CA1262519A

CA1262519A - Fibre reinforced plastics structures

Info

Publication number: CA1262519A
Application number: CA000471523A
Authority: CA
Inventors: Bronislaw Radvan; Anthony John Willis
Original assignee: Wiggins Teape Group Ltd
Current assignee: Wiggins Teape Group Ltd
Priority date: 1984-01-06
Filing date: 1985-01-04
Publication date: 1989-10-31
Also published as: ES539354A0; DK6985A; ES8606100A1; JPH0440372B2; KR920003059B1; PT79801A; DK6985D0; BR8500035A; NO850040L; GR850023B; FI850042A0; ATE54874T1; US4734321A; CN85100804A; PT79801B; MY103670A; DE3578785D1; EP0148760A2; FI850042L; IE57943B1

Abstract

- 22 _ ABSTRACT

An air permeable sheet-like structure comprising 20% to 60% by weight of reinforcing fibres having a high modulus of elasticity (as herein defined), and being between about 7 and about 50 millimetres long, and 40% to 80%
by weight of wholly or substantially unconsolidated particulate plastics material, and in which the fibrous and plastics components are bonded into an air permeable structure.

Description

:~6~5~5~

I~PROVEMENTS IM FIBRE REINFORCED
PLASTICS STR~CTURES

This invention relates to sheet-like ~ibrous structures, and in particular to such ~tructures ~or use ln the production o~ ~ibre rein~orced plastics materials or articles. The inve~tion also relates to a process ~or -~
5 making 6uch-materials. : .

Plastlcs sheet materials made ~rom thermoplastic resins are widely used ln the manu~acture o~ moulded articles.
Such materials are, however, not o~ great strength or rigl~ity, and ~here sue~ properties are required, ~lbre rein~orcement ls introduced.

Thu~, ~or e`~ample, ln the manu~actu~e o~ one such : i ma~erial, layers~o~ glass ~lbre mat are i~terposed between layer6~0~ ~hermopl~stics material, the composite structur:e~
being needled to produce a degree o~ i~*egration o~ the layers:and then heated under pres~ure to produce consolidated rigid sheets Xor u~e in moulding.

~o~ever, ~or~~atisiactory moulding o~ such sheets, they must be homoge~eously preheated. This rèquires both time and accurate temperature cont~ol i~ overheating;a~d ~ ~
: ~ degradation o~ the shee~ sur~aces is not to occur whils~ :
: :the~core portions o~ the~æheet~ are brought up to the required mouldlng témperature. Also, ~or a moulding o~:
: ~givè~ dime~sions, an optimum size o~ consolidated sheet is : raquired i~ e~cessive waste ~n the form o~ ~lash iæ to be .
3~i , .' , :;; ", . . , :

,~ . . ' : ~
.:
: : :
, ::

- 2 -avoided. As a result a moulder who manufactures a wide range of mouldings must carry a corresponding range o~ ¦
sheet slzes, be prepared to cut large sheets to an appropriate size or accept a high degree of wastage.

Furthermore, when used for deep draw moulding it ls found that such materials are not capable of being used to form mouldings o~ uniform structural strength. This is because the glass fibre mat is constituted of very long glass fibre strands (i.e. fibre bundles) of perhaps 200 10 centimetres or more which extend ln a random serpentine manner throughout the whole sheet. This substantially~
restricts their movement during moulding in that they~ ~
cannot flow ~ith the thermoplastics material constituti~g the remainder of the structure. As a result, relatlvely 15 thin part~ of the moulding such as st~ffening ribs are starved of ~ibre reinforcement. Additivnally, because o~
the mode of mahufacturé of such reinforced sheets, they have to be fully consolidated by the application o~ heat and pressure in order to be transportable. As a result, ao they can only be supplied to the moulder às flat, impermeable and rigid sheets which are di~icult to handle~
in a continuous moulding process.

It ls among the ob~ects of the present invention to provide a composite fibre and plastics material for ~se in 25 the moulding of fibre rein~orced plastics articles which overcomes or alle~iates the disadvantages of know~
materialæ as descrlbed above.

The in~e~tion therefore provldes an open sheet-like structure comprising 30 ~ ~rom 20% to 60~ by weight o~ rein~orcing fibres having a high modulus o~ elasticity (a~ herein defined), and ,, ,, , ,,., .~ ... . . .. ~ . ........... .. -.-.

.:

bet~een about 7 and about S0 millimetres long, and irom 40% to 80% by weight o~ wholly or substantlally un~onsolldated particulate pla~tics material - the ~brous and pla~tic~ components being bonded into an ir per~eable 6tructure.

Pre~erably, ~he ~ibres are in the ~orm oi~ ~ingle dl~c~ete ~lbres. Thu~, ~here gla~ ~ibres are u~ed, and ~re recelved in the ~orm of chopped ~trand bundle~, the bundleæ are broken down into ~1ngle ~ibres be~ore the ~tructure 18 iormed.
.. .. . .
10 A high modulu~ oi ela~tlcity i8 to be taken a~ meaninK a modulus o~ ela~tlcity 6ubstantially higher than that o~ a co~olidated sheet which could be ~ormed lrom the ~tructure. Fibres ~alllng into this category l~clude gla6~, carboD ~nd cera~c ~ibres and ~ibres 6uch a6 the 15 ara~ld iibre~ sold under the trademarks Kevlar a~d Nome~
and will gen~rally lnJlude any ~lbre having a modulus hlgher than 10,000 ~ega Pa~cal~.

Particulate pla~tics materlal iE to be taken a l~cluding short pla~tics ~lbres ~hich may be included to ~nhance the 20 cohesio~ o~ the structure during manu~acture.

Bonding may be e~ected by utillzing the thermal characterlætlcs o~ the plastlcs material wlthln the structure. Thu~ the structure may be heated ~u~lciently to caus0 a thermoplastic component to ~use at it~ sur~ac~s 25 to ad~acent particle~ and ilbre~. Or a po~t formable th~rmo~etti~g component may be ~o heated to produce a i~llar ef~ect. Care must be taken howe~er to ensure that the conditlons of heati~g are such as to pre~ent degradation o~ ths plastics material after bo~ding.

.

, Alternatively, a binder may be added during manufacture of the structure to effect bonding. Any binder may be used l!
which will effect a bond at a lower temperature than that which would result in consolidation of the plastics material within the structure. Suitable binders include polyvinyl alcohol, polyvinyl acetate, carboxymethyl cellulose and starch.

Individual fibres should not be shorter than about 7 millimetres, since shorter fibres do not provide adequate ¦
reinforcement in the ultimate moulded article. Nor should they be longer than 50 millimetres since such fibres are difficult to handle in the preferred manufac-turing process for the fibrous structure.

Preferably glass fibres are 13 microns in diameter or 15 less. Fibre of diameters greater than 13 microns will I
not so efficiently reinforce the plastics matrix after moulding.

Preferably, the plas~ics material is in a particulate form and may be a thermoplastic, a thermosetting plastic or a mi.xture of the two. Suitabla thermoplastics include polyethylene, polypropylene, polystyrne, acrylonitrylstyrene butadiene, polyethylene terephthalate, and polyvinyl chloride, both plasttcised and unplasticised.
It is anticipated that any thermoplastics powder may be used which is not chemically attacked by water and which can be sufficiently softened by heat to permit fusing and/
or moulding without being chemically decomposed.

Plastics powders need not be excessi~ely fine, but particles coarser than about 1.5 millimetres, as exempli-fied by coarse sand or ~ine rice grains, are unsatisfac- -tory in that they do not ~low sufficiently during the moulding process to produce a homogeneous structure.

-. . .~ ` :
:.~ : : . .. :. .

5~

The use of larger particles results in a significant reduction in the 1exurol modulus of the material when li consolidated. Preferably the plastics particles are not more than 1 millimetre in size.

Because the structure is permeable, it is capable of beingpreheated by hot air permeation. This technique permits rapid homogeneous heating of the whole structure in a manner which is difficult to achieve with consolidated sheets.
i!

Preferably, the degree of bonding is controlled to cohere the components whilst still retaining suficient flexibility to permit the structure to be reeled. In the reeled condition, it can be transported readily for use by a moulder in a continuous preheating and moulding pro-cess. Alternatively, and to minimize material wastage,shaped elements may be cut, pressed or stamped from the structure and supplied to the moulder in a form permitting articles to be moulded with minimum flash to be disposed of. The residual material may be recycled through the forming process, and neither the moulder nor the manufac-turer of the fibrous structure will be faced with the need to dispose of waste material.

Alternatively, the degree of bonding may be such as to produce a rigid, but still air permeable sheet where this will meet the moulder's requirements. This is 2ffected by adjusting ~he amount of the degree of fusing of the thermoplasticj or the amount of binder added to achieve the desired effect, the adjustment depending on the kinds of thermoplastics or binders used.
.

The porosity of the structure permits the optional introduction of liquid thermosetting resin by surface coating or impregnation. Such resins must, of course, be . ' . .

., : ~ ' ::,: ` .:

- ,: , 5~

of the slow curing or post ~ormable kind so as to permit delivery to the moulder and moulding before curing occurs.

Typically, the moulder will ~irst rapidly heat the structure to the moulding temperature o~ the ther~oplastic ¢omponent. The sheet will then be quickly trans~erred to the mouldlng press and pressed lnto the desired shape be~ore the curing o~ the thermosetting resin is complete.

The impregnation may be comp~ete, in ~hich a dense art,?cle will result or lt may be limited to the sur~ace layers o~
the ar~icle. Thi6 may confer su~icient increase in sti~ness over the original e~panded thermoplastic, together wlth a 6ealed sur~ace which pre~ents a ~urther ingres~ o~ other ~luids such as water or oll into the e~panded central zon~. An e~cess o~ liquid thermosetting ma~erialg on the sur~ace may also be u~ed to produce a very ~mooth glossy appearance which is desirable when the moulding is to be used as a substltute ~or sheet metal a~d ~hich is very di~icult to achie~e with conventio~al ~ibre reinrorced materials.

Th0rmo~etti~g resi~s ~hich may be used to impregnate the e~panded thermoplastics sheet i~clude phenolic a~d polyester resins, ~or e~ample phe~ol-~ormaldehyde resin, urea and melamine ~ormaldehyde resins, epo~y resins, unsaturated polyesters and polyurethan0s. Post ~ormable ~hermosetting materials may also be used.

Ia those cases where the moulder is only equipped to handle consolidated sheets, the ~ibrous structure may be consolidated by cutting into appropriate lengths and then heating and cooling under pressure. It will be appreciated that such consolldation can only be carried out when the plastics content o~ the sheet is wholly oi thermopiastics material.

~' , ~ ~-5~

In another aspect, the invention provides a process or the manufacture of a permeable sheet-like fibrous struc-ture, which includes forming a we~ with 20~ to 60% of single fibres having a high modulus of elasticity (as herein defined) and between 7 and 50 millimetres long, and 40% to 60% by weight of a wholly or substantially .
unconsolidated particulate plastics material r and then treating the web to bond the fibres and plastics material together.

Preferably, the web is formed by the process described in UK Patents Nos~ 1129757 and 1329409, which relate to methods of producing fibrous sheets on papermaking machinery. This process achieves a very uniform distri-bution of single fibres in the sheet, even when the ibres are much longer than can be handled in conventional papermaking machinery~

However, other web forming techniques may be used in certain clrcumstances. Thus, for example, such a struc-ture may be formed by using a very low consistency di~persion of fibres and plastics powder, together with a binder, and forming the structure of a paper machine with an "uphill wire". Alternatively, the web may be formed with the aid of a Rotiformer (Registered Trade !j Mark).

The web oE fibres and plastics powder may also be formed using a dry laying technique as described in UK Patent No. 1424682. In this case, the binder may be applied by means of a spray or by dipping and draining the web after t has be-n for~ed.

.
:; .
: . -:

In all c~cs }low(~v-~r, ~t~r ti~c wcb l~a~ bcen formcd it is treat~d, usually by heatin~, to cffcct boncling wlthout subs-t~nti~lly consolidating the plastics particles held in the web. Slight n~etering may be e~fected to ensurc that the structure produced has a constant thickness. }lowever, pressure and temperature conditions must be less than those which would compact the web and consolidate any ther~oplastic component or cure any thermosetting component which it may contain.

10 Optionally, where a customer is only equipped to ha~dle consolidated sheets, and the plastics content o~ the fibrous structure is wholly o~ thermoplastlcs material, the structure is cut into required lengths, after which it is subjected to heatin~ and cooling under pressure to 15 e~iect consolidation.

The invention will no~ be ~urther described wlth re~erence to th~ accompanying drawings in ~hich:-Figura 1 is a diagr~mmatic cross-section og part o~ a 1l ~ibrous ~tructure according to the inYention, l Figure ~ is a di~gra~matic ~lcroscopic vie~ o~ part o~ i~
the ~lbrou~ structure o~ Figure 1~ and ~1!

Figure 3 is a diagra~matic side elevation o~ an , apparatus ~or carrying out the pre~erred process o~ the i i~ventlon, 2S Pigure 4 is Q diagrammatic side elevation oi an apparatus for optionally carrying out an additional proces~ stepp ~nd Figure 5 is a graph illustrat~ng a ~eature o~ the invention.

.

S~

_ 9 _ Referring ~irst to Figures 1 and 2, this shows an nncompacted flbrous structure comprising fibres 1 bonded together at their points o~ lntersection 2 by a blnder so as to form a skeletal structure within the interstices of which a particulate plastlcs material 3 is also retained by the blnder.

Typically, the fibres are glass fibres 12 milli~etres long and 11 microns in diameter, the binder is polyvlnyl alcohol and the pl~stics material is polypropylene 10 part~cles.

Re~erring to Figure 3, this shows an apparatus ~or making a ~ibrous structure according to the pre~erred method oi the invention. There is shown at 10, the wet end o~ a Fourdrinier type papermaking machin~ i~cluding a headbox 15 11 ~hich contalns a dispersion 12. The di~persion 12 consi6ts o~ glass¦fibres and particulate polypropylene in a ~oamed aqueous medium. A suitable ~oaming agent consists o~ sodlum dodecylbe~zene sulphonate at a concentration oi 0.8% i~ water.

20 A~ter drainage on the Fourdrinier wire 13 with th~ aid of suction boxes 1~, a web 17 ls ~ormed o~ unbonded glass fibres interspersed with polypropylene particles. This is carei~ully trans~erred ~rom the Fourdrinier wire 13 to a short endless wire mesh belt 18 tensioned around rollers 25 l9o The belt 18 carries the ~eb 17 under sprays 20 which apply liquid binderO C)ptionally, tbe binder may be ~pplied by ~eans o~ a cur~ain coater o~ known design.
The ~eb is the~ *rans~erred to an endless travelling band 21 o~ ~tainless steel tens~oaed around rollers 22 and 30 which carries the web through a drying tunnel 23. Thls causes res~dual moistllre to be drive~ o~ and the binder to bond the ~ibres together. Towards the end o~ the .

5~

., -- 1 o -- `i drying tunnel, the web 17 is taken through a pair o~ rolls 24, whose function is to control the thickne~s of the resulting ~lbrous structure without applying pressure.
The resulting sheet material ls then taken in the direction o~ the arrow 25 ~or reeling~

Means ~or option~lly consolidating the material producèd as described above are sho~n in Figure 40 This shows a continuous hot press o~ the steel band type ~Sandvik Conveyors Ltd.) which may be employed to consolidate 10 materlal received directly ~rom the rolls 24 or material which has already been reeled. The press is shown at 30 in Flgure 4 ~herein a pair o~ travelling endless steel bands 31 are each retained around a pair o~ rotating drums 32 and 33. The separatlon between the pair o~ bands 31 15 decreases ~rom the inlet 34 to the outlet 35 and de~ines a i passage, throu~h which the ~eb (not shown) i~ conveyed .
~rom rlght to le~t. Bet~een drums 32 and 33 there are provided 8i~ se$s of roller chains 36a, 36b and 36c arranged in pairs on opposite ~ides oi the passage 20 ad~acent the bænds 31. The lower sets of chains 36a, 36b and 36c are ~i~ed but the upper sets are reciprocally mounted and connected to hydraulic rams 37. In this way, each palr o~ chains 36a, 36b and 36c serves to guide and maintain the bands 31 in position and also to consolidate 25 the web ~h71~t~belng conveyed through the passage.
Bet~een chains 36b and 36c, there are provided two nip rolls 38 which are disposed on opposite sides o~ the passage ad~acent the bands 31; the lower roll being supported by a hydraullc ~ack 39. These rolls 38 ~urther 30 assist in the consolidation of the web. ~ithin ~he setæ
o~ chains 38a and 36b are heating platens 40a and 40b which heat the bands 31 and in turn the web whilst coolin~
platens 40c are dlsposed wlthin the set o~ chains 36c.

il .. . . . . . ... .. . .

5~

Further adYantages o~ the present invention ~111 become apparent from the ~ollowing e~amples. Trade marks are identified with an asterisk.
Example 1 12 kg o~ polypropylene powder (P~C 860~ grade made by I.C.I. Ltd.) a~d 4 kg o~ gla~s ~ibre (~.C. grade, 13 ~
diameter, 12 mm long, were mixed ~lth 1~00 lltreæ o~ ~ater in a ~roth ~lotation cell (Denv~r Equlpme~t Co.) as described in ~.~. Patent~ 1 129 757 and 1 32~ 4090 Su~icient ~oami~g agent (~odium dodecyl benzene .
10 ~ulphonate) ~as added to produce~a ~ine bubbled ~oam with an air ¢ontent of appro~imately 67% by volume~ The ~oamed dlsperslon was then trans~ePred to the headbo~ :Ll o~ the ~pparatus ~hown in'~igure 3.

The suspension was deposited n~to ~he Fourdrlnler wlre 13 15 o~ ~ paper machine, and the water drained uslag the suction ~o~eæ 1~. The ~ibrous web was tran~erred onto the endleæs band 21 o~ polyes*er via the belt 18, but -wlthout the appllcatlon o~ binder, then dried in the tunnel drier 23 at 105C and reeled upO

Z0 A continuou~ hot presæ o~ the type ~hown 1~ Pigur~ 4 ~as heated to a temperature o~ 160~C 1~ the dru~ 32, ri~ing to ZOO-C ln the heatln~ plate~æ ~Oa, and to 270~C 1~ the ' heati~g platens 40b. Cold water ~a~ circulated through the cool~g plat~n~ 40c ~o a~ to maintai~ their 25 temperature at 20~C~ The ~eparatlon bstween the bands 31 ~a~ set at 5 mm at the inlet 34, decrea~ing to 2.3 ~m at the outlet 35. The reeled ~ibrou~ web ~a ~ed in at the inlet 34 at a speed o~ 2.5 m/min, and emerged ~ully con~olidated, ~ith a ~lat ~mooth ~ur~ce. The ultimate 30 te~lle ~trength o~ thi~ materlal ~as ~easured as 60 ~Nm~2.

. . .

s~ i ~ 12 -E~ample 2 A contl~uous web o~ 50% chopped strand glass ~ibre 11 ~m di~meter a~d 13 mi~limetres long and 50% powdered polypropylene by weight were used to prepare a ~oam0d dispersion generally as described in E~ample 1. This disperslo~ was then used to form a web on the wet end o~ a 1~1 metre wide paper-~aki~g machine. The 450 g/m2 moist web was produced at a speed o~ 8 m/min and impregnated by coating on the wire 18 with a lg polyvin~yl 10 alcohol solution to act as a binder. The ~eb ~as;then :
passed directly into a tunnel dryer 23. The ~irst section o~ the dryer ~a6 set at 105C in order to gently .
dry the web, although the subsequent three sections were .
set to 1~0-160C i.e. below the melting point o~ the ., 15 polypropylen0. The emerglng material, consisting o~
polypropylene ~articles retained i~ a web o~ separate glass ~ibreslbo~ded together had sui~icient strength to be~ :
reeled up and could be transported without dislntegration or serious lloss o~ polypropylene po~der~
.

20 The reel6 o~ material ~ere cut into 1.8 metres ~ 008-metres sheets. The sheets ~ere laminated ~ive at a ti~e, at a speed o~ ~.6 m/min ln a continuous double b~lt pre6s (made by Sandvik, Fellbach, ~est Germany). The iirst zo~e o~ the machine waæ 2.6 metres lo~g and oil heated to 25 300C (the ~ample temperature ~210~22UC); the pre~sure applied to the samples ~as 3 ~ar. The second zone o~ the .
machine was water cooled (pressure=2 bar) and the rigid ~ully consolidated ~heets emerged at about 80C, having ;
passed through a phase ~here all the air had been e~pelled ;
30 irom the porou~ web ~corresponding to a density o~
1.33g/cm33. These sheets were capable o~ moulding into seini-~inished artlcles. `~
.:
~.
:, , . ,, . ,, , .. ,, .. ,, . . .... . . . ... ~.. ~.. . .
.

5~.~

~ 13 Example 3 The proc~ss of Example 1 was carried out until the web was deposited on the endless ~and 21. A binder consisting of acrylic latex diluted to 0.75% solids was then applied I
5 by means of a conventional curtain coater (not shown) onto ~l the moving web. Excess latex solution was drawn through the web and recirculated. The web had a substance of 500 grams per square metre and 33 litres peri metre of latex was applied as the web moved at 9 metres per minute on the endless band, 2 litres being retained in each 9 metre length of the web.

Tab]e 1 lists Examples 4 to 10 in which sheets were pre pared gerlerally in accordancei with the process described , in Example 1 using the varlous fibres specified ~n a , matrix formed of polypropylene particles of less than 1 millimetre in size.

Table 2 lists Examples 11 to 21 in which sheets were pre~
pared generally in accordance with the process described in Example 1 using a variety o~ fibres in matrixes formed from three differing thermoplastic polymers.

The various Examples demonstrate the versatility of the invention and its applicability for use with a wide range of reinforcing ~ibres and thermoplastics.

Figure 5 is a graph demonstrating the effect of thermo- ¦
plastic particle siæe on the flexural modulus of consoli-dated sheets, the horizontal axis not being to a consistent scale for clarity of illustration. The graph shows that the flexural modulus begins to fall when the particle si~e is larger than 1 millimetre. ~eyond 1.5 millimetres in size the flexural modulus deteriorates significantly.
.
~.~i. ,, , - 14 - - ~
_ __ ~
~ 'b ~ o u~ n ~ ,~
~ Z ~ X ~ ~ D Z ~ c>
~ _ '_ --I .C H Lr~ OC\ d'-~ ^ a) ~ 0 ~ r X ~ ~ u~ ~ o ~ a~
~ h _ _.
X I~ ~ .
~ ~ . ~
U~ U~ Ul O O O O ~ ~ ~ ~
X ~ ~ ~ ~ ~D ~ N g @ r~ 1 I _ I cC ~ ~ On, O ~ ~ ~
I _ ~ e H V ~
~ ~ O O~ 0 It~
g ~o ~ a~ O

æ ~3 ~ ~ ~ , O ~ O _ 1~ ~ - - -1~ ~ ~ u~ro~ou~u~ .
I ~ S~ *~
~ ~ 13 ~ o~ U~ 8 o l o ~ g~ g ~ ~ P 2 ~ o V~ ~ ~ ~ ~ 3 ~ ~ ~6 3 _ O~ ~ ~ P ~ I o ~ D t lo ~ ~ 0~ 0~ IIS 1'`11 ~ 0 ~ J ~ !1 11 a 1I Y ~ 1l I I ~ ~ I ~i ~ O
1~4 ~, S~ g ~0 g g g ~0 ~ C!~
l ~ C~ D ~
E~l ~ a~ U7 r~
_l 1 I ~ ~ ~
z il .l : : :

EFF CT OF USING
THE ~ OPIL~STICS OI7~ER THAN POLYP:ROP LENE
_ __ _ . _ _ , Composite Gran~nag~Tensile Plexural E~ample Strength ~odulus ~ (g/m2 ) ~Pa) ~MPa) _ ~
1~20~ wt glass in PET3000 74 6100 1220~ wt carbon in PET 2075 121 10860 1340~ wt glass in PET3000 150 10700 , 1420~ wt gla~s in PPO2500 76 4300 15-40~ gla~3 in PPO 2500 116 7000 16.50~ wt glas~ in PPO2500 147 8600 1715~ wt carbon in PPO 2025 79 6750 1820~ wt carbon in PPO 2115 118 9900 1932~ wt carbon in PBT 1850 144 18890 20. 28~ ~t ~las9 ) in PBT 1890 155 135~0 lO~ wt c~rbon) 21~0~ ~t glu~ in P~ 1940 117 10290 , i_.

PET - Polyethylene Terephthalate PBT - Polybutylene Terep~thalate sold as 'Orgator TMNO'*b~ ~tochem UK
PPO = Polyphenylene Oxide sold as 'Noryl' by General Electric Units and fibre dimensions as in Table 1 .~

:~ ' .. .

S~l~

~ 16 Example 22 A polypropylene slurry ~as prepared by dispersing parti-culate polyproylene having a parricule size of less than 1 millimetre in water at 25% solids content in a high shear mixer with a dispersing agent sold under the trade name ' Catafix*'.

The resulting slurry was then further diluted to 7% solids and supplied to the inlet of a fan pump feeding stack to a Rotiformer (Registered Trade Mark). Singe glass fibres 11 micron diameter, 13 millimetres long were simultaneously fed to the fan pump inlet at a ratio of 40% by weight of the polypropylene.

The sheet formed on the Rotiformer was then spray treated with an acrylic latex binder diluted to 0.75% solids and reeled up. When subsequently consolidated, the sheet was seen to have a poorer formation than the sheets o Examples 1 and 2, although still acceptable. When consolida~ed the sheet had a substance of 562 grams per square metre on average (as between machine and cross directions) fIexural modulus of 6603 Mega Pascals and tensile strength of 53 Mega Pascals.

When the sheets remain permeable they can be subsequently moulded to shape by heating to a moulding temperature by the passage of hot air through the sheet and then subject-ing it to a moulding pr~cess as described in theApplicants So~pending Ca~aian ~atent Application No.
471r525 File~ 4th January 1985.

~) ' .,.
';
. . .
.: : .
: ~ "' ,

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. An air permeable sheet-like structure essentially of 20% to 60% by weight of single discrete reinforcing fibres having a modulus of elasticity higher than 10,000 mega pascals, and being between about 7 and about 50 millimetres long, and 40% to 80% by weight of unconsolidated particulate plastics material, the particulate plastics material having a particle size less than about 1.5 millimetres, and in which the fibrous and plastics components are bonded into an air permeable structure with the particulate plastics material retaining its particulate form in the air permeable structure.

2. An air permeable sheet like structure as claimed in claim 1 in which the particulate plastics material includes plastics material fibres.

3. An air permeable sheet like structure as claimed in claim 1 in which the components are bonded together by surface fusion of the particulate plastics material.

4. An air permeable sheet like structure comprising 20% to 60% by weight of single discrete reinforcing fibres having a modulus of elasticity higher than 10,000 mega pascals, and being between about 7 and about 50 millimetres long, and 40% to 80% by weight of unconsolidated particulate plastics material, selected from the group consisting of a thermoplastic and a thermosetting plastic material, the particulate plastics material having a particle size less than about 1.5 millimetres, and in which the fibrous and plastics components are bonded into an air per-meable structure with the particulate plastics material retaining its particulate form in the air permeable structure, in which the components are bonded together by a binder, in which the binder is selected from the group consisting of polyvinyl alcohol, polyvinyl acetate, carboxymethyl cellulose and starch.

5. An air permeable sheet like structure as claimed in claim 1 in which the fibres are glass fibres having a diameter of 13 microns or less.

6. An air permeable sheet like structure as claimed in claim 1 in which the plastics material is selected from the group consisting of a thermoplastic and a thermosetting plastic.

7. An air permeable sheet-like structure as claimed in claim 6 in which the plastics material is a thermoplastic material and is selected from the group consisting of polyethylene, polypropylene, polystyrene, acrylonitrylstyrene butadiene, polyethylene terephthalate, and polyvinyl chloride.

8. An air permeable sheet like structure as claimed in claim 1 in which the particles constituting the particulate plastics material are smaller than about 1 millimeter in size.

9. An air permeable sheet like structure as claimed in claim 8 in which the particles constituting the particulate plastics material are smaller than about 1 millimeter in size.

10. An air permeable sheet like structure as claimed in claim 1 in which the degree of bonding is controlled to cohere the components while still retaining sufficient flexibility to permit the structure to be reeled.

11. An air permeable sheet like structure as claimed in claim 1 in which the degree of bonding is controlled to produce a rigid but air permeable sheet.

12. An air permeable sheet like structure as claimed in claim 1 which has been coated or impregnated with a liquid thermosetting resin.

13. An air permeable sheet like structure as claimed in claim 12 in which said thermosetting resin is selected from the group consisting of phenolic and polyester resins.

14. An air permeable sheet like structure as claimed in claim 13 in which the resins are selected from the group consisting of phenol-formaldehyde resin, urea and melamine formaldehyde resins, epoxy resins, unsaturated polyesters and polyurethanes.

15. An air permeable sheet like structure as claimed in claim 5, in which the plastics material comprises a mixture of thermoplastic and thermosetting plastic.

16. An air permeable sheet like structure as claimed in claim 6 in which the plastics material is plasticised.

17. A process for the manufacture of a permeable sheet like fibrous structure which consists essentially of forming a web with 20% to 60% of single discrete fibres having a modulus of elasticity higher than 10,000 mega pascals and between 7 and 50 millimetres long, and 40% to 60%
by weight of unconsolidated plastics material selected from the group consisting of a thermoplastic and a thermosetting plastic material, the particulate plastics material having a particle size less than about 1.5 millimetres, and then treating the web to bond the fibres and plastics material together while maintaining the particulate form of the plastic material.

18. A process as claimed in claim 17 in which the particulate plastics material includes short plastics material fibres.

19. A process as claimed in claim 17 in which the components are bonded together by surface fusion of the particulate plastics material.

20. A process as claimed in claim 17 which the components are bonded together by a binder added during formation of the web.

21. A process as claimed in claim 17 in which the binder is selected from the group consisting of polyvinyl alcohol, polyvinyl acetate, carboxymethyl cellulose and starch.

22. A process as claimed in claim 17 in which the fibres are glass fibres having a diameter smaller than about 13 microns.

23. A process as claimed in claim 17 in which the plastics material is selected from the group consisting of a thermoplastic and a thermosetting plastic.

24. A process as claimed in claim 23 in which the plastics material is a thermoplastic material and is selected from the group consisting of polyethylene, polypropylene, polystyrene, acrylonitrylstyrene butadiene, polyethylene terephthalate, and polyvinyl chloride, both plasticised and unplasticised.

25. A process as claimed in claim 17 in which the degree of bonding is controlled to cohere the components while still retaining sufficient flexibility to permit the structure to be reeled.

26. A process as claimed in claim 17 in which the degree of bonding is controlled to produce a rigid but air permeable sheet.

27. A process as claimed in claim 17 in which the permeable sheet like structure is coated or impregnated with a liquid thermosetting resin.

28. A process as claimed in claim 27 in which the said thermosetting resin includes phenolic and polyester resins.

29. A process as claimed in claim 17 in which the web is made using a dry laying technique and a binder after the web has been formed.

30. A process as claimed in claim 17 in which the plastics content of the fibrous structure is wholly of thermoplastics material and the structure is subjected to heating and cooling under pressure to effect consolidation.

31. A process as claimed in claim 17 in which the sheet is subsequently moulded to a predetermined shape.

32. A process as claimed in claim 17 which includes forming the web on a paper making machine.