Stock material or miscellaneous articles – Structurally defined web or sheet – Discontinuous or differential coating – impregnation or bond
Patent
1994-08-03
1996-06-11
Ryan, Patrick J.
Stock material or miscellaneous articles
Structurally defined web or sheet
Discontinuous or differential coating, impregnation or bond
428247, 428260, 428282, 428286, 428290, 428298, 428302, 428303, 428332, 428339, 428213, B32B 2704, B32B 700
Patent
active
055254128
ABSTRACT:
A thermoplastic resin defines a core of a thermoformable thermoplastic composite material. The core is sufficiently thick to provide for a shaping of the composite material at an elevated temperature to any desired configuration. First and second layers of fabric material are disposed on opposite sides of the core. The fabric material may be formed of glass, carbon or aramid and may be formed from woven fibers, unidirectional or chopped fibers or random strand mats. The fabric layers have a thickness sufficient to impart strength and rigidity to the fabric material. Layers of a thermoplastic thermoformable resin material may be disposed on the layers of the fabric material. The thermoplastic layers impregnate the fabric layers, bond the fabric layers to the core and provide a smooth external surface to the composite material. The thermoplastic layers are of a sufficient thickness to maximize the flexural load strength of the composite material and to eliminate the formation of any rippling or buckling of the composite material. The core and the additional resin layers may be an acrylic, a polycarbonate or ABS. The core may be thicker than the combined thicknesses of the fabric layers and the thermoplastic layers. For example, each of the fabric layers may have a thickness in the order of eight mils (0.008") to nine mils (0.009"). The thickness of each of the thermoplastic layers may be in the order of seven mils (0.007") to nine mils (0.009"). The thickness of the thermoplastic composite material may be in the order of eighty five mils (0.085") to one hundred and twenty five mils (0.125").
REFERENCES:
patent: 4778717 (1988-10-01), Fitchmun
patent: 5338600 (1994-08-01), Fitchmun et al.
Blakeman David M.
Fitchmun Douglas R.
Perera Niran
Medical Materials Corporation
Roston Ellsworth R.
Ryan Patrick J.
Schwartz Charles H.
Weisberger Richard
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