Multiple function, self-repairing composites with special adhesives

• US 8,721,959 B2
• Filed: 09/09/2011
• Issued: 05/13/2014
• Est. Priority Date: 07/01/2005
• Status: Active Grant

• Current Assignee: Carolyn Dry
• Original Assignee: Carolyn Dry
• Inventors: Dry, Carolyn
• Primary Examiner(s): KENNEDY, TIMOTHY J
• Application Number:
  US13/229,297
• Publication Number:
  US 20120003463A1
• Time in Patent Office: 977 Days
• Field of Search: 264/248, 264/257, 264/349, 264/232, 264/313, 264/316, 264/553, 264/544, 264/546, 264/552, 264/570, 264/571, 264/572, 264/573
• US Class Current: 264/573
• CPC Class Codes: B29C 73/22 the article containing elements including a sealing composition, e.g. powder being liberated when the article is damaged
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: B32B 2250/05 5 or more layers
• CPC Class Codes: B32B 2250/42 Alternating layers, e.g. ABAB(C), AABBAABB(C)
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2307/306 Resistant to heat
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/762 Self-repairing, self-healing
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2457/00 Electrical equipment
• CPC Class Codes: B32B 2603/00 Vanes, blades, propellers, rotors with blades
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 7/04 Interconnection of layers
• CPC Class Codes: B32B 9/007 comprising carbon, e.g. graphite, composite carbon
• CPC Class Codes: B32B 9/02 comprising animal or vegetable substances , e.g. cork, bamboo, starch
• CPC Class Codes: B32B 9/04 comprising such particular substance 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 glass layer B32B17/06; layered products with at least two ceramic layers composed mainly of ceramic B32B18/00
• CPC Class Codes: C04B 14/34 Metals , e.g. ferro-silicon
• CPC Class Codes: C04B 14/42 Glass
• CPC Class Codes: C04B 2111/00612 as one or more layers of a layered structure
• CPC Class Codes: C04B 2111/28 Fire resistance, i.e. materials resistant to accidental fires or high temperatures
• CPC Class Codes: C04B 24/24 : Macromolecular compounds C04B24/14 takes precedence; macromolecular compounds comprising sulfonate or sulfate groups C04B24/16
• CPC Class Codes: C04B 28/02 : containing hydraulic cements other than calcium sulfates
• CPC Class Codes: Y10T 428/24744 : Longitudinal or transverse tubular cavity or cell
• CPC Class Codes: Y10T 428/249921 : Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 428/249924 : Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
• CPC Class Codes: Y10T 428/249954 : With chemically effective material or specified gas other than air, N, or carbon dioxide in void-containing component
• CPC Class Codes: Y10T 428/249971 : Preformed hollow element-containing
• CPC Class Codes: Y10T 428/249974 : Metal- or silicon-containing element
• CPC Class Codes: Y10T 428/249994 : Composite having a component wherein a constituent is liquid or is contained within preformed walls [e.g., impregnant-filled, previously void containing component, etc.]
• CPC Class Codes: Y10T 428/2902 : Channel shape
• CPC Class Codes: Y10T 428/2913 : Rod, strand, filament or fiber
• CPC Class Codes: Y10T 428/2924 : Composite
• CPC Class Codes: Y10T 428/2971 : Impregnation
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer
• CPC Class Codes: Y10T 428/31678 : Of metal
• CPC Class Codes: Y10T 442/2008 : Fabric composed of a fiber or strand which is of specific structural definition

Abstract

A system for self-repairing matrices such as concrete or cementitous matrices, polymeric matrices, and/or fibrous matrices, including laminates thereof The system includes repair agents retained in and/or on vessels, such as hollow fibers, within the matrix. Upon impact, the vessel rupture, releasing the chemicals. For multi-layer laminates, the systems provides a total dynamic energetic circulation system that functions as an in situ fluidic system in at least one layer or area. The energy from the impact ruptures the vessels to release the chemical(s), and mixes the chemical(s) and pushes the chemical(s) and/or resulting compound through the matrix. The repair agents can withstand high temperatures, such as the heat of processing of many laminates, e.g., 250-350° F.

Claims

1. A method of making a composite comprising:

placing a porous conduit on a first layer,

placing a second layer on top of a porous conduit, wherein the first and second lavers comprise fibers;

transferring a curable resin through the porous conduit and through the layers, the transferring comprising applying a pressure of from 0 psi to 10,000 psi;

voiding the porous conduit after the transferring; and

allowing the curable resin to harden to form a matrix, wherein the voided porous conduit is a tube positioned in the matrix.

2. The method of claim 1 further comprising sacrificing the conduit after transferring the resin to the layers such that a channel remains in the composite.

3. The method of claim 1 further comprising heating the cured resin such that the porous conduit disintegrates or melts and leaves an empty channel in the composite.

4. The method of claim 1, wherein at least one of the first layer and the second layer is prepared by filament winding.

5. The method of claim 1, wherein the process comprises applying a vacuum.

6. The method of claim 1, wherein the process comprises at least one of resin transfer molding, vacuum assisted resin transfer molding, injection molding, Seemann composite resin infusion molding process, and filament winding.

7. The method of claim 1,wherein the process comprises vacuum assisted resin transfer molding.

8. The method of claim 1 further comprising filling the channel with a chemical after the voiding.

9. The method of claim 8, wherein the chemical comprises at least one of a coolant, a conductive agent, a modifying agent, a reactive agent, a repair chemical, a thermal fluid, a sealant, and steam.

10. The method of claim 8, wherein the conduit comprises a first end and a second end, the method further comprising sealing at least one of the first and the second end.

11. The method of claim 1 further comprising sealing the voided conduit.

12. The method of claim 1, wherein the conduit is elastomeric.

13. The method of claim 1, wherein the resin is partially cured when the conduit is sacrificed.

14. The method of claim 1, wherein the conduit comprises metal.

15. The method of claim 1, further comprising z-pinning the composite.

16. The method of claim 1, wherein the fibers comprise organic fibers.

17. The method of claim 1, wherein the conduit comprises tubes.

18. The method of claim 1, wherein the resulting composite is able to withstand a ballistic force, is able to withstand impact force, is conductive, is radar absorbing, is self-repairing when damaged, is self-sensing when damaged, is self-sealing when damaged, is electricity generating when damaged, is internal pumping when damaged, is capable of self destruction, or a combination thereof.

19. The method of claim 1, wherein the layers comprise glass fibers.

20. The method of claim 2, wherein the conduit comprises a spring.

21. The method of claim 20, wherein the resulting composite is able to withstand a ballistic force, is able to withstand an impact force, is conductive, is radar absorbing, is self-repairing when damaged, is self-sensing when damaged, is electricity generating when damaged, is internal pumping when damaged, is capable of self-destruction, or a combination thereof.

22. The method of claim 1, wherein the composite further comprises a catalyst comprising at least one of a ring opening metathesis polymerization (ROMP) catalyst, a GRUBBs catalyst, ruthenium, iron, osmium, rhodium, iridium, palladium, platinum, a cyclic ester polymerization catalyst, and a cyclic amide polymerization catalyst.

23. The method of claim 22, wherein the catalyst is disposed in a bead.

24. The method of claim 22, wherein the composite withstands a ballistic force, is able to withstand an impact force, is conductive, is radar absorbing, is self-repairing when damaged, is self-sensing when damaged, is electricity generating when damaged, internally pumps when damaged, is capable of self destruction, or a combination thereof.

25. The method of claim 1, further comprising placing a plurality of hollow conduits between the first layer and the second layer, the plurality of hollow conduits being in the form of bundles of fibers oriented in parallel with one another.

26. The method of claim 1, further comprising placing a plurality of hollow conduits between the first layer and the second layer, the plurality of hollow conduits being in the form of a web.

27. The method of claim 1, further comprising a plurality of conduits, the conduits extend in a z direction, a y direction and an x direction.

28. The method of claim 1, wherein the ends of the porous conduit extend out to an edge or edges of the matrix.

29. The method of claim 28 further comprising sealing the ends of the porous conduit.

30. The method of claim 28, wherein the porous conduit is a spring.

31. The method of claim 1, wherein the porous conduit is a spring.