US 12,454,121 B2
Prepregs, cores and articles including expandable graphite materials
Ruomiao Wang, Forest, VA (US); Yu-Tsan Tseng, Kennesaw, GA (US); Mark O. Mason, Covington, VA (US); Troy D. Robertz, Lake Orion, MI (US); and Erich J. Vorenkamp, Pinckney, MI (US)
Assigned to Hanwha Azdel, Inc., Forest, VA (US)
Filed by HANWHA AZDEL, INC., Forest, VA (US)
Filed on Nov. 12, 2015, as Appl. No. 14/939,125.
Claims priority of provisional application 62/079,288, filed on Nov. 13, 2014.
Prior Publication US 2016/0168350 A1, Jun. 16, 2016
Int. Cl. C08J 9/228 (2006.01); B29C 44/34 (2006.01); B29C 70/02 (2006.01); B32B 5/02 (2006.01); B32B 5/22 (2006.01); B32B 5/24 (2006.01); B32B 5/26 (2006.01); B32B 5/32 (2006.01); B32B 27/06 (2006.01); B32B 27/08 (2006.01); B32B 27/12 (2006.01); B32B 27/18 (2006.01); B32B 27/28 (2006.01); B32B 27/30 (2006.01); B32B 27/32 (2006.01); B32B 27/34 (2006.01); B32B 27/36 (2006.01); C08J 5/10 (2006.01); C08J 5/24 (2006.01); C08J 9/00 (2006.01); B29K 105/04 (2006.01); B29K 507/04 (2006.01); B32B 5/18 (2006.01)
CPC B32B 27/12 (2013.01) [B29C 44/3415 (2013.01); B29C 70/025 (2013.01); B32B 5/02 (2013.01); B32B 5/22 (2013.01); B32B 5/245 (2013.01); B32B 5/26 (2013.01); B32B 5/32 (2013.01); B32B 27/065 (2013.01); B32B 27/08 (2013.01); B32B 27/18 (2013.01); B32B 27/281 (2013.01); B32B 27/283 (2013.01); B32B 27/285 (2013.01); B32B 27/286 (2013.01); B32B 27/288 (2013.01); B32B 27/302 (2013.01); B32B 27/304 (2013.01); B32B 27/308 (2013.01); B32B 27/32 (2013.01); B32B 27/34 (2013.01); B32B 27/36 (2013.01); B32B 27/365 (2013.01); C08J 5/10 (2013.01); C08J 5/244 (2021.05); C08J 5/249 (2021.05); C08J 9/228 (2013.01); B29K 2105/048 (2013.01); B29K 2507/04 (2013.01); B32B 5/18 (2013.01); B32B 2260/021 (2013.01); B32B 2260/046 (2013.01); B32B 2262/02 (2013.01); B32B 2262/0269 (2013.01); B32B 2262/10 (2013.01); B32B 2262/101 (2013.01); B32B 2262/103 (2013.01); B32B 2262/106 (2013.01); B32B 2262/108 (2013.01); B32B 2264/08 (2013.01); B32B 2266/0214 (2013.01); B32B 2266/06 (2013.01); B32B 2270/00 (2013.01); B32B 2307/3065 (2013.01); B32B 2605/00 (2013.01)] 17 Claims
 
1. An automotive thermoplastic composite article comprising:
a porous core layer comprising a web of open celled structures comprising random crossing over of a plurality of reinforcing fibers held together by a thermoplastic material, wherein the porous core layer comprises a porosity of 20% to 95%, and wherein the porous core layer further comprises non-covalently bonded expandable graphite particles homogeneously dispersed in the web of open celled structures of the porous core layer, wherein the automotive thermoplastic composite article meets the Federal Motor Vehicle Safety Standard 302 (FMVSS 302) flammability test dated 1991 and self-extinguishes, wherein the expandable graphite material lofts, under infrared heating conditions, at a loft temperature that is 20 degrees Celsius or higher than a melting point temperature of the thermoplastic material in the porous core layer, in which the porous core layer provides flame retardancy and is halogen free, and wherein the porous core layer further comprises covalently bound expandable graphite particles in the web of open celled structures of the porous core layer; and
a skin disposed on a first surface of the porous core layer.