Composite laminating matrix and method of laminate curing

Abstract

A composite laminating matrix comprising sodium silicate. The matrix may further comprise boron carbide, wherein the sodium silicate to boron carbide ratio is less than 30:1 by weight. The laminate ma

Description

The present invention relates to a composite laminating matrix comprising at least sodium silicate. The invention further relates to a product formed using said composite laminating matrix, a method of making a composite laminating matrix, and to a method of laminate curing using said composite laminating matrix. The invention further relates to a method of making a composite laminate product using an additional post-cure curing step. Current composite laminating matrices generally consistof a two-part resin and hardener which utilise epoxy polyester or vinyl bases. These systems, when used in conjunction with reinforcement materials such as carbon fibre, will create a stiff structure when cured within a mould to produce a composite laminated product. However, these systems are unable to handle high temperatures, with most not being able to exceed a service temperature of 160°C before breaking down, usually via combustion causing outgassing and emission of noxious fumes. To achieve such service temperatures the composite laminated products must undergo extensive post curing processing, typically for durations in excess of 15 hours. This issue makes composite laminate products unsuitable for high temperature applications. For instance, aircraft having carbon fibre laminate fuselages become difficult to extinguish once aflame, which can hamper emergency services attempting to assist an aircraft which is on fire. High temperature heat resistant products are used for heat shields, for instance on spacecraft, and such products would typically be formed from composite carbon ceramic materials. Brake discs may also be formed from such materials. However, such materials take a vast amount of time to manufacture, usually months or more, and require a lot of highly specialised equipment to manufacture. It is an objective of the present invention to provide a means of producing a carbon fibre product which has high temperature resistance, and which can be manufactured in a short space of time. According to a first aspect of the invention, there is provided a composite laminating matrix comprising sodium silicate. In a preferred embodiment, the composite laminating matrix further comprises boron carbide, wherein the ratio of sodium silicate to boron carbide is less than 30:1 by weight. There are many advantages to the present invention. The composite laminating matrix is capable of operating at temperatures continuously in excess of 800°C if one side is exposed to ambient air, and with transient peaks in excess of 1100°C. Where a product formed from the composite laminating matrix has been formed, and the product is fully surrounded by elevated temperatures, then the continuous heat-resistant limit is approximately 450°C. Products made from the composite laminating matrix have been demonstrated to maintain stiffness and functionality across these temperature ranges. The product can be directly exposed to flame without combusting. Only beyond 1100°C does the product start to become irreversibly damaged. The composite laminating matrix can be cured with or without an autoclave, only requiring the use of an oven capable of 300°C heat and a vacuum pump. This means that composite laminate products can be manufactured on a small scale using standard heating equipment. The use of sodium silicate and boron carbide forms a translucent matrix which can be used to even hand laminate reinforcement materials such as carbon fibre. The layering process is simple as the composite laminating matrix has been formulated to have good wetting out properties, meaning that it actively wicks into the reinforcement material. Additional benefits include the very low thermal conductivity of composite laminate products formed from the composite laminating matrix. It has been demonstrated to be possible to hold a 150mm square of a product formed using the composite laminating matrix in bare hands whilst using a blowtorch on the opposite corner to make that section glow without the holder getting burned. The composite laminating matrix can also be used to make thicker products since it can be cured at much greater thicknesses in one go. Typically, composites are laminated to a maximum thickness of around 5mm at a time, but with the present invention curing has been achievable at more than 20mm in one pass. A pure sodium silicate composite laminating material provides heat resistance properties, but does lack the stiffness imparted by the inclusion of boron carbide. Optionally, the ratio of sodium silicate to boron carbide may be at least 1:1 by weight. There is likely an upper limit of boron carbide that can be introduced viably into the composite laminating matrix, since many of the properties of the matrix are derived from the sodium silicate. More preferably, the ratio of sodium silicate to boron carbide may be at least 5:1 by weight. In one desirable embodiment, the ratio of sodium silicate to boron carbide may be or substantially be 10:1 by weight A desirable ratio between sodium silicate and boron carbide can produce a cost effective composite laminating matrix which also has a desirable appearance. Optionally, the composite laminating matrix may further comprise at least one additive component, and in particular, a high temperature materials and / or powder. Additives to the composite laminating matrix can improve the thermal or other characteristics thereof without deleteriously affecting the performance of the matrix herebefore described. According to a second aspect of the invention, there is provided a product formed as a composite laminate, comprising a reinforcement material laminated with the composite laminating matrix in accordance with the first aspect of the invention. A product formed from the composite laminating matrix will have exceptional thermal insulation properties and can be formed using comparatively small-scale heating equipment compared with, for example, ceramic heat shields. Optionally, the reinforcement material may be a carbon fibre material, the product having the appearance of a carbon fibre material. It may be desirable for a laminate product to have the appearance of a carbon fibre material in order to reassure a user that the behaviour of the laminate product is similar to that of a carbon fibre material and therefore can be used for similar purposes. According to a third aspect of the invention, there is provided a method of making a composite laminating matrix, the method comprising the step of mixing sodium silicate and boron carbide in an aqueous environment wherein the ratio of sodium silicate to boron carbide is less than 30:1 by weight. A desirable composite laminating matrix can be produced by the mixing of sodium silicate, which produces much of the thermal resistant properties of the composite laminating matrix, boron carbide which improves stiffness of the final product, and water to enable the mixture of the composite laminating matrix to be applied as a laminate. The composite laminating matrix can be applied easily as it has excellent wicking properties for layering onto a reinforcement material. According to a fourth aspect of the invention, there is provided a method of laminate curing, the method comprising the steps of: a] using the composite laminating matrix in accordance with the first aspect of the invention, applying the composite laminating matrix onto a reinforcement material to make a pre-cure composite laminate product; b] in a vacuum environment, heating the pre-cure composite laminate product for a first curing-cycle duration at a first curing-cycle temperature which is less than a preliminary cure temperature of the composite laminating matrix; c] increasing the first curing-cycle temperature to a second curing-cycle temperature over a second curing-cycle duration, the second curing-cycle temperature being greater than or equal to the preliminary cure temperature; d] heating the pre-cure composite laminate product at the second curingcycle temperature for a third curing-cycle duration to cure the pre-cure composite laminate product; and e] cooling the pre-cure composite laminate product to form a part-cured composite laminate product. The present method of laminate curing produces a desirable thermally insulating material akin to a carbon fibre product, without foaming during the curing process. This is achieved by the multiple step curing cycles, which drive off the water in the mixture slowly, since evaporation of moisture rapidly through the curing composite laminating matrix is what results in the non-desirable foaming. Optionally, during step b], the heating temperature is less than 80°C. The purpose of the Initial heating is to drive off water that is contained within the matrix which would otherwise lead to foaming or bubbling of the composite laminate product during the curing phase. It is therefore desirable that the initial heating temperature is less than a preliminary cure temperature of the composite laminate product, and the cure temperature will typically be greater than 100°C. Preferably, during step b], the heating temperature may be or approximately be ambient temperature. Since the water can be driven off the matrix at ambient temperature, it is desirable to perform the preliminary cure at ambient temperature so as to minimise heating costs. Optionally, the second cure temperature is greater than 100°C. Preferably, the second cure temperature may be 120°C. The purpose of the second cure temperature is to cure the composite laminate product once the water has been driven off. Typically, the second cure temperature will exceed the boiling point of water. Optionally, during step c], the increasing of the first curing-cycle temperature to the second curing-cycle temperature may occur at a rate of less than 5.0°C per minute. A slow ramping of the temperature during step c] has the advantage of slowly ensuring that all water is removed as the temperature increases without causing bubbling or foaming effects as the curing process occurs. Large increases in temperature have been demonstrated to cause foaming effects. During step c], the increasing of the first curing-cycle temperature to the second curingcycle temperature may occur at a rate of less than 1.0°C per minute. Increasing the temperature at a very slow rate is preferred since this will ensure that water is indeed removed. The present rate indicated provides a good balance between ensuring the absence of water and curing in a realistic and efficient amount of time. Preferably, during step b], the first curing-cycle duration may be 60 minutes. Optionally, during step c], the second curing-cycle duration may be selected based on at least on characteristic of the pre-cure composite laminate product to remove at least 99% of water present in the pre-cure composite laminate product. Different durations may be required depending on the composite laminate product to be produced. Larger products will require longer curing durations; however, the important feature of the invention is to ensure that there is negligible water remaining in the product at the point of curing since this is what will cause the bubbling or foaming effects found in the art. According to fifth aspect of the invention, there is provided a method of making a composite laminate product, the method comprising the steps of: a] creating a part-cured composite laminate product using a method in accordance with the fourth aspect of the invention; b] heating the part-cured composite laminate product for a first post-curing-cycle duration at a first post-curing-cycle temperature; c] increasing the first post-cure-cycle temperature to a second post-cure-cycle temperature over a second post-cure-cycle duration, the second post-cure-cycle temperature being greater than or equal to a final cure temperature; d] heating the part-cured composite laminate product at the second post-cure-cycle temperature for a third post-cure-cycle duration; and e] cooling the part-cured composite laminate product to form a composite laminate product. The use of a post-cure cycle ensures that the composite laminate product is set in a manner which avoids the reabsorption of moisture, and produces a stiff and heat-resistant final product. Optionally, the first post-curing-cycle temperature may be greater than 100°C. Preferably, the first post-curing-cycle temperature may be 120°C. The second post-cure-cycle temperature may be greater than 150°C to inhibit reabsorption of water by the part-cured composite laminate product. More preferably, the second post-cure-cycle temperature may be 300°C. There is a risk that water can be reabsorbed before a full cure has occurred and therefore it is desirable that the second post-cure-cycle temperature is greater than 150°C since this will ensure that no moisture can be reabsorbed. The effect is more marked at higher temperatures and a temperature of 300°C ensures that no moisture is reabsorbed Optionally, during step b], the heating of the part-cured composite laminate product over the first post-curing-cycle duration may occur at a rate of less than 5.0°C per minute. Furthermore, during step b], the heating of the part-cured composite laminate product over the first post-curing-cycle duration may occur at a rate of less than 1,0°C per minute. Preferably, during step c], the increasing of the first post-cure-cycle temperature to a second post-cure-cycle temperature over a second post-cure-cycle duration may occur at a rate of less than 5.0°C per minute. During step c], the increasing of the first post-cure-cycle temperature to a second post-cure-cycle temperature over a second post-cure-cycle duration may occur at a rate of less than 1.0°C per minute. Slow ramping of the temperatures ensures that there is no risk of subsequent foaming of the part-cured laminate product, and therefore that the final product is suitable for high-temperature applications. The invention will now be more particularly described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows an image of a pre-cure composite laminate product in a vacuum bag during a first curing cycle of a method of laminate curing in accordance with the fourth aspect of the invention; Figure 2 shows an example of a composite laminate product which has undergone a curing cycle at atmospheric pressure; Figure 3 shows a part-cured composite laminate product being demoulded following curing during a method of laminate curing in accordance with the fourth aspect of the invention; Figure 4 is a diagrammatic representation of a method of laminate curing in accordance with the fourth aspect of the invention; Figure 5 shows a sample of a composite laminate product which has been cured for an insufficient duration; Figure 6 shows a graph indicating the temperature difference across a composite laminate product in accordance with the second aspect of the invention as a function of applied temperature; Figure 7 shows an image of the composite laminate product tested in Figure 6; Figure 8 shows the application of heat to a composite laminate product in accordance with the second aspect of the invention, whilst held in a user’s bare hands; and Figure 9 shows the retention of heat by the composite laminate product of Figure 8 after the heat source is removed. The present invention involves making a composite laminating matrix suitable for creating a composite laminate product. The composite laminating matrix in one preferred embodiment comprises a sodium silicate solution at a dilution of 40% to distilled water. This is then blended with boron carbide powder having a grit particle size of F-1000. The ratio of sodium silicate to boron carbide in this embodiment is 10:1 by weight at 20°C. The composite laminating matrix must be stored in an airtight environment to avoid localised curing at ambient temperatures. It is possible to make the said composite laminating matrix in any appropriate manner. For instance, sodium silicate powder and boron carbide powder could be combined together in an aqueous environment at the appropriate ratio. This could be achieved by providing either component in solution, or by addition of water to a solid mix of the two components. It is anticipated however that it will be easier to obtain sodium silicate in solution for the purpose of creating the composite laminating matrix. To produce a composite laminate product, the aforementioned composite laminating matrix is applied onto a reinforcement material to yield a pre-cure composite laminate product. Typically, this would involve the insertion of the reinforcement material, such as a carbon fibre mesh or similar weave, into a mould, preferably coated in a PTFE release film to assist with release of the pre-cure composite laminate product. The composite laminating matrix is then applied to the reinforcement material in a layer using standard laminating techniques. The tested weight of composite laminating matrix within the examples provided was 2g / cm3 volume to ensure complete saturation of the reinforcement material. Any standard layering technique can be used such as spraying, hand painting, dabbing, rolling, etc. Once applied, a non-perforated PTFE release film can be placed over the mould to cover the pre-cure composite laminate product 10, preferably along with a heavy-duty breather material 12, taking care to ensure that the PTFE release film cannot pinch and form a seal on the mould. The entire pre-cure composite laminate product 10 and mould is then inserted into a vacuum bag 14 which is sealed using high temperature sealing tape. Typically, this would be a PTFE vacuum bag, as illustrated in Figure 1. The pre-cure composite laminate product 10 is then subjected to a curing cycle. In a preferred environment, the pre-cure composite laminate product 10 is held under vacuum at ambient temperatures, that is at approximately 30°C, for a first duration. This first duration is referred to as the first curing-cycle duration, and the temperature is the first curing-cycle temperature, and is selected so as to be less than a preliminary cure temperature of the composite laminating matrix. In the examples attempted, the preliminary cure temperature of the composite laminating matrix is approximately 120°C. The preliminary cure temperature may vary depending on the exact composition of the composite laminating matrix. The first curing-cycle must be performed under vacuum. This is to remove moisture from the pre-cure composite laminate product. It is preferred that the vacuum pump includes an inline moisture trap which is checked and drained regularly throughout the curing process as moisture evaporates from the pre-cure composite laminate product 10. Residual water will cause bubbling or foaming of the composite laminate product during securing process. An example of a failed product 16 exhibiting this behaviour is shown in Figure 2. The first curing-cycle temperature is then slowly increased to a second curing-cycle temperature over a second curing-cycle duration in which the second curing-cycle temperature is greater than or equal to the preliminary cure temperature. The present employment this is an increase in the temperature from 30°C to 120°C ramped over the course of 120 minutes. This is a ramp rate of 0.75°C per minute. It is preferable that this ramp rate is less than 5.0°C per minute, and more preferable that this ramp rate is less than 1,0°C per minute. Once the second curing-cycle temperature has been reached, here 120°C, the pre-cure composite laminate product is held at said second curing-cycle temperature for a third curing-cycle duration to cure the pre-cure composite laminate product 10. In the present embodiment, the third curing cycle duration is 300 minutes, that is, five hours. The duration of the second curing cycle is described above as being specific to the product that was being cured. It will however be appreciated that the duration may be selected based on at least one characteristic of the pre-cure composite laminate product 10 so as to remove at least 99% of water present in the pre-cure composite laminate product 10. The pre-cure composite laminate product 10 is then allowed to cool whilst remaining under vacuum conditions, to ambient temperature, at which point the pre-cure composite laminate product 10 is demoulded from its mould 18 to yield a part-cured composite laminate product 20. An example of a part-cured composite laminate product 20 being demoulded is shown in Figure 3. The part-cured composite laminate product 20 may at this point be suitable for use as a thermally resistant component. However, the heat resistance characteristics of the part-cured composite laminate product 20 can be improved by post-cure processing. The post-cure processing may comprise heating of the part-cured composite laminate product 20 for a first post-curing-cycle duration at a first post-curing-cycle temperature. In the present embodiment, this involved heating of the part-cured laminate product 20 to 120°C by ramping from ambient temperature over the course of 60 minutes. This equated to a ramp rate of approximately 1.66°C per minute. Once complete the first post-cure-cycle temperature is increased to a second-post-cure cycle temperature over a second post-cure-cycle duration, wherein the second postcure-cycle temperature is greater than or equal to a final cure temperature. The second post-cure-cycle temperature here is 300°C, and the second post-cure-cycle duration is 300 minutes. This equated to a ramp rate of approximately 0.6°C per minute. The part-cured composite laminate product 20 was then held at the second post-cure-cycle temperature for a third post-cure-cycle duration, which in the present arrangement was 60 minutes. It is noted, that an elevated second post-cure-cycle temperature of 450°C at the same ramp rate improved heat resistance of the eventual composite laminate product that was produced. This may be as a result of the higher temperature, the extended cure duration, or a combination thereof. The part-cured composite laminate product 20 was then allowed to cool to ambient temperature to form a composite laminate product. This composite laminate product is now fully cured and can be taken to elevated service temperatures. The method of the present invention can thus be summarised as follows, and is represented in Figure 4. A method of laminate curing is provided, indicated at M100. Using a composite laminating matrix as herebefore defined, the composite laminating matrix is applied, at step S101, onto a reinforcement material to make a pre-cure composite laminate product 10. There may be one or more layers provided. In a vacuum environment, the pre-cure composite laminate product 10 is heated, at step S102, for a first curing-cycle duration at a first curing-cycle temperature which is less than a preliminary cure temperature of the composite laminating matrix. The first curing-cycle temperature is increased, at step S103, to a second curing-cycle temperature over a second curing-cycle duration, the second curing-cycle temperature being greater than or equal to the preliminary cure temperature; The pre-cure composite laminate product 10 is then heated, at step S104, at the second curing-cycle temperature for a third curing-cycle duration to cure the pre-cure composite laminate product 10. The pre-cure composite laminate product 10 is then cooled, at step S105, to form a part-cured composite laminate product 20, which can be used in this form at step S106. The part-cured composite laminate product 20 may then be heated, at step S107, for a first post-curing-cycle duration at a first post-curing-cycle temperature. The first post-cure-cycle temperature is increased, at step S108, to a second post-cure-cycle temperature over a second post-cure-cycle duration, the second post-cure-cycle temperature being greater than or equal to a final cure temperature. The part-cured composite laminate product 20 is heated, at step S109, at the second post-cure-cycle temperature for a third post-cure-cycle duration. Finally, the part-cured composite laminate product 20 is cooled, at step S110, to form a composite laminate product. Examples Testing of various samples of composite laminate product has been conducted. Different compositions Five samples were made using a carbon fibre twill layup, which was made from recycled twill. The carbon fibre twill was then laminated according to the above-referenced method using the following composite laminating matrices: 1. 50g sodium silicate in aqueous solution; 2. 50g sodium silicate and 0.5g boron carbide in aqueous solution (100:1 ratio); 3. 50g sodium silicate and 2.0g boron carbide in aqueous solution (25:1 ratio); 4. 50g sodium silicate and 5.0g boron carbide in aqueous solution (10:1 ratio); and 5. 50 g sodium silicate and 10.0g boron carbide in aqueous solution (5:1 ratio). All five examples were able to resist localised hear of 1000°C. The first sample, however, was noticeably less stiff than the components including boron carbide, and applying torsion to the sample demonstrated fibre separation. It is therefore demonstrably possible to use a pure sodium silicate solution as a composite laminating matrix, but it may not be suitable for environments where there is likely to be a vibrational component, making it a less useful composite laminating matrix in the absence of the boron carbide. Increasing the boron carbide content increases the stiffness of the final composite laminate product significantly. The preferred ratio is 10:1, since beyond that point, stiffness increases are outweighed by the significant increase in cost, as well as reducing the desirability of the appearance. Vacuum curing Two 1mm thick twill, recycled, twill samples were made to demonstrate the need for the vacuum environment during curing. Both parts were put in the oven for the standard pre-and post-cure cycles. During the pre-cure, the non-vacuumed part expanded to nearly 5mm thick-this is due to the moisture getting trapped in the sodium silicate and forming bubbles internally. When the parts were then put in for the post-cure, the non-vacuumed part had failed forming surface ‘popcorn’ all over (from upwards of 200°C). The vacuumed part behaved as normal highlighting the necessity for the vacuum environment during this process. This is what is shown in Figure 2. Pre-cure timing To demonstrate the need for a wide variety of timings for the ramp on the pre-cure, another batch of samples were made, all at 10:1 sodium silicate to boron carbide with three at 1 mm thick and one at 5mm. The expected outcome was that the 5mm part would not be fully cured at the end of the pre-cure cycle. The expectation was correct, and the 5mm part 22 was still soft in the core whilst the 1 mm samples were solid. The 5mm sample 22 was bent to show this, allowing the outer twill to delaminate from the recycled core. This sample can be seen in Figure 5. The remaining 1mm thick parts were then used to test increased post-cure ramp rates. These tests showed that there is a definite volume to cure time ratio that needs to be calculated for the pre-cure as the 1mm samples had almost evaporated all their moisture content in the pre-cure and were insensitive to the post-cure ramp timing - this is highly unusual and unexpected. There were no visual imperfections or ‘popcorning’ and the samples were able to take the upwards of 1000°C test torch with no damage after the post-cure. The standard post-cure schedule is 60min hold at 30°C, 120min ramp to 120°C and 120min hold at 120°C. The 1mm samples were tested up to four times faster than this, but these are very small samples at 0.00001m3. AT testing The temperature difference across a 1mm three-layer test sample of composite laminate product 24 which was made with recycled carbon fibre felt having a weight of 100gsm, and which was laminated with the composite laminating matrix according to sample 4 recited above. Temperature was tested with a blowtorch 26, a containment cone, and thermocouples placed either side of the composite laminate product in the heat and ambient environment. Figure 6 shows the difference in temperature between the heated side and the ambient side, at different temperatures on the heated side, with Figure 7 showing the application of the heat to the composite laminate product 24. An improved AT was achieved by bonding two 1mm thick composite laminate products together with a 5mm air gap between, and subjecting the component to the same test. This yielded a AT of greater than 800°C. Examples of the thermal insulating properties of the composite laminate product 28 is shown in Figures 8 and 9, in which heat from a blowtorch is applied whilst a user holds the composite laminate product in their bare hands. Whilst examples have been shown of the composite laminating matrix having a preferred composition, it will be appreciated that the composition may be varied. It is anticipated that a ratio of sodium silicate to boron carbide be 30:1 or less by weight Is acceptable based on present experimental data. It is also anticipated that the ratio of sodium silicate boron carbide is at least 1:1 by weight, and more preferably 5:1 by weight. The composite laminating matrix described here before may be used as a base matrix to which other high temperature materials and powders, including but not limited to ceramic materials, can be added to modify the temperature and structural performance characteristics. Examples of viable additives include silicon carbide, zirconium oxide (yttria stabilised), aluminium oxide and so on. It is preferred that powders of F-800 and above are utilised in order to keep the grain size sufficiently small to pass through the reinforcement material. In practical terms it may be feasible to follow the method as defined in the present invention using a composite laminating matrix which comprises aqueous sodium silicate in the absence of boron carbide. It has however been found that the visual appearance of the product degrades with higher levels of boron carbide; the appearance of the laminate begins to degrade above around 30:1. It is therefore possible to provide a composite laminating matrix for making composite laminate products which, if cured according to the method set out herein, has extremely high thermal insulation properties that make it suitable for use as a heat-shield, and which is manufacturable using widely available curing facilities. This means that small-scale manufacture of thermally resistant products can be achieved. The words ‘comprises / comprising’ and the words ‘having / including’ when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps, or components, but do not preclude the presence or addition of one or more other features, integers, steps, components, or groups thereof. It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination. The embodiments described above are provided by way of examples only, and various 5 other modifications will be apparent to persons skilled in the field without departing from the scope of the invention as defined herein.

Claims

1. A composite laminating matrix comprising sodium silicate.

2. A composite laminating matrix as claimed in claim 1, further comprising boron carbide, wherein the ratio of sodium silicate to boron carbide is less than 30:1 by weight.

3. A composite laminating matrix as claimed in claim 2, wherein the ratio of sodium silicate to boron carbide is at least 1:1 by weight.

4. A composite laminating matrix as claimed in claim 3, wherein the ratio of sodium silicate to boron carbide is at least 5:1 by weight.

5. A composite laminating matrix as claimed in any one of claims 2 to 4, wherein the ratio of sodium silicate to boron carbide is or is substantially 10:1 by weight.

6. A composite laminating matrix as claimed in any one of the preceding claims, further comprising at least one additive component.

7. A composite laminating matrix as claimed in claim 6, wherein the additive component comprises a high temperature materials and / or powder.

8. A product formed as a composite laminate, comprising a reinforcement material laminated with the composite laminating matrix of any one of the preceding claims.

9. A product as claimed in claim 8, wherein the reinforcement material is a carbon fibre material, the product having the appearance of a carbon fibre material.

10. A method of laminate curing, the method comprising the steps of:a] using the composite laminating matrix of any one of claims 1 to 7, applying the composite laminating matrix onto a reinforcement material to make a pre-cure composite laminate product;b] in a vacuum environment, heating the pre-cure composite laminate product for a first curing-cycle duration at a first curing-cycle temperature which is less than a preliminary cure temperature of the composite laminating matrix;c] increasing the first curing-cycle temperature to a second curing-cycle temperature over a second curing-cycle duration, the second curing-cycle temperature being greater than or equal to the preliminary cure temperature;d] heating the pre-cure composite laminate product at the second curingcycle temperature for a third curing-cycle duration to cure the pre-cure composite laminate product; ande] cooling the pre-cure composite laminate product to form a part-cured composite laminate product.

11. A method as claimed in claim 10, wherein during step b], the heating temperature is less than 80°C.

12. A method as claimed in claim 11, wherein during step b], the heating temperature is or is approximately ambient temperature.

13. A method as claimed in any one of claims 10 to 12, wherein the second cure temperature is greater than 100°C.

14. A method as claimed in claim 13, wherein the second cure temperature is 120°C.

15. A method as claimed in any one of claims 10 to 14, wherein, during step c], the increasing of the first curing-cycle temperature to the second curing-cycle temperature occurs at a rate of less than 5.0°C per minute.

16. A method as claimed in claim 15, wherein, during step c], the increasing of the first curing-cycle temperature to the second curing-cycle temperature occurs at a rate of less than 1,0°C per minute.

17. A method as claimed in any one of claims 10 to 16, wherein, during step b], the first curing-cycle duration is 60 minutes.

18. A method as claimed in any one of claims 10 to 17, wherein during step c], the second curing-cycle duration is selected based on at least one characteristic of the pre-cure composite laminate product to remove at least 99% of water present in the pre-cure composite laminate product.

19. A method of making a composite laminate product, the method comprising the steps of:a] creating a part-cured composite laminate product using a method according to any one of claims 10 to 18;b] heating the part-cured composite laminate product for a first post-curing-cycle duration at a first post-curing-cycle temperature;c] increasing the first post-cure-cycle temperature to a second post-cure-cycle temperature over a second post-cure-cycle duration, the second post-cure-cycle temperature being greater than or equal to a final cure temperature;d] heating the part-cured composite laminate product at the second post-cure-cycle temperature for a third post-cure-cycle duration; ande] cooling the part-cured composite laminate product to form a composite laminate product.

20. A method as claimed in claim 19, wherein the first post-curing-cycle temperature is greater than 100°C.

21. A method as claimed in claim 20, wherein the first post-curing-cycle temperature is 120°C.

22. A method as claimed in any one of claims 19 to 21, wherein the second post-cure-cycle temperature is greater than 150°C to inhibit reabsorption of water by the part-cured composite laminate product.

23. A method as claimed in claim 22, wherein the second post-cure-cycle temperature is 300°C.

24. A method as claimed in any one of claims 19 to 23, wherein, during step b], the heating of the part-cured composite laminate product over the first post-curing-cycle duration occurs at a rate of less than 5.0°C per minute and more preferably of less than 1.0°C per minute.

25. A method as claimed in any one of claims 19 to 24, wherein, during step c], the increasing of the first post-cure-cycle temperature to a second post-cure-cycletemperature over a second post-cure-cycle duration occurs at a rate of less than5.0°C per minute and more preferably of less than 1.0°C per minute.

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