High impact strength fiber resin matrix composites
AssigneeAmerican Cyanamid Company
InventorsKevin R. Hirschbuehler, Bruce A. Stern
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Abstract
Improved fiber resin matrix prepreg fabrics are disclosed which are comprised of a first layer of reinforcing fabric coated with an epoxy resin composition and a discrete second layer of an epoxy resin modified with an elastomeric polymer. The discrete second layer is provided with a support comprising a gauze-like, lightweight fibrous mat or carrier of lightweight fibers that preserves the second "interleaf" layer during cure. Cured composites having the continuous interleaf layer intact exhibit high impact strength and resistance to impact damage. 6
Claims29
A method for producing an interleafed fiber resin matrix prepreg fabric comprising
- (1) incorporating a non-woven or woven fibrous mat or carrier of lightweight supporting filaments into an interleaf resin composition comprising
- (a) a first thermosetting epoxy resin composition containing
- (b) about 8% to 70% by weight of a rubbery vinyl addition polymer to provide a supported interleaf resin layer;
- and
- (2) introducing said supported interleaf resin layer to at least one surface of a fiber resin matrix comprising
- (a) a fabric of high-strength reinforcing filaments and
- (b) a second thermosetting epoxy resin composition coating and impregnating said fabric.
In a method for producing an interleafed fiber resin matrix prepreg comprising
- (A) a fiber resin matrix comprising (i) a fabric of interwoven high-strength reinforcing filaments coated and impregnated with (ii) a thermosetting epoxy resin composition, and
- (B) a discrete interleaf resin layer on at least one surface of said fiber resin matrix comprising (i) a thermosetting epoxy resin composition and (ii) about 8% to 70% by weight of a rubbery vinyl addition polymer, the improvement which comprises incorporating a fibrous mat or carrier of lightweight supporting filaments into said interleaf resin layer.
An interleafed fiber resin matrix prepreg fabric comprising
- (A) a fiber resin matrix comprising
- (i) 40% to 70% by weight high-strength filaments interwoven to form a reinforcing fabric, and
- (ii) 30% to 60% by weight of a first thermosetting epoxy resin composition coating said fabric, said first epoxy resin composition comprising (a) a polyepoxide compound or combination of polyepoxide compounds, and (b) a curing agent effective to catalyze polymerization of said polyepoxide compound;
- and
- (B) a discrete interleaf resin layer comprising
- (i) a non-woven or woven fibrous mat or carrier of lightweight supporting filaments, and
- (ii) a second thermosetting epoxy resin composition coating said non-woven or woven fibrous mat or carrier, said second epoxy resin composition comprising (a) a polyepoxide compound or a combination of polyepoxide compounds, (b) about 8% to 70% by weight of a rubbery vinyl addition polymer, and (c) a curing agent affective to catalyze polymerization of said polyepoxide compound.
Dependencies are inferred from the claim text.