Reformable Resin Filaments and Materials Formed Therewith

Abstract

The present teachings contemplate forming a reformable epoxy resin material into a monofilament having a denier of from about 50 to about 5000 and a glass transition temperature of less than about 200° C.; loading one or more monofilaments onto a spool; co-weaving the one or more monofilaments with a reinforcing fiber to form a woven material, the reinforcing fiber having a glass transition temperature of greater than 200° C.; heating the woven material to form a composite to a temperature so that only the one or more monofilaments soften but the reinforcing fiber does not.

1 . A method comprising:
 i) forming the monofilament of  claim 17 ;   ii) loading one or more of the monofilaments onto a spool;   iii) co-weaving the one or more monofilaments with a reinforcing fiber to form a woven material, the reinforcing fiber having a glass transition temperature of greater than 200° C.;   iv) heating the woven material to form a composite to a temperature so that only the one or more monofilaments softens but the reinforcing fiber does not.   
     
     
         2 . The method according to  claim 1 , wherein the reinforcing fiber is selected from the group consisting of glass fibers, carbon fibers, aramid fibers, polymer fibers (polyethylene, polypropylene, polyamide, polyester), metallic fibers, and combinations thereof. 
     
     
         3 . The method according to  claim 1 , wherein the resulting composite has a constant thickness as a result of the failure of the structural fibers to soften. 
     
     
         4 - 5 . (canceled) 
     
     
         6 . The method according to  claim 1 , wherein one or more of the denier or diameter of the monofilament is substantially similar to that of the reinforcing fiber. 
     
     
         7 . The method according to  claim 1 , wherein one or more of the denier or diameter of the monofilament is less than that of the reinforcing fiber. 
     
     
         8 . (canceled) 
     
     
         9 . The method according to  claim 1 , wherein the resulting composite is an epoxy laminate. 
     
     
         10 . The fibrous material product according to  claim 22 , wherein the resulting composite is substantially free of any film layer. 
     
     
         11 - 12 . (canceled) 
     
     
         13 . The fibrous material product of  claim 22 , wherein the monofilament develops adhesive properties upon softening. 
     
     
         14 . (canceled) 
     
     
         15 . The monofilament according to  claim 17 , wherein the monofilament is recyclable. 
     
     
         16 . (canceled) 
     
     
         17 . A monofilament having a denier of from about 200-3200 and a glass transition temperature of less than about 200° C. and comprising a reformable epoxy resin material. 
     
     
         18 . The monofilament of  claim 17 , wherein the reformable epoxy resin material is formed as a reaction product of a difunctional epoxy resin and a primary amine. 
     
     
         19 . The monofilament of  claim 17 , wherein the reformable epoxy resin material is formed as a reaction product of bisphenol A diglycidyl ether (BADGE) and monoethanolamine. 
     
     
         20 . The monofilament of  claim 17 , wherein the monofilament is drapable. 
     
     
         21 . The monofilament of  claim 17 , wherein the monofilament is woven to form an end product that is drapable. 
     
     
         22 . A fibrous material product formed from the monofilament of  claim 17  woven with one or more reinforcing fibers the one or more reinforcing fibers having a glass transition temperature of 200° C. or greater. 
     
     
         23 . The fibrous material product of  claim 22 , wherein the product is drapable. 
     
     
         24 . A ballistic composite material including one or more layers comprising a woven material formed from a plurality of the reformable epoxy resin monofilaments of  claim 17  and a plurality of reinforcing fibers. 
     
     
         25 . The composite material of  claim 24 , wherein the material is used to form a helmet, body armor, or a shield. 
     
     
         26 - 27 . (canceled) 
     
     
         28 . The composite material of  claim 24 , wherein the composite is formed in a heated press at a temperature below about 200° C. 
     
     
         29 . The composite material of  claim 24 , wherein the reinforcing fibers are selected from glass fibers, carbon fibers, aramid fibers, polymer fibers (polyethylene, polypropylene, polyamide, polyester), metallic fibers, and combinations thereof.