Fiber-reinforced composites, methods therefor, and articles comprising the same

Abstract

Disclosed herein are fiber-reinforced composites. These materials are useful in load-bearing components for mechanical systems, and other applications. Also disclosed herein are methods of making and using such composites, articles comprising the same, and the like. For example, some embodiments of the invention are generally directed to composites comprising discontinuous agents such as fibers or platelets which are positioned within a substrate, e.g., formed from a plurality of continuous fibers. In some cases, the discontinuous agents may be substantially aligned, for example, by attaching magnetic particles onto the agents and using a magnetic field to manipulate the agents. Other embodiments are generally directed to systems and methods for making or using such composites, kits involving such composites, or the like.

What is claimed is: 
     
         1 . An article, comprising:
 a composite comprising a plurality of continuous fibers defining a substrate, and a plurality of discontinuous agents contained within at least a portion of the substrate, wherein at least some of the plurality of discontinuous agents have a plurality of magnetic particles adsorbed thereto.   
     
     
         2 . The article of  claim 1 , wherein the plurality of discontinuous agents are contained within and positioned substantially orthogonal to the substrate. 
     
     
         3 . The article of any one of  claim 1  or  2 , wherein the plurality of continuous fibers define a fabric. 
     
     
         4 . The article of any one of  claims 1 - 3 , wherein at least some of the plurality of continuous fibers define a tow. 
     
     
         5 . The article of any one of  claims 1 - 4 , wherein at least some of the plurality of continuous fibers define a filament, a yarn, a strand, a veil, or a mat. 
     
     
         6 . The article of any one of  claims 1 - 5 , wherein at least some of the plurality of continuous fibers are assembled together to define the substrate. 
     
     
         7 . The article of any one of  claims 1 - 6 , wherein at least some of the plurality of continuous fibers are interwoven together to define the substrate. 
     
     
         8 . The article of  claim 7 , wherein at least some of the plurality of woven continuous fibers are bi-directional. 
     
     
         9 . The article of any one of  claim 7  or  8 , wherein at least some of the plurality of woven continuous fibers are multi-directional. 
     
     
         10 . The article of any one of  claims 7 - 9 , wherein at least some of the plurality of woven continuous fibers are quasi-isotropic. 
     
     
         11 . The article of any one of  claims 1 - 10 , wherein at least some of the plurality of continuous fibers are not woven together. 
     
     
         12 . The article of any one of  claims 1 - 11 , wherein at least some of the plurality of continuous fibers are uni-directional. 
     
     
         13 . The article of any one of  claims 1 - 12 , wherein at least some of the continuous fibers comprise natural fibers. 
     
     
         14 . The article of any one of  claims 1 - 13 , wherein at least some of the continuous fibers comprise synthetic fibers. 
     
     
         15 . The article of any one of  claims 1 - 14 , wherein at least some of the continuous fibers comprise carbon, basalt, silicon carbide, aramid, zirconia, nylon, boron, alumina, silica, borosilicate, mullite, and/or cotton. 
     
     
         16 . The article of any one of  claims 1 - 15 , wherein at least some of the continuous fibers are substantially parallel. 
     
     
         17 . The article of any one of  claims 1 - 16 , wherein the continuous fibers have an average length of at least 5 millimeters. 
     
     
         18 . The article of any one of  claims 1 - 17 , wherein the continuous fibers have an average diameter of between 10 micrometers and 100 micrometers. 
     
     
         19 . The article of any one of  claims 1 - 18 , wherein the continuous fibers have an average aspect ratio of length to diameter that is greater than or equal to 100. 
     
     
         20 . The article of any one of  claims 1 - 19 , wherein the discontinuous fibers have an average length of less than 5 millimeters. 
     
     
         21 . The article of any one of  claims 1 - 20 , wherein the discontinuous fibers have an average diameter of between 10 micrometers and 100 micrometers. 
     
     
         22 . The article of any one of  claims 1 - 21 , wherein the substrate has an average thickness of less than 10 cm. 
     
     
         23 . The article of any one of  claims 1 - 22 , wherein at least some of the plurality of discontinuous agents are randomly oriented. 
     
     
         24 . The article of any one of  claims 1 - 23 , wherein at least some of the plurality of discontinuous agents are substantially aligned. 
     
     
         25 . The article of any one of  claims 1 - 24 , wherein the plurality of discontinuous agents comprises at least 3% by mass of the composite. 
     
     
         26 . The article of any one of  claims 1 - 25 , wherein the plurality of discontinuous agents comprises no more than 97% by mass of the composite. 
     
     
         27 . The article of any one of  claims 1 - 26 , wherein at least some of the discontinuous agents comprise discontinuous fibers. 
     
     
         28 . The article of  claim 27 , wherein the discontinuous fibers have an average length of between 5 nm and 15 mm. 
     
     
         29 . The article of any one of  claim 27  or  28 , wherein the discontinuous fibers have an average length of between 5 mm and 15 mm. 
     
     
         30 . The article of any one of  claims 27 - 29 , wherein the discontinuous fibers have an average aspect ratio of length to diameter that is at least 5. 
     
     
         31 . The article of any one of  claims 27 - 30 , wherein the discontinuous fibers have an average aspect ratio of length to diameter that is less than 100,000. 
     
     
         32 . The article of any one of  claims 27 - 31 , wherein the discontinuous fibers have an average aspect ratio of length to diameter that is less than 100. 
     
     
         33 . The article of any one of  claims 1 - 32 , wherein at least some of the discontinuous fibers have an average length that substantially spans the thickness of the substrate. 
     
     
         34 . The article of any one of  claims 1 - 33 , wherein at least some of the discontinuous agents comprise platelets. 
     
     
         35 . The article of any one of  claims 1 - 34 , wherein at least some of the discontinuous agents comprise ellipsoids. 
     
     
         36 . The article of  claim 35 , wherein the platelets have a characteristic dimension of between 5 nm and 15 mm. 
     
     
         37 . The article of any one of  claim 35  or  36 , wherein the platelets have a characteristic dimension of between 5 mm and 15 mm. 
     
     
         38 . The article of any one of  claims 35 - 37 , wherein the platelets have a maximum dimension of less than 1 mm. 
     
     
         39 . The article of any one of  claims 1 - 38 , wherein at least some of the discontinuous agents comprise a natural material. 
     
     
         40 . The article of any one of  claims 1 - 49 , wherein at least some of the discontinuous agents comprise a synthetic material. 
     
     
         41 . The article of any one of  claims 1 - 40 , wherein at least some of the discontinuous agents comprise glass. 
     
     
         42 . The article of any one of  claims 1 - 41 , wherein at least some of the discontinuous agents comprise carbon fibers. 
     
     
         43 . The article of any one of  claims 1 - 42 , wherein at least some of the discontinuous agents are non-magnetic. 
     
     
         44 . The article of any one of  claims 1 - 43 , wherein at least some of the discontinuous agents are magnetic. 
     
     
         45 . The article of any one of  claims 1 - 44 , wherein at least some of the discontinuous agents comprise basalt, silicon carbide, silicon nitride, aramid, zirconia, nylon, boron, alumina, silica, borosilicate, mullite, boron nitride, and/or graphite. 
     
     
         46 . The article of any one of  claims 1 - 45 , wherein at least some of the discontinuous agents are uncoated. 
     
     
         47 . The article of any one of  claims 1 - 46 , wherein at least some of the discontinuous agents are coated with a coating. 
     
     
         48 . The article of  claim 47 , wherein the coating comprises a surfactant, a silane coupling agent, epoxy, glycerine, polyurethane, and/or an organometallic coupling agent. 
     
     
         49 . The article of any one of  claims 1 - 48 , wherein at least 1 vol % of the composite comprises the discontinuous agents. 
     
     
         50 . The article of any one of  claims 1 - 49 , wherein at least 5 vol % of the composite comprises the discontinuous agents. 
     
     
         51 . The article of any one of  claims 1 - 50 , wherein at least 20 vol % of the composite comprises the discontinuous agents. 
     
     
         52 . The article of any one of  claims 1 - 51 , wherein no more than 85 vol % of the composite comprises the discontinuous agents. 
     
     
         53 . The article of any one of  claims 1 - 52 , wherein at least some of the magnetic particles comprise a ferromagnetic material, iron oxide, nickel oxide, cobalt oxide, or an alloy comprising a rare earth metal. 
     
     
         54 . The article of any one of  claims 1 - 53 , wherein the magnetic particles have an average diameter of less than 10 micrometers. 
     
     
         55 . The article of any one of  claims 1 - 54 , wherein the composite further comprises a binder binding the plurality of continuous fibers and the plurality of discontinuous agents. 
     
     
         56 . The article of  claim 55 , wherein the binder comprises a resin. 
     
     
         57 . The article of any one of  claim 55  or  56 , wherein the binder comprises a thermoplastic. 
     
     
         58 . The article of any one of  claims 55 - 57 , wherein the binder comprises a thermoplastic melt. 
     
     
         59 . The article of any one of  claims 55 - 58 , wherein the binder comprises a thermoplastic resin. 
     
     
         60 . The article of any one of  claims 55 - 59 , wherein the binder comprises a thermoset. 
     
     
         61 . The article of any one of  claims 55 - 60 , wherein the binder comprises a volatile compound. 
     
     
         62 . The article of any one of  claims 55 - 61 , wherein the binder comprises an epoxy, polyester, vinyl ester, polyethylenimine, polyetherketoneketone, polyaryletherketone, polyether ether ketone, polyphenylene sulfide, polyethylene terephthalate, polycarbonates, poly(methyl methacrylate), acrylonitrile butadiene styrene, polyacrylonitrile, polypropylene, polyethylene, nylon, a silicone rubber, polyvinylidene fluoride, and/or styrene butadiene rubber. 
     
     
         63 . The article of any one of  claims 55 - 62 , wherein the binder comprises a pre-ceramic monomer. 
     
     
         64 . The article of  claim 63 , wherein the pre-ceramic monomer comprises a siloxane, a silazane, and/or a carbosilane. 
     
     
         65 . A method, comprising:
 providing a liquid comprising a plurality of discontinuous agents having a plurality of magnetic particles adsorbed thereto;   exposing the liquid to a plurality of continuous fibers defining a substrate;   applying a magnetic field to the liquid to cause alignment of at least some of the plurality of discontinuous agents within the plurality of continuous fibers; and   hardening the liquid to form a composite.   
     
     
         66 . The method of  claim 65 , wherein the liquid further comprises a solvent, and the method further comprises heating the liquid to remove at least some of the solvent. 
     
     
         67 . The method of  claim 66 , wherein the liquid comprises an organic solvent. 
     
     
         68 . The method of any one of  claim 66  or  67 , wherein the liquid comprises isopropanol, butanol, ethanol, acetone, toluene, and/or xylene. 
     
     
         69 . The method of any one of  claims 65 - 68 , wherein the liquid comprises a slurry. 
     
     
         70 . The method of any one of  claims 65 - 69 , wherein the liquid comprises a thermoset. 
     
     
         71 . The method of any one of  claims 65 - 70 , wherein the liquid comprises an oil. 
     
     
         72 . The method of any one of  claims 65 - 71 , wherein the liquid comprises water. 
     
     
         73 . The method of any one of  claims 65 - 72 , wherein exposing the liquid to a plurality of continuous fibers comprises coating the plurality of continuous fibers with the liquid. 
     
     
         74 . The method of any one of  claims 65 - 73 , wherein exposing the liquid to a plurality of continuous fibers comprises immersing the plurality of continuous fibers in the liquid. 
     
     
         75 . The method of any one of  claims 65 - 74 , wherein the magnetic field has a minimum field strength of at least 0.01 T. 
     
     
         76 . The method of any one of  claims 65 - 75 , wherein the magnetic field has a maximum field strength of no more than 10 T. 
     
     
         77 . The method of any one of  claims 65 - 76 , wherein the magnetic field is a time-varying magnetic field. 
     
     
         78 . The method of  claim 77 , wherein the time-varying magnetic field has a frequency of between 1 Hz and 500 Hz. 
     
     
         79 . The method of any one of  claims 65 - 78 , wherein at least 5 vol % of the liquid comprises the discontinuous agents. 
     
     
         80 . The method of any one of  claims 65 - 79 , wherein no more than 85 vol % of the liquid comprises the discontinuous agents. 
     
     
         81 . The method of any one of  claims 65 -, 80  wherein hardening the liquid to form a composite comprises causing the liquid to gel. 
     
     
         82 . The method of any one of  claims 65 - 81 , wherein hardening the liquid to form a composite comprises evaporating at least a portion of the liquid. 
     
     
         83 . The method of any one of  claims 65 - 82 , wherein hardening the liquid to form a composite comprises freezing at least a portion of the liquid. 
     
     
         84 . The method of any one of  claims 65 - 83 , wherein hardening the liquid to form a composite comprises removing at least a portion of the liquid. 
     
     
         85 . The method of any one of  claims 65 - 84 , further comprising permeating a binder into the composite. 
     
     
         86 . The method of  claim 85 , wherein at least some of the binder permeates into the composite via capillary action. 
     
     
         87 . The method of any one of  claim 85  or  86 , wherein at least some of the binder permeates into the composite via gravity. 
     
     
         88 . The method of any one of  claims 85 - 87 , wherein permeating a binder into the composite comprises applying pressure to the binder to cause the binder to permeate into the composite. 
     
     
         89 . The method of  claim 88 , wherein applying pressure comprises hot-pressing the binder into the composite. 
     
     
         90 . The method of any one of  claim 88  or  89 , wherein applying pressure comprises calendaring the binder into the composite. 
     
     
         91 . The method of any one of  claims 88 - 90 , wherein applying pressure comprises permeating the binder into the composite using vacuum infusion. 
     
     
         92 . The method of any one of  claims 88 - 91 , further comprising causing the binder to harden. 
     
     
         93 . The method of any one of  claims 88 - 92 , wherein the binder comprises a resin. 
     
     
         94 . The method of any one of  claims 88 - 93 , wherein the binder comprises a thermoplastic. 
     
     
         95 . The method of any one of  claims 88 - 94 , wherein the binder comprises a thermoplastic melt. 
     
     
         96 . The method of any one of  claims 88 - 95 , wherein the binder comprises a thermoplastic resin. 
     
     
         97 . The method of any one of  claims 88 - 96 , wherein the binder comprises a thermoset. 
     
     
         98 . The method of any one of  claims 88 - 97 , wherein the binder comprises a volatile compound. 
     
     
         99 . The method of any one of  claims 88 - 98 , further comprising heating the composite after permeating the binder into the composite. 
     
     
         100 . An article, comprising:
 a composite comprising a fabric defined by a plurality of continuous fibers, and a plurality of aligned discontinuous agents contained within pores within the fabric.   
     
     
         101 . An article, comprising:
 a layered composite comprising a plurality of plies, at least one ply comprising a plurality of continuous fibers defining a substrate, and a plurality of discontinuous agents contained within the substrate.   
     
     
         102 . The article of  claim 101 , wherein the plurality of discontinuous agents are contained within and positioned substantially orthogonal to the substrate. 
     
     
         103 . An article, comprising:
 a composite comprising a plurality of continuous fibers defining a substrate, and a plurality of discontinuous agents contained within the substrate, at least some of the plurality of discontinuous agents having a plurality of magnetic particles adsorbed thereto, wherein at least 20 vol % of the composite comprises the discontinuous agents.   
     
     
         104 . An article, comprising:
 a composite comprising a plurality of continuous fibers defining a substrate, and a plurality of discontinuous agents contained within at least a portion of the substrate.   
     
     
         105 . The article of  claim 104 , wherein at least some of the plurality of discontinuous agents have a plurality of magnetic particles adsorbed thereto.