SURFACING FILM FOR COMPOSITES WITH BARRIER LAYER

• US 20100151239A1
• Filed: 12/15/2009
• Published: 06/17/2010
• 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.
• Granted Patent: US 10,525,667 B2
• Time in Patent Office: Days
• US Class Current: 428/351
• 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; and

ii) at least one cured adhesive layer derived from high temperature cure adhesive;

wherein at least one cured adhesive layer is bound to the cured resin matrix; 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.

2. The fiber reinforced resin matrix composite laminate according to claim 1 wherein at least one barrier layer is substantially impermeable to organic solvents.

3. The fiber reinforced resin matrix composite laminate according to claim 1 wherein at least one barrier layer is substantially impermeable to water, organic solvents and gasses.

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

iii) at least one electrically conductive layer.

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

iv) at least one EMI shield layer.

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

v) at least one UV protection layer.

7. 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.

8. The fiber reinforced resin matrix composite laminate according to claim 1 comprising a barrier layer comprising a fluoropolymer.

9. The fiber reinforced resin matrix composite laminate according to claim 1 comprising a barrier layer comprising a non-perfluorinated fluoropolymer.

10. The fiber reinforced resin matrix composite laminate according to claim 1 comprising a cured adhesive layer comprising dicyandiamide-cured epoxy adhesive.

11. The fiber reinforced resin matrix composite laminate according to claim 1 comprising a cured adhesive layer comprising dicyandiamide-cured epoxy adhesive bound to a barrier layer comprising a non-perfluorinated fluoropolymer.

12. The fiber reinforced resin matrix composite laminate according to claim 1 comprising a cured adhesive layer comprising dicyandiamide-cured epoxy adhesive bound to a) a barrier layer comprising a non-perfluorinated fluoropolymer and b) the cured resin matrix.

13. The fiber reinforced resin matrix composite laminate according to claim 1 comprising a cured adhesive layer comprising no amine-cured epoxy adhesive.

51. The fiber reinforced resin matrix composite laminate according to claim 1 wherein the surfacing construction additionally bears at least one layer of paint.

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

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

b) providing a surfacing construction comprising;

i) at least one barrier layer; and

ii) at least one curable adhesive layer;

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

e) laying up the surfacing construction and the curable fiber reinforced resin matrix in the tool, with the surfacing construction in contact with the tool and with at least one curable adhesive layer in contact with the curable fiber reinforced resin matrix; and

f) curing the curable resin matrix and curable adhesive layer to make a fiber reinforced resin matrix composite laminate;

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

15. The method according to claim 14 wherein at least one curable adhesive layer has a composition different from that of the curable resin matrix.

16. The method according to claim 14 wherein at least one barrier layer is substantially impermeable to organic solvents.

17. The method according to claim 14 wherein at least one barrier layer is substantially impermeable to water, organic solvents and gasses.

18. The method according to claim 14 wherein the surfacing construction additionally comprises:

iii) at least one electrically conductive layer.

19. The method according to claim 14 wherein the surfacing construction additionally comprises:

iv) at least one EMI shield layer.

20. The method according to claim 14 wherein the surfacing construction additionally comprises:

v) at least one UV protection layer.

21. The method according to claim 14 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.

22. The method according to claim 14 wherein the surfacing construction comprises a barrier layer comprising a fluoropolymer.

23. The method according to claim 14 wherein the surfacing construction comprises a barrier layer comprising a non-perfluorinated fluoropolymer.

24. The method according to claim 14 wherein the surfacing construction comprises a curable adhesive layer comprising an epoxy adhesive and a dicyandiamide curative.

25. The method according to claim 14 wherein the surfacing construction comprises a curable adhesive layer comprising an epoxy adhesive and a dicyandiamide curative and a barrier layer comprising a non-perfluorinated fluoropolymer.

26. The method according to claim 14 wherein the surfacing construction comprises a curable adhesive layer comprising an epoxy adhesive and curative which contains no amine-containing curative.

27. The method according to claim 14 wherein at least one curable adhesive layer has a composition different from that of the curable resin matrix.

28. The method according to claim 14 wherein at least one curable adhesive layer has a composition which is the same as that of the curable resin matrix.

29. The method according to claim 14 wherein at least one curable adhesive layer is the curable resin matrix.

30. The method according to claim 14 wherein at least one curable adhesive layer is not the curable resin matrix.

31. 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; and

iii) at least one electrically conductive layer;

wherein the barrier layer(s) have a composition different from that of the cured resin matrix.

32. The fiber reinforced resin matrix composite laminate according to claim 31 wherein at least one barrier layer is substantially impermeable to organic solvents.

33. The fiber reinforced resin matrix composite laminate according to claim 31 wherein at least one barrier layer is substantially impermeable to water, organic solvents and gasses.

34. The fiber reinforced resin matrix composite laminate according to claim 31 wherein the surfacing construction additionally comprises:

ii) at least one cured adhesive layer.

35. The fiber reinforced resin matrix composite laminate according to claim 31 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.

36. The fiber reinforced resin matrix composite laminate according to claim 31 comprising a barrier layer comprising a fluoropolymer.

37. The fiber reinforced resin matrix composite laminate according to claim 31 comprising a barrier layer comprising a non-perfluorinated fluoropolymer.

52. The fiber reinforced resin matrix composite laminate according to claim 31 wherein the surfacing construction additionally bears at least one layer of paint.

38. A surfacing construction comprising at least one barrier layer and at least one curable adhesive layer.

39. The surfacing construction according to claim 38 wherein at least one barrier layer is substantially impermeable to organic solvents.

40. The surfacing construction according to claim 38 wherein at least one barrier layer is substantially impermeable to water, organic solvents and gasses.

41. The surfacing construction according to claim 38 additionally comprising:

iii) at least one electrically conductive layer.

42. The surfacing construction according to claim 38 additionally comprising:

iv) at least one EMI shield layer.

43. The surfacing construction according to claim 38 additionally comprising:

v) at least one UV protection layer.

44. The surfacing construction according to claim 38 additionally comprising:

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.

45. The surfacing construction according to claim 38 wherein at least one barrier layer comprises a fluoropolymer.

46. The surfacing construction according to claim 38 wherein at least one barrier layer comprises a non-perfluorinated fluoropolymer.

47. The surfacing construction according to claim 38 wherein at least one curable adhesive layer comprises an epoxy adhesive and a dicyandiamide curative.

48. The surfacing construction according to claim 38 wherein at least one curable adhesive layer comprises an epoxy adhesive and a dicyandiamide curative and at least one barrier layer comprises a non-perfluorinated fluoropolymer.

49. The surfacing construction according to claim 38 wherein no curable adhesive layer comprises an amine-containing curative.

50. The surfacing construction according to claim 48 wherein the non-perfluorinated fluoropolymer comprises units derived from vinylidene difluoride.