Lightweight thermoplastic composite including bi-directional fiber tapes

A non-porous fiber reinforced composite having an improved combination of flexural, impact, and heat distortion temperature characteristics, comprising:

• a fiber reinforced thermoplastic core comprising a plurality of reinforcing fibers bonded together with one or more first thermoplastic resins, said core comprising a first surface and a second surface;
• and
• a plurality of first skins applied to said first surface, wherein said first skins are bonded to each other,
• wherein each said first skin comprises one or more bi-directional continuous fiber tapes comprising a plurality of continuous fibers arranged in a first principal direction and a plurality of continuous fibers arranged in a second principal direction and one or more second thermoplastic resins impregnated with the bi-directional continuous fiber tape, the plurality of continuous fibers in each said first principal direction and said second principal direction being independently arranged in a corresponding first and second unidirectional orientation;
• and
• wherein, the composite demonstrates an improved combination of flexural, impact, and heat distortion temperature properties at reduced fiber content in the thermoplastic core;
• and
• wherein, the flexural modulus of the composite is greater than about 2000 MPa and the flexural strength is greater than about 15 MPa;
• and
• wherein, the impact energy is greater than about 11 J.