# US 2014/0360344 A1 · High performance thermoplastic composite laminates and composite structures made therefrom

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- Number: US 2014/0360344 A1
- Document ID: US20140360344A1
- Status: Published application
- Kind: A1
- Application number: 14/213,153
- Filed: 2014-03-14
- Published: 2014-12-11
- Earliest claimed: 2013-03-15
- Assignees: Gordon Holdings, Inc.
- Applicants: Gordon Holdings, Inc.
- Inventors: Edward D. Pilpel; Jonathan Spiegel; Benjamin D. Pilpel; Bruno Reich
- Web page: https://patentgrep.com/patent/US20140360344A1

## CPC

- B32B 27/281: {comprising polyimides}
- B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
- B32B 3/28: characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence)
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 5/024: {Woven fabric}
- B32B 5/12: characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/22: characterised by the presence of two or more layers which {are next to each other and are fibrous, filamentary, formed of particles or foamed (layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04)}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/03: with respect to the orientation of features (direction of fibres or filaments B32B5/12)
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/065: {of foam}
- B32B 27/08: of synthetic resin
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 27/18: characterised by the use of special additives
- B32B 27/285: {comprising polyethers}
- B32B 27/286: {comprising polysulphones; polysulfides}
- B32B 27/288: {comprising polyketones}
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 27/34: comprising polyamides
- B32B 27/36: comprising polyesters
- F41H 5/0428: {Ceramic layers in combination with additional layers made of fibres, fabrics or plastics}
- F41H 5/0457: {Metal layers in combination with additional layers made of fibres, fabrics or plastics}
- F41H 5/0478: {Fibre- or fabric-reinforced layers in combination with plastics layers}
- F41H 5/0485: {all the layers being only fibre- or fabric-reinforced layers}
- F41H 5/0492: {Layered armour containing hard elements, e.g. plates, spheres, rods, separated from each other, the elements being connected to a further flexible layer or being embedded in a plastics or an elastomer matrix}
- H01M 50/124: having a layered structure
- H01M 50/20: Mountings; Secondary casings or frames; Racks, modules or packs; Suspension devices; Shock absorbers; Transport or carrying devices; Holders (structural combination of accumulators with charging apparatus H01M10/46)
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2255/10: on synthetic resin layer or on natural or synthetic rubber layer
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/046: Synthetic resin
- B32B 2262/02: Synthetic macromolecular fibres
- B32B 2262/0269: Aromatic polyamide fibres
- B32B 2262/10: Inorganic fibres
- B32B 2262/101: Glass fibres
- B32B 2270/00: Resin or rubber layer containing a blend of at least two different polymers
- B32B 2307/20: having particular electrical or magnetic properties, e.g. piezoelectric
- B32B 2307/3065: Flame resistant or retardant, fire resistant or retardant
- B32B 2307/414: Translucent
- B32B 2307/50: having particular mechanical properties
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/581: Resistant to cut
- B32B 2307/714: Inert, i.e. inert to chemical degradation, corrosion
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2398/20: Thermoplastics
- B32B 2419/00: Buildings or parts thereof
- B32B 2451/00: Decorative or ornamental articles
- B32B 2571/02: defensive, e.g. armour plates or anti-ballistic clothing
- B32B 2605/00: Vehicles
- B32B 2605/10: Trains
- B32B 2605/12: Ships
- F41H 5/0471: {Layered armour containing fibre- or fabric-reinforced layers (in combination with ceramic layers F41H5/0428, with metal layers F41H5/0457)}
- Y02E 60/10: Energy storage using batteries
- Y10T 156/10: Methods of surface bonding and/or assembly therefor
- Y10T 428/1314: Contains fabric, fiber particle, or filament made of glass, ceramic, or sintered, fused, fired, or calcined metal oxide, or metal carbide or other inorganic compound [e.g., fiber glass, mineral fiber, sand, etc.]
- Y10T 428/24132: including grain, strips, or filamentary elements in different layers or components parallel
- Y10T 428/24694: Parallel corrugations
- Y10T 428/24744: Longitudinal or transverse tubular cavity or cell
- Y10T 428/249988: Of about the same composition as, and adjacent to, the void-containing component
- Y10T 428/249992: Linear or thermoplastic
- Y10T 428/31533: Of polythioether
- Y10T 428/3154: Of fluorinated addition polymer from unsaturated monomers
- Y10T 428/31623: Next to polyamide or polyimide
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- F41H: ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A fire resistant composite laminate includes a thermoplastic matrix material reinforced with fibers embedded in the matrix of the composite laminate, wherein the thermoplastic matrix material of the fire resistant composite laminate includes polyvinylidene fluoride (PVDF).

## Claims

### Claim 1

A fire resistant composite laminate comprising:
a thermoplastic matrix material reinforced with fibers embedded in the matrix of the composite laminate, wherein the thermoplastic matrix material of the fire resistant composite laminate comprises polyvinylidene fluoride (PVDF).

### Claim 2 (depends on 1)

The fire resistant composite laminate of claim 1, wherein the fibers comprise fiberglass fibers.

### Claim 3 (depends on 2)

The fire resistant composite laminate of claim 2, wherein the fiberglass fibers are selected from the group consisting of E-glass fibers, S-glass fibers, and a combination thereof.

### Claim 4 (depends on 3)

The fire resistant composite laminate of claim 3, wherein the laminate comprises a plied construction or a tape construction.

### Claim 5 (depends on 3)

The fire resistant composite laminate of claim 3, wherein the fibers are continuation fibers and the laminate comprises a tape construction.

### Claim 6 (depends on 4)

The fire resistant composite laminate of claim 4, further comprising and additional reinforcing material.

### Claim 7 (depends on 1)

A composite structure (10) comprising:
a first outer layer (12);
a second outer layer (14); and a
core (16) sandwiched between the first outer layer (12) and the second outer layer (14), wherein the core (16) comprises a foam; and
at least one of the first outer layer (12) and the second outer layer (14) comprises the fire resistant composite laminate of claim 1.

### Claim 8 (depends on 7)

The composite structure (10) of claim 7, wherein the fire resistant composite laminate comprises a plurality of composite plies including at least a first composite ply and a second composite ply, the first composite ply and the second composite ply each comprising the fibers embedded in the thermoplastic matrix; the plurality of composite plies being bonded together to form the fire resistant composite laminate.

### Claim 9 (depends on 7)

The composite structure (10) of claim 7, wherein at least one of the first outer layer (12) and the second outer layer (14) comprises a coating thereon.

### Claim 10 (depends on 7)

The composite structure (10) of claim 7, wherein the fibers are substantially parallel to each other.

### Claim 11 (depends on 8)

The composite structure (10) of claim 8, wherein the first composite ply and the second composite ply comprise fibers of different strength, and the first composite ply comprises E-glass fibers and the second composite ply comprises S-glass fibers.

### Claim 12 (depends on 7)

A panel comprising the composite structure (10) of claim 7.

### Claim 13 (depends on 7)

The composite structure (10) of claim 7, further comprising at least one intermediate layer (17) between the first outer layer (12) and the second outer layer (14).

### Claim 14 (depends on 13)

The composite structure (10) of claim 13, wherein the core comprises expanded polyvinylidene fluoride (PVDF) foam at a thickness greater than the thickness of the first outer layer (12), the second outer layer (14) and the at least one intermediate layer (17).

### Claim 15 (depends on 1)

A pipe comprising the fire resistant composite laminate of claim 1.

### Claim 16 (depends on 7)

A pipe comprising the composite structure of claim 7.

### Claim 17 (depends on 7)

A battery box comprising the composite structure of claim 7.

### Claim 18 (depends on 7)

A battery case comprising the composite structure of claim 7.

### Claim 19 (depends on 1)

A method of making the fire resistant composite laminate of claim 1, comprising forming the laminate into a unidirectional tape by melt processing.

### Claim 20 (depends on 19)

The method of claim 19, further comprising bonding the laminate to a core, the core comprising polyvinlyidene fluoride (PVDF) foam.

### Claim 21 (depends on 1)

A ballistic panel comprising the fire resistant composite laminate of claim 1.

### Claim 22

A fire resistant composite laminate comprising:
a polymeric matrix material reinforced with fibers embedded in the matrix of the composite laminate, wherein the polymeric matrix material of the fire resistant composite laminate comprises at least one of polyvinylidene fluoride (PVDF), polyether ether ketone (PEEK), polyphenylene sulfide (PPS) and polyetheramide (PEI).

### Claim 23 (depends on 22)

A fire retardant ballistic panel comprising the composite laminate of claim 22.

### Claim 24

A fire retardant ballistic panel comprising:
a fire resistant composite laminate comprising:
a fire resistant polymeric matrix material reinforced with fibers embedded in the matrix of the composite laminate, wherein the fire retardant ballistic panel achieves at least one protection level against a projectile as defined by NIJ Standard Armor grades II-A, II, III and IV when the projectile is directed at the panel.

### Claim 25

A fire retardant ballistic panel having a first face and a second face and comprising:
a strike face portion comprising a first plurality of plies each comprising fibers in a first polymeric matrix material comprising a first fire retardant resin; and
a support portion adjacent to the strike face portion, the support portion comprising a second plurality of plies each comprising fibers in a second polymeric matrix material comprising a second fire retardant resin, wherein each ply is bound to an adjacent ply.

### Claim 26 (depends on 25)

The fire retardant ballistic panel of claim 25 wherein at least one of the first polymeric matrix material and the second polymeric matrix material comprises polyvinylidene fluoride (PVDF).

### Claim 27 (depends on 26)

The fire retardant ballistic panel of claim 26 wherein the first plurality of plies comprises E-glass fibers and the second plurality of plies comprises S-glass fibers.

### Claim 28 (depends on 25)

The fire retardant ballistic panel of claim 25 wherein the panel achieves at least one protection level against a projectile as defined by NIJ Standard Armor grades II-A, II, III-A, III and IV when the projectile is directed at the strike face.

### Claim 29 (depends on 26)

The fire retardant ballistic panel of claim 26 wherein the fibers are substantially parallel to each other within their respective plies and wherein the plies are disposed so that fibers of each ply are disposed cross-wise to fibers of an adjacent ply.