     
     
         6 . The composite material of  claim 1  wherein said filler is a calcium carbonate filler. 
     
     
         7 . A composite material comprising:
 a first carbon fiber layer and a second carbon fiber layer   a first fiberglass layer and a second fiberglass layer, the first fiberglass layer and second fiberglass layer juxtaposed between the first carbon fiber layer and the second carbon fiber layer,   a polymeric flow media juxtaposed between the first fiberglass layer and the second fiberglass layer,   the layers permeated with a thermosetting polyester urethane hybrid resin comprising:   a polyester resin   an isocyanate resin   a peroxide catalyst   a promoter   and a filler.   
     
     
         8 . The composite material of  claim 7  wherein said carbon fiber is a mixture of amorphous carbon and graphitic carbon. 
     
     
         9 . The composite material of  claim 7  wherein the fiberglass and graphite are chopped. 
     
     
         10 . The composite material of  claim 7  wherein said promoter is a cobalt promoter. 
     
     
         11 . The composite material of  claim 7  wherein said filler is a calcium carbonate filler. 
     
     
         12 . The composite material of  claim 7  wherein the fiberglass is selected from the group S glass, E glass, C glass. 
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . (canceled) 
     
     
         17 . (canceled) 
     
     
         18 . The method of  claim 13  wherein said promoter is provided as a cobalt promoter. 
     
     
         19 . (canceled) 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . (canceled) 
     
     
         25 . (canceled) 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . A closed cavity mold having a plug, a bolster, and a skin, wherein said plug, bolster, and skin are formed as having a thermal conductivity of at least 10 W/mK, and said bolster and said skin further having a liquid flow through their interior for temperature control.