Hybrid composite articles and methods for their production
AssigneeComplastik Corporation
InventorDavid A. Evans
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Abstract
The present invention relates to high quality composite materials from fibrous materials, in which the composite incorporates a polymer matrix embedding individual fibers. The matrix is derived from polymer particles which penetrate into a strand and substantially fill gaps between individual fibers. Such penetration can occur by exposing the strand to a stable emulsion of the polymer particles. The invention also relates to novel composite structures which incorporation of various types of fibrous segments. These composite structures allow the use of inexpensive and readily available scrap materials. The composites of the present invention are lightweight materials displaying enhanced strength and durability.
Claims27
A method of forming a composite, comprising:
- providing a strand comprising a plurality of fibers;
- exposing the strand to a stable emulsion comprising polymer particles;
- and
- allowing the particles polymer particles to penetrate gaps between individual fibers.
An article, comprising:
- a mixture comprising fibrous segments and polymer particles, a portion of the particles penetrating substantially all ends of individual fibers in the fibrous segments, and the entire article being substantially rigid.
A composite, comprising:
- a plurality of fibrous segments;
- and
- a polymer matrix embedding the fibrous segments and ends of individual fibers of the fibrous segments.
Dependencies are inferred from the claim text.