COMPOSITE MATERIALS

• US 20110174522A1
• Filed: 09/11/2009
• Published: 07/21/2011
• Est. Priority Date: 09/26/2008
• Status: Active Grant

• Current Assignee: Hexcel Composites Limited (Hexcel Corporation)
• Original Assignee: Hexcel Composites Limited (Hexcel Corporation)
• Inventors: Simmons, Martin, Jeschke, Michael
• Granted Patent: US 9,174,410 B2
• Time in Patent Office: Days
• US Class Current: 174/122.R
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/02 Synthetic macromolecular fibres
• CPC Class Codes: B32B 2262/0261 Polyamide fibres
• 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 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2264/0264 Polyamide particles
• CPC Class Codes: B32B 2264/101 Glass
• CPC Class Codes: B32B 2264/108 Carbon, e.g. graphite particles
• 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 2307/206 Insulating
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 27/02 in the form of fibres or filaments not used
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• 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 27/306 : comprising vinyl acetate or vinyl alcohol (co)polymers
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/38 : comprising epoxy resins
• CPC Class Codes: B32B 27/42 : comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 29/002 : as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 5/12 : characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 5/28 : impregnated with or embedded in a plastic substance not used
• CPC Class Codes: B32B 7/06 : permitting easy separation
• CPC Class Codes: B32B 9/00 : Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
• CPC Class Codes: C08J 5/243 : using carbon fibres
• CPC Class Codes: C08J 5/248 : using pre-treated fibres
• CPC Class Codes: C08J 5/249 : characterised by the additives used in the prepolymer mixture
• CPC Class Codes: D01F 8/12 : with at least one polyamide as constituent
• CPC Class Codes: D01F 8/14 : with at least one polyester as constituent
• CPC Class Codes: D04H 3/147 : Composite yarns or filaments

Abstract

A prepreg comprising resin and at least one fibre layer and further comprising an electrically insulating layer and an electrically conducting layer is provided, and particularly wherein the conductive layer is at or near the top surface, beneath that is the insulating layer and beneath that is a fibre/resin interleaf structure.

Claims

1. A curable prepreg comprising:

a fibre/resin structure comprising one or more layers of fibres and uncured resin;

an electrically conductive layer located on top of said fibre/resin structure; and

an electrically insulating layer located between said electrically conductive layer and said fibre/resin structure.

19. A curable prepreg according to claim 1 wherein said fibre/resin structure comprises one or more layers of fibres and one or more layers of resin interleafed between said layers of fibres.

20. A curable prepreg according to claim 1 wherein said electrically conducting layer comprises metal coated carbon fibres.

21. A curable prepreg according to claim 1 wherein said electrically insulating layer comprises a porous electrically insulating polymer.

22. A curable prepreg according to claim 19 wherein said layers of resin comprise electrically conducting particles.

2-18. -18. (canceled)

23. In a curable prepreg comprising a fibre/resin structure and an electrically conductive layer, the improvement comprising increasing the lightning protection of said curable prepreg, when it is cured and painted, by locating an electrically insulating layer between said electrically conductive layer and said fibre/resin structure.

24. The improved curable prepreg according to claim 23 wherein said fibre/resin structure comprises one or more layers of fibres and one or more layers of resin interleafed between said layers of fibres.

25. The improved curable prepreg according to claim 23 wherein said electrically conducting layer comprises metal coated carbon fibres.

26. The improved curable prepreg according to claim 23 wherein said electrically insulating layer comprises a porous electrically insulating polymer.

27. The improved curable prepreg according to claim 24 wherein said layers of resin comprise electrically conducting particles.

28. A composite part comprising:

a fibre/resin structure comprising one or more layers of fibres and cured resin;

an electrically conductive layer located on top of said fibre/resin structure;

an electrically non-conductive layer of paint on top of said electrically conductive layer; and

an electrically insulating layer located between said electrically conductive layer and said fibre/resin structure.

29. A composite part according to claim 28 wherein said fibre/resin structure comprises one or more layers of fibres and one or more layers of resin interleafed between said layers of fibres.

30. A curable prepreg according to claim 28 wherein said electrically conducting layer comprises metal coated carbon fibres.

31. A curable prepreg according to claim 28 wherein said electrically insulating layer comprises a porous electrically insulating polymer.

32. A composite part according to claim 29 wherein said layers of resin comprise electrically conducting particles.

33. In a painted composite part comprising a fibre/resin structure and an electrically conductive layer, the improvement comprising increasing the lightning protection of said painted composite part by locating an electrically insulating layer between said electrically conductive layer and said fibre/resin structure.

34. The improved composite part according to claim 33 wherein said fibre/resin structure comprises one or more layers of fibres and one or more layers of resin interleafed between said layers of fibres.

35. The improved composite part according to claim 33 wherein said electrically conducting layer comprises metal coated carbon fibres.

36. The improved composite part according to claim 33 wherein said electrically insulating layer comprises a porous electrically insulating polymer.

37. The improved composite part according to claim 34 wherein said layers of resin comprise electrically conducting particles.