COMPOSITE ARTICLE INCLUDING VISCOELASTIC LAYER WITH BARRIER LAYER

• US 20100151186A1
• Filed: 12/15/2009
• Published: 06/17/2010
• Est. Priority Date: 12/15/2008
• Status: Abandoned Application

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Hebert, Larry S.
• Application Number:
  US12/637,915
• Publication Number:
  US 20100151186A1
• Time in Patent Office: Days
• US Class Current: 428/116
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/0276 Polyester 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 27/12 next to a fibrous or filamentary layer
• 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: C08J 2363/00 : Characterised by the use of epoxy resins; Derivatives of epoxy resins
• CPC Class Codes: C08J 5/243 : using carbon fibres
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like
• CPC Class Codes: Y10T 428/249939 : Two or more layers
• CPC Class Codes: Y10T 428/31507 : Of polycarbonate
• CPC Class Codes: Y10T 428/31511 : Of epoxy ether
• CPC Class Codes: Y10T 428/3154 : Of fluorinated addition polymer from unsaturated monomers

Abstract

Fiber reinforced resin matrix composite laminates are provided comprising first and second layers of fiber reinforced resin matrix comprising first and second resin matrices and a viscoelastic construction located between the first and second layers of fiber reinforced resin matrix, bound to the first and second resin matrices, comprising: i) at least one viscoelastic layer; and ii) at least one barrier layer. In some embodiments, the viscoelastic construction comprises at least two barrier layers which differ in composition from at least one viscoelastic layer and wherein the at least two barrier layers are bound to said first and second resin matrices. In some embodiments, the one or more barrier layer(s) may be substantially impermeable to organic solvents, and/or substantially impermeable to water, and/or substantially impermeable to gasses.

Claims

1. A fiber reinforced resin matrix composite laminate comprising:

a) a first layer of fiber reinforced resin matrix comprising a first resin matrix;

b) a second layer of fiber reinforced resin matrix comprising a second resin matrix; and

c) a viscoelastic construction located between said first and second layers of fiber reinforced resin matrix, bound to said first and second resin matrices, comprising;

i) at least one viscoelastic layer; and

ii) at least one barrier layer;

wherein said viscoelastic and barrier layers may be one and the same layer or may be different layers.

2. The fiber reinforced resin matrix composite laminate according to claim 1 wherein the viscoelastic construction comprises a single layer which is both a viscoelastic layer and a barrier layer.

3. The fiber reinforced resin matrix composite laminate according to claim 1 wherein the viscoelastic construction is a single layer which is both a viscoelastic layer and a barrier layer.

4. The fiber reinforced resin matrix composite laminate according to claim 1 wherein at least one viscoelastic layer differs in composition from at least one barrier layer.

5. The fiber reinforced resin matrix composite laminate according to claim 4 wherein the viscoelastic construction comprises at least two barrier layers which differ in composition from at least one viscoelastic layer and wherein the at least two barrier layers are bound to said first and second resin matrices.

6. The fiber reinforced resin matrix composite laminate according to claim 1 wherein said barrier layer(s) are substantially impermeable to organic solvents.

7. The fiber reinforced resin matrix composite laminate according to claim 1 wherein said barrier layer(s) are substantially impermeable to water, organic solvents and gasses.

8. The fiber reinforced resin matrix composite laminate according to claim 1 wherein at least one of the viscoelastic layers have a peak damping ratio (Tan δ

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

9. The fiber reinforced resin matrix composite laminate according to claim 1 wherein the viscoelastic construction additionally comprises at least one cured adhesive layer having a composition different from that of the resin matrix.

10. The fiber reinforced resin matrix composite laminate according to claim 1 wherein at least one of the first and second layer of fiber reinforced resin matrix additionally comprises at least one core layer of foam, wood, or honeycomb construction.

11. A method of making a fiber reinforced resin matrix composite laminate comprising the steps of:

a) providing a first curable fiber reinforced resin matrix comprising a first curable resin matrix;

b) providing a second curable fiber reinforced resin matrix comprising a second curable resin matrix;

c) providing a viscoelastic construction, comprising;

i) at least one viscoelastic layer; and

ii) at least one barrier layer;

wherein said viscoelastic and barrier layers may be one and the same layer or may be different layers;

d) providing a tool having a shape which is the inverse of the desired shape of the laminate;

e) laying up the first curable fiber reinforced resin matrix, viscoelastic construction and the second curable fiber reinforced resin matrix in the tool, in that order; and

f) curing the curable resin matrixes to make a fiber reinforced resin matrix composite laminate.

12. The method according to claim 11 wherein the viscoelastic construction comprises a single layer which is both a viscoelastic layer and a barrier layer.

13. The method according to claim 11 wherein the viscoelastic construction is a single layer which is both a viscoelastic layer and a barrier layer.

14. The method according to claim 11 wherein at least one viscoelastic layer differs in composition from at least one barrier layer.

15. The method according to claim 11 wherein the viscoelastic construction comprises at least two barrier layers which differ in composition from at least one viscoelastic layer and wherein the at least two barrier layers are bound to said first and second resin matrices.

16. The method according to claim 11 wherein said barrier layer(s) are substantially impermeable to organic solvents.

17. The method according to claim 11 wherein said barrier layer(s) are substantially impermeable to water, organic solvents and gasses.

18. The method according to claim 11 wherein at least one of the viscoelastic layers have a peak damping ratio (Tan δ

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

19. The method according to claim 11 wherein the viscoelastic construction additionally comprises at least one cured adhesive layer having a composition different from that of the resin matrix.

20. The method according to claim 11 wherein at least one of the first and second layer of fiber reinforced resin matrix additionally comprises at least one core layer of foam, wood, or honeycomb construction.

21. A viscoelastic construction, comprising:

i) at least one viscoelastic layer;

bound to

ii) at least one barrier layer,

where at least one barrier layer differs in composition from at least one viscoelastic layer.

22. The viscoelastic construction according to claim 21 which comprises at least two barrier layers bound to a viscoelastic layer.

23. The method according to claim 21 wherein said barrier layer(s) are substantially impermeable to organic solvents.

24. The method according to claim 21 wherein said barrier layer(s) are substantially impermeable to water, organic solvents and gasses.

25. The method according to claim 21 wherein at least one of the viscoelastic layers have a peak damping ratio (Tan δ

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

26. The method according to claim 22 wherein said barrier layer(s) are substantially impermeable to organic solvents.

27. The method according to claim 22 wherein said barrier layer(s) are substantially impermeable to water, organic solvents and gasses.

28. The method according to claim 22 wherein at least one of the viscoelastic layers have a peak damping ratio (Tan δ

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