US4058581A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of making thermoplastic resin composite
Assignee: ExxonMobil Technology and Engineering Co
•
Filing: 1976-10-28
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Granted: 1977-11-15
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Expires: 1996-10-28
Abstract
Abstract A unidirectional fiber reinforced thermoplastic stock material is prepared by passing fibers through a resin solution to coat the fibers. The coated fibers are treated to remove the solvent and thereafter are consolidated into the desired shape.
Inventors
- 👤 Im K. Park
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 13:43
CPC Classifications
B; B29; B29C; B29C70/00; B29C70/04; B29K; B29K2307/00
Claims Analysis
Total Claims: 9
Claim 1
Independent Claim
159 words
A method for producing a fiber reinforced thermoplastic resin stock having about 10 to 50% by volume of fiber therein comprising continuously passing graphite fiber material as a multiplicity of individual strands through a solution of thermoplastic resin to coat the fiber with resin solution, said resin being an acrylic acid grafted polyolefin and said solution having a viscosity in the range of about 2 to 4000 centipoise while being maintained at a temperature in the range of about 80° C to 145° C; treating the solution coated fibers to remove the solvent; consolidating said coated fibers into a predetermined cross-sectional shape and size while heating the coated fibers to a temperature sufficient to melt the resin; and, thereafter cooling the shaped resin coated fibers under confining pressures to a temperature below the melting point of the resin whereby a continuous fiber reinforced thermoplastic stock material is obtained having low fiber loadings between about 10 to 50% by volume.
Claim 2
Independent Claim
159 words
A method for producing a fiber reinforced thermoplastic resin stock having about 10 to 50% by volume of fiber therein comprising continuously passing graphite fiber material as a multiplicity of individual strands through a solution of thermoplastic resin to coat the fiber with resin solution, said resin being an acrylic acid grafted polyolefin and said solution having a viscosity in the range of about 2 to 4000 centipoise while being maintained at a temperature in the range of about 80° C to 145° C; treating the solution coated fibers to remove the solvent; consolidating said coated fibers into a predetermined cross-sectional shape and size while heating the coated fibers to a temperature sufficient to melt the resin; and, thereafter cooling the shaped resin coated fibers under confining pressures to a temperature below the melting point of the resin whereby a continuous fiber reinforced thermoplastic stock material is obtained having low fiber loadings between about 10 to 50% by volume.
Claim 3
Dependent Claim
22 words
The method of claim 1 wherein the fibers are consolidated into a predetermined cross-sectional shape and size in a compression molding die.
Claim 4
Dependent Claim
29 words
The method of claim 1 wherein the fibers are consolidated into a predetermined cross-sectional shape by pulling the coated fibers through a heated die and then a cooling die.
Claim 5
Dependent Claim
40 words
The method of claim 1 wherein the coated fibers are consolidated and shaped by passing the coated fibers between the nip of a pair of heated rolls thereby producing a sheet of composite material having substantially unidirectional continuous fiber reinforcement.
Claim 6
Dependent Claim
16 words
The method of claim 1 wherein layers of fibers are passed through the thermoplastic resin solution.
Claim 7
Dependent Claim
34 words
The method of claim 1 wherein the thermoplastic resin solution contains from 2 to 30% by weight of resin and has a viscosity when heated in the range of about 5 to 30 centipoise.
Claim 8
Dependent Claim
20 words
The method of claim 1 wherein the polymer solution contains from about 5 to about 12% by weight of resin.
Claim 9
Dependent Claim
30 words
The method of claim 1 wherein discontinuous fibers are suspended in the solution of thermoplastic resin whereby the stock material has substantially unidirectional continuous fibers and random oriented discontinuous fibers.
References Cited (Backward Citations)
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1980-11-14 | 1981-05-16 | 1981-11-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1984-11-14 | 1985-05-16 | 1985-11-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1988-11-14 | 1989-05-16 | 1989-11-15 | $7700.00 | Window Closed / Lapsed |