초록 ▼

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 the

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. Layering 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 a 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.

대표청구항 ▼

A process of preparing a fiber reinforced thermoplastic molded product having a glossy surface comprising the steps of: (a) blending discrete, single, reinforcing fibers, and thermoplastic fibers, to provide a uniformly blended non-needled, loose non-woven admixture devoid of liquid binder and disti

A process of preparing a fiber reinforced thermoplastic molded product having a glossy surface comprising the steps of: (a) blending discrete, single, reinforcing fibers, and thermoplastic fibers, to provide a uniformly blended non-needled, loose non-woven admixture devoid of liquid binder and distinctly different fiber layers or alternatingly distinctly different layers; (b) heating the admixture to at least the melting point of the thermoplastic fibers and applying pressure to the admixture to cause the thermoplastic fibers to melt, to eliminate air from the admixture and to press the admixture into a consolidated structure, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product; and (c) minimizing breakage of the reinforcing fibers during the practice of step (b) by limiting the pressure, so as to produce a consolidated structure with minimal fiber breakage and a Notched Izod of at least one. A consolidated, heat and pressure molded thermoplastic sheet of fibrous reinforced thermoplastic material having a flexural modulus above 200,000 psi, an ASTM standard D-523 gloss value above 20 at an angle of 20°, and a Notched Izod of at least three, prepared from a non-needled, non-woven web devoid of liquid binder and distinctly different fiber layers or alternatingly distinctly different layers, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product.