Patent ID: 8883908
Filing Date: 2014-11-11
Classification: B29B,B29C,B29K,C08K

Abstract:
1. A method of making a reinforced thermoplastic composite product comprising; a) preparing a monomer mixture containing one or more thermoplastic precursor monomers and one or more catalyst compounds, the monomer mixture containing no activator compounds, this mixture being such that when brought into contact with one or more inorganic reinforcing materials having one or more activator compounds on surfaces of the one or more reinforcement materials, said activator compound(s) being a material that will react with the monomer mixture to cause polymerization of the one or more monomers when in the temperature range of about 140 to about 200 degrees C. to produce a thermoplastic matrix, b) heating the one or more reinforcing materials to a temperature of at least about 130 degrees C., and/or c) heating the monomer mixture of step a) to a temperature of at least about 100 degrees C., and/or d) optionally heating a mold element, in which the polymerization of the monomer(s) will take place, to a temperature in the range of about 130 to about 200 degrees C., e) coating the surfaces of the one or more reinforcing materials having on their surfaces a dried coating of a size composition containing the one or more of said one or more activator compounds, with the monomer mixture of step a) prior to contact with the optionally heated mold element, f) bringing the monomer mixture coated reinforcing materials into contact with, the optionally heated mold element to form a desired shape of the dried size coated and the monomer mixture of step a) coated reinforcing materials, the monomer mixture of step a) forming a matrix around the reinforcing materials, and g) heating or maintaining the temperature of the desired shape in a range of about 140 to about 190 degrees C. until at least about 90 percent of the one or more monomers in an exterior portion of the desired shape have polymerized to one or more thermoplastic polymers.