Glass bubbles and low density sheet molding compound incorporating said glass bubbles

Abstract

A glass bubble includes a hollow glass body having an outer surface with a diameter of between about 16 micrometers and about 25 micrometers and a surface roughness of about 0.01% to about 0.1% of that diameter. A low density sheet molding compound incorporating a plurality of glass bubbles and resin is also disclosed.

Claims

1. A glass bubble, comprising: an air plasma treated hollow glass body having an outer surface with a diameter of between about 16 micrometers and about 25 micrometers and a surface roughness of about 0.01% to about 0.1% of said diameter, wherein air plasma treatment provides a surface energy to enhance chemical bonding of the hollow glass body.

2. A low density sheet molding compound, comprising a resin and a plurality of glass bubbles as set forth in claim 1.

3. A glass bubble, comprising: an air plasma treated hollow glass body having an outer surface with a diameter of between 16 micrometers and 25 micrometers and a surface roughness of 0.01% to 0.1% of said diameter, wherein air plasma treatment provides a surface energy to enhance chemical bonding of the hollow glass body.

4. A low density sheet molding compound, comprising a resin and a plurality of air plasma treated glass beads, each of said plurality of air plasma treated glass beads consisting of an air plasma treated hollow glass body having an outer surface with a diameter of between 16 micrometers and 25 micrometers and a surface roughness of 0.01% to 0.1% of said diameter, wherein air plasma treatment provides a surface energy to enhance chemical bonding between the plurality of glass beads and the resin.

5. The low density sheet molding compound of claim 4 having a density of about 1.2 g/cm.sup.3.

Description

BRIEF DESCRIPTION OF THE DRAWING FIGURES

(1) The accompanying drawing figures incorporated herein and forming a part of the specification, illustrate several aspects of the method and product of the method and together with the description serve to explain certain principles thereof. In the drawing figures:

(2) FIGS. 1a and 1b are schematic representations illustrating a glass bubble with an original smooth surface and the same glass bubble with a roughened surface after undergoing the method of surface treatment described herein.

(3) FIG. 2a is a schematic illustration of one possible embodiment of a device for subjecting glass bubbles in a spherical container with a roughened inner surface to rotation and spinning along two different axes A.sub.1, A.sub.2.

(4) FIG. 2b is a view similar to FIG. 2a but showing an alternative embodiment wherein the processing vessel is cylindrical in shape.

(5) FIG. 3a is a schematic illustration of one possible way to subject a plurality of glass bubbles to an air plasma treatment utilizing a vibrating conveyor belt.

(6) FIG. 3b is a schematic view illustrating an alternative embodiment wherein the glass bubbles are subjected to air plasma treatment while rolling down a ramp or a slide.

(7) FIG. 3c is a schematic illustration of another embodiment wherein a plurality of glass bubbles subjected to an air plasma treatment by dropping and falling through a tube.

(8) Reference will now be made in detail to the present preferred embodiments of the method, examples of which are illustrated in the accompanying drawing figures.

DETAILED DESCRIPTION

(9) Reference is now made to FIG. 1a illustrating a single glass bubble 10 comprising a hollow body 12 and a smooth outer surface 14. As shown in FIG. 1b, after being subjected to the method of treating that outer surface, the glass bubble 10 includes a hollow outer body 12 with a roughened outer surface 20. In one useful embodiment, the treated glass bubble 10 has a diameter of between about 16 m and about 25 m and a surface roughness of about 0.01% to about 0.1% of that diameter: that is, a surface roughness of between 160 nm to 2500 nm. A plurality of surface treated glass bubbles 10 as disclosed have a density of about 1.2 g/cm .sup.3. Further, the roughened outer surface 20 has the desired interfacial interaction with a resin to provide a low density sheet molding compound with desired mechanical properties and performance when used as a motor vehicle panel component.

(10) In order to achieve the desired roughening of the glass bubble surface 20, the glass bubbles may be subject to roughening in a spinning and rotating processing vessel as illustrated in FIGS. 2a and 2b, or air plasma treatment as illustrated in FIGS. 3a-3c or both.

(11) FIG. 2a illustrates one possible embodiment of a device 30 for processing the glass bubbles 10. The device 30 includes a processing vessel 32 of spherical shape that has a roughened internal lining 34. The processing vessel 32 is supported at two opposed points by means of the yoke 36. A drive motor 38 rotates (see action arrow B) the yoke 36 and, therefore, the processing vessel 32 about a first axis A.sub.1. A second drive motor 40 is carried on the yoke 36 and functions to spin the processing vessel 32 about a second axis A.sub.2 (see action arrow C). In the illustrated embodiment, the first axis A.sub.1 and the second axis A.sub.2 are substantially perpendicular to each other.

(12) A controller 42 connected to the two drive motors 38, 40 allows the speed of the drive motors to be set and changed as desired during the processing of the glass bubbles 10. The goal is to ensure that the entire outer surface of the plurality of glass bubbles 10 are roughened consistently throughout so as to provide an outer surface roughness of about 0.01% to about 0.1% of a diameter of the plurality of glass bubbles. Toward this end, the processing vessel 32 may be spun about axis A.sub.1 at a speed of between about 60 rpm and 600 rpm while being rotated about axis A.sub.2 at a speed of between about 60 rpm and 600 rpm. The controller 42 also allows the direction of spinning and the direction of rotating of the processing vessel 32 to be reversed as desired. Thus, for example, the processing vessel 32 may be rotated by the drive motor 38 in a first direction at a speed of between 60 and 600 rpm for a first period of time of, for example, from five to sixty seconds and then rotated in a second direction at a speed of between 60 and 600 rpm for a second period of time of, for example, from five to sixty seconds. Similarly, the processing vessel 32 may be spun by the drive motor 40 in a third direction at a speed of between 60 and 600 rpm for third period of time of, for example, from five to sixty seconds and then spun in a fourth direction at a speed of between 60 and 600 rpm for fourth period of time of, for example, from five to sixty seconds. The rotating and spinning and the periods of time may be sequential or overlapping. The reversing of direction aids in ensuring that the outer surface 20 of the glass bubbles 10 receive consistent overall roughening.

(13) FIG. 2b illustrates a device 46 similar to the device 30 illustrated in FIG. 2a. The device 46 includes a processing vessel 48 having a roughened lining 50, a yoke 52, a first drive motor 54, a second drive motor 56 and a controller 58. The two devices 30, 46 operate identically, the only difference is the processing vessel 48 in the second device 46 is cylindrical in shape rather than spherical in shape.

(14) Reference is now made to FIGS. 3a-3c illustrating three different devices for providing an air plasma treatment to the glass bubbles 10. In the embodiment illustrated in FIG. 3a, the glass bubbles 10 are positioned on a face 60, of a vibrating conveyor belt 62. Accordingly, the glass bubbles 10 bounce up and down as they move along the vibrating conveyor belt 62 through an air plasma stream 64 emanating from the overlying plasma probe 66.

(15) As illustrative FIG. 3b, the glass bubbles 10 roll down an incline, slide or ramp 68 through a plasma stream 70 emanating from the overlying plasma probe 72.

(16) In the embodiment illustrated in FIG. 3c, the glass bubbles 10 fall or drop through the tube 74 falling through the air plasma stream 76 emanating from the opposed plasma probes 78. In any of the air plasma treatment embodiments illustrated in FIGS. 3a-3c, the glass bubbles 10 are subjected to air plasma temperatures of between about 23 C. and about 500 C. and undergo an increase in surface energy that enhances their chemical bonding to a resin such as used in the production of a sheet molding compound. This increases the overall mechanical performance of a part made from that low density sheet molding compound thereby making the parts useful as panels such as hoods or the like in a motor vehicle.

(17) With the unique size and shape of glass spheres, the above three treatment processes are specially designed to allow for a full surface treatment. The bouncing, sliding and falling movements ensure that the glass bubbles have full exposure to the plasma stream. A full surface treatment imparts better mechanical properties and performance to the glass bubbles than a partial treatment.

(18) In summary, numerous benefits result from the surface treatment method disclosed in this document whether that method comprises only processing the glass bubbles 10 in the spinning and rotating processing vessels 32, 48 illustrated in FIGS. 2a and 2b, only processing the glass bubbles by means of the air plasma treatments illustrated in FIGS. 3a-3c or subjecting the glass bubbles to both rotating and spinning in the processing vessel and air plasma treatment.

(19) By increasing the roughness and/or surface energy of the surface 20 of the treated glass bubbles 10, chemical bonding between the glass bubbles and any resin used to make low density sheet molding compounds is enhanced thereby providing those sheet molding compounds with superior mechanical properties allowing their use as various panel components of a motor vehicle. This advantageously allows the production of lower weight motor vehicles which are characterized by increased fuel economy. Accordingly, the method disclosed herein and the resulting glass bubbles and low density sheet molding compound products made using the glass bubbles 10 with the roughened surfaces 20 represents a significant advance in the art.

(20) The foregoing has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Obvious modifications and variations are possible in light of the above teachings. All such modifications and variations are within the scope of the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.