Prepregs, cores, composites and articles including repellent materials
AssigneeHanwha Azdel, Inc.
InventorsYankai Yang, Yu-Tsan Tseng, Erich Vorenkamp, Mark O Mason
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Abstract
Prepregs, cores and composite articles are described that comprise lighter weight materials and/or lower amounts of adhesive than commonly used. In some instances, one or more components of the articles may comprise a repellent material or repellent treatment to reduce the overall absorption rate of adhesive into the components of the article.
Claims17
A method of reducing an amount of adhesive used to couple components of a composite article comprising a porous core layer and a substrate coupled to a surface of the porous core layer using a thermoplastic adhesive, the method comprising:
- pre-treating a surface of the substrate, prior to formation of the composite article, with a repellent material that is effective to decrease absorption of the thermoplastic adhesive into the substrate when the substrate is coupled to the porous core layer to retain at least 50% of the thermoplastic adhesive on the surface of the pre-treated substrate, wherein the porous core layer comprises a web of open celled structures defined by random crossing over of reinforcing materials held together by a thermoplastic material, wherein the surface of the substrate pre-treated with the repellent material comprises a repellency grade number of at least 3 as tested by ISO 23232 dated 2009, and wherein a porosity of the porous core layer is greater than 50%;
- and
- coupling the pre-treated substrate to the porous core layer through the thermoplastic adhesive between the pre-treated substrate and the porous core layer to form the composite article.
A method of reducing an amount of adhesive used to couple components of a composite article comprising a porous core layer and a scrim coupled to a surface of the porous core layer using a thermoplastic adhesive, the method comprising:
- pre-treating a surface of the scrim, prior to formation of the composite article, with a repellent material that is effective to decrease absorption of the thermoplastic adhesive into the scrim when the scrim is coupled to the porous core layer to retain at least 50% of the thermoplastic adhesive on the surface of the pre-treated scrim, wherein the porous core layer comprises a web of open celled structures defined by random crossing over of reinforcing materials held together by a thermoplastic material, wherein the surface of the scrim pre-treated with the repellent material comprises a repellency grade number of at least 3 as tested by ISO 23232 dated 2009, and wherein a porosity of the porous core layer is greater than 50%;
- disposing the thermoplastic adhesive on the pre-treated surface of the scrim prior to coupling the scrim to the porous core layer through the thermoplastic adhesive;
- and
- coupling the pre-treated scrim to the porous core layer through the disposed thermoplastic adhesive between the pre-treated substrate and the porous core layer to form the composite article.
A method of reducing an amount of adhesive used to couple components of a composite article comprising a porous core layer and a substrate coupled to a surface of the porous core layer using a thermoplastic adhesive, the method comprising:
- pre-treating a surface of the substrate, prior to formation of the composite article, with a repellent material that is effective to decrease absorption of the thermoplastic adhesive into the substrate when the substrate is coupled to the porous core layer to retain at least 50% of the thermoplastic adhesive on the surface of the pre-treated substrate, wherein the surface of the substrate pre-treated with the repellent material comprises a repellency grade number of at least 3 as tested by ISO 23232 dated 2009, wherein a porosity of the porous core layer is greater than 50%, and in which the substrate comprises a film, a frim, a foil, a woven fabric or a non-woven fabric;
- and
- coupling the pre-treated substrate to the porous core layer through the thermoplastic adhesive between the pre-treated substrate and the porous core layer to form the composite article.
Dependencies are inferred from the claim text.