US20100129663A1 - Surfacing film for composite structures - Google Patents

Surfacing film for composite structures Download PDF

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Publication number
US20100129663A1
US20100129663A1 US12/625,002 US62500209A US2010129663A1 US 20100129663 A1 US20100129663 A1 US 20100129663A1 US 62500209 A US62500209 A US 62500209A US 2010129663 A1 US2010129663 A1 US 2010129663A1
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surfacing film
cured
curable
layered construction
surfacing
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Dmitriy Salnikov
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3M Innovative Properties Co
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3M Innovative Properties Co
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Priority to US12/625,002 priority Critical patent/US20100129663A1/en
Assigned to 3M INNOVATIVE PROPERTIES COMPANY reassignment 3M INNOVATIVE PROPERTIES COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SALNIKOV, DMITRIY
Publication of US20100129663A1 publication Critical patent/US20100129663A1/en
Priority to US15/482,898 priority patent/US10442550B2/en
Abandoned legal-status Critical Current

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    • 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
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/022—Mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64D—EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
    • B64D45/00—Aircraft indicators or protectors not otherwise provided for
    • B64D45/02—Lightning protectors; Static dischargers
    • 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of 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
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B32B27/281—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyimides
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B32B27/285—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyethers
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/38—Layered products comprising a layer of synthetic resin comprising epoxy resins
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/42—Layered products comprising a layer of synthetic resin comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
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    • 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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
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    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/02—Synthetic macromolecular particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/06—Vegetal particles
    • B32B2264/062—Cellulose particles, e.g. cotton
    • B32B2264/067—Wood particles
    • 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
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/107—Ceramic
    • B32B2264/108—Carbon, e.g. graphite particles
    • 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
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/12—Mixture of at least two particles made of different materials
    • 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
    • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
    • 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
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/202—Conductive
    • 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
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31511—Of epoxy ether
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31678—Of metal

Definitions

  • This invention relates to surfacing films for polymeric fiber-reinforced composites, optionally including electrically conductive layers, which display high erosion resistance, high corrosion resistance, and high resistance to microcracking, the films being selected such that the storage modulus of the composite bearing the surfacing film is not greatly elevated compared to the storage modulus of the bare composite.
  • the present disclosure provides a layered construction having a storage modulus G′ t25 at 25° C., comprising: a) a cured polymeric composite having a storage modulus G′ s25 at 25° C.; and b) a cured surfacing film bound thereto; wherein G′ t25 is no more than 118% of G′ s25 , more typically no more than 115%, more typically no more than 112%, in some embodiments no more than 110%, in some embodiments no more than 108%, in some embodiments no more than 106%, and in some embodiments no more than 104%.
  • G′ t25 is at least 101% of G′ s25 .
  • the present disclosure provides a layered construction having a storage modulus G′ t-54 at ⁇ 54° C., comprising: a) a cured polymeric composite having a storage modulus G′ s-54 at ⁇ 54° C.; and b) a cured surfacing film bound thereto; wherein G′ t-54 is no more than 122% of G′ s-54 , more typically no more than 118%, more typically no more than 115%, more typically no more than 111%, in some embodiments no more than 110%, in some embodiments no more than 107%, and in some embodiments no more than 104%. In some of the foregoing embodiments, G′ t-54 is at least 101% of G′ s-54 .
  • the cured surfacing film comprises an electrically conductive layer, typically a metal layer, which may optionally be a foil, expanded foil, mesh, cloth, wires, or the like.
  • the cured surfacing film comprises a cured epoxy resin which may optionally be a chain-extended epoxy resin. Typically the resin excludes phosphorus.
  • the layered construction displays high erosion resistance. In some embodiments the layered construction displays high corrosion resistance. In some embodiments the layered construction displays high resistance to microcracking. In some embodiments the layered construction displays high resistance to microcracking in response to thermal shock. In some embodiments the layered construction displays high resistance to microcracking in response to mechanical stress.
  • the present disclosure provides a method of making a layered construction comprising the steps of: a) providing a curable polymeric composite; b) providing a curable surfacing film; c) providing a tool having a shape which is the inverse of the desired shape of the layered construction; d) laying up the curable surfacing film and the curable polymeric composite, in that order, in the tool; and e) curing the curable polymeric composite and curable surfacing film.
  • the resulting layered construction has a storage modulus G′ t25 at 25° C., wherein a construction made in the same manner but lacking the curable surfacing film has a storage modulus G′ s25 at 25° C.; and wherein G′ t25 is no more than 118% of G′ s25 , more typically no more than 115%, more typically no more than 112%, in some embodiments no more than 110%, in some embodiments no more than 108%, in some embodiments no more than 106%, and in some embodiments no more than 104%.
  • G′ t25 is at least 101% of G′ s25 .
  • the resulting layered construction has storage modulus G′ t-54 at ⁇ 54° C., wherein a construction made in the same manner but lacking the curable surfacing film has a storage modulus G′ s-54 at ⁇ 54° C.; wherein G′ t-54 is no more than 122% of G′ s-54 , more typically no more than 118%, more typically no more than 115%, more typically no more than 111%, in some embodiments no more than 110%, in some embodiments no more than 107%, and in some embodiments no more than 104%. In some of the foregoing embodiments, G′ t-54 is at least 101% of G′ s-54 .
  • curing is carried out under sub-atmospheric pressure, typically less than 90% of one atmosphere, more typically less than 50% of one atmosphere, and more typically less than 10% of one atmosphere.
  • the curable surfacing film comprises an electrically conductive layer, typically a metal layer, which may optionally be a foil, expanded foil, mesh, cloth, wires, or the like.
  • the curable surfacing film comprises a curable epoxy resin which may optionally be a chain-extended epoxy resin. Typically the resin excludes phosphorus.
  • the resulting layered construction displays high erosion resistance.
  • the resulting layered construction displays high corrosion resistance.
  • the resulting layered construction displays high resistance to microcracking.
  • the resulting layered construction displays high resistance to microcracking in response to thermal shock.
  • the resulting layered construction displays high resistance to microcracking in response to mechanical stress.
  • FIG. 1 is diagram of a layered construction as described in the Examples section, below.
  • FIG. 2 is diagram of a layered construction as described in the Examples section, below.
  • FIG. 3 is a micrograph of a prior art layered construction as described in the Examples section, below.
  • FIG. 4 is a micrograph of a prior art layered construction as described in the Examples section, below.
  • FIG. 5 is a micrograph of a prior art layered construction as described in the Examples section, below.
  • FIG. 6 is a micrograph of a prior art layered construction as described in the Examples section, below.
  • FIG. 7 is a micrograph of a layered construction according to the present disclosure, as described in the Examples section, below.
  • FIG. 8 is a micrograph of a layered construction according to the present disclosure, as described in the Examples section, below.
  • the present disclosure relates in general to a surfacing material to surface composite structures and methods of using same.
  • Fiber reinforced resin matrix composite laminates has become widely accepted for the variety of applications in aerospace and automotive industries because their light weight, high strength and stiffness. Weight reduction benefits and performance enhancements are the biggest drivers behind implementation of fiber reinforced resin matrix composite laminates into industrial applications.
  • Various airspace components being manufactured from fiberglass and carbon fibers reinforced composites including airplane fuselage sections and wing structures. But being light and strong, composite structures are not nearly as electrically conductive as previously widely utilized aluminum structures.
  • Composite structures and in particular composite aircrafts what are not constantly grounded must rely on a lightning protection system capable of rapidly dissipate charge throughout the bulk of its structure as a means of electrical energy dissipation.
  • a metallic lightning strike component may be encapsulated into surfacing film.
  • the lightning strike protection system has to be sufficiently conductive, lightweight and durable.
  • the durability of the lightning strike protection system depends in great part on the reliability of the surfacing polymer encapsulating the metallic component.
  • Lightning protection systems tend to experience bulk microcracking and surface cracking due to the continuous changes in temperature, humidity and pressure, differences in coefficients of thermal expansion of different components, locked-in internal stresses, less then ideal interfacial adhesion between metallic component and surfacing polymer as well as continuous cyclical stresses on various aircraft components.
  • Microcracking and surface cracking may make metallic component of a lightning protection system susceptible to corrosion and subsequent loss of electrical conductivity by allowing moisture penetration. Corrosion deterioration of lightning strike protection can lead to increased inspection time, increased maintenance time and cost and potential compromise of aircraft safety. Microcracking and surface cracking can extend into the surface finish producing visual defects on the painted surfaces and further increase maintenance costs.
  • This disclosure demonstrates that the ability of the cured composite articles with surfacing film according to the present disclosure to resist microcracking is related to elastic (storage) modulus (G′) of the surfacing film.
  • Elastic (storage) modulus (G′) may be tested by conventional methods, typically Rheometric Dynamic Analyzer, torsion mode, as described in the Examples. Improved microcracking resistance was found for the surfacing films according to the present disclosure where the films are selected such that the storage modulus of the composite bearing the surfacing film is not greatly elevated compared to the storage modulus of the bare composite. This selection may also be stated as follows: the storage modulus for the composite with surfacing film measured at 25° C.
  • [G′ t25 ] is no more than 118% of the storage modulus for the composite without surfacing film measured at 25° C. [G′ s25 ], more typically no more than 115%, more typically no more than 112%, in some embodiments no more than 110%, in some embodiments no more than 108%, in some embodiments no more than 106%, and in some embodiments no more than 104%. This selection may also be stated as follows: the storage modulus for the composite with surfacing film measured at ⁇ 54° C. [G′ t-54 ] is no more than 118% of the storage modulus for the composite without surfacing film measured at ⁇ 54° C.
  • [G′ s-54 ] more typically no more than 115%, more typically no more than 112%, in some embodiments no more than 110%, in some embodiments no more than 108%, in some embodiments no more than 106%, and in some embodiments no more than 104%.
  • Composites useful in the present disclosure may comprise any suitable reinforcement components, which may include metal, wood, polymer, carbon particles or fibers, glass particles or fibers, or combinations thereof, and may include any suitable matrix component, which may include as polyester, vinyl ester, epoxy, phenolic, polyimide, polyamide, polypropylene, PEEK, or other such polymers or combinations thereof, and may optionally be made using pre-preg materials.
  • the curable surfacing film comprises curable epoxy resin.
  • the curable surfacing film comprises a curable epoxy resin which may optionally be a chain-extended epoxy resin.
  • the curable surfacing film comprises a core shell rubber toughening agent.
  • the curable surfacing film comprises a urethane modified epoxy resin.
  • the curable surfacing film comprises a CTBN modified epoxy resin.
  • the curable surfacing film comprises a phenoxy resin.
  • the curable surfacing film comprises micronized phenoxy resin.
  • the curable surfacing film comprises a phenolic hardener. Typically the resin excludes phosphorus.
  • composition of the curable surfacing film is typically different from the composition of the curable matrix polymer of the polymeric composite.
  • the composition of the cured surfacing film is typically different from the composition of the cured matrix polymer of the polymeric composite.
  • the curable surfacing film comprises an electrically conductive layer, typically a metal layer, which may optionally be a foil, expanded foil, mesh, cloth, wires, or the like.
  • the curable surfacing film may have any suitable thickness, typically between 0.05 and 1.0 mm.
  • the layered construction may be made by any suitable method.
  • a curable surfacing film and a curable polymeric composite are laid up, in that order, in a tool having a shape which is the inverse of the desired shape of the layered construction the curable polymeric composite and curable surfacing film are cured.
  • curing is accomplished with application of heat.
  • curing is carried out under sub-atmospheric pressure, typically less than 90% of one atmosphere, more typically less than 50% of one atmosphere, and more typically less than 10% of one atmosphere.
  • EPONTM 1004F a medium molecular weight bisphenol A-based polyepoxide resin having an epoxide equivalent weight of from 800 to 950 grams/equivalent, by Hexion Specialty Chemicals GmbH, available from Resolution Performance Products, Houston, Tex. D.E.H.TM 85: Unmodified phenolic hardener having an active hydrogen equivalent weight of from 250 to 280 grams/equivalent, available from Dow Chemical Company, Midland, Mich.
  • PAPHEN® PKHP-200 micronized phenoxy resin, having a particle size of ⁇ 200 microns, available from Phenoxy Associates, Rock Hill, S.C. USA.
  • HYPOXTM M UA10 HyPoxTM UA10 Urethane Modified Bisphenol A Epoxy Resin, available from CVC Specialty Chemicals Inc., Moorestown, N.J., USA.
  • HYPOXTM RA95 HyPoxTM RA95 CTBN Modified Bisphenol A Epoxy Resin, available from CVC Specialty Chemicals Inc., Moorestown, N.J., USA.
  • KANE ACE® MX 120 a 25% concentrate of core shell rubber toughening agent in unmodified liquid epoxy resin based on Bisphenol-A, available from Kaneka Texas Corporation, 6161 Underwood Road, Pasadena Tex. 77507.
  • EPALLOY® 7200 A chemically modified bisphenol A diglycidyl ether undiluted resin available from CVC Specialty Chemicals Inc., Moorestown, N.J., USA.
  • AMICURE® CG-1400 Dicyandiamide curing agent available from Air Products and Chemicals, Incorporated, Allentown, Pa.
  • OMICURETM U-52 Aromatic substituted urea (4,4′ methylene bis(phenyl dimethyl urea)) used as a latent accelerator for the dicyandiamide cure of epoxy resins, available from CVC Specialty Chemicals Inc., Moorestown, N.J., USA.
  • AF-555 3MTM Scotch-WeldTM Structural Adhesive Film AF-555 U 0.015, an unsupported, thermosetting epoxy structural adhesive designed for curing at temperatures of 300° F. (149° C.) to 350° F. (177° C.), available from 3M Company, St. Paul, Minn.
  • AF-191 3MTM Scotch-WeldTM Structural Adhesive Film AF-191 U 0.05, an unsupported, thermosetting, modified epoxy designed for bonding composites, metal to metal and metal to honeycomb components where high strength and peel at 350° F. (177° C.), available from 3M Company, St. Paul, Minn.
  • AF-325 3MTM Scotch-WeldTM Low Density Composite Surfacing Film AF-325, Blue, 0.035, available from 3M Company, St. Paul, Minn.
  • FM® 300-2K FM® 300-2K 0.08 red modified epoxy adhesive film comprising a knit carrier for support available from Cytec Engineered Materials Technical Service Havre de Grace, Md. 21078.
  • SYNSKIN® HC 9837.1 Epoxy-based composite surfacing film designed to improve the surface quality of honeycomb stiffened composite parts, comprising a non-woven fabric for support. Available from Henkel Corporation, Aerospace Group, 2850 Willow Pass Road, Bay Point, Calif.
  • Pre-Preg A woven carbon fiber/epoxy resin composite pre-preg material available from Critical Materials, Incorporated, Poulsbo, Wash., as BMS 8-256, TYPE 4, CLASS 2, STYLE 3K-70-PW, CYCOM® 970/PWC T300 3K VT 42′′.
  • the polyepoxide resins and flow modifier (if applicable) indicated in Table 1 were charged into a 200 gram capacity plastic container in the indicated ratios.
  • the container was heated for about 15 minutes in a forced air oven set at 125° C., after which it was removed and placed in a planetary-type mixer (SPEED MIXERTM, Model DA 400 FV, available from Synergy Devices Limited, Buckinghamshire, United Kingdom) set at a speed of 2750 rpm for 1 minute.
  • the container with the blend of polyepoxide resins and flow modifier (if applicable) was then returned to the oven and equilibrated at about 120° C. for between 15 and 20 minutes.
  • a toughening modifier was added to the resin/modifier blend and it was mixed as described above, after which the container was removed from the planetary mixer and allowed to cool below 100° C. The curing agents were then added and the blend was mixed as described above. After removal from the mixer, the inside wall of the container was scraped down followed by putting the container back into the mixer for another cycle. The resin composition obtained was used immediately to prepare an uncured, Liner-supported surfacing film.
  • the heated [90° C./194° F.] composition from the “Preparation of Resin Compositions” procedure above was coated between two 0.005 inch (0.13 millimeters) thick paper Liners, each having a silicone release coating on one side and a polyethylene coating on the opposite side, such that the surfacing film contacted the silicone-coated side of each Liner.
  • a Liner supported surfacing film was obtained.
  • the Liner/surfacing film/Liner sandwich was stored for 24 hours at room temperature (about 72° F. (22° C.)), then stored at ⁇ 20° F. ( ⁇ 29° C.) until further use.
  • a sample of a Liner/surfacing film/Liner sandwich was equilibrated at room temperature prior to use.
  • the Liner from one side of the sandwich measuring about 11.5 inches (29.2 centimeters) long and about 6 inches (15.2 centimeters) wide, was removed and Expanded Copper Foil was placed onto the exposed surfacing film surface.
  • Expanded Copper Foil was placed onto an exposed surface of a comparative surfacing film. This Expanded Copper Foil was slightly larger in size than the sandwich.
  • the Liner was replaced over the Expanded Copper Foil and this lay-up was passed between two rubber-coated, heated nip rollers at a temperature of approximately 140° F. (60° C.).
  • the position of the upper roller and its contact pressure with the lower drive roller was controlled by air pressurized pistons having an air supply pressure of about 20 psi (137.9 kPa).
  • a surfacing film having an Expanded Copper Foil embedded therein and having a release Liner on each side was obtained.
  • cured, woven carbon fiber reinforced polymeric composite articles 10 having surfacing film 40 on one outer surface of a composite substrate 30 were made by the following process.
  • a layer of a comparative surfacing film was used for comparative examples. This lay-up was placed in a vacuum bag with surfacing film directly against the tool surface which was then positioned in an autoclave.
  • a full vacuum of about 28 inches Hg was applied at room temperature (approximately 72° F. (22° C.)) for 10 to 15 minutes after which the external pressure was gradually increased to 55 psi (397 kPa).
  • the vacuum bag was kept under full vacuum (28 inches of Hg) for the duration of the cure cycle, and the temperature was raised at 5° F./minute (2.8° C./minute) up to 350° F. (177° C.) and held there for 2 hours.
  • the cured polymeric composite article 10 with surfacing film 40 on one surface was then cooled at 10° F./minute (5.5° C./minute) to room temperature, at which point the pressure was released, and the cured article having an approximate thickness of 0.045 inches (0.114 mm) was removed from the autoclave and vacuum bag.
  • cured, woven carbon fiber reinforced polymeric composite articles 20 having surfacing film 50 incorporating lightning strike protection in the form of an Expanded Copper Foil 60 on one outer surface of a composite substrate 30 were made by the following process.
  • the testing apparatus was assembled using a 0.177 caliber air gun (“Drozd Air Gun”, European American Armory Corporation, Cocoa, Fla.,) and 1 ⁇ 2 inch (1.27 cm) diameter polyvinyl chloride tube as the barrel section.
  • 4.5 mm Grade II acetate pellets (Engineering Laboratories, Inc, Oakland, N.J.) are propelled through use of the pellet gun which is connected to a tank of compressed nitrogen (Oxygen Service Company, St. Paul, Minn.) set at about 60 psi (414 kPa).
  • Samples are continuously coated with a stream of water delivered through use of a water pump (Part No. 23609-170, VWR, West Chester, Pa.). Velocity of the pellets was measured with a CED Millennium Chronograph, available from Competitive Edge Dynamics LLC, Orefield, Pa.
  • test specimens were machined on the diamond saw from larger test panels prepared as described above. The samples were tested by adhering approximately 0.5 inch by 0.5 inch (1.27 cm by 1.27 cm) specimens of Cured Polymeric Composite Articles with Surfacing Film or Cured Polymeric Composite Articles with Surfacing Film with Incorporated Expanded Copper Foil on one outer surface to a round 304 stainless steel plate having an outer diameter of 7.6 cm and a central hole with a diameter of 0.35 cm. Test specimens were positioned un-surfaced composite surface down to the stainless steel substrate. 3MTM Scotch-WeldTM 2158 B/A two part adhesive kit was used to adhere samples to the stainless steel substrate. The adhesive used to adhere samples to the substrates was allowed to cure on for 24 hours at 75° F. (24° C.) before testing. The tests were conducted at a shot rate of 10 shots/sec. The test results are shown in Tables 2 and 3.
  • FIG. 3 is a micrograph of a test sample of CEx-5 (FM® 300-2K) with Copper, after testing on the rain erosion simulator.
  • FIG. 4 is a micrograph of a test sample of CEx-3 (AF-191) with Copper after testing on the rain erosion simulator.
  • FIG. 5 is a micrograph of a test sample of CEx-1 (AF-325) with Copper after testing on the rain erosion simulator.
  • FIG. 6 is a micrograph of a test sample of CEx-2 (AF-555) with Copper after testing on the rain erosion simulator.
  • FIG. 7 is a micrograph of a test sample of Ex-1 (SF-1) with Copper after testing on the rain erosion simulator.
  • FIG. 8 is a micrograph of a test sample of Ex-4 (SF-4) with Copper after testing on the rain erosion simulator.
  • Test specimens with approximate dimensions of 5.0 inch (12.7 cm) by 1.5 inch (3.8 cm) by 0.045 inch (0.114 cm) were machined on the diamond saw from larger test panels prepared as described above.
  • test specimens representing each example or comparative example prepared as described above with incorporation of Expanded Copper Foil were conditioned at 75° F./ambient humidity for seven days before being placed into the dual chamber thermal shock oven where one chamber is capable of maintaining ⁇ 67° F. ( ⁇ 54° C.) and another chamber is capable of maintaining 180° F. (80° C.). Equilibration time at each temperature was 10 minutes. 1000 hours of exposure time is achieved in approximately seven days.
  • Samples examination for crack detection was performed using the same microscope used for cracks detection of samples for rain erosion simulation.
  • Test specimens with approximate dimensions of 1.5 inch (3.8 cm) by 1 ⁇ 4 inch (0.635 cm) by 0.045 inch (0.114 cm) were machined on the diamond saw from larger test panels prepared as described above with incorporation of Expanded Copper Foil.
  • a test specimen of similar dimensions was prepared from only three plies of cured woven carbon fiber reinforced composite without any surfacing film on the outer surface. The samples were tested by utilizing Rheometric Dynamic Analyzer using torsion method with a 1 Hz or 10 Hz frequency and 0.2% or 1.0% applied strain and at isothermal conditions at 75° F. (24° C.) or ⁇ 67° F. ( ⁇ 54° C.). Testing at 10 Hz, 1.0% strain, 75° F.
  • microcracking resistance of the surfacing films according to the present disclosure was superior to the comparative examples.
  • G′ elastic (storage) modulus
  • the ability of the cured composite articles with surfacing film according to the present disclosure incorporating Expanded Copper Foil on one outer surface to resist microcracking is related to elastic (storage) modulus (G′) of the surfacing film (in particular, as tested by conventional methods, typically Rheometric Dynamic Analyzer, torsion mode, as described above.) Improved microcracking resistance was found for the surfacing films according to the present disclosure, especially where the ratio of storage modulus G′ s for the three plies of composite substrate without surfacing film to storage modulus G′ s +G′ sr for the three plies of composite substrate with surfacing film with incorporated lightning strike protection had a value of 0.85 or more; i.e., microcracking resistance coefficient [C] was ⁇ 0.85.
  • the storage modulus for the composite with surfacing film measured at 25° C. [G′ t25 ] is no more than 118% of the storage modulus for the composite without surfacing film measured at 25° C. [G′ s25 ], more typically no more than 115%, more typically no more than 112%, in some embodiments no more than 110%, in some embodiments no more than 108%, in some embodiments no more than 106%, and in some embodiments no more than 104%.
  • the storage modulus for the composite with surfacing film measured at ⁇ 54° C. [G′ t-54 ] is no more than 118% of the storage modulus for the composite without surfacing film measured at ⁇ 54° C.
  • [G′ s-54 ] more typically no more than 115%, more typically no more than 112%, in some embodiments no more than 110%, in some embodiments no more than 108%, in some embodiments no more than 106%, and in some embodiments no more than 104%.

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BRPI0921248A2 (pt) 2016-02-23
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WO2010062892A1 (en) 2010-06-03
US10442550B2 (en) 2019-10-15

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