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, the metal layer being an outermost layer and extending across at least 50% of 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 . (canceled) 
     
     
         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 . (canceled) 
     
     
         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 and extends across at least 50% of the first thermoset layer; 
   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 . (canceled) 
     
     
         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 . (canceled) 
     
     
         17 . (canceled) 
     
     
         18 . (canceled) 
     
     
         19 . The method of  claim 11  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 a core on first thermoset layer, the core including a plurality of cells bonded together; 
 disposing the second thermoset layer on the core. 
 
     
     
         20 . The method of  claim 11 , further comprising coating at least a portion of one or more molding surfaces of the mold with a rubber material, and wherein disposing the metal layer in a mold includes disposing the metal layer on the rubber material in the mold. 
     
     
         21 . (canceled) 
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . (canceled) 
     
     
         25 . (canceled) 
     
     
         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, the metal layer extending across at least 50% of the first thermoset layer.   
     
     
         30 . The composite structure of  claim 29  wherein the metal layer includes an aluminum foil, a perforated 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.