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Polyolefinic Materials for Plastic Composites

Inactive Publication Date: 2008-10-23
DOW GLOBAL TECH LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0009]Various aspects of the present invention are predicated upon the discovery of unique combinations of materials, processing steps, or both, that result in a relatively high degree of retained morphology in the elongated member materials (as compared with its initial morphology upon its initial stretch and prior to processing to form a composite article). In this manner, the teachings herein advantageously allow for the beneficial preservation of properties such as impact properties in the resulting composite articles.

Problems solved by technology

The difference of material types between the glass and the thermoplastic matrix tends to complicate any reclamation or recycling efforts with these GMT materials.
To date, efforts to provide a suitable thermoplastic reinforcement form that can readily be processed to form a resulting article, particularly an article that is shaped by molding or forming under elevated temperature, have been limited.
With each additional heat history, the opportunity for morphology change is increased, with the attendant loss of mechanical properties, such as impact strength.
As a result, this places practical restrictions upon the processing steps and conditions for making composites.

Method used

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  • Polyolefinic Materials for Plastic Composites
  • Polyolefinic Materials for Plastic Composites
  • Polyolefinic Materials for Plastic Composites

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0145]Performance of a consolidated sheet (1.85 mm thickness) of coextruded tape including an propylene-ethylene copolymer co-extruded with a polypropylene homopolymer as disclosed herein (designated as Sample X) (about 0.04 mm thick by 3 mm wide) is compared with the performance of materials such as that available commercially under the designation CURV™ (denoted respectively as “Sample A” and “Sample B”) in the 1.5 and 2.2 mm thicknesses shown), using a falling dart impact test (per ISO 7765-1) at room temperature and at (−)40° C. FIGS. 5A and 5B illustrate data obtainable according to a preferred embodiment of the present invention.

example 2

[0146]A spare tire bin is injection molded with a polypropylene bulk material, along with a three layer (3 L) consolidated twill woven coextruded polypropylene tape (about 0.04 mm thick by 3 mm wide) intermediate form on one side of the polypropylene bulk material. The resulting article is ruck free and exhibits a 400% improvement as compared with a 40% long glass fiber composite with a 20% glass filled polypropylene matrix, when impacted at 8 MPH at −30° C. A complete ductile break is observed without shattering; i.e., no flying pieces are observed during impact.

example 3

[0147]Example 2 is repeated but the intermediate form is placed on both sides of the polypropylene bulk material, exhibiting enhanced stiffness and impact resistance relative to the Example 2 composite.

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Abstract

A reinforced composite article and method for making the same. The article and method employ at least one elongated member as a reinforcement phase. Specific elongated members are multiple layer structures wherein the layers are each polyolefinic (e.g., at least one of the layers may be a propylene-based polymer, such as a propylene-ethylene copolymer, an isotactic polypropylene homopolymer, or a combination thereof). Optionally, at least one of the layers may include a non-migratory process aid or surface modifier agent. An intermediate form including the elongated member may made and processed (for example, with a step of consolidation) to form a composite article.

Description

CLAIM OF PRIORITY[0001]The present application claims priority to, and the benefit of the filing date of, U.S. Provisional Application Nos. 60 / 621,463 filed on Oct. 22, 2004 (Attorney Docket No. 63863; 1062-041P1); 60 / 717,965 filed on Sep. 16, 2005 (Attorney Docket No. 63863B; 1062-041P2); 60 / 718,025 filed on Sep. 16, 2005 (Attorney Docket No. 64371; 1062-051P1); and 60 / 725,399 filed on Oct. 11, 2005 (Attorney Docket No. 63863C; 1062-041P3), (Express Mail No. EV789808245US), all of which are incorporated by reference.CROSS-REFERENCE TO RELATED APPLICATIONS[0002]The present application is related to concurrently filed, commonly owned, copending application entitled Apparatus and Process for Manufacturing Shaped Plastic Reinforced Composite Articles (Attorney Docket No. 64371A; 1062-051WO); Plastic Composite Articles and Methods of Making Same (Attorney Docket No. 63863E; 1062-41WO2); Improved Microlayer Structures and Methods (Attorney Docket No. 63863F; 1062-41WO3); and Improved Com...

Claims

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Application Information

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IPC IPC(8): D03D15/00
CPCB29C43/36Y10T428/264B29C70/04B29C2043/3602B29C2043/3631B29K2023/0641B29K2023/12B32B1/00B32B27/32D03D15/00D03D15/0088D10B2321/021D10B2321/022D10B2401/041D10B2505/02Y10T428/24942Y10T428/13Y10T428/24975Y10T428/2495Y10T428/139Y10T428/1359Y10T428/1303Y10T156/10Y10T428/1352Y10T428/1393B29C51/004Y10T428/31909Y10T442/2008Y10T428/31504Y10T428/31913D03D15/46D03D15/283
Inventor CHEN, HONGYUCHUM, WING S.WEVERS, RONALDMCLEOD, DAVID G.
Owner DOW GLOBAL TECH LLC
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