Polymer composites and methods of making

Patent metadata

Field	Value
Publication number	US-2021122125-A1
Application number	US-201816603482-A
Country	US
Kind code	A1
Filing date	May 18, 2018
Priority date	Jun 1, 2017
Publication date	Apr 29, 2021
Grant date	—

Abstract

Polymer composites and methods of making wherein the polymer composites include a continuous matrix phase and a reinforcing phase, with varying properties (material and/or physical).

First claim

1 . A polymer composite in the form of a fiber or rod, the composite comprising:
a fully cured continuous matrix phase comprising contiguous first and second polymeric regions, wherein:
the first polymeric region has a first modulus or a first Tg;
the second polymeric region has a second modulus or a second Tg; and
the second modulus is different than the first modulus and/or the second Tg is different than the first Tg; and
a reinforcing phase comprising continuous fibers.

2 . The polymer composite of claim 1 wherein the first polymeric region and the second polymeric region comprise the same polymer composition, and wherein the continuous matrix phase comprises a thermally cured epoxy resin.

3 . A polymer composite in the form of a fiber or rod, the composite comprising:
a fully cured continuous matrix phase comprising contiguous first and second polymeric regions, wherein the contiguous first and second polymeric regions have different material properties; and a reinforcing phase comprising continuous fibers; wherein the polymer composite comprises contiguous first and second composite regions, each having different physical properties.

4 . The polymer composite of claim 3 , wherein the first and second composite regions each have a bending strength, wherein the bending strength of the first composite region is different than the bending strength of the second composite region.

5 . The polymer composite of claim 3 , wherein the first and second composite regions each have a stiffness, wherein the stiffness of the first composite region is different than the stiffness of the second composite region.

6 . The polymer composite of claim 3 , wherein the first polymeric region and the second polymeric region comprise the same polymer composition cured differently.

7 . The polymer composite of claim 3 , wherein the first polymeric region has a first modulus or a first Tg; the second polymeric region has a second modulus or a second Tg; and the second modulus is different than the first modulus and/or the second Tg is different than the first Tg.

8 . A method for producing a fully cured polymer composite, the method comprising:
providing a polymer resin and a reinforcing material dispersed therein; curing the polymer resin in a first polymeric region at a first rate, and curing the polymer resin in a second polymeric region at a second rate, to form the fully cured polymer composite; wherein the first and second cure rates are different; and wherein the first polymeric region is contiguous with the second polymeric region in the fully cured polymer composite.

9 . The method of claim 8 wherein curing comprises thermally curing.

10 . A fully cured polymer composite made according to the method of claim 8 .

11 . The polymer composite of claim 1 , wherein the first polymeric region and the second polymeric region comprise different polymer compositions.

12 . The polymer composite of claim 1 , wherein the first polymeric region and the second polymeric region comprise a same polymer composition cured differently.

Assignees

• 3M Innovative Properties Co

Inventors

• Mcdowell Erin A
• Etter Jo A
• Jost Kristy A
• Ouderkirk Andrew J
• Kieschke Robert R
• Andreasen Rachel

Classifications

• B29C35/0222

  the curing continuing after removal from the mould (B29C35/0233 takes precedence) · CPC title

• B29K2995/0082

  Flexural strength; Flexion stiffness · CPC title

• B29C70/16 Primary

  using fibres of substantial or continuous length {(non-woven fabrics per se D04H3/00)} · CPC title

• B29C71/02

  Thermal after-treatment {(B29C71/0063 and B29C71/0072 take precedence)} · CPC title

• B29K2063/00

  Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material · CPC title