Patent US4925729A successfully refreshed from Google Patents.
US4925729A
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US
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Fiber reinforced thermoplastic articles and process for the preparation thereof
Assignee: Phillips Petroleum Co
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Filing: 1988-09-29
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Granted: 1990-05-15
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Expires: 2008-09-29
Abstract
Abstract Processes for preparing fiber reinforced thermoplastic articles are provided, for example, thermoplastic fibers and reinforcement fibers can be intermingled to produce a composite yarn, which is used to weave a fabric, then the fabric heated to produce a reinforced article. As another example, thermoplastic yarn and reinforcement yarn can be woven together to produce a composite fabric, which, upon heating, produces a reinforced article.
Inventors
- 👤 James E. O'Connor
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 18:31
CPC Classifications
B; B29; B29B; B29B15/00; B29B15/08; B29B15/10; B29B15/105; C; C08; C08J; C08J5/00; C08J5/04; C08J5/047; C08J5/048; D; D03; D03D; D03D1/00; D03D15/00; D03D15/40; D03D15/47; D03D15/50; D03D15/587; B29K; B29K2281/00; D10; D10B; D10B2101/00; D10B2101/10; D10B2101/12; D10B2401/00; D10B2401/04; D10B2401/041; D10B2505/00; D10B2505/02; Y; Y10; Y10T; Y10T428/00; Y10T428/24; Y10T428/24628; Y10T428/24636; Y10T428/29; Y10T428/2904; Y10T428/2905; Y10T428/2913; Y10T428/2918; Y10T428/2929; Y10T428/2931; Y10T442/00; Y10T442/30; Y10T442/3065; Y10T442/313; Y10T442/3138
Claims Analysis
Total Claims: 31
Claim 1
Independent Claim
70 words
A process for the preparation of a batt of composite staple, said process comprising: (a) intermingling individual filaments of at least one fibrous poly(arylene sulfide) material and individual filaments of at least one fibrous reinforcement material to produce a composite yarn; (b) passing said composite yarn to a staple cutter to produce a composite staple; and (c) laying up said composite staple to produce a batt of said composite staple.
Claim 2
Dependent Claim
70 words
A process for the preparation of a batt of composite staple, said process comprising: (a) intermingling individual filaments of at least one fibrous poly(arylene sulfide) material and individual filaments of at least one fibrous reinforcement material to produce a composite yarn; (b) passing said composite yarn to a staple cutter to produce a composite staple; and (c) laying up said composite staple to produce a batt of said composite staple.
Claim 3
Dependent Claim
23 words
A process in accordance with claim 1 wherein said fibrous reinforcement material is selected from the group consisting of: glass, carbon, and aramid.
Claim 4
Dependent Claim
14 words
A process as in claim 2 further comprising needle-punching said batt of composite staple.
Claim 5
Dependent Claim
75 words
A process for the preparation of a fiber reinforced poly(arylene sulfide) composite article, said process comprising (a) heating a batt formed from cut composite staple of a hybrid yarn containing individual fibers of poly(arylene sulfide) and individual fibers of a fibrous reinforcing material to a temperature at least as high as the melting point of the poly(arylene sulfide) fibers; and (b) pressing the thus heated batt under a pressure sufficient to form the composite article.
Claim 6
Dependent Claim
75 words
A process for the preparation of a fiber reinforced poly(arylene sulfide) composite article, said process comprising (a) heating a batt formed from cut composite staple of a hybrid yarn containing individual fibers of poly(arylene sulfide) and individual fibers of a fibrous reinforcing material to a temperature at least as high as the melting point of the poly(arylene sulfide) fibers; and (b) pressing the thus heated batt under a pressure sufficient to form the composite article.
Claim 7
Dependent Claim
28 words
A process as in claim 4 wherein the reinforcement material is selected from the group consisting cf glass, carbon and aramid and the thermoplastic comprises a poly(arylene sulfide).
Claim 8
Dependent Claim
28 words
A process as in claim 5 wherein the heated batt is pressed under a pressure of between about 50 and about 500 psig to form the composite article.
Claim 9
Dependent Claim
20 words
A process as in claim 6 wherein the temperature is in the range of about 285° to about 350° C.
Claim 10
Dependent Claim
30 words
A process as in claim 7 further comprising maintaining said temperature and pressure for a period of time sufficient to allow for the escape of air from the composite article.
Claim 11
Dependent Claim
100 words
A process for the preparation of a fiber reinforced thermoplastic article, said process comprising: (a) intermingling at least one fibrous poly(arylene sulfide) material and at least one fibrous reinforcement material to produce a composite yarn; (b) passing said composite yarn to a staple cutter to produce a composite staple; (c) laying up said composite staple to produce a batt of said composite staple; and (d) heating said batt to a temperature at least as high as the melting point of said poly(arylene sulfide) for a time sufficient to allow intimate contact between said poly(arylene sulfide) and said fibrous reinforcement material.
Claim 12
Dependent Claim
100 words
A process for the preparation of a fiber reinforced thermoplastic article, said process comprising: (a) intermingling at least one fibrous poly(arylene sulfide) material and at least one fibrous reinforcement material to produce a composite yarn; (b) passing said composite yarn to a staple cutter to produce a composite staple; (c) laying up said composite staple to produce a batt of said composite staple; and (d) heating said batt to a temperature at least as high as the melting point of said poly(arylene sulfide) for a time sufficient to allow intimate contact between said poly(arylene sulfide) and said fibrous reinforcement material.
Claim 13
Dependent Claim
39 words
A process in accordance with claim 9 wherein said fibrous reinforcement material is selected from the group consisting of: glass, carbon, aramid, boron, boron nitride, ceramic, iron, nickel, chromium, copper, aluminum, and mixtures of any two or more thereof.
Claim 14
Dependent Claim
46 words
A process in accordance with claim 9 wherein said heating is carried out at a temperature of about 285° to about 350° C. for about 1 minute to about 60 minutes under sufficient pressure to maintain intimate contact between said thermoplastic material and said reinforcement material.
Claim 15
Dependent Claim
20 words
A process in accordance with claim 9 wherein said batt produced to step (c) is needle-punched prior to step (d).
Claim 16
Dependent Claim
11 words
The article produced in accordance with the process of claim 9.
Claim 17
Dependent Claim
37 words
A process in accordance with claim 9 wherein the quantity of fibrous reinforcement material employed is maintained within the range of about 40 up to 80 wt. %, based on the total weight of the composite yarn.
Claim 18
Dependent Claim
30 words
A process in accordance with claim 14 wherein the range of 2 up to 10 plies of said fabric are subjected to the heating conditions set forth in step (c).
Claim 19
Dependent Claim
22 words
A process in accordance with claim 9 wherein said composite batt is molded prior to being subjected to said heating step (d).
Claim 20
Dependent Claim
37 words
A process in accordance with claim 9 wherein the quantity of fibrous reinforcement material employed is maintained within the range of about 40 up to 80 wt. %, based on the total weight of the resulting fabric.
Claim 21
Dependent Claim
83 words
A process for the preparation of a composite batt useful for the production of fiber reinforced thermoplastic articles, said composite batt comprising poly(arylene sulfide) staple fibers and reinforcement staple fibers, said process comprising: (a) intermingling at least one fibrous poly(arylene sulfide) material and at least one fibrous reinforcement material to produce a composite yarn; (b) passing said composite yarn to a staple cutter to produce a composite staple; and (c) laying up said composite staple to produce a batt of said composite staple.
Claim 22
Dependent Claim
83 words
A process for the preparation of a composite batt useful for the production of fiber reinforced thermoplastic articles, said composite batt comprising poly(arylene sulfide) staple fibers and reinforcement staple fibers, said process comprising: (a) intermingling at least one fibrous poly(arylene sulfide) material and at least one fibrous reinforcement material to produce a composite yarn; (b) passing said composite yarn to a staple cutter to produce a composite staple; and (c) laying up said composite staple to produce a batt of said composite staple.
Claim 23
Dependent Claim
50 words
A fabric comprising a plurality of thermoplastic yarns and a plurality of reinforcing yarns, wherein the thermoplastic yarns are formed from individual filaments of poly(arylene sulfide) polymer, and wherein the reinforcing yarns are formed from individual filaments selected from the group consisting of carbon fibers, glass fibers, and aramid fibers.
Claim 24
Dependent Claim
50 words
A fabric comprising a plurality of thermoplastic yarns and a plurality of reinforcing yarns, wherein the thermoplastic yarns are formed from individual filaments of poly(arylene sulfide) polymer, and wherein the reinforcing yarns are formed from individual filaments selected from the group consisting of carbon fibers, glass fibers, and aramid fibers.
Claim 25
Dependent Claim
25 words
A fabric as in claim 19 which comprises from about 40% to about 80% by weight based on total weight of fabric of reinforcing yarns.
Claim 26
Dependent Claim
24 words
A fabric as in claim 20 wherein the poly(arylene sulfide) polymer has a melt flow in the range of 75 to 800 g/10 min.
Claim 27
Dependent Claim
22 words
A fabric as in claim 21 comprising in the range of from about 55% to about 65% by weight of reinforcing yarns.
Claim 28
Dependent Claim
18 words
A fabric as in claim 22 wherein the filaments of the poly(arylene sulfide) polymer comprise poly(p-phenylene sulfide) polymer.
Claim 29
Dependent Claim
14 words
A fabric as in claim 23 wherein the reinforcing yarn comprises continuous carbon fibers.
Claim 30
Dependent Claim
63 words
A fiber reinforced thermoplastic article comprising a composite fabric prepared by weaving at least one poly(arylene sulfide) yarn with at least one reinforcement yarn, wherein said composite fabric is heated to a temperature at least as high as the melting point of said poly(arylene sulfide) yarn for a time sufficient to allow intimate contact between said poly(arylene sulfide) yarn and said reinforcement yarn.
Claim 31
Dependent Claim
63 words
A fiber reinforced thermoplastic article comprising a composite fabric prepared by weaving at least one poly(arylene sulfide) yarn with at least one reinforcement yarn, wherein said composite fabric is heated to a temperature at least as high as the melting point of said poly(arylene sulfide) yarn for a time sufficient to allow intimate contact between said poly(arylene sulfide) yarn and said reinforcement yarn.
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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) | 1993-05-14 | 1993-11-13 | 1994-05-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-05-14 | 1997-11-13 | 1998-05-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-05-14 | 2001-11-13 | 2002-05-15 | $7700.00 | Window Closed / Lapsed |