Composite materials

• US 9,603,229 B2
• Filed: 02/05/2015
• Issued: 03/21/2017
• 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): Cole, Elizabeth M
• Application Number:
  US14/614,448
• Publication Number:
  US 20150156854A1
• Time in Patent Office: 775 Days
• US Class Current: 1/1
• 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. An interleaf composite material which is curable to form a panel, that is not penetrated by a lightning strike, said composite material comprising:

at least four conductive fibrous layers comprising a plurality of electrically conductive fibers;

electrically insulating resin layers located between said conductive fibrous layers, said electrically insulating resin layers each having an average thickness and comprising a resin formulation comprising a polymeric resin; and

conductive bridges that extend across said electrically insulating resin layers to provide electrical connections between said conductive fibrous layers wherein said conductive bridges comprise electrically conductive particles wherein at least 50%, of said electrically conductive particles have a diameter that is within 10 μ

m of the average thickness of said electrically insulating resin layers and wherein the number of said electrically conductive bridges is sufficient to prevent penetration of said composite material by a lightning strike once said interleaf composite material has been cured to form said panel.

2. An interleaf composite material according to claim 1 wherein said electrically conductive particles are present in an amount of between 0.2 vol. % and 2.0 vol. % of said interleaf composite material.

3. An interleaf composite material according to claim 1 wherein said resin formulation comprises electrically conductive nano materials.

4. An interleaf composite material according to claim 1 wherein said electrically conductive particles comprise a non-electrically conductive core and an electrically conductive coating surrounding said core.

5. An interleaf composite material according to claim 4 wherein said core comprises a thermoplastic polymer.

6. An interleaf composite material according to claim 1 wherein said electrically conductive particles have an aspect ratio of between 1 and 10.

7. An interleaf composite material according to claim 1 wherein said electrically conductive fibers are carbon fibers.

8. An interleaf composite material according to claim 1 wherein said electrically conductive particle is a carbon particle.

9. An interleaf composite material according to claim 1 wherein said polymeric resin comprises a toughening agent and/or toughening particles.

10. An interleaf composite structure comprising a composite material according to claim 1 wherein said polymeric resin has been cured.

16. A method for making an interleaf composite material according to claim 9 wherein said electrically conductive particles have an aspect ratio of between 1 and 10.

11. A method for making an interleaf composite material which is curable to form a panel that is not penetrated by a lightning strike, said method_comprising the steps of:

providing at least four conductive fibrous layers comprising a plurality of electrically conductive fibers;

providing electrically insulating resin layers located between said conductive fibrous layers, said electrically insulating resin layers each having an average thickness and comprising a resin formulation comprising a polymeric resin; and

forming conductive bridges extending across said resin layers to provide an electrical connection between said conductive fibrous layers wherein said conductive bridges comprise electrically conductive particles wherein at least 50% of said electrically conductive particles have a diameter that is within 10 μ

m of the average thickness of said electrically insulating resin layers and wherein the number of said electrically conductive bridges is sufficient to prevent penetration of said composite material by a lightning strike once said interleaf composite material has been cured to form said panel.

12. A method for making an interleaf composite material according to claim 11 wherein said electrically conductive particles are present in an amount of between 0.2 vol. % and 20 vol. % of said composite material.

13. A method for making an interleaf composite material according to claim 11 wherein said resin formulation additionally comprises electrically conductive nano materials.

14. A method for making an interleaf composite material according to claim 11 wherein said electrically conductive particle comprises a non-electrically conductive core and an electrically conductive coating surrounding said core.

15. A method for making an interleaf composite material according to claim 14 wherein said core comprises a thermoplastic polymer.

17. A method for making an interleaf composite material according to claim 11 wherein said electrically conductive fibers are carbon fibers.

18. A method for making an interleaf composite material according to claim 11 that includes the additional step of curing said polymeric resin to form said panel.

19. A method for making an interleaf composite material according to claim 11 wherein said electrically conductive particle is a carbon particle.

20. A method for making an interleaf composite material according to claim 11 wherein said polymeric resin comprises a toughening agent and/or toughening particles.