Glossy finish fiber reinforced molded product

Claim 2

A consolidated, heat and pressure-molded fiber reinforced thermoplastic composition produced from a non-needled non-woven of discrete reinforcing fibers and thermoplastic fibers, devoid of liquid binders and distinctly different fiber layers or alternating distinctly different layers, suitable for cosmetic or appearance applications, having a surface appearance value recorded at 20° and 60° gloss angle measurement for ASTM standard D-523 exceeding 10 and 50, respectively, thermoplastic material from providing the matrix for reinforcing fibers in the molded product.

Claim 3

The composite of claim 1 composed of inorganic fibers in a thermoplastic matrix.

Claim 4

The composite of claim 1 consisting of multiple consolidated layers.

Claim 5

A corrugated, unconsolidated fibrous web of discrete inorganic and/or organic reinforcing fibers and thermoplastic fibers blended together in a weight ratio of about 10:90 to about 60:40, and formed into a non-needled, loose non-woven web of discrete fibers, devoid of liquid binder.

Claim 6

A corrugated, unconsolidated fibrous web of discrete inorganic and/or organic reinforcing fibers and thermoplastic fibers blended together in a weight ratio of about 10:90 to about 60:40, and formed into a non-needled, loose non-woven web of discrete fibers, devoid of liquid binder.

Claim 7

A consolidated heat and pressure molded thermoplastic sheet having an automotive Class A glossy surface finish produced by consolidation of an unconsolidated fibrous non-woven web of discrete reinforcing fiber intimately blended with discrete thermoplastic fibers having a melt index in the range of about 2 to about 500, the reinforcing and thermoplastic fibers present in a weight ratio of about 10:90 to about 60:40, devoid of liquid binders and distinctly different fiber layers or alternating distinctly different layers, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product.

Claim 8

A consolidated heat and pressure molded thermoplastic sheet having an automotive Class A glossy surface finish produced by consolidation of an unconsolidated fibrous non-woven web of discrete reinforcing fiber intimately blended with discrete thermoplastic fibers having a melt index in the range of about 2 to about 500, the reinforcing and thermoplastic fibers present in a weight ratio of about 10:90 to about 60:40, devoid of liquid binders and distinctly different fiber layers or alternating distinctly different layers, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product.

Claim 9

A consolidated heat and pressure molded thermoplastic sheet having an automotive Class A glossy surface finish produced by consolidation of an unconsolidated corrugated fibrous non-woven web of discrete reinforcing fiber intimately blended with discrete thermoplastic fibers having a melt index in the range of about 2 to about 500, the reinforcing and thermoplastic fibers present in a weight ratio of about 10:90 to about 60:40, devoid of liquid binders and distinctly different fiber layers or alternating distinctly different layers, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product.

Claim 10

A consolidated heat and pressure molded thermoplastic sheet having an automotive Class A glossy surface finish produced by consolidation of an unconsolidated corrugated fibrous non-woven web of discrete reinforcing fiber intimately blended with discrete thermoplastic fibers having a melt index in the range of about 2 to about 500, the reinforcing and thermoplastic fibers present in a weight ratio of about 10:90 to about 60:40, devoid of liquid binders and distinctly different fiber layers or alternating distinctly different layers, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product.

Claim 11

A consolidated, heat and pressure molded thermoplastic sheet having an automotive Class A surface finish produced by subjecting a starting material devoid of distinctly different fiber layers or alternating distinctly different layers and liquid binder and containing from 10 to 60% by weight discrete reinforcing fibers, blended with fibers of thermoplastic resin, the blend resulting in the form of a loose non-woven web, to heat and pressure, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product.

Claim 12

A consolidated, heat and pressure molded thermoplastic sheet having an automotive Class A surface finish produced by subjecting a starting material devoid of distinctly different fiber layers or alternating distinctly different layers and liquid binder and containing from 10 to 60% by weight discrete reinforcing fibers, blended with fibers of thermoplastic resin, the blend resulting in the form of a loose non-woven web, to heat and pressure, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product.

Claim 13

A shaped, three-dimensional article made of the thermoplastic sheet of claim 7.

Claim 14

A process of making a three-dimensional shaped article comprising heating the thermoplastic sheet of claim 7 pressing the heated sheet into the desired shape.

Claim 15

The process of claim 9 in which the sheet is heated and pressed simultaneously.

Claim 16

A process of preparing a fiber reinforced thermoplastic molded product having a glossy surface, the process comprising the steps of: (1) opening the fiber bundles of a reinforcing fiber into discrete staple filaments; (2) opening the fiber bundles of a thermoplastic fiber into discrete stale filaments; (3) blending, without addition of liquid binder, the discrete reinforcing fibers and thermoplastic fibers in a weight ratio of about 10:90 to about 60:40 and forming the blended fibers into a non-needled non-woven web where the fibers are discrete, as opposed to in a bundle or mat; and (4) heating the web to at least the melting point of the thermoplastic fibers and applying pressure to the web to cause the thermoplastic fibers to melt, eliminating air from the web, and pressing the non-woven web into a consolidated sheet, thermoplastic material from melted thermoplastic fibers melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product.

Claim 17

A process of preparing a fiber reinforced thermoplastic molded product having a glossy surface, the process comprising the steps of: (1) opening the fiber bundles of a reinforcing fiber into discrete staple filaments; (2) opening the fiber bundles of a thermoplastic fiber into discrete stale filaments; (3) blending, without addition of liquid binder, the discrete reinforcing fibers and thermoplastic fibers in a weight ratio of about 10:90 to about 60:40 and forming the blended fibers into a non-needled non-woven web where the fibers are discrete, as opposed to in a bundle or mat; and (4) heating the web to at least the melting point of the thermoplastic fibers and applying pressure to the web to cause the thermoplastic fibers to melt, eliminating air from the web, and pressing the non-woven web into a consolidated sheet, thermoplastic material from melted thermoplastic fibers melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product.

Claim 18

The process of claim 11 in which the web of step (3) is corrugated prior to consolidation step (4).

Claim 19

The process of claim 11 or 12 in which the reinforcing fibers are glass, carbon, aramid, steel or mixtures thereof.

Claim 20

The process of claim 11 or 12 in which thermoplastic powder is added to the web prior to consolidation.

Claim 21

The process of claim 11 or 12 in which the reinforcing fibers constitute up to 60% by weight of the web and the balance is substantially thermoplastic fibers.

Claim 22

The process of claim 11 or 12 in which the thermoplastic fibers have a melt index in the range of about 2 to about 500.

Claim 23

The process of claim 11 or 12 in which the resulting product has a surface gloss value of at least 10 at 20° and 50 at 60° measurements.

Claim 24

A process according to claim 11 in which multiple web layers are consolidated prior to heating of the thermoplastic to its melt point.

Claim 25

A process according to claim 11 in which multiple layers are heated and fused in separate steps.

Claim 26

A process according to claim 11 in which multiple layers are heated and fused in sequential steps.

Claim 27

A process according to claim 19 in which the sequential step is fusing a layer of fibers or fiber incorporating powder to or on a film of thermoplastic polymer.