Structural composite laminate, and process of making same

Abstract

A structural composite laminate and method of making the same are provided. The laminate includes first and second skins or laminas, and a core positioned between the first and second laminas. The core contains thermoplastic and/or substantially inelastic polymeric particles with inter-particle interstices between the polymeric particles. Optionally, the polymeric particles are arranged discontinuously to establish gaps between adjacent particles along at least one dimension of the laminate.

1 - 20 . (canceled) 
     
     
         21 . A structural composite laminate comprising:
 a first lamina;   a second lamina; and   a core positioned between the first and second laminas, the core comprising deformed, non-porous thermoplastic polymeric particles that are discrete from one another with inter-particle voids extending surface to surface from and to respective surfaces of the thermoplastic polymeric particles that are adjacent to one another, wherein the deformed, non-porous thermoplastic polymeric particles are placed and substantially retained in a deformed state by applying sufficient compressive force to the first and second laminas to permanently deform the thermoplastic polymeric particles there between and releasing the compressive force without delaminating the first and second laminas from the thermoplastic polymeric particles.   
     
     
         22 . The structural composite laminate of  claim 21 , wherein the first and second laminas comprise metals. 
     
     
         23 . The structural composite laminate of  claim 21 , wherein the core possesses a monolayer of the thermoplastic polymeric particles. 
     
     
         24 . The structural composite laminate of  claim 21 , wherein the core possesses a plurality of layers of the thermoplastic polymeric particles stacked one on top of another. 
     
     
         25 . The structural composite laminate of  claim 21 , further comprising:
 a first adhesive joining the first lamina to the core; and   a second adhesive joining the second lamina to the core.   
     
     
         26 . The structural composite laminate of  claim 21 , wherein the thermoplastic polymeric particles comprise copolymers thermally bonding the first and second outer layers to one another free of a separate adhesive layer. 
     
     
         27 . The structural composite laminate of  claim 21 , wherein the thermoplastic polymeric particles are arranged discontinuously from one another along at least one dimension of the laminate. 
     
     
         28 . The structural composite laminate of  claim 21 , wherein the thermoplastic polymeric particles have a compression set greater than 30 percent as measured by ASTM D395 at 50° C. for 24 hours. 
     
     
         29 . A structural composite laminate comprising:
 a first lamina;   a second lamina; and   a core positioned between the first and second laminas, the core comprising deformed, non-porous substantially inelastic polymeric particles that are discrete from one another with inter-particle voids extending surface to surface from and to respective surfaces of adjacent substantially inelastic polymeric particles, wherein the deformed, non-porous substantially inelastic polymeric particles are placed and substantially retained in a deformed state by applying sufficient compressive force to the first and second laminas to permanently deform the substantially inelastic polymeric particles there between and releasing the compressive force without delaminating the first and second laminas from the substantially inelastic polymeric particles.   
     
     
         30 . The structural composite laminate of  claim 29 , wherein the first and second laminas comprise metals. 
     
     
         31 . The structural composite laminate of  claim 29 , wherein the core possesses a monolayer of the substantially inelastic polymeric particles. 
     
     
         32 . The structural composite laminate of  claim 29 , wherein the core possesses a plurality of layers of the substantially inelastic polymeric particles stacked one on top of another. 
     
     
         33 . The structural composite laminate of  claim 29 , further comprising:
 a first adhesive joining the first lamina to the core; and   a second adhesive joining the second lamina to the core.   
     
     
         34 . The structural composite laminate of  claim 29 , wherein the substantially inelastic polymeric particles comprise copolymers thermally bonding the first and second outer layers to one another free of a separate adhesive layer. 
     
     
         35 . The structural composite laminate of  claim 29 , wherein the substantially inelastic polymeric particles are arranged discontinuously from one another along at least one dimension of the laminate. 
     
     
         36 . The structural composite laminate of  claim 29 , wherein the substantially inelastic polymeric particles have a compression set greater than 30 percent as measured by ASTM D395 at 50° C. for 24 hours. 
     
     
         37 . A structural composite laminate made by a process comprising:
 applying a compression force to a plurality of solid yet deformable discrete, non-porous, substantially inelastic polymeric particles situated between first and second lamina to deform the polymeric particles into a deformed state, and releasing the compression force without delaminating the first and second lamina from the substantial inelastic polymeric particles to form a structural composite laminate, the structural composite laminate comprising the first and second lamina bonded to the non-porous, substantially inelastic polymeric particles substantially retained in the deformed state and with inter-particle voids extending surface to surface from and to respective surfaces of adjacent particles of the non-porous, substantially inelastic polymeric particles.   
     
     
         38 . The structural composite laminate of  claim 37 , wherein the first and second laminas comprise metals. 
     
     
         39 . The structural composite laminate of  claim 37 , wherein the core possesses a monolayer of the substantially inelastic polymeric particles. 
     
     
         40 . The structural composite laminate of  claim 37 , wherein the core possesses a plurality of layers of the substantially inelastic polymeric particles stacked one on top of another.