Thermoplastic Epoxy Core-Shell Phase for Composite Bonding
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Solution Overview
Problem
There is a need for lightweight composite materials that maintain structural rigidity and bonding strength, while incorporating additives without increasing viscosity, and requiring minimal surface topographical variations, and being compatible with dissimilar materials.
Innovation Solution
A multi-phase polymeric material comprising a thermoplastic epoxy matrix and a core-shell polymeric phase, where the core-shell particulates are dispersed throughout the matrix, allowing for phase separation during processing to enhance impact resistance and bonding properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a toughening agent is included in a resin during resin infusion, then impact and damage resistance properties are enhanced, but viscosity of the resin is increased
Solution Approach 1:
The toughening agent is segmented into discrete particulated form rather than being dissolved in the resin. This allows the toughening agent to be incorporated without increasing resin viscosity, as the particles remain separate and do not contribute to the bulk fluid viscosity during infusion.
Solution Approach 2:
The invention creates a composite material system consisting of resin matrix combined with discrete particulated toughening agents. This composite approach allows both components to maintain their individual properties (resin remains low viscosity, particles provide toughness) while achieving the desired synergistic effect.
2Strength
If additives are incorporated into adhesive/bonding materials, then bonding strength is improved, but viscosity of the materials is increased
Solution Approach 1:
Additives are incorporated as discrete particulated phases separated from the resin matrix. This segmentation allows additives to be present without increasing the resin's bulk viscosity, as the particles do not contribute to the fluid flow characteristics during processing.
3Strength
If core-shell particulates are dispersed throughout the matrix, then impact resistance is enhanced, but manufacturing complexity is increased
Solution Approach 1:
The core-shell particulates are pre-formed and pre-dispersed in the resin matrix before the actual bonding or composite formation process. This preliminary preparation simplifies subsequent manufacturing steps, as the toughening agent is already in its final dispersed state and does not require complex in-process addition or processing.
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
The solution provides improved lap shear strength, impact resistance, and the ability to incorporate additives without affecting viscosity, while ensuring compatibility and minimal surface variations, thus enhancing the structural integrity of composite materials.
Implementation Method 1
allowing for phase separation during processing to enhance impact resistance and bonding properties
Data Source
AI summary
A composite article (30), comprising at least one fibrous layer (12), and at least one thermoplastic epoxy web layer (14) located in direct planar contact with the at least one fibrous layer (12), the at least one thermoplastic epoxy web layer (14) being adapted to substantially phase separate during a molding and/or curing process.