REINFORCED THERMOSETTING COMPOSITE MATERIAL

Abstract

The invention relates to a reinforced thermosetting composite, characterized in that it comprises sand, inert powder, thermosetting resin and fibers, a novel composition that enables advances to be made in relation to the prior art, allowing planners and constructors to implement their projects with alternatives that are more advanced and affordable than existing ones. This composite is totally impermeable, with a lower specific weight than cement concrete, and high compressive strength and tensile strength. It does not oxidize like iron or steel and is highly durable in terms of weather-resistance. Furthermore, important waste is used in the formulation of the composite, but no water, and the composite is sustainable as it can be recycled to produce new parts, and as such is eco-friendly.

Claims

1. A reinforced thermosetting composite material, characterized by comprising a mixture of, in percentage by weight, about 30-50% of sand, about 15-30% of fine inert powder, about 20-30% of resin of thermosetting resin, about 4-10% of fibers.

2. The reinforced thermosetting composite material according to claim 1, characterized in that one or more thermosetting resins are used.

3. The reinforced thermosetting composite material according to claim 2, characterized in that the resin is rigid or flexible polyester.

4. The reinforced thermosetting composite material according to claim 1, characterized in that the fibers are of the metallic, carbon, glass or natural type, or mixtures thereof.

5. The reinforced thermosetting composite material according to claim 1 or 4, characterized in that the fibers are in the thread segments form ranging in length from about 2-10.

6. A reinforced thermosetting composite material comprised of sand, fine powder, polyester resin, characterized by employing fibers with the objective of increasing its mechanical characteristics.

7. The reinforced thermosetting composite material according to claim 4, characterized in that the fiber is glass fiber.

8. The reinforced thermosetting composite material according to claim 1, characterized in that the inert fine powder is ashes from the burning of mineral coal, ore powder waste or gravel powder.

9. The reinforced thermosetting composite material according to any one of claims 1 to 7, characterized in that it comprises a mixture, in percentage by weight, of about 50% of dry sand, about 20% of dry mineral coal ashes, about 25% of resin of thermosetting resin, about 5% of fibers.

Description

DESCRIPTION OF THE INVENTION

[0011] The reinforced thermosetting composite material according to the present invention is defined as a composition comprising sand, fine powder, thermosetting resin and fibers.

[0012] More specifically, the reinforced composite material according to the present invention comprises a mixture, in percentage by weight, of about 30-50% of sand, about 15-30% of inert fine powder, about 20-30% of resin of thermosetting resin, about 4-10% of fibers.

[0013] Typically, one or more thermosetting resins can be used, but when only one is used, it is preferably rigid or flexible polyester.

[0014] The fibers used in the reinforced composite material according to the present invention can be metallic, carbon, glass or natural fibers, or mixtures thereof, among others as long as compatible with the other components of the reinforced composite material according to the present invention.

[0015] Preferably, glass fiber is used and, when used, it is preferably in the thread segments form.

[0016] A preferred formulation example of the reinforced composite material according to the present invention comprises a mixture, in percentage by weight, of about 50% of dry sand, about 20% of dry mineral coal ashes, about 25% of resin of thermosetting resin, about 5% of fibers.

[0017] A percentage of about 5% by weight of fibers seems low, but as usually said fibers have low specific weight, their volume is significant in the final product.

[0018] In the mixture of components of the reinforced composite material according to the present invention, a suitable mixer should be used, since the fibers will be in the form of short length threads, usually ranging from 2 to 10 cm, and the mass becomes quite consistent with gradual addition of said glass fibers. It can be considered that it is a “heavy mass” that must be mixed properly. Typically, a Sigma type mixer is used, not excluding others.

[0019] The thermosetting resin is preferably pre-accelerated and its catalyzing process, that is, the hardening reaction, is initiated as soon as components are mixed in the mixer, for a period of time sufficient to prepare the mixture and then transfer it to the mold for later pressing.

[0020] Alternatively, the mixture of components can be subjected to injection molding processes.

[0021] Also, with the use of fibers in the composite material, it is possible to obtain greater mechanical strengths, not only related to compression, but mainly tensile strength of the molded product. If there were no such fibers, the bond strength between the composition materials would depend exclusively on the resin anchored with the sand. As opposed to that, by employing fibers according to the present invention, said anchorage becomes a trinomial based on sand, resin and fibers, enabling greater strengths, mainly tensile strength, since the fibers will also be spread horizontally along the body of the part produced.

[0022] In addition, the reinforced composite material according to the present invention is eco-friendly, as it does not employ water in its composition, but rather important industrial waste, such as ashes from the burning of mineral coal or ore powder waste, such as gravel powder, among others. Additionally, it is sustainable, since instead of being discarded after any type of use, if applicable, it can be crushed and reused in the production process of new parts.

[0023] Thus, it is apparent to a person skilled in the art that pre-molded products manufactured with the reinforced composite material object of the present invention will be much stronger, and project leads may enjoy advantages in reduced dimensions, weight and costs in their projects, which cannot be achieved by other existing or proposed products on the market. It is especially suitable for various applications, and can be useful in replacing cement concrete in buildings, wooden crossties on railroads, wood and glass in furniture and utensils, among other numerous applications, since it is totally impermeable, has low specific weight, high compressive strength and tensile strength, does not oxidize like iron and steel and is highly durable exposed to weather.