STRUCTURAL COMPOSITE LAMINATES
First Claim
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1. A method of forming a composite laminate for providing sealing, baffling or reinforcement to a structure, the method comprising:
- providing a reinforcement layer having a high surface tension of at least about 35 dynes/cm;
locating an epoxy-based expandable structural foam material onto the reinforcement layer to form the composite laminate wherein the surface tensions of the structural foam and reinforcement layer are within about 15 dynes/cm of one another;
wherein the high surface tensions of the reinforcement layer and structural foam provide sufficient wetting for load transfer from the structural foam to the reinforcement layer to;
i. increase the tensile strength of the composite laminate; and
ii. increase the lap shear strength of the composite laminate.
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Abstract
A composite laminate is formed from a structural foam and a reinforcement layer. The matched surface tensions of the structural foam and reinforcement layer result in increased bond strength between the structural foam and the reinforcement layer, thus providing for improved physical characteristics including improved lap shear and flexural strength.
9 Citations
22 Claims
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1. A method of forming a composite laminate for providing sealing, baffling or reinforcement to a structure, the method comprising:
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providing a reinforcement layer having a high surface tension of at least about 35 dynes/cm; locating an epoxy-based expandable structural foam material onto the reinforcement layer to form the composite laminate wherein the surface tensions of the structural foam and reinforcement layer are within about 15 dynes/cm of one another; wherein the high surface tensions of the reinforcement layer and structural foam provide sufficient wetting for load transfer from the structural foam to the reinforcement layer to; i. increase the tensile strength of the composite laminate; and ii. increase the lap shear strength of the composite laminate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A composite laminate for providing sealing, baffling or reinforcement to a structure comprising:
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a reinforcement layer having a surface tension of at least about 35 dynes/cm; and an epoxy-based expandable structural foam material located onto the reinforcement layer to form the composite laminate wherein the surface tensions of the structural foam and reinforcement layer are within about 15 dynes/cm of one another so that adhesion between the structural foam and reinforcement layer is improved. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20)
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21. A method of forming a composite laminate for providing sealing, baffling or reinforcement to a structure, the method comprising:
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providing a polymeric reinforcement layer having a surface tension of at least about 35 dynes/cm wherein the reinforcement layer includes a carboxylic acid or an amine chemical functional group; locating an epoxy-based expandable structural foam material onto the reinforcement layer by a co-extrusion process to form the composite laminate wherein the structural foam material comprises; i. an epoxy resin; ii. an epoxy/elastomer adduct, the adduct including about 1;
3 to 3;
1 parts of epoxy to elastomer; andiii. a core/shell polymer impact modifier; wherein the epoxy resin forms a covalent bond with the carboxylic acid, or amine of the reinforcement layer upon exposure to temperatures greater than 150°
C.;exposing the composite structure to a temperature greater than 150°
C. so that a covalent bond is formed between the reinforcement layer and structural foam;wherein the covalent bond allows for load transfer from the structural foam to the reinforcement layer to increase the tensile strength of the composite laminate. - View Dependent Claims (22)
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Specification