Composite article and method of manufacture
OwnerMasanori Kubota, Ayako Kubota +2inventors
InventorsMasanori Kubota, Ayako Kubota, Munetaka Kubota, Alexander Kubota
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Abstract
The present invention relates to a composite article and to a process for manufacturing the composite article. The composite article comprises multiple layers including high tenacity fibers incorporated into a fabric and a core thermoplastic resin. The fabric may be coated with a surface treatment agent and a polymer matrix resin. Single or multiple layers of the composite articles may be formed into a composite part having high strength, rigidity, fast molding cycle time and extremely good conformability in a 3-dimensional mold. The composite parts formed by this process have high part strength in all directions.
Claims20
A method of manufacture of a prepreg comprising:
- a) coating a fabric with a surface treatment agent;
- b) simultaneously or thereafter coating the fabric with a polymer matrix resin to form a treated, coated fabric;
- c) thereafter drying the treated, coated fabric;
- and
- d) thereafter applying a core thermoplastic resin onto the treated, coated fabric to form the prepreg.
A method of manufacturing a 2-ply prepreg comprising:
- a) coating at least two fabrics with a surface treatment agent;
- b) simultaneously or thereafter coating each fabric with a polymer matrix resin to form a first treated, coated fabric and a second treated, coated fabric;
- c) thereafter drying each treated, coated fabric;
- d) thereafter applying a core thermoplastic resin to a surface of each treated, coated fabric to form a first prepreg and a second prepreg;
- and
- e) thereafter adhering the first and second prepregs together to form a 2-ply prepreg.
A method of forming a composite part comprising:
- a) coating at least two fabrics with a surface treatment agent;
- b) simultaneously or thereafter coating each fabric with a polymer matrix resin to form a first treated, coated fabric and a second treated, coated fabric;
- c) thereafter drying each treated, coated fabric;
- d) thereafter applying a core thermoplastic resin to a surface of each treated, coated fabric to form a first prepreg and a second prepreg;
- e) thereafter adhering the first and second prepregs together to form a 2-ply prepreg;
- and
- f) thereafter forming the 2-ply prepreg into the composite part.
Dependencies are inferred from the claim text.