WO1998034782A1 - Composite material suitable for aircraft interiors - Google Patents
Composite material suitable for aircraft interiors Download PDFInfo
- Publication number
- WO1998034782A1 WO1998034782A1 PCT/US1998/002546 US9802546W WO9834782A1 WO 1998034782 A1 WO1998034782 A1 WO 1998034782A1 US 9802546 W US9802546 W US 9802546W WO 9834782 A1 WO9834782 A1 WO 9834782A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- prepreg
- resin
- weight
- substrate
- composite material
- Prior art date
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/0405—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres
- C08J5/042—Reinforcing macromolecular compounds with loose or coherent fibrous material with inorganic fibres with carbon fibres
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
- C08J5/06—Reinforcing macromolecular compounds with loose or coherent fibrous material using pretreated fibrous materials
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
- C08J5/247—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs using fibres of at least two types
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/24—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
- C08J5/249—Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs characterised by the additives used in the prepolymer mixture
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2361/00—Characterised by the use of condensation polymers of aldehydes or ketones; Derivatives of such polymers
- C08J2361/04—Condensation polymers of aldehydes or ketones with phenols only
- C08J2361/06—Condensation polymers of aldehydes or ketones with phenols only of aldehydes with phenols
-
- 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
- Y10T428/30—Self-sustaining carbon mass or layer with impregnant or other layer
-
- 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
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2631—Coating or impregnation provides heat or fire protection
-
- 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
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2926—Coated or impregnated inorganic fiber fabric
- Y10T442/2984—Coated or impregnated carbon or carbonaceous fiber fabric
Definitions
- the present invention relates to a prepreg that may contain a thermoset resin with
- thermoset resin flame retardant materials and a substrate impregnated with the thermoset resin that may
- ABS acrylonitrile butadiene styrene
- polypropylene such as polycarbonates, acrylonitrile butadiene styrene (ABS) and polypropylene.
- thermoplastics have
- thermosets even when such compounded thermoplastics are used. Also because of the relatively high melt viscosities and a lower modulus, thicker wall sections and, in some cases,
- ribs must be designed into molded parts to provide adequate rigidity and help to prevent
- thermoplastics also exhibit the phenomena
- thermoset resin thick wall designs due to low modulus would be to use a thermoset resin.
- thermoset resins i.e., epoxies and phenolics
- the composite material should be inexpensive, lightweight, and have a smooth surface finish.
- the composite material should be able to be compression molded into metal molds, sandwiched,
- a conventional composite material used for aircraft interiors included a woven
- the invention provides a prepreg particularly suitable for use in the fabrication of aircraft interior non-structural components, such as floors, ceiling, overhead bins, and doors.
- the invention further provides a composite material which is lightweight, tough, and
- the composite material may also have a smooth surface finish that permits the
- the composite material may be decorated without additional sanding.
- the composite material may
- the composite material may also satisfy the FAA aircraft interior flammability requirements of a low heat
- a composite material comprising a
- thermoset resin having flame retardant components, a carbon paper substrate
- said carbon paper may comprise a
- thermoset resin may be a phenolic novolac resin
- amount of resin may be equal to between 50% and 80% by weight based on the total weight
- the substrate may have metal fibers to increase the electromagnetic shielding of the prepreg.
- the invention is particularly applicable to a composite material which is suitable for
- the invention broadly is a prepreg that may comprise a thermoset resin that may be
- prepreg refers to a combination of a substrate such as a mat, fabric, nonwoven material or roving, and a resin that may be
- thermosetting resin usually advanced to a B cure stage.
- a stage In the cure cycle of a thermosetting resin, an A stage
- a B stage is an intermediate stage in the reaction in which the thermosetting resin
- substrate is usually precured to this stage to facilitate handling and processing prior to final
- a C stage is the final stage in curing the thermosetting resin in which the resin
- thermoset phenol formaldehyde resin i.e., a formaldehyde condensate
- phenolic resins may be of either the novolac or resole type. However, the novolacs are
- the novolacs and resoles are phenol formaldehyde resins. The differences between these two
- phenolic resins result primarily from the ratio of phenol to formaldehyde used in the
- the resole resins are typically prepared with a molar excess of
- resins are prepared with a molar excess of phenol to formaldehyde usually about 1.25:1
- the resole type resin is a relatively lower molecular
- the substrate employed in the present invention may be any discontinuous
- fiber including carbon, glass, kevlar or other conventional fiber reinforcements.
- results may be achieved with a carbon paper substrate having a weight of approximately 3 ounces per square yard. This material permits the prepreg manufacturer to achieve a higher
- a preferred carbon paper may be prepared from “PAN” fibers, wherein “PAN” refers to
- an alcohol binder such as polyvinyl alcohol (PVA) may be used.
- PVA polyvinyl alcohol
- the alcohol binder may be used.
- a prefe ⁇ ed substrate may comprise about 5% by weight of PVA.
- Lower weight substrate materials such as those having weights of 2 and 2.5 ounces
- the substrate may contain 0.5 inch length and/or 1.0
- the substrate may contain between 50%> to 100% by weight
- a preferred substrate may contain 50% by weight of 0.5 inch length and 50% by
- the length of the fibers may be varied depending on
- a resin composition may be prepared by dissolving the thermoset resin in a
- Solvents which may be used include acetone, methyl ethyl ketone, methylene chloride, or any other low boiling point (less than 60 degrees C.) solvent.
- additives such as pigments, flame retardants, lubricants, or cure
- phenolic resin may be stored at room temperatures while the resole type phenolic resin
- the prepreg may comprise between 20% to 50%> by weight of the substrate and
- a preferred prepreg may comprise about
- Suitable fire retardant materials may include halogen/antimony
- preferred flame retardant may be a phosphate ester, such as that manufactured by Hoechst
- the substrate may be impregnated with the resin composition
- the substrate may be any organic resin composition by means which are conventional in the art.
- the substrate may be any organic resin composition by means which are conventional in the art.
- the substrate may be any organic resin composition by means which are conventional in the art.
- the substrate may be any organic resin composition by means which are conventional in the art.
- the substrate may be any organic resin composition by means which are conventional in the art.
- the substrate may be any organic resin composition by means which are conventional in the art.
- the substrate may be any organic resin composition by means which are conventional in the art.
- the substrate may be any organic resin composition by means which are conventional in the art.
- the substrate may be any organic resin composition by means which are conventional in the art.
- the substrate may be any organic resin composition by means which are conventional in the art.
- the substrate may be any organic resin composition by means which are conventional in the art.
- the substrate may be any organic resin composition by means which are conventional in the art.
- the substrate may be any organic resin composition by means which are conventional in the art.
- the substrate and the resin composition may then be run through the resin composition.
- the substrate and the resin composition may then be run through the resin composition.
- the substrate and the resin composition may then be run through the resin composition.
- the resulting prepreg may be sheeted, stacked or rolled, and then shipped or stored.
- molded articles may be prepared from the prepregs in accordance with the invention by means which are well known to those skilled in the art including compression
- the prepreg may be molded into highly detailed pieces with
- molded article being produced.
- several sheets of the prepreg may be cut and
- the arrangement of the sheets depends upon the article being produced.
- the prepregs of the present invention provide a design
- the molded articles in accordance with the invention may have a smooth, opaque,
- the prepreg in accordance with the invention has a high resin to substrate ratio of 50 - 80%> resin so that a molded article made with the prepreg may have a smooth resin
- paint or vacuum molded decorative light color polymer films may be applied to the surface of the molded article, in accordance
- the prepreg in accordance with the invention may be handled in a similar manner as
- the molded articles may also have a
- a molded article formed with the prepreg in accordance with the invention also has
- the prepreg may have electromagnetic interference (EMI) shielding properties as
- the discontinuous, filamentized substrate may provide some EMI shielding.
- stainless steel fibers may provide some EMI shielding.
- additional fibers described above may have EMI shielding of greater than 40 dB over a wide
- the discontinuous filamentized substrate without the additional fibers may also provide acoustic shielding because the substrate, which is not
- HOSTAFLAN AP422 a phosphate ester flame retardant available from Hoechst
- HEXA Hexamethylenetetramine
- SOCCI wax refers to a Carnauba wax emulsion containing 50% solids in water
- BLACK Solution refers
- carbon paper refers to a 3 oz/yd, 7 to 10 micrometer diameter, 50%o 1 inch chop, 50% 1/2" chop, 5% PVA sized PAN based carbon
- An example of the prepreg in accordance with the invention may have the
- composition and a range by weight of components set forth below:
- a resin solution was prepared by combining the phenolic novalac resin, the
- ammonium polyphosphate the tetra-bromobisphenol-A, the antimony trioxide, the zinc
- the impregnated paper was run through a pair of driven stainless steel nip rolls set at
- a sample of the prepreg was cured by heating for 80 seconds at from 150-180E F at from 1500-3200 psi in matched metal dies. The cured sample had the
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU61545/98A AU6154598A (en) | 1997-02-11 | 1998-02-10 | Composite material suitable for aircraft interiors |
CA 2288186 CA2288186A1 (en) | 1997-02-11 | 1998-02-10 | Composite material suitable for aircraft interiors |
EP98906284A EP0964780A4 (en) | 1997-02-11 | 1998-02-10 | Composite material suitable for aircraft interiors |
NO995346A NO995346D0 (en) | 1997-02-11 | 1999-11-02 | Composite material suitable for aircraft interior |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/798,234 US5714419A (en) | 1994-08-04 | 1997-02-11 | Composite material suitable for aircraft interiors |
US08/798,234 | 1997-02-11 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1998034782A1 true WO1998034782A1 (en) | 1998-08-13 |
Family
ID=25172873
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1998/002546 WO1998034782A1 (en) | 1997-02-11 | 1998-02-10 | Composite material suitable for aircraft interiors |
Country Status (6)
Country | Link |
---|---|
US (1) | US5714419A (en) |
EP (1) | EP0964780A4 (en) |
AU (1) | AU6154598A (en) |
CA (1) | CA2288186A1 (en) |
NO (1) | NO995346D0 (en) |
WO (1) | WO1998034782A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7785694B2 (en) | 2004-01-05 | 2010-08-31 | Airbus Deutschland Gmbh | Panel arrangement for an interior lining of a passenger cabin in an aircraft |
Families Citing this family (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH10107391A (en) * | 1996-09-30 | 1998-04-24 | O K Print:Kk | Wiring board and substrate for it |
ATE283163T1 (en) * | 1997-05-15 | 2004-12-15 | Toray Industries | FABRIC PREPREG AND WET PROCESS FOR PRODUCING THE SAME |
US6242638B1 (en) | 1999-03-12 | 2001-06-05 | Vantico Inc. | Cyanate esters having flame resistant properties |
US6890638B2 (en) | 2002-10-10 | 2005-05-10 | Honeywell International Inc. | Ballistic resistant and fire resistant composite articles |
GB0307697D0 (en) * | 2003-04-02 | 2003-05-07 | Hexcel Composites Ltd | A pigmented panel assembly |
US20110054087A1 (en) * | 2005-06-15 | 2011-03-03 | Chopdekar Vilas M | Flame-Retardant cyanate esters |
WO2009131729A2 (en) * | 2008-01-28 | 2009-10-29 | Lewcott Corporation | Fiber-based ablative and high temperature pre-preg material |
CN104379640B (en) * | 2011-12-05 | 2017-09-05 | Csir公司 | The artifact and its manufacture method of a kind of fire resisting |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5122417A (en) * | 1987-09-17 | 1992-06-16 | Toa Nenryo Kogyo Kabushiki Kaisha | Fiber-reinforced composite resin pultrusion products and method of manufacturing the same |
US5128199A (en) * | 1990-02-26 | 1992-07-07 | Board Of Trustees Operating Michigan State University | Method for fiber coating with particles |
US5149584A (en) * | 1990-10-23 | 1992-09-22 | Baker R Terry K | Carbon fiber structures having improved interlaminar properties |
Family Cites Families (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CA982725A (en) * | 1971-10-07 | 1976-01-27 | Kureha Kagaku Kogyo Kabushiki Kaisha | Process for producing vinyl chloride resin composition |
US3985704A (en) * | 1975-06-19 | 1976-10-12 | Rohm And Haas Company | Methacrylate-butadiene-styrene graft polymers and process for their production |
US4379876A (en) * | 1980-07-11 | 1983-04-12 | Rohm And Haas Company | Methyl methacrylate-butadiene-styrene impact modifier polymers, polyvinyl chloride, compositions and methods |
JPS57209979A (en) * | 1981-06-19 | 1982-12-23 | Teijin Ltd | Ultraviolet light absorber and method for using same |
US4529755A (en) * | 1982-10-23 | 1985-07-16 | Denki Kagaku Kogyo Kabushiki Kaisha | Epoxy resin composition for encapsulating semiconductor |
US4446255A (en) * | 1982-12-29 | 1984-05-01 | Celanese Corporation | Sized carbon fibers suitable for use in composites of improved impact resistance |
US4719255A (en) * | 1984-08-23 | 1988-01-12 | Kabushiki Kaisha Toshiba | Epoxy resin composition for encapsulation of semi-conductor device |
DE3852839T2 (en) * | 1987-04-27 | 1995-06-22 | Mitsubishi Gas Chemical Co | Thermosetting resin composition. |
JP2877309B2 (en) * | 1988-01-06 | 1999-03-31 | 株式会社東芝 | Method for producing rubber-modified phenolic resin |
US5216077A (en) * | 1988-01-06 | 1993-06-01 | Kabushiki Kaisha Toshiba | Rubber-modified phenolic resin composition and method of manufacturing the same |
JPH04117426A (en) * | 1990-09-05 | 1992-04-17 | Kubota Corp | Nonburning synthetic resin building material having electromagnetic radiation shielding property |
US5360861A (en) * | 1993-05-28 | 1994-11-01 | General Electric Company | Polyester-carbonate resin compositions of improved impact-resistance |
US5607769A (en) * | 1994-08-04 | 1997-03-04 | Fiberite, Inc. | Composite material |
-
1997
- 1997-02-11 US US08/798,234 patent/US5714419A/en not_active Expired - Fee Related
-
1998
- 1998-02-10 CA CA 2288186 patent/CA2288186A1/en not_active Abandoned
- 1998-02-10 WO PCT/US1998/002546 patent/WO1998034782A1/en not_active Application Discontinuation
- 1998-02-10 EP EP98906284A patent/EP0964780A4/en not_active Withdrawn
- 1998-02-10 AU AU61545/98A patent/AU6154598A/en not_active Abandoned
-
1999
- 1999-11-02 NO NO995346A patent/NO995346D0/en not_active Application Discontinuation
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5122417A (en) * | 1987-09-17 | 1992-06-16 | Toa Nenryo Kogyo Kabushiki Kaisha | Fiber-reinforced composite resin pultrusion products and method of manufacturing the same |
US5128199A (en) * | 1990-02-26 | 1992-07-07 | Board Of Trustees Operating Michigan State University | Method for fiber coating with particles |
US5149584A (en) * | 1990-10-23 | 1992-09-22 | Baker R Terry K | Carbon fiber structures having improved interlaminar properties |
Non-Patent Citations (1)
Title |
---|
See also references of EP0964780A4 * |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7785694B2 (en) | 2004-01-05 | 2010-08-31 | Airbus Deutschland Gmbh | Panel arrangement for an interior lining of a passenger cabin in an aircraft |
Also Published As
Publication number | Publication date |
---|---|
EP0964780A4 (en) | 2000-09-06 |
NO995346L (en) | 1999-11-02 |
US5714419A (en) | 1998-02-03 |
EP0964780A1 (en) | 1999-12-22 |
CA2288186A1 (en) | 1998-08-13 |
NO995346D0 (en) | 1999-11-02 |
AU6154598A (en) | 1998-08-26 |
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