Fireproof protection integrating fabrication system for composite structures
A composite structure having a substrate is protectively covered during fabrication by a barrier layer, such as an intumescent mat or felt, into which a fire resisting agent such as phenolic resin or water, or oil based intumescent coating is infused in-situ before attachment to the substrate and completion of composite structure fabrication. The barrier layer is infused in-situ with the phenolic resin before attachment by adhesive bonding to the substrate or infusion is performed during formation of the underlying substrate layer so as to achieve attachment without adhesive.
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The present invention relates generally to fabrication of composite structures in such a manner as to endow it with protective properties.
BACKGROUND OF THE INVENTIONComposite structures having a substrate made of a structural material such as glass/vinyl ester are presently utilized for shipboard use. Because of flammability concerns in regard to such structures, passive fire protection has been proposed involving attachment of insulation blankets by means of self tapping screws. Installation of such fire protection for composite structures is both labor intensive and costly, especially in Naval shipboard types of seawater environments. It is therefore an important object of the present invention to provide less costly and less labor intensive fire protection for the foregoing referred to types of composite structures.
SUMMARY OF THE INVENTIONIn accordance with the present invention, during fabrication of a composite structure having a solid substrate made of a preferred shipboard material such as glass/vinyl ester or a sandwich type substrate, a protective barrier layer is applied to such substrate with a fire resisting agent such as phenolic resin, water or an oil-based intumescent coating. According to certain embodiments, the barrier layer in its position or place is permeated or infused in situ with the phenolic resin before attachment by adhesive bonding to the substrate. According to other embodiments, the substrate is formed at the same time the barrier layer is infused with the phenolic resin so that it attaches the barrier layer to the substrate without use of adhesive.
A more complete appreciation of the invention and many of its attendant advantages will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawing wherein:
Referring now to the drawing in detail,
With continued reference to
As an alternative, the barrier layer 14 may be formed from other materials into which the fire resisting agent, such as the phenolic resin, is introduced in-situ by scrimping so as to provide protection from damage from fire and high temperature conditions during normal use of the composite structure, as well as to resist water and solvent damage.
It will be apparent from the foregoing description, that the protective barrier layer 14 or 14′ covers either a solid type substrate 12 or a composite core type substrate 12′ and that the fire resisting agent is introduced in-situ, for example by infusion of the phenolic agent, either before attachment of the barrier layer by bonding adhesive 16 or during formation of the substrate to avoid use of such bonding adhesive for attachment purposes.
Obviously, other modifications and variations of the present invention may be possible in light of the foregoing teachings. It is therefore to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
Claims
1. In a process for protective fabrication of a composite structure to be exposed to seawater environments, the improvement residing in a sequence of steps including: a) forming a barrier; b) introducing a fire resisting agent into the barrier after said forming thereof: c) forming a substrate; and d) attaching the barrier to the substrate in underlying relation thereto before completing the fabrication of the composite structure; wherein said introducing of the fire resisting agent comprises: infusion into the barrier.
2. In a process for protective fabrication of a composite structure to be exposed to seawater environments, the improvement residing in a sequence of steps including: a) forming a barrier, b) introducing a fire resisting agent into the barrier after said forming thereof: c) forming a substrate; and d) attaching the barrier to the substrate in underlying relation thereto before completing the fabrication of the composite structure; wherein said attaching of the barrier to the substrate is performed by providing an adhesive between the barrier and the substrate.
3. In a process for protective fabrication of a composite structure to be exposed to seawater environments, the improvement residing in a sequence of steps including: a) forming a barrier; b) introducing a fire resisting agent into the barrier after said forming thereof: c) forming a substrate; and d) attaching the barrier to the substrate in underlying relation thereto before completing the fabrication of the composite structure; wherein said introducing of the fire resisting agent is performed by infusion thereof into the barrier during said forming of the substrate to effect said attaching of the barrier to the substrate without using an adhesive.
5270105 | December 14, 1993 | Conroy et al. |
20010031350 | October 18, 2001 | Day et al. |
- Publication entitled “Fire Protection of Glass/Vinyl Ester Composites for Structural Applications” by U. Sorathia and C. Beck for 41st Internation SAMPE Symposium dated 24-28, 1996 pp. 687-697.
Type: Grant
Filed: Mar 29, 2001
Date of Patent: Nov 1, 2005
Assignee: The United States of America as represented by the Secretary of the Navy (Washington, DC)
Inventor: Usman A. K. Sorathia (Arnold, MD)
Primary Examiner: Aileen Felton
Attorney: Jacob Shuster
Application Number: 09/822,308