Patent ID: 9650498
Date: 2017-05-16
CPC Classifications: B29B,B29C,B29K,C08K

Claim:
1. A method of making an interim product for making a reinforced thermoplastic composite product, or for making a reinforced thermoplastic product comprising: a) preparing a monomer mixture containing one or more thermoplastic precursor monomers preheated to a temperature above its melting point and one or more catalyst compounds, the monomer mixture containing no activator compounds, the catalyst compound(s) causing polymerization of the monomer(s) when brought into contact with an inorganic fiber reinforcement material having one or more activator compounds on the surfaces of the inorganic fiber reinforcement material, the activator compound being a material that will react with the monomer mixture to cause polymerization of the monomer in the temperature range of about 140 to about 200 degrees C. to produce a thermoplastic matrix around the inorganic fiber reinforcement material, b) feeding one or more layers of the monomer(s) mixture of step (a) onto a moving belt, the monomer(s) mixture having a temperature of at least about 100 degrees C., but below 140 degrees C., c) feeding one or more layers of inorganic fiber reinforcement material selected from a group consisting of woven roving or yarn fabric and/or scrim, chopped strand mat, continuous strand mat, nonwoven mat, chopped roving, chopped strands of fibers, chopped filaments and veil mat in any desired combination onto the one or more layers of the monomer mixture, and d) impregnating the one or more layers of inorganic fiber reinforcement material and coating inorganic fibers with the monomer mixture to form an interim product comprising coated inorganic fiber reinforcement material and a matrix of the mixture of step (a).