Prepregs, cores, composites and articles including repellent materials

Abstract

Prepregs, cores and composite articles are described that comprise lighter weight materials and/or lower amounts of adhesive than commonly used. In some instances, one or more components of the articles may comprise a repellent material or repellent treatment to reduce the overall absorption rate of adhesive into the components of the article.

1 - 80 . (canceled) 
     
     
         81 . A composite article comprising:
 a core comprising a web of open celled structures defined by random crossing over of reinforcing materials held together by a thermoplastic material, the core comprising a repellent treatment on a surface of the core, in which the repellent treatment is effective to decrease absorption of a fluid into voids of the core; and   a substrate disposed on the core.   
     
     
         82 . The article of  claim 81 , in which the reinforcing materials comprise reinforcing fibers. 
     
     
         83 . The article of  claim 82 , in which the reinforcing fibers are present from about 20 weight percent to about 80 weight percent based on the weight of the core. 
     
     
         84 . The article of  claim 82 , in which the reinforcing fibers comprise metal fibers, metalized inorganic fibers, metallized synthetic fibers, glass fibers, carbon fibers, aramid fibers, ceramic fibers and combinations thereof. 
     
     
         85 . The article of  claim 81 , further comprising an adhesive layer disposed on the at least one surface comprising the repellent treatment. 
     
     
         86 . The article of  claim 85 , in which the adhesive layer comprises a polyolefin adhesive, an ethylene-vinyl acetate adhesive, a polyamide adhesive, a polyester adhesive, a polyurethane adhesive, a thermoplastic polyurethane adhesive, a styrene block copolymer adhesive, a polycarbonate adhesive, a fluoropolymeric adhesive, a silicone adhesive, a silicone rubber adhesive, an elastomeric adhesive, or a pyrrole adhesive. 
     
     
         87 . The article of  claim 85 , in which the substrate comprises a film, a frim, a scrim, a foil, a woven fabric or a non-woven fabric. 
     
     
         88 . The article of  claim 85 , in which the repellent material is effective to render the adhesive temperature and/or viscosity insensitive. 
     
     
         89 . The article of  claim 81 , in which the thermoplastic material comprises polyethylene, polypropylene, polystyrene, acrylonitrylstyrene, butadiene, polyethyleneterephthalate, polybutyleneterephthalate, polybutylenetetrachlorate, polyvinyl chloride, polyphenylene ether, polycarbonates, polyestercarbonates, thermoplastic polyesters, polyimides, polyamides, polyetherimides, acrylonitrile-butylacrylate-styrene polymers, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone, polyether sulfone, poly(1,4phenylene) compounds, silicones and combinations thereof. 
     
     
         90 . The article of  claim 81 , further comprising a flame retardant in the core or the substrate or both. 
     
     
         91 . A composite article comprising:
 a core comprising a web of open celled structures defined by random crossing over of reinforcing materials held together by a thermoplastic material; and   a substrate disposed on the core, the substrate comprising a repellent treatment on at least one surface of the substrate, the repellent treatment effective to decrease absorption of a fluid into the substrate.   
     
     
         92 . The article of  claim 91 , in which the reinforcing materials comprise reinforcing fibers. 
     
     
         93 . The article of  claim 92 , in which the reinforcing fibers are present from about 20 weight percent to about 80 weight percent based on the weight of the core. 
     
     
         94 . The article of  claim 92 , in which the reinforcing fibers comprise metal fibers, metalized inorganic fibers, metallized synthetic fibers, glass fibers, carbon fibers, aramid fibers, ceramic fibers and combinations thereof. 
     
     
         95 . The article of  claim 91 , further comprising an adhesive layer disposed on the at least one surface comprising the repellent treatment. 
     
     
         96 . The article of  claim 95 , in which the adhesive layer comprises a polyolefin adhesive, an ethylene-vinyl acetate adhesive, a polyamide adhesive, a polyester adhesive, a polyurethane adhesive, a thermoplastic polyurethane adhesive, a styrene block copolymer adhesive, a polycarbonate adhesive, a fluoropolymeric adhesive, a silicone adhesive, a silicone rubber adhesive, an elastomeric adhesive, or a pyrrole adhesive. 
     
     
         97 . The article of  claim 95 , in which the substrate comprises a film, a frim, a scrim, a foil, a woven fabric or a non-woven fabric. 
     
     
         98 . The article of  claim 95 , in which the repellent material is effective to render the adhesive temperature and/or viscosity insensitive. 
     
     
         99 . The article of  claim 91 , in which the thermoplastic material comprises polyethylene, polypropylene, polystyrene, acrylonitrylstyrene, butadiene, polyethyleneterephthalate, polybutyleneterephthalate, polybutylenetetrachlorate, polyvinyl chloride, polyphenylene ether, polycarbonates, polyestercarbonates, thermoplastic polyesters, polyimides, polyamides, polyetherimides, acrylonitrile-butylacrylate-styrene polymers, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone, polyether sulfone, poly(1,4phenylene) compounds, silicones and combinations thereof. 
     
     
         100 . The article of  claim 91 , further comprising a flame retardant in the core or the substrate or both. 
     
     
         101 - 220 . (canceled)