Prepreg, laminate body, fiber reinforced composite material, and manufacturing method for fiber reinforced composite material
AssigneeToray Industries, Inc.
InventorsAlfred P. Haro, Nobuyuki Arai
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Abstract
A permeable laminate body containing at least one partially impregnated prepreg which includes at least component (A) containing a matrix of reinforcing fiber, component (B) containing a thermosetting resin, and, optionally, component (C) containing a particle or a fiber of a thermoplastic resin exhibits long out time processability with good storage stability, achieving when molded and cured a fiber reinforced composite having a low void ratio and providing excellent mechanical performance.
Claims28
A partially impregnated prepreg configured to be laid up in multiple plies in a laminate body, the partially impregnated prepreg comprised of a component (A) comprising a matrix of reinforcing fiber and a component (B) comprising a thermosetting resin, wherein i) the matrix of reinforcing fiber is partially impregnated by component (B) and ii) the laminate body has a permeability of at least 4.0E-14 m2 after an out time of 20 days at 23° C. and a void ratio after cure of <1%.
A process for making a partially impregnated prepreg, comprising partially impregnating a component (A) comprising a matrix of reinforcing fiber with a component (B) comprising a thermosetting resin to form the partially impregnated prepreg, wherein component (B) is selected to have viscosity characteristics such that when the prepreg is laid up in multiple plies after an out time of 20 days at 23° C. to form a laminate body, the laminate body has a permeability of at least 4.0E-14 m2 and the void ratio of the laminate body after cure is <1%.
A partially impregnated prepreg, comprising a component (A) comprising a matrix of reinforcing fiber and a component (B) comprising a thermosetting resin, wherein component (A) is partially impregnated by component (B) and wherein component (B) comprises an amount of one or more epoxy resins which are solid at 30° C. and/or an amount of at least one thermoplastic resin dissolved in the thermosetting resin which is or are effective to impart to component (B) a viscosity at 30° C. of between about 20,000 and 140,000 Pa•s and a minimum viscosity of between about 0.1 and about 15 Pa•s.
A process for making a fiber reinforced composite material, comprising the steps of a) laying up a plurality of plies of prepreg to obtain a laminate body and b) curing the laminate body to obtain the fiber reinforced composite material, wherein the prepreg comprises a partially impregnated prepreg comprised of a component (A) comprising a matrix of reinforcing fiber and a component (B) comprising a thermosetting resin, wherein i) the matrix of reinforcing fiber is partially impregnated by component (B) and ii) the partially impregnated prepreg, when laid up in multiple plies after an out time of 20 days at 23° C., provides a test laminate body having a permeability of at least 4.0E-14 m2 and a void ratio after cure of <1%.
A process for making a fiber reinforced composite material, the process comprising:
- i) forming a laminate body having a permeability of at least 4.0E-14 m2 after an out time of 20 days at 23° C. by laying up a plurality of plies of prepreg, each ply comprising a partially impregnated prepreg comprised of a component (A) including a matrix of reinforcing fiber and a component (B) including a thermosetting resin, wherein the matrix of reinforcing fiber is partially impregnated by component (B);
- and
- ii) curing the laminate body to obtain a fiber reinforced composite material having a void ratio after cure of <1%.
Dependencies are inferred from the claim text.