Poly(arylene sulfide) resins reinforced with glass fibers
AssigneePhillips Petroleum Company
InventorsDavid A. Soules, Randy L. Hagenson
Life of this patent
Estimating the term…
Abstract
Continuous, woven and non-woven glass fibers are impregnated with certain silanes before use of the fibers to make reinforced thermoplastic composites using pultrusion or compression molding. Continuous, woven and non-woven glass fiber reinforced composites are also made by concurrently combining the fibers with certain silanes and a thermoplastic matrix material using pultrusion or compression molding.
Claims34
A method of preparing a continuous glass fiber reinforced thermoplastic composite comprising:
- (a) passing continuous glass fibers through a slurry bath containing a mixture of poly(arylene sulfide) having a melt flow within the range of about 1 to about 800 grams per 10 minutes and at least one polysulfide organosilane, to impregnate said glass fibers;
- and
- (b) heating and shaping said impregnated glass fibers.
A method of preparing a continuous glass fiber reinforced thermoplastic composite comprising:
- (a) impregnating continuous glass fibers with at least one polysulfide organosilane within the formula:
- ##STR8## wherein n is an integer from 1 to 30;
- wherein each of R.sub.1 and R.sub.2 is H or an alkyl group having 1 to 30 carbon atoms;
- wherein each of R.sub.5, R.sub.6, R.sub.7, R.sub.8, R.sub.9 and R.sub.10 is an alkyl group having from 1 to 30 carbon atoms;
- wherein x is 0 or 1;
- wherein y is 0 to 1;
- and wherein each of R.sub.3 and R.sub.4 is an alkylene group having from 1 to 30 carbon atoms;
- (b) thereafter impregnating said continuous glass fibers with poly(arylene sulfide) having a melt flow within the range of about 1 to about 800 grams per 10 minutes;
- (c) heating and shaping said impregnated continuous glass fibers.
A method of making a glass fiber reinforced thermoplastic composite comprising:
- (a) impregnating a woven glass fabric with at least one silane within the formula:
- ##STR9## wherein n is an integer from 1 to 30;
- wherein each of R.sub.1 and R.sub.2 is H or an alkyl group having 1 to 30 carbon atoms;
- wherein each of R.sub.5, R.sub.6, R.sub.7, R.sub.8, R.sub.9 and R.sub.10 is an alkyl group having from 1 to 30 carbon atoms;
- wherein x is 0 or 1;
- wherein y is 0 or 1;
- and wherein each of R.sub.3 and R.sub.4 is an alkylene group having from 1 to 30 carbon atoms;
- and
- (b) thereafter compression molding one or more of said woven glass fabrics with poly(arylene sulfide) having a melt flow within the range from about 1 to about 800 grams per 10 minutes.
A method of making a glass fiber reinforced thermoplastic composite comprising laminating one or more woven glass fiber fabrics with a mixture of poly(arylene sulfide) having a melt flow within the range from about 1 to about 800 grams per 10 minutes and at least one polysulfide organosilane having the formula:
- ##STR10## wherein n is an integer from 1 to 30;
- wherein each of R.sub.1 and R.sub.2 is H or an alkyl group having 1 to 30 carbon atoms;
- wherein each of R.sub.5, R.sub.6, R.sub.7, R.sub.8, R.sub.9 and R.sub.10 is an alkyl group having from 1 to 30 carbon atoms;
- wherein x is 0 or 1;
- wherein y is 0 or 1;
- and wherein each of R.sub.3 and R.sub.4 is an alkylene group having from 1 to 30 carbon atoms.
A method of preparing a glass fiber reinforced thermoplastic composite comprising:
- (a) impregnating said non-woven glass fabric with at least one silane within the formula:
- ##STR11## wherein n is an integer from 1 to 30;
- wherein each of R.sub.1 and R.sub.2 is H or an alkyl group having 1 to 30 carbon atoms;
- wherein each of R.sub.5, R.sub.6, R.sub.7, R.sub.8, R.sub.9 and R.sub.10 is an alkyl group having from 1 to 30 carbon atoms;
- wherein x is 0 or 1;
- wherein y is 0 or 1;
- and wherein each of R.sub.3 and R.sub.4 is an alkylene group having from 1 to 30 carbon atoms;
- (b) compression molding one or more layers of said impregnated non-woven glass fabric with poly(arylene sulfide) having a melt flow within the range of about 1 to about 800 grams per 10 minutes.
A method of preparing a glass reinforced thermoplastic composite comprising compression molding one or more layers of non-woven glass fabric with a mixture of poly(arylene sulfide) having a melt flow within the range of about 1 to about 800 grams per 10 minutes and at least one silane within the formula:
- ##STR12## wherein n is an integer from 1 to 30;
- wherein each of R.sub.1 and R.sub.2 is H or an alkyl group having 1 to 30 carbon atoms;
- wherein each of R.sub.5, R.sub.6, R.sub.7, R.sub.8, R.sub.9 and R.sub.10 is an alkyl group having from 1 to 30 carbon atoms;
- wherein x is 0 or 1;
- wherein y is 0 or 1;
- and wherein each of R.sub.3 and R.sub.4 is an alkylene group having from 1 to 30 carbon atoms.
A woven glass fiber reinforced composite comprising:
- (a) poly(arylene sulfide) having a melt flow within the range of about 1 to about 800 grams per 10 minutes;
- (b) at least one silane within the formula:
- ##STR13## wherein n is an integer from 1 to 30;
- wherein each of R.sub.1 and R.sub.2 is H or an alkyl group having 1 to 30 carbon atoms;
- wherein each of R.sub.5, R.sub.6, R.sub.7, R.sub.8, R.sub.9 and R.sub.10 is an alkyl group having from 1 to 30 carbon atoms;
- wherein x is 0 or 1;
- wherein y is 0 or 1;
- and wherein each of R.sub.3 and R.sub.4 is an alkylene group having from 1 to 30 carbon atoms;
- and
- (c) a woven glass fabric.
A non-woven glass fiber reinforced composite comprising:
- (a) poly(arylene sulfide) having a melt flow within the range of about 1 to about 800 grams per 10 minutes;
- (b) at least one silane within the formula:
- ##STR14## wherein n is an integer from 1 to 30;
- wherein each of R.sub.1 and R.sub.2 is H or an alkyl group having 1 to 30 carbon atoms;
- wherein each of R.sub.5, R.sub.6, R.sub.7, R.sub.8, R.sub.9 and R.sub.10 is an alkyl group having from 1 to 30 carbon atoms;
- wherein x is 0 or 1;
- wherein y is 0 or 1;
- and wherein each of R.sub.3 and R.sub.4 is an alkylene group having from 1 to 30 carbon atoms;
- and
- (c) a non-woven glass fabric.
Dependencies are inferred from the claim text.