Prepregs, towpregs and preforms
AssigneeHenkel Corporation
InventorsWei Helen Li, Stanley L. Lehmann, Raymond S. Wong
Life of this patent
Estimating the term…
Abstract
The present invention relates to prepregs, towpregs and preforms made from curable compositions of (a) benzoxazines, (b) a combination of adducts a first of which is prepared from hydroxy-containing compounds, isocyanate-containing compounds and phenolic compounds and the second of which is prepared from the first adduct and epoxy-containing compounds, (c) components reactive with the benzoxazine, such as epoxy resins, episulfide resins and oxetane resins, (d) tougheners, such as polyether sulfones, ATBN and core shell materials and (e) a silica component, where the silica has a mean particle diameter on the order of 10−9 meters.
Claims36
A curable composition comprising:
- A) a benzoxazine component,
- B) a combination of adducts one of which is prepared from hydroxy-containing compounds, isocyanate-containing compounds and a first phenolic compound and the second of which is prepared from the first adduct, an epoxy-containing compound and a second phenolic compound,
- C) an epoxy resin component,
- D) a polyether sulfone toughener comprising the structure:
- and
- E) a silica having a particle size in the range of 1 to 1,000 nm.
A prepreg or towpreg made from
- A. a matrix resin composition comprising:
- (a) a benzoxazine component;
- (b) a component reactive with the benzoxazine component;
- (c) a silica component having a mean particle diameter on the order of 10−9 meters;
- (d) a thermoplastic particle component;
- (e) a toughening adduct;
- and
- (f) optionally, a curative or catalyst;
- and
- B. (a) continuous fiber or fabric,
- wherein the prepreg or towpreg when cured demonstrates at least one of the following properties (normalized to 60% fiber volume fraction):
- (i) compression after impact of at least 30 ksi {210 Mpa} at 270 in-lbs (30 Joules) impact;
- (ii) open hole compression of at least 30 ksi {210 Mpa};
- (iii) fire heat release HRR less than 65 kW/m2 and HR of less than 65 kW*min/m2, smoke density less than 100, toxic material release performance of less than 1000 ppm for CO, less than 150 ppm for each HCN and HCl and less than 100 ppm for each HF, nitrogen oxides and sulfur;
- and
- (iv) Hot/Wet Tg of at least 140° C.
A resin film infused preform comprising:
- A. a matrix resin composition comprising:
- (a) a benzoxazine component;
- (b) a component reactive with the benzoxazine component;
- (c) a silica component having a mean particle diameter on the order of 10−9 meters;
- (d) a thermoplastic particle component;
- (e) a toughening adduct;
- and
- (f) optionally, a curative or catalyst;
- and
- B. (a) a plurality of fiber or fabric plies,
- wherein the resin film infused preform when cured demonstrates at least one of the following properties (normalized to 60% fiber volume fraction):
- (i) compression after impact of at least 27 ksi {190 Mpa} at 270 in-lbs (30 Joules) impact;
- (ii) open hole compression of at least 30 ksi {210 Mpa};
- (iii) fire heat release HRR less than 65 kW/m2 and HR of less than 65 kW*min/m2, smoke density less than 100, toxic material release performance of less than 1000 ppm for CO, less than 150 ppm for each HCN and HCl and less than 100 ppm for each HF, nitrogen oxides and sulfur;
- and
- (iv) Hot/Wet Tg of at least 140° C.
A preform for a resin transfer molding process made from a matrix resin composition comprising:
- (a) a benzoxazine component;
- (b) a binder comprising a component reactive with the benzoxazine component;
- (c) optionally, a silica component having a mean particle diameter on the order of 10−9 meters;
- (d) a thermoplastic particle component;
- (e) a toughening adduct;
- (f) optionally, a curative or catalyst;
- and
- (g) carbon fiber,
- wherein when cured the product of the resin transfer molding process demonstrates at least one of the following properties (normalized to 60% fiber volume fraction):
- (i) compression after impact of at least 30 ksi {210 Mpa} at 270 in-lbs (30 Joules) impact;
- (ii) open hole compression of at least 30 ksi;
- (iii) fire heat release HRR less than 65 kW/m2 and HR of less than 65 kW*min/m2, smoke density less than 100, toxic material release performance of less than 1000 ppm for CO, less than 150 ppm for each HCN and HCl and less than 100 ppm for each HF, nitrogen oxides and sulfur;
- (iv) Hot/Wet Tg of at least 140° C.;
- and
- (v) elongation of 1.5% to 6%.
Dependencies are inferred from the claim text.