US 11,859,062 B2
Method for producing a thermodeformable polymer/fiber composite
Michael Kalbe, Ludwigshafen am Rhein (DE); Mirko Flory, Ludwigshafen am Rhein (DE); Rainer Scheidhauer, Ludwigshafen am Rhein (DE); and Hans Horler, Ludwigshafen am Rhein (DE)
Assigned to BASF SE, Ludwigshafen am Rhein (DE)
Appl. No. 17/267,662
Filed by BASF SE, Ludwigshafen am Rhein (DE)
PCT Filed Jun. 12, 2019, PCT No. PCT/EP2019/065309
§ 371(c)(1), (2) Date Feb. 10, 2021,
PCT Pub. No. WO2020/030330, PCT Pub. Date Feb. 13, 2020.
Claims priority of application No. 18188499 (EP), filed on Aug. 10, 2018.
Prior Publication US 2021/0324154 A1, Oct. 21, 2021
Int. Cl. C08J 5/04 (2006.01); B29C 51/12 (2006.01); B29C 51/22 (2006.01); B29C 51/26 (2006.01); B29C 70/06 (2006.01); B29C 70/50 (2006.01); C08G 18/62 (2006.01); C08G 18/70 (2006.01); C08G 18/76 (2006.01); C08J 5/06 (2006.01); C08J 5/10 (2006.01); B29C 70/12 (2006.01); B29C 51/46 (2006.01); B29K 75/00 (2006.01); B29K 105/12 (2006.01)
CPC C08J 5/045 (2013.01) [B29C 51/12 (2013.01); B29C 51/22 (2013.01); B29C 51/264 (2013.01); B29C 51/266 (2013.01); B29C 70/06 (2013.01); B29C 70/12 (2013.01); B29C 70/50 (2013.01); C08G 18/622 (2013.01); C08G 18/6237 (2013.01); C08G 18/6254 (2013.01); C08G 18/706 (2013.01); C08G 18/7664 (2013.01); C08G 18/7671 (2013.01); C08J 5/06 (2013.01); C08J 5/10 (2013.01); B29C 51/46 (2013.01); B29K 2075/00 (2013.01); B29K 2105/12 (2013.01); C08J 2375/04 (2013.01); C08J 2375/06 (2013.01); C08J 2433/06 (2013.01)] 17 Claims
 
1. A process for producing a thermoformable polymer/fiber composite using a fibrous substrate, an organic di- or polyisocyanate compound I and a polymer P, where
the fibrous substrate is introduced into a gas stream, then
the fibrous substrate in the gas stream is contacted with an aqueous dispersion of a polymer P having a glass transition temperature Tg and an organic di- or polyisocyanate compound I, then
the fibrous substrate that has been contacted with the aqueous dispersion of the polymer P and the organic di- or polyisocyanate compound I is dried in the gas stream and then deposited, then
the deposited fibrous substrate obtained is converted to a fiber web, and then
the fiber web obtained is consolidated at a temperature ≥Tg to give a thermoformable polymer/fiber composite,
which comprises effecting the aqueous dispersion of the polymer P by free-radically initiated emulsion polymerization of a mixture of ethylenically unsaturated monomers P [monomers P] in an aqueous medium in the presence of a polymer A, where the polymer A is formed from
a) 80% to 100% by weight of at least one ethylenically unsaturated mono- and/or dicarboxylic acid [monomers A1] and
b) 0% to 20% by weight of at least one further ethylenically unsaturated monomer which differs from the monomers A1 [monomers A2], in copolymerized form,
and where the monomers P are chosen in terms of type and amount such that the polymer P obtained has a glass transition temperature Tg≥20° C. measured according to DIN EN ISO 11357-2 (2013-09).