Patent US5028478A successfully refreshed from Google Patents.
US5028478A
Expired / Lapsed
US
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Fiber reinforced composite materials having resin practice inter-layer zones
Assignee: Troy Industries Inc
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Filing: 1987-12-24
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Granted: 1991-07-02
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Expires: 2007-12-24
Abstract
Abstract Tough laminated composite material which comprise (A) long reinforcing fibers, (B) a matrix resin mixed with the long reinforcing fibers and (C1) a resin, preferably in the form of fine resin particles, forming a phase separate from said matrix resin which is localized in inter-layer zones, wherein 90% or more of said resin (C1) is localized in inter-layer zones and/or wherein the border length factor in the inter-layer zones is 2.5 or more and prepegs used to form the composite materials.
Inventors
- 👤 Nobuyuki Odagiri
- 👤 Shigeru Suzue
- 👤 Hajime Kishi
- 👤 Takeji Nakae
- 👤 Akimitsu Matsusaki
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 15:05
CPC Classifications
C; C08; C08J; C08J5/00; C08J5/24; C08J5/241; C08J5/243; F; F17; F17C; F17C2209/00; F17C2209/21; F17C2209/2154; Y; Y10; Y10S; Y10S428/00; Y10S428/902; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249924; Y10T428/24994; Y10T428/25; Y10T428/254; Y10T428/26; Y10T428/31504; Y10T428/31551; Y10T428/31562; Y10T428/31721; Y10T428/31725; Y10T428/31786; Y10T442/00; Y10T442/30; Y10T442/3472; Y10T442/3528; Y10T442/3545
Claims Analysis
Total Claims: 40
Claim 1
Independent Claim
94 words
A tough laminated composite material, comprising: (A) at least two lamination layers comprising high strength long reinforcing fibers; (B) a matrix resin which is at least in part thermosetting mixed with said reinforcing fibers; and (C1) thermoplastic resin particles independently dispersed in a matrix resin or partially integrated with each other in a matrix resin, wherein 90% or more of said particles are localized in inter-layer zones which have a thickness which is 30% of the thickness of said lamination layers, wherein the border length factor in said inter-layer zones is 2.5 or more.
Claim 2
Dependent Claim
94 words
A tough laminated composite material, comprising: (A) at least two lamination layers comprising high strength long reinforcing fibers; (B) a matrix resin which is at least in part thermosetting mixed with said reinforcing fibers; and (C1) thermoplastic resin particles independently dispersed in a matrix resin or partially integrated with each other in a matrix resin, wherein 90% or more of said particles are localized in inter-layer zones which have a thickness which is 30% of the thickness of said lamination layers, wherein the border length factor in said inter-layer zones is 2.5 or more.
Claim 3
Dependent Claim
22 words
The laminated composite material of claim 1, wherein said thermoplastic resin is a resin having in the main chain an amide bond.
Claim 4
Dependent Claim
22 words
The laminated composite material of claim 1, wherein said thermoplastic resin is a resin having in the main chain an imide bond.
Claim 5
Dependent Claim
22 words
The laminated composite material of claim 1, wherein said thermoplastic resin is a resin having in the main chain a sulfone bond.
Claim 6
Dependent Claim
15 words
The laminated composite material of claim 1, wherein said thermoplastic resin is a polyamide resin.
Claim 7
Dependent Claim
32 words
The laminated composite material of claim 1, wherein the quantity of said particles is within the range of 1 to 30 parts by weight to 100 parts by weight of matrix resin.
Claim 8
Dependent Claim
15 words
The laminated composite material of claim 1, wherein said thermoplastic resin is a polyamideimide resin.
Claim 9
Dependent Claim
15 words
The laminated composite material of claim 1, wherein said thermoplastic resin is a semi-IPN resin.
Claim 10
Dependent Claim
14 words
The laminated composite material of claim 1, wherein said matrix resin contains a polyethersulfone.
Claim 11
Dependent Claim
20 words
The laminated composite material of claim 1, wherein said particles have an average particle diameter of 0.5 to 60 microns.
Claim 12
Dependent Claim
25 words
The laminated composite material of claim 1, wherein said particles are formed of a resin having a G IC of 1500 J/m 2 or more.
Claim 13
Dependent Claim
28 words
The laminated composite material of claim 1, wherein the resin of said particles is a polyamide which has a semi-IPN (interpenetrating polymer network) structure with an epoxy resin.
Claim 14
Dependent Claim
14 words
The laminated composite material of claim 1, wherein said particles are spherical in shape.
Claim 15
Dependent Claim
19 words
The laminated composite material of claim 1, wherein said thermoplastic resin particles are independently dispersed in said matrix resin.
Claim 16
Dependent Claim
18 words
The laminated composite material of claim 1, wherein said thermoplastic resin particles are partially integrated with each other.
Claim 17
Dependent Claim
165 words
A tough laminated composite material formed of a plurality of lamination layers, comprising: (A) a plurality of layers of carbon or graphite reinforcing fibers having a length of 5 cm or more which have a tensile strength of at least 450 kgf/mm 2 and a tensile elongation of at least 1.6%, said reinforcing fibers within each layer being arranged in a single direction; (B) a matrix resin formed of thermosetting resin or a mixture of thermosetting resin and a thermoplastic resin impregnated in said layers of reinforcing fibers; and (C1) a layer of fine thermoplastic resin particles dispersed in said matrix resin having an average particle diameter of 0.5 to 60 microns which forms an inter-layer zone located between at least two of said layers of said reinforcing fibers, wherein 90% or more of said particles are localized in inter-layer zones which have a thickness which is 30% of said lamination layer and the border length factor in said inter-layer zones is 2.5 or more.
Claim 18
Dependent Claim
165 words
A tough laminated composite material formed of a plurality of lamination layers, comprising: (A) a plurality of layers of carbon or graphite reinforcing fibers having a length of 5 cm or more which have a tensile strength of at least 450 kgf/mm 2 and a tensile elongation of at least 1.6%, said reinforcing fibers within each layer being arranged in a single direction; (B) a matrix resin formed of thermosetting resin or a mixture of thermosetting resin and a thermoplastic resin impregnated in said layers of reinforcing fibers; and (C1) a layer of fine thermoplastic resin particles dispersed in said matrix resin having an average particle diameter of 0.5 to 60 microns which forms an inter-layer zone located between at least two of said layers of said reinforcing fibers, wherein 90% or more of said particles are localized in inter-layer zones which have a thickness which is 30% of said lamination layer and the border length factor in said inter-layer zones is 2.5 or more.
Claim 19
Dependent Claim
44 words
The laminated composite material of claim 16, wherein the matrix resin consists essentially of an epoxy resin and said thermoplastic resin is selected from the group consisting of polyamide, polycarbonate, polyacetal, poly(phenylene oxide), poly(phenylene sulfide), polyallylate, polyester, polyamideimide, polysulfone, polyethersulfone, polyetheretherketone, polyaramid and polybenzimidazole.
Claim 20
Dependent Claim
16 words
The laminated composite material of claim 17, wherein said thermoplastic resin is polyamide, polyethersulfone or polysulfone.
Claim 21
Dependent Claim
17 words
The laminated composite material of claim 16, wherein said matrix resin consists essentially of an epoxy resin.
Claim 22
Dependent Claim
16 words
The laminated composite material of claim 16, wherein the resin of said particles is a polyamide.
Claim 23
Dependent Claim
77 words
A prepreg suitable for use in a laminated composite material, comprising: (A) high strength long reinforcing fibers; (B) a matrix resin which is at least in part thermosetting mixed with said reinforcing fibers; and (C2) fine thermoplastic resin particles dispersed in a matrix resin wherein 90% or more of said particles are localized near a surface of the prepreg within a depth which is 30% of the thickness of the prepreg from the surface of the prepreg.
Claim 24
Dependent Claim
77 words
A prepreg suitable for use in a laminated composite material, comprising: (A) high strength long reinforcing fibers; (B) a matrix resin which is at least in part thermosetting mixed with said reinforcing fibers; and (C2) fine thermoplastic resin particles dispersed in a matrix resin wherein 90% or more of said particles are localized near a surface of the prepreg within a depth which is 30% of the thickness of the prepreg from the surface of the prepreg.
Claim 25
Dependent Claim
18 words
The prepreg of claim 21, wherein said particles have an average particle diameter of 0.1 to 150 microns.
Claim 26
Dependent Claim
18 words
The prepreg of claim 21, wherein said particles have an average particle diameter of 0.5 to 60 microns.
Claim 27
Dependent Claim
23 words
The prepreg of claim 21, wherein said particles are formed of a resin having a G IC of 1500 J/m 2 or more.
Claim 28
Dependent Claim
33 words
The prepreg of claim 21, wherein said particles are produced from a combination of a thermosetting resin and a thermoplastic resin and which has, or can develop, a semi-IPN (interpenetrating polymer network) structure.
Claim 29
Dependent Claim
14 words
The prepreg of claim 21, wherein the resin of said particles is a polyamide.
Claim 30
Dependent Claim
29 words
The prepreg of claim 21, wherein the resin of said particles is a polyamide which has, or can develop, a semi-IPN (interpenetrating polymer network) structure with an epoxy resin.
Claim 31
Dependent Claim
14 words
The prepreg of claim 21, wherein the fine resin particles are spherical in shape.
Claim 32
Dependent Claim
20 words
The prepreg of claim 21, wherein said thermoplastic resin is a resin having in the main chain an amide bond.
Claim 33
Dependent Claim
20 words
The prepreg of claim 21, wherein said thermoplastic resin is a resin having in the main chain an imide bond.
Claim 34
Dependent Claim
20 words
The prepreg of claim 21, wherein said thermoplastic resin is a resin having in the main chain a sulfone bond.
Claim 35
Dependent Claim
30 words
The prepreg of claim 21, wherein the quantity of said particles is within the range of 1 to 30 parts by weight to 100 parts by weight of matrix resin.
Claim 36
Dependent Claim
13 words
The prepreg of claim 21, wherein said thermoplastic resin is a polyamideimide resin.
Claim 37
Dependent Claim
13 words
The prepreg of claim 21, wherein said thermoplastic resin is a semi-IPN resin.
Claim 38
Dependent Claim
12 words
The prepreg of claim 21, wherein said matrix resin contains a polyethersulfone.
Claim 39
Dependent Claim
26 words
The prepreg of claim 21, wherein the resin of said particles is a polyamide which has a semi-IPN (interpenetrating polymer network) structure with an epoxy resin.
Claim 40
Dependent Claim
12 words
The prepreg of claim 22, wherein said particles are spherical in shape.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1994-07-01 | 1994-12-31 | 1995-07-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-07-01 | 1998-12-31 | 1999-07-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-07-01 | 2002-12-31 | 2003-07-02 | $7700.00 | Window Closed / Lapsed |