Polymer composite structure reinforced with shape memory alloy and method of manufacturing same

Abstract

A moldable resin for producing a molded part. The resin is reinforced with shape memory alloy (SMA) particles. In one preferred form NITINOL® alloy particles are used for the SMA particles. The NITINOL® alloy particles may comprise cylindrical, oval or spherical shaped particles. The SMA particles provide superelastic, reversible strain properties that significantly improve the damage resistance, damage tolerance (e.g. compression-after-impact (CAI) strength) and elevated temperature performance of the part without negatively affecting the hot-wet compression strength of the part.

What is claimed is:  
     
         1 . A moldable resin for use in a molding process to form a molded part at least partially therefrom, the moldable resin comprising: 
 a base resin;    a plurality of shape memory alloy (SMA) particles interspersed in said base resin; and    wherein said SMA particles are suspended in said base resin and serve to enhance a specific property of said base resin.    
     
     
         2 . The moldable resin of  claim 1 , wherein said SMA particles comprise NITINOL® alloy particles.  
     
     
         3 . The moldable resin of  claim 1 , wherein said SMA particles are less than about 1% of a total volume of said resin.  
     
     
         4 . The moldable resin of  claim 1 , wherein said SMA particles comprise between about 1% and 50% by volume of said resin.  
     
     
         5 . The moldable resin of  claim 1 , wherein said SMA particles comprise at least about 50% by volume of said resin.  
     
     
         6 . The moldable resin of claim 1 , wherein said SMA particles comprise SMA particles in their austenitic phase.  
     
     
         7 . The moldable resin of  claim 1 , wherein said SMA particles comprise SMA particles in their martensitic phase.  
     
     
         8 . The moldable resin of  claim 1 , wherein said SMA particles comprise a mixture of SMA particles in martensitic and austenitic phases.  
     
     
         9 . The moldable resin of  claim 1 , wherein said base resin comprises a thermoplastic resin.  
     
     
         10 . The moldable resin of  claim 1 , wherein said base resin comprises a thermosetting resin.  
     
     
         11 . The moldable resin of  claim 1 , wherein said resin is suitable for use in injection molding and compression molding processes.  
     
     
         12 . The moldable resin of  claim 1 , wherein said SMA particles are formed in at least one of the group of shapes comprising: spherical, cylindrical and oval.  
     
     
         13 . The moldable resin of  claim 1 , wherein said SMA particles comprise granules intermixed within said base resin.  
     
     
         14 . The moldable resin of  claim 1 , wherein said SMA particles comprise a size of between about 0.005 micron to about 50 micron.  
     
     
         15 . The moldable resin of  claim 1 , wherein said SMA particles comprise a size of at least about 50 microns.  
     
     
         16 . The moldable resin of  claim 1 , wherein said SMA particles comprise a size of no more than about 0.005 micron.  
     
     
         17 . A moldable resin for use in an injection molding process to make an injection molded part, the moldable resin comprising: 
 a base resin comprised of one of a thermoplastic or thermosetting plastic resin; and    a plurality of shape memory alloy (SMA) particles added to the base resin to enhance a property of said base resin.    
     
     
         18 . The moldable resin of  claim 17 , wherein said SMA particles are in their austenitic phase when added to the base resin.  
     
     
         19 . The moldable resin of  claim 17 , wherein said SMA particles are in their martensitic phase when added to the base resin.  
     
     
         20 . The moldable resin of  claim 17 , wherein said SMA particles comprise NITINOL® alloy particles.  
     
     
         21 . The moldable resin of  claim 17 , wherein said SMA particles comprise less than about 1.0% by volume of said resin.  
     
     
         22 . The moldable resin of  claim 17 , wherein said SMA particles comprise between about 1.0% to about 50% by volume of said resin.  
     
     
         23 . A moldable resin for use in a compression molding process to make a compression molded part, the moldable resin comprising: 
 a base resin comprised of one of a thermoplastic or thermosetting plastic resin; and    a plurality of shape memory alloy (SMA) particles added to the base resin to enhance a property of said base resin without affecting a moldability of said base resin.    
     
     
         24 . The moldable resin of  claim 23 , wherein said SMA particles comprise NITINOL® alloy particles.  
     
     
         25 . The moldable resin of  claim 24 , wherein said NITINOL® alloy particles are provided in their austenitic phase when added to said base resin.  
     
     
         26 . The moldable resin of  claim 24 , wherein said NITINOL® alloy particles are provided in their martensitic phase when added to said base resin.  
     
     
         27 . The moldable resin of  claim 23 , wherein said SMA particles comprise a shape in accordance with one of the group of shapes comprising: oval, spherical and cylindrical.  
     
     
         28 . The moldable resin of  claim 23 , wherein said SMA particles comprise granules added to said base resin.