Zephyros, Inc.

Sylvain Gleyal

Henry E Richardson

Laurent Meistermann

Brandon Madaus

Craig Chmielewski

Alex Gutierrez

Alejandro Gutierrez

The present invention contemplates a method for forming a composite structure including a plurality of rigid layers and one or more reformable epoxy resin layers. The resulting composite is molded to form a non-planar composite structure.

Reformable epoxy resin for composites

A structural reinforcement for an article including a carrier () that includes: (i) a mass of polymeric material () having an outer surface; and (ii) at least one fibrous composite Insert () or overlay () having an outer surface and including at least one elongated fiber arrangement (e.g., having a plurality of ordered fibers). The fibrous Insert () or overlay () is envisioned to adjoin the mass of the polymeric material in a predetermined location for carrying a predetermined load that Is subjected upon the predetermined location (thereby effectively providing localized reinforcement to that predetermined location). The fibrous insert () or overlay () and the mass of polymeric material () are of compatible materials, structures or both, for allowing the fibrous insert or overlay to be at feast partially joined to the mass of the polymeric material. Disposed upon at least a portion of the carrier () may be a mass of activatable material (). The fibrous insert () or overlay () may include a polymeric matrix that includes a thermoplastic epoxy.

Composites with thermoplastic epoxy polymeric phase, articles such as carriers made therewith and associated methods

A structural reinforcement for an article including a carrier () that includes: (i) a mass of polymeric material () having an outer surface; and (ii) at least one fibrous composite Insert () or overlay () having an outer surface and including at least one elongated fiber arrangement (e.g., having a plurality of ordered fibers). The fibrous Insert () or overlay () is envisioned to adjoin the mass of the polymeric material in a predetermined location for carrying a predetermined load that Is subjected upon the predetermined location (thereby effectively providing localized reinforcement to that predetermined location). The fibrous insert () or overlay () and the mass of polymeric material () are of compatible materials, structures or both, for allowing the fibrous insert or overlay to be at least partially joined to the mass of the polymeric material. Disposed upon at least a portion of the carrier () may be a mass of activatable material (). The fibrous insert () or overlay () may include a polymeric matrix that includes a thermoplastic epoxy.

A structural reinforcement for an article including a carrier () that includes: (t) a mass of polymeric material () having an outer surface; and (ii) at least one fibrous composite Insert () or overlay () having an outer surface and including at least one elongated fiber arrangement (e.g., having a plurality of ordered fibers). The fibrous Insert () or overlay () is envisioned to adjoin the mass of the polymeric material in a predetermined location for carrying a predetermined load that Is subjected upon the predetermined location (thereby effectively providing localized reinforcement to that predetermined location). The fibrous insert () or overlay () and the mass of polymeric material () are of compatible materials, structures or both, for allowing the fibrous insert or overlay to be at feast partially joined to the mass of the polymeric material. Disposed upon at least a portion of the carrier () may be a mass of activatable material (). The fibrous insert () or overlay () may include a polymeric matrix that includes a thermoplastic epoxy.

The present invention contemplates a method for enclosing a panel edge comprising forming a panel structure having at least one edge, applying a reformable epoxy resin material onto the at least one edge, and contacting the reformable epoxy resin material within about 10 minutes, or even about 5 minutes of applying the reformable epoxy resin material such that the reformable epoxy resin material is below its glass transition temperature and dry to the touch upon contact.

Growing community of inventors

Rochester, MI, United States of America

Sylvain Gleyal