Plastic composite articles and methods of making same
First Claim
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1. A method for making a shaped composite article, comprising the steps of:
- a. providing at least one elongated member of a first thermoplastic material and having a surface portion capable of melting prior to the melting of an adjoining or internal portion; and
b. processing the elongated member into an intermediate form that includes a plurality of repeating structural units that are generally free to move relative to each other, wherein the form is capable of being processed to form a shaped composite article including an exposed portions, and that is ruck-free over the exposed portions of the form in the resulting composite article and has a relatively high degree of retained orientation in the unit;
wherein the at least one elongated member further comprises a non-migratory process aid agent in an amount less than about 10% by weight of the material of the elongated member;
wherein the step of processing the elongated member into an intermediate form includes a step of disposing one of the repeating structural units relative to another; and
wherein the plurality of repeating structural units are capable of being arranged to define a pattern; and
wherein the first thermoplastic material is coextruded to include a layer that includes a propylene-ethylene copolymer and an adjoining layer that includes an isotactic polypropylene homopolymer.
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Abstract
A reinforced composite article and method for making the same. The article and method employ at least one elongated plastic member as a reinforcement phase. An intermediate form including the elongated member is made and can be processed, for example, to form a composite article with a smooth exposed reinforcement surface.
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Citations
6 Claims
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1. A method for making a shaped composite article, comprising the steps of:
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a. providing at least one elongated member of a first thermoplastic material and having a surface portion capable of melting prior to the melting of an adjoining or internal portion; and b. processing the elongated member into an intermediate form that includes a plurality of repeating structural units that are generally free to move relative to each other, wherein the form is capable of being processed to form a shaped composite article including an exposed portions, and that is ruck-free over the exposed portions of the form in the resulting composite article and has a relatively high degree of retained orientation in the unit;
wherein the at least one elongated member further comprises a non-migratory process aid agent in an amount less than about 10% by weight of the material of the elongated member;wherein the step of processing the elongated member into an intermediate form includes a step of disposing one of the repeating structural units relative to another; and wherein the plurality of repeating structural units are capable of being arranged to define a pattern; and wherein the first thermoplastic material is coextruded to include a layer that includes a propylene-ethylene copolymer and an adjoining layer that includes an isotactic polypropylene homopolymer. - View Dependent Claims (2, 3, 4, 5, 6)
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Specification