• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
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    • 专利摘要:
    curable composite material, and methods for making a curable composite material and for making a curable composite part. curable prepregs having enhanced capacity for removing gases from within prepregs and between layers of prepregs in a prepreg placement before and / or during consolidation and curing. each curable prepreg is a woven fabric impregnated with resin that has undergone a treatment to create an array of openings in at least one main surface. the location of the openings is specific to the weave pattern of the fabric. moreover, when these prepregs are placed and subjected to a volume reduction process to form a composite part, a shorter volume decrease time can be achieved compared to the use of prepregs without the same surface openings.
    公开号:BR112015014928B1
    申请号:R112015014928-6
    申请日:2013-12-20
    公开日:2021-03-30
    发明作者:Mark Roman；Stephen J. Howard；Jack D. Boyd；Scott Lucas
    申请人:Cytec Industries Inc.；
    IPC主号:
    专利说明:

    FUNDAMENTALS
    [001] Fiber-reinforced polymeric composites are high-performance structural materials that are composed of a resin matrix and reinforcement fibers. These fiber-reinforced polymeric composites have been used to manufacture structural parts that require high strength and / or low weight and resistance to aggressive environments. Examples of such structural parts include aircraft components (for example, tails, wings, fuselages, propellers). The fibers reinforce the resin matrix, carrying most of the load supported by the composite, while the resin matrix carries a minor portion of the load supported by the composite and also transfers load from broken fibers to intact fibers. In this way, these polymeric composites can withstand loads greater than each of the matrix resin or fibers can withstand alone. In addition, by customizing the reinforcement fibers to a particular geometry or orientation, the composite can be efficiently designed to minimize weight and volume.
    [002] Polymeric composites reinforced with fibers are traditionally made from sheets of fibers impregnated with resin, also known as prepregs. To form a composite part from the prepregs, a plurality of layers of prepregs can be placed inside a mold and heat can be applied to make the matrix resin flow, allowing consolidation of the prepregs layers. The applied heat can further cure or polymerize the matrix component.
    [003] The consolidation of prepregs to form composites in this way presents problems, however. Gases, such as air and other volatiles, can be trapped within the individual prepreg and between layers of prepreg during placement. In addition, volatiles can also evolve during the heating and / or curing of prepregs. These gases are difficult to remove from placement, as the matrix substantially inhibits the movement of the gases and can result in porosity within the final cured composite. Porosity refers to voids within the cured composite material. This porosity could also negatively affect the mechanical properties of the final cured composite.
    [004] Techniques have been developed to intensify the removal of trapped gases during the manufacture of composites, however, the problems continue. For example, edge respirators can be employed to apply vacuum to the edge of prepregs to extract gases from the sides of the prepreg layers. However, removing trapped gases from prepregs in this manner is slow and may not remove substantially all trapped gases.
    [005] The manufacture of composite parts from these prepregs requires volume reduction and a certain curing cycle to manufacture the part and develop the structural properties necessary for final use in any structure. Potentially and depending on the manufacturing method, volume reduction cycles before curing can be time consuming, adding additional cost. It would be desirable to have a methodology that can help to reduce the amount of time for volume reduction before curing when applicable. SUMMARY
    [006] Curable prepregs having enhanced capacity for removing gases from within prepregs and between layers of prepregs in a prepreg placement before and / or during consolidation and curing are described herein. Each curable prepreg is a resin-impregnated fabric that has been treated to create an array of openings on at least one main surface. The location of the openings is specific to the weave pattern of the fabric. In addition, when these prepregs are placed and subjected to a volume shrinking process to form a composite part, a shorter volume shrinkage time can be achieved compared to using prepregs without the same surface openings. BRIEF DESCRIPTION OF THE DRAWINGS
    [007] FIG. 1 schematically illustrates a portion of fabric where fibers are grouped in a passage in the weaving direction and then in clusters in the transverse direction.
    [008] FIG. 2 schematically shows a partially impregnated fabric according to an embodiment of the present disclosure.
    [009] FIG. 3 schematically shows openings created in a prepreg surface according to one embodiment of the present disclosure.
    [0010] FIG. 4 schematically shows openings created on opposite surfaces of a prepreg according to one embodiment of the present disclosure.
    [0011] FIG. 5 schematically shows a prepreg partially impregnated according to one embodiment.
    [0012] FIG. 6 shows the prepreg of FIG. 5 after heat treatment.
    [0013] FIG. 7 schematically shows a portion of a satin weft fabric.
    [0014] FIG. 8 schematically shows a resin surface with surface openings formed in the satin weft fabric of FIG. 7.
    [0015] FIG. 9 schematically shows a partially impregnated prepreg that has been subjected to heat treatment to create surface openings according to another embodiment.
    [0016] FIG. 10 schematically shows a portion of a single weave fabric.
    [0017] FIG. 11 schematically shows a resin surface with surface openings formed in the single weft fabric.
    [0018] FIG. 12 illustrates an exemplary prepreg system that is capable of making a prepreg fabric.
    [0019] FIG. 13 schematically shows a configuration for assembling a honeycomb core sandwich structure according to an example.
    [0020] FIG. 14 schematically shows the hive core sandwich structure produced from the assembly shown in FIG. 13.
    [0021] FIGS. 15 to 17 are microphotographs showing a top view image of a heat-treated prepreg surface in 1 minute, 4 minutes and 7.5 minutes, respectively, where the prepreg was produced using a satin weft fabric according to a example.
    [0022] FIG. 18 is a micrograph showing the top view image of a heat-treated prepreg surface, in which the prepreg was produced using a single weft fabric according to another example.
    [0023] FIG. 19 is a micrograph showing the top view image of a prepreg surface cured with air bubbles formed below the surface.
    [0024] FIG. 20 shows the cross-sectional view of a cured composite panel composed of untreated prepreg material.
    [0025] FIG. 21 shows the cross-sectional view of a cured composite panel composed of heat-treated prepreg material.
    [0026] FIG. 22 shows the effect of a process of decreasing the standard volume and resulting porosity in composites made of untreated 5320-1 / 8HS prepreg material using a 16-hour vacuum retention prior to curing.
    [0027] FIG. 23 shows the effect of an intensified volume and porosity reduction process resulting in composites made of prepreg 5320-1 / 8HS material heat treated using a 16 hour vacuum retention prior to curing.
    [0028] FIG. 24 shows the effect of a standard process and resulting porosity in composites made from untreated 5320-1 / 8HS prepreg material using a 0.5 hour vacuum retention prior to curing.
    [0029] FIG. 25 shows the effect of an intensified process and resulting porosity in composites made of prepreg 5320-1 / 8HS material heat treated using a vacuum retention of 0.5 hour before curing.
    [0030] FIG. 26 shows the effect of a standard process and resulting porosity on composites made from untreated 5320-1 / PW prepreg material using a 16 hour vacuum retention prior to curing.
    [0031] FIG. 27 shows the effect of an intensified process and resulting porosity in composites made of prepreg material 5320-1 / PW heat treated using a retention 16 hours under vacuum before curing.
    [0032] FIG. 28 shows the effect of a standard process and resulting porosity on composites made of untreated 5320-1 / PW prepreg material using a 0.5 hour vacuum retention prior to curing.
    [0033] FIG. 29 shows the effect of an intensified process and resulting porosity in composites made of prepreg 5320-1 / PW material heat treated using a 0.5 hour vacuum retention prior to curing. DETAILED DESCRIPTION
    [0034] The curable prepreg disclosed here is composed of a fabric impregnated with resin. The fabric has two opposite faces and a weave pattern in which one or more filament strands in a first weave direction float over one or more filament strands in a second weaving direction, then pass under one or more filament strands in the second weaving direction, where a transverse / bottom location on one side of the fabric is created when a first filament yarn in the first weaving direction passes over a second filament yarn in the second weaving direction, then passes under a third adjacent filament yarn in the second weaving direction, or when the first filament yarn passes under a second filament yarn in the second weaving direction, then through a third adjacent filament yarn in the second weaving direction. The transverse / bottom location in this context refers to the portion of the first filament cable that is rising or falling between the second and third adjacent filament cables.
    [0035] The fabric to produce the prepreg is made from fiber cables. The filament ropes are interwoven in a weaving pattern in which one or more filament ropes in a first weaving direction float over one or more filament ropes in a second weaving direction, then pass under one or more filament ropes in the same second weaving direction. Due to the weave configuration, the two main faces of the fabric contain pockets in them, so they are neither smooth nor flat everywhere.
    [0036] FIG. 1 schematically illustrates that, due to the weave configuration of the fabric, there are pockets P created on the fabric surface whenever there is a portion of filament cable that crosses or passes under another transverse filament cable, that is, the transverse location /bottom. Still referring to FIG. 1 going from left to right, when a filament yarn 11 in the first weaving direction crosses over another filament yarn 12 in a second / transverse weaving direction, then passes under an adjacent filament yarn 13 in the same second / transverse weaving direction, a portion of the "down" filament cable T1 is created and when the filament cable 11 passes under the filament cable 13, then over an adjacent filament cable 14 in the second / transverse weave direction one "up" T2 filament cable portion is created. These two portions of filament cable "up" and "down" result in pockets P. In other words, if the fabric is located on a horizontal planar surface, pocket P is created whenever there is a change in the elevation of the cable filament in relation to the planar surface. It should be understood that FIG. 1 shows just one example of a fabric weave and that more complex fabric weaves, such as tri-axial weave, are contemplated here.
    [0037] The curable prepreg also has a hot melt curable resin film covering each face of the fabric and partially penetrates through the thickness of the fabric, leaving an intermediate section of the fabric in the direction of the thickness, substantially free of the resin film. A matrix of openings is formed in one or both resin films, where each opening exposes the pocket (P in FIG. 1) formed at the transverse / lower location in the weave pattern of the fabric according to one embodiment. In some embodiments, the resin film is continuous everywhere, except where the openings are located. According to another embodiment, the matrix of openings in the resin is aligned with the interstices in the fabric. This modality belongs to certain fabrics, such as flat weave fabric.
    [0038] The openings are configured to allow gases, such as air, to flow from the middle section of the fabric to at least one outer surface of the prepreg or at least one outer surface of the prepreg to the middle section or an outer surface of the prepreg to an opposite surface, or a combination thereof. The openings also allow for gas transfer, as well as vacuum establishment that provides the driving force for the resin to impregnate vacuum-rich areas.
    [0039] The openings disclosed here are specific to the fabric weave, unlike prepregs with surface openings formed by conventional mechanical techniques that are used to form a global hole pattern or random hole pattern.
    [0040] For the purposes of this document, the term "curable" means not completely cured and includes the condition not cured.
    [0041] Each filament cable is a bundle of fiber filaments. The number of filaments in each bundle can be in multiples of 1000, for example, 1000 to 75,000. Filament cables having less than 15,000 filaments per bundle are contemplated for the intended purposes disclosed herein. The term "filament" refers to a relatively flexible continuous structure having a high length to width ratio.
    [0042] Fiber materials for fiber filament cables include, but are not limited to, glass (including electric or E-glass), carbon (including graphite), aramid (eg Kevlar), high modulus polyethylene ( PE), boron, quartz, basalt, ceramic, polyester, poly-p-phenylene-benzobisoxazole (PBO) and their combinations. For the production of high-performance composite materials, for example, materials for aerospace applications, fibers that have tensile strength greater than 3500 MPa are desirable.
    [0043] The weave configuration of the fabric is not limited and may include flat weave, satin weave, twill weave and the like. In a fabric roll, the longitudinal filament cables are in the direction of the warp and the lateral filament cables are in the direction of the weft. In a flat weft, the warp and weft filament cables form a simple cross pattern. Each weft filament cable crosses the warp filament cable over one, then under the next, and so on. The satin weft is characterized by two or more weft filament cables that pass over a single warp filament cable, or vice versa, two or more filament cables floating over a single warp filament cable. The twill weave is characterized by passing the warp filament cable over one or more weft filament cables and then under one or more weft filament cables and so on, with an offset between rows to create the characteristic diagonal pattern.
    [0044] FIG. 2 schematically illustrates a partially impregnated fabric (i.e., layers of prepreg or prepreg fabric) according to one embodiment of the present disclosure. A fabric with fiber filament cables 20 is covered on both long sides with an upper resin film 21 and a lower resin film 22. Each resin film partially penetrates through the thickness (Tf) of the fabric, leaving an intermediate section of the fabric substantially free of the resin. After partial impregnation, a plurality of closed air pockets 23 are formed between the resin films and the fabric, as illustrated in FIG. 2. The closed air pockets coincide with the pockets formed at the transverse / lower locations in the fabric weave.
    [0045] The weight ratio of fabric to matrix resin in the porous curable prepreg can be varied, as dictated by the application. In one embodiment, the weight fraction of the fabric can vary from 20% by weight to 80% by weight based on the total weight of the prepreg. In another embodiment, the weight fraction of tissue in a porous prepreg is less than 20% by weight, when the porous prepreg is used as a surface film on a composite substrate or prepreg placement. The fraction of the prepreg occupied by the matrix resin can also be varied as desired. In certain embodiments, the matrix resin can occupy between about 20% by weight and 80% by weight of the prepreg based on the total weight of the prepreg. Prepregging method
    [0046] According to one embodiment, the method for making the curable prepreg disclosed above includes partial impregnation of a fabric with a curable resin matrix followed by a heat treatment to create a matrix of surface openings. The method for partially impregnating the fabric with a matrix resin is not limited, but a "hot melt" prepregging method is preferred. In general, this prepregging method is characterized by impregnating a layer of fabric with a hot melt resin composition, in molten form, to yield a partially impregnated prepreg. The impregnation can be done by sandwiching a layer of fabric between two resin films and pressing the laminate obtained by hot plates, heated rolls or by a method in which the laminate is pressed between hot metal belts. Alternatively, the fabric is laminated to a resin film on one side only, leaving the other side substantially free of resin.
    [0047] As an example, a hot melt curable resin composition can be applied in the form of a thin resin film on a release paper and the resulting resin film released therefrom is laminated and formed into a layer of fabric. Heat is applied to lower the viscosity of the resin film, so that it is in a molten state and can penetrate the fabric to a desired level, preferably only partially through the fabric in order to leave a central dry portion. It should be understood that the high temperature applied during impregnation is lower than the initial cure temperature of the hot melt resin. Sufficient pressure is also applied during lamination, so that the resin film partially penetrates through the thickness of the fabric layer, thereby resulting in the fabric layer being partially impregnated with the resin composition in the thickness direction. The matrix resin remains uncured immediately after impregnation. For some embodiments, the resin film applied to each side of the fabric can have a film weight of 10 to 200 gsm (g / cm2) and the fabric can have a weight per fabric area (FAW) of 100 to 600 gsm. After partial impregnation, a continuous resin film covers one or both of the main faces of the fabric and partially penetrates through the thickness of the fabric, leaving the middle section of the fabric substantially free of the resin.
    [0048] During heat treatment, a release or support paper is left on the exposed surface of the prepreg resin film and heat is applied until the resin film becomes flowable. In certain embodiments, the viscosity of the resin during heat treatment is lower than 500 Poise at 90 ° C. Heating is carried out until the portions of resin film on the air pockets open, creating openings in the resin film that correspond to the locations of the air pockets. The resin film breaks by dehumidifying the release film with the resin moving laterally towards the areas adjacent to the pocket. In some cases, the resin film breaks at the edges of the air bubble and moves laterally inward, leaving a minimal drop of resin that is removed when the release paper is peeled from the prepreg. The openings can be created on a surface of the prepreg as illustrated in FIG. 3 (openings 30), or on both opposite surfaces of the prepreg as illustrated in FIG. 4 (openings 40). As a result of heat treatment, the openings create fluid passages for transporting air or other gases from the outer surface (s) of the prepreg to the middle section of the fabric.
    [0049] The heat treatment to create openings in the prepreg can be carried out as a post-treatment after the fabric has been partially impregnated with the resin films by a standard prepregging process. Alternatively, heat treatment can be done in situ during the prepregging process. It should be understood that the high temperature applied during the heat treatment is lower than the starting cure temperature of the matrix resin, and is used to start the resin flow in order to open the closed air pockets. This flow of resin can lead to a lower volume factor. Volume factor is defined as the ratio of the thickness of uncured prepreg materials to their thickness when completely cured.
    [0050] In one embodiment, a satin weaving fabric impregnated with resin is subjected to a post-treatment to create a matrix of openings. With reference to FIG. 5, a satin weft fabric 50 is sandwiched between an upper resin film 51 and a lower resin film 52. The upper resin film 51 is formed on a release paper 53 and the lower resin film 52 is formed on a paper release (or support) 54. The release paper can be coated with a silicone film. The resulting laminate is subjected to hot pressing to form a partially impregnated prepreg, for example, in a prepregging machine. After resin impregnation, air pockets 55 are created below the resin film. Next, with reference to FIG. 6, the release paper 54 which is attached to the lower resin film 52 is replaced by a polyester film 56. The polyester film is placed on one side after removing one of the release papers, to facilitate lamination of the final prepreg . Still referring to FIG. 6, the prepreg partially impregnated with the release paper and the polyester film in it is then heated in a heating cycle, whereby the resin portions of the upper resin film 52 that are on the air pockets break and move / flow away from air pockets. As a result, openings 57 are created in the resin film 51. Heat treatment can be carried out by exposing the prepreg to a heat source which is adjusted to a predetermined temperature for a selected period of time. The prepreg can be stationary during exposure to heat, or it can be in motion through a heating zone via a continuous process. Alternatively, other heating sources can be used, such as Hot Plate, Laser, heated drum, ultrasonic, jet of hot air, etc.). The temperature and time period of the heat treatment can be varied depending on the viscosity of the minimum resin to allow flow and sufficient time for the flow to occur. Thinner resin films flow faster, so higher film weights require more time. As an example, the post-treatment can be applied to a roll of prepreg material in the form of a web that has been formed via a standard continuous prepreg fabrication method. In such a post-treatment, the continuous prepreg is unrolled and continuously transported, under tension, through a horizontal heating oven where the prepreg is exposed to heat and then wrapped in a take-up roll. Depending on the length of the oven, the time of exposure to heat versus the speed of transport can be controlled to create the desired openings. In one embodiment, the impregnation resin is a hot melt epoxy matrix which is a viscoelastic solid at room temperature (20 ° C to 25 ° C) and is curable within the temperature range of 250 ° F to 350 ° F (121 ° C to 177 ° C); the heating cycle can be carried out for 0.25 to 20 minutes within the range of 120 ° F to 250 ° F (49 ° C to 121 ° C).
    [0051] FIG. 7 shows an exemplary satin weave configuration, more specifically, 8-Harness satin weave and locations 70 where air pockets can be created when the satin weave fabric is partially impregnated with the resin films as described above. It should be understood that, in reality, the intersecting filament cables shown in FIG. 7 are actually closer and more tightly woven. FIG. 8 schematically shows a surface of thermally treated prepreg after impregnation with resin and heat treatment as described above with reference to FIGS. 5 and 6, and the locations of the openings in the resin film in relation to the transverse / lower locations in the fabric weaving.
    [0052] FIG. 9 schematically shows a partially impregnated flat woven fabric 95 that has been subjected to heat treatment to create openings 100 that are formed through the upper and lower resin films 96, 97. The resin films 96, 97 are supported by release papers / support 98, 99, respectively.
    [0053] FIG. 10 shows an exemplary flat woven fabric and the interstices 101 formed therein. It should be understood that, in reality, the intersecting filament cables shown in FIG. 7 are actually closer and more tightly woven. FIG. 11 schematically shows a surface of heat-treated prepreg after impregnation with resin and heat treatment as described above with reference to FIG. 9, and the locations of the openings in the resin film in relation to the interstices 101 in the fabric web. Note that the openings are aligned with the interstices 11.
    [0054] FIG. 12 schematically shows an exemplary prepregging system that is able to manufacture a prepreg fabric and provide heat treatment in situ. With reference to FIG. 12, a continuous fabric web 80 is conveyed to a first pressure clamping zone formed by a pair of heated pressure rollers 81, 82. The fabric web 80 is sandwiched between two resin films 83, 84 which are unwound of feed rollers 85, 86. Each of the resin films 83, 84 is formed on a continuous release paper. The resin films 83, 84 are pressed on the upper and lower faces, respectively, of the fabric web 80 with the help of pressure rollers 81, 82. The pressure and heat of the pressure rollers 81, 82 make the films resin 83, 84 partially impregnate the fabric web 80, thereby forming a partially impregnated prepreg. The partially impregnated prepreg then passes over a heating plate 87. At this point, heating is performed to create openings in the prepreg. After heat treatment, the resulting porous prepreg is transported through a cooling plate 88, where the porous prepreg is cooled to solidify the resin. The cooled prepreg is then transported by pulling rollers 89, 90 and guided by additional guide rollers to a winding roll 91 where it is rolled up. This type of process is particularly suitable for creating openings in a prepreg that is based on the use of a flat weave fabric, particularly low GSM fabrics, where the heat treatment is fast due to the fineness of the fabric and the film (s) ( s) of impregnation.
    [0055] The openings formed in the heat-treated prepregs are irregular in shape and are not uniform in size. The shapes and sizes of the openings depend on the weave pattern and the heat treatment time. The size of the openings increases as the resin flow progresses over time. As examples, the openings may be of substantially circular cross-section with a diameter in the range of 0.1 to 3 mm or approximately rectangular in cross-section with width and length within the range of 0.1 mm to 3 mm. In addition, after a certain period of treatment time, for example, a treatment time of 1 to 8 minutes may be sufficient to create the openings. In addition, after a certain period of treatment time, some openings may become connected to each other, depending on the initial proximity of the openings to each other. In some cases, some trapped air pockets may not open due to imperfect processing conditions, for example, when the release paper is not adherent to the resin film during heat treatment. Matrix Resin
    [0056] The matrix resin to produce the curable prepreg described here is based on a curable hot melt composition, characterized in that it is initially a solid or semi-solid at approximately room temperature (20 ° C to 25 ° C), if it melts at an elevated temperature at which the material is applied, solidified by cooling and is curable by curing. In addition, the matrix resin must have sufficient viscosity and wetting characteristics to allow the formation of air pockets and, subsequently, the formation of openings through the heat treated air pockets. In one embodiment, the hot melt resin composition is a curable thermosetting resin composition composed of one or more thermosetting resins as the main component and is substantially free of any organic solvent, such as acetone, methyl ethyl ketone (MEK), dioxolane , alcohol. When used to produce a finished cured product, these thermoset resins are cured using a catalyst or curing agent, heat or a combination of the two.
    [0057] Suitable thermosetting resins may include, but are not limited to, epoxies, unsaturated polyesters, bismaleimide and combinations thereof. These thermoset resins can be completely cured by using heat, or a curing agent, or a combination thereof. Catalysts can be used to accelerate the curing reaction. When thermosetting resins are fully cured, they become hardened and cannot be converted back to their original shape.
    [0058] In one embodiment, the matrix resin is a thermosetting composition based on epoxy that contains one or more multifunctional epoxy resins as the main polymeric component. Suitable epoxy resins include aromatic diagly polyglycidyl derivatives, aromatic primary monamines, aminophenols, polyhydric phenols, polyhydric alcohols, polycarboxylic acids. Examples of suitable epoxy resins include polyglycidyl ethers of bisphenols, such as bisphenol A, bisphenol F, bisphenol S and bisphenol K; and polyglycidyl ethers of novolacs based on cresol and phenol.
    [0059] Suitable bismaleimide resins may include N, N'bismaleimides of 1,2 ethanediamine, 1,6-hexanediamine, trimethyl-1,6-hexanediamine, 1,4-benzene-diamine, 4,4'-methylenebisbenzenamine, 2 -methyl- 1,4-benzenediamine, 3,3'-methylenebisbenzenamine, 3,3'sulfonylbisenzenamine, 4,4'-sulfonyl-bisbenzenamine, 3,3'oxybisenzenamine, 4,4'oxybisenzenamine, 4,4'-methylenebisciclohexanamine 1,3-benzenodimethanamine, 1,4-benzene-dimethanamine and 4,4'-cyclohexanobisbenzenamine and their mixtures.
    [0060] The matrix resin may additionally include, in small amounts, thermoplastic materials such as polysulfones, polyether sulfones, polyether ketones (e.g., polyether ketones (PEK), polyether ether ketones (PEEK), polyether ketones) ketone (PEKK) and the like), their combinations, and their precursors. One or more thermoplastic materials are added to the matrix resin to increase the prepreg's toughness, tackiness and draping ability.
    [0061] The matrix resin, as discussed here, may also comprise additives, in smaller amounts, to influence one or more of the mechanical, rheological, electrical, optical, chemical and / or thermal properties of the matrix. Such additives can also comprise materials that react chemically with the matrix, interact with the matrix or are not reactive with the matrix. Examples of additives may include, but are not limited to, stiffening particles, flame retardants, ultraviolet (UV) stabilizers, antioxidants, dyes and fillers (for example, smoked silica, alumina, calcium carbonate, talc) to intensify one or more more than data tolerance, toughness, wear resistance.
    [0062] Prepregs with surface openings (ie, porous prepregs), as disclosed herein, are configured to allow dimensional stability of the openings. The openings, once formed, can remain dimensionally stable for a selected period of time. In certain embodiments, the openings may remain dimensionally stable during storage of the porous prepregs. Dimensional stability can be provided by customizing the viscosity of the matrix resin. The matrix resin is formulated to form dimensionally stable openings at about room temperature, but the resin is able to flow at an elevated temperature during consolidation or curing to fill the openings.
    [0063] "Total impregnation", as discussed herein, refers to the incorporation of substantially all fibers of the fabric within the matrix resin. "Partial impregnation", as discussed herein, refers to impregnation that is less than complete impregnation, so there are regions of dry fibers that are not incorporated within the matrix resin. In a preferred embodiment, the matrix resin is applied to both surfaces of the fabric layer, but the resin only penetrates partially through the thickness of the fabric, so as to leave an intermediate section of the fabric, in the direction of the thickness, substantially free of resin.
    [0064] The term "dimensional stability" as used herein refers to the ability of a structure to maintain the dimension within a selected range for a selected period of time. In certain embodiments, the selected range can be determined by the ability of the structure to perform a desired function, such as allowing a gas to pass at a selected rate under a selected pressure.
    [0065] The term "room temperature", as used herein, refers to temperatures within the range of 20 ° C to 25 ° C. Placement of prepregs and composite parts
    [0066] To form a composite piece, a plurality of curable prepregs disclosed herein can be placed in a prepreg placement and then the placement is consolidated and cured. Consolidation and healing can be carried out in a single stage or separately.
    [0067] Prepregs with surface openings (i.e., porous prepregs) have been found to facilitate the removal of gases from individual prepregs and prepreg placement containing one or more porous prepregs thereon before and / or during consolidation and thus , reduce the volume of porosity within composites formed therefrom compared to composites formed without porous prepregs. For example, the openings provide escape routes for gases from within the porous prepregs and allow gases to be removed from the prepregs more easily and in greater volume compared to untreated prepregs. The gases may include gases that originate from within the matrix resin or the resin-free zone of the partially impregnated prepreg or gases that originate from the interlayer region between layers of prepreg. In particular, porous prepregs allow the removal of gases that can evolve from the resin composition during consolidation.
    [0068] The term "prepreg placement", as used herein, refers to a plurality of prepregs that are placed adjacent to each other in a stacking arrangement. In certain embodiments, the prepregs within the placement can be positioned in a selected orientation with respect to each other. In another embodiment, the prepregs can optionally be sewn together with a spinning material in order to inhibit their relative movement from a selected orientation. In additional embodiments, "placements" may comprise any combination of fully impregnated prepregs, partially impregnated prepregs and porous prepregs, as discussed herein. Placements can be manufactured by techniques that may include, but are not limited to, manual placement, automated tape placement (ATL), automated fiber placement (AFP) and filament winding.
    [0069] The consolidation or reduction of volume refers to a process that occurs under the action of one or more of heating, vacuum formation and applied pressure, reason why the matrix resin flows in order to displace empty spaces. For example, consolidation may result in, but is not limited to, resin flow into voids between fibers in the prepreg, voids between prepregs and the like.
    [0070] The terms "cure" and "cure" as used herein may include polymerization and / or crosslinking processes. Curing can be carried out by processes that include, but are not limited to, heating, exposure to ultraviolet light and exposure to radiation. In additional embodiments, the matrix resin within the porous prepreg can be formulated or partially cured in order to exhibit a selected tack or stickiness.
    [0071] When a plurality of curable prepregs with surface openings are used in a prepreg placement, the placement has an uncanny ability to remove gases (e.g., air) trapped within the prepregs and between layers of prepregs. During consolidation / decrease in volume of the prepreg placement, the openings and resin-free regions within the prepregs provide multiple routes for gases trapped within the prepregs and between the prepregs to escape, thereby reducing the porosity within the resulting consolidated composite. Consequently, upon curing, the cured composite exhibits improved mechanical properties. For example, cured composites having residual porosity less than 1% by volume, based on the total volume of the composite, can be achieved in this way.
    [0072] When openings are formed on both main surfaces of the curable prepeg, gases can travel through the prepreg entering one surface and exiting through the opposite surface. The openings also allow the vacuum to fully penetrate the prepeg laminate stack. In addition, the openings create channels with transverse / lower locations to create air passage along the interface of two adjacent prepeg layers. Various flow paths can be created by any combination of surface openings, interlayer regions and non-impregnated (resin-free) portions of the prepregs. For example, gases from the interlayer region between adjacent prepregs can enter through openings on one side of a prepreg and then through the resin-free intermediate section of the same prepreg in order to escape to the outside. Alternatively, gases can flow from an interlayer region to the next interlayer region via openings on opposite sides of each prepreg and eventually flow out of the prepreg placement. This is an improvement compared to standard products without heat treatment, because in a standard product where the resin film remains intact, it is more difficult to get air to transfer between layers and to the layer core, whereas with heat-treated material, air transfer is intensified due to the number of openings. These various flow paths considerably enhance the ability of trapped gases to escape prepreg placement and also create channels with adjacent up / down regions to create vents along the interface of two adjacent layers.
    [0073] The viscosity of the matrix resin can be controlled to flow and fill empty spaces within and between prepregs during consolidation. For example, in one embodiment, the viscosity of the matrix resin can be controlled by formulating the resin to flow and fill the voids by applying heat, without external pressure. In another embodiment, the viscosity of the matrix resin can be controlled by formulating the resin to flow and fill voids by applying heat and external pressure and, optionally, under vacuum. Advantageously, by allowing openings and other voids to be filled during consolidation, the porosity of the resulting composite is substantially reduced or eliminated.
    [0074] Decreasing volume of prepreg placement can be accomplished using a vacuum bag configuration. In this configuration, the placement of curable prepreg can be placed in contact with a tool and then closed with an impermeable membrane. The tool can have a relatively planar surface, curved surface or other three-dimensional configuration. In one embodiment, a breather layer, such as an impregnated fiberglass sheet, can be positioned adjacent to at least one of the horizontal surfaces of the surface breather placement. Sealing tapes can also be used, as necessary, to create an approximately vacuum tight seal between the tool and the membrane. To inhibit the flow of resin out of the placement, or to improve the flow of gas, one or more dams can also be placed adjacent to the edges of the placement. A perforated release film (for example, perforated polyester film) can be inserted between the breather layer and the prepreg placement and a solid release film (for example, polyester film) can be inserted between the prepreg placement and the tool to facilitate the removal of the consolidated composite from the configuration. The closed volume is evacuated and the placement is heated slowly until consolidation occurs. Heating can be applied by placing the vacuum bag configuration in an oven or in an autoclave. In addition, heating can be carried out with pressure (for example, in an autoclave) or without pressure (for example, inside an oven), in order to lower the viscosity of the matrix and induce pressure differentials that allow the matrix resin flow. The resin flow can fill empty spaces within the prepreg placement and displace gases from the placement when the matrix viscosity is low enough to facilitate volume decrease. Consequently, the placement is cured at a higher temperature inside the same autoclave or oven to produce a final composite part.
    [0075] It has been found that the amount of time under vacuum before curing, otherwise referred to as the volume decrease cycle, could be substantially reduced when the heat-treated prepregs are processed in the vacuum bag configuration discussed above. This is a result of the ability of intensified prepregs to remove air and gases, as discussed earlier.
    [0076] A composite sandwich structure can be produced using the porous prepregs disclosed here. In one embodiment, a central core 130 composed of wood, foam, honeycomb or other structural materials is sandwiched between two prepreg settings 131, 132, as shown in FIG. 13, in which some or all of the layers of prepregs in the placement contain surface openings. The resulting composite sandwich structure is illustrated by FIG. 14. Optionally, folded layers can be placed between layers of porous prepregs in order to create elongated reinforcement zones. In addition, non-impregnated or partially impregnated light curtains, such as fiberglass, carbon, thermoplastic or other woven or non-woven materials, can be introduced within the placements at selected locations to facilitate gas removal or to increase properties mechanical damage tolerance.
    [0077] When the prepreg placement incorporates a core structure, an adhesive material can also be employed in order to bond the core to the prepreg material prior to curing the prepreg placement. As the open central core structures, such as the honeycomb structure, can contain a significant amount of gases, the adhesive layer can also be perforated in order to facilitate the removal of the gases.
    [0078] The heat treatment disclosed here can be incorporated into the manufacturing process of a composite part in a parts builder, either before or during placement. Heat treatment of any prepreg layer could be carried out in situ during the prepreg placement process by applying heat to a prepreg material or layer before it is placed, what it is being placed on, or after a prepreg layer has been placed and before laying a subsequent next layer. For example, the process may include: placing a layer of prepreg covered on a surface with a release paper or polyester film; heat treat using a heated roller, hot air rod, hot iron, etc., to form surface openings; remove the release paper / polyester film; put the next layer of prepreg; and repeated as necessary until a prepreg placement of desired thickness is formed. EXAMPLES
    [0079] The following examples are provided to demonstrate the benefits of the disclosed curable prepregs modalities. These examples are discussed for illustrative purposes and should not be construed to limit the scope of the disclosed modalities. Example 1
    [0080] A prepreg fabric was prepared by a hot melt process using a prepregging machine in which two resin films formed from a hardened epoxy based resin, Cycom 5320 (available from Cytec Industries Inc.) are pressed against the upper and lower surfaces of an 8-Harness carbon fiber satin weaving fabric, so the fabric is sandwiched between the two resin films. Each resin film was formed on a silicone coated release paper and has a unit area weight of 106 gsm per film. The carbon fiber fabric has a FAW of (370) gsm and a thickness of 0.0146 in. Heat and pressure were applied to the laminate to cause the resin films to melt and partially penetrate through the thickness of the fabric. One of the release papers was replaced with a smooth polyester film after prepregging to facilitate roll up. The prepreg pre-impregnated with the release paper on top and polyester film underneath was heated in an oven for 2 to 5 minutes at 200 ° F (93 ° C). This heat cycle time was considered to be sufficient to open the closed air pockets without impacting the mechanical or physical characteristics of the prepreg. FIGS. 15 to 17 show the top view image of the prepreg surface, with the release paper removed, in 1 minute, 4 minutes and 7.5 minutes, respectively, of heating time. The openings coincided with the transverse / lower locations (i.e., up / down portions of filament cable) in the satin weaving fabric. As can be seen from FIGS. 15 to 17, the sizes of the openings have become larger over time. After 7.5 minutes, some openings, which were aligned in the same row and adjacent to the transverse / lower locations of the adjacent filament cables were touching each other, as can be seen from the image in FIG. 13. These openings correspond to the upward / downward filament cable portions of the satin weaving fabric (as indicated by reference number 70 in FIG. 7). It was noted that the openings were formed only on the side of the thermally treated prepreg release paper. Example 2
    [0081] A prepreg fabric was prepared using the prepregging system shown in FIG. 12. The fabric used was a plain weave carbon fiber fabric and the resin films applied to opposite sides of the fabric were formed from Cycom 5320 epoxy based resin. Each resin film was formed on a release paper silicone coated and has a unit area weight of 55 gsm. The carbon fiber fabric has a FAW of 190 gsm and a thickness of 0.0083 ". For partial impregnation, 20 psi were applied in the first tightening zone; 220 ° F (104 ° C) was the temperature in the heating plate; and a clearance of less than 0.5 in (12.7 mm) was provided in the second clamping zone to limit the compaction force Fig. 18 shows the top view image of the prepreg surface heat treated with the release paper The openings on the surface of the prepreg coincide with the interstices in the flat weave fabric, and it was observed that the openings were formed on both main surfaces of the heat-treated prepreg. Example 3
    [0082] For comparison, a control prepreg was prepared as described in Example 1, without post-heat treatment to create surface openings. FIG. 19 shows the surface of the resulting prepeg with closed air bubbles formed below the continuous resin film. These air bubbles correspond to the up / down filament cable portions in the satin weaving fabric. Thus, it can be seen that, without heat treatment before curing, air trapped in air pockets and the air between layers that cannot escape remained in the resulting cured prepreg due to the fact that the continuous resin film limits the removal of pre-preg air. Example 4
    [0083] A 12 "x12" monolithic panel consisting of 15 layers of 5320 / 8HS prepreg material as described in Example 1 was constructed and cured. For comparison, the same panel was constructed using untreated 5320 / 8HS pre-preg material and cured under the same conditions. The resulting porosity was reduced from 1.31% without treatment to 0.04% with heat treatment. FIG. 20 shows the cross section of the panel composed of untreated material, and FIG. 21 shows the cross section of the panel composed of thermally treated material. Example 5
    [0084] A honeycomb core sandwich structure was assembled based on the configuration shown in FIG. 13, in which 10 layers of porous prepreg (201) were placed over a hive core (202) and 14 layers of porous prepreg (203) were placed under the hive core. The porous prepreg layers were produced by partially impregnating satin weaving carbon fiber fabric with Cycom 5320 resin, followed by heat treatment to create surface openings, as described in Example 1. The assembled sandwich structure was vacuum bagged, consolidated at room temperature and cured in an oven (not autoclave).
    [0085] For comparison, a standard honeycomb core sandwich structure was assembled, consolidated and cured in the same way, except that the prepreg layers were not heat treated to create the surface openings.
    [0086] Porosity was measured in different sections of the cured product, including flange, chamfered sections, central core and an average porosity was calculated. Porosity was measured by visual microscopy of cross sections of polished panel.
    [0087] The cured product resulting from the use of porous prepregs was considered to contain about 0.05% porosity, on average, compared to 2.0% porosity for the standard cured product. Example 6
    [0088] A honeycomb core sandwich structure was assembled using layers of porous prepreg and was based on the configuration of FIG. 13. The porous prepreg layers used for this structure were composed of flatwoven carbon fiber fabric and Cycom 5320 resin and the openings in the prepreg layers were produced by heating in situ during the prepregging process as described in Example 2. Subsequently, the assembled sandwich structure was vacuum bagged, consolidated at room temperature and cured in an oven (not autoclave). For comparison, a standard honeycomb core sandwich structure was assembled, consolidated and cured in the same way, except that the prepreg layers were not heat treated to create the surface openings.
    [0089] The cured product resulting from the use of porous prepregs was considered to contain about 0.18% porosity, on average, compared to 1.74% porosity for the standard cured product. Example 7
    [0090] Composite panels were manufactured from 5320-1 / 8HS prepregs in order to determine whether the amount of time under vacuum before curing, otherwise known as the volume decrease cycle, could be reduced, thereby lowering the overall time of cure. Vacuum time before curing ranged from 0.5 hour to 16 hours using heat treated prepregs and untreated prepregs (as a control).
    [0091] 12 "x12" monolithic panel consisting of 15 layers of 5320-1 / 8HS heat-treated prepreg material as described in Example 1 was constructed and cured using two different curing cycles. For comparison, the same panel was constructed using untreated 5320 / 8HS pre-preg material and cured under the same two curing cycles. The first curing cycle consisted of a 16-hour vacuum retention prior to curing. The second curing cycle consisted of a 0.5 hour vacuum retention prior to curing.
    [0092] C-scan was used to determine whether the cured panels were free of porosity. C-scan is a non-destructive inspection technique for composites in which a short pulse of ultrasonic energy is incident on a sample. Measurement of the transmitted pulse indicates attenuation in the incident pulse sample. The attenuation of the pulse is influenced by voids, delamination, curing state of the resin, the fraction of fiber volume, the condition of the fiber / matrix interface and any strange inclusions present. Thus, the ability to c-scan to determine the amount of porosity present in a finished panel or part is an accepted way in the quality control industry. The sensitivity of the c-scan can detect porosity up to a very low percentage, such as less than 2% voids. These panels are compared to a known porosity reference panel in order to determine the amount of porosity present in the sample under inspection. The panels demonstrated the ability to show differentiation as measured by c-scan in the range of 0.00% to 2.00% accurately. The panels were also destructively tested and cross-sectioned to determine the% porosity to compare with the c-scan using a cross-sectioned polished surface. The cross-sectional images of the tested composite panels are shown in FIGS. 22 to 25.
    [0093] The porosity resulting from the retention of 16 hours under vacuum reduced the porosity 1.46% without treatment to 0.02% with heat treatment. FIG. 22 shows the cross section of the panel made up of untreated prepreg material and FIG. 23 shows the cross section of the panel composed of thermally treated material. The porosity resulting from the 0.5 hour vacuum retention reduced the porosity from 2.53% without treatment to 1.06% with heat treatment. FIG. 24 shows the cross section of the panel composed of untreated material, and FIG. 25 shows the cross section of the panel composed of thermally treated material.
    [0094] The results show that the amount of time under vacuum before curing can be substantially decreased by using heat-treated prepregs. This is a result of the ability of heat-treated prepregs to remove air and gases, as discussed earlier. Example 8
    [0095] Composite panels were manufactured from 5320-1 / PW prepregs in order to determine whether the amount of time to decrease in volume under vacuum before curing could be reduced, thereby lowering the overall curing time. Vacuum time before curing ranged from 0.5 hour to 16 hours using both heat-treated and untreated prepregs (as a control).
    [0096] 12 "x12" monolithic panel consisting of 15 layers of 5320-1 / PW heat-treated prepreg material as described in Example 1 was constructed and cured using two different curing cycles. For comparison, the same panel was constructed using untreated 5320-1 / PW pre-preg material and cured under the same two curing cycles. The first curing cycle consisted of a 16-hour vacuum retention prior to curing. The second curing cycle consisted of a 0.5 hour vacuum retention prior to curing. The composite panels produced were tested as described in Example 7, and the cross-sectional images of the tested composite panels are shown in FIGS. 26 to 29.
    [0097] The porosity resulting from the retention of 16 hours under vacuum reduced the porosity from 0.83% without treatment to 0.23% with heat treatment. FIG. 26 shows the cross section of the panel made up of untreated prepreg material and FIG. 27 shows the cross section of the panel composed of thermally treated material. The porosity resulting from the 0.5 hour retention under vacuum has not been shown to reduce porosity, indicating that 0.5 hour residence in vacuum before curing is insufficient time to remove air for the tested PW-based material. FIG. 28 shows the cross section of the panel made up of untreated prepreg material and FIG. 29 shows the cross section of the panel composed of thermally treated material.
    [0098] Although the previous description has shown, described and pointed out the fundamental innovative characteristics of the present teachings, it will be understood that various omissions, substitutions and changes in the shape of the details of the device, as illustrated, as well as its uses, can be made by those skilled in the art, without departing from the scope of the present teachings. Therefore, the scope of the present teachings should not be limited to the previous description, but should be defined by the appended claims.
    [0099] The terms "approximately", "about" and "substantially" as used herein represent an amount close to the declared quantity that still performs the desired function or achieves the desired result. For example, the terms "approximately", "about" and "substantially" may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% and within less than 0.01% of the declared quantity.
    权利要求:
    Claims (15)
    [0001]
    1. Curable composite material, characterized by the fact that it comprises: a fabric having two opposite faces and a weave pattern in which one or more filament strands in a first weaving direction float over one or more filament strands in a second direction of weaving then passes under one or more filament cables in the second weaving direction; where a pocket is defined on the fabric surface when a first filament cord in the first weave direction passes over a second filament cord in the second weave direction, then, beneath an adjacent third filament cord in the second weave direction , or when the first filament cable passes under a second filament cable in the second weaving direction, then over an adjacent adjacent filament cable in the second weaving direction, and the pocket location is defined by the portion of the first filament cable that is going up or down between the second and third adjacent filament cables; a hot melt curable resin film covering one or both sides of the fabric and partially penetrating through the thickness of the fabric leaving an inner section of the fabric in the direction of thickness, substantially free of the resin film, in which the film of hot-melt resin is substantially solid at a temperature within the range of 20 ° C to 25 ° C and becomes flowable at an elevated temperature below an initial curing temperature of the resin film; and an array of openings in at least one of the resin films, each opening exposing at least a portion of the pocket on the fabric surface and configured to create a fluid flow path from the inner section of the fabric to at least one outer surface of the material composite, or at least one outer surface of the composite material for the inner section, or an outer surface of the composite material for an opposite outer surface, or combination thereof.
    [0002]
    2. Curable composite material, characterized by the fact that it comprises: a fabric having two opposite faces and a weave pattern in which a filament cable in a first weaving direction passes over another filament cable in a second weaving direction, then , passes under an adjacent filament cable in the second weaving direction, and interstices are defined between adjacent filament cables; a hot melt curable resin film covering one or both sides of the fabric and partially penetrating through the thickness of the fabric leaving an inner section of the fabric in the direction of thickness, substantially free of the resin film, in which the film of hot-melt resin is substantially solid at a temperature within the range of 20 ° C to 25 ° C and becomes flowable at an elevated temperature below an initial curing temperature of the resin film; and an array of openings in at least one of the resin films, each opening exposing an interstice in the fabric and configured to create a fluid flow path from the inner section of the fabric to at least one outer surface of the composite material, or at least an outer surface of the prepreg for the inner section, or an outer surface of the composite material to an opposite outer surface, or a combination thereof.
    [0003]
    3. Curable composite material according to claim 1, characterized by the fact that the weave pattern of the fabric is satin weave or twill weave.
    [0004]
    4. Curable composite material according to claim 2, characterized in that the weave pattern of the fabric is flat weave.
    [0005]
    5. Curable composite material according to claim 4, characterized in that the openings are formed through opposite external surfaces of the prepreg.
    [0006]
    6. Curable composite material according to claim 1, characterized by the fact that the weave pattern is satin weave, the openings are formed through one or both surfaces of the prepreg.
    [0007]
    7. Curable composite material according to any one of the preceding claims, characterized in that the hot melt resin film comprises one or more thermosetting resins as a major component and is substantially free of any organic solvent.
    [0008]
    8. Curable composite material according to any one of the preceding claims, characterized in that the hot melt resin film comprises one or more epoxy resins, a curing agent and at least one thermoplastic or elastomeric compound.
    [0009]
    9. Curable composite material according to any one of the preceding claims, characterized in that each filament cable comprises a plurality of fiber filaments comprising a material selected from: glass, carbon, aramid, polyethylene (PE), boron, quartz, basalt, ceramic, polyester, poly-p-phenylene-benzobisoxazole (PBO) and their combinations.
    [0010]
    10. Method for making a curable composite material with a matrix of surface openings, the method characterized by the fact that it comprises: (a) partially impregnating a fabric with a curable, hot melt resin such that, after partial impregnation , a continuous resin film covers one or both of the main faces of the fabric and partially penetrates through the thickness of the fabric leaving an intermediate section of the fabric, in the direction of the thickness, substantially free of said resin, in which the curable, melting resin The hot film is in the form of a thin resin film on a release paper, in which the hot melt resin film is substantially solid at a temperature within the range of 20 ° C to 25 ° C and becomes flowable at a temperature elevated below a resin film start cure temperature, and where during partial impregnation, heat is applied at a temperature lower than the hot melt resin start cure temperature; where the fabric has two opposite faces and a weave pattern in which one or more filament strands in a first weave direction pass over one or more filament strands in a second weave direction, then pass under one or more filament cables in the second weaving direction; wherein a pocket is defined on one side of the fabric when a first filament cord in the first weave direction passes a second filament cord in the second weave direction, then, under an adjacent third filament cord in the second weave direction, or when the first filament cable passes under a second filament cable in the second weaving direction, then over an adjacent third filament cable, and where the partially impregnated fabric comprises a plurality of closed air pockets, each air pocket coincides with a pocket on the fabric surface; and (b) heating the partially impregnated fabric while the release paper is left on the exposed surface of the resin film on at least one side of the fabric so that the resin film becomes fluid and, subsequently, portions of the resin film on the air pockets rupture by dehumidifying the surface of the release paper, thereby creating openings in the resin film that correspond to the locations of the expanded air pockets, where the openings are configured to provide fluid flow paths from the inner section of the fabric for at least one outer surface of the composite material, or at least one outer surface of the composite material for the inner section, or from an outer surface of the composite material to an opposite surface, or combination thereof.
    [0011]
    11. Method for making a curable composite material with a matrix of surface openings, the method characterized by the fact that it comprises: (a) partially impregnating a fabric with a curable, hot melt resin such that, after impregnation partial, a continuous resin film covers one or both of the main faces of the fabric and partially penetrates through the thickness of the fabric leaving an intermediate section of the fabric, in the direction of the thickness, substantially free of said resin, in which the curable, melting resin The hot melt film is in the form of a thin resin film on a release paper, in which the hot melt resin film is substantially solid at a temperature within the range of 20 ° C to 25 ° C and becomes flowable at a elevated temperature below a resin film start cure temperature, and where during partial impregnation, heat is applied at a temperature lower than the hot melt resin start cure temperature and, where the fabric has two opposite faces and a weaving pattern in which a filament cable in a first weaving direction passes over another filament cable in a second weaving direction, then passes under an adjacent filament cable in the second direction of weaving, interstices are defined between adjacent filament cables; and (b) heating the partially impregnated fabric while the release paper is left on the exposed surface of the resin film on at least one side of the fabric so that the resin film becomes fluid and, subsequently, portions of the resin film on the interstices open by dehumidifying the surface of the release paper, thereby creating openings in the resin film that correspond to the locations of the interstices, where the openings are configured to provide fluid flow paths from the inner section of the fabric to at least one surface outer of the composite material, or at least one outer surface of the composite material for the inner section, or from an outer surface of the composite material to an opposite surface, or combination thereof.
    [0012]
    Method according to claim 10 or 11, characterized in that the outer surface of the resin film is covered with a release paper or polyester film during heating.
    [0013]
    13. Method for manufacturing a curable composite part, characterized by the fact that it comprises: placing a plurality of layers of prepregs to form a prepreg placement, in which at least some of the layers of prepregs are layers of porous prepregs with surface openings, and each layer of porous prepreg is the composite material produced by the method as defined in one of claims 10 to 12.
    [0014]
    14. Method for making a curable composite part, characterized by the fact that it comprises: forming a wide composite material by a method as defined in one of claims 10 to 12; cutting the broad composite material into prepreg layers of predetermined sizes; placing the prepreg layers to form a prepreg placement, wherein the heating step is performed to form openings in the material before the material is cut.
    [0015]
    15. Method for making a composite part, characterized by the fact that a total curing time is reduced as a result of a decrease in the volume decrease time before curing, said method comprising: placing a plurality of curable composite material as defined in one of claims 1 to 9, to form a composite placement; decrease the volume of the composite placement to remove air and volatiles from it by: (a) sealing a vacuum bag over the composite placement; (b) creating a vacuum from within said vacuum bag; (c) applying external pressure to the vacuum bag; and (c) continue to create a vacuum and apply pressurization for a predetermined period of time; and cure the placement of composite after decreasing in volume.
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    同族专利:
    公开号 | 公开日
    KR102176663B1|2020-11-09|
    MX2015007367A|2015-10-14|
    CN104903390B|2018-06-15|
    US10329696B2|2019-06-25|
    EP2900739A1|2015-08-05|
    KR20150100811A|2015-09-02|
    US10821680B2|2020-11-03|
    WO2014100543A1|2014-06-26|
    EP2900739B1|2018-03-14|
    US20140174632A1|2014-06-26|
    CN104903390A|2015-09-09|
    US20140174641A1|2014-06-26|
    CA2896062A1|2014-06-26|
    TWI643730B|2018-12-11|
    US9802358B2|2017-10-31|
    US9259879B2|2016-02-16|
    US20190153634A1|2019-05-23|
    CA2896062C|2020-09-15|
    TW201436999A|2014-10-01|
    RU2618068C2|2017-05-02|
    MY170880A|2019-09-11|
    US20180009176A1|2018-01-11|
    RU2015129705A|2017-01-27|
    AU2013361142B2|2017-04-20|
    AU2013361142A1|2015-05-07|
    JP2016501971A|2016-01-21|
    MX367475B|2019-08-23|
    JP6300326B2|2018-03-28|
    BR112015014928A2|2017-07-11|
    ES2672333T3|2018-06-13|
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    法律状态:
    2018-02-27| B25A| Requested transfer of rights approved|Owner name: CYTEC INDUSTRIES INC. (US) |
    2018-03-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-03-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-03-20| B06I| Publication of requirement cancelled [chapter 6.9 patent gazette]|Free format text: ANULADA A PUBLICACAO CODIGO 6.6.1 NA RPI NO 2462 DE 13/03/2018 POR TER SIDO INDEVIDA. |
    2020-05-26| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2021-03-09| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-03-30| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 20/12/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201261740560P| true| 2012-12-21|2012-12-21|
    US61/740,560|2012-12-21|
    PCT/US2013/076819|WO2014100543A1|2012-12-21|2013-12-20|Curable prepregs with surface openings|
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