KR20150131192A - High performance thermoplastic composite laminates and composite structures made therefrom - Google Patents

Abstract

The refractory composite laminate includes a thermoplastic matrix material reinforced with fibers embedded in the matrix of the composite laminate, wherein the thermoplastic matrix material of the refractory composite laminate comprises polyvinylidene fluoride (PVDF).

Description

 TECHNICAL FIELD [0001] The present invention relates to a high performance thermoplastic composite laminate and a composite structure made from the same. BACKGROUND OF THE INVENTION [0002]

The present invention relates generally to composite laminates and composite structures made therefrom, and more particularly to high performance thermoplastic composite laminates and composite structures made therefrom, and methods of making the same.

The use of synthetic materials has often been limited to components that experience low levels to mitigate structural loads. However, there has been a need for lightweight, low cost, high performance composites that can meet aerospace and general transport needs, for example, in terms of corrosion resistance, salt tolerance, smoke and / or toxicity requirements. In addition, there is a need for such an industry field related to armor or ballistic materials for vehicles and manpower, particularly in relation to industrial fields related to power generation, construction and land and sea, as well as, for example, exist.

The embodiments of the present invention overcome the above-mentioned problems and deal with the aforementioned industrial needs.

According to aspects described herein, there is provided a refractory composite laminate comprising a thermoplastic matrix material reinforced with fibers embedded in a matrix of a composite laminate. The thermoplastic matrix material of the refractory composite laminate includes polyvinylidene fluoride (PVDF).

According to further aspects mentioned herein, there is provided a refractory composite laminate comprising a polymer matrix material reinforced with fibers embedded in a matrix of a composite laminate. The polymer matrix material of the refractory composite laminate includes at least one of polyvinylidene fluoride (PVDF), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), and polyetheramide (PEI).

According to still further aspects described herein, there is provided a flame retardant ballistic panel comprising a fire resistant composite laminate. Wherein said composite laminate comprises a refractory polymeric matrix material reinforced with fibers embedded in a matrix of said composite laminate, said flame retardant ballistic panel comprising an elastomeric material selected from the group consisting of International Armor Standard Armor grades (NIJ Standard Armor grades) at least one protection level against projectiles as defined by II-A, II, III-A, III and IV.

According to still further aspects described herein, there is provided a flame retardant ballistic panel having a first side and a second side, comprising: a plurality of flame retardant ballistic panels each comprising fibers in a first polymer matrix material comprising a first flame retardant resin And a striking surface portion including first plies. The flame retardant ballistic panel further comprises a support portion adjacent the striking surface portion. The support portion includes a plurality of second plies, each of the second plies comprising fibers in a second polymer matrix material comprising a second flame retardant resin, and each plies being bonded to an adjacent plies.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a schematic diagram illustrating a perspective view of a high performance composite structure, according to embodiments, including a core.
BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 a is a schematic diagram illustrating an enlarged view of the high performance composite structure of Figure 1;
Figure 2 is a schematic diagram illustrating the perspective of the core of Figure 1, in accordance with embodiments.
Figure 3 is a schematic diagram illustrating layers / plies as a non-limiting example, which may be included as a laminate of the composite structure, according to embodiments.
4 is a general schematic view of an apparatus used to produce a composite laminate of the composite structure, for example, according to embodiments.
Figure 5 is a rear view of a refrigeration trailer comprising composite structures and / or laminates, according to embodiments.
6 is a perspective view of an air cargo container including composite structures and / or laminates, according to embodiments.
7 is a perspective view of a railway cargo container including composite structures and / or laminates, according to embodiments.
8 is a perspective view of an integrated intermodal container comprising composite structures and / or laminates, according to embodiments.
9 shows a battery case comprising a composite structure and / or a composite laminate according to embodiments;
10 illustrates a battery box comprising a composite structure and / or a laminate according to embodiments;
11 is a schematic partial cross-sectional perspective view of a flame retardant ballistic panel according to embodiments.

The present invention, in accordance with embodiments, describes high performance thermoplastic composite laminates and high performance composite structures made therefrom, and methods for making such laminates and structures. Certain resins that the present inventors are also able to meet, for example, some of the requirements of aerospace applications typically require special processes for the preparation of the resin as well as the pre-treatment of the resins to make the final product, And that it is difficult to process, such high strength laminates and structures provide a more substantial solution. For example, raw material olefin resins generally lose their properties when doped with flame retardant additives, often leading to a significant reduction in the mechanical properties of the induced structure. In addition, such materials do not meet the typical flame retardant requirements of the aerospace and other transportation industries. Thus, according to embodiments, the present inventors have found that it is possible, for example, to combine high performance flame retardant resins with thermoplastic compositions which result in high performance composites from a mechanical point of view as well as provide corrosion resistance and which do not have any ignition, It was determined whether the industry could meet the need by combining high strength fibers in the matrix (i. E. By providing significant resistance / delay to ignition, smoke and toxicity).

As will be described in greater detail below, according to embodiments, a synthetic material composed of a continuous fiber reinforced thermoplastic material that can be easily manufactured is described and is characterized by a high strength-to-weight ratio, impact resistance, fatigue resistance, Temperature resistance, salt tolerance, and / or low toxicity or toxicity, as well as other necessary properties for use in commercial applications. Further, as will be described in further detail below, embodiments advantageously include the use of high strength fibers such as "E" and "S" fiberglass and polyvinylidene fluoride (PVDF) Non-fusible and non-fusible, non-fusible, non-fusible, non-fusible, non-fusible, Non-toxic synthetic products. The inventors have also found that materials such as carbon, aramid, basalt and boron are suitable and advantageous as the synthetic materials described herein.

The inventors have also found that the use of unidirectional tapes for the construction of the laminates described herein can improve the mechanical performance of the composite over, for example, conventional textile laminates. Also, the use of fibers, such as fiberglass, can reduce the amount (e.g., 50 wt% to 85 wt%) of the relatively high cost resin (e.g., PVDF) employed for smoke, ignition and toxicity requirements To be replaced by cost-effective materials, and to provide the required mechanical properties. However, the inventors have also noted that the laminates described herein can provide excellent strength and reduced ignition as well as laminated laminates, as well as in tape laminated form, which will be further described below . Generally, in accordance with embodiments, the high strength reinforced thermoplastic materials and structures described herein comprise a combination of thermoplastic matrix materials, high strength reinforcing fibers, and possibly other reinforcing materials as needed.

Turning now to the drawings, one aspect described herein is a method of forming a first outer layer / sheath 12, as shown in Figures 1 and 1A; A second outer layer / sheath 14; And a core (16) interposed between the first outer layer (12) and the second outer layer (14). It should be noted that the core 16 does not need to be directly attached to the first outer layer 12 and / or the second outer layer 14. For example, as shown in Figures 1 and 1a, at least one intermediate layer / sheath 17 may also be positioned between the first outer layer 12 and the second outer layer 14. Thus, according to embodiments, the core 16 may be interposed between two intermediate layers 17, for example. Some layers 17 may be employed if desired. As a further alternative, no intermediate layer 17 may be employed.

First, although the structure 10 shown in Figs. 1 and 1A has been described as a composite "interposer panel" having a generally rectangular shape, the shape of the composite structure 10 is not limited to such a shape, It is noted that the substrate 10 may be formed of any suitable shape, size and thickness based on the end use article or the like. Thus, the composite structure 10 including the core 16 as well as the layers / laminates 12, 14 and 17 may be formed in any suitable shape, size, thickness, dimensions, etc. And may also be formed of any suitable article / product form. Further detailed descriptions and examples of configuration information of such articles are disclosed below in accordance with embodiments.

The core 16 of Figures 1 and 1a includes a suitable material, typically a foam. According to one embodiment, the foam comprises polyvinylidene fluoride (PVDF) foam, for example Zotek brand PVDF foam. However, according to embodiments, the core 16 may comprise any suitable material, including, for example, the materials described herein for layers 12, 14 and 17 and any combination thereof. .

With respect to the first outer layer 12, the second outer layer 14 and the at least one intermediate layer 17 as well as the materials for the assembly and their construction, the following non-limiting materials and methods are known . Although specific thermoplastic materials are listed below, embodiments of the composite structure 10, including the first and second outer layers 12 and 14, may be made from any of a variety of thermoplastic materials, with and without additional reinforcing agents It should be noted that not only can they be made of suitable fiber-reinforced thermoplastic resins, but also include any suitable thermoplastic sheaths / layers.

According to one embodiment, the "intervening panel 10" described in FIGS. 1 and 1A is an expanded thermoplastic foam (e.g., core 16) joined by use of a suitable adhesive, (E.g., layers 12 and / or 14 and / or 17) that are provided on opposite sides of the sheet. In one embodiment, the layers or layers of laminates provided on opposite sides may be composed of fiber reinforced thermoplastic tapes having, for example, unidirectional and / or multiphasic fiber alignment, based on the properties of the final product desired have. Thus, according to a particularly suitable embodiment, the high strength layers / shells 12/12 comprising the core 16 with, for example, high strength continuous fiber (e.g. fiberglass) reinforced PVDF resin matrix and PVDF foam, 14) is provided. By mixing the structures described herein with the PVDF material, it is possible to provide desirable ignition resistance / suppression properties for the resulting structures and products.

According to embodiments, at least one of the first outer layer 12, the second outer layer 14, and the intermediate layer 17 comprises a plurality of (preferably at least one) first composite ply and second composite ply Wherein the first composite ply and the second composite ply each comprise a plurality of fibers in a thermoplastic matrix; The plurality of composite plies are joined together to form a composite laminate. According to some embodiments, all of said first outer layer 12, said second outer layer 14 and said intermediate layer 17 (s) comprise such features. At least one of the layers (12, 14, 17) and core (16) comprises PVDF according to embodiments.

The composite laminate of at least one of the first outer layer 12, the second outer layer 14 and the intermediate layer 17 (s) may each comprise one or more synthetic plies, For example, the first composite ply and the second composite ply are joined together according to the embodiments. Each ply includes a plurality of fibers. The plurality of fibers of each of the first composite ply and the second composite ply are implanted with a thermoplastic matrix material.

According to embodiments, the thermoplastic matrix material can be, but is not limited to, polyvinylidene fluoride (PVDF), polyvinylidene fluoride (PVDF), polyvinylidene fluoride (PEEK), polyetheretherketone (PSS), polyetheramide (PEI), general fluorinated polymers and other engineering materials such as polyamide (nylon), polyethylene, polypropylene, polyethylene terephthalate, polyphenylene sulfide, polyetheretherketone May comprise any material or combination of materials of thermoplastic nature suitable for applications involving resins, other thermoplastic polymers, and / or combinations thereof.

In one embodiment, the plurality of fibers in the first composite ply are substantially parallel to each other, and the plurality of fibers in the second composite ply are substantially parallel to one another. Thus, the fibers of each ply are oriented in the longitudinal direction (i.e., they are aligned with each other), and traverses the ply in succession according to one embodiment. Composite plies are sometimes referred to as plies or sheets and, according to embodiments, have the characteristic of "unidirectional" with respect to the longitudinal orientation of the fibers.

According to further embodiments of the present invention, the plurality of fibers in the first composite ply are disposed in cross-shape (across) the plurality of fibers in the second composite ply. For example, the fibers in the first composite ply may be crossed at an angle of greater than about 0 degrees to less than about 90 degrees, particularly about 15 degrees to about 75 degrees, for a plurality of fibers in the second composite ply . It is noted that from 0 degrees to about 90 degrees may be employed depending on the embodiments.

Also, the plurality of fibers in the first composite ply are, according to embodiments, equal to or different from the plurality of fibers in the second composite ply. Thus, according to embodiments, various types of fibers are used in the synthetic ply, including fibers of different strengths. Examples of fibers include E-glass and S-glass fibers. E-glass is a low alkali borosilicate glass with good electrical and mechanical properties and good chemical resistance. Its high resistance makes E-glass suitable for electromechanical laminate boards. The indication "E" relates to electricity.

S-glasses are materials of high strength and high cost for E-glass. S-glasses are generally magnesia-alumina-silicate glasses that are employed in aerospace applications with high tensile strength. Originally, "S" symbolizes high strength. Both E-glass and S-glass are particularly suitable for use in the embodiments described herein.

E-glass fibers can be incorporated into a wide range of fiber weights and thermoplastic polymer matrix materials. The E-glass may be used in an amount of from about 10 to about 40 ounces per square yard (oz./sq. Yd.), Especially from about 19 to about 30, more preferably from about 21.4 to about 28.4 oz. sq. yd. Lt; / RTI > range. By way of non-limiting example, the minimum weight of the cross (X) ply is about 18 oz./sq. yd. < / RTI > At 70% by weight of fibers, the consolidation may be 70% of 18 oz.

The amount of S-glass or E-glass fiber in the synthetic ply optionally ranges from about 40 to about 90 weight percent (wt.%) Thermoplastic matrix in the ply, based on the combined weight of the thermoplastic matrix plus fibers, 50 to about 85 weight percent, more preferably about 60 to about 80 weight percent thermoplastic matrix.

Other fibers can also be incorporated, optionally in combination with E-glass and / or S-glass, instead of E- and / or S-glass. Such fibers include ECR, A and C glass as well as other glass fibers such as: quartz, magnesia aluminunino silicate, non-alkali aluminoborosilicate, soda borosilicate, soda silicate, soda lime- Alumina silicates, lead silicates, non-alkaline lead boroaluminas, non-alkaline barium boroaluminas, non-alkaline zinc boro aluminas, non-alkaline iron aluminosilicates, cobalt borates, alumina fibers, asbestos, boron, silicon carbide, Graphite, and polyolefins such as polyethylene, polyvinyl alcohol, saran, aramid, polyamide, polybenzimidazole, polyoxadiazole, polyphenylene, PPR, petroleum and coal pitch (isotropic), mesophase pitch, Such as those obtained from the carbonization of acrylonitrile, ceramic fibers, metal fibers such as steel, aluminum metal alloys, etc. The formed from carbon fiber.

Kevlar or high strength organic polymer fibers formed from aramids that are shaped with various carbon fibers can be used where relatively high performance is required and costs justified. High performance, monoformed oriented fiber bundles generally have a tensile strength of more than 7 grams per denier. Such high performance fiber bundles can be made from aramid, expanded chain ultra high molecular weight polyethylene (UHMWPE), poly [p-phenylene-2,6-benzobisoxazole] (PBO), and poly [diimidazopyridinylene Roxy) phenylene] or combinations thereof. The use of such ultra high tensile strength materials is particularly useful for composite panels with added strength properties

Thus, fiber types known to those skilled in the art can be employed as long as they do not depart from the broad aspects of the embodiments described herein. For example, aramid fibers such as those sold under the tradename Twaron and Technora; Basalt, carbon fibers such as those sold under the trade names Toray, Fortafil and Zoltek; A liquid crystal polymer (LCP), such as LCP, sold under the trade name Vectran, although not exclusively. Based on the foregoing, the embodiments also contemplate the use of organic, inorganic and metallic fibers, either alone or in combination.

The composite plies include fibers that are optionally continuous, cut, optionally mixed and / or woven, according to embodiments. In particular embodiments, the synthetic plies described herein comprise fibers oriented in the longitudinal direction, but excluding fibers oriented in the non-longitudinal direction.

In addition, optional additional materials, such as foams, metals (e.g., aluminum steels, other iron-containing and / or non-ferrous metals, etc.), plastics, epoxides, composites, chemical and / According to the examples, for example, to provide uniform mechanical, dimensional or other characteristics uniformly throughout the material in the thermoplastic synthetic structure and / or the specific region of the laminate described herein, the reinforcing agent, additives and / Can be used as an insert. Thus, any combination of fibers, optional additional materials, reinforcing agents, and the like, can be applied to any of the synthetic materials, laminates, and structures described herein, in any desired combination with any suitable amount and the above- Can be adopted.

Also, in the use of continuous reinforcing fibers, for example, in the structure of synthetic materials, the fiber length corresponding to the length of the material or structure can provide much greater strength when measured parallel to the fiber orientation direction. For example, the ability to sustain acquisitions through penetration of reinforcing fibers with the requisite matrix material as well as consistent fiber alignment and tensile strength can lead to structures / laminates that exhibit, for example, enhanced physical properties in the composite material .

Since the fibers in the composite ply are oriented in the longitudinal direction, according to embodiments, synthetic ply in a composite laminate can be placed with the fibers in a special relationship with the fibers in one or more other composite plies of the laminate .

In a particular embodiment, the fibers in the tape or ply are substantially parallel to one another and the composite laminate comprises a plurality of plies having fibers, said one ply fibers being arranged in an intersecting fashion with respect to the fibers in adjacent plies, For example, at an angle of about 90 degrees or less with respect to the fibers in adjacent ply. The fibers are evenly distributed across the ply according to embodiments. Other examples include a tape comprising batch fibers in a thermoplastic matrix and two ply of fibers in which the material is in a thermoplastic matrix material, wherein the fibers in one ply are about 90 degrees , ≪ / RTI > cross-fly tapes or laminates.

The thermoplastic matrix of one or more plies of the composite laminate described herein for use as a material for at least one of the first outer layer 12 and the second outer layer 14 may be, for example, RTI ID = 0.0 > PVDF. ≪ / RTI > Non-limiting examples of thermoplastic materials include, but are not limited to, polyamide (nylon), polyethylene, polypropylene, polyethylene terephthalate, polyphenylene sulfide, polyether ketone, combinations thereof and the like. Also, as will be discussed further below, polyvinylidene fluoride (PVDF), alone or in any combination with the other matrix components mentioned herein, may be employed in the matrix, and such PVDF material Lt; RTI ID = 0.0 > refractory < / RTI > to the resulting structure.

However, it has been found that the use of polyethylene in the thermoplastic matrix material can, for example, result in a composite laminate having improved rupture resistance with less weight of rupture protection per unit compared to polypropylene-based composite laminates. Polyethylenes are also more consistent in price than polypropylenes, which tend to be highly variable due to the complex manufacturing processes required to produce propylene monomers. As will be described in greater detail below, since the weight of the polyethylene composite laminate is smaller than, for example, the polypropylene composite laminate, more cargo can be carried in such a material or in a lined container, It improves fuel efficiency and cost effectiveness in the trucks, motorcycles or vessels in which they are used.

According to embodiments, copolymers composed of polyethylene and polypropylene may also be used as the thermoplastic matrix. For example, copolymers having greater than about 50 weight percent polyethylene may be used with up to about 50 weight percent polypropylene additives, based on their application and characterization requirements.

In further embodiments, the thermoplastic matrix of one or more plies is formed from coextruded polyethylene and polyethylene terephthalate (often referred to as poly (ethylene terephthalate)), which is usually shortened as PET in any suitable weight percent combinations, . For example, according to embodiments, PET polymers employed include synthetic fibers; Beverages, food and other liquid containers; Thermoforming applications; And thermoplastic PET polymer resins used in engineering resins having a combination of glass fibers. PET homopolymers can be changed to comonomers such as CHDM or isophthalic acid, which lower the melting temperature and also reduce the crystallinity of PET. Thus, the resin can be formed thermally with low temperature and / or low applied force. Such PET homopolymers and copolymers, according to embodiments, are combined with a selective release film for later application, and such optional layers can also be laminated to the base composite structure.

Thus, the polymeric matrix material for use in the various embodiments described herein comprises a polyethylene thermoplastic polymer. The thermoplastic loading weight varies based on the physical property requirements of the intended use of the product. As will be appreciated, most of the polyethylene is classified in different categories based on concentration and branching, and the mechanical properties of the polyethylene depend on such variables as the degree and type of branching, crystal structure and molecular weight. Specific examples include low density polyethylene (LDPE), ultra high molecular weight polyethylene (UHMWPE), ultra low molecular weight polyethylene (ULMWPE or PE-WAX), high molecular weight polyethylene (HMWPE), high density polyethylene (HDPE), high density crosslinked polyethylene (HDXLPE) (PEX or XLPE), medium density polyethylene (MDPE), linear low density polyethylene (LLDPE), ultra low density polyethylene (VLDPE), and combinations thereof. Particular use types of polyethylene include HDPE, LLDPE and in particular LDPE, as well as combinations thereof. According to embodiments, further details of the special properties of the various types of polyethylene for use in the thermoplastic matrix described herein are published in the following.

LDPE has a concentration in the range of 0.910-0.940 g / cm < ³ > and a high long chain branch. Thus, the chains are not typically packed in the crystal structure hermetically. Such materials exhibit strong intermolecular forces as moment-dipole induced-dipole attraction decreases. This results in low tensile strength and increased ductility. LDPE is produced by free radical polymerization. The high branches with long chains allow the dissolved LDPE to have unique and desirable flow properties.

UHMWPE is a polyethylene having a molecular weight of one million, generally about 3 to 6 million. The high molecular weight results in that the chain packing them less effective in the liquid crystal structure, as evidenced by the UHMWPE sun seemed very resistant material, a high concentration of polyethylene (for example, 0.930-0.935 g / cm ³⁾ smaller concentrations than the . UHMWPE can be produced by any catalyst technique, and is representative of Ziegler catalysts. As a result of UHMWPE's excellent toughness and abrasion resistance, abrasion resistance and excellent chemical resistance, such materials can be used in a wide variety of applications.

HDPE has a concentration greater than or equal to 0.941 g / cm < ^{3 &} gt ;. HDPE has low branches and therefore strong intermolecular forces and tensile strength. HDPE can be produced by chromium / silica catalysts, Ziegler-Natta catalysts and / or metallocene catalysts. Lack of branching is ensured by proper selection of catalysts (e.g., chromium catalysts or chitin-Natta catalysts) and reaction conditions.

PEX (or referred to as XLPE) is a medium for high density polyethylene containing cross-linking introduced into the polymer structure, which converts the thermoplastic resin to an elastomer. Thus, high temperature properties are improved, flow is reduced and chemical resistance is enhanced.

MDPE is 0.926-0.940 g / cm < ³ > Lt; / RTI > MDPE can be produced using chromium / silica catalysts, chigler-natans catalysts and / or metallocene catalysts. MDPE has good shock and drop resistance characteristics. This material is also less notch sensitive than HDPE and also exhibits better stress crack resistance than HDPE.

LLDPE is 0.915-0.925 g / cm < ³ > Lt; / RTI > LLDPE is a generally linear polymer having an excellent number of short branches, prepared by copolymerization of ethylene with short chain alpha-olefins (e.g., 1-butene, 1-nucene, and 1-octene) to be. LLDPE has higher tensile strength than LDPE, and has higher impact resistance and breakthrough resistance than LDPE. LDPE also exhibits properties such as toughness, flexibility and relative transparency.

VLDPE is 0.880-0.915 g / cm < ³ > Lt; / RTI > VLDPE is a generally linear polymer having high levels of short chain branches, prepared by copolymerization of ethylene with short chain alpha-olefins (e.g., 1-butene, 1-hexene and 1-octene) . VLDPE is generally produced using metallocene catalysts, for example, higher amounts of comonomer aggregates are exhibited by these catalysts. VLDPEs can also be used as impact modifiers when mixed with other polymers.

In addition to the specific polymers described above, any of the aforementioned copolymers / combinations are contemplated for use in accordance with the embodiments described herein. As a further non-limiting example, in addition to or in place of copolymerization with alpha-olefins, ethylene (or polyethylene) can be copolymerized with a wide range of other monomers and ionic mixtures to form nonionizing radicals . Examples include vinyl acetate in which the resulting product is an ethylene-vinyl acetate copolymer (EVA), and / or suitable acrylates. In addition, the thermoplastic matrix may comprise polyvinylidene fluoride (PVDF) alone or in any combination with other matrix components known to impart fire resistance to the structures induced herein.

According to the embodiments described herein, the thermoplastic matrix of the synthetic plies of one of the synthetic laminates described herein may comprise polyethylene alone or in combination with other polymers / copolymers / constituents, for example, , And PVDF. For example, polyethylene / PVDF can be used as a matrix material with high molecular weight thermoplastic polymers, including but not limited to polypropylene, nylon, PEI (polyetherimide) and copolymers thereof as well as any combination thereof. Can be adopted.

According to embodiments, the synthetic ply comprises from about 60 to about 10 weight percent, especially from about 50 to about 10 weight percent, and more preferably from about 40 to about 15 weight percent, of the polymerization matrix. Other exemplary ranges include about 40 to about 20 weight percent and about 30 to about 25 weight percent. Note that the weight percentages stated above are weight percent of the polymeric matrix material of the ply, as the weight of the polymeric matrix material plus fibers.

In an exemplary embodiment, the fiber content in one or more synthetic plies is greater than about 50% by weight (based on the weight of fibers plus the polymeric matrix of the ply), particularly about 85% by weight or less, Various types of fibers are suitable, and glass fibers are particularly suitable for achieving strength.

In a further exemplary embodiment, the composite laminate described herein comprises first ply and second ply which are joined together with respective fibers in at least mutual crossing relationship, said first ply being connected to said second ply Wherein the matrix of one or both of the first and second plies comprises polyethylene. Thus, the composite laminate comprises at least two different kinds of fibers. In other words, the fibers in at least the first composite ply are disposed in a crossing relationship with the other fibers in the adjacent second composite ply, and optionally at 90 degrees with the other fibers in the adjacent second composite ply. For ease of explanation, the first composite ply and the second composite ply so arranged are often described by a mutual crossing relationship (optionally 90 degrees with each other), without special mention of the fibers in each ply.

The phrase "different fibers" should be broadly understood to mean that the composite laminate is made of two different materials or different grades of the same material. For example, as will be described in greater detail below with respect to the use of the composite laminates described herein, one side of the panel comprising the composite laminate can be formed using Kevlar 129, The rear or back portion may be formed using a higher performance material.

Optionally, the composite laminate may also comprise a synthetic ply disposed in parallel with the adjacent synthetic ply, particularly adjacent ply containing the same kind of fibers as in the first synthetic ply. At least one of the plies, particularly the matrix material of all plies, comprises polyethylene. In addition, the matrix material may vary from ply to ply and may also be in the form of different thermoplastics, polymers, and combinations thereof. Thus, a portion of the composite laminate comprising the first fiber type may be formed in part by laminating the individual composite plies in sequence in parallel relation to each other.

In a particularly useful embodiment, the composite laminate comprises synthetic plies, which contain E- and S-glass fibers, respectively, and are oriented at an angle of about 90 relative to each other in a ply configuration.

An exemplary form for the ply in the composite laminate having at least the first ply and the second ply is such that the second ply has to be at 90 [deg.] With respect to the second ply. Other angles may also be selected for desired properties having less than 90 degrees with respect to the second sheet. Certain embodiments use three sheet configurations, where the first sheet is considered to define a reference direction (i.e., 0 degree), and the second sheet is considered to define a first angle relative to the first sheet (e.g., (E.g., about 45 degrees), and the third sheet is disposed at a second angle (e.g., a negative acute angle) different from the first angle with respect to the first sheet That is, an acute angle from the second sheet in the opposite angular direction (e.g., about -45 degrees, or in the same sense, a reflection angle of about 315 degrees relative to the first sheet in the same direction as the second sheet)]. Accordingly, the second and third sheets may be perpendicular to each other or not perpendicular to each other. The thermoplastic matrix facilitates relative movement of fibers of adjacent plies during the final molding of the article of manufacture.

According to further embodiments, at least two layers of synthetic ply having approximately the same surface density are arranged in a 0 to 90 degree configuration, or alternatively, at an angle of about 15 to about 75 degrees. It is noted that the term "surface density" (generally expressed in pounds per square foot (lbs./sq. Ft.)) Can be employed to compare different layer types of relative strength. The high surface density corresponds to the high breaking strength of the layers. Composite laminates comprising at least two layers of synthetic ply having a second layer having a greater surface density than the first layer have also been employed in accordance with the embodiments. An example of a suitable areal density for a composite laminate according to embodiments is about 1 to 10 lbs./sq. ft. < / RTI >

3 schematically illustrates a non-limiting example of a composite laminate 200, which according to embodiments comprises a first outer layer 12, a second outer layer 14, and a middle layer < RTI ID = 0.0 > (S) 17, and may also be employed for a composite article structure according to any requirement, for example, which will be described in more detail below. The composite laminate 200 includes at least a first composite ply 220 and a second composite ply 240 according to embodiments. However, the composite laminate includes any number of ply required in the form of cross-ply, tri-ply, quadruple-ply, and the like. As described above, according to embodiments, the thermoplastic matrix material of at least one ply comprises PVDF, and may also include polyethylene and the like. As such non-limiting examples, the composite plies 220 and 240 may each be a unidirectional sheet or a ply comprising longitudinally oriented fibers. The composite plies 220 and 240 can be produced separately in a continuous process and stored in separate rolls. A composite laminate as described herein, such as the exemplary composite laminate 200 described in FIG. 3, includes at least two composite plies that are bound together, for example, in a crossing relationship with each of the fibers . It should be noted that any suitable thermoplastic materials may be employed for such one or more layers. It should also be appreciated that FIG. 3 illustrates a non-limiting example of one particular arrangement for the various layers, so that the order and materials may vary as desired. Thus, the layers for plies 220 and 240 may be present in any desired combination or order.

It is also noted that one or more additional layers may be employed in the structure shown in FIG. For example, one or more layers of high strength fibers, such as, for example, blended thermoplastic fibers, glass fibers, and the like, may be applied to any portion of the layup (e.g., Or between the layers and / or the outer layers of the structure). Examples of such structural layers include the use of a mixed laminate product. A suitable commercially available product for such layers is TWINTEX ^TM , a trademark registered by Fiber Glass Industries. According to the manufacturer, TWINTEX ^® is a thermoplastic glass reinforcing agent (roving) made of mixed E-glass and polypropylene filaments and can be woven with highly suitable fibers. Strengthening is completed by heating the roving above the melting temperature of the polypropylene matrix (180 占 폚 -230 占 폚) and applying pressure before cooling under pressure. Examples of the glass content include 53, 60 and 70% by weight. The size and shape of the other layers shown in Figures 1 and 1a as well as the structural layers can be tailored as desired based on the desired application.

According to embodiments, the thermoplastic matrix material for the first outer layer 12, the second outer layer 14 and / or the intermediate layer 17 may further comprise a thermosetting resin or a mixture thereof I give the facts. For example, the fibers as described above and in the amounts described above may also be incorporated into the thermoplastic / thermoset resin matrix material based on the desired application. Non-limiting examples of thermosetting resin matte materials include phenolic resins, polyesters, epoxides, combinations thereof, and the like.

Various methods may be employed in connection with the methods of making synthetic materials and structures described herein. For example, various methods may be employed, such as injection of fibers in the ply and selective encapsulation by a matrix material including, for example, a doctor blade process, lamination, drawing, extrusion, have. Other synthetic plies and other synthetic materials, synthetic laminates, panels, etc. of the composite laminates described herein may be produced by any suitable process, including those described herein, according to embodiments It will be possible.

By way of non-limiting example, a " interposed panel "such as a single laminate, a laminate laminate and / or a composite structure 10 can be formed, for example, And can be produced from monolithic tapes. Multi-ply laminates are typically produced on a hydraulic or air compression press with heating and cooling capability in a single molding. A particularly suitable method is to produce the material on a continuous belt press using Teflon. Steel belts with heating, compression and cooling capabilities can also be used. Such a method can produce a continuous laminate that can be produced in rolls.

Further, according to embodiments, the sheets comprised of the composite materials described herein may be formed from a combination of core materials such as, for example, PVDF foam by Zotek to form a multilayer sheet and / Such as aerospace inner panels, as a combination of two or more of the following: < RTI ID = 0.0 > a < / RTI > In addition, laminates of various types such as cross-ply, triple-ply, quadruple-ply and the like can be used for packaging / winding or filament winding for pipes with reinforced structural characteristics, high corrosion resistance and / I give the facts. Also, according to embodiments, articles of manufacture, including, for example, the structural panels and pipes described herein, may also be used in a variety of applications that require corrosion resistance, fire resistance, internal combustion, and poisoning resistance combined with lightweight and / , Oil, gas and mining industries. Thus, it is noted that the synthetic materials described herein are suitable for use in many industrial applications and also beneficially have multiple applications. For example, the examples / structures of the composite materials described herein may include, but are not limited to, the walls including the lid of the aircraft and the floor of the interior room area as well as other aircraft structures Space use; Motor vehicle and bus applications / structures including floor, wall and cover; Oil drilling equipment applications; Special transportation applications including fire-fighting containers; Refractory / retardant armor and ballistic applications such as fire resistant / retardant ballistic composite panels, and the like.

Additionally, the embodiments described herein advantageously employ pre-impregnated (interlaminar) thermoplastic materials comprising continuously reinforced fibers injected with a thermoplastic matrix into a unidirectional tape, produced by a drawing or extrusion processing process can do. In this regard, for example, in the case of composite panels, such as composite panel 10, a structure comprising multiple layers of thermoplastic tape reinforced pre-reinforced continuous fibers may be made from the same, similar or different material extensions Lt; RTI ID = 0.0 > thermoplastic foam. ≪ / RTI >

In accordance with further embodiments, in conjunction with the synthetic materials and methods for making the articles described herein, fiber reinforced composite plies (e.g., a plurality of fibers, for example, Exemplary processing equipment suitable for producing the first and second composite plies 220, 240 (including the first and second composite plies 220, 240) include, for example, Mashninpavik Herbert < (R) > And a standard belt laminating system using coated belts, such as a mill available commercially from Maschinenfabrik Herbert Meyer GmbH.

It should also be noted that a variety of different methods may be employed, for example, in synthetic plies joined together to form alternative synthetic laminates of the above or further described above. Such methods include sequentially laminating the composite ply to form a composite laminate, applying liquids, hot melt, reactive hot melt or film, epoxy, methyl acrylate And an adhesive in the form of a urethane. Sonic vibration welding and solvent bonding can also be employed. Generally, a composite laminate can be constructed from a plurality of plies, by sequentially laminating the plies and by heating and exposing the plies to pressure, for example in a press, to melt adjacent plies together.

U.S. Patent No. 8,201,608, assigned to the same assignee and incorporated herein by reference, discloses suitable apparatus and methods for making synthetic sheet materials. Such apparatus and methods may be used to produce the composite laminates, materials, and structures described herein.

Accordingly, reference is made to the following apparatus and method for modifying some of the drawings to accommodate the composite laminates and structures described herein.

An example of suitable devices that may be used to produce, for example, the composite laminate 200 of FIG. 3, among other synthetic laminate plates and structures described herein is shown in general block designation as 31 in FIG. As shown in FIG. 3, the apparatus 31 includes a unwinding station 32. During operation, a composite material, such as, for example, a synthetic ply comprising a plurality of fibers in a thermoplastic matrix is fed or unwound from the rolls in the unwinding station 32 for further processing according to embodiments . The apparatus 31 further comprises a tacking station 34 adjacent to the unwinding station 32 wherein additional layers of composite material are wound on the unwound material 32 from the unwinding station 32, Lt; / RTI > These additional layers may be configured such that the fibers forming part of the additional layers of composite material can be oriented at different angles relative to the fibers in the composite material being unwound from the unwinding station 32. [ However, the embodiments are not limited to such an aspect, since the fiber forming portions of the additional layers may also be oriented substantially parallel to the fiber forming portions of the unwound from the unwinding station 32. The apparatus 31 comprises an optional second unwinding station 36 adjacent the tacking station, wherein at least one additional layer of composite material can be unwound from the rolls of composite material. These layers can be unwound on the top of the unwound composite material from any additional layers added to the first unwinding station 32 and the tacking station 34. Downstream of the tacking station 34, a heating station 38 is provided, where the layers of composite material can be heated and joined together. Further, a processing station 40 is provided downstream of the heating station 38. The processing station 40 includes at least one calender roll assembly 41, which is described in greater detail below. An absorption station 42 is located downstream of the processing station 40 to wind the composite laminate. The overall process of the composite material from the unwinding station 32 to the absorber station 42 is referred to as "treatment direction" shown as an arrow in Fig. The terms "upstream" and "downstream" are often used herein to refer to positions or orientations for the processing direction.

It should be noted that, according to embodiments, the specific shape, size and configuration of the composite laminate can be made using the processing apparatus described above, if desired. Once the desired composite laminate is made, for example, for one, more than one, or all of the layers of the composite structure 10, the composite structure 10 may be assembled in a desired shape and configuration, The elements are joined together.

For example, the composite structures 10 and / or composite laminates produced using the above-described apparatus and methods can be used in a wide variety of end-use applications, particularly cargo handling container components and cargo carrier applications, Lt; / RTI > In some embodiments, the composite structure 10 and / or composite laminates described herein may be used in a variety of applications such as walls, liners, panels, flooring, containers, and other structures in buildings and transportation applications such as airplanes, trailers, Lt; RTI ID = 0.0 > cargo < / RTI > For example, such materials can be used to make panels, liners, containers, flooring, such as sub-floors, doors, ceilings, walls and wall covers, etc., of varying sizes and strengths. Particularly suitable embodiments also include composite structures 10 configured for structural components and pipes requiring structural and / or corrosive resistance, such as panels, liners, shipping containers, structural composites for aerospace applications, motor vehicles, trucks, buses, ) And / or composite laminates.

Other types of materials may be used alone or in combination with each other based on the desired application. Such articles as described herein may be provided to a strong and durable structure or the like. In particular, the composite structures 10 and / or composite laminates described herein may be constructed as inducing end-use products, such as walls, doors, panels, liners. Containers, ceilings, and the like. Such articles exhibit favorable characteristics in terms of strength, light weight, corrosion resistance, ignition inhibition, flame retardancy, poisoning resistance, and the like.

Further, non-limiting examples of particular end use products / applications for the composite structures 10 and / or synthetic laminates described herein are described next. In Fig. 5, the composite structure 10 and / or composite laminates described herein can be used as a liner for internal parts of, for example, land trailers or other transport vehicles, vessels, containers, and the like. FIG. 5 illustrates a liner 700 located in the interior portion 702 in the example of the onshore trailer 704. According to embodiments, the liner 700 may provide a composite panel that exhibits better properties than, for example, standard chopped glass thermosetting resin products. For example, the liner 700 comprising polyethylene can be made lighter than some polypropylene-based panels, more cleanable, more speckled, and also more abrasion-resistant. Liner 700 may be positioned as an interior wall liner or wall lid, as well as a loop liner. Thus, the liner 700 may have other shipping applications as well as applications for refrigerated containers (rippers), wall covers. The liner 700 may be configured as a durable, semi-rigid structure or panel specially designed and constructed to improve thermal efficiency in refrigeration containers such as reefers, according to embodiments.

5, the composite structure 10 and / or composite laminates described herein may be used in a variety of applications including, for example, trailers or other vehicles, vessels, containers, etc. Or as a panel 710 for the flooring or sub-flooring of the sub-floor. The panel 710 may also be covered with a coating, such as durable flooring materials made of synthetic materials and / or synthetic laminates described herein in accordance with embodiments.

It is also noted that the embodiments described herein may include configurations and configurations of any combination of the above embodiments.

It should also be appreciated that the synthetic laminates described herein generally can also be applied to many types of cargo carriers, such as trailers, vans, transport vehicles, motor vehicles, aircraft, ships, shipping containers used therein, It will be possible. Additionally, in accordance with the intention herein, the term "trailer" may include all such cargo carriers, and thus the term "shipping container" may include any shipping container used therein.

Thus, according to additional end-use applications, the composite structure 10 comprising the composite laminates described herein has been described in accordance with the embodiments as being generally comprised of panels for full terrestrial trailer truck application Other applications are described herein, such as, for example, an inner liner / panel configured for a maneuver, an inner liner / panel configured for an aircraft, an inner liner / panel for a container such as an integrated transport container, a building structure, Lt; RTI ID = 0.0 > embodiments.

Structures such as the container itself may also be manufactured and / or modified using the composite material, the structure and the laminates described above. 6 depicts a side view of an air cargo container 970 that may include a composite structure 10 and / or a composite laminate as described herein within container 970, according to embodiments. As shown in FIG. FIG. The container 970 can also be made of the synthetic material and / or used for retrofitting as described above.

According to a further end use application, Fig. 7 is a perspective view of a motor vehicle 980 including a composite structure 10 and / or a composite laminate as a liner 982 according to embodiments. The liner described herein may be located at various locations in the container body, such as the interior position of the driveline wall, among other locations.

Figure 8 also shows a schematic perspective view of an integrated transport container 990 including a composite structure 10 as a composite liner 992, according to embodiments. The integrated transport container 990 includes a loop portion 994, an interior side wall 996, a floor material 998, and a door portion 999. As described herein, a liner according to an embodiment may be positioned at various locations, for example, in a container or other structures. For example, as shown in FIG. 8, the liner 992 may be positioned as a cover or integrally on the bottom 998. The liner 992 can also be located on at least a portion of the inner sidewall 996 as well as on the interior of the loop portion 994. 8 also illustrates a scuff panel 997 that may be made of and / or coated with the liner 992 described herein. It is also noted that the integrated transport container 990 can be moved from one mode of transport to another mode, such as a ship or truck, from a rail without having to unload the contents of the container. The size of the container 990 meets the standard ISO requirements according to embodiments. For example, the length can vary from 8 feet to 50, and the height can vary from 8 feet to 9 feet, to 6 inches.

Figure 9 illustrates another application for the composite structure 10 and / or composite laminates described herein. In particular, Figure 9 shows a battery case comprising the composite structure 10 and / or the composite laminate according to the embodiments. Figure 10 illustrates a battery box comprising the composite structure 10 and / or the composite laminate according to further applications, particularly embodiments.

It should also be appreciated that the composite structures 10 and / or composite laminates described herein may be attached to structures, such as attached to interior flooring, side walls, loops, scuff plates, as well as other container portions It will be possible. Likewise, all or a portion of, for example, air cargo, rails, and integrated transport container, pipes, etc., may be made of the composite structure 10 and / or composite laminates described herein. In addition, the panels, liners, and structures described herein may be employed as part or all of the outer surface of the structures described herein, such as a trailer container or the like. In such a case, the structure may include UV and / or abrasion resistance characteristics. Modifications using the composite structures 10 and / or composite laminates made from them, including panels, liners, etc., are also included in this embodiment.

 In addition, as described above, the embodiments described herein can also be applied as a marmer or ballistic material, for example, for a vehicle or a human. For example, the embodiments described herein can be used as flame retardant ballistic compositions or panels. By way of non-limiting examples, for example, the structures shown in Figures 1, 3 and 11 may be employed as flame retardant synthetic ballistic panels. The ballistic materials and panels may be used to provide flame retardant ballistic protection for stationary structures such as control rooms or protective stations and to provide a flameproof ballistic for the passengers of a vehicle, May be used to produce a portable ballistic shield such as a ballistic clipboard for use. 11, the panel 20 includes a plurality of first ply 22a, 22b, etc. and also includes a striking surface portion 22 that provides striking surface 23 of the panel do. The plies in the portion 22 are synthetic plies, each comprising a plurality of first types of fibers 24 disposed in a first matrix material 26. The fibers 24 are generally parallel to one another in each ply, and as described by the plies 22a, 22b, the plies in this case are the fibers in one ply, And are arranged to cross each other at 90 [deg.]. However, according to embodiments, it will be appreciated that the arrangement may be at other joined angles, for example, less than 90 degrees. The panel 20 also includes a support 28 that includes an optional backside layer 30 and an interior portion 33. The inner portion 33 comprises a plurality of composite plies each comprising a second type of fibers 35 in a second matrix material 37. The backside portion 30 includes a non-synthetic ply made of a matrix material, for example, which has substantially no fibers therein. In other embodiments, the number of plies and their configuration may vary based on the application. The panel 20 can be formed by laminating cross plies of tapes comprising a first type of fibers and cross plies and non-composite plies of a tape comprising a second type of fibers, as described herein, For example. For example, a panel can be made of a plurality of plies by stacking a plurality of plies in turn and heating and pressurizing the plies in a press, for example, to mix adjacent plies together.

In one embodiment, the ballistic panel 20 has in principle a striking face portion comprising E-glass fibers as low performance fibers and a support portion comprising S-glass fibers as high performance fibers. Based on performance criteria for a particular panel, the thickness of the panel and the relative thickness of the E-glass and S-glass portions of the panel may vary. Suitably, the S-glass plies and the E-glass plies are approximately equal in weight contribution to the panel.

In certain embodiments, the E-glass fibers may be in accordance with ASTM D578-98, paragraph 4.2.2, and have a roving yield of about 250-675 yards / pound (yd / lb.) Or about 735 And roving tex of -1985 grams / kilometer (g / km). The S-glass fibers may be in accordance with ASTM C 162-90 and / or ASM 3832B, and may comprise filaments having a diameter of about 9 micrometers, and may also contain 675-1600 g / km of roving- And a yield of 735 yards / lb.

It should be noted, however, that the fibers described in some or all of the embodiments described above may be used as any combination for the reference fibers 24 and 35 described above. Likewise, the composite materials described in some or all of the embodiments described above may also be used in any combination thereof for the plies of panel 20.

The contents of the synthetic ply may be described in terms of the fly weight ratio of the fibers and the fibers contributing as matrix material and the yield of the fiber used. For example, in one embodiment, the composite ply may comprise E-glass in a polypropylene matrix material. The fibers may have a yield of about 56-1800 yards per pound of fiber and include about 675 yards per pound of fibers and the fibers may also have a weight in the form of a matrix material plus fibers, 92%, suitably 60-80%. The filament diameter may have a range of, for example, about .005 - .025 micrometers. In addition, the matrix materials may include any and all of the matrix materials in any combination, as referred to in the various described embodiments, suitably including, for example, PVDF as described herein ≪ / RTI > includes flame retardant polymeric matrix materials such as flame retardant polymers. Thus, the matrix materials described in some or all of the embodiments described above may be used for the first matrix material 26 and the second matrix material 37 and any combination thereof.

It should also be noted that the ballistic materials comprising the panels may be tested according to a standard that assesses their ability to withstand ballistic impacts. Such a standard is described, for example, by the Department of Justice's National Institute of Justice, entitled "NIJ Standard for Ballistic Resistance Protection Materials (NIJ Standard)" . Because the ballistic treatment imposed by bullets or other projectiles is based on, for example, its composition, shape, aperture, weight and impact velocity, the NIJ standard has been classified as a protection provided by the following different armor classes : Type II-A (low speed 357 magnum and 9 mm), Type II (high speed 357 magnum and 9 mm); Type III-A (44 magnum, sub-machine gun and 9 mm), Type III (high power rifle), and Type IV (armor-piercing rifle).

In particular, type II-A (low speed 357 magnum and 9 mm): the armor classified as Type II-A has a nominal weight of 10.2 g and a measurement speed of 381 +/- 15 m / s. The Type II-A ballistic material is also protected against a standard test round in the form of a 357 Magnum jacketed soft point (JSP). The Type II-A ballistic material also has a nominal weight of 8 grams and a 9 mm < RTI ID = 0.0 > Can be protected against full metal jacketed rounds.

Type II (high speed 357 magnum; 9 mm): This armor protects against a projectile skin against a 357 Magnum JSP with a nominal weight of 10.2 g and a measurement speed of 425 +/- 15 m / s. The Type II ballistic material is also protected against a 9 mm full metal jacket round having a nominal weight of 8 g and a measurement speed of 358 +/- 12 m / s.

Type III-A (44 Magnum, 9 mm subgun): This armor is a gas-inspired LSW (Lead) with a nominal weight of 15.55 g and a measurement speed of 426 +/- 15 m / s, semiwad cutter, 44 magnum. Type III-A ballistic materials are also protected against 9mm sub-machine gun rounds. These bullets are 9mm full metal jackets with a nominal weight of 8g and a measurement speed of 426 +/- 15 m / s.

Type III (High Power Rifle): This armor is protected against 7.62 mm (308 Winchester®) ammunition and most handgun treatments.

Type IV (armor-piercing rifle): This armor is protected against a 30 caliber armor piercing round with a nominal weight of 10.8 g and a measurement speed of 868 +/- 15 m / s.

In addition to the above, other tests on ballistic materials include the V ₅₀ test defined by MIL-STD-622, the V ₅₀ ballistic test on the armor. U.S. Patent No. 7,598,185 further describes such a test, which is incorporated herein by reference.

Advantageously, the embodiment including the flame-retardant ballistic panel described herein, when the projectile to pass through a standard ₅₀ V test described above as well as they are pointing to the panel, the above-described reference standard NIJ armor grade II- A, II, III-A, III and IV of the present invention.

Further, for example, the composite materials and / or laminates of the composite structure 10 have been described in some embodiments as one or two plies, for example, although the embodiments are not limited to such aspects , Any suitable multiple ply (e.g., cross-ply, tri-ply, quad-ply, etc.) may also be employed for any laminate of, for example, the composite structure 10, Lt; RTI ID = 0.0 > and / or < / RTI > end-use applications. Thus, for example, in a thermoplastic matrix comprising polyethylene, ply composed of low-cost and low-performance E-glass fibers, and ply composed of high-cost and high-performance S-glass fibers in a thermoplastic matrix comprising polyethylene A structure such as a panel, a liner, a container, or the like can be manufactured.

According to embodiments, the formation of the panel from the plies, which actually include the thermoplastic matrix material and which comprises the thermoplastic matrix material, can be accomplished under lower pressure for a shorter period of time than is necessary for the thermosetting resin matrix material to cure have. In addition, a panel composed of plies containing a thermoplastic matrix material comprising polyethylene does not require any degassing and also produces little or no volatile organic compounds (VOC). Optionally, metal or ceramic or other materials may be added to the composite panel as described herein. Also, once fabricated, the panels and other structures described herein may be coated, for example, with additional composites, elastomers, metal housings, etc., to protect against ultraviolet radiation, moisture or other environmental influences have. In addition, additives may be incorporated into the matrix material (s) for situations such as fire resistance, flame retardancy and poisoning, and for cosmetic purposes.

It will also be appreciated that the final durability, strength as well as other desirable properties of the final product are based, for example, on the type, size and orientation of the reinforcement and other materials employed, as well as the thermoplastic material will be. The durability and strength of the final product is also based on the overall dimensional form of the final product including, for example, length, width, thickness, cross-sectional area, and the like.

As used herein, terms such as " first, "" second, " and the like have been used to distinguish one element from another, not as an intention to denote any order, quantity or significance. Also, the indefinite articles ("a" and "an ", as used herein) are not intended to limit the quantity and are used to denote at least one of the related items. When the term "about" used in the phrase representing a number is included, the phrase is not considered to require the exact numerical value described in that phrase. It is also noted that some and / or all of the features of the embodiments described herein may be combined in any combination with any and / or all of the features of other embodiments described herein.

Although the present invention has been described with reference to specific embodiments thereof, it will be apparent to those skilled in the art, on the basis of the reading and understanding of the above description, that it is within the spirit and scope of the invention, It is understood that various modifications and alternatives to the embodiments described above are possible.

It is to be understood that the invention is not to be limited to the specific constructions and / or drawings described above and that all modifications and equivalents within the scope of the present invention are included.

Claims (29)

As fire-resistant synthetic laminate,
And a thermoplastic matrix material reinforced with fibers embedded in the matrix of said composite laminate,
Wherein the thermoplastic matrix material of the refractory composite laminate comprises polyvinylidene fluoride (PVDF). The refractory composite laminate of claim 1, wherein the fibers comprise fiberglass fibers. 3. The refractory composite laminate of claim 2, wherein the fiberglass fibers are selected from the group consisting of E-glass fibers, S-glass fibers, and combinations thereof. The refractory composite laminate according to claim 3, wherein the laminate includes a plied construction or a tape structure. 4. The refractory composite laminate according to claim 3, wherein the fibers are continuous fibers, and the laminate comprises a tape structure. The refractory composite laminate according to claim 4, further comprising an additional reinforcing material. As the composite structure 10,
A first outer layer (12);
A second outer layer (14); And
A core (16) interposed between the first outer layer (12) and the second outer layer (14) and comprising foam,
Wherein at least one of the first outer layer (12) and the second outer layer (14) comprises a refractory composite laminate according to claim 1. 8. The method of claim 7, wherein the refractory composite laminate comprises a plurality of synthetic plies having at least one first synthetic plies and a second synthetic plies, wherein the first synthetic plies and the second synthetic plies each comprise (10) comprising buried fibers, said composite plies being joined together to form said refractory composite laminate. 8. The composite structure (10) of claim 7, wherein at least one of the first outer layer (12) and the second outer layer (14) comprises a coating thereon. 8. The composite structure (10) of claim 7, wherein the fibers are substantially parallel to one another. 9. The method of claim 8, wherein the first synthetic ply and the second synthetic ply include fibers of different strengths, wherein the first synthetic ply comprises E-glass fibers and the second synthetic ply comprises S- (10). A panel comprising a composite structure (10) according to claim 7. 8. The composite structure (10) of claim 7, further comprising at least one intermediate layer (17) between the first outer layer (12) and the second outer layer (14). 14. The method of claim 13, wherein the core comprises an expanded polyvinylidene fluoride (PVDF) layer having a thickness greater than the thickness of the first outer layer (12), the second outer layer (14) ) Composite structure (10) comprising a foam. A pipe comprising the refractory composite laminate according to claim 1. A pipe comprising a composite structure according to claim 7. A battery box comprising a composite structure according to claim 7. A battery case comprising a composite structure according to claim 7. A method of manufacturing a refractory composite laminate according to claim 1,
And forming the laminate by unidirectional tape by a melting process. 20. The method of claim 19, further comprising bonding the laminate to a core, wherein the core comprises polyvinylidene fluoride (PVDF) foam. A ballistic panel comprising a refractory composite laminate according to claim 1. As fire-resistant synthetic laminate,
And a polymer matrix material reinforced with fibers embedded in the matrix of the composite laminate, wherein the polymer matrix material of the refractory composite laminate is selected from the group consisting of polyvinylidene fluoride (PVDF), polyetheretherketone (PEEK), polyphenylene A refractory composite laminate comprising at least one of sulfide (PPS) and polyetheramide (PEI). A flame retardant ballistic panel comprising a composite laminate according to claim 22. As flame retardant ballistic panels,
And a refractory synthetic laminate,
Wherein said refractory composite laminate comprises a refractory polymeric matrix material reinforced with fibers embedded in a matrix of said composite laminate, wherein said flame retardant ballistic panel comprises an elastomeric material selected from the group consisting of International Armor Standard Armor grades NIJ Standard Armor grades) A flame retardant ballistic panel that achieves at least one level of protection against said projectile as defined by II-A, II, III-A, III and IV. A flame retardant ballistic panel having a first side and a second side,
A striking surface portion comprising a plurality of first plies, the first plies each comprising fibers in a first polymer matrix material comprising a first flame retardant resin; And
A support portion adjacent the striking surface portion, the support portion comprising a plurality of second plies, the second plies each comprising fibers in a second polymer matrix material comprising a second flame retardant resin, Is coupled to an adjacent ply, the flame retardant ballistic panel comprising the support portion. 26. The flame retardant ballistic panel of claim 25, wherein at least one of the first polymer matrix material and the second polymer matrix material comprises polyvinylidene fluoride (PVDF). 27. The flame retardant ballistic panel of claim 26, wherein the plurality of first plies comprises E-glass fibers and the plurality of second plies comprises S-glass fibers. 26. A method as claimed in claim 25, wherein the panel is adapted to withstand the projectile as defined by International Bulletproof Standard Standard armor grades II-A, II, III-A, III and IV when the projectile is directed to the striking surface A flame retardant ballistic panel that achieves at least one level of protection. 27. The flame retardant ballistic panel of claim 26, wherein the fibers are substantially parallel to each other within respective plies, the plies being arranged such that the fibers of each plies are arranged in a cruciform arrangement with the fibers of adjacent plies.

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