Surfacing and/or joining method

Abstract

A method for surfacing a polymeric composite article and/or for joining (for example, by bonding or by co-curing) the article and an adherend (for example, a second polymeric composite article) comprises (a) providing a cured or curable polymeric composite article; (b) providing a curable composition comprising (1) at least one thermosetting resin, and (2) at least one preformed, substantially non-functional, particulate modifier comprising at least one elastomer; and (c) directly or indirectly applying the composition to at least a portion of at least one surface of the article.

1 . A method comprising
 (a) providing a cured or curable polymeric composite article;   (b) providing a curable composition comprising
 (1) at least one thermosetting resin, and 
 (2) at least one preformed, substantially non-functional, particulate modifier comprising at least one elastomer; 
   wherein the curable composition contains no liquid rubber polymer,   and   (c) directly or indirectly applying said composition to at least a portion of at least one surface of said article.   
   
   
       2 . The method of  claim 1 , wherein said article is a cured polymeric composite article. 
   
   
       3 . The method of  claim 1 , wherein said thermosetting resin is selected from the group consisting of epoxide resins, maleimide resins, cyanate ester resins, and mixtures thereof. 
   
   
       4 . The method of  claim 3 , wherein said thermosetting resin is an epoxide resin. 
   
   
       5 . The method of  claim 1 , wherein said modifier is a core-shell polymer modifier. 
   
   
       6 . The method of  claim 5 , wherein said core-shell polymer modifier has a polyacrylate shell and a synthetic rubber core. 
   
   
       7 . The method of  claim 1 , wherein said modifier is in the form of microparticles. 
   
   
       8 . The method of  claim 1 , wherein said modifier is included in said curable composition in a concentration of about 2 to about 30 weight percent, based upon the total weight of said curable composition. 
   
   
       9 . The method of  claim 1 , wherein said method further comprises bringing at least a portion of at least one surface of at least one adherend into contact with said composition in a manner such that said composition becomes sandwiched between said article and said adherend. 
   
   
       10 . The method of  claim 9 , wherein said adherend comprises at least one of a polymeric composite article, a protective article, a paint replacement system, and a lightning protection system. 
   
   
       11 . The method of  claim 10 , wherein said paint replacement system comprises a paint replacement applique and said lightning protection system comprises a lightning protection applique. 
   
   
       12 . The method of  claim 1 , wherein said method further comprises at least partially curing the composition. 
   
   
       13 . The method of  claim 9 , wherein said method further comprises at least partially curing the composition. 
   
   
       14 . The method of  claim 1 , wherein said thermosetting resin is an epoxide resin and said modifier is a core-shell polymer modifier. 
   
   
       15 . A method comprising
 (a) applying an uncured mass of a curable composition to at least one of a polymeric composite article and an adherend said curable composition comprising
 (1) at least one thermosetting resin, and 
 (2) at least one preformed, substantially non-functional, particulate modifier comprising at least one elastomer; 
   wherein the curable composition contains no liquid rubber polymer;   (b) sandwiching said uncured mass of said curable composition between said article and said adherend; and   (c) curing said composition to form a joint between said article and said adherend.   
   
   
       16 . A structure comprising
 (a) a cured or curable polymeric composite article; and   (b) a cured or curable composition comprising
 (1) at least one thermosetting resin, and 
 (2) at least one preformed, substantially non-functional, particulate modified comprising at least one elastomer; 
   wherein the cured or curable composition contains no liquid rubber polymer;   said composition being in contact with at least a portion of at least one surface of said article.   
   
   
       17 . The structure of  claim 16 , wherein said article is a cured polymeric composite article. 
   
   
       18 . The structure of  claim 16 , wherein said thermosetting resin is selected from the group consisting of epoxide resins, maleimide resins, cyanate ester resins, and mixtures thereof. 
   
   
       19 . The structure of  claim 18 , wherein said thermosetting resin is an epoxide resin. 
   
   
       20 . The structure of  claim 16 , wherein said modifier is a core-shell polymer modifier. 
   
   
       21 . The structure of  claim 20 , wherein said core-shell polymer modifier has a polyacrylate shell and a synthetic rubber core. 
   
   
       22 . The structure of  claim 16 , wherein said modifier is in the form of microparticles. 
   
   
       23 . The structure of  claim 16 , wherein said modifier is included in said cured or curable composition in a concentration of about 2 to about 30 weight percent, based upon the total weight of said composition. 
   
   
       24 . The structure of  claim 16 , wherein said composition is at least partially lured. 
   
   
       25 . The structure of  claim 16 , wherein said structure is a joined structure that further comprises at least one adherend that is joined to said article by at least one joint comprising said cured composition. 
   
   
       26 . The structure of  claim 25 , wherein said adherend comprises at least one of a polymeric composite article, a protective article, a paint replacement system, and a lightning protection system. 
   
   
       27 . The structure of  claim 26 , wherein said paint replacement system comprises a paint replacement applique and said lightning protection system comprises a lightning protection applique. 
   
   
       28 . The structure of  claim 16 , wherein said thermosetting resin is an epoxide resin and said modifier is a core-shell polymer modifier.