JPWO2019203893A5

JPWO2019203893A5 -

Info

Publication number: JPWO2019203893A5
Application number: JP2020524608A
Authority: JP
Publication date: 2023-02-16

Description

「活性のある」（化学活性）熱硬化粒子と周囲の樹脂マトリックスの間のＣＴＥの不適合が殆ど又は全く起こらず、その結果として、硬化した複合積層体は、剥離及び微小亀裂に対する改善された耐性を示すことが分かった。本明細書に開示される「活性のある」熱硬化粒子の使用は、周囲のマトリックス樹脂とは異なる化学的性質を有する熱可塑性又は架橋した熱可塑性強化粒子を層間強化粒子として使用する航空宇宙産業で使用される従来の方法からの逸脱である。
Little or no CTE mismatch between the "active" (chemically active) thermoset particles and the surrounding resin matrix occurs, resulting in cured composite laminates with improved resistance to delamination and microcracking was found to show The use of "active" thermoset particles disclosed herein is an aerospace application that uses thermoplastic or crosslinked thermoplastic reinforcing particles that have different chemistries than the surrounding matrix resin as interlaminar reinforcing particles. It is a departure from conventional methods used in industry .

Claims

A fiber reinforced polymer composite structure comprising:
Two or more layers of reinforcing fibers impregnated or infused with a curable matrix resin, the reinforcing fibers comprising one or more thermosetting resins and at least one curing agent;
chemically active thermosetting particles positioned in the interlaminar regions between adjacent layers of reinforcing fibers;
The chemically active thermoset particles are derived from a thermoset resin composition comprising one or more epoxy resins and at least one amine compound as a curing agent, wherein the molar ratio of epoxy groups to amine groups is 100%. a ratio such that there is either an deficiency or excess of the amount of amine required to react with all the epoxy groups of
A fiber reinforced polymer composite structure wherein each chemically active thermoset particle contains either uncrosslinked epoxy functional groups or unreacted amine groups capable of forming covalent bonds with a crosslinked polyepoxide.

A method of manufacturing a fiber reinforced polymer composite structure comprising:
(a) forming thermoset particles having chemically active functional groups on the surface of the particles;
(b) forming a plurality of prepreg plies, each prepreg ply comprising reinforcing fibers impregnated or infused with a curable matrix resin;
(c) depositing thermoset particles on at least one surface of each prepreg ply;
(d) laying up prepreg plies having particles thereon in a stacked arrangement such that there are particles positioned between adjacent prepreg plies thereby forming a prepreg layup;
(e) consolidating the prepreg layup; and (f) curing the prepreg layup;
with
The thermoset particles in (a) form a thermoset composition comprising one or more thermoset resins and at least one curing agent, wherein the molar ratio of thermoset resin to curing agent is 100%. A ratio that is inadequate or in excess of the amount of amine required to react with all of the epoxy resins and has functional groups that are chemically reactive to cure the thermosetting resin composition. Formed by forming a crosslinked resin and pulverizing the crosslinked resin ,
During curing in (f), the chemically active functional groups of the thermoset particles form covalent bonds with the matrix resin surrounding the particles.

A method of manufacturing a fiber reinforced polymer composite structure comprising:
(a) forming thermoset particles having chemically active functional groups on the surface of the particles;
(b) forming a curable matrix resin composition comprising one or more thermoset resins, at least one curing agent, and thermoset particles;
(c) impregnating multiple layers of reinforcing fibers with a curable resin composition to form prepreg plies, each prepreg ply comprising reinforcing fibers impregnated or infused with a curable matrix resin composition; the particles remaining on the outer surface of the reinforcing fiber layer;
(d) laying up prepreg plies having particles thereon in a stacked arrangement, thereby forming a prepreg layup;
(e) consolidating the prepreg layup; and (f) curing the prepreg layup;
with
The thermoset particles in (a) form a thermoset composition comprising one or more thermoset resins and at least one curing agent, wherein the molar ratio of thermoset resin to curing agent is 100%. A ratio such that the amount of amine is inadequate or in excess of the amount of amine required to react with all of the epoxy resin groups to cure the thermosetting resin composition to remove chemically reactive functional groups. Formed by forming a cured resin having and pulverizing the cured resin ,
During curing in (f), the chemically active functional groups of the thermoset particles form covalent bonds with the matrix resin surrounding the particles.

A method of manufacturing a fiber reinforced polymer composite structure comprising:
(a) forming thermoset particles having chemically active functional groups on the surface of the particles;
(b) forming a resin film from the first curable resin composition that does not contain the thermoset particles;
(c) forming a resin film from a second curable resin composition comprising one or more thermoset resins, at least one curing agent, and said thermoset particles;
(d) impregnating a layer of reinforcing fibers with at least one resin film formed from the first curable resin composition using heat and pressure, thereby forming a layer of resin-impregnated reinforcing fibers;
(e) contacting one surface of the layer of resin-impregnated reinforcing fibers with at least one resin film formed from a second curable resin composition, thereby forming a particle-containing prepreg ply;
(f) forming additional particle-containing prepreg plies according to steps (d) and (e);
(g) laying up the prepreg plies in a stacked arrangement thereby forming a prepreg layup;
(h) consolidating the prepreg layup; and (i) curing the prepreg layup;
with
The thermoset particles in (a) form a thermoset composition comprising one or more thermoset resins and at least one curing agent, wherein the molar ratio of thermoset resin to curing agent is 100%. A ratio that is inadequate or in excess of the amount of amine required to react with all of the epoxy resins and has functional groups that are chemically reactive to cure the thermosetting resin composition. A method formed by forming a cured resin and pulverizing the cured resin, and during curing in (i) the chemically active functional groups of the thermoset particles form covalent bonds with the matrix resin surrounding the particles.