Sizing compositions and sized products for thermoplastic composites
AssigneeJohns Manville
InventorsRajappa Tadepalli, Kiarash Alavi, Jawed Asrar, Klaus Friedrich Gleich
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Abstract
Sizing compositions to size fibers or particles used in plastic composites are described. The compositions may include a solution with a polymerization compound selected from: (a) at least one non-isocyanate-containing polymerization initiator (PI) for initiating the polymerization of caprolactam monomers; or (b) at least one precursor for a non-isocyanate-containing PI for initiating the polymerization of caprolactam monomers. Methods of making the sizing the composition, as well as methods of making reinforced thermoplastic composites from sized fibers or particles, are also described.
Claims20
A method of making a reinforced thermoplastic composite from sized fibers or particles, the method comprising:
- forming the sized fibers or particles from a sizing solution comprising at least one non-isocyanate-containing polymerization initiator (PI) for initiating the polymerization of caprolactam monomers, at least one precursor for a non-isocyanate-containing PI for initiating the polymerization of caprolactam monomers, or both, wherein:
- the PI does not contain a silicon-containing coupling moiety;
- forming a mixture by introducing the sized fibers to a binder solution comprising one or more types of caprolactam monomers and one or more catalysts operable to catalyze the polymerization of the caprolactam monomers when they are brought into contact with the PI or the precursor of the PI proximate to a surface of the sized fibers or particles;
- and
- increasing a temperature of the mixture to a polymerization temperature or above, wherein the caprolactam monomers polymerize into a polyamide binder component of the reinforced thermoplastic composite.
A method of making a reinforced thermoplastic composite from sized fibers or particles, the method comprising:
- forming the sized fibers or particles from a sizing solution comprising a polymerization compound, wherein the polymerization compound comprises a first precursor, wherein the first precursor is not a polymerization initiator (PI);
- forming a mixture by introducing the sized fibers to a binder solution comprising one or more types of caprolactam monomers, a catalyst operable to catalyze the polymerization of the caprolactam monomers, and a second precursor, wherein the second precursor is not a PI;
- reacting the first precursor with the second precursor to form a PI for initiating the polymerization of caprolactam monomers, wherein:
- the PI does not contain an isocyanate, and
- the PI does not contain a silicon-containing coupling moiety;
- and
- increasing a temperature of the mixture to a polymerization temperature or above, wherein the caprolactam monomers polymerize into a polyamide binder component of the reinforced thermoplastic composite.
Dependencies are inferred from the claim text.