POLYMER FIBER COMPOSITE

• US 20170313041A1
• Filed: 11/17/2014
• Published: 11/02/2017
• Est. Priority Date: 11/17/2014
• Status: Active Grant

• Current Assignee: Hewlett-Packard Development Company, L.P. (HP Inc.)
• Original Assignee: Hui He
• Inventors: YUEN, HANG YAN, HE, HUI
• Granted Patent: US 10,639,870 B2
• Time in Patent Office: Days
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/103 Metal fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2264/0257 Polyolefin particles, e.g. polyethylene or polypropylene homopolymers or ethylene-propylene copolymers
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2307/706 Anisotropic
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2457/00 Electrical equipment
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/322 comprising halogenated polyolefins, e.g. PTFE
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: B32B 27/36 comprising polyesters
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/16 : characterised by features of a layer formed of particles, e.g. chips, powder or granules layer formed of natural mineral particles B32B19/00; layer being formed of wood fibres, chips or particles B32B21/02
• CPC Class Codes: B32B 5/22 : characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B32B 5/28 : impregnated with or embedded in a plastic substance not used
• CPC Class Codes: B32B 5/30 : one layer being formed of particles, e.g. chips, granules, powder

Abstract

Provided in one example is a composite. The composite includes: a porous core layer including a fluoropolymer; a first layer disposed over at least a portion of the core layer; and a second layer disposed over at least a portion of the first layer. The first layer includes fibers that compose at least one of unidirectional fibers and woven fibers. The second layer includes a polymer. The composite is permeable to air but impermeable to liquid wafer.

Claims

1. A composite, comprising:

a porous core layer composing a fluoropolymer;

a first layer disposed over at least a portion of the core layer, the first layer composing fibers that comprise at least one of unidirectional fibers and woven fibers; and

a second layer disposed over at least a portion of the first layer, the second layer comprising a polymer;

wherein the composite is permeable to air but impermeable to liquid water.

2. The composite of claim 1, wherein the fluoropolymer comprises at least one of polytetrafluoroethylene (“

PTFE”

) and expanded polytetrafluoroethylene (“

ePTFE”

).

3. The composite of claim 1, wherein the core layer has an average pore size of less than or equal to about 3 Å

.

4. The composite of claim 1, wherein the fibers comprise at least one of carbon fibers, glass fibers, aramid fibers, and titanium fibers.

5. The composite of claim 1, wherein the fibers are embedded in a polymeric matrix in the first layer, the polymeric matrix comprising at least one of a thermoplastic and a thermoset.

6. The composite of claim 1, wherein the fibers comprise woven fibers

7. The composite of claim 1, wherein the polymer in the second layer composes at least one of nylon and polyester.

8. The composite of claim 1, wherein the polymer in the second layer has an average pore size of between about 1 μ

m and about 500 μ

m.

9. The composite of claim 1, wherein the composite has a flexural modulus of at least 10 GPa.

10. An electronic device, comprising

an electrical circuit;

a housing exterior to the electrical circuit the housing composing a composite comprising;

a porous core layer comprising a fluoropolymer;

a first layer disposed over at least a portion of the core layer, the first layer comprising fibers that comprise at least one of unidirectional fibers and woven fibers, and

a second layer disposed over at least a portion of the first layer, the second layer comprising a polymer.

11. The electronic device of claim 10, wherein the composite is permeable to air.

12. The electronic device of claim 10, wherein composite is impermeable to liquid water.

13. A method of making, comprising;

disposing over at least a portion of a core layer a first layer, the core layer comprising a fluoropolymer and the first layer comprising fibers that comprise at least one of unidirectional fibers and woven fibers;

disposing over at least a portion of the first layer a second layer, the second layer comprising a polymer; and

thermal forming the core layer, the first layer, and the second layer into a composite;

wherein the composite a part of a housing of an electronic device and is permeable to air and impermeable to liquid water.

14. The method of claim 13, wherein the fluoropolymer comprises at least one of polytetrafluoroethylene (“

PTFE”

) and expanded polytetrafluoroethylene (“

ePTFE”

).

15. The method of claim 13, further comprising impregnating the fibers in a polymeric matrix in the first layer.