Expanded fiber composite structure for use in a charged air filt

Details Expanded fiber composite structure for use in a charged air filt Expanded fiber composite structure for use in a charged air filt

1992-12-18

1995-03-14

Withers, James D.

Stock material or miscellaneous articles

Structurally defined web or sheet

Edge feature

55524, 55527, 210340, 2105001, 210507, 210508, 210509, 428218, 428288, 428290, 428297, 4283044, 4283105, 4283166, B32B 2302, B01D 3912, B03C 302

Patent

active

053976304

ABSTRACT:
An expanded fiber composite structure and process for making an expanded fiber composite structure are provided. The expanded fiber composite structure is made up of a fiber mat held in partial compression by a monolithic plastic coating on the fibers, the structure having a plurality of interstitial voids which may optionally be filled with a polymeric interstitial material. The process includes impregnating a fiber mat with a plastic material, compressing the mat to impregnate the mat with the plastic, fully wetting each fiber and creating a substantially void-free fiber/plastic matrix, and reducing the compressive forces on the mat, allowing the fibers to rebound and expand the mat to a predetermined desired thickness, in the process creating the interstitial voids. The structure is then cooled such that the plastic material stiffens and itself retains the structure at the desired thickness. The process optionally employs the addition of a molten polymeric material to the expanded or lofted mat, the material filling the interstitial voids in the structure. The composite structure may optionally be produced from a fully compressed plastic-impregnated fiber mat by heating to a temperature sufficient to loft the material and controlling the amount of lofting after the heat is applied.

REFERENCES:
patent: 3933643 (1976-01-01), Calvin et al.
patent: 4643940 (1987-02-01), Shaw et al.
patent: 4765915 (1988-08-01), Diehl

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