Blended thermoplastic and thermoset materials and methods
AssigneeJohns Manville
InventorAlan Michael Jaffee
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Abstract
Structural panels and methods of making composite material for such structural panels may include applying a resin to a nonwoven fibrous web, where the nonwoven fibrous web includes a combination of glass fibers and polymer fibers. The web may be dried at a first stage temperature at or below a curing temperature of the resin for a time sufficient to substantially dry but not substantially cure the resin. The web may be laminated at a second stage temperature sufficient to fully cure the resin to produce a composite material. The second stage temperature may be above the melting point of the polymer fibers, and the resin may cause the composite material to retain a substantially rigid shape upon completion of the laminating operation.
Claims15
A method of making a composite material, the method comprising:
- applying a resin to a nonwoven fibrous web, wherein the nonwoven fibrous web comprises a combination of glass fibers and polymer fibers;
- drying the web at a first stage temperature at or below a curing temperature of the resin for a time sufficient to substantially dry but not substantially cure the resin;
- and
- laminating the web at a second stage temperature sufficient to fully cure the resin to produce the composite material, wherein the second stage temperature is above the melting point of the polymer fibers, and wherein the resin causes the composite material to retain a substantially rigid shape upon completion of the laminating operation.
A structural panel comprising:
- a core material;
- a nonwoven laminated material, wherein a first surface of the nonwoven laminated material is coupled with a first surface of the core material, and wherein the nonwoven laminated material comprises a nonwoven fibrous web including a combination of glass fibers and polymer fibers and a B-staged resin characterized by a curing temperature above the melting temperature of the polymer fibers.
A nonwoven laminated material comprising a nonwoven fibrous web including a combination of glass fibers and polymer fibers and a B-staged resin characterized by a curing temperature above the melting temperature of the polymer fibers
Dependencies are inferred from the claim text.