U.S. patent application number 14/875874 was filed with the patent office on 2016-01-28 for fiber-containing prepregs and methods and systems of making.
The applicant listed for this patent is JOHNS MANVILLE. Invention is credited to Jawed Asrar, Michael J. Block, Klaus Friedrich Gleich, Asheber Yohannes, Mingfu Zhang.
Application Number | 20160024266 14/875874 |
Document ID | / |
Family ID | 51900336 |
Filed Date | 2016-01-28 |
United States Patent
Application |
20160024266 |
Kind Code |
A1 |
Zhang; Mingfu ; et
al. |
January 28, 2016 |
FIBER-CONTAINING PREPREGS AND METHODS AND SYSTEMS OF MAKING
Abstract
Methods of making a fiber-containing prepregs may include
drawing unsized fibers from a batch of molten glass. The method may
also include applying a sizing composition to the unsized fibers to
form a plurality of sized fibers, where the sizing composition
includes a first polymerization agent for polymerizing caprolactam.
The method may further include weaving the plurality of sized
fibers into a fabric. Another step may include melting a reactive
resin composition to form a melted reactive resin composition,
where the reactive resin composition may include caprolactam. The
melted reactive resin composition may be applied to the fabric. The
method may further include heating the fabric and the melted
reactive resin composition to a polymerization temperature, where
the caprolactam polymerizes to form a fiber-resin amalgam including
a polyamide. Another step may be to form the fiber-resin amalgam
into the fiber-containing prepreg.
Inventors: |
Zhang; Mingfu; (Highlands
Ranch, CO) ; Gleich; Klaus Friedrich; (Nuremberg,
DE) ; Yohannes; Asheber; (Littleton, CO) ;
Block; Michael J.; (Centennial, CO) ; Asrar;
Jawed; (Englewood, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
JOHNS MANVILLE |
Denver |
CO |
US |
|
|
Family ID: |
51900336 |
Appl. No.: |
14/875874 |
Filed: |
October 6, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14278484 |
May 15, 2014 |
9186852 |
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14875874 |
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14088034 |
Nov 22, 2013 |
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14278484 |
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Current U.S.
Class: |
428/474.7 ;
264/258; 428/480; 524/1 |
Current CPC
Class: |
B32B 2262/10 20130101;
B32B 5/32 20130101; B32B 2262/101 20130101; B32B 2262/103 20130101;
B32B 2305/076 20130101; C08J 5/04 20130101; B32B 2262/106 20130101;
B29C 70/52 20130101; B29L 2009/00 20130101; B32B 2262/02 20130101;
C08J 2377/02 20130101; B29B 15/122 20130101; C08J 2367/03 20130101;
B29C 70/50 20130101; C08J 5/24 20130101; C08J 5/06 20130101; B29C
48/285 20190201 |
International
Class: |
C08J 5/24 20060101
C08J005/24; B29C 70/50 20060101 B29C070/50; B32B 5/32 20060101
B32B005/32 |
Claims
1. A fiber-containing prepreg comprising: a first plurality of
fibers; a second plurality of fibers made of a different material
than the first plurality of fibers; and a polymerized resin formed
from a reactive resin composition.
2. The fiber-containing prepreg of claim 1, wherein at least one of
the first plurality of fibers and the second plurality of fibers
are reactive fibers with a reactive agent present on the surface of
the fibers.
3. The fiber-containing prepreg of claim 1, wherein the first
plurality of fibers and the second plurality of fibers are formed
into a fiber mat.
4. The fiber-containing prepreg of claim 1, wherein the first
plurality of fibers and the second plurality of fibers are formed
into one or more layers of fiber mat.
5. The fiber-containing prepreg of claim 1, wherein the first
plurality of fibers are formed into a first fiber mat and the
second plurality of fibers are formed into a second fiber mat.
6. The fiber-containing prepreg of claim 5, wherein the prepreg
comprises a stack of layers of the first fiber mat and the second
fiber mat on top of each other.
7. The fiber-containing prepreg of claim 1, wherein the first
plurality of fibers comprises fibers selected from glass fibers,
inorganic fibers, carbon fibers, metal fibers, organic polymer
fibers, and mineral fibers.
8. The fiber-containing prepreg of claim 1, wherein the second
plurality of fibers comprises fibers selected from glass fibers,
inorganic fibers, carbon fibers, metal fibers, organic polymer
fibers, and mineral fibers.
9. The fiber-containing prepreg of claim 1, wherein the first
plurality of fibers comprises glass fibers and the second plurality
of fibers comprises carbon fibers.
10. The fiber-containing prepreg of claim 1, wherein the
polymerized resin comprises a polyamide polymer or a polybutylene
terephthalate polymer.
11. The fiber-containing prepreg of claim 1, wherein the reactive
resin composition comprises caprolactam.
12. The fiber-containing prepreg of claim 1, wherein the reactive
resin composition comprises a cyclic butylene terephthalate.
13. The fiber-containing prepreg of claim 2, wherein the reactive
agent comprises a coupler-initiator compound that includes (i) a
coupling moiety to form a covalent bond with the at least one of
the first plurality of fibers and the second plurality of fibers,
and (ii) an initiator moiety that initiates a polymerization
reaction of the reactive resin composition.
14. The fiber-containing prepreg of claim 2, wherein the reactive
agent comprises a polymerization catalyst.
15. A fiber-reinforced composite article comprising: a
fiber-containing prepreg comprising: (i) a first plurality of
fibers; (ii) a second plurality of fibers made from a different
material than the first plurality of fibers; and (iii) a second
polymerized resin formed from a prepreg reactive resin
composition.
16. The fiber-reinforced composite article of claim 15, wherein at
least one of the first plurality of fibers and the second plurality
of fibers are reactive fibers with a reactive agent present on the
surface of the fibers.
17. The fiber-reinforced composite article of claim 15, wherein the
first plurality of fibers and the second plurality of fibers are
formed into a fiber mat.
18. The fiber-reinforced composite article of claim 15, wherein the
first plurality of fibers and the second plurality of fibers are
formed into one or more layers of fiber mat.
19. The fiber-reinforced composite article of claim 15, wherein the
first plurality of fibers are formed into a first fiber mat and the
second plurality of fibers are formed into a second fiber mat.
20. The fiber-reinforced composite article of claim 19, wherein the
prepreg comprises a stack of layers of the first fiber mat and the
second fiber mat on top of each other.
21. The fiber-reinforced composite article of claim 15, wherein the
first plurality of fibers comprises fibers selected from glass
fibers, inorganic fibers, carbon fibers, metal fibers, organic
polymer fibers, and mineral fibers.
22. The fiber-reinforced composite article of claim 15, wherein the
second plurality of fibers comprises fibers selected from glass
fibers, inorganic fibers, carbon fibers, metal fibers, organic
polymer fibers, and mineral fibers.
23. The fiber-reinforced composite article of claim 15, wherein the
first plurality of fibers comprises glass fibers and the second
plurality of fibers comprises carbon fibers.
24. A method of making a fiber-containing prepreg, the method
comprising: forming a stack of fiber mats in contact with a
reactive resin composition, wherein the stack of fiber mats
comprises layers of a first fiber mat and a second fiber mat
stacked on top of each other, and wherein the first fiber mat
comprises a first plurality of fibers, and the second fiber mat
comprises a second plurality of fibers made of a different material
than the first plurality of fibers; and curing the reactive resin
composition in the stack of fiber mats to form the fiber-containing
prepreg.
25. The method of claim 24, wherein the first plurality of fibers
comprises fibers selected from glass fibers, inorganic fibers,
carbon fibers, metal fibers, organic polymer fibers, and mineral
fibers.
26. The method of claim 24, wherein the second plurality of fibers
comprises fibers selected from glass fibers, inorganic fibers,
carbon fibers, metal fibers, organic polymer fibers, and mineral
fibers.
27. The method of claim 24, wherein the first plurality of fibers
comprises glass fibers and the second plurality of fibers comprises
carbon fibers.
28. The method of claim 24, wherein at least one of the first
plurality of fibers and the second plurality of fibers are reactive
fibers that have a reactive agent present on the surface of the
fibers.
29. The method of claim 28, wherein the reactive agent comprises a
coupler-initiator compound that includes (i) a coupling moiety to
form a covalent bond with the at least one of the first plurality
of fibers and the second plurality of fibers, and (ii) an initiator
moiety that initiates a polymerization reaction of the reactive
resin composition.
30. The method of claim 24, wherein the reactive agent comprises a
polymerization catalyst.
31. The method of claim 24, wherein the reactive resin composition
comprises caprolactam.
32. The method of claim 24, wherein the reactive resin composition
comprises a cyclic butylene terephthalate.
33. The method of claim 24, wherein the curing of the reactive
resin composition in the stack of fiber mats comprises heating the
reactive resin composition to a polymerization temperature for the
resin.
34. The method of claim 24, wherein the curing of the reactive
resin composition in the stack of fiber mats comprises pressing and
heating the stack of fiber mats.
35. A method of making a fiber-containing prepreg, the method
comprising: forming one or more layers of fiber mat in contact with
a reactive resin composition, wherein the one or more layers of
fiber mat comprise a first plurality of fibers and a second
plurality of fibers made of a different material than the first
plurality of fibers; and curing the reactive resin composition in
the one or more layers of the fiber mat to form the
fiber-containing prepreg.
36. The method of claim 35, wherein the first plurality of fibers
comprises fibers selected from glass fibers, inorganic fibers,
carbon fibers, metal fibers, organic polymer fibers, and mineral
fibers.
37. The method of claim 35, wherein the second plurality of fibers
comprises fibers selected from glass fibers, inorganic fibers,
carbon fibers, metal fibers, organic polymer fibers, and mineral
fibers.
38. The method of claim 35, wherein the first plurality of fibers
comprises glass fibers and the second plurality of fibers comprises
carbon fibers.
39. The method of claim 35, wherein at least one of the first
plurality of fibers and the second plurality of fibers are reactive
fibers that have a reactive agent present on the surface of the
fibers.
40. The method of claim 39, wherein the reactive agent comprises a
coupler-initiator compound that includes (i) a coupling moiety to
form a covalent bond with the at least one of the first plurality
of fibers and the second plurality of fibers, and (ii) an initiator
moiety that initiates a polymerization reaction of the reactive
resin composition.
41. The method of claim 35, wherein the reactive agent comprises a
polymerization catalyst.
42. The method of claim 35, wherein the reactive resin composition
comprises caprolactam.
43. The method of claim 35, wherein the reactive resin composition
comprises a cyclic butylene terephthalate.
44. The method of claim 35, wherein the curing of the reactive
resin composition in the one or more layers of the fiber mat
comprises heating the reactive resin composition to a
polymerization temperature for the resin.
45. The method of claim 35, wherein the curing of the reactive
resin composition the one or more layers of the fiber mat comprises
pressing and heating the one or more ayers of the fiber mat.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/278,484 filed May 15, 2014, which is a
continuation-in-part of U.S. patent application Ser. No. 14/088,034
filed Nov. 22, 2013, entitled "Fiber-Containing Prepregs and
Methods and Systems of Making" (the parent application) which is
incorporated herein by reference for all purposes.
BACKGROUND OF THE INVENTION
[0002] Conventional methods of making fiber-reinforced composites
include bringing together a plurality of fibers with a resin
composition and shaping the amalgam of fibers and resin composition
into the final composite article. The fibers may include glass
fibers that are organized into a woven pattern or randomly
assembled into a nonwoven collection or mat. The resin composition
applied to the fibers may be a powder, a suspension in a liquid
medium, or a melt of thermoplastic polymer.
[0003] There can be many challenges applying the resin composition
to plurality of fibers to make a homogeneous mixture of the fibers
and resin composition in the amalgam. For example, when the resin
composition is a powder, there is significant difficulty
distributing the particles of the powdered composition beyond the
surface of the fibers into the bulk. This can be especially
challenging for woven fibers that are difficult or impossible to
mechanically mix with the particles. Reducing the particle size to
allow them to fit through the interstitial spaces between the
fibers may help distribute them beyond the service layer, but
milling the particles to very small sizes often requires complex
and expensive processing. Moreover, fine-grained particles of
organic materials mixed in air can create an explosion hazard, and
should be applied to the fibers under an inert (i.e., reduced
oxygen) atmosphere.
[0004] There are also challenges applying liquid resin compositions
to fibers. If the liquid resin composition is a melt of
thermoplastic polymer, it often has a viscosity significantly
higher than water. A high viscosity melt makes the resin material
difficult to impregnate into the bulk of the fibers. Increasing the
temperature of the melt to reduce its viscosity can cause unwanted
reactions or decomposition in the resin material, making this
viscosity-reduction technique of limited value. Another technique
increases the pressure on the amalgam using a double belt press in
order to drive the high-viscosity melt into the fibers. However,
this technique is prone to damaging and distorting the fibers,
especially fibers that have been fashioned into a woven fabric. In
some instances, the resin material can be mixed or dissolved in a
solvent to reduce its viscosity and make it easier to wet the
fibers. However, many thermoplastic resin materials are not easily
dissolved, and additional time and steps may be required to
separate (e.g., evaporate) the solvent from the fiber and resin
amalgam. Similar problems can occur for resin compositions made of
a suspension of particles in a liquid carrier medium such as water.
In addition to the challenges getting the particles to quickly and
evenly disperse throughout the fibers, additional steps are often
needed to remove the solvent from the amalgam.
[0005] These and other problems are addressed by the present
application, which includes the making and use of prepregs that
have a resin material dispersed in a plurality of fibers. The
prepregs may be used in fiber-containing composite articles, and
reduce or eliminate the number of time-consuming process steps
needed to combine resin compositions with the fibers.
BRIEF SUMMARY OF THE INVENTION
[0006] Methods and systems for making fiber-reinforced prepregs
from reactive fibers and reactive resin compositions are described.
The reactive fibers may include one or more agents that facilitate
the polymerization of the reactive resin composition and/or bond
the polymerized resin to the fibers. The reactive resin composition
may include monomers and/or oligomers having a low melt viscosity
before they are polymerized. After the reactive fibers and reactive
resin composition are combined, they may be cured to polymerize the
resin and form the fiber-reinforced prepreg. The polymerized
prepregs may be incorporated into a fiber-reinforced composite
article, where the prepregs may be heated, pressed or otherwise
processed to make the article.
[0007] The fiber-reinforced prepregs may include sheets, particles
(e.g., pellets), and tapes of glass fibers held together by the
resin matrix. The prepregs may be shaped, stacked, assembled,
incorporated into a mold, or otherwise processed to form a
fiber-reinforced composite article. Using the prepregs may
eliminate time-consuming process steps for applying and dispersing
resin materials through the fibers during the formation of the
fiber-reinforced composite article.
[0008] Embodiments may include methods of making a fiber-containing
prepreg. The methods may include the steps of providing a plurality
of fibers, and applying a reactive resin composition to the
plurality of fibers to make a mixture of the plurality of fibers
and the resin composition. The reactive resin composition may
include at least one of monomers and oligomers capable of
polymerizing into a polymerized resin matrix. The mixture may be
heated to a polymerization temperature where the monomers,
oligomers, or both polymerize to form a fiber-resin amalgam that
includes the polymerized resin matrix. The fiber-resin amalgam may
be formed into the fiber-containing prepreg.
[0009] Embodiments may further include methods of forming a
fiber-reinforced composite article. The methods may include
providing a plurality of fibers, and applying a reactive resin
composition to the fibers in order to make a mixture of the fibers
and the resin composition. The reactive resin composition may
include monomers and/or oligomers capable of polymerizing into a
polymerized resin matrix. The methods may further include heating
the mixture to a polymerization temperature in order to polymerize
monomers and/or oligomers and form a fiber-resin amalgam and
includes the polymerized resin matrix. The fiber-resin amalgam may
be formed into at least one fiber-containing prepreg, and the
prepreg may be integrated into the fiber-reinforced composite.
[0010] Embodiments may still further include fiber-containing
prepregs. The prepregs may include a plurality of fibers, and a
polymerized resin matrix. The polymerized resin matrix is formed by
applying a reactive resin composition to the plurality of fibers,
and polymerizing the reactive resin composition into the
polymerized resin matrix. The reactive resin composition may
include monomers and/or oligomers capable of polymerizing into the
polymerized resin matrix
[0011] Embodiments may yet further include fiber-reinforced
composite articles made with the fiber-containing prepregs. At
least a portion of the articles include fibers held together in a
resin matrix that is supplied by the fiber-containing prepregs. The
prepregs themselves include a plurality of fibers and a polymerized
resin matrix.
[0012] Embodiments may also include methods of making a
fiber-containing prepreg. The method may include drawing unsized
fibers from a batch of molten glass. The method may also include
applying a sizing composition to the unsized fibers to form a
plurality of sized fibers, where the sizing composition includes a
first polymerization agent for polymerizing caprolactam. The method
may further include weaving the plurality of sized fibers into a
fabric. Another step may include melting a reactive resin
composition to form a melted reactive resin composition, where the
reactive resin composition may include caprolactam. The melted
reactive resin composition may be applied to the fabric. The method
may further include heating the fabric and the melted reactive
resin composition to a polymerization temperature, where the
caprolactam polymerizes to form a fiber-resin amalgam including a
polyamide. Another step may be to form the fiber-resin amalgam into
the fiber-containing prepreg.
[0013] Embodiments may further include a method of making a
fiber-containing prepreg. The method may include applying a
reactive resin powder onto a woven fabric. As an example, the
reactive resin powder may include caprolactam. Additionally, the
woven fabric may include fibers that have been treated with a
sizing composition. The sizing composition may include a
polymerization agent for polymerizing caprolactam. The method may
also include heating the reactive resin powder to a polymerization
temperature, where, for instance, the caprolactam polymerizes to
form a fiber-resin amalgam. The fiber-resin amalgam may include a
polyamide. Another step may include forming the fiber-resin amalgam
into the fiber-containing prepreg.
[0014] Embodiments may include a method of making a
fiber-reinforced composite as well. The method may include drawing
an unsized fiber from a batch of molten glass. Sizing composition
may be applied to the unsized fiber, where the sizing composition
may include at least one polymerization agent for polymerizing
caprolactam. A reactive resin composition may be applied to the
sized fiber. The reactive resin composition may, for example,
include caprolactam. The reactive resin composition may be heated
to a polymerization temperature. If the reactive resin composition
includes caprolactam, the caprolactam may polymerize to form a
fiber-resin amalgam including a polyamide.
[0015] Additional embodiments and features are set forth in part in
the description that follows, and in part will become apparent to
those skilled in the art upon examination of the specification or
may be learned by the practice of the invention. The features and
advantages of the invention may be realized and attained by means
of the instrumentalities, combinations, and methods described in
the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] A further understanding of the nature and advantages of the
present invention may be realized by reference to the remaining
portions of the specification and the drawings wherein like
reference numerals are used throughout the several drawings to
refer to similar components. In some instances, a sublabel is
associated with a reference numeral and follows a hyphen to denote
one of multiple similar components. When reference is made to a
reference numeral without specification to an existing sublabel, it
is intended to refer to all such multiple similar components.
[0017] FIG. 1 is a flowchart showing selected steps in a method of
making a prepreg according to embodiments of the invention;
[0018] FIG. 2 is a flowchart showing selected steps in a method of
making a fiber-reinforced article according to embodiments of the
invention;
[0019] FIGS. 3A-C show exemplary prepregs made according to present
methods;
[0020] FIG. 4 shows an exemplary fiber-reinforced article made
according to the present methods;
[0021] FIG. 5 is a flowchart showing selected steps in a method of
making a prepreg according to embodiments of the invention;
[0022] FIG. 6 is a flowchart showing selected steps in a method of
making a prepreg according to embodiments of the invention; and
[0023] FIG. 7 is a flowchart showing selected steps in a method of
making a fiber-reinforced composite according to embodiments of the
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The present application includes methods of making prepregs
having a polymerized resin matrix made from a reactive resin
composition that includes monomers and/or oligomers that can
polymerize to form the resin matrix. Exemplary prepregs may include
a plurality woven or nonwoven glass fibers combined with the
reactive resin composition that may include a polyalkylene
terephthalate precursor such as cyclic butylene terephthalate
(CBT), or a polyamide precursor such as caprolactam. In some
examples, the plurality of fibers may include reactive glass fibers
that contain a polymerization agent to facilitate the
polymerization of the reactive resin composition. In a subset of
the examples, the polymerization agent may include a coupling
moiety that covalently bonds the polymerization agent to the glass
fiber, and an initiator moiety that initiates the polymerization of
the reactive resin composition. Exemplary prepregs may include
sheets that either lay flat or get wound into a cylindrical roll
for packaging and transport, and particles (e.g., pellets) that are
packaged and shipped as fiber-reinforced thermoplastic starting
materials to be cut, shaped, pressed, molded, etc., into a
fiber-reinforced composite article.
Exemplary Methods of Making Fiber-Containing Prepregs
[0025] FIG. 1 is a flowchart showing an exemplary method 100 of
making the fiber-containing prepregs. The method 100 may include
providing a plurality of fibers 102 that become the fiber component
of the prepreg. A reactive resin composition may be applied to the
plurality of fibers 104. The reactive resin composition may be
heated to a melting temperature so that it can be applied as a
liquid to the plurality of fibers. The melting temperature may be
below a polymerization temperature for the reactive resin
composition, so that the composition may be applied in a
low-viscosity, unpolymerized state that makes it easier to wet and
impregnate the plurality of fibers.
[0026] When the reactive resin composition is added to the
plurality of fibers, they form a mixture that may be heated to a
polymerization temperature for the monomers and/or oligomers 106.
Polymerizing the resin composition forms a fiber-resin amalgam with
the plurality of fibers, and the amalgam may be formed into the
fiber-containing prepreg 108. For example, the fiber-resin amalgam
may be cooled from the polymerization temperature to a
solidification temperature where the resin composition solidifies
into the polymerized resin matrix. The solid amalgam of fibers and
the polymerized resin matrix may then be cut, chopped, crushed,
comminuted, etc., into the fiber-containing prepreg. Additional
details of the exemplary method 100 are provided below.
Exemplary Fibers
[0027] The fibers may be one or more types of fibers chosen from
glass fibers, inorganic fibers, carbon fibers, metal fibers,
organic polymer fibers, and mineral fibers, among other kinds of
fibers. Exemplary glass fibers may include "E-glass`, "A-glass",
"C-glass", "S-glass", "ECR-glass" (corrosion resistant glass),
"T-glass", and fluorine and/or boron-free derivatives thereof.
Exemplary inorganic fibers may include aluminum oxide, silicon
carbide, silicon nitride, silicon carbide, and basalt fibers, among
others. Exemplary carbon fibers may include graphite,
semi-crystalline carbon, and carbon nano tubes, among other types
of carbon fibers. Exemplary metal fibers may include aluminum,
steel, and tungsten, among other types of metal fibers. Exemplary
organic polymer fibers may include poly aramid fibers, polyester
fibers, and polyamide fibers, among other types of organic polymer
fibers.
[0028] The fiber length may range from short-to-intermediate
chopped fibers (1 to 100 mm in length) to long fibers, including
continuous fibers, rovings, and wound fibers, among others. The
plurality of fibers may have an orderly arrangement, such as a
woven fiber mat, or may have a non-ordered arrangement such as a
nonwoven mat. For example, the fibers may be arranged as a
mono-axial and/or multi-axial, woven and/or non-woven, continuous
and/or chopped strand mat. The mats may have multiple sections with
different weave styles, as well as combinations of woven and
non-woven sections. In addition, the mats may have regions where
fibers are incorporated, for example to allow better wet out and
resin penetration.
[0029] In some instances, the plurality of fibers may be treated
with a sizing composition that can enhance the fibers' physical
characteristics in a number of ways including increased hardness,
increased mechanical strength, greater wettability, and increased
adhesion between the fibers and resin. The sizing composition may
also enhance the chemical reactivity of the fibers by providing
them with reactive agents that initiate and/or promote the
polymerization of the resin composition that come in contact with
the "reactive" fibers. The reactive agents may include
coupler-initiator compounds that include a silicon-containing
moiety that forms a covalent bond with an exposed surface of the
glass fiber, and an initiator moiety that initiates a
polymerization reaction in the resin composition that comes in
contact with the coupler-initiator compound bound to the glass
fiber. In some examples, this initiator moiety is a caprolactam
blocked isocyanate moiety that initiates a ring-opening
polymerization reaction of caprolactam when the reactive fibers
come in contact with caprolactam monomers in the resin composition.
Exemplary reactive glass fibers are described in co-assigned U.S.
patent application Ser. Nos. 13/335,690; 13/335,761; 13/335,793;
and 13/335,813, all filed Dec. 22, 2011, and U.S. patent
application Ser. No. 13/788,857, filed Mar. 7, 2013. The entire
contents of all the applications are herein incorporated by
reference for all purposes.
[0030] A polymerization agent may be found exclusively in the
reactive fibers, or may be shared between the fibers and the
reactive resin composition. Conversely, a polymerization agent may
be found exclusively in the reactive resin composition while not
being present on the reactive fibers. When multiple polymerization
agents are used, some may be present exclusively on the reactive
fibers while others are present exclusively in the reactive resin
composition. In additional examples, all of the polymerization
agents may be shared between the reactive fibers and reactive resin
composition.
Exemplary Reactive Resin Compositions
[0031] The method 100 may include applying a reactive resin
composition to the plurality of fibers 104. The reactive resin
composition may include monomers and/or oligomers capable of
polymerizing into a polymerized resin matrix that binds the
plurality of fibers. Exemplary reactive resin compositions may
include caprolactam. Caprolactam is a cyclic amide of caproic acid
with an empirical formula (CH.sub.2).sub.5C(O)NH, which may be
represented by the structural formula:
##STR00001##
[0032] Caprolactam has a low melting point of approximately
68.degree. C. and a melted viscosity (4-8 cP) that is close to
water, making it well suited for wetting and impregnating glass
fibers. Typically, the caprolactam-containing reactive resin
composition may be introduced to the plurality of fibers as a
liquid melt, but may also be introduced as a dry powder that is
subsequently melted and polymerized around the fibers.
[0033] Caprolactam-containing reactive resin compositions may also
include polymerization agents such as a caprolactam polymerization
catalyst. Exemplary catalysts may include a salt of a lactam, and
the salt may be an alkali metal salt, an alkali-earth metal salt,
and/or a Grignard salt of the caprolactam. For example the
polymerization catalyst may be an alkali metal salt of caprolactam,
such as sodium caprolactam. In another example, the polymerization
catalyst may be a Grignard salt of the caprolactam, such as a
magnesium bromide salt of the caprolactam. As noted in the
discussion of reactive glass fibers above, polymerization agents
may also be present on the fibers, and in some instances a
polymerization agent may be present in both the reactive resin
composition and on the fibers. Incorporating a polymerization agent
on the reactive glass fibers can reduce or eliminate its presence
in the reactive resin composition, which may increase the pot-life
of the reactive resin composition prior to being applied to the
fibers.
[0034] Exemplary reactive resin compositions may include oligomers
of a cyclic alkylene terephthalate, such as cyclic butylene
terephthalate (CBT). An exemplary CBT, whose ring includes two
butyl groups and two terephthalate groups, is illustrated
below:
##STR00002##
[0035] It should be appreciated that the present CBT may include
additional butyl and/or terephthalate groups incorporated into the
ring. It should also be appreciated that some exemplary CBT may
have other moieties coupled to the CBT ring. CBT may comprise a
plurality of dimers, trimers, tetramers, etc., of butylene
terephthalate.
[0036] CBT resins are typically solids at room temperature (e.g.,
about 20.degree. C.), and begin to melt at around 120.degree. C. At
around 160.degree. C., CBTs are generally fully melted with a
liquid viscosity of about 150 centipoise (cP). As the molten CBTs
are heated further, the viscosity may continue to drop, and in some
instances may reach about 30 cP at about 190.degree. C. The CBT
monomers and/or oligomers may be selected to have a melting
temperature range of, for example, 120-190.degree. C.
[0037] CBT-containing reactive resin compositions may be introduced
to the plurality of fibers as a melt or a dry powder of CBT
particles. The reactive resin composition may include additional
compounds such as polymerization catalysts, polymerization
promoters, colorants, flame retardants, ultraviolet stabilizers,
and fillers including inorganic particles and carbon nanotubes,
among other additional compounds. When the resin particles are
oligomers of a CBT, the polymerization catalyst is selected to
drive the polymerization of these types of macrocyclic oligoesters.
Exemplary polymerization catalysts may include organometallic
compounds such as organo-tin compounds and/or organo-titanate
compounds. One specific polymerization catalyst for the CBT
monomers and oligomers may be butyltin chloride dihydroxide.
[0038] The CBT-containing reactive resin composition may also
include a polymerization promoter that accelerates the
polymerization rate of the monomers and/or oligomers. When the
resin particles include CBT, the polymerization promoter may by an
alcohol and/or epoxide compound. Exemplary alcohols may include one
or more hydroxyl groups, such as mono-alcohols (e.g., butanol),
diols (e.g., ethylene glycol, 2-ethyl-1,3-hexanediol,
bis(4-hydroxybutyl)terephthalate), triols, and other polyols.
Exemplary epoxides may include one or more epoxide groups such as
monoepoxide, diepoxide, and higher epoxides, such as bisphenol A
diglycidylether. They may also include polyol and polyepoxides,
such as poly(ethylene glycol).
Exemplary Reactive Resin Combinations
[0039] The reactive resin compositions may include a single type of
monomer and/or oligomer such as caprolactam or CBT, or
alternatively may include two or more types of monomers and/or
oligomers. For example, the reactive resin composition may include
both caprolactam and CBT. In some examples, the combination of
monomers/oligomers may be selected to form a melt suspension of
higher melting point monomers/oligomers in a liquid medium made
from a lower melting point monomer/oligomer. For example, a
combination of caprolactam and CBT may be selected with CBT
monomer/oligomers having melting points significantly above the
melting point of caprolactam. When this reactive resin combination
is heated above the melting point of the caprolactam it forms a
liquid medium in which the CBT particles are suspended. The
application of this reactive resin suspension on a glass fiber
substrate can create a inhomogeneous distribution of the two types
of monomers/oligomers in the resin-fiber mixture. This can be
beneficial for prepreg designs where a higher resin density is
desired on or near the surface of the prepreg.
[0040] Additional reactive resin compositions include combinations
of first and second resin systems having different polymerization
temperatures. This may allow the formation of a semi-reactive
prepreg that contains a polymerized resin matrix of the first resin
system having a lower polymerization temperature, while also
containing unpolymerized monomers/oligomers of the second resin
system having a higher polymerization temperature. For example, a
reactive resin combination of caprolactam and CBT may be selected
such that the CBT has a higher polymerization temperature than the
caprolactam. Alternatively, a reactive resin combination can be
formulated of two different types of cyclic alkylene terephthalates
and/or a bimodal molecular weight distribution of CBT oligomers
having different polymerization temperatures.
[0041] A bimodal or multi-modal distribution of oligomer/polymer
melting points in the prepreg can be advantageous to the final
molded product that incorporates the prepreg. For example, the low
molecular weight (low melting temperature) component of the prepreg
may melt and flow easily in the interstitial spaces between the
plurality of fibers, while the high molecular weight (high melting
temperature) component(s) may hold tighter to the fibers preventing
an inhomogeneous distribution of resin across the fiber-reinforced
article. These bimodal or multimodal distributions of resin melting
temperatures in the prepreg can be useful for making
fiber-reinforced articles with a high weight (i.e., loading) of the
resin relative to the weight of the fibers (i.e., a high
resin-to-fiber loading ratio).
Exemplary Techniques for Adding the Reactive Resin Compositions to
the Fibers
[0042] The reactive resin composition may be added to the plurality
of fibers using a variety of application techniques depending on
whether the reactive resin composition is a melt or powder. For
example, when the resin composition is a melt of monomers and/or
oligomers, they may be applied to the fibers by spraying, curtain
coating, kiss rolling, doctor blade coating, sheet die coating, and
dip and squeeze coating, among other techniques. If the resin
composition is a dry powder, techniques for applying the powders to
the plurality of fibers may include fluidized bed applications,
powder scattering, and powder spraying, among others.
Heating the Fiber-Resin Mixture
[0043] After the reactive resin composition has been added to the
plurality of fibers, the fiber-resin mixture may be heated to a
polymerization temperature at which the monomers and/or oligomers
start to polymerize. For a reactive resin composition that includes
caprolactam monomers, the polymerization temperature may be about
120.degree. C. or more (e.g., about 120.degree. C. to about
220.degree.). A reactive resin composition that includes CBT may
have a more variable threshold polymerization temperature depending
on the CBT oligomers present. Typically, threshold polymerization
temperature for reactive resin compositions including CBT range
from about 170-190.degree. C. For prepreg manufacturing processes
where the polymerized resin matrix is not melted, an upper limit on
the polymerization temperature for the monomers and/or oligomers
may be the melting temperature of the polymer. For example, a
reactive resin composition that includes caprolactam may have a
upper limit of a polymerization temperature that is the melting
temperature of the PA-6 polymer formed by the caprolactam (i.e.,
.about.220.degree. C.). Similarly, a reactive resin composition
that includes CBT may have an upper limit of a polymerization
temperature that is the melting temperature of the PBT polymers it
forms (e.g., about 225.degree. C.).
[0044] As noted above, when the reactive resin composition is a
combination of two or more types of reactive monomers and/or
oligomers, the heating temperature of the resin-fiber mixture may
be chosen to be above a threshold polymerization temperature of one
type of monomer/oligomer but below a threshold polymerization
temperature of the other type of monomer/oligomer. For example, a
reactive resin composition that includes both caprolactam and CBT
monomers and/or oligomers may be heated to 120-170.degree. C.,
which may polymerize the caprolactam to PA-6 without significantly
polymerizing the CBT to PBT. The resulting fiber-resin amalgam will
include a polymerized resin matrix of PA-6 combined with a
polymerizable resin of CBT. The fiber-resin amalgam may be
processed into a reactive prepreg that includes a polymerized resin
matrix of PA-6 and pre-polymerized CBT. The reactive prepreg may be
incorporated into a fiber-reinforced article, where the processing
conditions may include polymerizing the CBT into PBT.
Processing the Fiber-Resin Amalgam into a Prepreg
[0045] The heat curing of the monomers and/or oligomers form a
fiber-resin amalgam of the plurality of fibers and the polymerized
resin matrix. Initially, the polymerized resin matrix may be close
to or above the polymer melting temperature, and the fibers and
matrix may be blended, pressed, and/or extruded into the rough
shape of the fiber-containing prepreg. Alternatively, the
fiber-resin amalgam may be cooled below the melting temperature of
the polymerized resin matrix causing the amalgam to solidify. The
solidification of the fiber-resin amalgam does not necessarily
create an inflexible and brittle prepreg. The polymerized resin
matrix may be selected to form a flexible layer of the prepreg
material that can be flexed or bent without cracking, fracturing,
or flaking.
Exemplary Methods of Making Fiber-Reinforced Composite Articles
[0046] FIG. 2 is a flowchart showing an exemplary method 200 of
making the fiber-reinforced composite articles. The method 200 may
include providing a plurality of fibers 202 that become the fiber
component of a prepreg that is incorporated into the article. A
reactive resin composition may be applied to the plurality of
fibers 204. The reactive resin composition may include monomers
and/or oligomers capable of polymerizing into a resin matrix under
the appropriate curing conditions. The addition of the reactive
resin composition to the plurality of fibers forms a fiber-resin
mixture that is heated to a polymerization temperature of the resin
composition 206. The heating facilitates the polymerization of the
monomers and/or oligomers in the reactive resin composition, and
creates a fiber-resin amalgam from the plurality of fibers held by
the polymerized resin matrix. The amalgam may then be processed
into the fiber-containing prepregs 208, and the prepregs may then
be formed into the fiber-reinforced composite article 210 by
incorporating them into the article.
[0047] Exemplary techniques for forming the prepregs into the
fiber-reinforced composite articles may include compression molding
of a single prepreg layer, multiple prepreg layers, and/or pellets
of prepreg material into the fiber-reinforced article. When the
prepreg includes pre-polymerized and/or partially-polymerized
resin, the compression molding process may include a heating step
(e.g., hot pressing) to fully polymerize the resin. Heat may also
be used in the compression molding of fully-polymerized prepregs to
melt and mold the prepreg into the shape of the final article.
[0048] The prepregs may also be used to in conjunction with other
fibers and resin materials to make the final composite article. For
example, the prepreg may be placed in selected sections of a tool
or mold to reinforce the article and/or provide material in places
that are difficult to reach for thermoset and/or thermoplastic
resins. For example, the prepregs may be applied to sharp corners
and other highly structured areas of a mold or layup used in
reactive injection molding processes (RIM), structural reactive
injective molding processes (SRIM), resin transfer molding
processes (RTM), vacuum-assisted resin transfer molding processes
(VARTM), spray-up forming processes, filament winding processes,
long-fiber injection molding processes, and pultrusion, among
others.
[0049] As noted above, examples of the present prepregs may include
a resin matrix of polymerized PA-6 and unpolymerized or partially
polymerized CBT. The pre-polymerized or partially polymerized CBT
can be converted to PBT and form a fully-polymerized
fiber-reinforced article under isothermal processing
conditions.
Exemplary Fiber-Containing Prepregs
[0050] FIGS. 3A-C show some exemplary prepregs made using the
present methods.
[0051] FIG. 3A shows a sheet 302 of woven glass fabric and
polymerized resin. In some instances, a plurality of prepreg sheets
302 may be stacked directly on top of each other, or sandwiched
between other layers of materials. Additional details about
arranging a plurality of prepreg layers in a layup for the
fiber-reinforced composite article can be found in co-assigned U.S.
patent application Ser. No. 13/915,023, filed Jun. 11, 2013, the
entire contents of which are herein incorporated by reference for
all purposes.
[0052] FIG. 3B shows a pile of prepreg pellets 304 that may be
formed by chopping, grinding, milling, crushing, or otherwise
comminuting the heated fiber-resin amalgam.
[0053] The heated fiber-resin amalgam may be cooled to a
comminuting temperature, which may be a temperature at or below the
glass transition temperature for the resin materials in the
prepreg. The prepreg pellets 304 may be added as a dry powder or as
a component of a liquid suspension to the final fiber-reinforced
composite article.
[0054] FIG. 3C shows a roll 308 of prepreg material that may be
used as sheet molding compound (SMC), among other applications. In
some embodiments, the prepreg material may be sandwiched between
film layers that prevent contamination of the prepreg as well as
the bonding of adjacent layers on the roll. The film layers are
selected to easily peel away from the prepreg when it is ready to
be used in making fiber-reinforced articles. Alternatively, the
film layers may be compatible with the prepreg, and incorporated in
the composite part after molding.
Exemplary Fiber-Reinforced Composite Articles
[0055] FIG. 4 shows an exemplary fiber-reinforced composite wind
turbine blade 502 formed by the present prepregs. The blade 402 is
one of many types of articles that can be formed by the present
prepregs. Other articles may include vehicle parts (e.g., aircraft
parts, automotive parts, etc.), appliance parts, containers,
etc.
Additional Exemplary Methods
[0056] FIG. 5 is a flowchart showing an exemplary method 500 of
making a fiber-containing prepreg. Method 500 may include drawing
unsized fibers 502 through bushing from a batch of molten glass.
The unsized fibers may be cooled by a mist of water. Method 500 may
also include applying a sizing composition to the unsized fibers
504 to form a plurality of sized fibers, where the sizing
composition includes a first polymerization agent for polymerizing
caprolactam. The first polymerization agent may also include a
coupling moiety that covalently bonds the polymerization agent to
the unsized fibers. The polymerization agent may include a silane
moiety. In addition, the first polymerization agent may include a
polymerization initiator or catalyst. The polymerization agent may
further include an initiator moiety that initiates polymerization
of the reactive resin composition. For example, the initiator
moiety may initiate the polymerization of caprolactam. Possibly as
a result of the structure of the first polymerization agent,
applying the sizing composition to the unsized fibers 504 may
include covalently bonding the first polymerization agent to the
unsized fibers. Steps 502, 504, and 506 may occur at the same
facility.
[0057] Applying a polymerization agent, such as an initiator, to
the fibers as they are being formed may provide advantages over
applying the polymerization agent to fibers that have already been
sized. Sizing compositions often may be applied to fibers in order
to minimize abrasion between fibers. These sizing compositions
often include a lubricant and/or a film former and may coat the
surface of the glass fibers. An already sized fiber may then
inhibit or prevent adhesion between the polymerization agent and
the surface of the glass fibers. The sizing composition, if applied
before the polymerization agent, may coat the glass fibers and
compromise the surface of the glass fibers so that a polymerization
agent may not readily adhere to the surface. Applying the sizing
composition containing a polymerization agent directly to the
fibers as they are being formed also may decrease the number of
processing steps and may decrease costs.
[0058] The plurality of sized fibers may be woven into a fabric as
in step 506. Another step may include melting a reactive resin
composition as in step 508 to form a melted reactive resin
composition, where the reactive resin composition may include
caprolactam. The reactive resin composition may include a second
polymerization agent. This second polymerization agent may assist
in polymerizing caprolactam. The second polymerization agent may
include an initiator or catalyst. The initiator in the second
polymerization agent may be different from the initiator in the
first polymerization agent. An initiator that may be present in the
first polymerization agent may not be present in the second
polymerization agent. Similarly, an initiator that may be present
in the second polymerization agent may not be present in the first
polymerization agent. The plurality of fibers may be continuous and
not chopped.
[0059] The melted reactive resin composition may be applied to the
fabric 510. This may result in a fabric impregnated with the resin
composition. Method 500 may further include heating the fabric and
melted reactive resin composition 512 to a polymerization
temperature, where the caprolactam polymerizes to form a
fiber-resin amalgam including a polyamide. Another step may be to
form the fiber-resin amalgam into the fiber-containing prepreg
514.
[0060] FIG. 6 is a flowchart showing an exemplary method 600 of
making a fiber-containing prepreg. Method 600 may include applying
reactive resin powder onto a woven fabric 602. The reactive resin
powder may include caprolactam, and the woven fabric may include
fibers that have been treated with a sizing composition. The sizing
composition may be any sizing composition previously discussed. The
woven fabric may be formed by drawing unsized fibers from a batch
of molten glass, then applying the sizing composition to the
unsized fibers to form a plurality of sized fibers, and weaving the
plurality of sized fibers into the woven fabric. The plurality of
fibers may be produced by a direct roving process. The sizing
composition may include a polymerization agent. As an example, the
reactive resin powder may include caprolactam. The reactive resin
powder may include an initiator or catalyst. The reactive resin
powder may then be melted.
[0061] Method 600 may also include heating the reactive resin
powder 604 to a polymerization temperature, where, for instance,
the caprolactam polymerizes to form a fiber-resin amalgam. The
fiber-resin amalgam may include a polyamide. Another step may
include forming the fiber-resin amalgam into the fiber-containing
prepreg 606.
[0062] FIG. 7 is a flowchart showing an exemplary method 700 of
making a fiber-reinforced composite. Method 700 may include drawing
an unsized fiber 702 through bushing from a batch of molten glass.
Sizing composition may be applied to the unsized fiber 704, where
the sizing composition may include at least one polymerization
agent for polymerizing caprolactam. The at least one polymerization
agent may be any polymerization agent previously described.
[0063] A reactive resin composition may be applied 706 to the sized
fiber. The reactive resin composition may be applied to several
sized fibers simultaneously or nearly simultaneously. These sized
fibers may be in a tow, which may include thousands of fibers. The
fibers may be the same or different in material or diameter. The
reactive resin composition may, for example, include caprolactam.
The reactive resin may also include a polymerization initiator or a
polymerization catalyst or both an initiator and a catalyst. The
reactive resin, when applied to the sized fiber, may be in a powder
form. Or the reactive resin may be melted when applied to the sized
fiber. The reactive resin composition may be applied to the sized
fiber in a pultrusion process. The reactive resin composition may
be heated 708 to a polymerization temperature. If the reactive
resin composition includes caprolactam, the caprolactam may
polymerize to form a fiber-resin amalgam including a polyamide.
[0064] Having described several embodiments, it will be recognized
by those of skill in the art that various modifications,
alternative constructions, and equivalents may be used without
departing from the spirit of the invention. Additionally, a number
of well-known processes and elements have not been described in
order to avoid unnecessarily obscuring the present invention.
Accordingly, the above description should not be taken as limiting
the scope of the invention.
[0065] Where a range of values is provided, it is understood that
each intervening value, to the tenth of the unit of the lower limit
unless the context clearly dictates otherwise, between the upper
and lower limits of that range is also specifically disclosed. Each
smaller range between any stated value or intervening value in a
stated range and any other stated or intervening value in that
stated range is encompassed. The upper and lower limits of these
smaller ranges may independently be included or excluded in the
range, and each range where either, neither or both limits are
included in the smaller ranges is also encompassed within the
invention, subject to any specifically excluded limit in the stated
range. Where the stated range includes one or both of the limits,
ranges excluding either or both of those included limits are also
included.
[0066] As used herein and in the appended claims, the singular
forms "a", "an", and "the" include plural referents unless the
context clearly dictates otherwise. Thus, for example, reference to
"a process" includes a plurality of such processes and reference to
"the fiber" includes reference to one or more fibers and
equivalents thereof known to those skilled in the art, and so
forth.
[0067] Also, the words "comprise," "comprising," "include,"
"including," and "includes" when used in this specification and in
the following claims are intended to specify the presence of stated
features, integers, components, or steps, but they do not preclude
the presence or addition of one or more other features, integers,
components, steps, acts, or groups.
* * * * *