US 8,940,132 B2 · Manufacturing process for hybrid organic and inorganic fibre-filled composite materials

Abstract

The present invention relates to a process for the manufacture of structural hybrid thermoplastic composites where organic and inorganic fibers are well dispersed in a thermoplastic matrix. The process comprises defibrillating the organic fibers with or without the presence of surface active agents using a mixer at a high shear and at a temperature lower than the decomposition temperature of organic fibers and melting point of the surface active agents to separate the hydrogen bonded fibers and generate microfibers, followed by blending and dispersion of the organic fibers in the thermoplastic matrix to produce a fiber composite, followed by further blending and dispersion of the fiber composite with inorganic fibers at a low shear to get the moldable hybrid composite, followed by extrusion, injection or compression-injection molding. Low shear mixing maintains the inorganic fiber length. The process produces high performance composite materials having excellent performance properties and are ideally suited for automotive, aerospace, furniture, sports articles, upholstery and other structural and semi-structural applications.

Claims16

Dependent claims

A method of producing a lignocellulosic and inorganic fiber hybrid thermoplastic composite, characterized in that the method comprises:

(a) defibrillating lignocellulosic fibers in a high shear thermo kinetic mixer in the presence of a surface active agent at a temperature less than the decomposition temperature of the lignocellulosic fibers, during a defibrillation duration that is operable to:
(i) achieve separation of the lignocellulosic fibers;
(ii) develop microfibers on the surface of the lignocellulosic fibers,
(iii) coat the lignocellulosic fibers, with the surface active agent;
(b) dispersing and blending the lignocellulosic fibers obtained in (a) with a melted thermoplastic for a first dispersion duration, thereby forming a first melt composition in situ in the same high shear thermo kinetic mixer;
and
(c) dispersing inorganic fibers with the first melt composition using a low shear mixer at a temperature less than the decomposition temperature of the lignocellulosic fibers for a second dispersion duration that is operable to:
(i) achieve the dispersion and blending of the inorganic fibers in the first melt composition, thereby forming a second melt composition;
(ii) substantially maintain the fiber lengths of the inorganic fibers during the second dispersion duration;
and (iii) achieve interfacial adhesion of the thermoplastic with the lignocellulosic fibers and inorganic fibers in the second melt composition.

7 more elements

Dependencies are inferred from the claim text.

Manufacturing process for hybrid organic and inorganic fibre-filled composite materials

Life of this patent

Manufacturing process for hybrid organic and inorganic fibre-filled composite materials

Life of this patent

Abstract

Claims16