# US 11,027,503 B2 · Fiber reinforced polymer composite material and preparation method thereof > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,027,503 B2 - Document ID: US11027503B2 - Status: Granted - Kind: B2 - Application number: 16/063,086 - Filed: 2017-01-02 - Published: 2020-08-27 - Granted: 2021-06-08 - Earliest claimed: 2016-01-05 - Assignees: Covestro Deutschland AG - Applicants: Covestro Deutschland AG - Inventors: James Chen; Zhijiang Li - Web page: https://patentgrep.com/patent/US11027503B2 ## CPC - B29C 70/086: {and with one or more layers of pure plastics material, e.g. foam layers (applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86)} - B29C 70/08: comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers - B29C 70/226: {the structure comprising mainly parallel filaments interconnected by a small number of cross threads} - B29C 70/521: {and impregnating the reinforcement before the die} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) ## Abstract The invention relates to a fiber reinforced polymer composite material and a preparation method thereof, wherein the fiber reinforced polymer composite material comprises a polymeric resin matrix in a continuous phase, and chemical fiber fabric and reinforced fibers dispersed in the polymeric resin matrix, and the chemical fiber fabric covers the reinforced fibers so as to avoid exposure of the reinforced fibers to an outside surface of the composite material. The invention reduces or even avoids exposure of the reinforced fibers of the fiber reinforced polymer composite material, and can be used for manufacturing cable bridges, frames of doors, windows and curtain walls, etc. The method for preparing the fiber reinforced polymer composite material of the invention effectively improves the performance of the composite material and also reduces the cost of surface treatment and increases production efficiency. ## Claims ### Claim 1 A fiber reinforced polymer composite material, wherein: a. the fiber reinforced polymer composite material comprises a polymeric resin matrix in a continuous phase, and chemical fiber fabric and reinforced fibers dispersed in the polymeric resin matrix, and the chemical fiber fabric covers the reinforced fibers so as to avoid exposure of the reinforced fibers to an outside surface of the composite material; b. the chemical fiber fabric is selected from the group consisting of plain cloth, twill, and sateen prepared from continuous fibers by a weaving method; or fabric prepared by a knitting method; or fabric directly prepared by a stitchbonding method and has a grammage in the range of 10-1800 g/m2; and c. the fiber reinforced polymer composite material is prepared by a pultrusion process or a continuous laminate process. ### Claim 2 (depends on 1) The fiber reinforced polymer composite material according to claim 1, wherein the chemical fiber fabric is selected from the group consisting of poly(ethylene terephthalate) fiber, nylon, vinylon, polyvinyl chloride fiber, acrylic fiber, spandex, polyolefin fiber, regenerated cellulose fiber, polynosic fiber fabric, and composite fiber fabric comprising a combination of any thereof. ### Claim 3 (depends on 1) The fiber reinforced polymer composite material according to claim 1, wherein a fiber surface of the chemical fiber fabric is adhered by one or more additives selected from the group consisting of an ultraviolet stabilizer, a release agent, a flame retardant, a conductivity improver, a film forming agent and a pigment. ### Claim 4 (depends on 1) The fiber reinforced polymer composite material according to claim 1, wherein a fiber surface of the chemical fiber fabric is adhered by a light and aging resistant resin coating or an anti-corrosion resin coating or a fire retardant coating selected from the group consisting of aliphatic polyurethane resin, acrylic resin, fluorocarbon resin, organosilicone resin, silicate coating, furan resin, phenolic resin and intumescent flame retardant coating. ### Claim 5 (depends on 1) The fiber reinforced polymer composite material according to claim 1, wherein the polymeric resin is thermosetting resin or thermoplastic resin. ### Claim 6 (depends on 1) The fiber reinforced polymer composite material according to claim 1, wherein the reinforced fibers are selected from the group consisting of glass fiber, carbon fiber, Kevlar fiber, basalt fiber and natural fabric fiber. ### Claim 7 (depends on 1) A method for preparing the fiber reinforced polymer composite material according to claim 1, the method comprising: i) covering reinforced fibers with chemical fiber fabric selected from the group consisting of plain cloth, twill, and sateen prepared from continuous fibers by a weaving method; or fabric prepared by a knitting method; or fabric directly prepared by a stitchbonding method; ii) impregnating the chemical fiber fabric and the reinforced fibers with liquid polymeric resin; iii) curing or hardening the resin so that the resin is combined with the chemical fiber fabric and the reinforced fibers as a whole to obtain the composite material; and iv) continuously molding the composite material using a pultrusion process or a continuous laminate process. ### Claim 8 (depends on 7) The method according to claim 7, wherein the curing or hardening temperature ranges from −5° C. to 250° C. ### Claim 9 (depends on 7) The method according to claim 7, wherein the pressure for impregnating the chemical fiber fabric and the reinforced fibers with the resin is 1-100 bar. ### Claim 10 (depends on 1) An article prepared from the fiber reinforced polymer composite material according to claim 1. ### Claim 11 (depends on 10) The article according to claim 10, wherein the article is selected from the group consisting of: cable bridges, frames of doors, windows and curtain walls, frames of ladders, tent poles or pipes, antiglare shields, floors, sucker rods, telegraph poles and cross arms, guardrails, gratings, architectural sectional materials, container sectional materials and plates, bike racks, fishing rods, cable cores, insulator core rods, radomes, and single-layer or sandwiched continuous plates.