Abstract: A sulfur reaction product formed by reacting elemental sulfur with an amine or epoxy compound containing reactive functionality. Such reaction product can be incorporated into a thermosettable resin composition as a modifier. When the thermosettable composition containing such sulfur reaction product is cured, the resulting crosslinked thermoset displays improved stress relaxation characteristics in line with vitrimer like behaviors.

Abstract: A multifunctional surfacing material capable of providing lightning strike protection (LSP) and burn-through resistance. In one embodiment, the multifunctional surfacing material is composed of a conductive layer positioned between two resin layers, at least one of which contains one or more fire retardant compounds. In another embodiment, the multifunctional surfacing material is composed of a conductive layer positioned between two resin layers one of which is a thermally-stable layer. The surfacing material is co-curable with a composite substrate, e.g. prepreg or prepreg layup, which contains fiber-reinforced matrix resin.

Abstract: A multifunctional surfacing material capable of providing lightning strike protection (LSP) and burn-through resistance. In one embodiment, the multifunctional surfacing material is composed of a conductive layer positioned between two resin layers, at least one of which contains one or more fire retardant compounds. In another embodiment, the multifunctional surfacing material is composed of a conductive layer positioned between two resin layers one of which is a thermally-stable layer. The surfacing material is co-curable with a composite substrate, e.g. prepreg or prepreg layup, which contains fiber-reinforced matrix resin.

Abstract: A resin infusion method that incorporates a melt-on-demand approach. The method includes: (a) providing a curable resin composition in the form of a block of frozen resin (20); (b) coupling the block of frozen resin (20) to an inlet port of a heated extruder (22), which comprises at least one rotating screw (24) housed within a heated barrel (25); (c) progressively melting the block of frozen resin (20) at the inlet port and concurrently feeding the melt resin through the heated barrel (25) to produce a liquid resin having a viscosity suitable for resin infusion; (d) continuously feeding the liquid resin exiting from the extruder to a mold, which contains a fibrous preform; and (e) introducing the liquid resin into the fibrous preform, wherein the block of frozen resin (20) provides an amount of resin composition sufficient for infusing the entire fibrous preform.

Abstract: A multifunctional surfacing material capable of providing lightning strike protection (LSP) and burn-through resistance. In one embodiment, the multifunctional surfacing material is composed of a conductive layer positioned between two resin layers, at least one of which contains one or more fire retardant compounds. In another embodiment, the multifunctional surfacing material is composed of a conductive layer positioned between two resin layers one of which is a thermally-stable layer. The surfacing material is co-curable with a composite substrate, e.g. prepreg or prepreg layup, which contains fiber-reinforced matrix resin.

Abstract: A manufacturing process, which includes: (i) preparing a preform; (ii) laying the preform within a mold; (iii) heating the mold to a predetermined temperature; and (iv) injecting a modified resin system, wherein the modified resin system is formulated to have a viscosity below a threshold viscosity at a specific temperature and a high level of toughness. In one embodiment, the modified resin system contains a combination of epoxies, a curing agent, core-shell rubber particles, a thermoplastic material in an amount of less than 7% by weight, wherein in a cured condition, the thermoplastic material is separated into aggregate domains from the base resin, each aggregate domain having an island-like morphology.

Abstract: A multifunctional surfacing material capable of providing lightning strike protection (LSP) and burn-through resistance. In one embodiment, the multifunctional surfacing material is composed of a conductive layer positioned between two resin layers, at least one of which contains one or more fire retardant compounds. In another embodiment, the multifunctional surfacing material is composed of a conductive layer positioned between two resin layers one of which is a thermally-stable layer. The surfacing material is co-curable with a composite substrate, e.g. prepreg or prepreg layup, which contains fiber-reinforced matrix resin.

Abstract: A resin infusion method that incorporates a melt-on-demand approach. The method includes: (a) providing a curable resin composition in the form of a block of frozen resin (20); (b) coupling the block of frozen resin (20) to an inlet port of a heated extruder (22), which comprises at least one rotating screw (24) housed within a heated barrel (25); (c) progressively melting the block of frozen resin (20) at the inlet port and concurrently feeding the melt resin through the heated barrel (25) to produce a liquid resin having a viscosity suitable for resin infusion; (d) continuously feeding the liquid resin exiting from the extruder to a mold, which contains a fibrous preform; and (e) introducing the liquid resin into the fibrous preform, wherein the block of frozen resin (20) provides an amount of resin composition sufficient for infusing the entire fibrous preform.

Abstract: A manufacturing process, which includes: (i) preparing a preform; (ii) laying the preform within a mold; (iii) heating the mold to a predetermined temperature; and (iv) injecting a modified resin system, wherein the modified resin system is formulated to have a viscosity below a threshold viscosity at a specific temperature and a high level of toughness. In one embodiment, the modified resin system contains a combination of epoxies, a curing agent, core-shell rubber particles, a thermoplastic material in an amount of less than 7% by weight, wherein in a cured condition, the thermoplastic material is separated into aggregate domains from the base resin, each aggregate domain having an island-like morphology.

Abstract: Method of preparing a particle dispersion within a polymer is disclosed. The dispersion may include core shell rubber particles and the polymer may include epoxies. The particles are capable of being substantially dispersed within the polymer so as to substantially inhibit agglomeration of the particles. Mechanical properties, such as toughness are improved while glass transition temperature and viscosity are not substantially impaired by the presence of the particles.

Abstract: Method of preparing a particle dispersion within a polymer is disclosed. The dispersion may include core shell rubber particles and the polymer may include epoxies. The particles are capable of being substantially dispersed within the polymer so as to substantially inhibit agglomeration of the particles. Mechanical properties, such as toughness are improved while glass transition temperature and viscosity are not substantially impaired by the presence of the particles.

Abstract: Embodiments of the invention are directed to modified resin systems for use in liquid resin infusion (LRI) processes, variations of LRI processes and other suitable processes. In one embodiment, the modified resin system includes a novel combination of at least one base resin, an amount of particles within a predetermined range and an amount of thermoplastic material within a predetermined range wherein, when combined, the modified resin system has an average viscosity below a threshold average viscosity at a specific temperature and a high level of toughness. The modified resin system may additionally include a curing agent and other suitable components.