# US 9,518,171 B1 · Continuous fiber-polyolefin composites and methods of making

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 9,518,171 B1
- Document ID: US9518171B1
- Status: Granted
- Kind: B1
- Application number: 14/852,020
- Filed: 2015-09-11
- Granted: 2016-12-13
- Earliest claimed: 2015-09-11
- Assignees: TDA Research, Inc.
- Applicants: TDA Research, Inc.
- Inventors: Michael D Diener
- Web page: https://patentgrep.com/patent/US9518171B1

## CPC

- B29C 43/003: {characterised by the choice of material}
- B29C 70/42: for producing articles of definite length, i.e. discrete articles
- C08J 5/042: {with carbon fibres}
- B29K 2023/00: Use of polyalkenes {or derivatives thereof} as moulding material
- B29K 2105/08: of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K 2307/04: Carbon
- B29L 2031/7532: {Artificial members, protheses}
- C08J 2323/06: Polyethene
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

The present invention relates to polyolefin matrix composites reinforced with continuous carbon fibers, and a process for making them. The polymer-fiber composite material comprises a plurality of continuous fibers; and a polyolefin matrix, wherein, the polyolefin matrix comprises polyolefin polymer chains with a number average molecular weight of at least 1×106 amu, and wherein, the polymer-fiber composite has a notched impact strength greater than the notched impact strength of a neat polyolefin, wherein the neat polyolefin has an equivalent chemical composition and number average molecular weight as the polyolefin of the polyolefin matrix in the polymer-fiber composite material. The present invention also relates to articles of manufacture made substantially from polyolefin matrix composites reinforced with continuous carbon fibers as well as orthopedic implant devices having a wear surface, or bearing comprising a polyolefin matrix composite reinforced with continuous carbon fibers.

## Claims

### Claim 1

A polymer-fiber composite material, the composite material comprising:
(a) a plurality of continuous fibers; and
(b) a polyolefin matrix,
wherein, the continuous fibers are not chemically attached to an olefin polymerization catalyst;
wherein, the polyolefin matrix comprises polyolefin polymer chains with a number average molecular weight of at least 1×106 amu; and
wherein, the composite material has a notched impact strength greater than 500 kJ/m2 as measured according to ASTM F2231.

### Claim 2 (depends on 1)

The composite material of claim 1, wherein the continuous fibers are carbon fibers.

### Claim 3 (depends on 2)

The composite material of claim 2, wherein the continuous fibers are at least 2 inches long.

### Claim 4 (depends on 1)

The composite material of claim 1, wherein the polyolefin matrix comprises polyolefin polymer chains with a number average molecular weight of at least 4×106 amu.

### Claim 5 (depends on 4)

The composite material of claim 4, wherein the polyolefin matrix comprises polyethylene.

### Claim 6 (depends on 5)

The composite material of claim 5, further comprising:
(c) at most 200 milligrams of titanium per kilogram of polyethylene;
(d) at most 500 milligrams of aluminum per kilogram of polyethylene; and
(e) at most 300 milligrams of chlorine per kilogram of polyethylene.

### Claim 7 (depends on 4)

An article of manufacture comprising the composite material of claim 4.

### Claim 8 (depends on 7)

The article of manufacture of claim 7, wherein the continuous fibers are carbon fibers.

### Claim 9 (depends on 8)

The article of manufacture of claim 8, wherein the continuous fibers traverse a length of the article of manufacture.

### Claim 10 (depends on 9)

The article of manufacture of claim 9, wherein the polyolefin matrix comprises polyethylene.

### Claim 11 (depends on 10)

The article of manufacture of claim 10, wherein the article of manufacture is a bearing of an orthopedic implant.