PVC and PVC alloy formulations for use as resins in thermoplastic continuous fiber reinforcement composites and methods of formulating the same
AssigneeSekisui Kydex, LLC
InventorsSean Stabler, Nathan Wright
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Abstract
Disclosed herein are thermoplastic polymer matrix compositions for a continuous fiber reinforced thermoplastic composite article, comprising at least one of poly(vinyl chloride) and/or chlorinated poly(vinyl chloride). Also disclosed herein are methods for formulating thermoplastic polymer matrix compositions suitable for impregnating continuous fibers for continuous fiber-reinforced thermoplastic composite articles, wherein the thermoplastic polymer matrix compositions have sufficient viscosity and thermal stability to impregnate continuous fibers and withstand thermal treatment at high temperatures and long residence times without decomposing.
Claims20
A thermoplastic polymer matrix composition for a continuous fiber reinforced thermoplastic composite article, comprising:
- 100 phr of poly(vinyl chloride) having a k-value of at least about 30 and about 60 or less;
- 1.5 to 4 phr of one or more tin-based stabilizers or co-stabilizers;
- 10 to 30 phr of one or more styrene-based or acrylic-based core-shell modifiers;
- 0.1 to 5 phr of one or more acrylic-based process aids;
- and
- 0.5 to 5 phr of one or more polyolefin- or polyester-based lubricants.
A method of formulating a thermoplastic polymer matrix composition for a continuous fiber reinforced thermoplastic composite article,
- wherein the composition comprises:
- poly(vinyl chloride) having a k-value of at least about 30 and about 60 or less;
- 1.5 to 4 phr of one or more tin-based stabilizers or co-stabilizers;
- 10 to 30 phr of one or more styrene-based or acrylic-based core-shell modifiers;
- 0.01 to 0.1 to 5 phr of one or more acrylic-based process aids;
- and
- 0.5 to 5 phr of one or more polyolefin- or polyester-based lubricants, the method comprising:
- adjusting the dynamic thermal stability of the composition, measured by a two-roll mill stability test, to at least 30 minutes at 320° F., by adding one or more stabilizers, co-stabilizers, and/or lubricants to the composition;
- and
- adjusting the viscosity of the composition, as measured by capillary rheology at 390° F. and a shear rate of 94.25 s−1, to at least 1,000 Pa's by adding one or more lubricants, blend polymers, and/or process aids to the composition.
A composite material, comprising:
- a thermoplastic polymer matrix composition comprising:
- poly(vinyl chloride) having a k-value of at least about 30 and about 60 or less;
- 1.5 to 4 phr of one or more tin-based stabilizers or co-stabilizers;
- 10 to 30 phr of one or more styrene-based or acrylic-based core-shell modifiers;
- 0.01 to 0.1 to 5 phr of one or more acrylic-based process aids;
- and
- 0.5 to 5 phr of one or more polyolefin- or polyester-based lubricants;
- and
- a reinforcing material comprising continuous fibers in contact with the thermoplastic polymer matrix composition,
- wherein the thermoplastic polymer matrix composition impregnates the reinforcing material.
Dependencies are inferred from the claim text.