Fiber-reinforced composite articles and methods of making them

Patent metadata

Field	Value
Publication number	US-10780609-B2
Application number	US-201715820293-A
Country	US
Kind code	B2
Filing date	Nov 21, 2017
Priority date	Jun 11, 2013
Publication date	Sep 22, 2020
Grant date	Sep 22, 2020

Abstract

Methods of making prepregs are described. The methods include the steps of forming a fiber-containing substrate, and contacting the fiber-containing substrate with a resin mixture. The resin mixture may include polymer particles mixed in a liquid medium, and the polymer particles may be coated on the fiber-containing substrate to form a coated substrate. The liquid medium may be removed from the coated substrate to form the prepreg. The prepregs may be used to make fiber-reinforced articles.

First claim

What is claimed is:

1. A prepreg comprising:
a fiber-containing substrate; and
resin particles comprising a first plurality of particles and a second plurality of particles, wherein the resin particles are coated on the fiber-containing substrate from a resin mixture containing the resin particles dispersed in a liquid medium, wherein:
the first plurality of particles consist of a thermoplastic polymer, and
the second plurality of particles consist of pre-polymerized particles consisting of at least one of monomers or oligomers.

2. The prepreg of claim 1 , wherein the thermoplastic polymer comprises a polyamide polymer.

3. The prepreg of claim 2 , wherein the polyamide polymer comprises nylon-6 or nylon-6,6.

4. The prepreg of claim 1 , wherein the thermoplastic polymer comprises polybutylene terephthalate.

5. The prepreg of claim 1 , wherein the fiber-containing substrate comprises a woven fabric, a multiaxial fabric, a stitched fabric, or a nonwoven fabric.

6. The prepreg of claim 1 , wherein the monomers or oligomers comprise a cyclic alkylene terephthalate.

7. The prepreg of claim 6 , wherein the cyclic alkylene terephthalate comprises cyclic butylene terephthalate.

8. The prepreg of claim 1 , wherein the prepreg does not comprise water.

9. The prepreg of claim 1 , wherein the fiber-containing substrate comprises glass fibers, basalt fibers, carbon fibers, polymer fibers, or natural fibers.

10. The prepreg of claim 1 , wherein the fiber-containing substrate comprises aramid fibers or cellulose fibers.

11. The prepreg of claim 1 , wherein the resin particles have an average particle diameter of 1 μm to 50 μm.

12. The prepreg of claim 1 , wherein the fiber-containing substrate comprises a polymerization catalyst.

13. The prepreg of claim 1 , further comprising:
a layer of thermoplastic polymer,
wherein:
the fiber-containing substrate contacts the layer of thermoplastic polymer.

14. The prepreg of claim 13 , wherein the thermoplastic polymer comprises a polyamide polymer.

15. The prepreg of claim 13 , wherein:
the layer of thermoplastic polymer is a first layer of thermoplastic polymer,
the fiber-containing substrate is a first fiber-containing substrate,
the prepreg further comprising:
a second fiber-containing substrate contacting the first layer of thermoplastic polymer, and
a second layer of thermoplastic polymer contacting the second fiber-containing substrate.

16. The prepreg of claim 15 , wherein the prepreg does not comprise an adhesive.

17. The prepreg of claim 15 , wherein the second thermoplastic polymer comprises a polyamide polymer.

18. The prepreg of claim 17 , wherein the polyamide polymer comprises nylon-6 or nylon-6,6.

19. The prepreg of claim 1 , wherein the prepreg is in a roll product.

Assignees

• Johns Manville
• Jonhs Manville

Inventors

• Zhang Mingfu
• Asrar Jawed
• Gleich Klaus Friedrich
• Yohannes Asheber

Classifications

• C08J5/247

  using fibres of at least two types · CPC title

• C08J5/246

  using polymer based synthetic fibres · CPC title

• C08J5/245

  using natural fibres · CPC title

• C08J5/244

  using glass fibres · CPC title

• C08J5/243

  using carbon fibres · CPC title