US5098624A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Glossy finish fiber reinforced molded product and processes of construction
Assignee: CH Masland and Sons
•
Filing: 1990-10-31
•
Granted: 1992-03-24
•
Expires: 2010-10-31
Abstract
Abstract Fiber reinforced thermoplastic molded products, sheets, and the like, having a glossy surface are produced by intimately blending discrete reinforcing fibers (e.g. fiberglass) and thermoplastic fibers (e.g. polypropylene or polycarbonate) into a web. The web is heated to the melting point of the thermoplastic fibers while applying pressure, to eliminate air and press the web into a consolidated structure. Breakage of the reinforcing fibers is minimized by limiting the thickness of the web and limiting the pressure so as to produce a consolidated structure with minimal fiber breakage and a Notched Izod of at least one. Layered consolidated structures, some without reinforcing fibers, may be heated and pressed together to form a final structure having a thickness greater than the individual structures. The great majority of the fibers are provided so that the fibers of each type are within the range of about 0.5-5 inches. A sheet capable of replacing an automotive metal panel (that is having sufficiently high gloss, rigidity and impact characteristics) is provided, the sheet having Notched Izod of at least about two and preferably at least about five. Products with Notched Izods of up to eight or nine may be achieved.
Inventors
- 👤 Rayna W. Smith
- 👤 Gerald W. Miller
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 12:04
CPC Classifications
B; B29; B29C; B29C70/00; B29C70/04; B29C70/28; B29C70/54; B29C70/543; B29C70/40; B29C70/42; B29C70/46; B29C70/467; B29K; B29K2995/00; B29K2995/0018; B29K2995/0022; B29L; B29L2031/00; B29L2031/30; B29L2031/3005; Y; Y10; Y10T; Y10T428/00; Y10T428/31
Claims Analysis
Total Claims: 9
Claim 1
Independent Claim
180 words
A process of preparing a fiber reinforced thermoplastic product having high modulus, high ductility and an ASTM standard D-523 gloss value above 20 at 20°, comprising the steps of: (a) providing a reinforcing fiber in the form of discrete, single, staple filaments; (b) providing a thermoplastic fiber in the form of discrete staple filaments; (c) practicing steps (a) and (b) so that the length of the great majority of fibers of each type is within the range of about 0.5-5 inches; (d) intimately blending the discrete reinforcing and thermoplastic fibers into a loose non-needled non-woven web without addition of liquid binder; and (e) heating the loose non-woven web to at least the melting point of the thermoplastic fibers and applying pressure to the web to cause the thermoplastic fibers to melt to eliminate air from the web and press the web into a consolidated product, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product, said molded product being devoid of distinctly different fiber layers or alternating distinctly different layers through the thickness thereof.
Claim 2
Dependent Claim
180 words
A process of preparing a fiber reinforced thermoplastic product having high modulus, high ductility and an ASTM standard D-523 gloss value above 20 at 20°, comprising the steps of: (a) providing a reinforcing fiber in the form of discrete, single, staple filaments; (b) providing a thermoplastic fiber in the form of discrete staple filaments; (c) practicing steps (a) and (b) so that the length of the great majority of fibers of each type is within the range of about 0.5-5 inches; (d) intimately blending the discrete reinforcing and thermoplastic fibers into a loose non-needled non-woven web without addition of liquid binder; and (e) heating the loose non-woven web to at least the melting point of the thermoplastic fibers and applying pressure to the web to cause the thermoplastic fibers to melt to eliminate air from the web and press the web into a consolidated product, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product, said molded product being devoid of distinctly different fiber layers or alternating distinctly different layers through the thickness thereof.
Claim 3
Dependent Claim
48 words
A method as recited in claim 1 wherein the thickness of the web and the temperature and pressure conditions are controlled during forming so as to minimize breakage of the reinforcing fiber, and so as to provide a product with a Notched Izod of at least about 1.
Claim 4
Dependent Claim
25 words
A process as recited in claim 1 wherein step (c) is practiced so that the organic fibers have a diameter of 0.020 inches or less.
Claim 5
Independent Claim
136 words
A method of producing a fiber reinforced thermoplastic molded part or prefrom having high modulus, high ductility and an ASTM standard D-523 gloss value above 20 at 20°, comprising the steps of: (a) blending discrete, single, reinforcing fibers, and thermoplastic fibers, intimately together into a loose non-needled non-woven batt without addition of liquid binder; (b) inserting the batt in a combination press/mold; and (c) applying heat and pressure to the batt with the press/mold so as to melt the thermoplastic fibers while eliminating air from the web and so as to form loose non-woven batt into a molded part or preform, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product, said molded product being devoid of distinctly different fiber layers or alternating distinctly different layers through the thickness thereof.
Claim 6
Independent Claim
136 words
A method of producing a fiber reinforced thermoplastic molded part or prefrom having high modulus, high ductility and an ASTM standard D-523 gloss value above 20 at 20°, comprising the steps of: (a) blending discrete, single, reinforcing fibers, and thermoplastic fibers, intimately together into a loose non-needled non-woven batt without addition of liquid binder; (b) inserting the batt in a combination press/mold; and (c) applying heat and pressure to the batt with the press/mold so as to melt the thermoplastic fibers while eliminating air from the web and so as to form loose non-woven batt into a molded part or preform, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product, said molded product being devoid of distinctly different fiber layers or alternating distinctly different layers through the thickness thereof.
Claim 7
Dependent Claim
51 words
A method as recited in claim 4 wherein the thickness of the batt and the temperature and pressure conditions are controlled during forming so as to minimize breakage of the reinforcing fiber, and so as to provide the molded part or preform with a Notched Izod of at least about three.
Claim 8
Dependent Claim
172 words
A process of preparing a fiber reinforced thermoplastic product having high modulus, high ductility and an ASTM standard D-523 gloss value above 20 at 20°, comprising the steps of: (a) providing a reinforcing fiber in the form of discrete, single, staple filaments; (b) providing a thermoplastic fiber in the form of discrete staple filaments; (c) practicing steps (a) and (b) so that the organic fibers have a diameter of 0.020 inches or less; (d) intimately blending the discrete reinforcing and thermoplastic fibers into a loose non-needled non-woven web without addition of liquid binder; and (e) heating the loose non-woven web to at least the melting point of the thermoplastic fibers and applying pressure to the web to cause the thermoplastic fibers to melt to eliminate air from the web and press the web into a consolidate product, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product, said molded product being devoid of distinctly different fiber layers or alternating distinctly different layers through the thickness thereof.
Claim 9
Dependent Claim
172 words
A process of preparing a fiber reinforced thermoplastic product having high modulus, high ductility and an ASTM standard D-523 gloss value above 20 at 20°, comprising the steps of: (a) providing a reinforcing fiber in the form of discrete, single, staple filaments; (b) providing a thermoplastic fiber in the form of discrete staple filaments; (c) practicing steps (a) and (b) so that the organic fibers have a diameter of 0.020 inches or less; (d) intimately blending the discrete reinforcing and thermoplastic fibers into a loose non-needled non-woven web without addition of liquid binder; and (e) heating the loose non-woven web to at least the melting point of the thermoplastic fibers and applying pressure to the web to cause the thermoplastic fibers to melt to eliminate air from the web and press the web into a consolidate product, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product, said molded product being devoid of distinctly different fiber layers or alternating distinctly different layers through the thickness thereof.
References Cited (Backward Citations)
US2483405A
Cited
US2543101A
Cited
GB826012A
Cited
US3671615A
Cited
US3850723A
Cited
US4083913A
Cited
US4044188A
Cited
US4145227A
Cited
US4098943A
Cited
US4195112A
Cited
US4390489A
Cited
US4290988A
Cited
US4469543A
Cited
US4258093A
Cited
US4258094A
Cited
US4269884A
Cited
US4263364A
Cited
US4407885A
Cited
US4474846A
Cited
US4418031A
Cited
US4359132A
Cited
US4479999A
Cited
US4424250A
Cited
US4379802A
Cited
US4379801A
Cited
US4576853A
Cited
US4568581A
Cited
US4873133A
Cited
US4716072A
Cited
US4751134A
Cited
US4948661A
Cited
US4950439A
Cited
US4943472A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-03-24 | 1995-09-23 | 1996-03-24 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-03-24 | 1999-09-23 | 2000-03-24 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-03-24 | 2003-09-23 | 2004-03-24 | $7700.00 | Window Closed / Lapsed |