Polyamide Thermoplastic Particles in Epoxy Prepregs

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Solution Overview

Problem

Existing prepregs face challenges in maintaining high compression strength and damage tolerance under hot and wet conditions while also achieving high interlaminar fracture toughness, often resulting in negative impacts on other desirable properties.

Innovation Solution

The use of a matrix composed of difunctional epoxy resin, multifunctional epoxy resins, thermoplastic particles as polyamide condensation products, and a curing agent in pre-impregnated composite materials, which includes thermoplastic particles made from a methyl derivative of bis(4-aminocyclohexyl)methane and 1,10-decane dicarboxylic acid, enhances the composite's strength, damage tolerance, and interlaminar fracture toughness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If higher modulus resins are selected to increase compression strength, then compression strength is improved, but damage tolerance is reduced

Engineering Contradiction:

Improvecompression strengthVSAvoiddamage tolerance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent uses a composite resin system combining epoxy matrix with thermoplastic particles (polyester, polyamide, or polyimide) to achieve both high compression strength and damage tolerance. The thermoplastic particles act as toughening agents that improve damage tolerance while the epoxy provides the base compression strength, resolving the contradiction between these two properties.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the resin parameters by controlling the amount of thermoplastic particles (5-50 wt% of total resin) and selecting specific types of thermoplastic particles with different glass transition temperatures. This parameter adjustment allows optimization of both compression strength and damage tolerance simultaneously.

Inventive Principle:

Principle #35Parameter changes

2Strength

If compression strength is maintained under hot and wet conditions, then compression strength is improved, but interlaminar fracture toughness is reduced

Engineering Contradiction:

Improvecompression strength under hot and wet conditionsVSAvoidinterlaminar fracture toughness

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent employs a composite resin system with epoxy matrix and thermoplastic particles that maintains compression strength under hot and wet conditions while improving interlaminar fracture toughness. The thermoplastic particles provide toughening that prevents the trade-off between maintaining strength in harsh environments and preserving fracture toughness.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent adjusts resin composition parameters by incorporating 5-50 wt% thermoplastic particles with specific glass transition temperatures to maintain compression strength at elevated temperatures and humidity while simultaneously improving interlaminar fracture toughness, resolving the contradiction between these properties under hot and wet conditions.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach results in composite parts with unexpectedly high damage tolerance and interlaminar fracture toughness, maintaining high compressive strength even under 180°F wet conditions, without compromising the physical or chemical characteristics of the uncured prepreg or the cured composite.

Implementation Method 1

The matrix includes a thermoplastic particle component, a thermoplastic toughening agent and a curing agent. As a feature of the present invention, the thermoplastic particle component is composed of thermoplastic particles that comprise a polyamide

Methodology Applied

Scientific EffectThermoplastic particle reinforcement:

Implementation Method 2

The matrix includes a resin component made up of difunctional epoxy resin in combination with one or more multifunctional epoxy resins and a curing agent

Methodology Applied

Scientific EffectChemical bonding: Chemical Bonding

Data Source

PatentEP2888316B1Composite material with polyamide particles

Publication Date: 2022.10.19 HEXCEL CORP

AI summary

Pre -impregnated composite material (prepreg) is provided that can be cured/molded to form composite parts having high compression strength under hot and wet conditions, as well as, high damage tolerance and interlaminar fracture toughness. The matrix resin includes a thermoplastic particle component that includes polyamide particles which are composed of the polymeric condensation product of a methyl derivative of bis(4-aminocyclohexyl)methane and an aliphatic 1, 10-decane dicarboxylic acid.