Reinforcement for composite materials and method for making the reforcement

Abstract

A reinforced composite structure is disclosed comprising at least a reactive resin, thermosetting system or other suitable resin composition sandwiched between two metal, thermoplastic or ceramic substrate materials. The structure can also be modified through the addition of one or more fabrics, metallic meshes, fibers, polymer spacers or other suitable materials positioned within the resin composition and sandwiched between the substrate materials. The resulting structure comprises a composite with reduced thickness and weight as compared to solid metal panels of corresponding flexural strength. The composition of the structure also allows for the tailoring of the properties to affect sound abatement, insulation, strength, and toughness among other characteristics. The structure can be formed and cut to shape to fit any of a number of suitable applications such as ceiling tiles and bulkhead panels in marine vessels.

1 ) A composite comprising at least one heat cured epoxy composition that is reinforced with at least one fibrous composition and located between two substrates.  
   
   
       2 ) The composite of  claim 1  wherein the substrates comprise aluminum.  
   
   
       3 ) The composite of  claim 1  wherein the heat cured epoxy composition further comprises a curing agent comprising at least one metal acrylate.  
   
   
       4 ) The composite of  claim 3  wherein the metal acrylate comprises zinc diacrylate.  
   
   
       5 ) A fiber comprising a heat curable epoxy functional compound and at least one metal acrylate curing agent.  
   
   
       6 ) The fiber of  claim 5  wherein the fiber is substantially free of at least one member selected from the group consisting of polyamides, dicyandiamides, imidizoles, imidizole compounds, amines, ureas, substituted ureas, boron trifluoride and complexes, polysulfides, anhydrides, melamines, amidoamines, and phenol/formaldehyde.  
   
   
       7 ) The fiber of  claim 5  wherein the metal acrylate curing agent comprises zinc diacrylate.  
   
   
       8 ) The composite of  claim 1  wherein the fibrous composition comprises the fiber of  claim 7 .  
   
   
       9 ) The fiber of  claim 5  further comprising at least one phenoxy resin.  
   
   
       10 ) The composite of  claim 1  wherein the fibrous composition comprises fiberglass.