CA1216723A - Stampable plastic reinforced composite - Google Patents
Stampable plastic reinforced compositeInfo
- Publication number
- CA1216723A CA1216723A CA000423474A CA423474A CA1216723A CA 1216723 A CA1216723 A CA 1216723A CA 000423474 A CA000423474 A CA 000423474A CA 423474 A CA423474 A CA 423474A CA 1216723 A CA1216723 A CA 1216723A
- Authority
- CA
- Canada
- Prior art keywords
- stampable
- reinforcing material
- resin
- composite
- fibers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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- Reinforced Plastic Materials (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A STAMPABLE PLASTIC REINFORCED COMPOSITE
A stampable composite comprised of a blend of a thermoplastic resin and 5 to 60 percent by weight of reinforcing material having a length of 3 to 10 centi-meters, subjecting said composite to sufficient temper-ature and pressure to cause said resin to melt and wet out said fibers.
A STAMPABLE PLASTIC REINFORCED COMPOSITE
A stampable composite comprised of a blend of a thermoplastic resin and 5 to 60 percent by weight of reinforcing material having a length of 3 to 10 centi-meters, subjecting said composite to sufficient temper-ature and pressure to cause said resin to melt and wet out said fibers.
Description
:3L2~67~3 A STAMPABLE PLASTIC REINFORCED COMPOSITE
Techn~cal ~ield ~ .~
This inven-~ion relates to a stampable thermoplastic res:i.n long fiber reinforced composite that contains 5 to 60 weight percent o~ fibers having a melting point in excess of 350C. and lengths predominantly greater than .3 cm and up to 10 or more centime~ers with a meltable thermoplastic resin, preferably having a glass transition temperature less than 120C. and sufficient to be present as 95 to ll0 weight percent of said composite~
Background o~ the Invention In today's society plastics are used to produce products that are eventua:lly discarded~ For example, p]astic bottles, wrapping film are only a few of the many plastic products that are discarded and present the problem of how to reclaim and use them economically.
Some governmental Jurisdictions have place strong restriction on the use of throw-away beer.and pop bottles, to rnention a few problems occasioned by disposable plastic products.
Disclosure and Practice of the Invention _ _~
We have discovered that thermoplastics, such as scrap, or so called off specification plastic, or plastics in its forms as chopped film, fibers, monofilaments or flakes can be mixed with a reinforcing material having a melting point in excess of 350C. and the plastic can be caused to wet the reinforcing material, preferably a silicious - fiber or high melting polyamides, to give a sheet that is stampable or compression meltable to gi~e a shaped product of good strength. Also~ this process lends itself to the continuows method of forming stampable composites, essentially in sheet form as the thermoplastic and the rein~orcing material can be chopped simultaneously and dropped onto a collecting surface, pre~erably a moving belt.
'' ,~
; .
The ratio of the reinforcing material to the~thermo-plastic resin preferably is controlled by the differences in the speed of the chopper for the materiaI with the final thickness of the sheet being controlléd by the speed of the belt. In the continuous process, preferably the belt is passed through a serles of nips formed by rolls having temperatures above the melting point of the thermoplastic resin to melt the resin so it can wet the reinforcing material and then the belt moves through a L0 coolirlg station, such as a water bath to cool or quench the sheet so it can he removed from the belt.
The nature of this invention can be understood by ref`erence to the drawing, wherein the figure is a schematic side elevational view of the continuous :l5 apparatus for making the stampable thermoplastic reinforced sheet.
Referring more particularly to the drawing, numerical 1 represents a base plate having positioned thereon a moveable belt 2. The moveable belt 2 is mounted on a drive roll 3 and an idler roll 4. Belt 2 moves beneath chute 5 and under heated rolls 6 and 7, and over roll 8 to press the material on belt 2 as it moves through the respective nips 9 and 10 formed by the rollsi.to melt the resin and cause it to wet ou-t the reinforcing material.
As the belt 2 moves toward driver roll 3, it passes through a cooling or quench station 11, where water from jets 12 strikes the under side ol the belt to cool the thermoplastic resin beneath the melting point of the resin and the air jet 13 blows away any free water.
Chute 5 connects to two choppers 14 and 15.
In this embodiment, a bank 16 of rolls of continuous fabric feeds strands 17 of fiber glass rovings through the comb 18 into the chopper 14 where the strands are cut into the desired length, for example 0.3 to about 6 and 3~j up to 10 centimeters and drops the chopped fibers into leg 19 of chute 5 to be directed onto belt 2.
~Z~ %3 Chopper 15 ha a belt 20 conveying thermoplastic resin to it and as the resin drops into the chopper, it is cut to size to permit the resin to fall down by leg 21 of chute 5. The chopped strands of fiber glass and resin are mixed to fall preferably as a random mixture onto the belt 2 as the mixture leaves the cooling or quench station as a sheet :it may be taken up on a roll 22 or '~ alternately rnay be cut into panels and retained until it is used to stamp out the desired finished product.
Representative of the thermoplastic resins useful in this invention are polyethylene~ polyvinylchloride and polyesters that are used in multimillion ~o billion pounds annually or those used on a much smaller scale.
Particularly desired are polyethylene terephthalate (PET) scrapg polyamides (nylons) and polybutylene terephalates.
Representative of the reinforcing materials are those of high tensile strength having a melting point in excess of 350C., such as glass fibers, carbon fibers and aramid f`ibers. The silicious fibers are preferred from a cost and utility stand point, but the high tensile polyamides of polyaramide class like those available from the Dupont Company are very satisfactory where the silicious fibers are not desired.
The nature of this invention is further exemplified by the following representative examples wherein all parts and percentages are by weight unless otherwise indicated.
Example l Scrap polyester tire cord yarn was chopped to lengths of approximately 2.5 cm. This material was then thoroughly mixed with fiberglass which had been chopped to lengths to give a ratio of 30% glass fibers and 70%
chopped tire cord by weight. This mixture was evenly spread into a 15 x 15 x 1.4 cm frame mold using aluminum foil separators which had been coated with a release agent. This was then placed -Ln a platen press having platen temperatures of 288C. and pressed for l-l/2 minutes.
Techn~cal ~ield ~ .~
This inven-~ion relates to a stampable thermoplastic res:i.n long fiber reinforced composite that contains 5 to 60 weight percent o~ fibers having a melting point in excess of 350C. and lengths predominantly greater than .3 cm and up to 10 or more centime~ers with a meltable thermoplastic resin, preferably having a glass transition temperature less than 120C. and sufficient to be present as 95 to ll0 weight percent of said composite~
Background o~ the Invention In today's society plastics are used to produce products that are eventua:lly discarded~ For example, p]astic bottles, wrapping film are only a few of the many plastic products that are discarded and present the problem of how to reclaim and use them economically.
Some governmental Jurisdictions have place strong restriction on the use of throw-away beer.and pop bottles, to rnention a few problems occasioned by disposable plastic products.
Disclosure and Practice of the Invention _ _~
We have discovered that thermoplastics, such as scrap, or so called off specification plastic, or plastics in its forms as chopped film, fibers, monofilaments or flakes can be mixed with a reinforcing material having a melting point in excess of 350C. and the plastic can be caused to wet the reinforcing material, preferably a silicious - fiber or high melting polyamides, to give a sheet that is stampable or compression meltable to gi~e a shaped product of good strength. Also~ this process lends itself to the continuows method of forming stampable composites, essentially in sheet form as the thermoplastic and the rein~orcing material can be chopped simultaneously and dropped onto a collecting surface, pre~erably a moving belt.
'' ,~
; .
The ratio of the reinforcing material to the~thermo-plastic resin preferably is controlled by the differences in the speed of the chopper for the materiaI with the final thickness of the sheet being controlléd by the speed of the belt. In the continuous process, preferably the belt is passed through a serles of nips formed by rolls having temperatures above the melting point of the thermoplastic resin to melt the resin so it can wet the reinforcing material and then the belt moves through a L0 coolirlg station, such as a water bath to cool or quench the sheet so it can he removed from the belt.
The nature of this invention can be understood by ref`erence to the drawing, wherein the figure is a schematic side elevational view of the continuous :l5 apparatus for making the stampable thermoplastic reinforced sheet.
Referring more particularly to the drawing, numerical 1 represents a base plate having positioned thereon a moveable belt 2. The moveable belt 2 is mounted on a drive roll 3 and an idler roll 4. Belt 2 moves beneath chute 5 and under heated rolls 6 and 7, and over roll 8 to press the material on belt 2 as it moves through the respective nips 9 and 10 formed by the rollsi.to melt the resin and cause it to wet ou-t the reinforcing material.
As the belt 2 moves toward driver roll 3, it passes through a cooling or quench station 11, where water from jets 12 strikes the under side ol the belt to cool the thermoplastic resin beneath the melting point of the resin and the air jet 13 blows away any free water.
Chute 5 connects to two choppers 14 and 15.
In this embodiment, a bank 16 of rolls of continuous fabric feeds strands 17 of fiber glass rovings through the comb 18 into the chopper 14 where the strands are cut into the desired length, for example 0.3 to about 6 and 3~j up to 10 centimeters and drops the chopped fibers into leg 19 of chute 5 to be directed onto belt 2.
~Z~ %3 Chopper 15 ha a belt 20 conveying thermoplastic resin to it and as the resin drops into the chopper, it is cut to size to permit the resin to fall down by leg 21 of chute 5. The chopped strands of fiber glass and resin are mixed to fall preferably as a random mixture onto the belt 2 as the mixture leaves the cooling or quench station as a sheet :it may be taken up on a roll 22 or '~ alternately rnay be cut into panels and retained until it is used to stamp out the desired finished product.
Representative of the thermoplastic resins useful in this invention are polyethylene~ polyvinylchloride and polyesters that are used in multimillion ~o billion pounds annually or those used on a much smaller scale.
Particularly desired are polyethylene terephthalate (PET) scrapg polyamides (nylons) and polybutylene terephalates.
Representative of the reinforcing materials are those of high tensile strength having a melting point in excess of 350C., such as glass fibers, carbon fibers and aramid f`ibers. The silicious fibers are preferred from a cost and utility stand point, but the high tensile polyamides of polyaramide class like those available from the Dupont Company are very satisfactory where the silicious fibers are not desired.
The nature of this invention is further exemplified by the following representative examples wherein all parts and percentages are by weight unless otherwise indicated.
Example l Scrap polyester tire cord yarn was chopped to lengths of approximately 2.5 cm. This material was then thoroughly mixed with fiberglass which had been chopped to lengths to give a ratio of 30% glass fibers and 70%
chopped tire cord by weight. This mixture was evenly spread into a 15 x 15 x 1.4 cm frame mold using aluminum foil separators which had been coated with a release agent. This was then placed -Ln a platen press having platen temperatures of 288C. and pressed for l-l/2 minutes.
2~7~3 1~
The pressure was released and the frame mold was immersed in cold water.
Upon removal of the aluminum foil separators and inspecting the sample, it was found that the glass fibers were completely covered with the clear water white resin.
There was no evidence of glass fiber breakage and dis-tributlon of glass fibers was nearly uniform and random.
.
Example 2 ~n a typical experiment, polyester monofilament was ~ut into 2.5 to 3.8 cm lengths and placed in a suitable container. To this was added enough chopped fiberglass strand, about 3 to 4 cm long, to make up 30% by weight of the mlxture. The two materials were mixed by hand until the fiberglass was thoroughly dispersed throughout the thermoplastic monofilament. The mixture was dried at 110C. for two days or vacuum dried at that temperature for at least 12 hours. It is also possible to dry the fiberglass and mono~llament separately and mix them together after drying. Sixty grams of the above mixture were placed in a 15 x 15 x 1.4 cm mold frame. The mold frame and bulky ~ibers were covered with metal plates and placed in a hydraulic press at 288C. Initially, the fibers were squeezed together under minimal pressure until the material was at melt temperature (3 minutes).
The pressure was then increased to 100-1200 psi and the sample was left in the press for two minutes. The mold frame and sample were removed from the press and quenched immediately in an ice bath. The sample was removed from the mold and had uniform fiberglass dispersion with no fiber degradation. ~here the monofilament was PET with an Intrinsic Viscosity o~ .93 the following properties were obtained:
Tensile 21,292 p5i Flexural Strength 27,396 psi Flexural Modulus 1.123 x 106 psi Notched Izod Impact 17.6 ft~lbs~in HDT, 26L~ psi 225C.
- 12167~3 Example 3 Polyester bottles made from Goodyear grade VFR 6001 polyester were cut into strips about 1.9 cm long and 0.15 cm wide. To these strips were added 1. 27 cm chopped fiberglass strand until 3n% of the total material was 5 fiberglass. The materials were thoroughly mixed together and dried. The polyester/fiberglass mixture was molded at a press temperature of 288C. using a 15 x 15 x 1.4 cm mold frame according to the procedure in Example 2. The reinforced sheet obtained had good fiberglass distribution and substantial mechanical properties. Similar sheets were also produced in which the polymer source was ground scrap polye-thylene terephthalate (PET)bottles.
Example 4 15 PET monofilament with an intrinsic viscosity of . 93 was mixed with 3.18 cm chopped fiberglass strand in a 70/30 weight ratio. The dried mixture was molded into several 20.3 x 20.3 x 0.3 cm sheets according to the procedure in Example 2. All the reinforced sheets 20 produced had good fiberglass distribution and with no fiber degradation. The PET component of one of the reinforced sheets was crystallized by heating at 188C.
in a press. The sheet became white and opaque. In either the crystalline or amorphous state the reinforced PET's 25 exhibit good physical properties as evidenced by the data below.
Crystalline Amorphous Flexural Modulus 21,915 psi 26,178 psi Flexural Strength . 880 x 10 psi .823 x 1o6 psi Notched Izod Impact 14.9 ft-lbs/in 17. 5 ft-lbs/in The reinforced the-~moplastic panels molded in Example 4 were stamped or compression molded into a round disc-shaped part of varying thickness~. Various conditions were 35 used in the molding trials, but as long as the reinforced PET was above its glass transition temperature, the ~Z~6~23 sheets could be forrned into the round dish. The formed parts exh~bited good strength and impact properties.
Other combinations of fiberglass and thermoplastic polyester were molded in the same manner as described in the previous examples. A table of all the different variations is shown below. Physical properties were obtained on all the samples.
; PET Type IV Glass % Glass Len~th (cm) ]0 Film 1.04 30 3.18 Film 0.75 3 3.18 Monofilament 0.92 30 3.18 " 0.72 30 3.18 " 0.93 20 3.18 " 0.93 40 3.18 " 0.93 30 0.31 " 0.93 30 o.63 " -93 3 1.27
The pressure was released and the frame mold was immersed in cold water.
Upon removal of the aluminum foil separators and inspecting the sample, it was found that the glass fibers were completely covered with the clear water white resin.
There was no evidence of glass fiber breakage and dis-tributlon of glass fibers was nearly uniform and random.
.
Example 2 ~n a typical experiment, polyester monofilament was ~ut into 2.5 to 3.8 cm lengths and placed in a suitable container. To this was added enough chopped fiberglass strand, about 3 to 4 cm long, to make up 30% by weight of the mlxture. The two materials were mixed by hand until the fiberglass was thoroughly dispersed throughout the thermoplastic monofilament. The mixture was dried at 110C. for two days or vacuum dried at that temperature for at least 12 hours. It is also possible to dry the fiberglass and mono~llament separately and mix them together after drying. Sixty grams of the above mixture were placed in a 15 x 15 x 1.4 cm mold frame. The mold frame and bulky ~ibers were covered with metal plates and placed in a hydraulic press at 288C. Initially, the fibers were squeezed together under minimal pressure until the material was at melt temperature (3 minutes).
The pressure was then increased to 100-1200 psi and the sample was left in the press for two minutes. The mold frame and sample were removed from the press and quenched immediately in an ice bath. The sample was removed from the mold and had uniform fiberglass dispersion with no fiber degradation. ~here the monofilament was PET with an Intrinsic Viscosity o~ .93 the following properties were obtained:
Tensile 21,292 p5i Flexural Strength 27,396 psi Flexural Modulus 1.123 x 106 psi Notched Izod Impact 17.6 ft~lbs~in HDT, 26L~ psi 225C.
- 12167~3 Example 3 Polyester bottles made from Goodyear grade VFR 6001 polyester were cut into strips about 1.9 cm long and 0.15 cm wide. To these strips were added 1. 27 cm chopped fiberglass strand until 3n% of the total material was 5 fiberglass. The materials were thoroughly mixed together and dried. The polyester/fiberglass mixture was molded at a press temperature of 288C. using a 15 x 15 x 1.4 cm mold frame according to the procedure in Example 2. The reinforced sheet obtained had good fiberglass distribution and substantial mechanical properties. Similar sheets were also produced in which the polymer source was ground scrap polye-thylene terephthalate (PET)bottles.
Example 4 15 PET monofilament with an intrinsic viscosity of . 93 was mixed with 3.18 cm chopped fiberglass strand in a 70/30 weight ratio. The dried mixture was molded into several 20.3 x 20.3 x 0.3 cm sheets according to the procedure in Example 2. All the reinforced sheets 20 produced had good fiberglass distribution and with no fiber degradation. The PET component of one of the reinforced sheets was crystallized by heating at 188C.
in a press. The sheet became white and opaque. In either the crystalline or amorphous state the reinforced PET's 25 exhibit good physical properties as evidenced by the data below.
Crystalline Amorphous Flexural Modulus 21,915 psi 26,178 psi Flexural Strength . 880 x 10 psi .823 x 1o6 psi Notched Izod Impact 14.9 ft-lbs/in 17. 5 ft-lbs/in The reinforced the-~moplastic panels molded in Example 4 were stamped or compression molded into a round disc-shaped part of varying thickness~. Various conditions were 35 used in the molding trials, but as long as the reinforced PET was above its glass transition temperature, the ~Z~6~23 sheets could be forrned into the round dish. The formed parts exh~bited good strength and impact properties.
Other combinations of fiberglass and thermoplastic polyester were molded in the same manner as described in the previous examples. A table of all the different variations is shown below. Physical properties were obtained on all the samples.
; PET Type IV Glass % Glass Len~th (cm) ]0 Film 1.04 30 3.18 Film 0.75 3 3.18 Monofilament 0.92 30 3.18 " 0.72 30 3.18 " 0.93 20 3.18 " 0.93 40 3.18 " 0.93 30 0.31 " 0.93 30 o.63 " -93 3 1.27
Claims (5)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A stampable composite composed of a fibrous reinfor-cing material having its surface wet out with a melted thermo-plastic resin to give a blend of 5 to 60 percent by weight of a fibrous reinforcing material having a length of 0.3 to about 10 centimeters and a solid thermoplastic resin.
2. The stampable composite of Claim 1 wherein the reinforcing material has a melting point in excess of 250°C and is a fiber.
3. A method of forming a stampable composite comprising blending solid thermoplastic resin with 5 to 60 percent by weight of fibers having a length 3 to about 10 centimeters subjecting said blend to heat and pressure to wet out said fibers with melted resin.
4. The stampable composite of Claim 1 wherein the reinforcing material is a silicious fiber.
5. The stampable composite of Claim 1 wherein the reinforcing material is a high tensile polyamide of the polyaramide class.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US36233182A | 1982-03-26 | 1982-03-26 | |
| US362,331 | 1982-03-26 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1216723A true CA1216723A (en) | 1987-01-20 |
Family
ID=23425658
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000423474A Expired CA1216723A (en) | 1982-03-26 | 1983-03-14 | Stampable plastic reinforced composite |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1216723A (en) |
-
1983
- 1983-03-14 CA CA000423474A patent/CA1216723A/en not_active Expired
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |