Thermoplastic epoxy materials with core shell phase

1 . A composite article, comprising:

i) at least one fibrous layer; and

ii) a matrix material in direct contact with the at least one fibrous layer, the matrix material comprising a monoethanolamine and a diepoxide, wherein the monoethanolamine and diepoxide react to form a thermoplastic condensation reaction product during processing;

wherein the matrix material includes hydroxyl moieties and epoxy moieties which react to form a generally linear backbone polymer chain with ether linkages;

wherein the matrix material contains an additive;

wherein the additive is a toughening agent comprising a core shell material present in an amount of at least 5.7% by weight of the matrix material;

wherein as a result of the amount of core shell material, the matrix material in its green state has a viscosity as measured according to ISO 6721-10:2015, at a temperature of 170° C. at 11 radians/second (rad/s) of at least 3060 Pa·s and a shear strength as measured by ISO 4587:2003 of at least 14.9 Mpa;

wherein during a molding process, at least a portion of the matrix material liquifies, and the liquified matrix material and the additive impregnate the at least one fibrous layer; and

wherein the liquified matrix material solidifies resulting in the reaction product.

2 . The composite article of claim 1 , wherein the diepoxide comprises a bisphenol A liquid epoxy.

3 . The composite article of claim 1 , wherein the composite article is substantially free of any liquid or powder adhesive and/or bonding material.

4 . The composite article of claim 2 , wherein the reaction product is formed during a molding and/or curing process.

5 . The composite article of claim 1 , wherein the additive is embedded within the matrix material.

6 . The composite article of claim 1 , wherein the at least one fibrous layer comprises a carbon fiber material.

7 . The composite article of claim 1 , wherein the shear strength, is up to about 31.7 MPa, and wherein the viscosity is up to 7290 Pa·s.

8 . The composite article of claim 7 , wherein the composite article has less than about twenty percent by volume of aggregates of particles of the additive.

9 . The composite article of claim 1 , wherein the toughening agent is a core shell toughening agent.

10 . The composite article of claim 9 , wherein the core shell toughening agent includes particulates having an elastomeric core and a shell including at least one meth (acrylic) acid, ester thereof, and/or nitrile thereof.

11 . The composite article of claim 8 , wherein the diepoxide is bisphenol F.

12 . The composite article of claim 9 , wherein the toughening agent is characterized by particles that are nanoparticles.

13 . The composite article of claim 12 , wherein the toughening agent has a glass transition temperature (T g ) of between about 65° C. and about 125° C.

14 . The composite article of claim 1 , wherein the composite article forms a protective gear.

15 . The composite article of claim 1 , wherein the composite article is processed by molding, and the reaction product forms during the molding.

16 . The composite article of claim 2 , wherein the at least one fibrous layer is employed in the form of a random distribution, a weave, a non-woven mat, a plurality of generally axially aligned fibers, a plurality of axially intertwined fibers, or any combination thereof.

17 . The composite article of claim 1 , wherein the composite article includes at least two fibrous layers.

18 . The composite article of claim 1 , wherein the composite article has a glass transition temperature of between about 65° C. and about 72° C.

19 . The composite article of claim 1 , wherein the composite article includes an epoxy resin injected about the reaction product during a curing process.

20 . The composite article of claim 1 , wherein the matrix material comprises a polyhydroxy amino ether.