Continuous glass fiber reinforced polymer composites in appliances

Abstract

The use of a continuous glass reinforced fiber containing polymer composite capable of being thermally formed into various shapes and used in-home appliances such as a clothes washing or drying drum or basket or a dishwasher tub. The polymer composites can also be used to produce a garage wall panel or components for washer drums or baskets.

1 . A reinforced washer drum comprising:
 a washer drum having an exterior surface and an interior surface in which the exterior surface comprises a composite of thermoplastic molded reinforcing layers, wherein each layer material comprises a plurality of interwoven or layered continuous glass fiber reinforced thermoplastics.   
     
     
         2 . The reinforced washer drum of  claim 1  wherein the plurality of interwoven or layered continuous glass fiber reinforced thermoplastics comprises about 30 to 90 wt % of at least one thermoplastic polyolefin. 
     
     
         3 . The reinforced washer drum of  claim 2  wherein the plurality of interwoven or layered continuous glass fiber reinforced thermoplastics further comprises about 9 to 69 wt % of at least one continuous glass-like reinforcement fiber. 
     
     
         4 . The reinforced washer drum of  claim 3  wherein the plurality of interwoven glass fiber reinforced thermoplastic substrates further comprises about 1 to 30 wt % of at least one mineral filler. 
     
     
         5 . A method of producing a non-metallic shaft receiving back panel for a washing machine drum comprising the steps of:
 interweaving a plurality of continuous glass fiber reinforced thermoplastics to form a sheet of glass reinforced thermoplastic substrate; and   molding the sheet of reinforced thermoplastic substrate to form the shaft receiving back panel for the washing machine drum such that the back panel includes a bearing-receiving channel having a plurality of bearings securely retained within the bearing-receiving channel.   
     
     
         6 . The method of  claim 5 , wherein the plurality of interwoven continuous glass fiber reinforced thermoplastics comprises about 30 to 90 wt % of at least one thermoplastic polyolefin. 
     
     
         7 . The method of  claim 6 , wherein the plurality of interwoven continuous glass fiber reinforced thermoplastics further comprises about 9 to 69 wt % of at least one glass-like reinforcement fiber. 
     
     
         8 . The method of  claim 7 , wherein the plurality of interwoven continuous glass fiber reinforced thermoplastics further comprises about 1 to 30 wt % of at least one mineral filler. 
     
     
         9 . A reinforced dishwasher tub comprising:
 a dishwasher tub having an exterior surface and an interior dish treating area facing surface in which the exterior surface comprises a composite of thermoplastic molded reinforced layers wherein each layer comprises a plurality of interwoven interwoven continuous glass fiber reinforced thermoplastics.   
     
     
         10 . The reinforced dishwasher drum of  claim 9  wherein the plurality of interwoven continuous glass fiber reinforced thermoplastics comprises about 30 to 90 wt % of at least one thermoplastic polyolefin. 
     
     
         11 . The reinforced dishwasher drum of  claim 10  wherein the plurality of interwoven continuous glass fiber reinforced thermoplastics further comprises about 9 to 69 wt % of at least one glass-like reinforcement fiber. 
     
     
         12 . The reinforced dishwasher drum of  claim 11  wherein the plurality of interwoven continuous glass fiber reinforced thermoplastics further comprises about 1 to 30 wt % of at least one mineral filler. 
     
     
         13 . A method of producing a wall panel containing a plurality of slots that receive a plurality of tool engaging members comprising the steps of:
 coextruding a continuous glass reinforced fiber polymer material between two other polymer component containing layers to form a wall panel material comprising three layers of material;   passing the wall panel material through a mold that produces a plurality of spaced apart slots in one planer surface of the wall panel material; and   cutting the wall panel components to a predetermined length.   
     
     
         14 . The method of  claim 13 , wherein the continuous glass reinforced fiber polymer material comprises about 30 to 90 wt % of at least one thermoplastic polyolefin. 
     
     
         15 . The method of  claim 14 , wherein the continuous glass reinforced fiber polymer material further comprises about 9 to 69 wt % of at least one glass-like reinforcement fiber. 
     
     
         16 . The method of  claim 15 , wherein the continuous glass reinforced fiber polymer material further comprises about 1 to 30 wt % of at least one mineral filler.