Linerless prepregs, composite articles therefrom, and related methods
First Claim
Patent Images
1. A resin composition forming an initial matrix material during preparation of a composite article, the composition comprising:
- an essentially uncured initial resin comprising at least one thermosetting resin and, optionally, at least one thermoplastic resin;
at least one curative for the at least one thermosetting resin; and
at least one viscosity modifier;
wherein viscosity of the initial resin in the resin composition is less than about 6 Pa·
s when tested at 25°
C.;
wherein the resin composition is capable of impregnating a reinforcement material to form a prepreg capable of being used to form the composite article without use of release liners; and
wherein the resin composition is capable of remaining impregnated throughout the reinforcement material, without partial curing, until final cure of the resin composition to form the composite article.
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Abstract
Linerless prepreg, composite articles therefrom, and related methods are disclosed. In linerless prepreg according to the invention, matrix material is impregnated into a reinforcement material without the need for any release liners during manufacture or storage thereof. Beneficially, prepreg of the invention is capable of being easily wound into a roll or stacked for storage, without sticking to itself when it is later used in the manufacture of composite articles.
30 Citations
27 Claims
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1. A resin composition forming an initial matrix material during preparation of a composite article, the composition comprising:
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an essentially uncured initial resin comprising at least one thermosetting resin and, optionally, at least one thermoplastic resin; at least one curative for the at least one thermosetting resin; and at least one viscosity modifier; wherein viscosity of the initial resin in the resin composition is less than about 6 Pa·
s when tested at 25°
C.;wherein the resin composition is capable of impregnating a reinforcement material to form a prepreg capable of being used to form the composite article without use of release liners; and wherein the resin composition is capable of remaining impregnated throughout the reinforcement material, without partial curing, until final cure of the resin composition to form the composite article. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 22, 23, 24, 25, 26, 27)
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19. A linerless prepreg comprising:
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a reinforcement material; and a matrix material, wherein a layer of the linerless prepreg is capable of being stacked adjacent another layer of the linerless prepreg or rolled upon itself without significantly sticking to the adjacent linerless prepreg layer or itself when used in manufacture of a composite article therefrom.
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20. A linerless prepreg comprising:
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a reinforcement material; and a matrix material, wherein a layer of the linerless prepreg is capable of being stacked adjacent another layer of the linerless prepreg or rolled upon itself without significantly sticking to the adjacent linerless prepreg layer or itself when used in manufacture of a composite article therefrom, and, wherein an amount of force required to separate adjacent stacked layers of the linerless prepreg is less than about 3 N/cm as measured according to a 180-degree peel angle test conducted at a testing speed of 30 cm/min (12 in/min). - View Dependent Claims (21)
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Specification