Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – At least one aryl ring which is part of a fused or bridged...
Reexamination Certificate
2000-01-31
2002-05-28
Niland, Patrick D. (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
At least one aryl ring which is part of a fused or bridged...
C428S001400, C428S357000, C428S359000, C428S383000, C428S423100, C523S200000, C523S205000, C523S206000, C523S217000, C523S400000, C523S444000, C524S589000, C524S590000, C524S492000, C524S493000, C524S494000, C524S495000, C524S496000, C525S403000, C525S408000, C525S438000, C525S440030, C525S452000, C525S453000, C525S454000
Reexamination Certificate
active
06395823
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to polymer matrix composites composed of a polymer, a thermoplastic polyurethane, and a reinforcing fiber and articles made from the composites of the present invention.
BACKGROUND OF THE INVENTION
The prior art discloses compounding polymers with a fiber (e.g. glass or carbon) or other polymers to produce a reinforced composite. The object of producing the reinforced composite is to increase or enhance the physical properties of the composite. In particular, increasing the thermal and hydrolytic stability of the composite would be advantageous.
The prior art discloses the combination of polyurethanes and polymers in order to increase the mechanical properties of the resultant blend. U.S. Pat. No. 5,519,094 to Tseng et al. and U.S. Pat. No. 5,258,445 to Sperk et al. disclose the combination of a thermoplastic polyurethane, a polyester, and a glass fiber to produce a molding composition. International Patent No. WO 95/26432 to Wagner et al. disclose the preparation of an abrasion resistant polyester blend composed of a thermoplastic polyester, a thermoplastic polyurethane, and optionally, nonpolymeric additives that exhibits improved processing safety. Canadian Patent No. 1,111,984 (hereafter CA '111) discloses a poly(butylene terephthalate)/polyurethane molding composition. Tseng et al., Sperk et al., Wagner et al., and CA '111 teach one of ordinary skill in the art to use a higher amounts of polyurethane in order to increase or enhance the mechanical properties of the blend.
In light of the above it would be very desirable to produce a polymer composite that possesses increased hydrolytic and thermal stability, mechanical strength, and ductility. Moreover, it would be advantageous to produce a polymer composite that requires smaller amounts of polyurethane while possessing superior physical properties.
SUMMARY OF THE INVENTION
In accordance with the purpose(s) of this invention, as embodied and broadly described herein, this invention, in one aspect, relates to a composite made by the process comprising melt mixing
(a) a polymer having at least one isocyanate reactive group, wherein the polymer is from 30 to 90% by weight of the composite;
(b) a thermoplastic polyurethane at from 0.1 to less than 10% by weight of the composite; and
(c) a reinforcing fiber at from 9.9 to 60% by weight of the composite,
wherein the sum of the weight percentages of components (a)-(c) is equal to 100%, wherein the polymer (a) is not a polyamide.
The invention further relates to a composite prepared by the process comprising melt mixing
(a) a polymer having at least one isocyanate reactive group, wherein the polymer is from 25 to 90% by weight of the composite;
(b) a thermoplastic polyurethane at from 0.1 to 10% by weight of the composite;
(c) a reinforcing fiber at from 9.8 to 60% by weight of the composite, and
(d) an epoxy compound at from 0.1 to 5% by weight of the composite,
wherein the sum of the weight percentages of components (a)-(d) is equal to 100%.
The invention further relates to a composite prepared by the process comprising melt mixing
(a) a polyester or a liquid crystalline polymer;
(b) a thermoplastic polyurethane at from 0.1 to 10% by weight of the composite; and
(c) a reinforcing fiber,
wherein the sum of the weight percentages of components (a)-(c) is equal to 100%.
The invention further relates to a composite comprising
(a) a polymer having at least one isocyanate reactive group, wherein the polymer is from 30 to 90% by weight of the composite;
(b) a thermoplastic polyurethane at from 0.1 to less than 10% by weight of the composite; and
(c) a reinforcing fiber at from 9.9 to 60% by weight of the composite,
wherein the sum of the weight percentages of components (a)-(c) is equal to 100%, wherein the polymer (a) is not a polyamide.
The invention further relates to a composite comprising
(a) a polymer having at least one isocyanate reactive group, wherein the polymer is from 25 to 90% by weight of the composite;
(b) a thermoplastic polyurethane at from 0.1 to 10% by weight of the composite;
(c) a reinforcing fiber at from 9.8 to 60% by weight of the composite, and
(d) an epoxy compound at from 0.1 to 5% by weight of the composite,
wherein the sum of the weight percentages of components (a)-(d) is equal to 100%.
The invention further relates to a method for making a composite, comprising melt mixing
(a) a polymer having at least one isocyanate reactive group, wherein the polymer is from 30 to 90% by weight of the composite;
(b) a thermoplastic polyurethane at from 0.1 to less than 10% by weight of the composite; and
c) a reinforcing fiber at from 9.9 to 60% by weight of the composite,
wherein the sum of the weight percentages of components (a)-(c) is equal to 100%, wherein the polymer (a) is not a polyamide.
The invention further relates to a method for making a composite, comprising melt mixing
(a) a polymer having at least one isocyanate reactive group, wherein the polymer is from 25 to 90% by weight of the composite;
(b) a thermoplastic polyurethane at from 0.1 to 10% by weight of the composite;
(c) a reinforcing fiber at from 9.8 to 60% by weight of the composite, and
(d) an epoxy compound at from 0.1 to 5% by weight of the composite,
wherein the sum of the weight percentages of components (a)-(d) is equal to 100%.
Additional advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
DETAILED DESCRIPTION OF THE INVENTION
The present invention may be understood more readily by reference to the following detailed description of preferred embodiments of the invention and the Examples included therein.
Before the present compositions of matter and methods are disclosed and described, it is to be understood that this invention is not limited to specific synthetic methods or to particular formulations, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.
In this specification and in the claims which follow, reference will be made to a number of terms which shall be defined to have the following meanings:
The singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise.
“Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.
The term “isocyanate reactive group” is any group that can react with an isocyanate moiety as shown in Equation 1. Examples of isocyanate reactive groups include, but are not limited to hydroxyl groups, amino groups, carbonate groups, or carboxyl groups.
A “carbonyl compound” is any carboxylic acid, ester, acid halide, or anhydride. The term “dicarbonyl compound” is any dicarboxylic acid, diester, diacid halide, or dianhydride.
The term “glycol” is any compound that possesses at least two hydroxyl groups. Additionally, a glycol can be any precursor compound that is readily converted to a compound possessing two hydroxyl groups. An example of such a compound is hydroquinone (I), which can be converted to biphenol (II) using techniques known in the art.
In accordance with the purpose(s) of this invention, as embodied and broadly described herein, this invention, in one aspect, relates to a composite made by the process comprising melt mixing
(a) a polymer having at least one isocyanate reactive group, wherein the polymer is from 30 to 90% by weight of the composite;
(b) a thermoplastic polyu
Brink Andrew E.
Owens Jeffrey T.
Boshears B. J.
Eastman Chemical Company
Graves, Jr. Bernard J.
Niland Patrick D.
Tubach Cheryl J.
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