Thermoplastic composite, method for preparing thermoplastic composite, and panel

Patent metadata

Field	Value
Publication number	US-2020032012-A1
Application number	US-201716337088-A
Country	US
Kind code	A1
Filing date	Jun 21, 2017
Priority date	Sep 29, 2016
Publication date	Jan 30, 2020
Grant date	—

Abstract

Provided are a thermoplastic composite and a preparation method therefor, the composite comprising: a fiber structure having a network structure comprising at least one layer of fiber woven sheet; thermoplastic resin particles having a particle diameter of 1-50 μm; and a particulate flame retardant, wherein the thermoplastic resin particles and the particulate flame retardant are impregnated into the fiber structure. In addition, a panel comprising a thermo-compressed product of the thermoplastic composite is provided.

First claim

1 . A thermoplastic composite material, comprising:
a fiber structure having a network structure that includes one or more layers of fiber woven sheets; thermoplastic resin particles that have particle diameters of 1 μm to 50 μm; and particulate flame retardants, wherein the thermoplastic resin particles and particulate flame retardants are impregnated into the fiber structure.

2 . The thermoplastic composite material of claim 1 , wherein the fiber woven sheet has a satin weave structure, a twill weave structure or a plain weave structure.

3 . The thermoplastic composite material of claim 1 , wherein the fiber structure having a network structure has a structure in which two or more of the fiber woven sheets are stacked alternately, isotropically, orthogonally, asymmetrically and orthogonally, or asymmetrically.

4 . The thermoplastic composite material of claim 1 , wherein the fiber woven sheet includes any one selected from a group consisting of glass fiber, cerakwool fiber, mineral fiber, carbon fiber and a combination thereof.

5 . The thermoplastic composite material of claim 1 , wherein fiber of the fiber woven sheet has a cross section with average diameters of 5 μm to 20 μm.

6 . The thermoplastic composite material of claim 1 , wherein the thermoplastic resin particles and the particulate flame retardants are dry-impregnated into the fiber structure.

7 . The thermoplastic composite material of claim 1 , wherein the thermoplastic resin particle includes any one selected from a group consisting of polypropylene, polystyrene, acrylonitrile butadiene styrene (ABS), polymethyl meta acrylate (PMMA), polyethylen glycol (PEG), thermoplastic poly urethane (TPU), polydimethylsiloxane (PDMS), high density polyethylene (HDPE), low density polyethylene (LDPE), high impact polystyrene (HIPS), poly lactic acid (PLA), polyethylene oxide (PEO) and a combination thereof.

8 . The thermoplastic composite material of claim 1 , wherein the particulate flame retardant has particle diameters of 1 μm to 10 μm.

9 . The thermoplastic composite material of claim 1 , wherein the particulate flame retardant has specific gravity of 1 to 3.

10 . The thermoplastic composite material of claim 1 , wherein the particulate flame retardant includes a phosphorus-based flame retardant, a nitrogen-based flame retardant or a phosphorus and nitrogen-based flame retardant.

11 . The thermoplastic composite material of claim 1 , wherein the thermoplastic composite material includes 20 to 30 parts by weight of the particulate flame retardant with respect to 100 parts by weight of the thermoplastic resin particle.

12 . A method for manufacturing a thermoplastic composite material, comprising:
manufacturing a fiber structure having a network structure including one or more layers of fiber woven sheets; manufacturing a thermoplastic resin particle having particle diameters of 1 μm to 50 μm; dry-mixing the thermoplastic resin particle and a particulate flame retardant; and impregnating the mixed thermoplastic resin particle and particulate flame retardant into the fiber structure.

13 . The method for manufacturing a thermoplastic composite material of claim 12 , the step of manufacturing a thermoplastic resin particle having particle diameters of 1 μm to 50 μm, comprising:
inserting a thermoplastic resin into an extruder;
forming melted thermoplastic resin spray liquid from the thermoplastic resin; and
obtaining a thermoplastic resin particle having particle diameters of 1 μm to 50 μm by Attorney Docket No. 5230-0863 spraying the melted thermoplastic resin spray liquid through a spraying nozzle and simultaneously cooling the same.

14 . The method for manufacturing a thermoplastic composite material of claim 13 ,
the step of forming melted thermoplastic resin spray liquid from the thermoplastic resin, comprising: transferring the thermoplastic resin to a spraying nozzle; and heating the thermoplastic resin in the spraying nozzle and forming melted thermoplastic resin spray liquid.

15 . The method for manufacturing a thermoplastic composite material of claim 13 , wherein the melted thermoplastic resin spray liquid is injected into the spraying nozzle together with air.

16 . The method for manufacturing a thermoplastic composite material of claim 12 , wherein the step of dry-mixing the thermoplastic resin particle and a particulate flame retardant is performed using a ball-milling method.

17 . The method for manufacturing a thermoplastic composite material of claim 12 , wherein the step of impregnating the mixed thermoplastic resin particle and particulate flame retardant into the fiber structure comprises dispersing the thermoplastic resin particle and particulate flame retardant on the fiber structure and allowing the same into meshes in a network structure of the fiber structure.

18 . A panel, comprising a thermo-compressed product of the thermoplastic composite material according to claim 1 .

Assignees

• Lg Hausys Ltd

Inventors

• Kang Kyoung-Min
• Kang Sung-Yong
• Kim Min-Gyung
• Park Chang-Young
• Lim Jae-Ho

Classifications

• C08J5/04 Primary

  Reinforcing macromolecular compounds with loose or coherent fibrous material · CPC title

• B32B5/26

  another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} · CPC title

• C08J3/201

  Pre-melted polymers · CPC title

• C08L101/00

  Compositions of unspecified macromolecular compounds · CPC title

• C08J3/203

  Solid polymers with solid and/or liquid additives · CPC title