Glossy finish fiber reinforced molded product and processes of c

Plastic and nonmetallic article shaping or treating: processes – Forming articles by uniting randomly associated particles – With reshaping or surface embossing of formed article

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156148, 156296, 264122, 264257, B29C 4302

Patent

active

050716085

ABSTRACT:
Fiber reinforced thermoplastic molded products, sheets, and the like, having a glossy surface are produced by intimately blending discrete reinforcing fibers (e.g. fiberglass) and thermoplastic fibers (e.g. polypropylene or polycarbonate) into a web. The web is heated to the melting point of the thermoplastic fibers while applying pressure, to eliminate air and press the web into a consolidated structure. Breakage of the reinforcing fibers is minimized by limiting the thickness of the web and limiting the pressure so as to produce a consolidated structure with minimal fiber breakage and a Notched Izod of at least one. Layered consolidated structures, some without reinforcing fibers, may be heated and pressed together to form a final structure having a thickness greater than the individual structures. The great majority of the fibers are provided so that the fibers of each type are within the range of about 0.5-5 inches. A sheet capable of replacing an automotive metal panel (that is having sufficiently high gloss, rigidity and impact characteristics) is provided, the sheet having a Notched Izod of at least about two and preferably at least about five. Products with Notched Izods of up to eight or nine may be achieved.

REFERENCES:
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patent: 4229397 (1980-10-01), Fukuta et al.
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patent: 4258094 (1981-03-01), Benedyk
patent: 4290988 (1981-09-01), Nopper et al.
patent: 4390489 (1983-06-01), Segal
patent: 4418031 (1983-11-01), Doerer et al.
patent: 4568581 (1986-02-01), Peoples, Jr.
WO88/09406, Dec. 1988.

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