Composite materials

• US 8,105,964 B2
• Filed: 12/20/2010
• Issued: 01/31/2012
• Est. Priority Date: 11/06/2006
• Status: Active Grant

• Current Assignee: Hexcel Composites Limited (Hexcel Corporation)
• Original Assignee: Hexcel Composites Limited (Hexcel Corporation)
• Inventors: Cawse, John L., Simmons, Martin, Green, George
• Primary Examiner(s): Salvatore, Lynda
• Application Number:
  US12/972,830
• Publication Number:
  US 20110091718A1
• Time in Patent Office: 407 Days
• Field of Search: 442/61, 442/70, 442 72- 74, 442/110, 442/111
• US Class Current: 442/61
• 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 2260/023 Two or more layers
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2264/02 Synthetic macromolecular particles
• CPC Class Codes: B32B 2264/10 Inorganic particles
• CPC Class Codes: B32B 2264/105 Metal
• CPC Class Codes: B32B 2264/108 Carbon, e.g. graphite particles
• CPC Class Codes: B32B 2305/076 Prepregs
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/206 Insulating
• CPC Class Codes: B32B 2307/212 Electromagnetic interference shielding
• CPC Class Codes: B32B 2571/00 Protective equipment
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• 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: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C08J 5/042 with carbon fibres
• CPC Class Codes: C08J 5/06 using pretreated fibrous materials
• CPC Class Codes: C08J 5/10 characterised by the additives used in the polymer mixture
• CPC Class Codes: C08J 5/243 using carbon fibres
• CPC Class Codes: C08J 5/249 : characterised by the additives used in the prepolymer mixture
• CPC Class Codes: H05F 3/02 : by means of earthing connections
• CPC Class Codes: Y10S 428/929 : Electrical contact feature
• CPC Class Codes: Y10S 428/931 : Components of differing electric conductivity
• CPC Class Codes: Y10T 29/49117 : Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49194 : Assembling elongated conductors, e.g., splicing, etc.
• CPC Class Codes: Y10T 428/249921 : Web or sheet containing structurally defined element or component
• CPC Class Codes: Y10T 428/25 : Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/254 : Polymeric or resinous material
• CPC Class Codes: Y10T 428/268 : Monolayer with structurally defined element
• CPC Class Codes: Y10T 428/31504 : Composite [nonstructural laminate]
• CPC Class Codes: Y10T 442/2016 : Impregnation is confined to a plane disposed between both major fabric surfaces which are essentially free of impregnating material
• CPC Class Codes: Y10T 442/209 : At least one coating or impregnation contains particulate material
• CPC Class Codes: Y10T 442/2107 : At least one coating or impregnation contains particulate material
• CPC Class Codes: Y10T 442/2115 : At least one coating or impregnation functions to fix pigments or particles on the surface of a coating or impregnation
• CPC Class Codes: Y10T 442/2123 : At least one coating or impregnation contains particulate material
• CPC Class Codes: Y10T 442/2418 : Coating or impregnation increases electrical conductivity or anti-static quality
• CPC Class Codes: Y10T 442/2426 : Elemental carbon containing
• CPC Class Codes: Y10T 442/67 : Multiple nonwoven fabric layers composed of the same inorganic strand or fiber material
• CPC Class Codes: Y10T 442/673 : Including particulate material other than fiber

Abstract

A composite material, the composite material comprising at least one prepreg, said prepreg comprising at least one polymeric resin and at least one fibrous reinforcement; and conducting particles dispersed in the polymeric resin.

Claims

1. A composite material comprising:

a first conductive fibrous layer comprising a plurality of electrically conductive fibers;

a second conductive fibrous layer comprising a plurality of electrically conductive fibers;

a resin layer located between said first conductive fibrous layer and said second conductive fibrous layer and defining an average thickness therebetween, said resin layer comprising a polymeric resin, a plurality of thermoplastic toughening particles and a plurality of electrically conductive particles;

wherein at least 50% of said conductive particles have a diameter that is within 10 μ

m of the average thickness of said resin layer.

2. The composite material of claim 1, wherein at least 90% of said conductive particles have a diameter between 0.3 μ

m and 100 μ

m.

3. The composite material of claim 1, wherein the diameter of each of said conductive particles is the largest cross-sectional diameter or dimension of a respective particle.

4. The composite material of claim 1, wherein said conductive particles have an aspect ratio between 1 and 10.

5. The composite material of claim 1, wherein said conductive particles comprise carbon particles.

6. A composite material comprising:

a first conductive fibrous layer comprising a plurality of electrically conductive fibers;

a second conductive fibrous layer comprising a plurality of electrically conductive fibers;

a resin layer located between said first conductive fibrous layer and said second conductive fibrous layer and defining an average thickness therebetween, said resin layer comprising a polymeric resin, a plurality of thermoplastic toughening particles and a plurality of electrically conductive particles defining an average diameter;

wherein said electrically conductive particles have an average diameter between 0.3 μ

m and 100 μ

m, and wherein said resin layer has a average thickness between 10.3 μ

m and 110 μ

m.

7. The composite material of claim 6, wherein at least 90% of said conductive particles have a diameter between 0.3 μ

m and 100 μ

m.

8. The composite material of claim 6, wherein the average diameter of said conductive particles is determined based on the largest cross-sectional diameter or dimension of each of said conductive particles.

9. The composite material of claim 6, wherein said conductive particles have an aspect ratio between 1 and 10.

10. The composite material of claim 6, wherein said conductive particles comprise carbon particles.

11. A prepreg comprising:

a conductive fibrous layer comprising a plurality of electrically conductive fibers;

a resin layer located on at least one side of side conductive fibrous layer, said resin layer comprising a polymeric resin, a plurality of thermoplastic toughening particles and a plurality of electrically conductive particles;

wherein said resin layer is configured to join with a corresponding resin layer of an adjoining prepreg and thereby define an interleaf resin layer thickness; and

wherein at least 50% of said conductive particles in said resin layer have a diameter that is within 10 μ

m of the interleaf resin layer thickness.

12. The prepreg of claim 11, wherein at least 90% of said conductive particles have a diameter between 0.3 μ

m and 100 μ

m.

13. The prepreg of claim 11, wherein the diameter of each of said conductive particles is the largest cross-sectional diameter or dimension of a respective particle.

14. The composite material of claim 11, wherein said conductive particles have an aspect ratio between 1 and 10.

15. The composite material of claim 11, wherein said conductive particles comprise carbon particles.

18. The prepreg of claim 13, wherein the diameter of each of said conductive particles is the largest cross-sectional diameter or dimension of a respective particle.

19. The composite material of claim 13, wherein said conductive particles have an aspect ratio between 1 and 10.

20. The composite material of claim 13, wherein said conductive particles comprise carbon particles.

16. A prepreg comprising:

a conductive fibrous layer comprising a plurality of electrically conductive fibers;

a resin layer located on at least one side of said conductive fibrous layer, said resin layer comprising a polymeric resin, a plurality of thermoplastic toughening particles and a plurality of electrically conductive particles;

wherein said resin layer is configured to join with a corresponding resin layer of an adjoining prepreg and thereby define an interleaf resin layer thickness; and

wherein said electrically conductive particles have an average diameter between 0.3 μ

m and 100 μ

m, and wherein said interleaf resin layer has an average thickness between 10.3 μ

m and 110 μ

m.

17. The prepreg of claim 16, wherein at least 90% of said conductive particles have a diameter between 0.3 μ

m and 100 μ

m.