Project Title:

Thermosetting Plasticizers for Low-Cost Resin Transfer Molding of High Temperature PMR Composites

94-1	04.10	3200



Thermosetting Plasticizers for Low-Cost Resin Transfer Molding of 

High Temperature PMR Composites

Abstract:

Foster-Miller proposes to develop a new type of RTM-processible, 

addition-cured PMR resin matrix composite that exceeds the 

requirements for commercial aircraft engine components operating in 

air at 600@F. The technology will be designed to provide composite 

structures that improve the thrust-to-weight ratio of advanced jet 

engines. Our approach combines three enabling technologies to 

produce an innovative, low-cost, high temperature structural 

composite. These include RTM processing, high temperature, 

addition-cured PMR polymer matrix resins and thermosetting 

plasticizers (TP's) for enhancing the flow of PMR resins. During 

RTM, the TP will lower viscosity and increase resin flow, 

facilitating complete fill of the fiber preform with PMR resin 

precursor. Upon consolidation and cure of the composite at elevated 

temperatures, the TP will co-cure with the resin by an addition 

process, forming a high Tg, thermally stable, crosslinked composite 

matrix. The multi-use potential of this advanced composite system 

and its use of low-cost materials and process will facilitate its 

application in automotive and electronic components.

In Phase I, we will develop RTM-processable PMR formulations using 

thermosetting plasticizers, produce RTM neat resin and composite 

test specimens and analyze test specimens for key processing, 

thermal and mechanical properties.


Our proposed thermosetting plasticizers will enable the manufacture 

of high temperature PMR polymer matrix composite aircraft engine 

components useful at 590@K (600@F) for >20,000 hr via automated 

methods such as RTM, filament-winding and pultrusion. These 

components will substantially lower the cost and increase the 

thrust-to-weight ratio for advanced commercial aircraft jet 

engines. Commercial applications include automotive components, 

electronic packaging and large robotic structures.


Key Words


Foster-Miller, Inc.

350 Second Avenue

Waltham, MA 02154-1196