Prepreg Composition for Thermoset Laminates

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Solution Overview

Problem

Existing prepreg materials for thermoset glass fibre reinforced composite laminates suffer from inferior mould flow properties, leading to defects like voids and fibre misalignment, and require lengthy maturation times, which hinder efficient production.

Innovation Solution

A composition comprising two different base thermoset polymer components, one reactive and one non-reactive to a thickening agent, along with a polyether polyol and catalyst, improves mould flow properties and reduces thickening time, using unsaturated polyesters or vinylesters, isocyanate, and crosslinking initiators.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If conventional thickening agents (isocyanates) are used with hydroxyl containing polymers, then thickening speed is fast, but mould flow properties deteriorate causing voids and fibre misalignment

Engineering Contradiction:

Improvethickening speedVSAvoidmould flow properties

Core Design Contradiction:

SpeedVSManufacturing precision

Solution Approach 1:

The resin system is segmented into two distinct base thermoset polymer components: one containing groups reactive to the thickening agent and another containing no reactive groups. This segmentation allows the reactive component to provide fast thickening while the non-reactive component maintains good mould flow properties, resolving the contradiction between thickening speed and mould flow quality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite resin system combining two different base thermoset polymer components with complementary properties. The reactive component provides thickening functionality while the non-reactive component provides flow characteristics, creating a composite material that achieves both fast thickening and good mould flow properties simultaneously.

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If conventional resin compositions are used, then thickening can be achieved, but maturation time extends to several days, reducing productivity

Engineering Contradiction:

Improveprepreg qualityVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The composition is prepared in advance with all necessary components (reactive polymer, non-reactive polymer, thickening agent, catalyst) already mixed and ready. This preliminary preparation allows the thickening process to proceed rapidly without requiring extended maturation time, as the reactive components are pre-positioned to react immediately when the thickening agent is introduced.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention changes the chemical parameters of the resin system by introducing a catalyst and specific polymer combinations that enable rapid thickening at room temperature. This parameter change reduces the maturation time from several days to 24-48 hours, significantly improving productivity while maintaining prepreg quality.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If single base thermoset polymer is used, then composition is simple, but mould flow properties are inferior leading to defects

Engineering Contradiction:

Improvecomposition complexityVSAvoidmould flow properties

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The resin system is divided into two functional segments: a reactive base thermoset polymer component that provides thickening capability and a non-reactive base thermoset polymer component that provides excellent mould flow properties. This segmentation allows each component to specialize in its function, with the non-reactive component ensuring superior mould flow without requiring complex additional additives.

Inventive Principle:

Principle #1Segmentation

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 composition enhances the quality and efficiency of prepreg production, reducing maturation time from days to 24-48 hours at room temperature, minimizing defects, and allowing for more economical and predictable manufacturing of thermoset composite laminates.

Implementation Method 1

Isocyanates react fast with hydroxyl groups, and are therefore often used as thickening agents together with hydroxyl containing polymers

Methodology Applied

Scientific EffectChemical reaction between thickening agent and hydroxyl groups: Chemical Bonding

Implementation Method 2

The composition further comprises a polyether polyol, which gives a rapid thickening at room temperature

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

crosslinking initiator

Methodology Applied

Scientific EffectCrosslinking reaction: Chemical Bonding

Data Source

PatentEP1985665B1Preparing composition for composite laminates

Publication Date: 2015.09.16 ABB TECHNOLOGY LTD

AI summary

A composition for the production of a prepreg for the manufacture of thermoset composite laminates, a method for the production of a prepreg, the prepreg, and a thermoset glass fibre reinforced composite laminate manufactured by curing the prepreg. The composition comprises unsaturated polyesters or vinylesters (A, B), a catalyst (C), a thickening agent (D), and a crosslinking initiator (E), a first component (A) of the unsaturated polyesters or vinylesters comprising reactive groups that react with the thickening agent (D), and a second component (B) of the unsaturated polyesters or vinylesters not comprising any groups that react with the thickening agent (D), the composition also comprising a polyether polyol (F).