Patent ID: 8029633
Filing Date: 2011-10-04
Classification: B29C,B29K

Abstract:
1. A method of consolidation of thermoplastic fibrous layers comprising: a) providing a plurality of fibers, the fibers comprising: b) forming the fibers into a fibrous layer selected from the group consisting of woven, non-woven, unidirectional, and knit, wherein the fibrous layers contain interstices between the fibers within each fibrous layer; c) applying a second layer to at least a portion of the surface of the fibrous layer such that the second layer covers at least a portion of the first layers of the fibers, the second layer comprising a second polymer, wherein the second polymer comprises a co-polymer having at least 50% α-olefin units and is characterized by a number-average molecular weight of about 7,000 g/mol to 50,000 g/mol, a viscosity of between about 2,500 and 150,000 cP measured at 170° C., wherein the viscosity of the second polymer is not greater than about 10 percent of the viscosity of the first polymer measured at 170° C., and a melting temperature lower than the melting temperature of the exterior surface of the core; and, d) applying heat and optionally pressure to the fibrous layer causing: