Alternative Polyolefin Composite Veil/Compatibilizing Mat Materials

Abstract

A compatibilized polyolefin/polyolefin composite material includes a polyolefin/polyolefin composite substrate and a reinforcing mat formed from reinforcing fibers and a thermoplastic polymer powder. The mat may also incorporate an optional emulsion polymer binder. In addition the compatibilized polyolefin/polyolefin composite material may incorporate an additional film layer so that the mat is sandwiched between the substrate and the film layer. A method of producing such materials from a to polyolefin/polyolefin composite substrate that is topologically/mechanically bonded to a reinforcing mat formed from reinforcing fibers and thermoplastic polymer powder is also described.

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       16 . A method of compatibilizing a polyolefin/polyolefin composite material, comprising:
 contacting a reinforcing mat formed from reinforcing fibers selected from a group consisting of glass fibers, carbon fibers, aramid fibers, kenaf fibers, hemp fibers, cellulose fibers, and mixtures thereof and a thermoplastic polymer selected from a group of materials consisting of phenolic powders, phenoxy based epoxy powders, polyester melt adhesive powders, modified polyethylene based resin powders, PVC/PVDC copolymer powders, EVA powders, PVA powders, acrylic powders, polyester powders, PVC/PVAc copolymer powders and mixtures thereof with a polyolefin/polyolefin composite substrate;   applying sufficient temperature and pressure for a sufficient time to consolidate said mat and said polyolefin/polyolefin composite substrate.   
   
   
       17 . The method of  claim 16  wherein prior to said contacting step the method includes preparing an aqueous suspension of said reinforcing fibers and said thermoplastic polymer, forming a sheet-like material from said aqueous suspension, dewatering said sheet-like material and densifying said sheet-like material to produce said reinforcing mat. 
   
   
       18 . The method of  claim 16 , further including selecting for application to said mat and said substrate a pressure of between about 50 to about 300 psi and a temperature of between about 350 to about 450° F. for a period of time between about 10 to about 300 seconds. 
   
   
       19 . The method of  claim 16 , further including adding a film against said mat. 
   
   
       20 . The method of  claim 19 , further including selecting said film from a group of materials consisting of VC, PVC/PVAc copolymer; PVC/PVCD copolymer, PVDC, ABS, acrylic, polyester and mixtures thereof. 
   
   
       21 . The method of  claim 19 , further including selecting for application to said film, said mat and said substrate a pressure between about 50 to about 300 psi and a temperature between about 350 to about 450° F. for a period of time between about 10 to about 300 seconds. 
   
   
       22 . The method of  claim 19 , further including providing a polymer binder in said mat. 
   
   
       23 . The method of  claim 19 , further including providing an acrylic emulsion in said mat.