Production of thermoset composites containing thermoplastic fill

Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor

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15624423, 15624427, 1563073, 264136, 264137, 264257, 264258, 26433111, 26433118, 525282, 525524, B29C 4320

Patent

active

049541951

ABSTRACT:
A process for increasing the damage tolerance in thermoset composites without loss of processibility or mechanical properties of the thermoset, by controlled solubility of a thermoplastic filler in the base thermoset. The process includes mixing spherical particles of a selected thermoplastic, such as polyimide, of particle size ranging from about 10 to 80 microns, with a hot thermoset resin, such as a bismaleimide, to form a uniform dispersion of the resin mixture, employing about 5 to about 40% of the thermoplastic by weight of the mixture of the two resins. The particles of thermoplastic are non-agglomerating and insoluble in the resin mixture. The hot resin dispersion is then applied to fiber reinforcement, such as carbon fiber tapes, to form pre-pregs. Upon curing the thermoset at elevated temperature, the thermoplastic particles dissolve in the thermoset resin, forming a composite with no definable boundary interfaces between the thermoplastic and thermosetting resins.

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