Glass mat thermoplastic composite
First Claim
1. A composition of a fiber reinforced laminate material of a multi-layered laminate having two or more layers, wherein following heating using a compression molding or thermoforming process the laminate material forms a composite having a Class-A surface that is resin rich, said laminate material comprising:
- a) a layer comprised of a thermoplastic resin;
b) a layer comprised of a polymerizable component comprised of chemically reactive components;
c) a layer of reinforcing fibers. wherein the layer of reinforcing fibers is sufficiently open as to be permeable to impregnation/saturation by the thermoplastic resin and to enable the migration of the chemically reactive components, when the laminate is under heat and compression; and
wherein at the temperatures of molding the polymerizable component has a lower viscosity than the thermoplastic.
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Accused Products
Abstract
A composition of a fiber reinforced laminate material that when thermoformed or compression molded forms a composite having a Class-A surface that is resin rich. The laminate material has a layer of a thermoplastic resin with an initiator and catalyst; a glass mat; an intra-layer of a polymerizable component that is a lower viscosity mixture of oligomers, monomers and thermoplastic resin; a second glass mat, and another layer of a thermoplastic resin with an initiator and catalyst. When thermoformed or compression molded, the combination of heat and pressure force the low viscosity polymerizable component through the permeable glass mats and toward the surface. The initiator and catalyst cause the polymerizable component to polymerize forming a Class-A surface that is resin rich. The thermoplastic resin thoroughly permeates the reinforcing fiber forming a composite having a core with a nearly uniform mixture of reinforced glass fiber and thermoplastic resin.
24 Citations
42 Claims
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1. A composition of a fiber reinforced laminate material of a multi-layered laminate having two or more layers, wherein following heating using a compression molding or thermoforming process the laminate material forms a composite having a Class-A surface that is resin rich, said laminate material comprising:
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a) a layer comprised of a thermoplastic resin;
b) a layer comprised of a polymerizable component comprised of chemically reactive components;
c) a layer of reinforcing fibers. wherein the layer of reinforcing fibers is sufficiently open as to be permeable to impregnation/saturation by the thermoplastic resin and to enable the migration of the chemically reactive components, when the laminate is under heat and compression; and
wherein at the temperatures of molding the polymerizable component has a lower viscosity than the thermoplastic. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 26, 27, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42)
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15. A method for forming a fiber reinforced laminate material of a multi-layered laminate having three or more layers, wherein following heated compression molding, said composite has a Class-A surface that is resin rich, said method comprising the steps of:
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a) extruding an intra-layer of polymerizable components between a first layer of reinforcing fibers and a second layer of reinforcing fibers;
b) essentially simultaneously extruding an first layer of thermoplastic resin on an outer side of the first layer of reinforcing fibers and a second layer of thermoplastic resin on an outer side of the second layer of reinforcing fibers; and
,c) laminating the first layer of thermoplastic resin, the first layer of reinforcing fibers, the intra-layer of polymerizable components, the second layer of reinforcing fibers and the second layer of thermoplastic resin; and
d) cooling the laminate, therein forming the fiber reinforced laminate material. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 28)
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Specification