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US 10,472,474 B2Granted
Semipreg with thermoplastic toughened novolac-based epoxy resin matrix
AssigneeHexcel Corporation
InventorsKathlyn Lizette Baron, Gordon Emmerson, Yen-Seine Wang
Life of this patent
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Abstract
A semipreg that can be cured/molded to form aerospace composite parts including rocket booster casings. The semipreg includes a fibrous layer and a resin layer located on one side of the fibrous layer. The resin layer includes an epoxy component that is a combination of a hydrocarbon epoxy novolac resin and a trifunctional epoxy resin and optionally a tetrafunctional epoxy resin. The resin matrix includes polyethersulfone as a toughening agent and a thermoplastic particle component.
Claims6
A semipreg comprising:
- A) a fibrous layer comprising carbon fibers, said fibrous layer comprising a first side and a second side, said fibrous layer having a thickness defined by the distance between said first side and said second side;
- and
- B) a resin layer comprising uncured resin located on the first side of said fibrous layer, said uncured resin penetrating into said fibrous layer to an impregnation depth, said impregnation depth being less than the thickness of said fibrous layer, said uncured resin comprising:
- a) an epoxy resin component comprising a hydrocarbon epoxy novolac resin and a triglycidyl aminophenol epoxy resin;
- b) a thermoplastic particle component comprising a combination of polyimide particles and particles that comprise a polyamide which is the polymeric condensation product of 1,10-decane dicarboxylic acid and an amine component having the formula
- where both R2 are hydrogen and both R1 are methyl or hydrogen;
- c) a thermoplastic toughening agent which comprises polyether sulfone;
- and
- d) a curing agent.
6 more elements
A method for making a semipreg, said method comprising the steps of:
- A) providing a fibrous layer comprising carbon fibers, said fibrous layer comprising a first side and a second side, said fibrous layer having a thickness defined by the distance between said first side and said second side;
- and;
- and
- B) applying an uncured resin to the first side of said fibrous layer, said uncured resin penetrating into said fibrous layer to an impregnation depth, said impregnation depth being less than the thickness of said fibrous layer, said uncured resin comprising:
- a) an epoxy resin component comprising a hydrocarbon epoxy novolac resin and a triglycidyl aminophenol epoxy resin;
- b) a thermoplastic particle component comprising a combination of polyimide particles and particles that comprise a polyamide which is the polymeric condensation product of 1,10-decane dicarboxylic acid and an amine component having the formula
- where both R2 are hydrogen and both R1 are methyl or hydrogen;
- c) a thermoplastic toughening agent which comprises polyether sulfone;
- and
- d) a curing agent.
7 more elements
Dependencies are inferred from the claim text.