Patent EP0270955A2 successfully refreshed from Google Patents.
EP0270955A2
Expired / Lapsed
EP
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Reinforced plastic
Assignee: Phillips Petroleum Co
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Filing: 1987-11-27
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Granted: —
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Expires: 2007-11-27
Abstract
Abstract A process to form a fiber-reinforced prepreg and shaped objects having a continuous thermoplastic matrix of poly(arylene sulfide ketone) resins is provided. The prepreg is useful to form composites with high temperature resistance. The prepreg is prepared by pultrusion of resin-impregnated fiber reinforcement through a shaped die. The reinforcement can be impregnated from a liquid slurry of resin particles and a wetting agent.
Inventors
- 👤 James Edward O'connor
- 👤 John Frederick Geibel
- 👤 William Herbert Beever
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-11-08 03:59
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/22; B32B5/24; B32B5/26; B32B5/28; C; C08; C08G; C08G75/00; C08G75/02; C08G75/0204; C08G75/0236; C08G75/024; C08G75/025; C08G75/0259; C08G75/0277; C08J; C08J5/00; C08J5/04; B32B2260/00; B32B2260/02; B32B2260/021; B32B2260/04; B32B2260/046; B32B2262/00; B32B2262/10; B32B2262/106; B32B2305/00; B32B2305/07; B32B2305/076; B32B2305/08; C08J2381/00; C08J2381/02; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249924; Y10T428/24994; Y10T428/24995; Y10T428/29; Y10T428/2913; Y10T428/2929; Y10T428/2933; Y10T428/2938; Y10T428/294; Y10T428/2964; Y10T428/2967
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
154 words
A process comprising: a. providing a supply of high molecular weight poly(arylene sulfide ketone) resin in form of particles, said poly(arylene sulfide ketone) resin having a softening temperature and having a calcium content, said particles being suspended in a slurry liquid to form a slurry, b. providing a supply of fiber reinforcement in continuous form, the fiber of which is stable at the softening temperature of the poly(arylene sulfide ketone) resin, c. impregnating the fiber reinforcement with said particles by passing the fiber reinforcement through the slurry to form a resin-impregnated reinforcement, d. heating the resin-impregnated reinforcement to a temperature sufficient to evaporate the slurry liquid and to soften the resin, e. subjecting the heated resin-impregnated reinforcement to a compressive force to consolidate the resin and the fiber reinforcement to form a fiber-reinforced continuous thermoplastic matrix and f. cooling the fiber-reinforced continuous thermoplastic matrix to a temperature below the softening temperature of the resin.
Claim 2
Dependent Claim
154 words
A process comprising: a. providing a supply of high molecular weight poly(arylene sulfide ketone) resin in form of particles, said poly(arylene sulfide ketone) resin having a softening temperature and having a calcium content, said particles being suspended in a slurry liquid to form a slurry, b. providing a supply of fiber reinforcement in continuous form, the fiber of which is stable at the softening temperature of the poly(arylene sulfide ketone) resin, c. impregnating the fiber reinforcement with said particles by passing the fiber reinforcement through the slurry to form a resin-impregnated reinforcement, d. heating the resin-impregnated reinforcement to a temperature sufficient to evaporate the slurry liquid and to soften the resin, e. subjecting the heated resin-impregnated reinforcement to a compressive force to consolidate the resin and the fiber reinforcement to form a fiber-reinforced continuous thermoplastic matrix and f. cooling the fiber-reinforced continuous thermoplastic matrix to a temperature below the softening temperature of the resin.
Claim 3
Dependent Claim
17 words
A process of claim 1 wherein the poly(arylene sulfide ketone) resin comprises a poly(phenylene sulfide ketone) resin.
Claim 4
Dependent Claim
53 words
A process of claim 2 wherein the poly(phenylene sulfide ketone) resin is made by reacting 4,4'-dichlorobenzophenone with a sulfur source in a polar solvent to yield a poly(phenylene sulfide ketone) resin having an inherent viscosity greater than 0.5 dl/g and subsequently contacting said poly(phenylene sulfide ketone) resin with an aqueous calcium ion solution.
Claim 5
Dependent Claim
48 words
A process of claim 2 wherein the poly(phenylene sulfide ketone) resin has a melt flow rate of less than about 1000 g/10 min as determined by ASTM D 1238 at 371°C, an inherent viscosity greater than 0.5 dl/g, and an ash content of less than 5 weight percent.
Claim 6
Dependent Claim
19 words
A process of claim 1 wherein the slurry is aqueous and contains an effective amount of a wetting agent.
Claim 7
Dependent Claim
33 words
A process according to claim 5 wherein the wetting agent is selected from the group consisting of polyoxyethylated vegetable oils, ethoxylated alkylphenols, ethoxylated aliphatic alcohols, alkylaryl polyether alcohols and polyoxyalkylene oxide block copolymers.
Claim 8
Dependent Claim
18 words
A process according to claim 6 wherein the wetting agent comprises an octylphenoxypoly(ethyleneoxy)ethanol or a polyoxyethylated castor oil.
Claim 9
Dependent Claim
17 words
A process of claim 1 wherein the resin particles have a size of less than 15 microns.
Claim 10
Dependent Claim
43 words
The process of claim 1 wherein said fiber reinforced continuous thermpolastic matrix comprises a prepreg in the form of a tape, rod, sheet or shaped profile, said process further comprising cutting the prepreg and said prepreg is cut into pieces of determined length.
Claim 11
Dependent Claim
37 words
The process of claim 1 wherein the concentration of the resin particles in the slurry is maintained to produce a resin-impregnated reinforcement containing from about 20 to about 75 weight percent of the poly(arylene sulfide ketone) resin.
Claim 12
Dependent Claim
32 words
The process of claim 10 wherein the slurry is aqueous and contains a wetting agent in a concentration of from about 1 to 20 weight percent of the amount of the resin.
Claim 13
Dependent Claim
41 words
The process of claim 1 wherein the fiber reinforcement comprises a fiber selected from the group consisting of glass fiber, carbon, aromatic polyamide, metal beryllia, magnesia, alumina, silica, zirconia, thoria, boron nitride, boron carbide, silicon carbide and aluminosilicate and mixtures thereof.
Claim 14
Dependent Claim
70 words
The process of claim 1 wherein the compressive force is applied in an elongated die in which the entrance cross-section is larger than the exit cross-section, with the temperature in the entrance region being above the melting point of said poly(arylene sulfide ketone) resin and the temperature in the exit region being such as to maintain at least a portion of said poly(arylene sulfide ketone) resin in the molten state.
Claim 15
Dependent Claim
36 words
The process of claim 1 further comprising winding the resin impregnated fiber reinforcement on a mandrel, wherein the resin impregnated fiber reinforcement is subjected to the compressive force after or while being wound on the mandrel.
Claim 16
Dependent Claim
24 words
A prepreg comprising a unidirectional fiber reinforcement embedded in a continuous matrix of thermoplastic resin, wherein said resin comprises a poly(arylene sulfide ketone) .
Claim 17
Dependent Claim
24 words
A prepreg comprising a unidirectional fiber reinforcement embedded in a continuous matrix of thermoplastic resin, wherein said resin comprises a poly(arylene sulfide ketone) .
Claim 18
Dependent Claim
13 words
A prepreg of claim 15 wherein the unidirectional fiber reinforcement comprises carbon fiber.
Claim 19
Dependent Claim
13 words
A prepreg of claim 16 wherein the thermoplastic resin comprises poly(phenylene sulfide ketone).
Claim 20
Dependent Claim
29 words
A laminated article formed from at least two fiber-reinforced prepregs as in claim 15 comprising at least two layers of fiber reinforcement embedded in a continuous thermoplastic resin matrix.
Claim 21
Dependent Claim
21 words
The composition of claim 15 wherein a detectable amount of calcium in excess of that detectable from the reinforcement is present.
References Cited (Backward Citations)
No citation records indexed.
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