Thermoplastic composite material

A thermoplastic composite material which comprises

• A) at least 15 percent by weight of one or more organic fibrous materials;
• and
• B) at least 15 percent by weight of a thermoplastic binder, wherein said binder comprises a mixture formed from a mixture of at least two different polyacrylate dispersions;
• wherein, the thermoplastic binder comprises at least 40% by weight of a copolymer of n-butyl acrylate and styrene, and wherein the thermoplastic composite material has a flow transition temperature in a range of 70° C. to 130° C.

A thermoplastic composite material which comprises:

• A) at least 15 percent by weight of one or more organic fibrous materials;
• and
• B) at least 15% by weight of a thermoplastic binder, wherein said binder comprises a mixture formed from a mixture of at least two different polyacrylate dispersions;
• wherein the thermoplastic binder comprises at least 50% by weight of at least one polyacrylate obtained from an anionic dispersion, wherein the thermoplastic composite material has a flow transition temperature in a range of 70° C. to 130° C.

A composite material comprising:

• A) at least 15 percent by weight of one or more organic fibrous materials;
• and
• B) at least 15 percent by weight of a thermoplastic binder wherein said binder comprises a mixture formed from a mixture of at least tow different polyacrylate dispersions;
• and wherein the thermoplastic binder comprises at least one polyacrylate obtained from a cationic dispersion having a minimum film forming temperature of at least about 40° C., and wherein the thermoplastic composite material has a flow transition temperature in a range of 70° C. to 130° C.

A process for the production of a thermoplastic composite material comprising:

• a) forming an aqueous mixture by combining at least 15 percent by weight of one or more organic fibrous materials having fibers with a stretched fiber length of 0.1 to 15 mm, and at least 15 percent by weight of a thermoplastic binder, wherein said binder comprises a solids portion of a mixture of at least one anionic polymer dispersion and at least one cationic polymer dispersion;
• b) treating said aqueous mixture with an aqueous solution of an aluminum salt or a copper salt;
• to form a mixture comprising the thermoplastic composite material and an aqueous phase;
• c) separating at least a portion of the aqueous phase from the thermoplastic composite material;
• and
• d) drying said thermoplastic composite material.

A process for surface coating of an object comprising:

• 1) heating an object and a thermoplastic composite material having a flow transition temperature in a range of 70° C. to 130° C. comprising:
• A) at least 15 percent by weight of one or more organic fibrous materials;
• and
• B) at least 15 percent by weight of a thermoplastic binder, wherein said binder comprises a mixture formed from a mixture of at least two different polyacrylate dispersions, to a temperature above the flow transition temperature of the thermoplastic composite material;
• 2) applying the thermoplastic composite material to the object;
• and
• 3) cooling the object and the thermoplastic composite material to a temperature below the flow transition temperature of the thermoplastic composite material;
• wherein, an adhesive, to establish a permanent bond, is applied between the thermoplastic composite material and a surface of the object to be coated;
• the adhesive comprising:
• a) about 40 to 100 parts of an aqueous polyester polyurethane dispersion;
• b) about 20 to 40 parts of an aqueous polyacrylate dispersion;
• and
• c) about 15 to 30 parts of an EVA copolymer.