US4426470A
Expired / Lapsed
US
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Aqueous method of making reinforced composite material from latex, solid polymer and reinforcing material
Assignee: Dow Chemical Co
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Filing: 1982-09-16
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Granted: 1984-01-17
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Expires: 2002-09-16
Abstract
Abstract Reinforced polymer composites having a uniform mix of fiber, polymer and binder and having good physical properties are prepared by forming dilute aqueous slurries of a solid heat fusible organic polymer, a reinforcing material and a bound charge latex binder.
Inventors
- 👤 Ritchie A. Wessling
- 👤 Larry D. Yats
- 👤 Darryl K. Tolbert
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-26 01:25
CPC Classifications
D; D21; D21H; D21H13/00; D21H13/36; D21H13/38; D21H13/40; C; C08; C08J; C08J3/00; C08J3/20; C08J3/205; C08J3/21; C08J3/215; Y; Y10; Y10T; Y10T428/00; Y10T428/249921; Y10T428/249924; Y10T428/24994
Claims Analysis
Total Claims: 28
Claim 1
Independent Claim
125 words
Process for making a composite, which is capable of being heat fused into a reinforced polymer sheet, which comprises A. forming a dilute aqueous slurry of (1) from about 19 to about 79 percent of solid heat fusible organic polymer particles, (2) from about 10 to about 80 percent of a reinforcing material and (3) from about 1 to about 10 percent of a latex binder of a substantially water-insoluble organic polymer having either anionic or cationic bound charges, the percentages being by weight based on a dry solids basis, and B. flocculating the slurry during agitation with a polymeric flocculant opposite in charge to that of the latex binder, C. collecting the solids in the form of a mat, D. dewatering and E. drying.
Claim 2
Dependent Claim
125 words
Process for making a composite, which is capable of being heat fused into a reinforced polymer sheet, which comprises A. forming a dilute aqueous slurry of (1) from about 19 to about 79 percent of solid heat fusible organic polymer particles, (2) from about 10 to about 80 percent of a reinforcing material and (3) from about 1 to about 10 percent of a latex binder of a substantially water-insoluble organic polymer having either anionic or cationic bound charges, the percentages being by weight based on a dry solids basis, and B. flocculating the slurry during agitation with a polymeric flocculant opposite in charge to that of the latex binder, C. collecting the solids in the form of a mat, D. dewatering and E. drying.
Claim 3
Dependent Claim
57 words
Process of claim 1 wherein the solid fusible organic polymer is polyethylene, ultra high molecular weight polyethylene, chlorinated polyethylene, a bipolymer of ethylene and acrylic acid, polypropylene, polyvinylchloride, a bipolymer of a major proportion of vinylidene chloride and a minor proportion of at least one other α,β-ethylenically unsaturated monomer copolymerizable therewith, or a styrene homopolymer or copolymer.
Claim 4
Dependent Claim
12 words
Process of claim 1 wherein the reinforcing material comprises compatibilized glass fibers.
Claim 5
Dependent Claim
13 words
Process of claim 1 wherein the reinforcing material comprises heat cleaned glass fibers.
Claim 6
Dependent Claim
22 words
Process of claim 3 or claim 4 wherein the reinforcing material comprises up to 10 percent by weight of milled glass fibers.
Claim 7
Dependent Claim
21 words
Process of claim 3 or claim 4 wherein the reinforcing material comprises up to 10 percent by weight of cellulose pulp.
Claim 8
Dependent Claim
11 words
Process of claim 1 wherein the latex is an anionic latex.
Claim 9
Dependent Claim
14 words
Process of claim 7 wherein the latex is a bound charge anionic styrene-butadiene latex.
Claim 10
Dependent Claim
15 words
Process of claim 8 wherein the latex solids contain a copolymerized α,β-ethylenically unsaturated carboxylic acid.
Claim 11
Dependent Claim
11 words
Process of claim 1 wherein the latex is a cationic latex.
Claim 12
Dependent Claim
14 words
Process of claim 10 wherein the latex is a bound charge cationic styrene-butadiene latex.
Claim 13
Dependent Claim
18 words
Process of claim 1 wherein the dilute aqueous slurry comprises from 0.01 to 5.0 percent by weight solids.
Claim 14
Dependent Claim
18 words
Process of claim 1 including the additional step of heat fusing the mat into a reinforced polymer sheet.
Claim 15
Dependent Claim
10 words
Process of claim 13 which is a scrapless forming process.
Claim 16
Dependent Claim
10 words
Process of claim 13 which is a compression molding process.
Claim 17
Dependent Claim
85 words
A composite, in the form of a dried mat, which comprises (a) from about 19 to about 79 percent by weight of a solid heat fusible polymer in particulate form, (b) from about 10 to about 80 percent by weight of a reinforcing material, and (c) from about 1 to about 10 percent by weight of the solids of a substantially water-insoluble organic polymer latex having either anionic or cationic bound charges, which composite is capable of being heat fused into a reinforced polymer sheet.
Claim 18
Dependent Claim
85 words
A composite, in the form of a dried mat, which comprises (a) from about 19 to about 79 percent by weight of a solid heat fusible polymer in particulate form, (b) from about 10 to about 80 percent by weight of a reinforcing material, and (c) from about 1 to about 10 percent by weight of the solids of a substantially water-insoluble organic polymer latex having either anionic or cationic bound charges, which composite is capable of being heat fused into a reinforced polymer sheet.
Claim 19
Dependent Claim
30 words
The composite of claim 16 which, when heat fused into a reinforced polymer sheet, is capable of being compression molded without substantial change in the distribution of the reinforcing material.
Claim 20
Dependent Claim
20 words
The composite of claim 16 which also contains a polymeric flocculant opposite in charge to that of the latex binder.
Claim 21
Dependent Claim
12 words
The composite of claim 18 wherein the flocculant is an acrylamide polymer.
Claim 22
Dependent Claim
13 words
The composite of claim 16 wherein the solid heat fusible polymer is polyethylene.
Claim 23
Dependent Claim
19 words
The process of claim 1 wherein the dilute aqueous slurry comprises from 0.02 to 0.5 percent by weight solids.
Claim 24
Dependent Claim
24 words
Composite of claim 20 wherein the polyethylene powder is polyethylene powder in its as-polymerized state when such polymer has been prepared by organo-metallic catalysis.
Claim 25
Dependent Claim
11 words
Composite of claim 16 wherein the reinforcing material comprises glass fibers.
Claim 26
Dependent Claim
11 words
Composite of claim 23 wherein the glass fibers are heat cleaned.
Claim 27
Dependent Claim
10 words
Composite of claim 23 wherein the glass fibers are compatibilized.
Claim 28
Dependent Claim
19 words
Composite of claim 16 wherein the binder comprises a polymer of styrene, butadiene and an α,β-ethylenically unsaturated carboxylic acid.
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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) | 1987-01-16 | 1987-07-18 | 1988-01-17 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-01-16 | 1991-07-18 | 1992-01-17 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-01-16 | 1995-07-18 | 1996-01-17 | $7700.00 | Window Closed / Lapsed |