Multifunctional facial mask

Abstract

The present invention relates to multifunctional surfacing films, each comprising: (a) a single layer of a curable polymer composition having opposite first and second surfaces; (b) a peelable porous sheet disposed at or below the second surface; and (d) at least one functional material, optionally a porous sheet, arranged within the single layer of the curable polymer composition and located between the first surface and the peelable porous sheet, as well as methods for making and using such multifunctional surfacing films.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Patent Application No. 62 / 611,712 filed on December 29, 2017, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] The present invention relates to a multifunctional surfacing film and its preparation and use methods. The surfacing film comprises a curable polymer monolayer having two or more functional material porous sheets embedded in or on a polymer layer. The surfacing film can provide a dual purpose of acting as a peelable layer material and imparting performance characteristics so that the film can be used as an impact modifier or used in lightning protection, current dissipation, EMI shielding or heat transfer applications. The surfacing film is suitable for use on flat or curved surfaces, including outer and inner surfaces, such as those used to construct a series of polymers or polymer composite laminates and articles derived therefrom (e.g., aircraft parts) or parts used in motor vehicle applications. Background of the Invention

[0005] Aircraft are used in harsh environments and are often subjected to aggressive chemicals (e.g., paint strippers, de-icing fluids, jet fuels) and environmental conditions, including lightning strikes and other potential degradation mechanisms due to environmental stresses (e.g., UV, salt, acid, or thermal degradation). In addressing these issues, aircraft manufacturers face increasing pressure to reduce manufacturing costs, reduce weight, and improve aircraft performance. Summary of the invention

[0006] The present disclosure relates to multifunctional surfacing films that not only protect composite parts / substrates from environmental stresses and chemical exposure, but also provide a peelable porous sheet that reduces downstream manufacturing processes and costs, particularly during surface finishing. The surfacing films can also provide even more functions / benefits / properties, including but not limited to improved post-impact performance, lightning strike protection, current dissipation, EMI shielding, heat transfer performance, or a combination thereof. These surfacing films represent an advancement in aircraft manufacturing and performance. The present disclosure describes these surfacing films, as well as methods for preparing and using them.

[0007] Certain embodiments of the present disclosure include multifunctional facial films, each film comprising:

[0008] (a) a single layer of a curable polymer composition having opposing first and second surfaces:

[0009] (b) a first releasable porous sheet at least partially disposed within the monolayer of the curable polymer composition and located at or below the first surface; and

[0010] (c) optionally, at least one second porous sheet of functional material disposed within the curable polymer composition monolayer beneath the second surface and positioned between the second surface and the first peelable porous sheet.

[0011] Reference to "below" in describing the relative position of various sheets will be understood to mean behind or covered by the reference sheet, not necessarily below the reference sheet. The various embodiments discussed herein include a wide range of materials and properties of the surfacing film in a broad sense and of the individual components in particular. The surfacing film may contain additional additives distributed in the curable polymer composition and the interlayer porous sheet. The surfacing film may be suitable for a substrate with a profile and may have structural attributes and areal weights that provide significant advantages over conventional laminates.

[0012] Independent embodiments include those wherein the curable polymer composition is uncured, partially cured, or fully cured.

[0013] Other embodiments include methods of using these surfacing films to modify substrate surfaces to provide substrate surface functionality. In one set of embodiments, the method comprises:

[0014] (a) applying a multifunctional surfacing film to a substrate surface, desirably but not necessarily, to a co-curable substrate surface, by physically fixing (preferably adhering) the second surface of the multifunctional surfacing film to the optionally co-curable substrate surface to form an intermediate bonded composition;

[0015] (b) subjecting the intermediate bonding composition to conditions sufficient to allow (desirably induce) co-curing or otherwise bonding of the curable polymer composition of the substrate and the multifunctional surfacing film and thereby form a bond therebetween; and

[0016] (c) optionally removing the peelable porous sheet to provide an exposed new first surface. If or once the peelable porous sheet is removed, the exposed new first surface provides a surface to which an additional surface finish / decoration (e.g., paint, sticker, decal) layer can be applied. Desirably, little or no sanding, priming or other surface treatment of the exposed new first surface is required prior to applying the surface finish / decoration.

[0017] In another embodiment, the method of using these facial masks comprises

[0018] (a) applying the multifunctional surfacing film to the mold surface by physically placing the first surface of the multifunctional surfacing film on the mold surface and conforming the multifunctional surfacing film to the mold surface, thereby exposing the second surface of the multifunctional surfacing film;

[0019] (b) physically attaching at least one layer of an optionally co-curable substrate film to the second surface of the multifunctional surfacing film to form an intermediate bonded composition;

[0020] (c) subjecting the intermediate bonding composition to conditions sufficient to allow the curable polymer composition of at least one optionally curable substrate and the multifunctional surfacing film to co-cure or otherwise bond, thereby forming a bond therebetween;

[0021] (d) optionally removing the co-cured substrate and surfacing film from the mold; and

[0022] (e) further optionally removing the peelable porous sheet to provide an exposed new first surface suitable for application of one or more additional layers of surface finishing and / or decoration.

[0023] Certain embodiments incorporate at least one second functional material sheet onto the substrate, desirably as part of the multifunctional film, and all described embodiments should be understood to optionally include this feature. The multifunctional surfacing film achieves this goal with minimal weight and has the added benefit of providing a peel layer feature that facilitates simplified downstream manufacturing operations.

[0024] In some embodiments, these multifunctional facial films can be prepared by the following steps:

[0025] (a) continuously depositing a curable polymer composition onto a surface of a release liner to form a cast polymer composition having a first surface in contact with the release liner and a second surface opposite the first surface and the release liner;

[0026] (b) arranging, laying or otherwise positioning a first releasable porous sheet in the cast polymer composition while continuously depositing the curable polymer, preferably embossing the first releasable porous sheet into the first surface of the cast curable polymer composition such that the releasable porous sheet is positioned at or below the first surface of the curable polymer composition and below the releasable liner,

[0027] (c) while continuously depositing the curable polymer, and at the same or different time as depositing the first peelable porous sheet, providing at least one second functional material porous sheet positioned relative to the second surface such that the at least one second functional material porous sheet becomes at least partially embedded in the cast polymer composition at a selected distance from the second surface;

[0028] (d) optionally providing a second releasable liner adjacent to the second surface of the multifunctional surfacing film.

[0029] These methods offer the unique advantage of being able to combine a peelable porous sheet and a second functional material porous sheet at independently defined depths within the curable polymer layer to tailor the properties of the overlay layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The present application will be further understood when read in conjunction with the accompanying drawings. For the purpose of illustrating the subject matter, exemplary embodiments of the subject matter are shown in the accompanying drawings; however, the subject matter disclosed herein is not limited to the specific methods, devices, and systems disclosed. In addition, the drawings are not necessarily drawn to scale. In the drawings:

[0031] Figure 1 is a diagram of one embodiment of a multifunctional surfacing membrane having two sandwich porous sheets. Figure 1 One embodiment is shown wherein a single layer (100) of a multifunctional surfacing film comprises a curable polymer composition (110) combined with a peelable porous sheet (120) and a second functional material sheet (130).

[0032] Figure 2 is a schematic diagram of a composite structure in which a multifunctional film is applied directly to a substrate. Figure 2 An embodiment is described in which a single layer (200) of a multifunctional surfacing film comprises a curable polymer composition (210) combined with a peelable porous sheet (220) and a second functional material sheet (230), applied to an optionally co-cured substrate (240).

[0033] Figure 3 is a schematic diagram of a composite structure in which a multifunctional film is first applied to a mold and then to a substrate. More specifically, Figure 3 An embodiment is shown wherein a single layer (300) of a multifunctional surfacing film comprises a curable polymer composition (310) combined with a peelable porous sheet (320) and a second functional material sheet (330) positioned between an optional co-cured substrate (340) and a mold or tool (350).

[0034] Figure 4 Schematic diagram of an exemplary apparatus for preparing a multifunctional surfacing film (Nip Version A). In this embodiment, a peelable porous sheet (420) passes through a pressure roller (480) and stops at a first surface of a curable polymer composition (410) closer to a releasable liner, wherein a second functional material porous sheet (430) is positioned closer to the second surface and applied to the multifunctional surfacing film by a pressure roller (470). The sheets are applied to form a multifunctional surfacing film, such as it is conveyed on a paper carrier (440), and the completed surfacing film is conveyed to a winder (400) for winding for storage and transportation.

[0035] Figure 5It is a schematic diagram (Nip Version B) of producing a multifunctional veneer film. In this embodiment, a peelable porous sheet (520) passes through the other side of a pressure roller (580), where it is applied to a curable polymer composition (510), contrary to the diagram in Nip Version A. After being applied by a pressure roller (570), the peelable sheet (520) stops at a porous sheet (530) closer to the second functional material, contrary to being directly relative to a release liner (540). This results in weight reduction after removing the peelable sheet after curing. The finished veneer film is transported to a winder (500), where it is wound for storage and transportation. DETAILED DESCRIPTION

[0036] The invention relates to a multifunctional facial mask and a preparation method and a use method thereof.

[0037] The present disclosure may be more readily understood by reference to the following detailed description in conjunction with the accompanying drawings, which form a part of the present disclosure. It should be understood that the present invention is not limited to the specific products, methods, conditions or parameters described and / or illustrated herein, and that the terms used herein are only for the purpose of describing specific embodiments by way of example, and are not intended to limit any claimed invention. Similarly, any description of possible mechanisms of action or modes or causes of improvement is meant to be illustrative only, and the invention herein is not limited by the correctness or incorrectness of any such suggested mechanisms of action or modes or causes of improvement. Throughout this article, it should be recognized that the description relates to a multifunctional veneer and a method for preparing and using a multifunctional veneer.

[0038] In this disclosure, the singular forms "a," "an," and "the" include plural references, and a reference to a particular value includes at least that particular value unless the context clearly dictates otherwise. Thus, for example, reference to "a material" refers to at least one of such material and equivalents thereof known to those skilled in the art, and so forth.

[0039] When a value is expressed as an approximation by using the antecedent "about", it should be understood that a particular value forms another embodiment. Generally, the use of the term "about" represents an approximation that can vary according to the desired properties that the disclosed subject matter seeks to obtain, and should be interpreted in the specific context of its use based on its function, and those skilled in the art will be able to interpret it as such. In some cases, the number of significant figures for a particular value can be a non-limiting method for determining the scope of the word "about". In other cases, the gradient used in a series of values ​​can be used to determine the expected range available for the term "about" for each value. When present, all ranges are inclusive and combinable. That is, reference to the value stated in the range includes each value within the range.

[0040] It should be understood that certain features of the invention described in the context of separate embodiments for clarity may also be provided in combination in a single embodiment. Conversely, various features of the invention described in the context of a single embodiment for brevity may also be provided separately or in any sub-combination. Finally, while an embodiment may be described as part of a series of steps or as part of a broader composition or structure, each embodiment may also be considered an independent embodiment in its own right.

[0041] General considerations for membranes and single polymer layers

[0042] In certain embodiments, the multifunctional facial mask comprises:

[0043] (a) a single layer of a curable polymer composition having opposing first and second surfaces;

[0044] (b) a first peelable porous sheet disposed at or below the first surface; and

[0045] (c) optionally, at least one porous sheet of a second functional material disposed within the curable polymer composition monolayer beneath the second surface and between the second surface and the peelable porous sheet.

[0046] As used herein, the term curable polymer composition "single layer" refers to both the composition and the related integrity of the curable polymer composition. Unless otherwise specified herein, a curable polymer composition single layer refers to a layer without observable interlayer discontinuity, as seen in a laminate of two similar or dissimilar polymer compositions. Relative to laminated composites, this characteristic provides additional strength and stability during environmental challenges (e.g., thermal shock or cycling) by minimizing or eliminating the mismatch of the thermal expansion coefficient of, for example, different layers or adhesives therebetween. A curable polymer composition single layer may also be described as a single cohesive polymer layer or an integral structural layer. According to the mode of preparing the polymer layer, the polymer itself may be uniformly composed throughout the film, or may be continuously varied along the length of the film or over the entire width of the film (i.e., from the first surface to the second surface), i.e., there is no sudden discontinuous polymer composition. As used herein, the term "relative", as in "relative first surface and second surface", refers to a flat surface (face) on either side of a film, sheet or layer; For example, on the opposite side of a curable polymer composition single layer.

[0047] In other embodiments, the requirement that the multifunctional surfacing film have a single layer of a curable polymer composition may be relaxed, and laminates comprising similar or different polymers may be contemplated. Alternatively, the multifunctional surfacing film itself may be laminated to another curable polymer composition comprising the same or different polymer as the surfacing film.

[0048] Additionally, while most embodiments are described with respect to "curable" polymer compositions, additional embodiments include those in which the composition is partially or fully cured, either by itself or co-cured with another curable polymer composition.

[0049] In certain embodiments, the curable polymer composition may include one or more thermosetting or thermoplastic resins, or a blend or mixture of the two. The polymer composition may include monomers, oligomers, or polymers of such materials. Exemplary non-limiting curable polymers include benzoxazine, bismaleimide, epoxy resin, (meth)acrylate, (meth)acrylamide, polyamide, polyester, polyimide, polyurethane, vinyl ester, or copolymers or mixtures thereof. Epoxy resins are particularly suitable for use in the methods herein. Polymers related to EA 9845, EA9895 and EA9897 resins show promising results. In some independent embodiments, the curable polymer composition is primarily an epoxy resin. For clarity, the use of "(meth)" in parentheses as exemplified in the term "(meth)acrylate" refers to independent embodiments of acrylate, methacrylate, or a mixture or copolymer comprising both.

[0050] Due to the aromatic nature of some of the polymers used, and in some cases, the method of making the film, in some embodiments, the polymer chains within the curable polymer composition can adopt an organized, almost liquid crystal orientation in the film, wherein the aromatic moieties are partially or completely arranged in a parallel array within the film. In other embodiments, due to the crosslinking or nature of the polymer, the polymer can adopt a more randomly oriented array within the film.

[0051] The polymer composition is preferably curable (e.g., crosslinkable) by applying light (UV, visible light, or infrared) or heat. This allows the use of sheet materials and control of the time of curing / co-curing with other substrates. Preferably, the polymer maintains its flexibility before application, so that it is preferably uncrosslinked or only partially crosslinked polymer. In some embodiments, the curable polymer comprises a partially cured (crosslinked) resin, which is mixed with a supplementary resin and / or catalyst immediately before the first peelable sheet and the second functional material porous sheet are combined between the porous layers, and is cured and prepared by a free radical method.

[0052] In addition to the strippable porous sheet and the functional material porous sheet, the polymer may contain various additives, which may be organic or inorganic in nature. These will be further described elsewhere herein, but may include UV absorbers or stabilizing additives (e.g., as described in U.S. Patent Application Publication No. 2010 / 0151239 or U.S. Patent No. 9,676,961), reinforcing fibers, or conductive materials.

[0053] General Considerations for Porous Sheets

[0054] As described herein, the first peelable porous sheet and the second functional material porous sheet are arranged in the matrix of the curable polymer composition. These sheets are most preferably aligned parallel to each other in the film and relative to the first surface and the second surface. Given this arrangement, the first peelable sheet and the second functional material sheet may also be generally referred to as interlayer sheets, because these sheets form a layered structure in otherwise an overall film structure.

[0055] As described elsewhere herein, at least a portion of the first peelable sheet and the second functional material sheet, preferably all porous, or preferably porous. Although these materials may also include non-porous material (for example, including cross-hatched solid band or sheet) or the part (for example, patch or sub-region part) of non-porous material, when processing relates to porous sheet from surface imprinting in the main body of curable polymer composition, the existence of porosity during manufacturing, if not necessary, is at least useful. When sheet is arranged in polymer composition, hole allows polymer flow through sheet, is imprinted in polymer composition desirably, as semi-solid by sieve or screen, optionally moistens or saturates sheet material. Once formed and finally solidified, the polymer included in the opening provides the physical connectivity between polymer molecules on either side of sheet, and can provide enhanced stability for the obtained cured film. The porosity in each sheet is preferably evenly distributed. The porosity of two types of sheets can be identical or different. In some cases, for a given total open area, a high density of small holes, slits or openings is preferred over a lower density of larger holes, slits or openings. In other cases, the reverse is true, while in other cases, a balance of the two size classifications may also provide advantages. In some embodiments, either or both of the first peelable porous sheet and the second functional material porous sheet independently have a nominal pore size in the range of 0.25-250 microns in diameter. In other embodiments, the dimensions can be characterized as 0.1-0.25 microns, 0.25-0.5 microns, 0.5-0.75 microns, 0.75-1 microns, 1-2.5 microns, 2.5-5 microns, 5-7.5 microns, 7.5-10 microns, from 10-25 microns, 25-50 microns, 50-75 microns, 75-100 microns, 100-125 microns, 125-150 microns, 150-175 microns, 175-200 microns, 200-250 microns, 250-500 microns, 500-750 microns, or any combination of two or more of these ranges, such as 1-75 microns. In the case where the openings are slits or other shapes, at least one dimension of the openings can also be within these ranges.

[0056] Peelable porous sheet

[0057] As described elsewhere herein, the first peelable porous sheet is included at or below the first surface. In a preferred embodiment, the peelable porous sheet is disposed below the first surface. The distance below the first surface can be specifically predetermined and controlled during the manufacturing process. The purpose of the peelable porous sheet is to provide the function of a sacrificial peeling layer in the post-curing composition for the veneer film, and at least has the properties generally associated with the function. In a preferred embodiment, the peelable porous sheet is located between 5% and 40% of the distance between the first surface and the second surface; that is, closer to the first surface, so that when the composition is cured and the peelable sheet is removed, about 5 to 10 weight %, 10 to 20 weight %, 20 to 30 weight %, 30 to 40 weight % or 40 to 50 weight % of the cured resin is also removed. In some embodiments, the predetermined positioning is achieved by physically embedding a fabric or expansion membrane on or in the surface of a curable polymer composition (desirably a cast polymer composition), as described elsewhere herein.

[0058] In some embodiments, the peelable porous sheet comprises a material comprising one or more fluorinated or perfluorinated polymers (such as polytetrafluoroethylene (PTFE or ), polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF or )), (meth)acrylate, (meth)acrylamide, polyester, polyamide, polyethylene, polypropylene, polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyethersulfone (PES), polyethyleneimine (PEI), poly(p-phenylenesulfide), polyvinyl chloride, or copolymers or mixtures thereof. Preferred exemplary fabrics may include polyester, polyamide, polyaramid such as Polyimide such as Carbon fibers, or glass or other inorganic fibers. In some embodiments, the fabric or expansion membrane may be coated or impregnated with a laminating binder resin. In other embodiments, no such additional laminating binder resin is used. Coating or impregnation of the expansion membrane or fabric may be achieved by any of a variety of methods well known to those skilled in the art. The polymer surface of the fabric or expansion membrane may optionally be coated with silica, siloxane, alumina or metal, or treated with plasma or silane. Polyester, nylon or mixtures thereof are particularly useful as fabrics or expansion membranes in this application.

[0059] In various embodiments, the thickness of the peelable porous sheet is in the range of 5 microns to 500 microns, or may be defined by one or more of the following ranges: 5-10 microns, 10-25 microns, 25-50 microns, 50-75 microns, 75-100 microns, 100-125 microns, 125-150 microns, 150-175 microns, 175-200 microns, 200-250 microns, 250-300 microns, 300-400 microns, or 400-500 microns, such as 25-125 microns or 75-200 microns. The holes, slits or openings are described elsewhere herein.

[0060] The peelable porous sheet typically comprises a fabric or an expanded film.

[0061] As used herein, the term "expanded film" refers to a sheet or film comprising perforated or through-hole porosity, for reasons provided elsewhere herein.

[0062] As used herein, the term "fabric" most generally refers to woven materials. Nonwoven materials may also be used, but are less preferred because they have a greater tendency to leave fiber residues / ends on the surface during removal of the peelable sheet after curing.

[0063] In some embodiments, when fabric is a woven fabric, the woven fabric comprises tightly woven monofilament or multifilament tows. Preferably tightly woven, high-density woven to provide a smooth finish compatible with the finish required for the final painted product. Therefore, preferred fabric tissues include plain weave, harness stain weave, crow-foot satin weave, ripstop weave or twill, wherein the crow-foot satin weave style is the most preferred. In an independent embodiment, the fabric can also include monofilament or multifilament / twisted yarn, or a combination of monofilament or multifilament / twisted yarn, wherein each yarn surface can be flat or textured independently. In an independent embodiment, the yarn has a maximum size of 100, 120, 14, 160, 180 or 200 deniers.

[0064] The closeness of fabric can be described according to warp ends per inch and fill ends per inch, which are easily understood by those skilled in the art of woven fabrics. Fabric or film of the present invention include independently containing at least 50 warp ends per inch, or at least 60, 70, 80, 90, 100, 120, 140 or 160 warp ends per inch, and at least 40 fill ends per inch, or at least 60, 80 or 100 fill ends per inch, and / or fabric is included in the yarn with minimum 50 yarns per inch in both the warp and the weft, and the yarn has maximum 150 deniers in the warp or weft. For example, good results are obtained, wherein fabric or film includes at least about 50-80 warp ends per inch and at least about 40 fill ends per inch. A preferred embodiment includes such a fabric structure, wherein fabric is woven with at least 120 warp ends per inch and at least 60 fill ends per inch. Such fabric structures are commercially available, for example, from Precision Fabrics Group of Greensboro, North Carolina. Exemplary compositions include polyester type 728 and nylon type 9646 materials that have been soured and heat set. Given the warp / fill parameters, and consistent with the thickness of the entire fabric, the fiber or yarn thickness is used, for example, to provide a minimum open weave.

[0065] The final surface finish of the article resulting from the removal of the sacrificial release outer layer can be further improved by using fabrics for the release outer layer that are subjected to an additional calendering process such that the removal of the release outer layer of these fabrics results in an even smoother, extremely low porosity article surface.

[0066] Another feature of the strippable porous sheet is that it has a tensile strength greater than that of the cured polymer composition, such that, for example, the strippable sheet does not break apart during its subsequent removal or leave individual filament strands that compromise the cleanliness of the surface finish after stripping.

[0067] Preferably, when tested according to ASTM-D5034, the peelable porous sheet exhibits a tensile strength in the range of 100N to 1500N to provide physical integrity to achieve its intended function. In other embodiments, the tensile strength is described as one or more of the following ranges: 100-200N, 200- to 300N, 300-400N, 400-500N, 500-600N, 600-700N, 700-800N, 800-900N, 900-1000N, 1000-1100N, 1100-1200N, 1200-1300N, 1300-1400N, 1400-1500N, such as 400N to 1000N.

[0068] Second (or more) functional material porous sheet

[0069] The multifunctional surfacing film of the present disclosure optionally comprises at least one second functional material sheet, at least a portion of which is in the form of a porous woven or nonwoven fabric, expanded metal foil or polymer film, grating, mesh, screen or web. Similarly, and for the same reasons as described elsewhere herein, it is desirable that most (if not all) functional sheets have a high degree of porosity for final product stability and manufacturability. In certain preferred embodiments, there are these additional functional material porous sheets.

[0070] In some embodiments, multiple functional material sheets can be used. Alternatively, a single sheet can contain materials with different functions (including so-called hybrid materials). It should be understood that the first peelable porous sheet provides the functional capabilities (i.e., peelability) of a multifunctional veneer film, but in the context used in this section, the term "functionality" refers to the properties of the sheet material, which imparts some properties to the film, and the properties improve performance, such as impact stability, dimensional stability, conductivity, and heat transfer capability, so as to provide improved strength, EMI shielding materials, and static and lightning protection to the substrate to which it is ultimately attached. In addition, the phrase "at least one second functional material sheet" can be one or more non-peelable functional materials to distinguish it from a peelable sheet. That is, it means an embodiment including the following: (a) one or more (non-peelable) functional materials, as described below; (b) two or more identical (non-peelable) functional materials, (c) two or more different (non-peelable) materials, or (d) two or more two or more (non-peelable) functional materials.

[0071] The physical properties of these second functional materials are similar to those described elsewhere herein for the first peelable porous sheet, at least in terms of thickness and porosity characteristics, but the composition and structure of these functional material porous sheets reflect the need for a different range of properties. For example, one or more second functional material sheets may not require the same tensile strength as the peelable porous sheet.

[0072] Likewise, the second functional material porous sheets may comprise woven fabrics and expanded membranes, but alternatively these sheets may also comprise nonwoven fabrics, nets, screens or meshes of continuous or chopped organic or inorganic fibers, including materials that are the same or similar to those used for the peelable porous sheets, i.e., one or more fluorinated or perfluorinated polymers such as polytetrafluoroethylene (PTFE or ), polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF or )), (meth)acrylates, (meth)acrylamides, polyesters, polyamides, polyethylene, polypropylene, polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyethersulfone (PES), polyethyleneimine (PEI), poly(p-phenylene sulfide), polyvinyl chloride, or copolymers or mixtures thereof. Other useful organic materials include polyaniline, polypyrrole, polythiophene, or copolymers or mixtures thereof, either alone or in combination with any other material described for this purpose. Aromatic polyamides (e.g., fibers) and imide fibers (e.g. ) are also attractive in this application. Because it is expected that the second functional material will remain in the multifunctional film after curing and during final use, the physical integrity or weaving properties of these sheets are not as important as those of the peelable materials; that is, they do not need to withstand the peeling operation.

[0073] The functional material may also include ceramic or glass fibers (e.g., containing oxides, carbides, nitrides, oxycarbides, oxynitrides, carbonitrides, or oxycarbonitrides of aluminum, boron, silicon, and / or titanium), metal ceramic fibers, carbon or metal fibers (e.g., containing aluminum, copper, iron, silver, tin, or zinc, or mixtures, alloys), or coating hybrids containing these materials. Exemplary materials include fibers or whiskers of aluminum oxide, aramid, boron, carbon, glass, silicon carbide, aluminum nitride, coating hybrids, or mixtures thereof, preferably glass, carbon, or metal coated fibers. As used herein, the term "fiber" includes fibers of macro, micro, or nano size, and includes wires passing through elongated single crystals also referred to as whiskers. In some cases, these materials are composites of various material classes, for example, including carbon coated metals, glass, or polymers; metal coated polymers, carbon, or glass; polymer coated glass, carbon, or metal, etc. In some cases, the functional material is conductive. In some embodiments, the functional material imparts magnetic properties to the surfacing film.

[0074] Typically, and in a preferred embodiment, at least one second functional material porous sheet is located near but below the second surface of the curable polymer composition. The second functional material sheet has a depth in the membrane to provide: the covered curable polymer composition is thick enough to be co-cured with the substrate provided subsequently. The second functional sheet is usually located between the peelable porous sheet and the second surface in the polymer composition. In an independent embodiment, at least one second functional material porous sheet is arranged at a position of 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80% or 90% of the distance between the second surface and the peelable porous sheet. For example, in some embodiments, at least one second functional material is arranged at a position substantially equidistant between the first surface and the peelable porous sheet. The positioning of the functional material porous sheet is deliberately controlled and specific. Preferably, as described above, it is arranged in a plane substantially parallel to the first surface and the second surface of the multifunctional membrane and is arranged between these surfaces; that is, the sheet is arranged at a predetermined position in the polymer composition and is located in a plane substantially parallel to the second surface. In independent separate embodiments, the local variance of the location of the functional sheet within the surfacing film is less than 20%, 15%, 10%, 5%, 2%, or 1% of the median location within the film.

[0075] Other features

[0076] In some embodiments, in addition to the strippable porous sheet and the second functional material sheet, the multifunctional veneer film is further included in at least one particle filler in the curable polymer composition. These fillers can include nanometer size, micron size and / or large-sized particle materials, and the particle materials are substantially uniformly distributed in the whole curable polymer between the strippable porous sheet and the functional material sheet. Due to a mode of constructing these veneer films, one or more particle fillers can be concentrated between the strippable porous sheet and the functional material sheet and adjacent to it, which is produced by the screening effect of combining these sheets into the curable polymer layer. These particle fillers can include one or more any functional materials described herein, such as ceramics, polymers, glass or metal / metalloid materials or their alloys, or the hybrid materials of coating, more particularly include carbides, nitrides or oxides, carbon, copper, nickel, Sn-Zn or stainless steel or aromatic polyamides of aluminum, boron, silicon, tin, zirconium or aluminum, and composite forms thereof.

[0077] The surfacing film is designed to be sufficiently flexible / pliable to conform to a shaped or contoured substrate, including a flat or substantially flat panel, a curved contour, a surface including a convex or concave shape, or a combination thereof, at least prior to curing. The curable surface coating composition can be applied to substantially conform to the contour shape of the substrate. This feature results from a combination of the degree of cure of the curable polymer composition and the thickness of the surfacing film, both of which are described elsewhere herein.

[0078] In addition, in some embodiments, the multifunctional facial film has a total thickness in the range of 12.5-12500 microns (0.5-500 mils), preferably 12.5-1250 microns (0.5-50 mils). In other embodiments, the total thickness can be described as the following ranges: 12.5-25 microns, 25-50 microns, 50-75 microns, 75-100 microns, 100-125 microns, 125-150 microns, 150-175 microns, 175-200 microns, 200-250 microns, 250-300 microns, 300-400 microns, 400-450 microns, 500-500 microns, 500-600 microns, 500-600 microns, 500-750 microns, 500-800 microns, 500-800 microns, 500-900 microns, 500-900 microns, 500-10 ... In some embodiments, the present invention relates to a nanostructured carbon foam having a thickness of 200-2000 microns, ...

[0079] In other embodiments, the multifunctional facial mask may have a pressure of 0.005-0.15 lb. / ft. 2The weight may be defined by one or more of the following ranges: 0.005 to 0.01 psf, 0.01 to 0.015 psf, 0.015 to 0.02 psf, 0.02 to 0.025 psf, 0.025 to 0.03 psf, 0.03 to 0.035 psf, 0.035 to 0.04 psf, 0.04 to 0.045 psf, 0.045 to 0.05 psf, 0.05 to 0.055 psf, 0.055 to 0.06 psf, 0.06 to 0.065 psf, 0.065 to 0.07 psf, 0.08 to 0.10 psf, 0.08 to 0.11 psf, 0.08 to 0.12 psf, 0.09 to 0.13 psf, 0.11 to 0.14 psf, 0.09 to 0.15 psf, 0.010 to 0.16 psf, 0.011 to 0.17 psf, 0.012 to 0.18 psf, 0.013 to 0.19 psf, 0.014 to 0.19 psf 0.7 to 0.075 psf, 0.075 to 0.08 psf, 0.08 to 0.085 psf, 0.085 to 0.09 psf, 0.09 to 0.095 psf, 0.095 to 0.1 psf, 0.1 to 0.105 psf, 0.105 to 0.11 psf, 0.11 to 0.115 psf, 0.115 to 0.12 psf, 0.12 to 0.125 psf, 0.125 to 0.13 psf, 0.13 to 0.135 psf, 0.135 to 0.14 psf, 0.14 to 0.145 psf, or 0.145 to 0.15 psf. For aircraft applications, preferred ranges include the following: 0.005 to 0.01 psf, 0.005 to 0.02 psf, 0.005 to 0.03 psf, 0.005 to 0.04 psf, 0.005 to 0.05 psf, or 0.005 to 0.06 psf, or some combination of two or more of these ranges.

[0080] The relative amounts of curable polymer and porous sheet are not necessarily critical, as long as the amounts of each are sufficient for each to achieve its respective purpose. However, in some embodiments, the ratio of the thickness of the curable polymer to the total thickness of the porous sheet is 10:1 to 8:1, 8:1 to 6:1, 6:1 to 5:1, 5:1 to 4:1, 4:1 to 2:1, 2:1 to 1:1, or 1:1 to 0.5:1, or the ratio is characterized by two or more of these ranges, such as 10:1 to 0.5:1.

[0081] In an independent embodiment, the multifunctional surfacing film comprises at least one releasable liner on the first surface, the second surface, or on both the first surface and the second surface. One or both of these releasable liners can be made of a cellulose film or a plastic film (e.g., paper, polyethylene, or polyester film). Such a liner is provided to protect the film and facilitate its handling and / or prevent reactions between adjacent layers on a roll or stack during manufacture, transportation, or application / use.

[0082] As described above, the multifunctional surfacing films may include curable, partially cured, and fully cured polymer compositions. In separate embodiments, these films may be physically contacted, physically attached to, or co-cured with other substrates, including laminate substrates, optionally wherein the substrate is a laminate, and optionally wherein the substrate is part of an aircraft or motor vehicle.

[0083] Method of applying a multifunctional surfacing film to a substrate

[0084] To this end, the present disclosure has highlighted some of the characteristics of the multifunctional surfacing films themselves, but the present invention also contemplates methods of making and using these surfacing films. As described elsewhere, it should be understood that the various features associated with the surfacing films also apply to both these methods and manufacture, and the comments / characteristics of the surfacing films also apply to the methods of making and using these surfacing films without the need to repeat them in the corresponding parts of the present disclosure.

[0085] These surfacing films can be applied to preformed structures (e.g. Figure 2 ), or can be used with a tool / mold on which the structure is constructed (e.g. Figure 3 ). In either case, it is desirable that the second surface of the surfacing film physically contacts and becomes attached to the final structure. This results in the first surface being disposed on the outside of the article or structure to which the film is attached as the outer surface layer of the article, and the second functional material sheet being attached to the structure beneath the first peelable porous sheet (i.e., inside the first peelable porous sheet), so that the first peelable porous sheet can subsequently be removed to provide an exposed first surface, leaving one or more second functional material sheets attached to the structure with the remainder of the surfacing film.

[0086] Thus, certain embodiments provide methods of providing functionality to a substrate surface, some methods comprising:

[0087] (a) applying a multifunctional surfacing film to a substrate surface by physically attaching the second surface of the multifunctional surfacing film to the substrate surface to form an intermediate bonded composition;

[0088] (b) subjecting the intermediate bonding composition to conditions sufficient to allow at least one optionally curable substrate (preferably a polymer composition) and the curable polymer composition of the multifunctional surfacing film to co-cure or otherwise bond, and thereby form a permanent bond therebetween. The "intermediate bonding composition" may be characterized by a bond ranging from merely physical contact, through slight adhesion due to the stickiness of one or both surfaces, to actual chemical bonding; although in a preferred embodiment, full bonding is not achieved until the composition is co-cured. The "permanence" of the bonding of the co-cured structure reflects that the adhesion of the bond between the cured substrate and the cured surfacing film is preferably of the same magnitude as the cohesive force of the cured surfacing film, the cured substrate, or both. In some embodiments, the resulting bond should be sufficient to exhibit a lap shear strength greater than or equal to 10 MPa (1450 psi) (according to ASTM D1002 or D5868).

[0089] In some embodiments, the substrate is a fiber reinforced composite part.The substrate may also include at least one of the following: a curable polymer matrix composition, reinforcing fibers impregnated with a curable polymer matrix, a honeycomb core, an expandable membrane, a potting compound, or a metal or ceramic surface.

[0090] In some embodiments, the substrate is a shaped structure that comprises or at least presents a surface of a polymer composition that is the same as or complementary to the curable polymer composition of the surfacing film, as described elsewhere herein.The substrate may be a laminate.

[0091] In other embodiments, the method comprises:

[0092] (a) applying the multifunctional surfacing film to the tool / mold surface by physically placing a first surface of the multifunctional surfacing film in contact with the mold surface and conforming the multifunctional surfacing film to the mold surface, leaving a second surface of the multifunctional surfacing film exposed;

[0093] (b) physically attaching at least one layer of an optionally co-curable substrate (optionally a film) to the second surface of the multifunctional surfacing film to form an intermediate bonded composition;

[0094] (c) subjecting the intermediate bonded composition to conditions sufficient to allow the curable polymer composition of at least one curable substrate and the multifunctional surfacing film to co-cure or otherwise bond, and thereby forming a bond therebetween and producing a functionalized co-cured or bonded structure. In such embodiments, it is generally preferred that a releasable liner and / or a release agent is between the mold surface and the first surface of the multifunctional surfacing film to assist in the subsequent removal of the product structure. The term "optionally co-curable" refers to the fact that the associated substrate film may or may not be curable so that the bonding mechanism is not co-cured, in the latter case, for example, the substrate film may be a thermoplastic polymer (e.g., PEEK or PEKK) or a ceramic or metal layer, in which case other adhesives may be used to secure the bond.

[0095] In either method or both methods, the conditions sufficient to allow co-curing include exposing the intermediate composition to enough heat or radiation conditions to co-cure the curable polymer composition of the substrate and the curable polymer composition of the multifunctional surfacing film, thereby forming a permanent bond therebetween. Such conditions depend on the specific material selected, and those skilled in the art will be able to determine the optimum conditions for forming such a bonding interface. Exemplary methods that can be used for co-curing materials include thermal curing or radiation curing, such as are commonly used for the material in question. The nature of the bonding between the co-cured substrate polymer and the multifunctional surfacing film depends on several factors, including the nature of processing conditions and individual components, ranging from mainly or completely physical to mainly or completely chemical. Those skilled in the art will understand those materials and processing conditions necessary for realizing the desired combination between substrate and surfacing film.

[0096] After the functionalized co-cured structure is prepared, and at a time selected by the user, the first peelable porous sheet can be removed from the cured composition to leave the exposed first surface of the cured polymer composition of the multifunctional surfacing film. Typically, this removal is carried out by stripping to leave a residual cured surfacing film comprising a second functional material on the substrate, wherein the exposed first surface serves as the site for paint application. It is desirable that, before applying an additional layer, it is rarely or almost not necessary (seldom present or almost not present) to sand, prime or other surface treatments are applied to the exposed new first surface. As a non-limiting example, it is preferred to add a surface treatment or primer paint less than 1000, 500, 100, 50, 10, 5 or 1 micron and / or before applying an additional surface finishing / decoration (e.g., paint) layer, the cured polymer composition is removed from the exposed new first surface. Depending on the predetermined depth of the first peelable porous sheet in the membrane or the nature of the fabric, removing the peelable porous sheet removes about 5wt% and about 60wt% of the pre-cured area weight of the multifunctional membrane and about 10wt% to 50wt% of the cured polymer composition, or as otherwise described herein. Incremental wt% ranges are considered to be additional embodiments, such as 5 to 10wt%, 10 to 15wt%, 15 to 20wt%, 20 to 25wt%, 25 to 30wt%, 30 to 35wt%, 35 to 40wt%, 40 to 45wt%, 45 to 50wt%, 50 to 55wt%, 55 to 60wt%, or two or more of these ranges. Desirably, at least one optional porous sheet of the second functional material is positioned in the multifunctional surfacing membrane so that after removing the first porous peelable sheet, it remains covered by the remaining cured surfacing membrane, preferably evenly covered, and most preferably covered by the remaining cured surfacing membrane of a selected thickness. Obtaining the desired surface suitable for painting without further treatment depends (at least in part) on the smoothness of the weave or surface of the fabric or film used for the first porous peelable sheet. It is also important that the peelable porous sheet exhibits sufficient structural integrity so that when it is removed from the cured surfacing film, it can be removed without leaving individual filament strands. Preferably the surface is free; desirably substantially free (meaning less than 5%, preferably 1%) of individual filament strands of the fabric or film.

[0097] In a particular embodiment, removing the first peelable porous sheet after curing the surfacing film provides an exposed first surface suitable for painting without additional surface conditioning or treatment. When some fabric strands are left, they can be removed by slight abrasion. Other embodiments include additional steps of applying such paint or other filled or unfilled or clear coating finishes, and the resulting articles. In some embodiments, the exposed first surface is suitable for painting without the need for a primer coating. Features associated with these suitability include an exposed first surface having an average surface roughness (e.g., from fabric indentation) (Ra) in the range of about 5 nm to about 50 microns, which can also be characterized as having an average surface roughness in one or more of the following ranges: 5 nm to 10 nm, 10 nm to 25 nm, 25 nm to 50 nm, 50 nm to 75 nm, 75 nm to 100 nm (0.1 micron), 0.1 micron to 0.25 micron, 0.25 micron to 0.5 micron, 0.5 micron to 0.75 micron, 0.75 micron to 1 micron, 1 micron to 2 microns, 2 microns to 3 microns, 3 microns to 4 microns, or 4 microns to 5 microns. One such exemplary range includes, for example, 0.1 micron to 3 microns. The term "suitable for painting" means that the resulting paint coating exhibits paint adhesion to the exposed first surface having a rating of at least 3, preferably at least 4, and more preferably at least 5 as measured by ASTM D3359, when applied and / or after stressing or both. Such stresses include one or more of: thermal cycling (e.g., 800 cycles from -65°C to +160°F), exposure of exposed surfaces to UV, water immersion and / or extreme temperature exposure, salt or acid spray exposure after application of paint (with or without primer) as described in ASTMs B117, B287, D7869, F483, F1110.

[0098] The method for applying the paint is not limited to any particular manner, although spraying is generally used to allow smooth coverage over large areas, or by using decals. Similarly, the choice of paint is not restrictive, as long as the paint is compatible with the final surface composition. Preferred paints are those comprising polyacrylates, polyesters, polymethacrylates, polyurethanes, or copolymers or mixtures thereof. Depending on the properties of the selected paint, the bonding of the paint to the exposed surface can be physical or chemical, or both. Compared with the first surface, the post-curing removal of the peelable sheet causes the exposed surface to have a larger contact surface area, which promotes physical paint adhesion. It is then expected that the exposed surface is exposed to a higher concentration of chemical groups that promote paint adhesion, compared to the chemical groups that would be present without the method herein. As a result, it is also expected that the increased chemical interaction between the exposed surface and the paint will easily lead to a more complete bonding, thus resulting in the need to eliminate a primer.

[0099] One of the many advantages of the present invention is that the co-cured surfacing film can remain on the substrate throughout the manufacturing and assembly process to protect the component from contaminants and chemical / environmental exposure, particularly exposure to UV sources, until the component is ready for painting or other surface coating. In some embodiments, it is preferred to minimize the amount of cured material removed with the peelable sheet so that the remaining cured surfacing material can continue to protect the composite component through continued processing during its life.

[0100] For this reason, various embodiments have been described for the method for preparing and / or using the multifunctional veneer film and the veneer film itself. It should also be understood that the various intermediate structures described herein are considered to be within the scope of the present disclosure, as separate embodiments, as products. Various embodiments of the present invention also include those products produced by the method described herein. The present invention is applicable to structures of any size, but is particularly attractive in terms of its ability to accommodate large structures. It is envisioned that such objects produced using the method described herein are included within the scope of the present invention. The envisioned structure includes those that can be any one or more of the following: the main structural elements, secondary structural elements, external elements, internal elements and the parts forming these elements in commercial and personal aircraft and aerospace applications, motor vehicles, watercraft (including ships), rail cars, tankers, storage tanks and wind turbines. It can also be used to prepare smaller articles, including but not limited to sports equipment (e.g., fishing rods, bicycle racks, etc.). When containing such partially or completely cured multifunctional films, each of these structures is considered to be a separate embodiment of the present disclosure.

[0101] Method for preparing multifunctional facial mask

[0102] Additional embodiments include those methods for making the multifunctional facial films described herein. Figure 4 and Figure 5 Two representations of examples of such methods are provided. One such method comprises:

[0103] (a) continuously depositing a curable polymer composition (410, 510) onto a surface of a releasable liner (440, 540) to form a cast polymer composition having a first surface in contact with the releasable liner and a second surface opposite to the first surface;

[0104] (b) arranging, laying or otherwise positioning a first peelable porous sheet (420, 520) in the cast polymer composition while continuously depositing the curable polymer (410, 510), preferably pressing (e.g., by pressing rollers (480, 580)) the first peelable porous sheet into the first surface of the cast curable polymer composition so that the peelable porous sheet is positioned at, adjacent to, at or below the first surface of the curable polymer composition and below the releasable liner,

[0105] (c) while continuously depositing the curable polymer, providing at least one second functional material, optionally porous sheet (430, 530) positioned relative to the second surface, such as using a press roller (470, 570), such that the at least one second functional material, optionally porous sheet (430, 530) is at least partially embedded in the cast polymer composition at a selected distance from the second surface;

[0106] (d) optionally providing a second releasable liner adjacent to the second surface of the multifunctional surfacing film.

[0107] In such methods, after the peelable porous sheet is pressed into the first surface of the curable polymer composition, at least one second functional material porous sheet becomes at least partially embedded in the cast polymer composition below the second surface. The immersion depth is (at least in part) controlled to a predetermined depth by the viscosity of the curable polymer composition (which depends at least in part on the temperature, the specific polymer composition, and the degree of cure in the polymer composition), the porosity of the interlayer sheet, and the pressure applied by a separate pressing roller used to press the interlayer sheet into the curable polymer composition.

[0108] In a related embodiment, the one or more methods further include passing the multifunctional surfacing film between at least one pair of non-porous rollers (480, 580), which non-porous rollers optionally include a non-porous lining, and further embedding at least one second functional material porous sheet (430, 530), a peelable porous sheet (420, 520), or at least one second functional material porous sheet and a peelable porous sheet in the cast curable polymer composition, each at a preselected distance from a corresponding surface of the curable polymer composition.

[0109] During or after forming the surfacing film, the second releasable liner can also be provided to the first surface of the surfacing film. In addition, once formed, film can be wound into the volume (spooled rolls) of winding on winder (400,500) for transportation and handling. The film prepared in this way is limited in its area size only by the property of the equipment for preparing them, and the standard width of these equipments comprises 30cm, 60cm, 90cm, 120cm all the way up to 200cm. In some embodiments, this standard width roll can be further cut into narrower width based on different applications, and it can be as small as 0.5cm. These comprise the automatic fiber processing (AFP) that can use 0.5 to 5cm width and the automatic tape laying (ATL) that can use 5 to 50cm width and other width combinations applied by other means. Similarly, the length of film can be tens of meters to hundreds of meters.

[0110] The following list of implementations is intended to supplement, not replace or substitute for, the previous descriptions:

[0111] Embodiment 1. A multifunctional facial mask, comprising:

[0112] (a) a single layer of a curable polymer composition having opposing first and second surfaces;

[0113] (b) a first peelable porous sheet disposed at or below the first surface; and

[0114] (c) at least one second functional material porous sheet disposed within the curable polymer composition monolayer below the second surface and between the second surface and the peelable porous sheet.

[0115] Embodiment 2. The multifunctional surfacing film according to embodiment 1, wherein the curable polymer composition comprises a thermosetting composition, a thermoplastic composition, or a mixture or blend thereof.

[0116] Embodiment 3. The multifunctional surfacing film according to any one of embodiments 1 or 2, wherein the curable polymer composition comprises a monomer, an oligomer or a polymer of the curable polymer composition.

[0117] Embodiment 4. A multifunctional surfacing film according to any one of embodiments 1 to 3, wherein the curable polymer composition comprises benzoxazine, bismaleimide, epoxy resin, (meth)acrylate, (meth)acrylamide, polyamide, polyester, polyimide, polyurethane, vinyl ester, or a copolymer or mixture thereof.

[0118] Embodiment 5. The multifunctional surfacing film according to any one of embodiments 1 to 4, wherein the curable polymer composition comprises an epoxy resin.

[0119] Embodiment 6. The multifunctional surfacing film according to any one of embodiments 1 to 5, wherein the polymer composition can be cured by applying (UV, visible light or infrared) light or heat. In some aspects of this embodiment, the supplementary resin and / or catalyst can be mixed immediately before bonding the interlayer peelable and functional sheets and cured by free radical methods.

[0120] Embodiment 7. A multifunctional surfacing film according to any one of embodiments 1 to 6, having a total thickness in the range of 25-12500 microns (1 to 500 mils), preferably in the range of 25 to 500 microns or 50 to 300 microns, or characterized by any one or more of these ranges described elsewhere herein.

[0121] Embodiment 8. The multifunctional surfacing film according to any one of embodiments 1 to 7, wherein the peelable porous sheet [within the monolayer of the curable polymer composition] is below the first surface.

[0122] Embodiment 9. The multifunctional surfacing film according to any one of embodiments 1 to 8, wherein the peelable porous sheet comprises a fabric or an expanded film, a perforated film or a mesh film.

[0123] Embodiment 10. The multifunctional surfacing film according to any one of embodiments 1 to 9, wherein the peelable porous sheet has one or more of the following properties:

[0124] (a) the peelable porous sheet comprises a fluorinated or perfluorinated polymer, polyester, polyamide, polyethylene, polypropylene, polyurethane, polyethylene naphthalate, polyethylene terephthalate, polybutylene terephthalate, polyetheretherketone, polyaryletherketone, polyethersulfone, polyethyleneimine, polyphenylene sulfide, polyacrylate, polymethacrylate, polyvinyl halide or a copolymer or mixture thereof;

[0125] (b) adhering (preferably embedding) the releasable porous sheet to, and most preferably embedding within, a curable polymer composition at a selected distance from the first surface by positioning or physically embedding a fabric or expanded film on or in the first surface, with or without a separate curable adhesive resin composition;

[0126] (c) the peelable porous sheet has a thickness in the range of 25-250 microns, preferably in the range of 40-125 microns [in the range of 5 microns to 500 microns];

[0127] (d) the peelable porous sheet has a nominal pore size in the range of 0.25-250 μm, preferably 1-70 μm;

[0128] (e) when tested according to ASTM-D5034, the peelable porous sheet exhibits a tensile strength in the range of 100N to 1500N, preferably 400N to 1000N;

[0129] (f) the peelable porous sheet is an expansion membrane;

[0130] (g) the peelable porous sheet is a woven fabric;

[0131] (h) the peelable porous sheet is a woven fabric comprising a woven monofilament tow or a woven multifilament tow;

[0132] (i) the peelable porous sheet is a woven fabric comprising a plain weave, a heald satin weave, a wrinkle satin weave, a tear-resistant weave or a twill weave;

[0133] (j) the peelable porous sheet is a woven fabric comprising monofilament or multifilament / twisted yarns, wherein the yarns have a flat or textured surface and a maximum dimension of 200 denier;

[0134] (k) the peelable porous sheet is a woven fabric having at least 50 warp yarns / inch and at least 40 weft yarns / inch or having at least 120 warp yarns / inch and at least 60 weft yarns / inch, and / or the fabric contains yarns having a minimum of 40 yarns / inch in the warp and weft directions, the yarns having a maximum of 150 denier in the warp or weft directions; and / or

[0135] (1) The peelable porous sheet is a woven fabric that can be rubbed, heat-set, and calendered to produce a smooth, tightly woven surface.

[0136] In certain aspects of this embodiment, removal of the peelable porous sheet from the cured surfacing film provides an exposed surface suitable for painting without the need for additional surface conditioning or treatment or priming; in these aspects, the resulting exposed surface provides many of the advantages and properties as described elsewhere herein.

[0137] Embodiment 11. The multifunctional surfacing film according to any one of embodiments 1 to 10, wherein at least one second functional material porous sheet is in the form of a porous woven or nonwoven fabric, expanded metal foil or perforated polymer film, grid, mesh, screen or mesh.

[0138] Embodiment 12. A multifunctional surfacing film according to any one of embodiments 1 to 11, wherein at least one second functional material porous sheet exhibits performance characteristics suitable for use as an impact modifier, heat transfer medium, EMI shielding material, lightning strike protection, electrostatic current dissipation, or a combination thereof.

[0139] Embodiment 13. A multifunctional facial film according to any one of embodiments 1 to 12, wherein the optional at least one functional material porous sheet has one or more of the following properties:

[0140] (a) at least one porous sheet of functional material comprising woven or non-woven fibers or filaments, such as continuous or chopped fibers or whiskers including alumina, aramid, boron, carbon, glass, metal, polymer, silicon carbide, aluminum nitride or hybrids and mixtures thereof, preferably glass, carbon and / or metal coated fibers; and a perforated polymer sheet which may or may not have been previously pyrolyzed;

[0141] (b) at least one porous sheet of functional material is electrically conductive;

[0142] (c) at least one porous sheet of functional material comprises aluminum, carbon, copper, nickel, silver or stainless steel;

[0143] (d) at least one porous sheet of functional material comprises polyacrylonitrile, and / or

[0144] (e) at least one porous sheet of a second functional material is positioned closer to the second surface than the peelable porous sheet within the curable polymer composition; in an independent embodiment, at least one porous sheet of a functional material is positioned at 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80% or 90% of the distance between the second surface and the peelable porous sheet.

[0145] Embodiment 14. The multifunctional surfacing film according to any one of embodiments 1 to 13, wherein the curable polymer composition further comprises at least one particulate filler. The multifunctional surfacing film according to any one of embodiments 1 to 13, wherein the curable polymer composition further comprises at least one filler or additive, which is organic, inorganic or a hybrid of the two, a polymer toughening component, or a particulate filler such as reinforcing fibers, conductive materials, and thixotropic agents.

[0146] Embodiment 15. The multifunctional facial mask according to embodiment 15, wherein at least one particulate filler or additive comprises nano-sized, micro-sized and / or macro-sized powders, particles, beads, flakes, whiskers or fibers or liquid blends.

[0147] Embodiment 16. A multifunctional veneer according to embodiment 14 or 15, wherein at least one filler or additive comprises ceramics, pre-reacted polymers, glass, metals or alloys, and hybrid compounds; for example, carbides, nitrides or oxides of aluminum, boron, silicon, tin, zirconium; or elemental aluminum, carbon, copper, nickel, Sn / Zn, or stainless steel; or reactive liquid rubber polymers, core-shell particles or thermoplastic polymers; or silver-coated glass flakes, carbon-coated glass beads or silver-coated aluminum particles.

[0148] Embodiment 17. The multifunctional surfacing film according to any one of embodiments 14 to 16, wherein at least one particulate filler or additive is substantially uniformly dispersed throughout the curable polymer. In certain aspects of this embodiment, the particulate filler is concentrated between and / or adjacent to the peelable porous sheet and the functional material porous sheet, which is caused by the sieving effect that combines these layers into the curable polymer layer.

[0149] Embodiment 18. The multifunctional surfacing film according to any one of embodiments 1 to 17, wherein the curable polymer composition comprises a UV resistant polymer (as described in US 2010 / 0151239) or a UV stabilizing additive (as described in US Pat. No. 9,676,961) positioned at the second surface.

[0150] Embodiment 19. The multifunctional surfacing film according to any one of embodiments 1 to 18, which is sufficiently pliable / flexible to conform to a shaped or contoured substrate.

[0151] Embodiment 20. The multifunctional surfacing film according to any one of embodiments 1 to 19, having a total area weight in the range of 0.010-0.150 lbs / ft2, preferably less than 0.060 lbs / ft2, or provided within any range as described elsewhere herein.

[0152] Embodiment 21. The multifunctional surfacing film according to any one of embodiments 1 to 20, wherein the first surface contacts the surface of a substrate. The substrate may comprise at least one of the following: a curable or cured polymer matrix composition, reinforcing fibers impregnated with a curable or cured polymer matrix, a honeycomb core, an expandable membrane, a potting compound, a ceramic, or a metal.

[0153] Embodiment 22. The multifunctional surfacing film according to any one of embodiments 1 to 21, wherein the polymer composition is cured.

[0154] Embodiment 23. The multifunctional surfacing film according to embodiment 22, wherein the polymer composition is co-cured to the surface of the substrate so that a chemical bond is formed between the substrate and the multifunctional surfacing film.

[0155] Embodiment 24. A method of providing functionality to a substrate surface, the method comprising:

[0156] (a) applying a multifunctional surfacing film to a substrate surface (the substrate surface comprising at least one curable substrate polymer composition) by physically attaching the second surface of the multifunctional surfacing film according to any one of embodiments 1 to 20 to the substrate surface to form an intermediate bonded composition;

[0157] (b) subjecting the intermediate bonding composition to conditions sufficient to allow at least one curable (or cured) substrate polymer (or other disclosed substrate) composition and the curable polymer composition of the multifunctional surfacing film to co-cure or otherwise bond, thereby forming a bond therebetween.

[0158] Embodiment 25. A method of providing functionality to a substrate surface, the method comprising:

[0159] (a) applying a multifunctional surfacing film to a mold surface (the substrate surface comprises at least one curable substrate polymer composition) by physically placing the first surface of the multifunctional surfacing film according to any one of claims 1 to 20 onto the mold surface and conforming the multifunctional surfacing film to the mold surface, thereby exposing the second surface of the multifunctional surfacing film;

[0160] (b) physically attaching at least one layer of an optionally co-curable substrate film to the second surface of the multifunctional surfacing film to form an intermediate bonded composition;

[0161] (c) subjecting the intermediate bonding composition to conditions sufficient to allow the at least one optionally curable base polymer composition and the curable polymer composition of the multifunctional surfacing film to co-cure or otherwise bond and thereby form a bond therebetween.

[0162] Embodiment 26. The method of embodiment 25, wherein a releasable liner is interposed between the mold surface and the first surface of the multifunctional surfacing film.

[0163] Embodiment 27. A method according to any one of embodiments 24 to 26, wherein the conditions sufficient to allow co-curing include exposing the intermediate composition to sufficient heat or radiation conditions to co-cure or otherwise bond the optionally curable polymer (or other substrate) composition and the multifunctional surfacing film of the substrate to form a bond therebetween.

[0164] Embodiment 28. The method of any one of embodiments 24 to 27, further comprising removing the peelable porous sheet from the co-cured structure to leave an exposed surface of the cured polymer composition of the multifunctional surfacing film. In some aspects of this embodiment, post-curing weight reduction is achieved by removing the peelable sheet from the composite structure.

[0165] Embodiment 29. The method of embodiment 28, further comprising painting the exposed surface without additional surface conditioning or treatment. In some aspects of this embodiment, the painted surface exhibits desirable paint adhesion properties according to ASTM D1654 even without a primer coating and / or after exposure to a harsh environment.

[0166] Embodiment 30. A method for manufacturing a multifunctional facial mask, comprising:

[0167] (a) continuously depositing a curable polymer composition onto a surface of a release liner to form a cast polymer composition having a first surface in contact with the release liner and a second surface opposite the first surface;

[0168] (b) while continuously depositing the curable polymer, imprinting a releasable porous sheet into the first surface of the cast curable polymer composition such that the releasable porous sheet is located at or below the first surface of the curable polymer composition below the release liner,

[0169] (c) while continuously depositing the curable polymer, optionally providing at least one porous sheet of a second functional material positioned relative to the second surface such that the at least one porous sheet of a second functional material becomes at least partially embedded in the cast polymer composition at a selected distance from the second surface;

[0170] (d) optionally providing a second releasable liner adjacent to the second surface of the multifunctional surfacing film. In particular aspects of this embodiment, at least one porous sheet of a second functional material is provided and positioned relative to the second surface.

[0171] Embodiment 31. The method of embodiment 30, wherein after imprinting the first peelable porous sheet into the second surface of the curable polymer composition, at least one second functional material porous sheet becomes at least partially embedded in the cast polymer composition.

[0172] Embodiment 32. The method of embodiment 29 or 30, further comprising passing the multifunctional surfacing film between at least one pair of non-porous rollers, further embedding the at least one second functional material porous sheet, the strippable porous sheet, or both the at least one functional material porous sheet and the strippable porous sheet in or within the cast curable polymer composition at a preselected distance from the respective surface, each at a preselected distance from the respective surface of the curable polymer composition. In certain aspects of this embodiment, the multifunctional film is further wound into a wound roll.

[0173] Embodiment 33. The method of embodiment 32, wherein the non-porous roller comprises a non-porous liner.

[0174] Embodiment 34. The method of any one of embodiments 30 to 33, further comprising partially curing (B-staging) the curable polymer composition.

[0175] Embodiment 35. The method according to any one of embodiments 30 to 33 further comprises winding the multifunctional film into a wound roll, wherein the wound multifunctional film roll is further cut into a specific target width as needed for use with dedicated automated equipment in the process of manufacturing a composite structure.

[0176] Embodiment 36. The slit multifunctional film roll of embodiment 35, used according to the method of any one of claims 24 to 26 together with automatic equipment specially designed for manufacturing composite structures, such as automatic fiber processing (AFP) machines and automatic tape laying (ATL) machines.

[0177] As those skilled in the art will appreciate, numerous modifications and variations of the present invention are possible in light of these teachings, and all are contemplated herein.

[0178] The disclosures of each patent, patent application, and publication cited or described in this document are incorporated herein by reference in their entirety, or at least for the purposes of their teachings in the context in which they are cited.

Claims

1. A multifunctional facial mask, comprising: (a) a single layer of a curable polymer composition having opposing first and second surfaces; (b) a first peelable porous sheet disposed within the curable polymer composition monolayer and located a predetermined and controlled distance below the first surface, the first peelable porous sheet comprising a fabric or an expanded film, a perforated film or a mesh film; and (c) at least one second functional material porous sheet, which is arranged in the single layer of the curable polymer composition and is located between the second surface and the peelable porous sheet, and the at least one second functional material porous sheet is in the form of a porous woven or non-woven fabric, an expanded metal foil or a polymer film, a grid, a net, a screen or a woven mesh.

2. The multifunctional surfacing film according to claim 1, wherein the curable polymer composition comprises a thermosetting composition, a thermoplastic composition, or a mixture or blend thereof.

3. The multifunctional surfacing film according to claim 1 or 2, wherein the curable polymer composition comprises a monomer, an oligomer or a polymer of the curable polymer composition.

4. The multifunctional surfacing film according to claim 1, wherein the curable polymer composition comprises benzoxazine, bismaleimide, epoxy resin, acrylate, methacrylate, acrylamide, methacrylamide, polyamide, polyester, polyimide, polyurethane, vinyl ester, or a copolymer or mixture thereof.

5. The multifunctional surfacing film according to claim 1, wherein the curable polymer composition comprises an epoxy resin.

6. The multifunctional surfacing film according to claim 1, wherein the curable polymer composition can be cured by applying light or heat.

7. The multifunctional surfacing film according to claim 1, wherein the curable polymer composition can be cured by applying UV, visible light or infrared light.

8. The multifunctional facial film according to claim 1 or 2, having a total thickness in the range of 25 micrometers to 12500 micrometers.

9. The multifunctional surfacing film according to claim 1 or 2, wherein the fabric or expanded membrane has one or more of the following properties: The peelable porous sheet has one or more of the following properties: (a) the peelable porous sheet comprises a fluorinated or perfluorinated polymer, polyester, polyamide, polyethylene, polypropylene, polyurethane, polyethylene naphthalate, polyethylene terephthalate, polybutylene terephthalate, polyetheretherketone, polyaryletherketone, polyethersulfone, polyethyleneimine, polyphenylene sulfide, polyacrylate, polymethacrylate, polyvinyl halide, or a copolymer or mixture thereof; (b) attaching a peelable porous sheet to a first surface by physically embedding a fabric or an expanded membrane onto or into the first surface with or without a separate curable adhesive resin composition; (c) the peelable porous sheet has a thickness in the range of 25-250 microns; (d) the peelable porous sheet has a nominal pore size in the range of 0.25-250 microns; (e) the peelable porous sheet exhibits a tensile strength in the range of 100 N to 1500 N when tested according to ASTM-D5034; (f) the peelable porous sheet is an expansion membrane; (g) the peelable porous sheet is a woven fabric; (h) the peelable porous sheet is a woven fabric comprising a woven monofilament tow or a woven multifilament tow; (i) the peelable porous sheet is a woven fabric comprising a plain weave, a heddle satin weave, a wrinkle satin weave, a tear-resistant weave or a twill weave; (j) the peelable porous sheet is a woven fabric comprising monofilament or multifilament / twisted yarns, wherein the yarns have a flat or textured surface and a maximum dimension of 200 denier; (k) the peelable porous sheet is a woven fabric having at least 50 warp yarns / inch and at least 40 weft yarns / inch or having at least 120 warp yarns / inch and at least 60 weft yarns / inch, and / or the fabric contains yarns having a minimum of 40 yarns / inch in the warp and weft directions, the yarns having a maximum of 150 denier in the warp or weft directions; and / or (l) The peelable porous sheet is a woven fabric that can be scoured, heat-set and calendered to produce a smooth, tightly woven surface.

10. The multifunctional surfacing film according to claim 9, wherein the peelable porous sheet has a thickness in the range of 40-125 microns.

11. The multifunctional surfacing film according to claim 9, wherein the peelable porous sheet has a nominal pore size in the range of 1-70 microns.

12. The multifunctional surfacing film according to claim 9, wherein the peelable porous sheet exhibits a tensile strength ranging from 400N to 1000N when tested according to ASTM-D5034.

13. The multifunctional surfacing film according to claim 1 or 2, wherein the at least one second functional material porous sheet exhibits performance characteristics suitable for use as an impact modifier, a heat transfer medium, an EMI shielding material, lightning strike protection, electrostatic current dissipation, or a combination thereof.

14. The multifunctional surfacing film according to claim 1 or 2, wherein the at least one functional material porous sheet has one or more of the following properties: (a) the at least one second functional material porous sheet comprises woven or non-woven fibers; and a perforated polymer sheet which may or may not be pre-pyrolyzed; (b) the at least one second functional material porous sheet is electrically conductive; (c) the at least one porous sheet of functional material comprises aluminum, carbon, copper, nickel, silver or stainless steel; (d) the at least one second functional material porous sheet comprises polyacrylonitrile, polyaniline, polypyrrole, polythiophene, or a copolymer or mixture thereof; and / or (e) the at least one second functional material porous sheet is positioned closer to the second surface than the strippable porous sheet within the curable polymer composition; in an independent embodiment, the at least one second functional material porous sheet is arranged at a position of 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80% or 90% of the distance between the second surface and the strippable porous sheet.

15. The multifunctional surfacing film according to claim 14, wherein the at least one second functional material porous sheet comprises continuous or chopped fibers or whiskers of alumina, aromatic polyamide, boron, carbon, glass, metal, polymer, silicon carbide, aluminum nitride or hybrids and mixtures thereof.

16. The multifunctional surfacing film according to claim 14, wherein the at least one second functional material porous sheet comprises continuous or chopped fibers or whiskers of glass, carbon and / or metal coated fibers.

17. The multifunctional surfacing film according to claim 1 or 2, wherein the curable polymer composition further comprises at least one filler or additive, organic, inorganic or a hybrid of the two, a polymer toughening component, or a particulate filler.

18. The multifunctional surfacing film according to claim 17, wherein the particle filler is a reinforcing fiber, a conductive material or a thixotropic agent.

19. The multifunctional facial mask of claim 17, wherein the at least one particulate filler or additive comprises nano-sized, micro-sized and / or macro-sized powders, particles, beads, flakes, whiskers or fibers or liquid blends.

20. The multifunctional facial film of claim 17, wherein the at least one particulate filler comprises a ceramic, a polymer, a glass, or a metal / metalloid material or an alloy thereof.

21. The multifunctional facial film according to claim 20, wherein at least one of the particle fillers comprises aluminum, boron, silicon, tin, zirconium, or aluminum carbide, nitride or oxide, carbon, copper, nickel, Sn-Zn, or stainless steel, or aromatic polyamide.

22. The multifunctional surfacing film of claim 17, wherein the at least one particulate filler or additive is substantially uniformly dispersed throughout the curable polymer.

23. The multifunctional surfacing film according to claim 1 or 2, wherein the curable polymer composition comprises a UV-resistant polymer or a UV-stabilizing additive located on the second surface.

24. The multifunctional facial film of claim 1 or 2, being sufficiently pliable / flexible to conform to a shaped or contoured substrate.

25. The multifunctional surfacing film of claim 1 or 2, having an area weight of less than 0.150 pounds per square foot.

26. The multifunctional facial film according to claim 1 or 2, wherein the second surface thereof contacts the surface of the substrate.

27. The multifunctional surfacing film according to claim 1 or 2, wherein the curable polymer composition is cured.

28. The multifunctional surfacing film of claim 27, wherein the curable polymer composition is co-cured or otherwise bonded to the surface of a substrate such that a chemical bond is formed between the substrate and the multifunctional surfacing film.

29. A method of providing functionality to a substrate surface, the method comprising: (a) applying the multifunctional surfacing film to the substrate surface, optionally comprising at least one curable substrate polymer composition, by physically attaching the second surface of the multifunctional surfacing film according to any one of claims 1 to 28 to the substrate surface to form an intermediate bonded composition; (b) subjecting said intermediate bonding composition to conditions sufficient to allow said at least one optionally curable substrate composition and said curable polymer composition of said multifunctional surfacing film to co-cure and thereby form a bond therebetween.

30. The method of claim 29, wherein the curable substrate composition is a polymer composition.

31. A method according to claim 29 or 30, wherein the conditions sufficient to allow co-curing include exposing the intermediate bonding composition to sufficient heat or radiation conditions to co-cure or otherwise bond the optionally curable polymer composition of the substrate and the multifunctional surfacing film to form a bond therebetween.

32. The method of claim 29 or 30, further comprising removing the peelable porous sheet from the co-cured structure to leave an exposed surface of the cured polymer composition of the multifunctional surfacing film.

33. A method of providing functionality to a substrate surface, the method comprising: (a) applying the multifunctional surfacing film to a mold surface by physically placing the first surface of the multifunctional surfacing film according to any one of claims 1 to 28 onto the mold surface and adapting the multifunctional surfacing film to the mold surface, leaving the second surface of the multifunctional surfacing film exposed; (b) physically attaching at least one layer of an optionally co-curable substrate film to the second surface of the multifunctional surfacing film to form an intermediate bonded composition; (c) subjecting said intermediate bonding composition to conditions sufficient to allow said at least one optionally curable substrate composition and said curable polymer composition of said multifunctional surfacing film to co-cure or bond and thereby form a bond therebetween.

34. The method of claim 33, wherein the curable substrate composition is a polymeric composition.

35. The method of claim 33 or 34, wherein a releasable liner is interposed between the mold surface and the first surface of the multifunctional surfacing film.

36. A method according to claim 33 or 34, wherein the conditions sufficient to allow co-curing include exposing the intermediate bonding composition to sufficient heat or radiation conditions to co-cure or otherwise bond the optionally curable polymer composition of the substrate and the multifunctional surfacing film to form a bond therebetween.

37. The method of claim 33 or 34, further comprising removing the peelable porous sheet from the co-cured structure to leave an exposed surface of the cured polymer composition of the multifunctional surfacing film.

38. The method of claim 37, further comprising painting the fresh surface without additional surface conditioning or treatment.

39. A method for manufacturing a multifunctional facial mask, comprising: (a) continuously depositing a curable polymer composition onto a surface of a release liner to form a cast polymer composition having a first surface in contact with the release liner and a second surface opposite the first surface; (b) while continuously depositing the curable polymer, imprinting a first releasable porous sheet into the first surface of the cast curable polymer composition such that the releasable porous sheet is disposed within the single layer of the curable polymer composition and is located a predetermined and controlled distance below the first surface of the curable polymer composition and below the release liner, (c) while continuously depositing the curable polymer, providing at least one porous sheet of a second functional material positioned relative to the second surface such that the at least one porous sheet of functional material becomes at least partially embedded in the cast polymer composition at a selected distance from the second surface; (d) optionally providing a second releasable liner adjacent to the second surface of the multifunctional surfacing film.

40. The method of claim 39, wherein after imprinting the peelable porous sheet into the first surface of the curable polymer composition, the at least one second functional material porous sheet becomes at least partially embedded in the cast polymer composition beneath the second surface.

41. The method according to claim 39 or 40 further comprises passing the multifunctional surfacing film between at least one pair of non-porous rollers, and further embedding the at least one second functional material porous sheet, the peelable porous sheet, or both the at least one second functional material porous sheet and the peelable porous sheet in the cast curable polymer composition, each at a preselected distance from the corresponding surface of the curable polymer composition.

42. The method of claim 41, wherein the non-porous roll comprises a non-porous liner.

43. The method of claim 39 or 40, further comprising partially curing the curable polymer composition.

44. The method according to claim 39 or 40, further comprising winding the multifunctional surfacing film into a wound roll, wherein the wound multifunctional surfacing film roll is further cut into a target width as needed for use with dedicated automated equipment in a process for manufacturing a composite structure.

45. The method of claim 44, wherein the cut multifunctional surfacing film is used with automated equipment specifically designed for making composite structures.

46. ​​The method of claim 45, wherein the automated equipment designed for fabricating the composite structure is an automated fiber processing (AFP) machine or an automated tape laying (ATL) machine.

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