Process for the production of glass fiber reinforced composite material

Claim 2

A process for the production of a glass fiber-reinforced composite material, which process comprises: treating glass fibers with a silane composition comprising silane molecules having amine functional groups and silane molecules having ethylenically-unsaturated functional groups; admixing the treated glass fibers with a polyolefin resin, and a fiber bonding agent comprising (a) from 0.05 to 15 weight percent of a polymerizable unsaturated organic compound having at least two polymerizable unsaturation groups and (b) from 0.05 to 5 weight percent of a vinyl-polymerizable unsaturated, hydrolyzable silane; the weight percentages of components (a) and (b) being based upon the total weight of the treated glass fibers; generating free radicals in the resulting mixture in an amount sufficient to cause bonding of the treated glass fibers with the polyolefin resin; and exposing the resultant mixture of glass fibers, polyolefin resin, and fiber bonding agent to conditions of temperature and pressure sufficient to cause the formation of a fiber-reinforced composite material.

Claim 3

A process for the production of a glass fiber-reinforced composite material, which process comprises: treating glass fibers with a silane composition comprising silane molecules having amine functional groups and silane molecules having ethylenically-unsaturated functional groups; admixing the treated glass fibers with a polyolefin resin, and a fiber bonding agent comprising (a) from 0.05 to 15 weight percent of a polymerizable unsaturated organic compound having at least two polymerizable unsaturation groups; (b) from 0.05 to 5 weight percent of a vinyl-polymerizable unsaturated, hydrolyzable silane; and (c) from 0.0025 to 2.5 weight percent of a free radical generator, the weight percentages of components (a) to (c) being based upon the total weight of the treated glass fibers; and exposing the resultant mixture of glass fibers, polyolefin resin, and fiber bonding agent to conditions of temperature and pressure sufficient to cause the formation of a fiber-reinforced composite material.

Claim 4

A process for the production of a glass fiber-reinforced composite material, which process comprises: treating glass fibers with a silane composition comprising silane molecules having amine functional groups and silane molecules having ethylenically-unsaturated functional groups; admixing the treated glass fibers with a polyolefin resin, and a fiber bonding agent comprising (a) from 0.05 to 15 weight percent of a polymerizable unsaturated organic compound having at least two polymerizable unsaturation groups; (b) from 0.05 to 5 weight percent of a vinyl-polymerizable unsaturated, hydrolyzable silane; and (c) from 0.0025 to 2.5 weight percent of a free radical generator, the weight percentages of components (a) to (c) being based upon the total weight of the treated glass fibers; and exposing the resultant mixture of glass fibers, polyolefin resin, and fiber bonding agent to conditions of temperature and pressure sufficient to cause the formation of a fiber-reinforced composite material.

Claim 5

A process according to claim 2 wherein the silane composition comprises at least one silane having an amine functional group and an ethylenically-unsaturated functional group in the same molecule.

Claim 6

A process according to wherein the silane composition comprises any one fatty ethenoid acylaminoorganoosilane compound represented by the general formula Y[N(Y).sub.c R.sub.2--c ].sub.x [N(W)R.sup.1 ].sub.y y[N(Y).sub.b R.sup.2 .sub.2-b (HX).sub.2 wherein R and R 1 are individually selected from the group consisting of divalent alkylene groups containing from two to six carbon atoms inclusive, divalent arylene groups containing from six to twelve carbon atoms inclusive, divalent substituted arylene groups containing from seven to twenty carbon atoms inclusive, and a divalent groups of the formula -C(═O)R 3 - wherein R 3 is a divalent alkylene group containing from two to six carbon atoms inclusive; R 2 is a monovalent alkyl or aryl group containing from one to ten carbon atoms or hydrogen; W is either hydrogen or -C(═O)R 4 - wherein R 4 is a monovalent hydrocarbon group containing from 8 to 24 carbon atoms and containing at least one double bond; Y is selected from the group consisting of hydrogen, -C(═O)R 4 , wherein R 4 is as defined above, R 2 and -R 5 Si(OR 6 ) 3-a (R 7 ) a , wherein R 5 is a divalent alkylene group containing from two to six carbon atoms inclusive, R 6 and R 7 are individually a monovalent alkyl or aryl group containing from one to six carbon atoms inclusive; and R 6 may also be a silicon containing moiety wherein the oxygen atom is directly bonded to the silicon atom of the R 6 silicon containing moiety; a has a value of zero, one or two; b has a value of zero, one or two; c has a value of zero or one; x and y have values such that x+y equals one to thirty, with the proviso that x is at least one; z has a value of zero or one; X is a halogen atom or an ester hydroxyl or anhydride group; w has a value equal to from zero to the sum of x+y+z provided that w does not exceed the total nitrogen atom in free amine form; with the proviso that at least one Y is -R 5 Si(OR 6 ) 30-a (R 7 ) a and at least one other Y is -C(═O)R 4 -; and when x =1, y =0 and z =0, then c =1.

Claim 7

A process according to wherein the silane composition comprises any one fatty ethenoid acylaminoorganoosilane compound represented by the general formula Y[N(Y).sub.c R.sub.2--c ].sub.x [N(W)R.sup.1 ].sub.y y[N(Y).sub.b R.sup.2 .sub.2-b (HX).sub.2 wherein R and R 1 are individually selected from the group consisting of divalent alkylene groups containing from two to six carbon atoms inclusive, divalent arylene groups containing from six to twelve carbon atoms inclusive, divalent substituted arylene groups containing from seven to twenty carbon atoms inclusive, and a divalent groups of the formula -C(═O)R 3 - wherein R 3 is a divalent alkylene group containing from two to six carbon atoms inclusive; R 2 is a monovalent alkyl or aryl group containing from one to ten carbon atoms or hydrogen; W is either hydrogen or -C(═O)R 4 - wherein R 4 is a monovalent hydrocarbon group containing from 8 to 24 carbon atoms and containing at least one double bond; Y is selected from the group consisting of hydrogen, -C(═O)R 4 , wherein R 4 is as defined above, R 2 and -R 5 Si(OR 6 ) 3-a (R 7 ) a , wherein R 5 is a divalent alkylene group containing from two to six carbon atoms inclusive, R 6 and R 7 are individually a monovalent alkyl or aryl group containing from one to six carbon atoms inclusive; and R 6 may also be a silicon containing moiety wherein the oxygen atom is directly bonded to the silicon atom of the R 6 silicon containing moiety; a has a value of zero, one or two; b has a value of zero, one or two; c has a value of zero or one; x and y have values such that x+y equals one to thirty, with the proviso that x is at least one; z has a value of zero or one; X is a halogen atom or an ester hydroxyl or anhydride group; w has a value equal to from zero to the sum of x+y+z provided that w does not exceed the total nitrogen atom in free amine form; with the proviso that at least one Y is -R 5 Si(OR 6 ) 30-a (R 7 ) a and at least one other Y is -C(═O)R 4 -; and when x =1, y =0 and z =0, then c =1.

Claim 8

A process according to claim 4 wherein the silane composition comprises [CH 3 (CH 2 CH═CH) 3 (CH 2 ) 7 CO][NCH 2 CH 2 NH][CH 2 CH 2 CH 2 Si(OMe) 3 ] 2 .

Claim 9

A process according to claim 2 wherein the silane composition comprises a first silane having an amine functional group and a second silane having an ethylenically-unsaturated functional group.

Claim 10

A process according to claim 6 wherein the first silane is at least one of τ-aminopropyltriethoxysilane, τ-aminopropyltrimethoxysilane, bis(trimethoxysilylpropyl)amine,

Claim 11

2-bis-(trimethoxysilylpropyl)ethanediamine, and isomers thereof, or trimethoxysilylpropyl substituted diethylene triamine.

Claim 12

2-bis-(trimethoxysilylpropyl)ethanediamine, and isomers thereof, or trimethoxysilylpropyl substituted diethylene triamine.

Claim 13

A process according to claim 7 wherein the first silane is at least one of τ-aminopropyltriethoxysilane or τ-aminopropyltrimethoxysilane.

Claim 14

A process according to claim 6 wherein the second silane is a vinyl silane.

Claim 15

A process according to claim 9 wherein the second silane is at least one of vinyltrimethoxysilane, vinyltriethoxysilane, vinyl tris(2-methoxyethoxy)silane or τ-methacryloxypropyltrimethoxysilane.

Claim 16

A process according to claim 2 wherein the fiber bonding agent further comprises not more than about 2.5 weight percent, based upon the weight of the glass fiber, of a surfactant comprising: (i) a siloxane containing at least one silicon-bonded alkyl group having at least 12 carbon atoms; or (ii) a polyoxyalkylene compound having one or more polyoxyalkylene blocks each bonded at one end to a siloxane block, an alkyl group having at least 12 carbon atoms, or an alkenyl group, and bonded at the other end to an alkoxy group, siloxane block or a hydroxy group.

Claim 17

A process according to claim 2 wherein the fiber bonding agent further comprises not more than about 15 weight percent, based upon the weight of the glass fiber, of an inert carrier.

Claim 18

A process according to claim 12 wherein the inert inorganic carrier comprises any one or more of porous silica, a silicates, alumina, an or a polymeric material.

Claim 19

A process according to claim 2 wherein the glass fibers are treated with a quantity of silane equal to 0.01 to 1 percent by weight of the glass fibers.

Claim 20

A process according to claim 2 wherein the glass fibers are treated with a size bath containing from 0.1 to 2 percent by weight of silane.

Claim 21

A process according to claim 9 wherein the size bath further comprises a film-forming material.

Claim 22

A process according to claim 16 wherein the film-forming material comprises at least one of a polyvinyl acetate, an acrylate, a polyolefin, a polyester, a phenol-formaldehyde resin, a urea, a polyurethane, an epoxy resin or a phenoxy resin.

Claim 23

A process according to claim 17 wherein the film-forming material comprises at least one epoxy resin.

Claim 24

A process according to claim 17 wherein the film-forming material comprises from 1 to 20 percent by weight of the size bath.

Claim 25

A process according to claim 2 wherein the polyolefin resin is polypropylene.

Claim 26

A process according to claim 2 wherein, in the fiber bonding agent, the polymerizable unsaturated organic compound having at least two polymerizable unsaturation groups is selected from the group consisting of the tri-, tetra- and penta-acrylates of poly(vinyl alcohol), pentaerythritol, methylolpropane, and dipentaerythritol and the tri-, tetra- and penta-methacrylates of pentaerythritol, methylolpropane, and dipentaerythritol.

Claim 27

A process according to claim 2 wherein, in the fiber bonding agent, the vinyl-polymerizable unsaturated, hydrolyzable silane is selected from the group consisting of τ-methacryloxypropyltrimethoxysilane, vinyltriethoxysilane, vinyltri(2-methoxyethoxy)silane, vinyltrimethoxysilane, vinyltrichlorosilane, τ-acryl-oxypropyltriethoxysilane, vinyltriacetoxysilane, ethynyltriethoxysilane and 2-propynyltrichlorosilane.

Claim 28

A process according to claim 2 wherein, in the fiber bonding agent, the free radical generator is selected from the group consisting of dicumyl peroxide, lauryl peroxide, azobisisobutyronitrile, benzoyl peroxide, tertiary butyl perbenzoate, di(tertiary butyl) peroxide, cumene hydroperoxide, 2,5-dimethyl-2,5-di(t-butylperoxy)hexane, tertiary butyl hydroperoxide and isopropyl percarbonate.

Claim 29

A process according to claim 2 wherein the fiber bonding agent is added in a pulverulent form produced by absorption of the liquid components of the fiber bonding agent on to a porous inert carrier.

Claim 30

A fiber-reinforced composite material produced by a process according to claim 2.

Claim 31

A fiber-reinforced composite material comprising: a polyolefin matrix; and a plurality of glass fibers dispersed throughout the polyolefin matrix, the glass fibers being bonded to the polyolefin matrix by the reaction product of: a silane composition comprising silane molecules having amine functional groups and silane molecules having ethylenically-unsaturated functional groups; with a fiber bonding agent comprising (a) from 0.05 to 15 weight percent of a polymerizable unsaturated organic compound having at least two polymerizable unsaturation groups; and (b) from 0.05 to 5 weight percent of a vinyl-polymerizable unsaturated, hydrolyzable silane; with or without (c) from 0.0025 to 2.5 weight percent of a free radical generator, the weight percentages of components (a) to (c) being based upon the total weight of the treated glass fibers.

Claim 32

A fiber-reinforced composite material comprising: a polyolefin matrix; and a plurality of glass fibers dispersed throughout the polyolefin matrix, the glass fibers being bonded to the polyolefin matrix by the reaction product of: a silane composition comprising silane molecules having amine functional groups and silane molecules having ethylenically-unsaturated functional groups; with a fiber bonding agent comprising (a) from 0.05 to 15 weight percent of a polymerizable unsaturated organic compound having at least two polymerizable unsaturation groups; and (b) from 0.05 to 5 weight percent of a vinyl-polymerizable unsaturated, hydrolyzable silane; with or without (c) from 0.0025 to 2.5 weight percent of a free radical generator, the weight percentages of components (a) to (c) being based upon the total weight of the treated glass fibers.

Claim 33

A fiber-reinforced composite material according to claim 26 wherein the reaction product is derived from a silane composition comprising at least one silane having an amine functional group and an ethylenically-unsaturated functional group in the same molecule.

Claim 34

A fiber-reinforced composite material according to claim 27 wherein the silane composition comprises any one fatty ethenoid acylaminoorganoosilane compound represented by the general formula Y[N(Y).sub.c R.sub.2-c ].sub.x [N(W)R.sup.1 ].sub.y [N(Y).sub.b R.sup.2 .sub.2-b ]x(HX).sub.w wherein R and R 1 are individually selected from the group consisting of divalent alkylene groups containing from two to six carbon atoms inclusive, divalent arylene groups containing from six to twelve carbon atoms inclusive, divalent substituted arylene groups containing from seven to twenty carbon atoms inclusive, and a divalent groups of the formula -C(═O)R 3 - wherein R 3 is a divalent alkylene group containing from two to six carbon atoms inclusive; R 2 is a monovalent alkyl or aryl group containing from one to ten carbon atoms or hydrogen; W is either hydrogen or -C(═O)R 4 - wherein R 4 is a monovalent hydrocarbon group containing from 8 to 24 carbon atoms and containing at least one double bond; Y is selected from the group consisting of hydrogen, -C(═O)R 4 -, wherein R 4 is as defined above, R 2 and -R 5 Si(OR 6 ) a ,(R 7 ) a , wherein R 5 is a divalent alkylene group containing from two to six carbon atoms inclusive, R 6 and R 7 are individually a monovalent alkyl or aryl group containing from one to six carbon atoms inclusive; and R 6 may also be a silicon containing moiety wherein the oxygen atom is directly bonded to the silicon atom of the R 6 silicon containing moiety; a has a value of zero, one or two; b has a value of zero, one or two; c has a value of zero or one; x and y have values such that x +y equals one to thirty, with the proviso that x is at least one; z has a value of zero or one; X is a halogen atom or an ester hydroxyl or anhydride group; w has a value equal to from zero to the sum of x +y +z provided that w does not exceed the total nitrogen atom in free amine form; with the proviso that at least one Y is -R 5 Si(OR 6 ) 3a (R 7 ) a and at least one other Y is -C(•O)R 4 -; and when x =1, y =0 and z =0, then c =1.

Claim 35

A fiber-reinforced composite material according to claim 28 wherein the silane composition comprises [CH.sub.3 (CH.sub.2 CH═CH).sub.3 (CH.sub.2).sub.7 CO][NCH.sub.2 CH.sub.2 NH][CH.sub.2 CH.sub.2 CH.sub.2 Si(OMe).sub.3 ].sub.2.

Claim 36

A fiber-reinforced composite material according to claim 26 wherein the reaction product is derived from a silane composition comprising a first silane having an amine functional group and a second silane having an ethylenically-unsaturated functional group.

Claim 37

A fiber-reinforced composite material according to claim 30 wherein the first silane is at least one of τ-aminopropyltriethoxysilane, τ-aminopropyltrimethoxysilane, bis(trimethoxysilylpropyl)amine, 1,2-bis-(trimethoxysilylpropyl)ethanediamine, or isomers thereof, and trimethoxysilylpropyl substituted diethylene triamine.

Claim 38

A fiber-reinforced composite material according to claim 31 wherein the first silane is at least one of τ-aminopropyltriethoxysilane or τ-aminopropyltrimethoxysilane.

Claim 39

A fiber-reinforced composite material according to claim 30 wherein the second silane is a vinyl silane.

Claim 40

A process according to claim 9 wherein the second silane is at least one of vinyltrimethoxysilane, vinyltriethoxysilane, vinyl tris(2-methoxyethoxy)silane or τ-methacryloxypropyltrimethoxysilane.