US2019389176A1PendingUtilityA1

Surfacing film for composites with barrier layer

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Assignee: 3M INNOVATIVE PROPERTIES COPriority: Dec 15, 2008Filed: Sep 6, 2019Published: Dec 26, 2019
Est. expiryDec 15, 2028(~2.4 yrs left)· nominal 20-yr term from priority
Inventors:Larry S. HebertNaiyong JingMichael D. Swan
B32B 27/065B32B 21/08B32B 2307/7265B32B 2307/3065B32B 2307/7242B32B 27/281B32B 2262/106B32B 27/08B32B 7/12B32B 27/20B32B 2270/00B32B 2307/202B32B 27/36B32B 3/12B32B 2262/0276B32B 27/40B32B 27/322B32B 27/18B32B 27/42B32B 27/38B32B 2262/101B32B 27/32B32B 25/18B32B 27/365B32B 2605/08B32B 2605/00B32B 2307/71Y10T428/31515Y10T428/2835Y10T156/10B32B 2605/18Y10T428/31504Y10T428/3154
71
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Claims

Abstract

Fiber reinforced resin matrix composite laminates are provided comprising: at least one layer of fiber reinforced resin matrix comprising a cured resin matrix; and a surfacing construction bound to the cured resin matrix and forming a surface of the laminate, comprising: at least one barrier layer; and at least one cured adhesive layer derived from high temperature cure adhesive. In some embodiments, barrier layer(s) may be substantially impermeable to organic solvents, water, and/or gasses. In another aspect, fiber reinforced resin matrix composite laminates are provided comprising: a) at least one layer of fiber reinforced resin matrix comprising a cured resin matrix; and b) a surfacing construction bound to the cured resin matrix and forming a surface of the laminate, comprising: at least one barrier layer; and at least one electrically conductive layer. In another aspect, a surfacing construction is provided comprising a barrier layer and a curable adhesive layer.

Claims

exact text as granted — not AI-modified
We claim: 
     
         1 . A method of making a fiber reinforced resin matrix composite laminate comprising the steps of:
 a) providing a curable fiber reinforced resin matrix comprising a curable resin matrix;   b) providing a surfacing construction comprising:
 i) at least one barrier layer; and 
 ii) at least one curable adhesive layer; 
   c) providing a tool having a shape which is the inverse of the desired shape of the laminate;   e) laying up the surfacing construction and the curable fiber reinforced resin matrix in the tool, with the surfacing construction in contact with the tool and with at least one curable adhesive layer in contact with the curable fiber reinforced resin matrix; and   f) curing the curable resin matrix and curable adhesive layer to make a fiber reinforced resin matrix composite laminate;   
       wherein the barrier layer(s) have a composition different from that of the curable adhesive layer(s) and the barrier layer(s) have a composition different from that of the cured resin matrix. 
     
     
         2 . The method according to  claim 1  wherein at least one curable adhesive layer has a composition different from that of the curable resin matrix. 
     
     
         3 . The method according to  claim 1  wherein at least one barrier layer is substantially impermeable to organic solvents. 
     
     
         4 . The method according to  claim 1  wherein at least one barrier layer is substantially impermeable to water, organic solvents and gasses. 
     
     
         5 . The method according to  claim 1  wherein the surfacing construction additionally comprises:
 iii) at least one electrically conductive layer. 
 
     
     
         6 . The method according to  claim 1  wherein the surfacing construction additionally comprises:
 iv) at least one EMI shield layer. 
 
     
     
         7 . The method according to  claim 1  wherein the surfacing construction additionally comprises:
 v) at least one UV protection layer. 
 
     
     
         8 . The method according to  claim 1  wherein the surfacing construction additionally comprises:
 vi) at least one viscoelastic layer having a peak damping ratio (Tan δ) of at least 1.0 as measured in shear mode by DMTA at 10 Hz. 
 
     
     
         9 . The method according to  claim 1  wherein the surfacing construction comprises a barrier layer comprising a fluoropolymer. 
     
     
         10 . The method according to  claim 1  wherein the surfacing construction comprises a barrier layer comprising a non-perfluorinated fluoropolymer. 
     
     
         11 . The method according to  claim 1  wherein the surfacing construction comprises a curable adhesive layer comprising an epoxy adhesive and a dicyandiamide curative. 
     
     
         12 . The method according to  claim 1  wherein the surfacing construction comprises a curable adhesive layer comprising an epoxy adhesive and a dicyandiamide curative and a barrier layer comprising a non-perfluorinated fluoropolymer. 
     
     
         13 . The method according to  claim 1  wherein the surfacing construction comprises a curable adhesive layer comprising an epoxy adhesive and curative which contains no amine-containing curative. 
     
     
         14 . The method according to  claim 1  wherein at least one curable adhesive layer has a composition different from that of the curable resin matrix. 
     
     
         15 . The method according to  claim 1  wherein at least one curable adhesive layer has a composition which is the same as that of the curable resin matrix. 
     
     
         16 . The method according to  claim 1  wherein at least one curable adhesive layer is the curable resin matrix. 
     
     
         17 . The method according to  claim 1  wherein at least one curable adhesive layer is not the curable resin matrix.

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