HIGH IMPACT STRENGTH FIBER RESIN MATRIX COMPOSITES

Abstract: Improved fiber resin matrix prepreg fabrics are disclosed which are comprised of a first layer of reinforcing fabric coated with an epoxy resin composition and a discrete second layer of an epoxy resin modified with an elastomeric polymer. The discrete second layer is provided with a support compris­ ing a gauze-like, lightweight fibrous mat or carrier of light-­ weight fibers that preserves the second "interleaf" layer dur­ ing cure. Cured composites having the continuous interleaf layer intact exhibit high impact strength and resistance to impact damage. In addition, high-performance fiber resin matrix composites are disclosed which are comprised of a first layer comprising reinforcing filaments coated with a thermosetting resin composition and a discrete second layer of a thermoplastic resin. When the composite layers are matched to provide certain minimum strength and elongation properties, composites of unusually high impact strength and resistance to impact damage are achieved which retain their high performance properties over a range of temperatures and environmental exposures.

Description: RESIN tGTRIX COMPOSITIONS AND COMPOSITES PREPARED THEREFROM BACKGROUND OF THE INVENTION This invention relates to fiber resin matrix materials and methods. More particularly, the invention relates to improved interleafed fiber resin matrix fabric sheeting having high impact strength. High strength to weight materials constructed from fiber resin matrix composites have become widely used in many industries where strength, corrosion resistance and light weight are desirable. For example, resin matrix materials are particularly well suited for use in aircraft structural members. Sporting equipment, such as tennis rackets and golf clubs, has also been successfully constructed from such materials. Bi-layer composites have been described therein which comprise (A) a fiber resin matrix layer of highstrength reinforcing filaments coated with a thermosetting epoxy resin and (B) a discrete interleaf layer of modified thermosetting epoxy resin, containing a rubbery, extensible polymer material. The composites are commonly formed into prepreg tapes, wherein the filaments are arranged in a flat, unidirectional array, and the tapes used to build, or "lay-up", a structural laminate, where the inter leaf layers provide special advantages in terms of shear and impact strength. When the reinforcing filaments are in the configuration of a fabric, however, great difficulty has been encountered in maintaining a continuous interleaf layer. When the bi-layer prepreg fabrics are laminated and cured under pressure, the thin interleaf resin layer is broken up, largely eliminating any improvements in performance. This is at least partially due to the construction of reinforcing fabrics: Fiber bundles, or "tows", of about 1,000 to 12,000 individual fibers are interwoven to form a high-strength fabric sheet, which is in turn coated and impregnated with thermosetting resin. On a microscopic level, the surface of such a fabric is very uneven, and a thin interleaf layer, when pressed between fabric sheets and cured, is easily disrupted. Attempting to preserve the inter leaf layer by changing the curing process or radically altering the interleaf layer are imperfect solutions: Changes in the curing conditions or chemistry increases the cost, time and expertise required and often result in inferior composites; applying a thicker layer of interleaf resin or reinforcing it also adds cost but also, and much more importantly, abrogates the high strength-to-weight ratio that gives fiber resin matrix materials their advantage over metals-. Fiber resin matrix composites are typically comprised of a dense layer of strong reinforcing filaments coated with a thermoset resin to form a curable sheet or tape. The composite can then be formed to desired shapes and cured. Numerous reinforced resin matrix composites have been described in the art, of which U.S. Patents 2,561,449 (Ruderman), 2,810,674 (Madden), 3,010,848 (Rochas et al), 3,649,435 (Varlas), 3,755,061 (Schurb), 3,914,494 (Park), 4,182,495 (Borgmeier et al), 4,309,473 (Minamisaway et al), 4,343,843 (Johnson et al) and 3,472,730 (Frigstad) and British Patent No. 1,182,377 are representative. It is known that composite laminates can be improved by interleafing thermoset films between the fiber-reinforced layers. In the Frigstad patent, U.S. 3,472,730, for example, filament-reinforced resinous sheeting is disclosed which comprises a thin layer of high-strength filaments coated with a heatcurable resin composition and a separate exterior film on at least one side of the filament-reinforced layer comprising a heatcurable resin composition modified with a resin that contains elastomeric material. It has been proposed to employ interleaf resins comprising a thermosetting epoxy resin modified with 8-70E by weight of a. rubbery vinyl addition polymer such that the shear modulus is greater than 50,000 psi and yield strength is greater than 3,000 psi at high temperatures provide fiber resin matrix composites having greatly improved resistance to impact damage over a wide range of temperatures. It has also been proposed to use lightweight woven cloths (scrims) in thermoset interleafed fabric resin matrix composites to improve the impact resistance of composites reinforced by high-strength woven fabrics. -- SUMMARY OF THE INVENTION In one aspect of the present invention it has now been discovered that incorporating a thin, non-woven or woven fibrous mat or carrier into the elastomeric interleaf resin layer sufficiently supports the interleaf during cure to provide a fiber resin matrix prepreg fabric having significantly increased impact resistance, without significantly adding to the gross weight of the final composite. The non-woven or woven fibrous mat or carrier comprising, e.g., lightweight glass, polyester, graphite, carbon, boron, polyaramide, cellulosic, etc. fibers, does not reinforce the interleaf or add strength to the ultimate composite, rather it supports the interleaf resin during cure, providing a final interleaf layer that is continuous and integral. The preserved continuous inter leaf layer in turn provides finished composites having greater impact strength and resistance to delamination after impact damage. According to this aspect of the invention interleafed prepreg fabric is produced by: (1) incorporating a lightweight fibrous mat or carrier of supporting filaments into an interleaf resin composition comprising (a) a first thermosetting epoxy resin composition containing (b) about 8%-to 70% by weight of a rubbery vinyl addition polymer to provide a supported interleaf resin layer, and (2) introducing said supported interleaf resin layer to at least one surface of a fiber resin matrix comprising (a) a fabric of high-strength reinforcing filaments and (b) a second thermosetting epoxy resin composition. Also contemplated are prepreg fabrics comprising (A) a fiber resin matrix layer comprising (i) interwoven high-strength reinforcing filaments and (ii) a thermosetting epoxy resin composition coating said interwoven einforcing filaments, and (B) a discrete interleaf resin layer comprising (i) a lightweight fibrous mat or carrier of supporting filaments and (ii) a modified thermosetting epoxy resin composition containing from about 8% to 70% by weight of a rubbery vinyl addition polymer. In another aspect it has also been discovered that certain resin composites comprising alternating layers of a filament-reinforced thermosetting resin, called a fiber resin matrix layer, and of a thermoplastic resin, called an interleaf resin layer, show greatly improved compression strength after impact without reduction in mechanical properties at elevated temperatures. Furthermore, by matching the fiber matrix resin and the thermoplastic inter leaf resin components according to this invention to minimize diffusion and migration during cure, high-strength, impact-resistant composites may be achieved which show marked improvement over known materials. In accordance with this aspect of the invention interleafed fiber resin matrix composites are provided, the composites comprising: (A) a fiber resin matrix layer comprising (i) high-strength reinforcing filaments, preferably about 60%-70% by weight, and (ii) a thermosetting resin composition, preferably about 30%-40% by weight, coating said filaments, and (B) a discrete interleaf resin layer comprising a thermoplastic resin, adhesively bondable to the fiber resin matrix layer, wherein said thermosetting resin composition (A)(ii) exhibits shear modulus of at least 50,000 psi at high temperatures under wet conditions, and said interleaf resin (B) exhibits shear modulus above 50,000 psi and a yield strength above 3,000 psi at high temperatures. Preferably the glass transition temperature, Tg, of the thermoplastic resin is relatively high, e.g., above about 1400C., to provide thermal stability at upper use temperatures. For the purposes of the present invention, the term "high temperatures" and "upper use temperatures" refers to temperatures in and above a range of from about 180OF. to over 400OF. The term "wet conditions" refers to a test condition where the sample to be tested has been immersed in water at 1600F. for 14 days, or to any environmental exposure to moisture that produces a like condition. The term "thermoplastic resins refers to a resin which is wholly thermoplastic as well as to thermoplastic/thermosetting resin blends wherein the thermosetting component is a minor constituent of the blend, present in an amount of no more than 40% by weight; based on the weight of the blend. DESCRIPTION OF THE DRAWINGS FIGURE 1 is an enlarged elevational exploded view of an interleafed prepreg fabric composite according to the present invention, showing separate fiber resin matrix and interleaf lamina, and the components of individual lamina, including a reinforcing fabric, a resin matrix covering said fabric, a discrete interleaf layer of elastomeric resin, and a lightweight fibrous mat or carrier incorporated in said interleaf layer. FIGURE 2 is a magnified detail of the reinforcing fabric of FIGURE 1, showing the interwoven tows of reinforcing filaments. FIGURE 3 is a magnified sectional view of a tow of FIGURE 2, showing the individual reinforcing filaments, numbering approximately 1,000 to 12,000, which make up each tow. FIGURE 4 is a magnified detail of a lightweight fibrous supporting mat, showing the random configuration of lightweight supporting filaments. The preferred nonwoven fibrous mat is shown in this figure, but it should be noted that woven lightweight supporting carriers, formed from interwoven lightweight supporting filaments, may also be used to support the interleaf layer. As used herein, the term "matw generally denotes a non-woven fibrous film, and the term "carrier1 generally denotes woven such films. The collective term "fibrous mat or carrier" is intended to cover a wide range of lightweight non-woven and woven films capable of supporting (and not necessarily reinforcing) the interleaf resin layer during curing, as will be described in more detail below. FIGURE 5 is a schematic of the process of preparing a fiber resin matrix composite of the present invention. FIGURE 6 is a schematic of a process for providing a thermoplastic interleafing material on a fiber resin matrix in accordance with this invention. FIGURE 7 is an enlarged cross-sectional view of the thermoplastic interleafed fiber resin matrix tape of the subject invention. FIGURE 8 is a portion of a stack of composites, illustrating (with exaggerated crosses) the desirable area of adhesive bonding between the discrete layers in cured composites according to the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention is directed to the provision of a laminate layer referred to as an inter leaf for use in a composite structure of a fiber resin matrix and the interleaf. The fundamental discovery underlying the present invention is that a resin having particular mechanical properties,- when used to provide thin, discrete layers between reinforcing fabric layers of a fiber resin matrix fabric composite, results in a composite having unique toughness, shear resistance, and resistance to impact damage, and these properties are exhibited over a broad range of temperatures, e.g., from -670F to 2000F. This performance is achieved by pairing a matrix resin having particular high-temperature properties and an interleaf resin having some elastomeric properties to form a composite structure of alternating fabric and interleaf layers. Thus, the invention further resides in the fact that resins have been developed that are well suited for use as particular interleaf materials to provide a fiber resin matrix and interleaf resin composite of superior toughness. It is particularly significant in this invention that the interleaf material contains a quantity of rubbery (elastomeric) material and that the interleaf resin and the resin of the fiber resin matrix be sufficiently compatible to form strong cross-links across the resin interface; yet, the interleaf material must be capable of being viscosity controlled to prevent intermixing, and a discrete interleaf layer must be achieved. It has been discovered that the interleafed composites of the present invention, besides exhibiting the high compression, tensile and flexural strengths characteristic of fiber resin matrices, also exhibit an unexpected ability to withstand impact damage, and over a wide range of temperatures (e.g., samples are tested at from -670F to +2000F). The interleafed composites of the present invention, for example, show greater toughness, greater resistance to shear impact, greater tolerance of impact damage and greater resistance to crack propagation than conventional fiber resin matrix composites. The dynamic relationship between the fiber resin matrix component and the inter leaf resin component of the present composites is complex, however in general the interleaf resin provides toughness, i.e., high impact strength, to the composite at all temperatures, while the matrix resin is highly resistant to the effects of wet conditions and changes in temperature. The interleaf resin layers are also designed to protect the fiber matrix layers by absorbing or otherwise "heading off" damaging forces before they reach levels harmful to the fiber resin matrix. When subjected to shear forces, for instance, the interleaf materials suitable for the purposes herein show great elongation above a certain shear stress level, and the components are paired so that the interleaf resin layer will flex and absorb the energy of the shear load as it approaches a level at which the fiber resin matrix will fail. If impact loads reach such levels that the structure cracks, the high strain capabilities of the interleaf layer help to maintain the integrity of the structure by increasing the energy required to drive cracks through the laminate. In this way crack propagation, even after damage, is curtailed; and by selecting the components to provide this sort of interprotective relationship, highperformance composites can be achieved. The reinforcing filaments useful in the present invention include, but are not limited to, filaments comprised of glass, carbon, graphite, silicon carbide, boron, polyaramide, polyester, polyamide, rayon, polybenzimidazole, polybenzothiazole, metal-coated such filaments, for example nickel-coated and/or silver-coated graphite fibers and filaments, or combinations of such filaments. In applications demanding a high strength to weight ratio or shear strength, carbon fibers, graphite filaments, polyaramid filaments or nickel-plated graphite filaments, such as disclosed in published European Patent Office Application Serial No. 83101195.2. are preferred. As discussed in referring to the drawings, above, individual reinforcing filaments are gathered in bundles, or tows, of approximately 1,000 to 12,000 filaments each and the tows are interwoven to form a flexible, strong fabric. Although reinforcing fabrics may appear to have a smooth surface, on a microscopic level the woven surface of the fabric is sufficiently irregular to disrupt the thin (e.g., about 0.0005 to 0.003 inch thick) interleaf layer under common curing conditions. The epoxy resin composition used to coat the reinforcing filaments (matrix resin) is comprised primarily of epoxy compounds having more than one epoxide group per molecule available for reaction. Such epoxy prepolymers include, but are not limited to, polyfunctional ethers of polyvalent phenols, for example pyrocatechol; resorcinol; hydroquinone; 4,4'-dihydroxydiphenyl methane; 4,4'-dihydroxy-3,3'-dimethyldiphenyl methane; 4,4 t -dihydroxydiphenyl dimethyl methane; 4,4'-dihydroxydiphenyl methyl methane; 4,4'-dihydroxydiphenyl cyclohexane; 4,4'-dihydroxy3,3'-dimethyldiphenyl propane; 4,4'-dihydroxydiphenyl sulphone; or tris-(4hydroxyphenyl) methane; polyglycidyl ethers of the chlorination and bromination products of the abovementioned diphenols; polyglycidyl ethers of novolacs (i.e., reaction products of monohydric or polyhydric phenols with aldehydes, formaldehyde in particular, in the presence of acid catalysts); polyglycidyl ethers of diphenols obtained by esterifying 2 mols of the sodium salt of an aromatic hydroxycarboxylic acid with 1 mol of a dihalogenoalkane or dihalogen dialkyl ether (see, U.K. 1,017,612); and polyglycidyl ethers of polyphenols obtained by condensing phenols and long-chain halogen paraffins containing at least 2 halogen atoms (see, U.K. 1,024,288). Other suitable compounds include polyepoxy compounds based on aromatic amines and epichlorohydrin, for example N,N' -diglycidylaniline; N,N'-dimethyl-N,N'diglycidyl-4,4'-diaminodiphenyl methane; N-diglycidyl4-aminophenyl glycidyl ether; N,N,N' ,N'-tetraglycidyl- 4,4'-diaminodiphenyl methane; and N,N,N',N'-tetra- glycidyl-1,3-propylene bis-4-aminobenzoate, the latter two compounds being most preferred. Glycidyl esters and/or epoxycyclohexyl esters or aromatic, aliphatic and cycloaliphatic polycarboxylic acids, for example phthalic acid diglycidyl ester and adipic ester diglycidyl and glycidyl esters of reaction products of 1 mol of an aromatic or dycloaliphatic dicarboxylic acid anhydride and ss mol of a diol or 1/n mol of a polyol with n hydroxyl groups, or hexahydrophthalic acid diglycidyl esters, optionally substituted by methyl groups, are also suitable. Glycidyl ethers of polyhydric alcohols, for example of 1,4-butanediol; 1,4-butenediol; glycerol; l,l,l-trimethylol propane; pentaerythritol and polyethylene glycols may also be used. Triglycidyl isocyanurate; and polyglycidyl thioethers of polyvalent thiols, for example of bis mercaptomethylbenzene; and diglycidyltrimethylene sulphone, -are also suitable. The epoxy resin composition will also include a curing agent for the epoxy resin. Such curing agents are well known to those skilled in the art, and preferred curing agents for the purposes herein will be diamines, including, but not limited to, diaminodiphenyl sulphone, diaminodiphenyl methane, phenylenediamine, etc. The amount of curing agent necessary for a particular application can be readily determined by persons skilled in the art and will vary according to the precise makeup of the resin composition, the curing conditions desired and other factors. However, by way of illustration, where a diamine curing agent is employed, from about 20 to 40 weight percent, most preferably about 27 to 31 weight percent, based on the total epoxy resin, has been found suitable. Fillers, dyes, pigments, plasticizers, curing catalysts and other such conventional additives and processing aids may be added to the epoxy resin compositions described herein before curing to influence the properties of the final resin composite. The modified heat-curable epoxy resin of the inter leaf layer comprises 30% by weight or more epoxy resin composition and from about 8% to 70% by weight of a rubbery vinyl addition polymer. The suitable epoxy resins (and curing agents) are of the same type disclosed above, although the particular epoxy resin employed in the inter leaf will typically be a different resin than that selected for use in the fiber resin matrix layer. The rubbery vinyl addition polymers contemplated herein include homopolymeric and copolymeric diene rubbers, derived from conjugated dines of 4 to 8 carbons such as butadiene, isoprene, propylene, chioroprene, and the like. These include but are not limited to copolymers of such dienes with each other and with one or more of such monomers as styrene, acrylonitrile, methacrylonitrile, acrylic acid, methacrylic acid, methyl methacrylate, and the like. Butadieneacrylonitrile polymers and carboxylic-functional butadiene-acrylonitrile polymers are most preferred. The amount of rubbery modifier present can vary from 8 to 70 weight percent, and the specific amounts employed must be sufficient to impart elasticity and toughness to the inter leaf resin. Preferably, about 8 to 24 weight percent of the modifier will be used; and where the preferred butadiene-acrylonitrile copolymers are employed, a level of about 10 to 15 weight percent is most preferred. Suitable supporting fibers for use in the nonwoven or woven fibrous mat or carrier are selected for their ability to preserve the continuity of the interleaf layer during the curing process, and accordingly the fibers must survive the curing temperatures, e.g., 3500F, without disintegrating. Beyond this requirment, the primary factor influencing selection of the most appropriate fibrous mat or carrier is weight. The lightweight fibrous mat or carrier must add as little weight as possible to the final prepreg sheet, preferably less than 5%. Lightweight fibrous mats and carriers of lightweight glass, carbon, graphite, boron, polyaramide, polyethylene, polyester, and cellulosic fibers, and the like, are contemplated, so long as they provide sufficient support during cure to preserve the resin interleaf layer. Non-woven fibrous mats are generally preferred over woven carriers of the same material, since the mat or carrier will normally weigh much less than the woven carrier, however where a woven support will serve the purposes described herein without disadvantageously increasing the weight of the final prepreg, it is entirely acceptable. Mats of spun polyester fibers are most preferred. The physical properties of the interleaf resin composition are not affected by the presence of the lightweight fibrous mat or carrier. The physical strength of the mat or carrier is almost insignificant compared to that of the cured resin, and for that reason the fibrous mat¯or carrier is not thought of in the art as "reinforcing" the interleaf layer. The bi-layered prepreg fabric sheeting of the invention is prepared by methods well known in the art. Typically, the high-strength reinforcing fabric is dipped over tension rollers in an epoxy resin composition dispersed in solvent, then introduced through wiping rollers to control the resin content, e.g., to about 30% to 60% by weight, preferably 40% to 45%. The resin-coated fabric is passed through a drying tower to remove solvent, then introduced through a laminator, where it is mated with release paper coated with the modified interleaf resin. The fibrous mat or carrier is most easily introduced after the mating of the layers, by being wound into the interleaf layer before the inter leaf resin dries. As soon as the resins are sufficiently dry to be handled, the bi-layer prepreg fabric is wound on a spool or otherwise conventionally stored for use in constructing high-strength composite structures. The viscosity of the inter leaf resin must be sufficiently high to provide the interleaf with the necessary toughness and to maintain the inter leaf resin as a discrete layer adjacent to the fabric resin matrix. As previously mentioned, however, crosslinking at the interface between the two resin layers is desireable (and most preferred). This conditionwill occur when the resin of the inter leaf is chemically compatible with the resin of the fiber resin matrix, so as to promote cross-linking, and loaded with the necessary amount of elastomeric (rubbery) material to define a discrete interleaf layer. It has been observed that the resin of the interleaf containing the necessary amount of modifier will have a Flow Test Number (flow percent), N, measuring less than about 12 from the following viscosity test: FLOW (VISCOSITY) TEST I. Prepare a laminate by coating 0.02 pounds per square foot on interleaf resin onto 120 glass fabric. 2. Stack four, 4" x 4" square plies of the laminate. 3. Weigh the uncured 4-ply stack. 4. Cure the stack at 3250F 60 psi for 15 minutes. 5. Trim all resin that is squeezed beyond the edge of the 120 glass fabric during the curing step (4). 6. Weigh the cured, trimmed stack. 7. Obtain the flow percentage, N, as follows: (weight of - (weight of trimmed, N= uncured stack) cured stack) x 100 (weight of uncured stack) A flow percent N below about 12 is required for optimal performance under this invention and preferably the N flow number will be between 5.5 and 7.7. Also, experimental data indicate that poor interleaf material is obtained when the N flow number is above about 14.6. In addition to the flow characteristics of a resin, an indication of the perfomance of laminated fiber resin matrix composites can be gained by subjecting cured samples of the resins to shear forces, and measuring the elongation (in inches) as a function of applied force (in lbs). The data from this test may be plotted, which typically generates a curve that ends at the point of applied force and elongation where the sample breaks. From this curve, the shear strain and shear stress of the resins can be calculated and the characteristic stress/strain curves plotted. The testing procedure is described more fully in Krieger, Jr., R.B., "Stiffness Characteristics of Structural Adhesives For Stress Analysis in Hostile Environment," American Cyanamid Co., Bloomingdale Plant, Havre de Grace, MD (May, 1979), incorporated herein by reference. When the fiber resin matrix and interleaf resin are properly matched according to the present invention, the shear stress/strain curves at various temperatures for the matrix resin and the interleaf resin show high modulus and other properties (yield, strain to failure, ultimate stress), discussed in more detail below. In practice, the interleaf material of this invention can be used to form a variety of different parts. For example, cover structures for airplane parts may be formed of fiber resin matrix-interleaf sheets stacked and cured to form 0.10-inch to 0.25-inch thin structural parts, for example wing and fuselage components. The fabric sheeting of this invention is suitable for primary structures having the highest performance requirements. The fiber resin matrix-interleaf fabric sheets range in thickness from 0.005 to 0.04 inch, the thickness varying according to resin content, type of fabric used, fiber count, etc. The fiber resin matrix-interleaf fabric sheets are also commonly laminated with the direction of the fabric weave oriented in different directions, e.g., 0 and 450 relative, depending on the stress requirements of the part. The relative thickness of the layers of the fiber resin matrix-interleaf resin sheet is also important. Preferably the discrete, mat- or carriersupported inter leaf layer will be in the range of about 0.0005 in. to 0.003 in. (or about 0.0004 to 0.03 pounds/square foot, most preferably 0.01 to 0.018 pounds/square foot), and the fabric resin matrix layer will be in -the range of about 0.005 in. to 0.014 in. The degree of elongation after reaching the yield point is important. The interleaf resin must have an overall elongation or strain to failure of at least 6%, preferably 9%, at -670F, and a strain to failure at room temperature of at least about 15%, preferably 25% or greater. This property is less important at elevated temperatures, but preferred interleaf resins will have a strain to failure of over 20%, most preferably over 50% at 2000F. The general configuration of a fiber resin matrix fabric prepreg according to the present invention is illustrated in the drawings. As seen in FIGURE 1, the bi-layer prepreg fabric sheet 10 of the invention is comprised of two layers: A fiber resin matrix layer 30 and a thin interleaf layer 20. The fiber resin matrix 30 is comprised of a fabric 11 made of interwoven tows of bundled high-strength reinforcing filaments, and fabric 11 is coated and impregnated with a thermosetting epoxy resin composition 12. Adjacent said fiber resin matrix layer 30 is interleaf layer 20, comprising a modified epoxy resin composition 22 (containing a rubbery vinyl addition polymer) supported by fibrous mat or carrier 21 made of lightweight supporting fibers. FIGURE 2 illustrates the structure of fabric 11, wherein tows 13 are interwoven to form a high-strength fabric sheet. FIGURE 3 illustrates the construction of tows 13 from bundles of individual reinforcing filaments 14, numbering approximately 1,000 to 12,000 per tow 13. The general configuration of the non-woven or woven fibrous mat or carrier 21 that supports the modified resin composition 22 of inter leaf layer 20 is detailed in FIGURE 4, wherein the non-woven, random arrangement of the lightweight supporting fibers 23 is shown. Bi-layered sheets 10 are typically stacked to form a prepreg laminate which is, in turn, shaped and cured to provide high performance fabric resin matrix composites, that is, fiber resin matrix composites wherein the reinforcing fiber matrix is in the configuration of a high-strength woven fabric. Another fundamental discovery underlying the present invention is that a resin having particular mechanical properties, when used to provide thin, discrete layers between fiber-reinforced layers of a fiber resin matrix composite, results in a composite having unique toughness, shear resistance, and resistance to impact damage, and these properties are maintained at elevated temperatures, e.g., up to 2700F., and even higher. This performance is achieved by pairing a matrix resin having particular high-temperature properties and a thermoplastic interleaf resin having adhesive bonding properties, a relatively high glass transition temperature and a relatively high strain to failure to form a composite structure of alternating fiber resin matrix and interleaft resin layers. This invention further resides in the use of thermoplastic materials as particular inter leaf materials, making possible fiber resin matrix and interleaf resin composites of superior toughness. It is another particularly significant aspect of this invention that the interleaf material comprises a thermoplastic material, that it contains at most a minor portion of thermosetting materials and that the interleaf resin and the resin of the fiber resin matrix are sufficiently compatible to form an adhesive bond at the resin interface. On a microscopic level, there may be an extremely thin layer at the matrix resin/interleaf resin interface, characteristic of adhesive-type bonding, where the thermoplastic interleaf material dissolves slightly in--the matrix resin; however, aside from this bonding interface, the interleaf material must be capable of maintaining a discrete interleaf layer, and no general intermixing of the interleaf layer and resin matrix layer occurs. The interleafed composites of the present invention exhibit high compression, tensile and flexural strengths as well as the ability to withstand impact damage. The interleafed composites of the present invention show greater toughness, greater resistance to shear impact, greater tolerance of impact damage and greater resistance to crack propagation than conventional' fiber resin matrix composites. With respect to stateof-the-art thermosetting interleafs, thinner thermoplastic films surprisingly are equivalent to thicker thermosetting films, with respect to their toughness. With conventional thermosetting interleafs, it is not possible to employ interleaf thicknesses below about 0.001 inch without significant loss of toughness of the composite, however the thermoplastic interleaf in the present invention may be utilized at such low thicknesses, e.g., on the order of 0.0005 inch, without adverse effect on toughness properties. As seen in FIGURE 5, the basic fiber matrix material may be produced by delivering reinforcing filaments 42 through conventional eye-boards 44 and 46 to a pressure roller assembly 48. The curable thermosetting resin composition (matrix resin) is coated in a layer 50 from a conventional film coating applicator 52 onto a substrate such as release paper 54 and passed through the pressure roller assembly 48. Release paper 56 is also delivered to the pressure roller assembly 48. The pressure rollers 50 are set at a temperature and pressure for imbedding the fibers 42 in the resin layer 50 to form a fiber resin matrix 58. Practice has taught that a temperature in the range of 1900F and pressures of one thousand pounds over a fifteen inch center are suitable for producing a fiber resin matrix 58. The fibers 42, the substrate 54 with resin layer 50 and the release paper 56 are delivered to the pressure rollers 48 and passed therethrough at the rate of 3-20 feet/minute. The feed of fiber 42 and resin layer 50 to the pressure rollers 48 is selected to produce a fiber resin matrix of about 30-40 weight percent (preferably 34 weight percent) resin and about 60-70 weight percent (preferably about 66 weight percent) fiber. For example, 120 filaments of 6R carbon fibers are delivered within a twelve inch width to the pressure rollers 48 with a layer of resin .013 to .018 pounds per square foot. The resulting fiber resin matrix 58 is thus reinforced by a closely packed array of filaments. Thereafter, as shown in FIGURE 6, the release paper on one side of the fiber resin matrix 58 is removed and the fiber resin matrix is passed through another set of pressure rollers 60 for the application of the interleaf material 62 to the fiber resin matrix 58. A layer of interleaf material 62 is typically extruded (by hot melt extrusion), or cast out of solvent, onto a carrier 68, cooled or dried, then laminated with the fiber resin matrix 58 through pressure rollers 60. The interleaf material 62 is deposited to provide an interleaf layer of about 0.0004 to 0.004 inches thickness. The exposed surface of the fiber resin matrix 58 is presented to the interleaf material 62 and the two are joined by the inherent adhesive nature of the matrix resin 58. The interleaf material is essentially thermoplastic and virtually without any adhesive characteristics. An interleafed fiber resin matrix composite 64 is thus produced and appears as shown in FIGURE 7. The reinforcing filaments useful in this aspect of the present invention have been illustrated above. Thermosetting resin compositions potentially useful as the matrix resin in the present invention include epoxy, polyimide, bis maleimide and acetyleneterminated resins. Polyimides potentially useful as matrix resins in the practice of the present invention include the polyimides disclosed in U.S. Patent Nos. 3,528,950; 3,745,149; 4,233,258; and 4,166,170. Bis maleimide resins which may be employed as the matrix resin include bis maleimides based on the following monomers: EMI21.1 wherein the isomeric species are meta, meta, meta, para or para, para and X = - CH2 -, -O-, -S-, or -C- , EMI21.2 meta or para EMI22.1 Acetylene-terminated resins which may be utilized as the matrix resin include resins based on EMI22.2 EMI23.1 wherein the - C=CH substituents each independently may be meta- or para - positioned. The thermoplastic resin of the interleaf comprises a high molecular weight engineering thermoplastic, much as a polyester, a polyamide, a polyaramid, a polyarylate, a polycarbonate, a poly(ester carbonate), a polybenzimidazole, a polyimide, a polyether imide, a polyamide imide, and the like. Preferably the thermoplastic will be a polyether ether ketone, abbreviated PEEK (ICI), a polyimide, e.g., KAPTOIQ' (DuPont), or a polyether imide, e.g., ULTEM (General Electric). As indicated, the thermoplastic resin may contain a minor amount (up to 40% by weight) of a thermosetting resin, which may for example be of the same composition as the matrix resin, as may be necessary or desirable in a given application to achieve suitable solvent resistance or other material properties of the interleaf. In addition, it may be advantageous in the practice of the present invention to utilize reinforcing materials in the interleaf, such as mat scrim, whiskers, particulates, chopped fibers or other second phase reinforcement, and in general the reinforcing material may suitably be employed in various amounts, such as for example up to about 50% by weight based on the total weight of the interleaf. It has been discovered that in order to provide the unique advantages of the present invention, the thermosetting resin compositions, that is, the matrix resin (which coats the reinforcing filaments), and the interleaf resin must exhibit specific properties. The matrix resin, when tested "neat", or without reinforcement, must show a minimum stiffness when subjected to shear forces, especially at high temperatures and under wet conditions. The matrix resin must have a shear modulus of at least 90,000 psi under hot, dry conditions, e.g., when subjected to shear at 1800'F-2700F, or a shear modulus of at least 50,000 psi under hot, wet conditions, e.g., when subjected to shear at 1800F-2700F after soaking in water at 1600F for 14 days. It is also necessary that the matrix resin have a shear modulus above about 100,000 at room temperature and extremely low temperatures, i.e., -67 F, however, this is ordinarily the case where the modulus at 1800-2000F is as high as 50,000 psi. Preferred matrix resin compositions will show an initial shear modulus of 90,000 psi or above under hot, wet conditions, and will show an initial shear modulus of 130,000 psi or above at room temperature and low temperatures. The most preferred thermosetting resins for use as a matrix resin will also exhibit high strength, for example an ultimate stress over 3000 psi, most preferably 5000 psi or above. The inter leaf resin must also exhibit a minimum initial shear modulus, and in addition the interleaf resin must show elongation above a minimum stress. This initial modulus is believed to transfer loads between the layers of the reinforcing fibers without large deformation of the structure. For the purposes herein, the interleaf material must have an initial shear modulus above 50,000 psi at high temperatures, preferably above 90,000 psi at 1800F-2700F. At room temperature the initial shear modulus for the interleaf should be at least about 100,000 psi (preferably at least 130,000 psi), and at -670F the shear modulus should be at least about 130,000 psi (preferably at least 150,000 psi); however, as with the matrix resin, such values at room temperature and low temperatures would be expected with high shear modulus at elevated temperatures. Most preferably, the interleaf resin will be slightly soluble in the uncured or partially cured thermosetting matrix resin at temperatures used to form the composites. This aids in providing adhesive bonding at each interface. The interleaf resin must, of course, also be able to survive the curing temperatures, usually about 3500F., that the composites are subjected to. The interleaf resin shows an initial rigidity (high modulus) when subjected to shear but at a certain level of shear stress, shows elongation (high ultimate strain). The point at which the resin begins to show high elongation in response to stress is the "yield strength" of the resin, and for the purposes herein, this must be at least about 3000 psi at high temperatures. Most preferred inter leaf resins will have a roo temperature yield strength of at least about 6000 psi and a high temperature yield strength of at least about 5000 psi. DESCRIPTION OF THE PREFERRED EMBODIMENTS In order that those skilled in the art may better understand the practice of the invention, the following examples are included by way of illustration, and not by way of limitation. EXAMPLES The following resin formulations were prepared in order to test the improvement of the present invention: parts by Resin A weight tetra(4,4' )N-glycidyl methylene dianiline (Ciba Geigy Araldite MY-720) 80 polyglycidyl ether of ortho-cresol formaldehyde novolac (Ciba Geigy ECN-1273) 20 diaminodiphenyl sulfone (Ciba Geigy Eporal- BT-976) 35 fumed silica (SiO2) (Cabot Cab-o-Sil M-5) 6 reaction product of toluene diisocyanate and dimethylamine Resin B tetra(4,4' )N-glycidyl methylene dianiline (Ciba Geigy Araldite- MY-720) 80 tetraglycidoxy tetraphenylethane (Shell Epon- 1031) 20 trimethylene glycol di-para-amino-benzoate 44 fumed silica (SiO ) 2 (Cabot Cab-o-Sil- M-5) 6 reaction product of toluene diisocyanate and dimethylamine 1 Resin C (interleaf resin) An inter leaf resin composition was prepared according to the following formulation. The following pre-mix was charged to a vessel and prepared in situ at 3000F for four hours: Parts by PART A weight carboxylic-functional butadiene/ acrylonitrile polymer (Goodyear Hycar 1472) 12 diglycidyl ether of tetrabromo bisphenol A (Dow DER 542) 65 diglycidyl ether of bisphenol A (Dow DER 331) 65 bisphenol A 2 triphenyl phosphine 0.1 diaminodiphenyl sulfone (Ciba Geigy Eporal- HT-976) 6.0 The pre-mix, or "prereact", was then charged to a vessel with the following additional ingredients: : Parts By Weight prereact (Part A) 150.1 Part B tetra(4,4' )N-glycidylmethylene dianiline 36.0 diaminodiphenyl sulfone 16.0 dicyandiamide (American Cyanamid) 8.0 carboxyl ic-functional butadiene-acrylonitrile polymer - 12.0 titanium dioxide 1.0 Amaplast yellow, dye 0.05 Green 2 Base, dye 0.05 Fiber resin matrix prepreg fabrics were prepared by coating the above formulations on high-strength reinforcing fabric woven from 3,000 filament count tows of CELION- high-strain graphite fiber (Celanese Plastics and Speciality Company), forming a fabric approximately 0.007 inch thick, having approximately 7 to 8 tows per inch. The fabric was coated to have a resin content of about 40%-45% by weight. In samples where an interleaf layer was included, the interleaf resin composition (Resin C) was applied in amounts between about 0.01 to 0.03 pounds per square foot (psf). In samples where a supporting non-woven fibrous mat was included, the mat was composed of Reemay 2105 lightweight spun polyester fiber, formed on a screen from a fibrous slurry. The mats weighed approximately .003 pounds per square foot (psf) and are similar to the gauzy supports used with film adhesives. Such mats added about 3-4% to the weight of the composites. A series of fiber resin matrix composite samples using graphite fabric were prepared from matrix resins A and B, interleaf resin C, and the Reemay 2105 mat. Prepreg fabric sheets were formed into 18-ply laminates, the orientation of the fabric weave being alternated according to the same quasi-isotropic pattern, and the 18-ply laminates were then autoclave cured two hours at 3500F and 100 psi pressure. The cured composites were cut into 4" x 6" panels and tested for compression strength after falling dart impact. The following results were observed: TABLE I Compression Strength (ksi) after Sample 1500 in.-1b./in. Impact Mean (# Standard Devioation) Resin A 29.5 29.59 30.72 (40% resin content) 33.3 30.51 (# 1.78) Resin A with .011 psf 30.9 29.65 Resin C Interleaf 28.4 (# 1.77) Resin B 29.6 30.5 32.9 31.46 (40.5% resin content) 33.0 29.2 33.59 (# 1.92) Resin B with .0174 psf 34.6 32.6 32.22 Resin C Interleaf 30.2 31.5 (# 1.86) Resin B with .028 psf 30.3 29.75 Resin C Interleaf 29.2 (# 0.78) Resin B with .013 psf 38.71 38.83 36.76 Resin C + .003 psf 35.16 34.36 (# 2.34) fibrous mat Resin B with .017 psf 37.31 41.22 39.62 Resin C + .003 psf 36.55 43.40 (# 3.24) fibrous mat Resin B with .021 psf 32.17 34.99 Resin C + .003 psf 37.81 (# 3.99) fibrous mat Resin A with .017 psf 38.9 38.3 Resin C + .003 psf 37.7 (# 0.85) fibrous mat A direct comparison of a Resin A composite, a Resin B composite and an inter leafed composite according to the present invention using the fiber resin matrix with Resin B and the mat-supported inter leaf layer using Resin C was also performed. 12-ply composites were tested for compression strength (warp) at room temperature, 2000F and 2000F after immersion of the test panel in 1600F water for two weeks. 18-ply panels were subjected to compression strength after impact (1500 in.-lb./in. impact energy). Resin A and Resin B laminates were prepared from 40% resin content prepreg fabric; interleafed Resin B/Resin C laminates were prepared from 458 resin content prepreg. The following results were observed: TABLE II Interleafed Resin A Resin B Composite Compression Strength after 1500 in.-lb./in. impact (ksi) 29.50 32.26 39.62 Compression -Strength (warp)(ksiX, at room temp. 103.5 108.3 100.4 at 2000F 89.3 88.0 79.0 at 2000F, wet* 70.8 63.0 61.9 *wet = sample immersed in water at 1600F for two weeks. Many variations of the invention will suggest themselves to those skilled in this art in light of the above detailed description, and all such obvious variations are within the full intended scope of this invention. For example, other reinforcing filaments, such as carbon, silicon carbide, boron, aramide, polyester, polyamide, and rayon, or metal-coated, such as nickel- and/or silver-coated such filaments and fibers, alone or in any combination, can be used. Alternative supporting filaments for the lightweight fibrous mat or carrier may also be used, including glass, graphite, polyaramide, etc. Matrix resin and interleaf resin-formulations also can be varied in weight ratio widely, depending on the precise properties desired and the intended use. By way of illustration, where the preferred embodiment of the examples is used, the preferred weight ratios are as follows: Matrix Resin Parts bv Weight Preferred Most Preferred (i) tetra (4,4') N-glycidyl dianiline 50-100 75-85 (ii) tetraglycidoxy tetra phenylethane 0-50 15-25 (iii) trimethylene glycol di-para-aminobenzoate 28-60 35-45 (iv) fumed silica 0-12 5-7 (v) reaction product of toluene diisocyanate and dimethylamine 0.1-2.5 0.1-2.5 The interlaf resin, Parts A and B likewise can be mixed in broad ranges, but preferably, and most preferably the weights of ingredients used will fall in the following ranges: : Interleaf, PART A Parts by Weight Preferred Most Preferred (i) a carboxylic-functional butadiene-acrylonitrile copolymer 6-18 10-15 (ii) diglycidyl ether of tetrabromobisphenol A 0-130 55-75 (iii) diglycidyl ether of bisphenol A 0-130 55-75 (iv) bisphenol A 1-6 1-3 (v) triphenyl phosphine 0.05-0.25 0.05-0.15 (vi) diaminodiphenyl sulfone 2-12 3-9 Interleaf, PART B (i) tetra f4,4') N-glycidyl methylenedianiline 25-50 30-40 (ii) diaminodiphenyl sulfone 10-30 10-20 (iii) dicyandiamide 2-12 5-10 (iv) a carboxylic functional butad iene-acrylontr ile copolymer 6-18 10-15 (v) titanium dioxide 0.5-1.5 0.05-1.5 Wide proportions of Part A to Part B can be used, but preferably, from 75 to 200 parts by weight of Part A will be present for each 100 parts by weight of Part B. EXAMPLE 1 A matrix resin according to the present invention was made according to the following formulation: parts by weight tetra(4,41)N-glycidyl methylene dianiline 80 (Ciba Geigy Araldite MY-720) tetraglycidoxy tetraphenylethane 20 (Shell Epon 1031) trimethylene glycol di-para-aminobenzoate 44 (Polaroid Polacureo 740 M) fumed silica (SiO ) 6 22 (Cabot Cab-o-Sile M-5) reaction product of toluene diisocyanate 1 and dimethylamine A fiber resin matrix was formed by coating the above formulation on a layer of collimated graphite fibers. Composites were formed as shown in FIGURE 7, by applying to the aforementioned fiber resin matrix an interleaf film, approximately 0.0005 inches thick, of a polyether polyimide (ULTIMO), which was cast out of solvent. The thermoplastic interleaf resin formed a discrete layer adjacent to the fiber resin matrix having an adhesive bond at the interface between the two layers. Composites were stacked and autoclave cured at 3500F and 100 psi for 2 hours to produce a structural part. Stacks of eight plies, all arranged with collimated fibers, i.e., extending in the same direction (00), were prepared for the Unidirectional Compresion Strength, or UNI-COMP, test. Stacks of sixteen plies with the fibers oriented equally at 00, 900 and + 450 were prepared for the Quasi-isotropic Compression Strength, or QUASI-COMP, test. Stacks of thirty-six plies with the fibers oriented at relative angles of 00, 900 and +450 were prepared for the Compression Strength After Impact, or COMP/IMPACT, test. The laminates exhibited the following properties: Temp. UNI-COMP QUASI-COMP COMP/IMPACT (0C) (KSI) (KSI) (1500 in-lbs/in) 230 181.4 97.2 51,000 930 163.5 83.8 1320 130.0 68.7 In practice, the interleaf material can be used to form a variety of different parts. For example, cover structures for airplane parts may be formed of fiber resin matrix-interleaf sheets stacked and cured to form 0.10-inch to 0.25-inch thin structural parts. Structural members such as wing panels will be much thicker. Fiber resin matrix-interleaf sheets according to this invention range in thickness from 0.0005 to 0.010 inch, thus, for example, a stack of twenty-five to fifty fiber resin matrix-interleaf sheets will form a ·-inch thick part. The fiber resin matrix-interleaf sheets are typically stacked with the direction of the fibers oriented in different directions, depending on the stress requirements of the part. For example, the maximum number of fiber resin matrix-interleaf sheets may be oriented in the 0 direction, i.e., the direction in which the maximum tension or compression forces will be imposed, and the remainder of the fiber resin matrix-interleaf sheets are oriented at 900 and plus or minus 450 from the 0 orientation. The relative thickness of the layers of the fiber resin matrix-interleaf resin sheet is also important. Preferably the inter leaf layer will be in the range of about .0004 in. to .002 in., and the fiber resin matrix layer will be in the range of about .007 in. to .009 in. EXAMPLE 2 A fiber resin was prepared using the following matrix resin formulation: parts by weight tetra (4,4')N-glycidyl methylene dioniline 100 (Ciba Geigy Araldite MY-720) trimethylene glycol di-para-aminobenzoate 48.4 (Polaroid Polacure 740 M) PKHH phenoxy resin based on epichlorohydrin 10 and bis phenol A (Union Carbide Corporation) boron trifluoride - monoethyl amine (BF .MEA) 0.5 3 Composites were formed by applying an extruded polyether polyimide (ULTEM ) layer 0.001 inch thick. Laminates were formed, cured and tested as in Example 1, and the following data were obtained: Temperature Compression Strength QUASI-COMP ( C) (KSI) 230 89 930 1320 88+4 1770 62 The laminates also exhibited a Critical Strain Energy Release Rate, G , of 3.15 in-lbs/sq in; and Ic Short Beam Shear Strength (unidirectional) of 13.1+0.4 KSI. A similar laminate showed a short beam shear strength (Quasi-isotropic) of 12.2 KSI. EXAMPLE 3 A fiber resin matrix was prepared using CYCOM2 1806 (American Cyanamid Company) as the matrix resin. Composites were prepared having a 0.001-inch inter leaf layer of the same polyether polyimide resin used in Example 2. Laminates were formed, cured and tested as in Example 2, and the following data were obtained: G , 2.0 in-lbs/sq in; edged delamination Ic strain, 0.77%; and Short Beam Shear Strength (Uni- directional) of 13.0+1.1 KSI. Microscopic examination showed good bonding of the interleaf to the matrix resin with no interfacial failure. EXAMPLE 4 A matrix resin having the following composition was prepared: parts by weight tetra (4,41 )N-glycidyl methylene dianiline 100 (Ciba Geigy Araldite- MY-720) ULTEM- polyether polyimide resin 10 (General Electric Company) trimethylene glycol di-para-aminobenzoate 46 (Polaroid Polacure- 740M) Composites were prepared having a 0.001-inch interleaf layer of the same polyether polyimide used in Example 2. Laminates prepared from the composites exhibited a Compression Strength After Impact of 48.0+3 KSI. EXAMPLE 5 A fiber resin matrix was prepared using CYCOMe 1808 (American Cyanamid Company) as the matrix resin. Composites were prepared having a 0.002-inch interleaf layer of a polyether-ether ketone (PEEK) which had been degreased with methylene chloride to remove anysurface soil or lubricant therefrom. Laminates exhibited a G of 1.23 in-lbs/sq in. Microscopic examination Ic showed good bonding of the interleaf to the matrix resin with no interfacial failure. EXAMPLE 6 Composites formed using the matrix resin of Example 5 and having a 0.0005-inch interleaf layer of polyamide (KAPTON') washed with methylene chloride were prepared. Laminates formed from the composites had a G of 2.05 in-lbs/sq in. Microscopic examination Ic showed good bonding of the interleaf to the matrix resin with no interfacial failure. EXAMPLE 7 Composites were prepared as in the previous examples having a bis(maleimide) matrix resin and a 0.001-inch interleaf layer of polyether polyimide (Example 2). Laminates formed from the composites had a G of Ic 1.38 in-lbs/sq in. Microscopic examination showed good bonding of the interleaf to the matrix resin with no interfacial failure. EXAMPLE 8 Composites identical to those of Example 7, except that the interleaf layer was 0.0005 inch thick were prepared. Laminates prepared from the composites showed a G of 1.43 in-lbs/sq in; an edged delamination Ic strain of .488; and Compression Strength After Impact of 31.4 KSI. EXAMPLE 9 Fabric resin matrix composites formed by impregnating a woven graphite fiber fabric with the resin of Example 5 and applying a 0.001-inch interleaf layer of a polyether polyimide (ULTEM) were prepared. Laminates prepared from the composites showed a G of Ic 1.36 in-lbs/sq in. Similar composites having a light weight non-woven polyester scrim placed between the interleaf and fiber resin matrix layers (in order to improve the fracture toughness of the composite) were prepared and formed into laminates which exhibited a G Ic of 3.02 in-lbs/sq in. EXAMPLES 10-15 The matrix resin denoted hereinbelow in Table I as Resin A had the following composition: parts by weight tetra (4,4')N-glycidyl methylene dianiline 100 (Ciba Geigy Araldite MY-720) diamino diphenyl sulfone 38 ULTEM polyether polyimide resin 10 (General Electric Company) reaction product of phenyl isocyanate 1.4 and N,N' - diethyl - 1,3 - diamino propane Six additional fiber resin matrix composites were prepared to further illustrate the advantage of the present invention. All composites employed CELION 6R graphite filaments and had a matrix resin content of approximately 34%. The matrix resin and interleaf resin combinations were as follows: TABLE I Sample Matrix Resin Interleaf 10 [CYCOMs 985]* 11 [Same as Example 1) - 12 [Same as Example 1] Modified epoxy** 13 (Same as Example 1] ULTIMO 14 Resin A - 15 Resin A ULTEM * A commercial fiber resin matrix material, sold by American Cyanamid Company. ** A thermoset epoxy resin modified with a carboxylicfunctional butadiene-acrylonitrile copolymer. The composites were formed into laminates and subjected to UNI-COMP, QUASI-COMP and COMP/IMPACT tests, as described above, with the results shown in Table II below. TABLE II Sample 10 11 12 13 14 15 UNI-COMP(KSI) RT 235 205 146 181 223 173 2000P 235 205 129 164 197 1662700F -- 200 -- 130 208 163 200 OF Wet 168 125 90 147 143 158 2700F Wet -- 52 -- 46 102 107 QUASI-COMP (KSI) RT 104 97 88 97 101 96 2000F 103 96 75 84 102 80 2700F -- 100 -- 69 100 72 2000F Wet 77 66 63 71 86 76 2000F Wet -- 36 -- 38 68 60 COMP/IMPACT (1500 in-lbs/in) 28.3 31.7 43.4 51.0 32.3 49.3 Considering the foregoing data in detail, it is seen that Sample 12, comprising a modified epoxy interleaf exhibits a 137% improvement in impact resistance (compressive strength after impact) relative to Sample 11 containing no interleaf (Sample 12 = 43.4; Sample 11 = 31.7), with both Samples 11 and 12 affording improvement over the conventional fiber resin matrix composites of Sample 10. The improvement in impact resistance achieved by Sample 12 over Sample 11, however, is realized at a sacrifice in elevated temperature compressive strength and compressive strength under high humidity conditions, especially with regard to uniaxial compressive strength (see, for example, at 2000F wet conditions, the compressive strength of Sample 12 is 90 KSI, while the corresponding value for Sample 11 is 125 KSI). Sample 13, illustrative of the present invention, shows an improvement in compressive stength after impact of 161%, with little change in compressive strength at either 2000F or 2700F, dry or wet, compared to the unmodified laminate of Sample 11. Samples 14 and 15 show the effect of using a thermoplastic interleaf in a high stiffness formulation designed to provide superior strength at a 2700F, wet condition. The utilization of the interleaf (Sample 15) does not significantly change either uniaxial or quasiisotropic compressive strength (within the experimental error of the test) relative to the unmodified laminate (Sample 14), yet improves the compression strength after impact from 32.3 to 49.3, an improvement of 153%. EXAMPLES 16-21 Samples 16-21 were prepared with the same matrix resin as Example 1 and in accordance with the procedure of Example 1 except for the interleaf, which was varied as follows: Sample 16: no interleaf Sample 17: same as Example 12 (thermoset epoxy modified with butadiene-acrylonitrile copolymer) Sample 18: same as Example 13 (wholly thermo plastic) Sample 19: interleaf formulation parts by weight ULTEM- polyether polyimide 300 (General Eléctric Company) Dow Dev 331 (Dow Chemical Company), 80 a diglycidyl ether of bis phenol A diamine diphenyl sulfone 16 dicyandiamide 4 Sample 20: interleaf formulation parts by weight ULTEM- 300 Modified epoxy of Example 12 100 Sample 21: interleaf formulation parts by weight ULTEM 300 ERL-0500 (Ciba Geigy), 70 trifunctional epoxy resin d iam inod iphenyl sulfone 30 The inter leafs of Sample 18-21 were cast on 2 0.005 Ibs/ft films from methylene chloride solution. All interleaf layers were dried for 1 hour at 2000F prior to being formed into composites. The resulting composites were then each laid up in the form of 16-ply laminates with a quasi-isotropic sequence, and then tested by ASTM D2344, Short Beam Shear Test, with the results (quasi-SBS) as shown in Table III below. TABLE III Quasi-SBS Data for Testing of Samples 16-21 by ASTM D2344 Sample 16 17 18 19 20 21 2000F, Dry 9.4 9.6 10.2 - 11.0 11.5 11.5 (control) 2000F, 5 weeks 5.7 5.9 6.0 6.7 7.0 6.7 Wet 2000F, 5 weeks 7.2 4.9 delami- 7.6 3.1 2.3 in Methylene nated Chloride The above data of Table III show that the solvent resistance (to methylene chloride) of the thermoplastic interleaf-containing composite (Sample 18) is markedly enhanced by combining the thermoplastic resin (ULTIMO) with 25% by weight of a thermosetting resin (including curative) as in Sample 19-21. The unmodified thermoplastic interleaf laminate totally delaminated-after one week in methylene chloride, while the thermoplastic/thermoset interleaf materials (Samples 19-21) retained 20% to 70% of their 2000F, dry short beam strength values after 5 weeks exposure and 34% to 1008 of their corresponding 2000F, 5 weeks wet SBS values. Many variations of the invention will suggest themselves to those skilled in this art in light of the above detailed description, and all such variations are within the full intended scope of this invention. For example, other filaments, such as carbon, silicon carbide, boron, aramid, polyester, polyamide, and rayon, or metal-coated, such as nickel- and/or silver-coated such filaments and fibers, alone or in any combination, can be used. Matrix resin formulations also can be varied in weight ratio widely, depending on the precise properties desired and the intended use. By way of illustration, a preferred matrix resin according to this invention may have the following components, in the following proportions, by weight: Ingredients parts by weight Preferred Most Preferred (i) tetra (4,4') N-glycidyl dianiline 50-100 75-85 (ii) tetraglycidoxy tetra phenylethane 0-50 15-25 (iii) trimethylene glycol di-para-aminobenzoate 28-60 35-45 (iv) fumed silica 0-12 5-7 (v) reaction product of toluene diisocyanate and dimethylamine O.1-2.5 0.1-2.5 All such obvious variations are within the full intended scope of the invention as defined by the appended claims.

Claims: CLAIMS: 1. A method for producing an interleafed fiber resin matrix prepreg fabric comprising (1) incorporating a non-woven or woven fibrous mat or carrier of lightweight supporting filaments into an interleaf resin composition comprising (a) a first thermosetting epoxy resin composition containing (b) about 8% to 70% by weight of a rubbery vinyl addition polymer to provide a supported interleaf resin layer; and (2) introducing said supported interleaf resin layer to at least one surface of a fiber resin matrix comprising (a) a fabric of high-strength reinforcing filaments and (b) a second thermosetting epoxy resin composition coating and impregnating said fabric. 2. The method of Claim 1, wherein said first thermosetting epoxy resin composition exhibits shear modulus of at least 50,000 psi and yield strength of at least 3,000 psi at high temperatures, and shear strain to failure of at least 6% at -670F and at least 15% at room temperature; and said second thermosetting epoxy resin composition exhibits shear modulus of at least 90,000 psi at high temperatures or at least 50,000 psi at high temperatures under wet conditions. 3. The method of Claim 1, wherein said supporting filaments are selected from the group consisting of lightweight glass, carbon, graphite, polyaramide, polyester, and cellulosic filaments. 4. The method of Claim 1, wherein said fabric is comprised of interwoven tows containing from about 1,000 to 12,000 high-strength reinforcing filaments. 5. The method of Claim 4, wherein said reinforcing filaments are selected from the group consisting of glass, carbon, graphite, silicon carbide, boron, polyaramide, polyester, polyamide, rayon, poly benzimidazole, and polybenzothiazole filaments, and metal-coated such filaments. 6. The method of Claim wherein said rubbery vinyl addition polymer comprises about 8% to 248 by weight of said inter leaf resin composition, said second thermosetting epoxy resin composition comprises about 35% to 60% by weight of said fiber resin matrix, and said fibrous mat or carrier comprises less than 5% by weight of the interleafed fiber resin matrix prepreg fabric. 7. The method of Claim 6, wherein a crosslinked interface is formed between said interleaf resin layer and said fiber resin matrix. 8. The method of Claim 1, wherein said first and second thermosetting epoxy resin compositions are, independently, comprised of epoxy compounds selected from the group consisting of polyglycidyl ethers of polyfunctional phenols, polyglycidyl ethers of the chlorination or bromination products of polyvalent phenols, polyglycidyl ethers of novolacs, polyepoxy compounds derived from aromatic amines and epichlorohydrin, and mixtures thereof. 9. The method of Claim 2, wherein said first and second thermosetting epoxy resin compositions both exhibit an ultimate shear stress above about 3,000 psi. 10. The method of Claim 8, wherein said epoxy resin compositions further include curing agents.

Inventors: EVANS, ROBERT E., HIRSCHBUEHLER, KEVIN RICHARD, STERN, BRUCE ALLEN
Applicants: AMERICAN CYANAMID COMPANY
Application year: 1985
Main classification: B32B27
IPC codes: B32B27, B32B5, B29C70, C08J5