Patent ID: 6531010
Filing Date: 2003-03-11
Classification: B29C,B29K,B29L,Y10S,Y10T

Abstract:
A process for the manufacture of a shaped structural member composite comprising a thermoplastic resin and a glass fabric, the method comprising:(a) providing a glass fabric; (b) introducing the glass fabric into a shaping station to introduce a prefold into an edge of the glass fabric, and to produce a preformed fabric shape conforming to a shape of a shaped composite; (c) introducing a thermoplastic resin and the preformed fabric into an extruder having an inlet zone and a combining zone wherein the thermoplastic resin and preformed fabric shape are combined to form a resin and fabric composite under conditions of sufficient pressure, temperature and shear to cause the thermoplastic resin composition to penetrate and wet individual glass fibers to the extent that the thermoplastic resin composition substantially coats the glass fibers in the glass fabric; and (d) extruding the resin and fabric composite through a shaping die to form the shaped structural member composite wherein the shaped structural member composite has properties which are: (i) modulus of elasticity of about 830 kpsi or greater; (ii) coefficient of thermal expansion of about 0.000022 in/in/Â° F. or less; (iii) shrinkage not to exceed about 0.28%; and (iv) impact strength of about 10 in-lbs or greater.