US 11,987,011 B2
Hybrid fiber based molding thermoplastic article and process of forming same
Probir Kumar Guha, Bloomfield Hills, MI (US); Philippe Bonte, Pouance (FR); Marc-Philippe Toitgans, Pouance (FR); and Dominique Boyer, Pouance (FR)
Assigned to Teijin Automotive Technologies, Inc., Auburn Hills, MI (US)
Appl. No. 16/464,552
Filed by Continental Structural Plastics, Inc., Auburn Hills, MI (US)
PCT Filed Nov. 28, 2017, PCT No. PCT/US2017/063379
§ 371(c)(1), (2) Date May 28, 2019,
PCT Pub. No. WO2018/102282, PCT Pub. Date Jun. 7, 2018.
Claims priority of provisional application 62/427,870, filed on Nov. 30, 2016.
Prior Publication US 2021/0107236 A1, Apr. 15, 2021
Int. Cl. B29C 70/02 (2006.01); B29B 15/10 (2006.01); B29C 70/12 (2006.01); B29C 70/20 (2006.01); B29C 70/46 (2006.01); B32B 5/02 (2006.01); B32B 5/08 (2006.01); B32B 5/10 (2006.01); B32B 5/12 (2006.01); B32B 5/26 (2006.01); B29K 101/12 (2006.01); B29K 105/10 (2006.01); B29K 105/16 (2006.01)
CPC B29C 70/025 (2013.01) [B29B 15/105 (2013.01); B29C 70/12 (2013.01); B29C 70/202 (2013.01); B29C 70/465 (2013.01); B32B 5/02 (2013.01); B32B 5/022 (2013.01); B32B 5/08 (2013.01); B32B 5/10 (2013.01); B32B 5/12 (2013.01); B32B 5/26 (2013.01); B29K 2101/12 (2013.01); B29K 2105/105 (2013.01); B29K 2105/165 (2013.01); B32B 2262/02 (2013.01); B32B 2262/101 (2013.01); B32B 2262/106 (2013.01); B32B 2264/10 (2013.01); B32B 2398/20 (2013.01)] 10 Claims
OG exemplary drawing
 
1. A stack comprising:
at least one layer of non-oriented fibers comprising glass fibers having diameters of 0.03 to 0.5 millimeters (mm), carbon fibers having diameters of 0.005 to 0.1 mm, and natural filler fibers having diameters of 0.01 to 0.3 mm, or a combination thereof; and
at least two layers of uni-directional and non-woven individual thermoplastic fibers composed of a first thermoplastic fiber having a length and a diameter, the first thermoplastic fiber being any of polyethylene, polypropylene, nylon polyamides, polyimides, polyether ether ketone (PEEK), polycarbonates, polyethylene terephthalate (PET), or a copolymer or mixture thereof, wherein said at least two layers of uni-directional non-woven thermoplastic fibers include a discontinuity in the length, each of the at least two layers having a zero angle defined by a long axis of an article;
wherein said at least two layers of uni-directional and non-woven individual thermoplastic fibers make up between 40 and 98 total weight percent of the stack fiber content; and
wherein said at least two layers of uni-directional non-woven thermoplastic fibers are angularly displaced from one another relative to the long axis to define a central mirror plane therebetween or a multiplanar pattern when said at least two layers are four layers.