Fiber reinforced porous sheets

D - Textiles – Paper – 04 – H

Patent

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D04H 1/42 (2006.01) C08J 5/04 (2006.01) D04H 1/54 (2006.01)

Patent

CA 2093670

A method of preparing porous fiber reinforced polymer composite sheets has been developed to allow a more efficient pre- heating of the sheet prier to molding and includes the steps of blending reinforcing fibers with resin matrix forming fibers to form a web. This web is then heated to a temperature wherein the resin matrix forming fibers melt and envelope the reinforcing fibers, tacking them together at crossover points. The resultant web can then be directly heated very efficiently for molding. This web is highly porous allowing rapid heating at moderate pressure differentials during subsequent preheat steps. The microstruc- ture created when the resin matrix forming fibers are initially melted further enhances heating capability because the structure re- tains porosity during the subsequent heating step required for molding. Because the resin matrix forming fibers initially were un- iformly blended, a highly uniform distribution of polymeric material within the reinforcing fiber matrix yields molded parts with very uniform properties.

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