Cytec Technology Corporation

Spencer Donald Jacobs

Jack D Boyd

Stephen J Howard

Mark Bonneau

Scott D Lucas

Gordon T Emmerson

Mark Richard Bonneau

Jack Douglas Boyd

Gordon Thomas Emmerson

Stephen Jacob Howard

Systems and methods for the reduction of volatile component content from shaped prepregs and prepreg layups and the layups and composites formed therefrom are disclosed. One or more shaped prepregs or prepreg layups are placed within an enclosure and a flow of a non-condensing gas is introduced adjacent at least one surface of the shaped prepregs or prepreg layups, accelerating the rate and/or the completeness of removal of volatile components from the shaped prepregs or prepreg layups. The shaped prepregs or prepreg layups may be further subjected to heat, vacuum, and external pressure to facilitate removal of the volatile components. Shaped prepregs and prepreg layups with volatiles reduced in this manner may be further consolidated with heat, external pressure and/or vacuum. Beneficially, reduced matrix bleed and reduced fiber movement may be achieved during processing, reducing manufacturing time and improving part quality.

Processing of polymer matrix composites

Particle toughened, fiber-reinforced composites include a fiber region and an interlayer region between the fibers. The fiber region includes a plurality of fibers at least partially within a first polymer composition including a first base polymer formulation and a first plurality of toughening particles. The interlayer region includes a second polymer composition including a second base polymer formulation and at least one of the first plurality of toughening particles and a second plurality of toughening particles. Examples of first and second pluralities of toughening particles, respectively, may include core shell rubbers and polyimides. Increasing concentration of the first plurality of toughening particles may improve the composite toughness while preserving thermal properties of the composite, such as weight loss after extended duration exposure to elevated temperature. It is further discovered that the relative placement of the toughening particles influences composite mechanical properties, such as compression after impact (CAI) strength.

Particle-toughened fiber-reinforced polymer composites

Particle-toughened polymer compositions include a base polymer formulation and a plurality of toughening particles. In certain embodiments, the base polymer formulation includes bismaleimides or other polymer resins capable of high temperature service. A first plurality of toughening particles may include core shell rubbers. A second plurality of toughening particles may be selected from a variety of polymer compositions, including polyimides, polyether ketone (PEK), polyether ether ketone (PEEK), polyether ketone ketone (PEKK), polyether imide, polyether sulfones, and polyphenylene oxide. It is found that increasing concentration of the core shell rubbers may improve the toughness of the composition while preserving thermal properties of the composition, such as glass transition temperature.

Particle-toughened polymer compositions

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Corona, CA, United States of America

Spencer Donald Jacobs