Surfacing film for composites with barrier layer

• US 10,525,667 B2
• Filed: 12/15/2009
• Issued: 01/07/2020
• Est. Priority Date: 12/15/2008
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Hebert, Larry S., Jing, Naiyong, Swan, Michael D.
• Primary Examiner(s): Shah, Samir
• Application Number:
  US12/637,879
• Publication Number:
  US 20100151239A1
• Time in Patent Office: 3,675 Days
• Field of Search: 428351
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2270/00 Resin or rubber layer containing a blend of at least two different polymers
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/71 Resistive to light or to UV
• CPC Class Codes: B32B 2307/7242 Non-permeable
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 25/18 comprising butyl or halobutyl rubber
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 2605/08 Cars
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/18 characterised by the use of special additives
• CPC Class Codes: B32B 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/281 comprising polyimides
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/322 comprising halogenated polyolefins, e.g. PTFE
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/365 : comprising polycarbonates
• CPC Class Codes: B32B 27/38 : comprising epoxy resins
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 27/42 : comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 3/12 : characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 156/10 : Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 428/2835 : including moisture or waterproof component
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 428/31515 : As intermediate layer
• CPC Class Codes: Y10T 428/3154 : Of fluorinated addition polymer from unsaturated monomers

Abstract

Fiber reinforced resin matrix composite laminates are provided comprising: at least one layer of fiber reinforced resin matrix comprising a cured resin matrix; and a surfacing construction bound to the cured resin matrix and forming a surface of the laminate, comprising: at least one barrier layer; and at least one cured adhesive layer derived from high temperature cure adhesive. In some embodiments, barrier layer(s) may be substantially impermeable to organic solvents, water, and/or gasses. In another aspect, fiber reinforced resin matrix composite laminates are provided comprising: a) at least one layer of fiber reinforced resin matrix comprising a cured resin matrix; and b) a surfacing construction bound to the cured resin matrix and forming a surface of the laminate, comprising: at least one barrier layer; and at least one electrically conductive layer. In another aspect, a surfacing construction is provided comprising a barrier layer and a curable adhesive layer.

Claims

1. A fiber reinforced resin matrix composite laminate comprising:

a) at least one layer of fiber reinforced resin matrix comprising a cured resin matrix; and

b) a surfacing construction bound to the cured resin matrix and forming a surface of the laminate, comprising;

i) at least one barrier layer, wherein the barrier layer comprises at least one of polyethylene, polyurethane, polycarbonate and polyimide and is substantially impermeable to moisture, oxygen, and an organic solvent selected from methylene chloride, benzyl alcohol and gasoline; and

ii) at least one cured adhesive layer derived from high temperature cure adhesive comprising a dicyandiamide-cured epoxy adhesive;

wherein at least one cured adhesive layer is directly bound to the cured resin matrix and wherein at least one cured adhesive layer is directly and continuously bound to at least one barrier layer; and

wherein the barrier layer(s) have a composition different from that of the cured adhesive layer(s), the barrier layer(s) have a composition different from that of the cured resin matrix, and the cured adhesive layer(s) have a composition different from that of the resin matrix;

wherein the high temperature cure adhesive cures in less than 6 hours at a temperature of greater than 180°

C. and fails to cure in 48 hours at a temperature of less than 25°

C.

2. The fiber reinforced resin matrix composite laminate according to claim 1 wherein the surfacing construction additionally comprises:

iii) at least one electrically conductive layer.

3. The fiber reinforced resin matrix composite laminate according to claim 1 wherein the surfacing construction additionally comprises:

iv) at least one EMI shield layer.

4. The fiber reinforced resin matrix composite laminate according to claim 1 wherein the surfacing construction additionally comprises:

v) at least one UV protection layer.

5. The fiber reinforced resin matrix composite laminate according to claim 1 wherein the surfacing construction additionally comprises:

vi) at least one viscoelastic layer having a peak damping ratio (Tan δ

) of at least 1.0 as measured in shear mode by DMTA at 10 Hz.

6. The fiber reinforced resin matrix composite laminate according to claim 1 wherein at least one barrier layer comprises a fluoropolymer.

7. The fiber reinforced resin matrix composite laminate according to claim 1 wherein at least one barrier layer comprises a non-perfluorinated fluoropolymer.

8. The fiber reinforced resin matrix composite laminate according to claim 1 wherein the at least one barrier layer comprises non-perfluorinated fluoropolymer.