EP0535214A1 - Unidirectional carbon/phenolic prepreg material and method of manufacture - Google Patents
Unidirectional carbon/phenolic prepreg material and method of manufactureInfo
- Publication number
- EP0535214A1 EP0535214A1 EP92911259A EP92911259A EP0535214A1 EP 0535214 A1 EP0535214 A1 EP 0535214A1 EP 92911259 A EP92911259 A EP 92911259A EP 92911259 A EP92911259 A EP 92911259A EP 0535214 A1 EP0535214 A1 EP 0535214A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- carbon fibers
- resin
- layer
- unidirectional carbon
- layers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 238000000034 method Methods 0.000 title claims abstract description 25
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- 239000000463 material Substances 0.000 title claims description 41
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 title description 6
- 229910052799 carbon Inorganic materials 0.000 title description 6
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 title description 3
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 59
- 239000004917 carbon fiber Substances 0.000 claims abstract description 59
- 229920001568 phenolic resin Polymers 0.000 claims abstract description 26
- 239000005011 phenolic resin Substances 0.000 claims abstract description 26
- 230000008569 process Effects 0.000 claims abstract description 17
- 239000000835 fiber Substances 0.000 claims description 28
- 229920005989 resin Polymers 0.000 claims description 23
- 239000011347 resin Substances 0.000 claims description 23
- 239000011162 core material Substances 0.000 claims description 22
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 20
- 239000011521 glass Substances 0.000 claims description 19
- 239000004744 fabric Substances 0.000 claims description 18
- 229920003002 synthetic resin Polymers 0.000 claims description 17
- 239000000057 synthetic resin Substances 0.000 claims description 17
- 239000002313 adhesive film Substances 0.000 claims description 16
- 239000002904 solvent Substances 0.000 claims description 13
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 8
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 5
- 238000010030 laminating Methods 0.000 claims description 5
- 238000003825 pressing Methods 0.000 claims description 4
- 239000004760 aramid Substances 0.000 claims description 3
- 229920003235 aromatic polyamide Polymers 0.000 claims description 3
- 239000012080 ambient air Substances 0.000 claims description 2
- 239000004687 Nylon copolymer Substances 0.000 claims 1
- 238000001035 drying Methods 0.000 claims 1
- 239000002648 laminated material Substances 0.000 abstract description 5
- 239000000779 smoke Substances 0.000 abstract description 3
- 238000002485 combustion reaction Methods 0.000 abstract description 2
- 230000002349 favourable effect Effects 0.000 abstract description 2
- 238000000576 coating method Methods 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 57
- 239000003822 epoxy resin Substances 0.000 description 6
- 229920000647 polyepoxide Polymers 0.000 description 6
- 230000008901 benefit Effects 0.000 description 5
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 5
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 description 3
- 230000000712 assembly Effects 0.000 description 3
- 238000000429 assembly Methods 0.000 description 3
- 239000011152 fibreglass Substances 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- 239000004593 Epoxy Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 231100000331 toxic Toxicity 0.000 description 2
- 230000002588 toxic effect Effects 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000012792 core layer Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000003517 fume Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 235000012907 honey Nutrition 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000013067 intermediate product Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000012778 molding material Substances 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000008439 repair process Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/02—Layered products comprising a layer of paper or cardboard next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
- B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
- B29B15/10—Coating or impregnating independently of the moulding or shaping step
- B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
- B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
- B29B15/125—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex by dipping
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
- B32B3/12—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
- C08J5/241—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres
- C08J5/243—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using inorganic fibres using carbon fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/021—Fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/101—Glass fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/106—Carbon fibres, e.g. graphite fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/558—Impact strength, toughness
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2317/00—Animal or vegetable based
- B32B2317/12—Paper, e.g. cardboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/18—Aircraft
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2361/00—Characterised by the use of condensation polymers of aldehydes or ketones; Derivatives of such polymers
- C08J2361/04—Condensation polymers of aldehydes or ketones with phenols only
- C08J2361/06—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
Definitions
- This invention relates to laminated materials and the individual layers of which such materials are composed, and more particularly, to such materials for use in aircraft interiors.
- desirable materials provide a high degree of strength, stiffness, and resis ⁇ tance to impact. These materials are commonly used in such applications as airplane interiors, cargo spaces and the like and are usually substantially planar, multi- layered materials which incorporate a synthetic resin. • Ideally, in addition to offering optimal strength-weight properties, the laminated material should be easy to cut, and easy to handle during installation and repair. In many cases, the laminated assemblies contain a layer or layers of molding material which incorporates a synthetic resin. These resin-impregnated materials are frequently known by the term "prepregs.” As used herein, and as used in the industry, this term refers to an intermediate product in the manufacturing process.
- the invention disclosed herein relates to a resin- impregnated material or "prepreg," a multi-layered lami ⁇ nate assembly which incorporates the prepreg disclosed herein, and a method for making such a material.
- prepreg resin- impregnated material
- multi-layered lami ⁇ nate assembly which incorporates the prepreg disclosed herein, and a method for making such a material.
- a preferred embodiment of the multi-layered laminate fea ⁇ tures superior strength, stiffness and impact resistance compared to similar materials presently known.
- a multi-layered prepreg comprises a substantially planar core material overlaid on one or both surfaces with other materials which provide additional structural strength and may individually help to bind the layers together.
- a cross- section of such a material would reveal an inner core material with other layers applied to one or both planar surfaces.
- the use of certain materials as the individual layers of a multi-layered prepreg assembly is well-known in the art. For example, use of woven glass cloth, fiberglass and carbon fibers is known and the general characteristics of each are familiar to those skilled in the art.
- Most prepreg assemblies feature one or more layers containing a type of fiber such as glass or carbon.
- a type of fiber such as glass or carbon.
- the properties of these layers and their methods of manufac- ture may vary.
- common fiberglass material is a sheet comprising numerous tiny glass fibers in a random array to which a resin is added, and the resulting composition may be shaped into a desired form.
- individual fibers may be woven in a cloth-like fashion which may provide certain advantages in strength and allows easier handling and manufacture.
- carbon fibers utilized in prepregs have been either woven or unidirectional. Unidirectional carbon fibers are not woven such that individual fibers run perpendicular to, and pass over and under one another; rather, all the individual fibers run parallel to one another and are commercially available in ribbon form wound onto spools.
- Characteristic of prepregs is use of a synthetic resin which aids in holding the layers together and provides structural strength and stiffness. Years ago, phenolic resins were widely used, but the phenolic-based prepregs exhibited less than ideal properties because the phenolic resins were brittle and did not bind well to the materials used as the core layer. With respect to the binding and brittleness properties, epoxy resins performed better than phenolic resins and offered advantages in the manufactur ⁇ ing process because epoxy resins could be used without first being dissolved in a solvent, which was necessary with the phenolic resins. Moreover, epoxy-based prepregs offered advantages in weight and strength and became widely used, largely phasing out the phenolic-based prepregs.
- the type of resin used also has a bearing on the type of fiber used.
- woven fibers are preferred because a sol ⁇ vent-based resin application system did not exist for use with unidirectional fibers.
- the use of unidirec ⁇ tional fibers has been limited to non-solvent based, epoxy resin application systems.
- a fabric of woven fibers is impregnated with a phenolic resin/solvent solution and dried, thus forming the pre ⁇ preg.
- the present invention enables the use of unidirection ⁇ al carbon fibers with phenolic resin/solvent solutions.
- a manufacturing process is described herein which produces sheets of phenolic-resin impregnated unidirectional carbon fibers which are ultimately used in forming a laminated assembly. Testing data has revealed that laminated assemblies which incorporate these prepregs have superior strength, stiffness and impact resistance properties while maintaining favorable smoke and burn characteristics.
- most aircraft interior prepregs are comprised of woven fiber ⁇ glass or woven carbon fibers which are coated with a solution of resin and laminated to both sides of a paper honeycomb core.
- varying thicknesses of the core and different types of fiberglass or carbon fibers may be used. Additionally different quantities, types and application processes of resin can be used.
- the amount of carbon present in an individual type of prepreg may be described by the "Areal weight" of the prepreg which measures the grams of carbon in a square meter of the final prepreg.
- the commercially available Amoco EXAS-33-500 epoxy-based prepreg has an Areal weight of about 150 g/m 2 and a laminated assembly featuring this prepreg has an impact resistance of approximately sixty inch-pounds.
- an embodiment of the present invention with an Areal weight of 150 g/m 2 has an impact resistance of up to 140 inch-pounds. Similar impact-resistance properties have been achieved with embodiment of the present invention with an Areal weight as low as 120 g/m 2 .
- Lincoln, Inc. weighs 1.6 times as much per area as that made according to the present invention and will withstand an impact of eighty-five inch-pounds.
- Another prepreg manufactured by Fibrerite, Inc. and used in the McDon ⁇ nell-Douglas MD-80, will withstand an impact of ninety inch-pounds but weighs twice as much as that of the present invention.
- FIGURE 1 illustrates a preferred embodiment of the present invention showing the individual layers of the final laminated assembly separated from each other to reveal the relationship of the individual layers of which the final prepreg is comprised.
- FIGURE 2 illustrates an apparatus which may be used in the manufacturing process of an individual sheet of resin- impregnated unidirectional carbon fibers.
- FIGURE 3 illustrates a preferred embodiment of the present invention showing a final laminated assembly with a partial cut-away of each individual layer to show one possible orientation of the individual layers.
- the inner core material may comprise a number of materials which are low in cost and light in weight.
- a preferred embodiment of the present invention utilizes a core 1 composed of an aramid paper pre-formed through a conventional process into a honeycomb pattern and dipped in phenolic resin.
- the film contains a phenolic resin and, although its structural properties are unknown, the adhesive film layers facilitate binding the inner core 1 to the outer layers.
- Sheets of unidirectional carbon fibers 3 and 3 1 are prepared by a novel process in which the fibers are immersed in a resin bath after being arranged into a sheet of uniform thickness.
- a novel manufacturing process for preparing such resin-impregnated fibers is disclosed herein, although impregnation of fibers with a synthetic resin is a known procedure that may be accomplished in a variety of ways.
- Layers 3 and 3' are two layers of resin- impregnated unidirectional carbon fibers which are identi- cal in manufacture and are oriented substantially perpen ⁇ dicular to one another such that the individual carbon fibers in the sheet are in a 0°/ 90 ° orientation.
- Layers 4 are composed of a glass scrim cloth which is attached to the layers of carbon fibers 3 and 3*. Ultimately, this assem ⁇ bly is cured in a laminating press to fuse the layers together for use as the final prepreg product.
- one preferred method is to draw strands or "ribbons" of Toray T-700 carbon fibers 12 from several spools 11.
- the number and orientation of the individual spools is for illustra- tive purposes only; in practice the number of spools 11 may be far greater, and the spools 11 could be placed in many suitable arrangements.
- the number of spools will vary as a function of the width and thickness of the spooled carbon fiber strands and the weight of carbon desired in the prepreg.
- the strands of carbon fibers 12 are passed through a guide 13 or series of guides which are oriented to align and assemble the strands to form a uniform sheet 14 of the desired width and thickness.
- Increasing the thicknesses of the sheet of the fibers thus assembled requires only the use of more spools of carbon fiber.
- Further uniformity in thickness can be achieved by passing the strands of carbon fiber under and over a series of cylindrical bars 15 such that the bars slightly deflect the path of the strands.
- the two cylindrical bars 15 shown in FIGURE 2 are meant to be representative of one or more of such apparatus as needed to create a continuous sheet of carbon fibers of uniform thickness.
- the strands of carbon fibers should form a sheet of substantially uniform thickness without gaps or holes in the sheet so that after being immersed in resin the fiber sheet of carbon fibers is continuous and uniform.
- the present invention describes a superior method of applying the resin.
- impregnating fibers with resin through the use of a resins dissolved in a solvent in a bath 16 rather than a pre-formed resin film reduces the viscosity of the resin which is believed to increase the degree to which the resin impregnates the fibers. It is further believed that this method increases the bonding of the resins to the fiber substrate.
- the resulting continuous sheet is then passed through a resin bath 16 to coat and impregnate the carbon fibers with phenolic resin.
- the phenolic-resin bath solution 17 contains liquid resin dissolved in a solvent.
- the resin is the commercially available phenolic resin Chem-Bond 6010.
- the phenolic-resin solution con ⁇ tains 60% phenolic resin solids dissolved in methanol.
- ethanol is added to bring the specific gravity of the resin-bath solution to approximately 0.94 g/ml.
- the resulting resin-impregnated continuous sheet of unidirectional carbon fibers is drawn underneath an edge 18 that removes excess resin from the sheet of fibers.
- This continuous sheet of unidirectional carbon fibers 19 is applied to a roll of silicone-coated paper 20 and passed through an oven 21 for six minutes with an ambient air temperature of approximately 210"F ⁇ 10°.
- a first layer of the unidirectional carbon fibers is prepared in a desired shape and size by laying out a series of the sheets of resin-impregnated carbon fibers with the treated-paper backing. Additional layers of resin-impregnated carbon fibers are applied to the first layer. Taking advantage of the treated paper backing, additional layers are applied so that the carbon fibers of each layer face and contact one another and so that the treated paper backing can be peeled off in preparation for applying another layer of carbon fibers or a different component of the final laminated assembly.
- a second layer of unidirec ⁇ tional carbon fibers is laid on top of, and substantially perpendicular to, the first layer.
- This assembly is termed a "o°/ 90 ° unidirectional carbon fiber prepreg.”
- the treated paper is removed from one side of this assem ⁇ bly.
- a layer of type 108 glass scrim cloth which covers one entire surface of the resulting prepreg and thus becomes an exterior surface of the final prepreg. This layer eases handling of the resulting prepreg and prevents fraying of the prepreg and other underlying material if the prepreg is cut to fit its intended use.
- another assembly compris ⁇ ing two layers of fibers 22 and one layer of glass scrim cloth 4, identical in size and manufacture to the one described immediately above, is prepared.
- a layer of adhesive film 2 is attached to both sides of a honey ⁇ comb paper core material 1 of the desired shape.
- the remaining paper backing is removed from the layers of carbon fibers and glass cloth, and the carbon fiber layer is placed most proximate to the core material so that a layer of carbon fibers directly contacts the adhesive film layer.
- the glass cloth layer constitutes both exterior layers of the final laminated assembly.
- the final laminated assembly is placed in a laminating press and cured for about ten minutes to two hours at a temperature of approx ⁇ imately 260-350"F at approximately 25-200 psi, preferably at about fifty psi.
- the resulting laminated assembly is 10-12mm thick, although the thickness can be varied depending on the allowable weight and desired strength.
- the unidirectional carbon fiber layers, the adhesive film layers and the layer of glass scrim cloth are combined without the inner core material.
- a 0°/ 90 ° unidirectional carbon fiber prepreg is prepared as described above.
- a layer of the glass scrim cloth is attached to one surface and the adhesive film layer is attached to the other surface.
- This assembly is bound together by placing it in a lami ⁇ nating press at approximately 5 psi and 125-175°F for ten minutes to two hours.
- This step may be performed under vacuum although the quality of the final prepreg does not appear to be affected by the vacuum environment.
- the layers of the prepreg are combined without the inner core material so that the essential elements of the prepreg may be commercially available without being bound to a particular core mater ⁇ ial.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Health & Medical Sciences (AREA)
- Inorganic Chemistry (AREA)
- Manufacturing & Machinery (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Reinforced Plastic Materials (AREA)
- Laminated Bodies (AREA)
Abstract
Matériaux stratifiés utilisés fréquemment comme revêtements internes d'avions, et utilisation de résines phénoliques et de fibres de carbone unidirectionnelles (14) pour former un préimprégné, comprenant la totalité des couches des matériaux stratifiés. On décrit également un nouveau procédé de fabrication d'un tel préimprégné ainsi que le produit de ce procédé. Le matériau stratifié obtenu présente des propriétés supérieures de résistance mécanique et de résilience, ainsi que des caractéristiques favorables quant à la combustion et au dégagement de fumée.Laminate materials frequently used as internal coatings for aircraft, and the use of phenolic resins and unidirectional carbon fibers (14) to form a prepreg comprising all of the layers of the laminate materials. A new process for manufacturing such a prepreg is also described, as well as the product of this process. The laminate material obtained exhibits superior mechanical strength and resilience properties, as well as favorable characteristics with respect to combustion and the generation of smoke.
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US68052591A | 1991-04-04 | 1991-04-04 | |
US680525 | 2000-10-06 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP0535214A1 true EP0535214A1 (en) | 1993-04-07 |
EP0535214A4 EP0535214A4 (en) | 1993-09-08 |
Family
ID=24731471
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP19920911259 Withdrawn EP0535214A4 (en) | 1991-04-04 | 1992-04-01 | Unidirectional carbon/phenolic prepreg material and method of manufacture |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP0535214A4 (en) |
JP (1) | JPH05508128A (en) |
WO (1) | WO1992017331A1 (en) |
Families Citing this family (17)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6242090B1 (en) | 1993-07-26 | 2001-06-05 | Hexcel Corporation | Fibre reinforced resin composite products |
US6139942A (en) * | 1997-02-06 | 2000-10-31 | Cytec Technology, Inc. | Resin composition, a fiber reinforced material having a partially impregnated resin and composites made therefrom |
FR2793813B1 (en) * | 1999-05-20 | 2001-06-15 | Schappe Sa | UNIDIRECTIONAL TABLE OF CARBON FIBERS |
FR2821790B1 (en) * | 2001-03-07 | 2004-04-16 | A Chomarat Cie Ets Fils D | PROCESS FOR PRODUCING A NEW REINFORCEMENT AND COATING PRODUCT AND NEW PRODUCT OBTAINED |
GB0205498D0 (en) | 2002-03-08 | 2002-04-24 | Structural Polymer Systems Ltd | Moulding material |
GB0307697D0 (en) | 2003-04-02 | 2003-05-07 | Hexcel Composites Ltd | A pigmented panel assembly |
JP4278677B2 (en) * | 2006-11-30 | 2009-06-17 | 株式会社ジャムコ | Sandwich panel |
JP4278678B2 (en) | 2006-11-30 | 2009-06-17 | 株式会社ジャムコ | Sandwich panel |
ITPD20070200A1 (en) † | 2007-06-08 | 2008-12-09 | Angeloni S R L G | FIBER REINFORCEMENT OF THE REINFORCEMENT TYPE FOR COMPOSITE MATERIAL |
ITTO20080252A1 (en) * | 2008-04-01 | 2009-10-02 | Fondazione Istituto Italiano Di Tecnologia | PROCEDURE FOR THE PRODUCTION OF FUNCTIONAL FABRIC BASED ON CARBON FIBER |
DE102012101295A1 (en) * | 2012-02-17 | 2013-08-22 | Lff Composite Technology Gmbh | Fiber composite material |
DE102013201388A1 (en) * | 2013-01-29 | 2014-07-31 | Evonik Industries Ag | Process for producing a metal-plastic hybrid component |
FR3006625B1 (en) * | 2013-06-06 | 2015-06-19 | Stratifies | COMPOSITE PANEL FOR FLOORS OR WALL CLADDING ELEMENTS, AND METHOD FOR MANUFACTURING SUCH PANEL |
US10953625B2 (en) * | 2014-01-23 | 2021-03-23 | Spartan Acquisition Llc | Unidirectional fiber composite system for structural repairs and reinforcement |
US10266292B2 (en) | 2015-01-22 | 2019-04-23 | Neptune Research, Llc | Carriers for composite reinforcement systems and methods of use |
ES2855114T3 (en) * | 2016-05-27 | 2021-09-23 | Airbus Operations Sl | Flame retardant polymer matrix composite structure |
JP2018162383A (en) * | 2017-03-27 | 2018-10-18 | 三菱ケミカル株式会社 | Fiber-reinforced resin material for use in impact resistant automotive outer panel |
Citations (10)
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GB1260409A (en) * | 1969-03-10 | 1972-01-19 | Sec Dep For Defence Formerly M | Carbon fibre reinforced resin plastics sheet |
US3726751A (en) * | 1971-01-08 | 1973-04-10 | Martin Marietta Corp | High performance ablative material construction |
FR2338137A1 (en) * | 1976-01-14 | 1977-08-12 | Celanese Corp | Phenol-formaldehyde resin polyamide terpolymer impregnated prepregs. - with reduced flame spread, smoke formation and toxic gases on burning |
EP0062973A2 (en) * | 1981-04-13 | 1982-10-20 | Mitsubishi Rayon Co., Ltd. | Laminated pre-impregnated carbon fiber structures |
EP0075033A1 (en) * | 1981-09-18 | 1983-03-30 | Hexcel Corporation | Sheet material, process for its production and a composite structure |
WO1985003032A1 (en) * | 1984-01-09 | 1985-07-18 | The Boeing Company | Composite material structure with integral fire protection |
EP0254872A2 (en) * | 1986-07-15 | 1988-02-03 | PROMAT GmbH | Lining element |
JPS6384932A (en) * | 1986-09-22 | 1988-04-15 | 旭化成株式会社 | Laminated panel |
US4820567A (en) * | 1986-10-22 | 1989-04-11 | United Technologies Corporation | Microcrack resistant fiber reinforced resin matrix composite laminates |
EP0355912A2 (en) * | 1988-08-15 | 1990-02-28 | Adprotech B.V. | Flat sandwich-shaped body |
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US4622091A (en) * | 1984-11-29 | 1986-11-11 | The Boeing Company | Resin film infusion process and apparatus |
US4900048A (en) * | 1987-10-02 | 1990-02-13 | Gleb Derujinsky | Integral seamless composite bicycle frame |
JPH01209129A (en) * | 1988-02-17 | 1989-08-22 | Nippon Steel Chem Co Ltd | Lightweight panel and preparation thereof |
-
1992
- 1992-04-01 JP JP92511380A patent/JPH05508128A/en active Pending
- 1992-04-01 WO PCT/US1992/002797 patent/WO1992017331A1/en not_active Application Discontinuation
- 1992-04-01 EP EP19920911259 patent/EP0535214A4/en not_active Withdrawn
Patent Citations (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1260409A (en) * | 1969-03-10 | 1972-01-19 | Sec Dep For Defence Formerly M | Carbon fibre reinforced resin plastics sheet |
US3726751A (en) * | 1971-01-08 | 1973-04-10 | Martin Marietta Corp | High performance ablative material construction |
FR2338137A1 (en) * | 1976-01-14 | 1977-08-12 | Celanese Corp | Phenol-formaldehyde resin polyamide terpolymer impregnated prepregs. - with reduced flame spread, smoke formation and toxic gases on burning |
EP0062973A2 (en) * | 1981-04-13 | 1982-10-20 | Mitsubishi Rayon Co., Ltd. | Laminated pre-impregnated carbon fiber structures |
EP0075033A1 (en) * | 1981-09-18 | 1983-03-30 | Hexcel Corporation | Sheet material, process for its production and a composite structure |
WO1985003032A1 (en) * | 1984-01-09 | 1985-07-18 | The Boeing Company | Composite material structure with integral fire protection |
EP0254872A2 (en) * | 1986-07-15 | 1988-02-03 | PROMAT GmbH | Lining element |
JPS6384932A (en) * | 1986-09-22 | 1988-04-15 | 旭化成株式会社 | Laminated panel |
US4820567A (en) * | 1986-10-22 | 1989-04-11 | United Technologies Corporation | Microcrack resistant fiber reinforced resin matrix composite laminates |
EP0355912A2 (en) * | 1988-08-15 | 1990-02-28 | Adprotech B.V. | Flat sandwich-shaped body |
Non-Patent Citations (2)
Title |
---|
DATABASE WPIL Week 8821, Derwent Publications Ltd., London, GB; AN 88-143594 & JP-A-63 084 932 (CIBA GEIGY AG & ASAHI CHEM. IND. KK) 15 April 1988 * |
See also references of WO9217331A1 * |
Also Published As
Publication number | Publication date |
---|---|
JPH05508128A (en) | 1993-11-18 |
WO1992017331A1 (en) | 1992-10-15 |
EP0535214A4 (en) | 1993-09-08 |
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