Claims Analysis
Total Claims: 11
Claim 1
Independent Claim
99 words
A method for producing an interleafed fiber resin matrix prepreg fabric comprising (1) incorporating a non-woven or woven fibrous mat or carrier of lightweight supporting filaments into an interleaf resin composition comprising (a) a first thermosetting epoxy resin composition containing (b) about 8% to 70% by weight of a rubbery vinyl addition polymer to provide a supported interleaf resin layer; and (2) introducing said supported interleaf resin layer to at least one surface of a fiber resin matrix comprising (a) a fabric of high-strength reinforcing filaments and (b) a second thermosetting epoxy resin composition coating and impregnating said fabric.
Claim 2
Independent Claim
99 words
A method for producing an interleafed fiber resin matrix prepreg fabric comprising (1) incorporating a non-woven or woven fibrous mat or carrier of lightweight supporting filaments into an interleaf resin composition comprising (a) a first thermosetting epoxy resin composition containing (b) about 8% to 70% by weight of a rubbery vinyl addition polymer to provide a supported interleaf resin layer; and (2) introducing said supported interleaf resin layer to at least one surface of a fiber resin matrix comprising (a) a fabric of high-strength reinforcing filaments and (b) a second thermosetting epoxy resin composition coating and impregnating said fabric.
Claim 3
Dependent Claim
78 words
The method of Claim 1, wherein said first thermosetting epoxy resin composition exhibits shear modulus of at least 50,000 psi and yield strength of at least 3,000 psi at high temperatures, and shear strain to failure of at least 6% at -67°F and at least 15% at room temperature; and said second thermosetting epoxy resin composition exhibits shear modulus of at least 90,000 psi at high temperatures or at least 50,000 psi at high temperatures under wet conditions.
Claim 4
Dependent Claim
25 words
The method of Claim 1, wherein said supporting filaments are selected from the group consisting of lightweight glass, carbon, graphite, polyaramide, polyester, and cellulosic filaments.
Claim 5
Dependent Claim
22 words
The method of Claim 1, wherein said fabric is comprised of interwoven tows containing from about 1,000 to 12,000 high-strength reinforcing filaments.
Claim 6
Dependent Claim
34 words
The method of Claim 4, wherein said reinforcing filaments are selected from the group consisting of glass, carbon, graphite, silicon carbide, boron, polyaramide, polyester, polyamide, rayon, polybenzimidazole, and polybenzothiazole filaments, and metal-coated such filaments.
Claim 7
Independent Claim
60 words
The method of Claim I,'wherein said rubbery vinyl addition polymer comprises about 8% to 24% by weight of said interleaf resin composition, said second thermosetting epoxy resin composition comprises about 35% to 60% by weight of said fiber resin matrix, and said fibrous mat or carrier comprises less than 5% by weight of the interleafed fiber resin matrix prepreg fabric.
Claim 8
Dependent Claim
21 words
The method of Claim 6, wherein a crosslinked interface is formed between said interleaf resin layer and said fiber resin matrix.
Claim 9
Dependent Claim
57 words
The method of Claim 1, wherein said first and second thermosetting epoxy resin compositions are, independently, comprised of epoxy compounds selected from the group consisting of polyglycidyl ethers of polyfunctional phenols, polyglycidyl ethers of the chlorination or bromination products of polyvalent phenols, polyglycidyl ethers of novolacs, polyepoxy compounds deprived from aromatic amines and epichlorohydrin, and mixtures thereof.
Claim 10
Dependent Claim
24 words
The method of Claim 2, wherein said first and second thermosetting epoxy resin compositions both exhibit an ultimate shear stress above about 3,000 psi.
Claim 11
Dependent Claim
14 words
The method of Claim 8, wherein said epoxy resin compositions further include curing agents.