High-strength low-heat release composites

Abstract

Embodiments disclosed herein relate to composite structures having high bending stiffness and low heat release properties and methods of making the same.

1 . A composite structure, comprising:
 a first thermoset layer having a first plurality of fibers and a first thermoset resin;   a second thermoset layer disposed below the first thermoset layer, the second thermoset layer having a second plurality of fibers and a second thermoset resin; and   a metal layer bonded to the first thermoset layer.   
     
     
         2 . The composite structure of  claim 1 , further comprising a core disposed between the first thermoset layer and the second thermoset layer, wherein the core includes a plurality of cells bonded together. 
     
     
         3 . The composite structure of  claim 2  wherein the plurality of cells includes a plurality of tubes bonded together in a parallel orientation or a polymer foam body. 
     
     
         4 . The composite structure of  claim 3  wherein the plurality of tubes includes polycarbonate tubes, polypropylene tubes, polystyrene tubes, or polyetherimide tubes. 
     
     
         5 . The composite structure of  claim 1  wherein:
 the first thermoset layer includes a plurality of glass fibers or a plurality of carbon fibers; and 
 the second thermoset layer includes a plurality of glass fibers or a plurality of carbon fibers. 
 
     
     
         6 . The composite structure of  claim 1  wherein:
 the first plurality of fibers has a density of about 80 gsm to about 300 gsm; and 
 the second plurality of fibers has a density of about 80 gsm to about 300 gsm. 
 
     
     
         7 . The composite structure of  claim 1 , further comprising a thermoplastic layer disposed beneath the metal layer, the thermoplastic layer including a high-temperature thermoplastic polymer including one or more of polyetherimide, polyether ether ketone, polytetrafluoroethylene, perfluoroalkoxy, polyfluoroethylenepropylene, or polyethylene terephthalate/polybutylene terephthalate. 
     
     
         8 . The composite structure of  claim 7  wherein:
 the thermoplastic layer includes a polyetherimide polymer; 
 the first thermoset resin includes an epoxy-polyurethane thermoset resin; and 
 the second thermoset resin includes the epoxy-polyurethane thermoset resin. 
 
     
     
         9 . The composite structure of  claim 1  wherein the metal layer includes an aluminum foil, an aluminum mesh, or a perforated aluminum sheet. 
     
     
         10 . The composite structure of  claim 1  wherein the metal layer includes an acid etched surface facing the first thermoset layer. 
     
     
         11 . A method of making a composite structure, the method comprising:
 disposing a lay-up in a mold, the lay-up including:
 a first thermoset layer having a first plurality of fibers; 
 a second thermoset layer disposed below the first thermoset layer, the second thermoset layer having a second plurality of fibers; and 
 a metal layer disposed on the first thermoset layer, wherein the metal layer is an outermost layer of the lay-up; 
   pressing the lay-up in the mold at a pressure of about 10 bar or less; and   at least partially curing the lay-up to form the composite structure.   
     
     
         12 . The method of  claim 11  wherein the metal layer includes an aluminum foil, an aluminum mesh, or a perforated aluminum sheet. 
     
     
         13 . The method of  claim 11  wherein the lay-up includes a core disposed between the first thermoset layer and the second thermoset layer, the core including a plurality of cells bonded together. 
     
     
         14 . The method of  claim 13  wherein the plurality of cells includes a plurality of tubes bonded together in a parallel orientation or a polymer foam body. 
     
     
         15 . The method of  claim 11  wherein:
 the first thermoset layer includes a first thermoset resin; 
 the second thermoset layer includes a second thermoset resin; and 
 one or more of the first thermoset resin or the second thermoset resin includes an epoxy-polyurethane thermoset resin. 
 
     
     
         16 . The method of  claim 11  wherein disposing a lay-up in a mold includes forming the lay-up. 
     
     
         17 . The method of  claim 16  wherein forming the lay-up includes applying the first thermoset resin onto the first plurality fibers to form the first thermoset layer and applying the second thermoset resin onto the second plurality of fibers to form the second thermoset layer. 
     
     
         18 . The method of  claim 11  wherein one or both of the first plurality of fibers or the second plurality of fibers includes carbon fibers or glass fibers. 
     
     
         19 . The method of  claim 18  wherein disposing the lay-up in a mold includes:
 disposing the metal layer in the mold; 
 disposing the first thermoset layer on the metal layer; 
 disposing the core on first thermoset layer; 
 disposing the second thermoset layer on the core. 
 
     
     
         20 . The method of  claim 11 , further comprising coating at least a portion of the mold with a rubber material. 
     
     
         21 . The method of  claim 20  wherein the rubber material includes a room-temperature vulcanizing silicone. 
     
     
         22 . The method of  claim 20  wherein disposing the metal layer in a mold includes disposing the metal layer on the rubber material in the mold. 
     
     
         23 . The method of  claim 11  wherein pressing the lay-up in the mold at a pressure of about 10 bar or less includes pressing the lay-up in the mold at a pressure of less than 9 bar. 
     
     
         24 . The method of  claim 11  wherein pressing the lay-up in the mold at a pressure of about 10 bar or less includes pressing the lay-up for a selected duration. 
     
     
         25 . The method of  claim 11  wherein pressing the lay-up in the mold at a pressure of about 10 bar or less includes pressing the lay-up in a heated mold. 
     
     
         26 . The method of  claim 11  wherein at least partially curing the lay-up to form the composite structure includes one or more of heating the lay-up while pressing the lay-up in the mold or allowing the lay-up to cool to an ambient temperature after pressing the lay-up in the mold. 
     
     
         27 . The method of  claim 11  wherein the mold is sized and shaped to form a panel for communication equipment, an exterior body panel, an interior body panel, a frame, a dashboard, a molding, a seat component, a table, a tray, a storage bin, a storage lid, a battery, or electromagnetic shielding. 
     
     
         28 . The method of  claim 11  wherein:
 first thermoset layer includes an epoxy-polyurethane resin on a first plurality of glass fibers or carbon fibers; and 
 the second thermoset layer includes the epoxy-polyurethane resin on a second plurality of glass fibers or carbon fibers. 
 
     
     
         29 . A composite structure, comprising:
 a first thermoset layer having a first plurality of fibers and a first thermoset resin;   a second thermoset layer disposed below the first thermoset layer, the second thermoset layer having a second plurality of fibers and a second thermoset resin;   a core disposed between the first thermoset layer and the second thermoset layer, wherein the core includes a plurality of cells bonded together; and   a metal layer bonded to an outer surface of the first thermoset layer.   
     
     
         30 . The composite structure of  claim 29  wherein the metal layer includes an aluminum foil, a perforate aluminum sheet, or an aluminum mesh. 
     
     
         31 . The composite structure of  claim 29  wherein the composite structure is sized and shaped as a panel for communication equipment, an exterior body panel, an interior body panel, a frame, a dashboard, a molding, a seat component, a table, a tray, a storage bin, a storage lid, a battery, or electromagnetic shielding.