Flexible polymer element for a curable composition

Process for the preparation of a curable composition comprising contacting a flexible polymer element with resin matrix by impregnating, injecting or infusing, or mixing;

• wherein the flexible polymer element is in the form of a mono or multi fiber, filament, ribbon, or mixtures or weave thereof and is in solid phase and adapted to undergo at least partial phase transition to fluid phase by solution on contact with the resin matrix component of the curable composition in which the flexible polymer element is soluble at a temperature which is less than the temperature for substantial onset of gelling and/or curing of the curable composition characterized in that the phase transition to fluid phase is by solution of the flexible soluble polymer element in the resin matrix component;
• wherein the flexible polymer element comprises at least one polyarylsulphone comprising ether-linked repeating units, optionally additionally comprising thioether-linked repeating units, the units consisting of
• -(PhAPh)n-
• and
• -(Ph)a-
• wherein A=CO or SO2, Ph is phenylene, n=1 to 2 and can be fractional, a=1 to 4 preferably a=1, 2, 3 and, can be fractional and when a exceeds 1, said phenylenes are linked linearly through a single chemical bond or a divalent group other than —CO— or —SO2— or are fused together directly or via a cyclic moiety, such as acid alkyl group, a (hetero) aromatic or cyclic ketone, amide, imide, imine;
• and
• wherein the resin matrix component is selected from the group consisting of an epoxy resin, an addition-polymerisation resin, a bis-maleimide resin, a formaldehyde condensate resin, a formaldehyde-phenol resin, a cyanate resin, an isocyanate resin, a Phenolic resin and mixtures of two or more thereof.

Method of preparing a complex shaped structure without use of a mould, comprising assembling a plurality of sections of a flexible polymer element by weaving and/or stitching to confer mechanical properties and/or to confer planarity, fold seams, reinforcing for hinges and bolt holes, or directional strengthening for assembly, and assembling the sections with use of flexible polymer element as stitching to hold the plurality of sections in place and infecting with a resin matrix component, wherein the flexible polymer element is in the form of a mono or multi fiber, filament, ribbon, or mixtures or weave thereof and is in solid phase and adapted to undergo at least partial phase transition to fluid phase by solution on contact with the resin matrix component of the curable composition in which the flexible polymer element is soluble at a temperature which is less than the temperature for substantial onset of gelling and/or curing of the curable composition characterized in that the phase transition to fluid phase is by solution of the flexible soluble polymer element in the resin matrix component;

• wherein the flexible polymer element is in the form of a mono or multi fiber, filament, ribbon, or mixtures or weave thereof and is in solid phase and adapted to undergo at least partial phase transition to fluid phase by solution on contact with the resin matrix component of the curable composition in which the flexible polymer element is soluble at a temperature which is less than the temperature for substantial onset of gelling and/or curing of the curable composition characterized in that the phase transition to fluid phase is by solution of the flexible soluble polymer element in the resin matrix component;
• wherein the flexible polymer element comprises at least one polyarylsulphone comprising ether-linked repeating units optionally additionally comprising thioether-linked repeating units, the units consisting of
• -(PhAPh)n-
• and
• -(Ph)a-
• wherein A=CO or SO2, Ph is phenylene, n=1 to 2 and can be fractional, a=1 to 4 preferably a=1, 2, 3 and, can be fractional and when a exceeds 1, said phenylenes are linked linearly through a single chemical bond or a divalent group other than —CO— or —SO2— or are fused together directly or via a cyclic moiety, such as acid alkyl group, a (hetero) aromatic or cyclic ketone, amide, imide, imine;
• and
• wherein the resin matrix component is selected from the group consisting of an epoxy resin, an addition-polymerisation resin, a bis-maleimide resin, a formaldehyde condensate resin, a formaldehyde-phenol resin, a cyanate resin, an isocyanate resin, a phenolic resin and mixtures of two or more thereof.