US 6,630,231 B2 · Composite articles reinforced with highly oriented microfibers

Abstract

A composite formed of a polymer matrix phase having a reinforcement phase including polymeric microfibers. The microfibers are preferably formed of a highly oriented polymer, having a high modulus value and a large surface area. The large surface area can serve to tightly bind the microfibers to the polymer matrix phase. The microfibers can be provided as a fully- or partially-microfibrillated film, as a non-woven web of entangled microfibers, or as a pulp having free fibers. The microfibers can be embedded in, or impregnated with, a polymer or polymer precursor. Some composite articles are formed from thermoset resins cured about a highly oriented polypropylene microfiber reinforcement phase, providing a strong, tough, moisture resistant article. One composite includes a matrix and reinforcement formed of the same material type and having substantially equal refractive indices, allowing the composite to be optically clear.

Claims47

Dependent claims

A composite article comprising:

a polymer matrix;
and
a plurality of microfibers embedded in the matrix,
wherein the microfibers are melt processed polymeric microfibers having an average effective diameter of less than 20 microns and a transverse aspect ratio of from 1.5:1 to 20:1.

1 more element

Dependencies are inferred from the claim text.

Facts

Application

09/809,446Filed 15 Mar 2001 · continuation in part

Priority

5 Feb 1999

Published

US 2001/0031594 A118 Oct 2001

Granted

7 Oct 2003

Term ends

Not estimatedThe source records don’t support an estimate.

Classification28 codes

B32B 5/26
One layer being a fibrous or filamentary layer: another layer next to it also being fibrous or filamentary
B32B 5/022
Characterised by structural features of a fibrous or filamentary layer: non-woven fabric
B32B 27/32
Layered products comprising a layer of synthetic resin: comprising polyolefins
B32B 27/36
Layered products comprising a layer of synthetic resin: comprising polyesters

Family

Application09/245,952Parent of this division · filed 5 Feb 1999

Application09/595,982Parent of this continuation-in-part · filed 16 Jun 2000

US 2001/0031594 A1Pre-grant publication · published 18 Oct 2001

US 6,432,347 B1Parent of this continuation-in-part

Application09/595,982Parent of this division

US 6,110,588 AParent of this division

US 6,630,231 B2This patent

From the US filing history. Foreign family members aren’t listed.

Composite articles reinforced with highly oriented microfibers

Life of this patent

Composite articles reinforced with highly oriented microfibers

Life of this patent

Abstract

Claims47