Patent ID: 8012577
Filing Date: 2011-09-06
Classification: C08J,D21H,Y10T

Abstract:
1. A consolidated composite article having a density, Dc, and comprising: (i) a polymer having a softening temperature and (ii) fibers, said composite article produced by: providing a matte, wherein said matte is a mixture comprising: from about 1 wt % to about 90 weight percent of said fibers; and from about 10 weight percent to about 90 weight percent particles of a polymer, said matte having a density, Dm, that is less than Dc; densifying said matte to a compressed density greater than 1.1 times Dm and less than 0.999 times Dc while at least a portion of said matte is at a temperature less than softening temperature of polymer, to provide a compressed matte; heating said compressed matte throughout to a temperature greater than said softening temperature at a density greater than 1.1 times Dm and less than 0.999 times Dc, to provide a preconsolidated matte; cooling at least a portion of said preconsolidated matte to a temperature less than said softening temperature, to provide a consolidated matte; stacking a plurality of said consolidated matte to provide an article having fiber orientation of each immediately adjacent and contacting matte at right angles; compressing the height of said article and heating throughout to a temperature greater than said softening temperature, to provide a consolidated composite article; and cooling at least a portion of said consolidated composite article to a temperature less than said softening temperature.