Structural composite laminate, and process of making same
AssigneeIntrinsix Corporation
InventorTimothy Alan Brinner
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Abstract
A structural composite laminate and method of making the same are provided. The laminate includes first and second skins or laminas, and a core positioned between the first and second laminas. The core contains thermoplastic and/or substantially inelastic polymeric particles with inter-particle interstices between the polymeric particles. Optionally, the polymeric particles are arranged discontinuously to establish gaps between adjacent particles along at least one dimension of the laminate.
Claims25
A process for making a structural composite laminate, comprising:
- providing a first lamina;
- depositing a plurality of solid yet deformable discrete, non-porous, thermoplastic polymeric particles having surfaces on the first lamina to establish a core, wherein inter-particle voids extend surface to surface from and to the respective surfaces of adjacent thermoplastic polymeric particles;
- applying a second lamina over the core;
- applying a sufficient compressive force to the first and second laminas to permanently deform the thermoplastic polymeric particles into a deformed state between the first and second laminas while retaining the inter-particle voids and maintaining the thermoplastic polymeric particles as non-porous;
- and
- releasing the compressive force without delaminating the first and second laminas from the thermoplastic polymeric particles to thereby provide a structural composite laminate comprising the first lamina, the second lamina, and a core between the first and second laminas the core comprising the non-porous thermoplastic polymeric particles substantially retained in the deformed state and having the inter-particle voids.
A process for making a structural composite laminate, comprising:
- providing a first lamina;
- depositing a plurality of solid yet deformable discrete, non-porous, substantially inelastic polymeric particles having surfaces on the first lamina to establish a core, wherein inter-particle voids extend surface to surface from and to the respective surfaces of adjacent substantially inelastic polymeric particles;
- applying a second lamina over the core;
- applying a sufficient compressive force to the first and second laminas to permanently deform the substantially inelastic polymeric particles into a deformed state between the first and second laminas while retaining the inter-particle voids and maintaining the polymeric particles as non-porous;
- and
- releasing the compressive force without delaminating the first and second laminas from the substantially inelastic polymeric particles to thereby provide a structural composite laminate comprising the first lamina, the second lamina, and a core between the first and second laminas, the core comprising the non-porous, substantially inelastic polymeric particles substantially retained in the deformed state and having the inter-particle voids.
A process for making a structural composite laminate, comprising:
- applying a compression force to a plurality of solid yet deformable discrete, non-porous, substantially inelastic polymeric particles situated between first and second lamina to deform the polymeric particles into a deformed state, and releasing the compression force without delaminating the first and second lamina from the substantial inelastic polymeric particles to form a structural composite laminate, the structural composite laminate comprising the first and second lamina bonded to the non-porous, substantially inelastic polymeric particles substantially retained in the deformed state with inter-particle voids extending surface to surface from and to respective surfaces of adjacent particles of the non-porous, substantially inelastic polymeric particles.
Dependencies are inferred from the claim text.