System for producing a fully impregnated thermoplastic prepreg
AssigneeJohns Manville
InventorsMingfu Zhang, Jawed Asrar
Life of this patent
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Abstract
A thermoplastic prepreg includes a mat, web, or fabric of fibers and hollow glass microspheres that are positioned atop the mat, web, or fabric of fibers or dispersed therein. The thermoplastic prepreg also includes a thermoplastic polymer that is fully impregnated through the mat, web, or fabric of fibers and the hollow glass microspheres so that the thermoplastic prepreg has a void content of less than 3% by volume of the thermoplastic prepreg. The thermoplastic material is polymerized monomers and oligomers in which greater than 90% by weight of the monomers or oligomers react to form the thermoplastic material.
Claims24
A thermoplastic prepreg comprising:
- a first layer composed of a fiber mat, web, or fabric;
- a second layer composed of a fiber mat, web, or fabric;
- a third layer positioned between the first layer and the second layer, the third layer including a lightweight filler material having a density of between 0.1 and 1.0 g/cm3;
- and
- a thermoplastic polymer that is fully impregnated through the fiber mat, web, or fabric of the first layer, the fiber mat, web, or fabric of the second layer, and the lightweight filler material of the third layer, the thermoplastic polymer being formed via in situ polymerization of monomers and oligomers in which greater than 90% of the monomers or oligomers react to form the thermoplastic polymer;
- wherein:
- the thermoplastic prepreg includes 5 to 95 weight percent of the thermoplastic polymer;
- and
- the thermoplastic prepreg includes between 1 and 30 weight percent of the lightweight filler material.
A thermoplastic prepreg comprising:
- a first layer including a first fiber mat, web, or fabric and a thermoplastic polymer impregnated through the first fiber mat, web, or fabric;
- a second layer including a second fiber mat, web, or fabric and a thermoplastic polymer impregnated through the second fiber mat, web, or fabric;
- and
- a third layer positioned between the first layer and the second layer, the third layer including a lightweight filler material having a density of between 0.1 and 1.0 g/cm3 and a thermoplastic polymer impregnated through the lightweight filler material;
- wherein:
- the thermoplastic polymer of the first layer, second layer, and third layer is formed via in situ polymerization of monomers and oligomers in which greater than 90% of the monomers or oligomers are polymerized;
- and
- the thermoplastic prepreg includes between 1 and 30 weight percent of the lightweight filler material.
Dependencies are inferred from the claim text.