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US 4,871,491 AGranted
Process for preparing composite articles from composite fiber blends
AssigneeBASF Structural Materials Inc.
InventorsPaul E. McMahon, Tai-Shung Chung, Lincoln Ying
Life of this patent
Estimating the term…
Abstract
A composite article is prepared by forming a continuous tow of continuous carbon fibers, forming a continuous tow of thermoplastic polymer fibers, uniformly and continuously spreading the thermoplastic polymer fibers to a selected width, uniformly and continuously spreading the carbon fiber tow to a width that is essentially the same as the selected width for the thermoplastic polymer fiber tow, intermixing the tows intimately, uniformly and continuously, in a relatively tension-free state, continuously withdrawing the intermixed tow and applying the tow to a mold and heating the tow.
Claims23
A process for preparing a composite article which comprises:
- (a) forming a continuous tow of continuous carbon fibers;
- (b) forming a continuous tow of continuous thermoplastic polymer fibers having a melting point of at least about 50.degree. C.;
- (c) uniformly and continuously spreading the thermoplastic polymer fiber tow to a selected width to preserve the separation of the individual fibers;
- (d) uniformly and continuously spreading the carbon fiber tow to a width that is essentially the same as the selected width for the thermoplastic polymer fiber tow;
- (e) intimately, uniformly and continuously intermixing the spread carbon fiber tow and the spread thermoplastic polymer fiber tow in a relatively tension-free state by bringing the tows into simultaneous contact with each other in substantially the same area such that there is provided a substantially uniform distribution of the thermoplastic fibers and the carbon fibers within an intimately intermixed tow;
- (f) continuously withdrawing tthe intimately intermixed tow;
- (g) applying the intimately intermixed tow to a mold;
- and
- (h) heating the intermixed tow to a temperature above the melting point of the thermoplastic fibers.
6 more elements
A process for preparingg a composite article which comprises:
- (a) forming a continuous tow of continuous carbon fibers;
- (b) forming a continuous tow of continuous thermoplastic polymer fibers having a melting point of at least about 50.degree. C.;
- (c) uniformly and continuously spreading the thermoplastic polymer fiber tow to a selected width to preserve the separation of the individual fibers;
- (d) uniformly and continuously spreading the carbon fiber tow to a width that is essentially the same as the selected width for the thermoplastic polymer fiber tow;
- (e) intimately, uniformly and continuously intermixing the spread carbon fiber tow and the spread thermoplastic polymer fiber tow in a relatively tension-free state by employing a gas intermixing means which directs a generally perpendicular gas flow onto the fibers and by bringing the tows into simultaneous contact with each other in substantially the same area such that there is provided a substantially uniform distribution of the thermoplastic fibers and the carbon fibers within an intimately intermixed tow;
- (f) continuously withdrawing the intimately intermixed tow;
- (g) applying the intimately intermixed tow to a mold;
- and
- (h) heating the intermixed tow to a temperature above the melting point of the thermoplastic fibers.
6 more elements
A process for preparing a composite article which comprises:
- (a) forming a continuous tow of continuous carbon fibers;
- (b) forming a continuous tow of continuous thermoplastic polymer fibers having a melting point of at least about 50.degree. C.;
- (c) uniformly and continuously spreading the thermoplastic polymer fiber tow to a selected width to preserve the separation of the individual fibers;
- (d) uniformly and continuously spreading the carbon fiber tow to a width that is essentially the same as the selected width for the thermoplastic polymer fiber tow;
- (e) intimately, uniformly and continuously intermixing the spread carbon fiber tow and the spread thermoplastic polymer fiber tow in a relatively tension-free state by employing a gas box which directs a generally perpendicular gas flow onto the fibers and by bringing the tows into simultaneous contact with each other in substantially the same area such that there is provided a substantially uniform distribution of the thermoplastic fibers and the carbon fibers within an intimately intermixed tow;
- (f) continuously withdrawing the intimately intermixed tow;
- (g) applying the intimately intermixed tow to a mold;
- and
- (h) heating the intermixed tow to a temperature above the melting point of the thermoplastic fibers.
6 more elements
A process for preparing a composite article which comprises:
- (a) forming a continuous tow of continuous carbon fibers;
- (b) forming a continuous tow of continuous thermoplastic polymer fibers having a melting point of at least about 50.degree. C.;
- (c) uniformly and continuously spreading the thermoplastic polymer fiber tow to a selected width to preserve the separation of the individual fibers;
- (d) uniformly and continuously spreading the carbon fiber tow to a width that is essentially the same as the selected width for the thermoplastic polymer fiber tow;
- (e) intimately, uniformly and continuously intermixing the spread carbon fiber tow and the spread thermoplastic polymer fiber tow in a relatively tension-free state by bringing the tows into simultaneous contact with each other in substantially the same area of a longitudinally extended, substantially horizontal, non-drawing rod such that there is provided a substantially uniform distribution of the thermoplastic fibers and the carbon fibers within an intimately intermixed tow;
- (f) continuously withdrawing the intimately intermixed tow;
- (g) applying the intimately intermixed tow to a mold;
- and
- (h) heating the intermixed tow to a temperature above the melting point of the thermoplastic fibers.
6 more elements
Dependencies are inferred from the claim text.