Reinforcing-thermoplastic mat and method of forming such a mat
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United States of America Patent
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app pub date -
Sep 3, 2004
filing date -
Oct 10, 2003
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Abstract
A method of forming a mixed fiber mat comprising forming a multi-layer mat from a first substantially planar structure of reinforcing fibers, such as a continuous strand fiberglass mat, and a first layer of thermoplastic fibers, such as polypropylene fibers. The multi-layer mat is subsequently needle-punched to intertwine the fibers. The mixed fiber mat preferably comprises a first continuous strand glass fiber mat and a first layer of thermoplastic fibers needle-punched together to intertwine the fibers. The mixed fiber mat can be heated to melt the thermoplastic fibers and then cooled to harden the thermoplastic to form a matrix. A composite is formed by this heating and cooling process. Other fibers can be substituted for the glass and polypropylene fibers.
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