US5219642A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Fibre reinforced stuctural thermoplastic composite materials
Assignee: Fiberite Inc
•
Filing: 1991-12-10
•
Granted: 1993-06-15
•
Expires: 2011-12-10
Abstract
Abstract A structural thermoplastic composite material comprises a laminate of a first layer of a fibre reinforced thermoformable crystalline polymer composite and an adherent layer of a second thermoformable polymer which has been applied to the first layer at a temperature above the melting point of the polymer of the first layer. The second polymer comprises an amorphous polymer having a Tg which is at least 10 DEG C. lower than the Tm of the other polymer, which is crystallisable in a subsequent annealing process, and which has a peak crystallisation time of at least 1 minute. Such a material can be bonded to itself or to a different material by the adherent layer at temperatures below the Tm of the matrix polymer.
Inventors
- 👤 Peter J. Meakin
- 👤 Philip A. Staniland
- 👤 Frederic N. Cogswell
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 07:41
CPC Classifications
B; B29; B29C; B29C66/00; B29C66/70; B29C66/73; B29C66/731; B29C66/7311; B29C66/73115; B29C65/00; B29C65/02; B29C66/72; B29C66/721; B29C66/7214; B29C66/72141; B29C66/73117; B29C66/737; B29C66/7377; B29C66/73771; B29C66/739; B29C66/7392; B29C66/73921; B29C66/90; B29C66/91; B29C66/914; B29C66/9141; B29C66/91411; B29C66/919; B29C66/9192; B29C66/91921; B29C66/91931; B29C70/00; B29C70/04; B29C70/06; B29C70/08; B29C70/086; B29C73/00; B29C73/04; B29C73/10; B32; B32B; B32B7/00; B32B7/02; B32B7/027; B29C65/18; B29C66/71; B29C66/7212; B29C66/727; B29C66/73772; B29C66/73775; B29C66/73776; B29C66/7394; B29C71/00; B29C71/0063; B29C71/02; B29K; B29K2023/00; B29K2023/10; B29K2023/12; B29K2067/00; B29K2071/00; B29K2077/00; B29K2081/00; B29K2081/06; B29K2105/00; B29K2105/04; B29K2105/06; B29K2995/00; B29K2995/0037; B29K2995/0039; B29K2995/0041; Y; Y10; Y10S; Y10S428/00; Y10S428/902; Y10T; Y10T428/00; Y10T428/24; Y10T428/24942; Y10T428/249921; Y10T428/249924; Y10T428/24994; Y10T428/29; Y10T428/2913; Y10T428/298; Y10T428/30
Claims Analysis
Total Claims: 19
Claim 1
Independent Claim
112 words
A structural thermoplastic composite material comprising a laminate of a first layer of a fibre-reinforced composite comprising a first thermoformable polymer and reinforcing filaments at least 50% by weight of which have a length in excess of 3 mm; a second adherent layer comprising a second thermoformable polymer, said second polymer being amorphous but crystallizable by annealing; having a glass transition temperature which is at least 10° C. lower than the melting point of said first polymer; and having a peak crystallization time of not less than about 1 minute; and said second layer having been applied to said first layer at a temperature above the melting point of said first polymer.
Claim 2
Dependent Claim
112 words
A structural thermoplastic composite material comprising a laminate of a first layer of a fibre-reinforced composite comprising a first thermoformable polymer and reinforcing filaments at least 50% by weight of which have a length in excess of 3 mm; a second adherent layer comprising a second thermoformable polymer, said second polymer being amorphous but crystallizable by annealing; having a glass transition temperature which is at least 10° C. lower than the melting point of said first polymer; and having a peak crystallization time of not less than about 1 minute; and said second layer having been applied to said first layer at a temperature above the melting point of said first polymer.
Claim 3
Dependent Claim
20 words
A material according to claim 1 wherein said second polymer has a peak crystallization time of at least 4 minutes.
Claim 4
Dependent Claim
20 words
A material according to claim 1 wherein said first polymer has a peak crystallization time of less than 30 seconds.
Claim 5
Dependent Claim
20 words
A material according to claim 1 wherein said first polymer has a peak crystallization time of less than 10 seconds.
Claim 6
Dependent Claim
115 words
A structural thermoplastic composite material comprising: a first fibre-reinforced composite material comprising a first thermoformable polymer and reinforcing filaments at least 50% by weight of which have a length in excess of 3 mm; and a second adherent material comprising a second thermoformable polymer, said second polymer: being amorphous but crystallizable by annealing; having a glass transition temperature which is at least 10° C. lower than the melting point of said first polymer; and having a peak crystallization time of not less than about 1 minute; and said second material comprising an exposed surface; said second material having been applied to said first material at a temperature above the melting point of said first polymer.
Claim 7
Dependent Claim
115 words
A structural thermoplastic composite material comprising: a first fibre-reinforced composite material comprising a first thermoformable polymer and reinforcing filaments at least 50% by weight of which have a length in excess of 3 mm; and a second adherent material comprising a second thermoformable polymer, said second polymer: being amorphous but crystallizable by annealing; having a glass transition temperature which is at least 10° C. lower than the melting point of said first polymer; and having a peak crystallization time of not less than about 1 minute; and said second material comprising an exposed surface; said second material having been applied to said first material at a temperature above the melting point of said first polymer.
Claim 8
Dependent Claim
151 words
A structural thermoplastic composite material comprising: a first fibre-reinforced composite material comprising a first thermoformable polymer and reinforcing filaments at least 50% by weight of which have a length in excess of 3 mm; and a second adherent material comprising a second thermoformable polymer, said second polymer: being amorphous but crystallizable by annealing; having a glass transition temperature which is at least 10° C. lower than the melting point of said first polymer; and having a peak crystallization time of not less than about 1 minute; and comprising an exposed surface; said second material having been applied to said first material at a temperature above the melting point of said first polymer, said composite material being bondable to another material by contacting said exposed surface to a surface of said other material to which it is to be bonded under conditions of heat and pressure insufficient to melt the first polymer.
Claim 9
Dependent Claim
151 words
A structural thermoplastic composite material comprising: a first fibre-reinforced composite material comprising a first thermoformable polymer and reinforcing filaments at least 50% by weight of which have a length in excess of 3 mm; and a second adherent material comprising a second thermoformable polymer, said second polymer: being amorphous but crystallizable by annealing; having a glass transition temperature which is at least 10° C. lower than the melting point of said first polymer; and having a peak crystallization time of not less than about 1 minute; and comprising an exposed surface; said second material having been applied to said first material at a temperature above the melting point of said first polymer, said composite material being bondable to another material by contacting said exposed surface to a surface of said other material to which it is to be bonded under conditions of heat and pressure insufficient to melt the first polymer.
Claim 10
Dependent Claim
15 words
A material according to claim 1 wherein said second layer comprises an exposed protective surface.
Claim 11
Dependent Claim
21 words
A composite material according to claim 1, wherein said second polymer has a peak crystallisation time of at least 2.5 minutes.
Claim 12
Dependent Claim
27 words
A composite material according to claim 1, wherein said first polymer preferably is a crystalline polymer preferably having a peak crystallisation time of less than 1 minute.
Claim 13
Dependent Claim
17 words
A composite material according to claim 1 wherein said first layer is reinforced with continuous, aligned filaments.
Claim 14
Dependent Claim
15 words
A composite material according to claim 1 wherein said first and second polymers are polyarlyethers.
Claim 15
Dependent Claim
66 words
A composite according to claim 1 wherein said first polymer is a polyetheretherketone containing units of formula --O--Ph--O--Ph--CO--Ph-- and said second polymer is a polyarylether containing units of formula IA and IB --Ph--CO--Ph.sup.1 --CO--Ph-- IA --Ar-- IB wherein: IA and IB are linked through either linkages; Ph is 1,4-phenylene; Ph 1 is 1,3-phenylene; and Ar is Ph 2 or Ph 3 , preferably Ph 2 .
Claim 16
Dependent Claim
17 words
A composite material according to claim 1 wherein said second layer is reinforced with continuous, aligned filaments.
Claim 17
Dependent Claim
30 words
A structural composite article comprising at least two structural composite materials comprising first and second layers according to claim 1, said materials being bonded together through their respective second layers.
Claim 18
Dependent Claim
31 words
A structural composite article comprising a first structural composite material according to claim 1 and a second structural material bonded thereto by the second layer of said first structural composite material.
Claim 19
Dependent Claim
27 words
A structural composite article according to claim 14 or 15 characterised by having a lap shear strength as determined by ASTM D1002 of at least 5 MPa.
References Cited (Backward Citations)
US4161564A
Cited
GB1570000A
Cited
EP0001879A1
Cited
US4500603A
Cited
EP0110672A2
Cited
US4468426A
Cited
US4760106A
Cited
US4623590A
Cited
US4767656A
Cited
US4654263A
Cited
US4728562A
Cited
US4604319B1
Cited
US4604319A
Cited
US4596860A
Cited
US4728561A
Cited
US4851287A
Cited
US4666547A
Cited
US4746710A
Cited
EP0235885A1
Cited
US4891084A
Cited
US4877682A
Cited
GB2204888A
Cited
US4919992A
Cited
EP0320155A2
Cited
US5066536A
Cited
EP0323076A2
Cited
US4929478A
Cited
US4877476A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1996-06-14 | 1996-12-14 | 1997-06-15 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2000-06-14 | 2000-12-14 | 2001-06-15 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2004-06-14 | 2004-12-14 | 2005-06-15 | $7700.00 | Window Closed / Lapsed |