Glass fiber mats, laminates reinforced with the same and methods for making the same

A reinforced polymeric laminate comprising:

• (a) a polymeric matrix material;
• and
• (b) a reinforcing mat having at least one primary and at least one secondary area comprising:
• (1) a first layer comprising a plurality of generally parallel, essentially continuous glass fiber strands oriented generally parallel to a longitudinal axis of the mat, at least a portion of outer surfaces of the first layer glass fiber strands having applied thereon at least a partial layer comprising at least a partially dried residue of a first coating composition which is compatible with a polymeric matrix material, wherein at least a first portion of the first layer glass fiber strands are positioned within the at least one primary area at a primary strand density and at least a second portion of the first layer glass fiber strands are positioned within the at least one secondary area at a secondary strand density which is different from the primary strand density;
• and
• (2) a second layer comprising a plurality of randomly oriented glass fiber strands positioned within the at least one primary area and the at least one secondary area and adjacent to a surface of the first layer, at least a portion of outer surfaces of the second layer glass fiber strands having applied thereon at least a partial layer comprising at least a partially dried residue of a second coating composition which is compatible with the polymeric matrix material, wherein the first and second layers are joined to hold the mat together.

A reinforced composite comprising at least one reinforced polymeric laminate comprising:

• (a) a polymeric matrix material;
• and
• (b) a reinforcing mat having at least one primary and at least one secondary area comprising:
• (1) a first layer comprising a plurality of generally parallel, essentially continuous glass fiber strands oriented generally parallel to a longitudinal axis of the mat, at least a portion of outer surfaces of the first layer glass fiber strands having applied thereon at least a partial layer comprising at least a partially dried residue of a first coating composition which is compatible with a polymeric matrix material, wherein at least a first portion of the first layer glass fiber strands are positioned within the at least one primary area at a primary strand density and at least a second portion of the first layer glass fiber strands are positioned within the at least one secondary area at a secondary strand density which is different from the primary strand density;
• and
• (2) a second layer comprising a plurality of randomly oriented glass fiber strands positioned within the at least one primary area and the at least one secondary area and adjacent to a surface of the first layer, at least a portion of outer surfaces of the second layer glass fiber strands having applied thereon at least a partial layer comprising at least a partially dried residue of a second coating composition which is compatible with the polymeric matrix material, wherein the first and second layers are joined to hold the mat together.

A method for making a mat adapted to reinforce a polymeric matrix material, the method comprising the steps of:

• (a) positioning a plurality of generally parallel, essentially continuous glass fiber strands oriented generally parallel to a longitudinal axis of the mat to form a first layer, at least a portion of outer surfaces of the first layer glass fiber strands having applied thereon at least a partial layer comprising at least a partially dried residue of a first coating composition which is compatible with a polymeric matrix material, wherein at least a first portion of the first layer glass fiber strands are positioned within an at least one primary area at a primary strand density and at least a second portion of the first layer glass fiber strands are positioned within an at least one secondary area at a secondary strand density which is different from the primary strand density;
• (b) dispersing a plurality of randomly oriented glass fiber strands within the at least one primary area and the at least one secondary area and adjacent to a surface of the first layer to form a second layer, at least a portion of outer surfaces of the second layer glass fiber strands having applied thereon at least a partial layer comprising at least a partially dried residue of a second coating composition which is compatible with the polymeric matrix material;
• and
• (c) joining the first and second layers to hold the mat together.

A method for reinforcing a polymeric matrix material to form a reinforced laminate, the method comprising the steps of:

• (a) positioning a plurality of generally parallel, essentially continuous glass fiber strands oriented generally parallel to a longitudinal axis of the mat to form a first layer, at least a portion of outer surfaces of the first layer glass fiber strands having applied thereon at least a partial layer comprising at least a partially dried residue of a first coating composition which is compatible with a polymeric matrix material, wherein at least a first portion of the first layer glass fiber strands are positioned within an at least one primary area at a primary strand density and at least a second portion of the first layer glass fiber strands are positioned within an at least one secondary area at a secondary strand density which is different from the primary strand density;
• and
• (b) dispersing a plurality of randomly oriented glass fiber strands within the at least one primary area and the at least one secondary area and adjacent to a surface of the first layer to form a second layer, at least a portion of outer surfaces of the second layer glass fiber strands having applied thereon at least a partial layer comprising at least a partially dried residue of a second coating composition which is compatible with the polymeric matrix material;
• and
• (c) joining the first and second layers to hold the mat together;
• (d) coating and impregnating at least a portion of the mat with the polymeric matrix material;
• and
• (e) at least partially curing the polymeric matrix material to form a reinforced laminate.