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US 4,948,661 AGranted
Glossy finish fiber reinforced molded product and processes of construction
AssigneeC. H. Masland & Sons
InventorsRayna W. Smith, Gerald W. Miller
Life of this patent
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AssigneeC. H. Masland & Sons
InventorsRayna W. Smith, Gerald W. Miller
Estimating the term…
Fiber reinforced thermoplastic molded products, sheets, and the like, having a glossy surface are produced by intimately blending discrete reinforcing fibers (e.g. fiberglass) and thermoplastic fibers (e.g. polypropylene or polycarbonate) into a web. The web is heated to the melting point of the thermoplastic fibers while applying pressure, to eliminate air and press the web into a consolidated structure. Breakage of the reinforcing fibers is minimized by limiting the thickness of the web and limiting the pressure so as to produce a consolidated structure with minimal fiber breakage and a Notched Izod of at least one. Layering consolidated structures, some without reinforcing fibers, may be heated and pressed together to form a final structure having a thickness greater than the individual structures. The great majority of the fibers are provided so that the fibers of each type are within the range of about 0.5-5 inches. A sheet capable of replacing an automotive metal panel (that is having sufficiently high gloss, rigidity and impact characteristics) is provided, the sheet having a Notched Izod of at least about two and preferably at least about five. Products with Notched Izods of up to eight or nine may be achieved.
A process of preparing a fiber reinforced thermoplastic molded product having a glossy surface comprising the steps of:
A process of preparing a fiber reinforced thermoplastic product having a glossy surface, comprising the steps of:
A method of producing a fiber reinforced thermoplastic molded part or perform having a glossy surface, comprising the steps of:
A process of preparing a fiber reinforced thermoplastic product having a glossy surface, comprising the steps of:
A consolidated, heat and pressure molded thermoplastic sheet of fibrous reinforced thermoplastic material having a flexural modulus above 200,000 psi, an ASTM standard D-523 gloss value above 20 at an angle of 20.degree., and a Notched Izod of at least three, prepared from a non-needled, non-woven web devoid of liquid binder and distinctly different fiber layers or alternatingly distinctly different layers, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product.
A fiber reinforced polypropylene consolidated, heat and pressure molded thermoplastic composite having a uniform distribution of reinforcing fibers, and an ASTM standard D-523 gloss value about 20 at an angle of 20.degree., with a Notched Izod of at least about 7, prepared from a non-needled, non-woven web devoid of liquid binder and distinctly different fiber layers or alternatingly distinctly different layers, thermoplastic material from melted thermoplastic fibers providing the matrix for reinforcing fibers in the molded product.
Dependencies are inferred from the claim text.