US 5,843,568 A · Fiber-reinforced article and a method for producing the same

Abstract

A fiber-reinforced article includes an expanded core layer having opposing first and second surfaces with a thickness defined therebetween. The expanded core layer is formed from a composition comprising a thermoplastic material and fibers with average length of not less than about 1 mm, with at least a portion of the fibers being coated with the thermoplastic material. The fibers collectively define a network structure in which the fibers are interconnected with each other and fixed relative to each other via the thermoplastic material so that the coated fibers define interstitial voids therebetween. The article further includes first and second skin layers, the first skin layer having a surface integrally connected to the first surface of the expanded core layer and the second skin layer having a surface integrally connected to the second surface of the expanded core layer.

Claims24

Dependent claims

A fiber-reinforced article comprising:

an expanded core layer having opposing first and second surfaces with a thickness defined therebetween, the expanded core layer being formed from a composition comprising a thermoplastic material and fibers with an average length of not less than about 1 mm, with at least a portion of the fibers being coated with the thermoplastic material, the fibers collectively defining a network structure in which the fibers are interconnected with each other and fixed relative to each other via the thermoplastic material so that the coated fibers define interstitial voids therebetween;
and
first and second skin layers, the first skin layer having a surface integrally connected to the first surface of the expanded core layer and the second skin layer having a surface integrally connected to the second surface of the expanded core layer, each of the two skin layers being formed from a composition comprising a thermoplastic material and fibers with an average length of not less than about 1 mm,
wherein the fiber-reinforcing article has an average expansion ratio of from about 1.5 to about 3.5.

1 more element

A method for producing a fiber-reinforced article, said method comprising the steps of:

(A) providing a molding apparatus having a first mold member and a second mold member, each of the mold members having a mold surface which opposes the mold surface of the other mold member, at least one of the mold members being movable relative to the other mold member;
(B) preparing a molten expandable composition comprising a thermoplastic material, fibers with average length of not less than about 1 mm, and a foaming agent;
(C) supplying the molten expandable composition to a cavity defined between the opposing mold surfaces, the cavity having a first volume during the supplying step, the first volume of the cavity being within a range of from about 0.3 times to about 0.65 times a predetermined volume of the fiber-reinforced article so that the cavity is filled with the molten expandable composition;
(D) moving at least one of the mold members to provide the cavity with a second volume that is equal to the predetermined volume of the fiber-reinforced article;
and
(E) maintaining the second volume of the cavity defined between the opposing mold surfaces so that the molten expandable composition is expanded to fill the cavity.

3 more elements

A method for producing a fiber-reinforced article, said method comprising the steps of:

(A) providing a molding apparatus having a female mold member and a male mold member, each of the mold members having a mold surface which opposes the mold surface of the other mold member, at least one of the mold members being movable relative to the other mold member;
(B) preparing a molten expandable composition comprising a thermoplastic material, fibers with an average length of not less than about 1 mm, and a foaming agent, a volume of the molten expandable composition being within a range of from about 0.3 times to about 0.65 times a predetermined volume of the fiber-reinforced article;
(C) supplying the molten expandable composition to the cavity defined between the opposing mold surfaces, the cavity having a first volume during the supplying step, the first volume of the cavity being larger than the volume of the molten expandable composition;
(D) moving at least one of the mold members so that a volume of the cavity is made the same as the volume of the molten expandable composition and the cavity is filled with the molten expandable composition;
(E) moving at least one of the mold members to provide the cavity with a second volume that is equal to the predetermined volume of the fiber-reinforced article;
and
(F) maintaining the second volume of the cavity defined between the opposing mold surfaces so that the molten expandable composition is expanded to fill the cavity.

4 more elements

Dependencies are inferred from the claim text.

Fiber-reinforced article and a method for producing the same

Life of this patent

Fiber-reinforced article and a method for producing the same

Life of this patent

Abstract

Claims24