JPWO2020120316A5

JPWO2020120316A5 -

Info

Publication number: JPWO2020120316A5
Application number: JP2021533612A
Authority: JP
Publication date: 2022-12-13

Claims

1. A polymer composite comprising tubular particles comprising at least one resin with incorporated fibers,
said tubular particles having an average length in the range of 0.5 mm to 60 mm and an average wall thickness in the range of 0.0005 mm to 30.0 mm;
A polymer composite material wherein said fibers have an average diameter in the range of 0.0005 mm to 5.0 mm.

2. The polymer composite of claim 1, wherein said tubular particles exhibit anisotropic mechanical properties.

2. The polymer composite of claim 1, wherein the tubular particles have a cross-sectional shape selected from the group consisting of ring- shaped , polygonal and any combination thereof, and wherein the tubular particles have a hollow structure.

The polymer composite of claim 1 , wherein said tubular particles have an average diameter in the range of 0.5mm to 60.0mm.

2. The polymer composite of claim 1, wherein said tubular particles have a ratio of said mean diameter to said mean wall thickness in the range of 1:1 to 120,000:1.

The tubular particles have a low bulk density in the range of 0.005-0.300 g/ml, a compacted density in the range of 0.010-0.60 g/ml and an elongational elasticity of 13000 psi (89.6 MPa) to 35000 psi (241 MPa). 2. The polymer composite of claim 1 , having a modulus .

2. The polymer composite of Claim 1, wherein the at least one resin comprises a foamed resin, a non-foamed resin, or a combination thereof.

2. The polymer composite of Claim 1, wherein said at least one resin comprises a thermoplastic polymer, a thermoset polymer, or a combination thereof.

9. The polymer composite of Claim 8 , wherein said thermoplastic polymer is a thermoplastic polyurethane foam.

Said thermoplastic polyurethane foam is foamed of i) polyether polyol, isocyanate component and chain extender, or ii) polyester polyol, isocyanate component and chain extender, or iii) polyolefin polyol, isocyanate component and chain extender. 10. The polymer composite of claim 9 , which is a reaction product.

said thermoplastic polymer is thermoplastic polyester elastomer (TPE), thermoplastic styrene elastomer (TPS), thermoplastic polyamide (TPA), thermoplastic vulcanizate (TPV), thermoplastic polyolefin (TPO) or any combination thereof 9. The polymer composite of claim 8 , comprising:

The thermoset polymer comprises one or more polyesters, one or more polyamides, one or more epoxy resins, one or more vinyl esters, one or more melamine formaldehyde, one or more Urea-formaldehyde, one or more phenolic resins, one or more silicones, one or more polyurethanes, one or more vulcanizates, polyureas, one or more phenol-formaldehydes, Duroplast, one or melamine resins, benzoxazines, one or more furan resins, one or more cyanate esters, thiolites, one or more diallyl-phthalates, or any combination thereof. of polymer composites.

2. The polymer composite of claim 1 , wherein said fibers are selected from the group consisting of glass fibers, basalt fibers, carbon fibers, thermoplastic polymer fibers, thermoset polymer fibers, and any mixtures thereof.

2. The polymer composite of claim 1 , wherein said tubular particles have an extensional modulus in the range of 13000 psi (89.6 MPa) to 35000 psi (241 MPa) as measured according to the procedure of ASTM D-638.

The fibers are thermoplastic polyester elastomer (TPE) fibers, thermoplastic styrene elastomer (TPS) fibers, thermoplastic polyamide (TPA) fibers, thermoplastic vulcanizate (TPV) fibers, thermoplastic polyolefin (TPO) fibers, or 2. The polymer composite of claim 1 , comprising any combination of

2. The fiber of claim 1 , wherein the fibers comprise polyester fibers, polyamide fibers, epoxy resin fibers, vinyl ester fibers, melamine formaldehyde fibers, urea formaldehyde fibers, phenolic resin fibers, silicone fibers, polyurethane fibers or any combination thereof. polymer composites.

2. The polymer composite of claim 1 , wherein both the resin and the fibers comprise thermoplastic polymers , thermoset polymers, or mixtures of thermoplastic and thermoplastic polymers.

Said polymer composite material comprises at least one adhesive, said adhesive being polyvinyl alcohol resins, acrylic resins, vinyl acetate-based resins, polyurethane-based resins, silicone-based resins, polyether-based resins, polyamides. 2. The polymer composite of claim 1 , comprising a base resin or any combination thereof .

2. The polymer composite of claim 1, wherein the polymer composite has an air flow rate of at least 2 ft ^<3> /min (0.000943895 m ^<3> /sec) as measured according to the procedure of ASTM D 3574 Test G.

A process for preparing the polymer composite of claim 1 , said process comprising at least:
a) providing at least one resin and fiber;
b) co-extrusion or pultrusion of the resin and fibers to incorporate the fibers into the resin to obtain a tubular extrudate;
c) dividing the tubular extrudate to form multiple tubular particles;
d) placing said plurality of tubular particles inside a mold; and e) bonding said plurality of tubular particles to form said polymer composite.

21. The method of claim 20 , wherein said bonding comprises steam heating said multiple tubular particles to melt them together, or adding at least one adhesive to bond said multiple tubular particles. Described process.

A cushioning material comprising the polymer composite of claim 1 .

23. A cushion formed from the cushioning material of claim 22 selected from the group consisting of shoe soles, furniture cushions, bed mattresses, automotive seat cushions, flooring substrates, outdoor walking/running surfaces, mats and pads. Goods.

1. A cushioning article comprising a polymeric composite comprising tubular particles comprising at least one resin with incorporated fibers;
said tubular particles having a length in the range of 0.5 mm to 60 mm, an average diameter in the range of 0.5 mm to 60.0 mm, and an average wall thickness in the range of 0.0005 mm to 5.0 mm;
said fibers having an average diameter in the range of 0.0005 mm to 5.0 mm;
A cushioning article wherein said fibers are separated from each other using a resin, unidirectionally oriented and aligned with each other, and said tubular particles are randomly oriented and fused together.