Claims
- 1. A composite article formed by:(a) placing in a mold a continuous linearly intermixed fiber tow comprising an intimately, uniformly and continuously intermixed blend of (i) about 90 to about 30% by volume, based on the total fiber content, of spun, continuous, individual, thermoplastic polymer fibers having a melting point of at least 50° C. (ii) as about 10 to about 70% by volume, based on the total fiber content, of continuous, individual carbon fibers wherein there is substantially uniform distribution of the thermoplastic fibers and the carbon fibers within the intermixed tow; and (b) heating the tow under pressure to the flow temperature of the thermoplastic polymer fibers.
- 2. A composite article formed at least in part by consolidating a continuous, linearly intermixed fiber tow comprising an intimately, uniformly and continuously intermixed blend of (i) about 90 to about 30% by volume, based on the total fiber content, of spun, continuous, individual, thermoplastic polymer fibers having a melting point of at least 50° C. and (ii) about 10 to about 70% by volume, based on the total fiber content, of continuous, individual carbon fibers wherein there is substantially uniform distribution of the thermoplastic fibers and the carbon fibers within the intermixed tow.
- 3. The composite article of claim 2, wherein the composite article is in the shape of a tennis racquet frame.
- 4. The composite article of claim 2, wherein the composite article is in the shape of a racquetball racquet frame.
- 5. The composite article of claim 2, wherein the composite article is in the shape of a hockey stick.
- 6. The composite article of claim 2, wherein the composite article is in the shape of a ski pole.
- 7. The composite article of claim 2, wherein the composite article is in the shape of a fishing rod.
- 8. The composite article of claim 2, wherein the composite article is in the shape of a golf club shaft.
- 9. The composite article of claim 2, wherein the composite article is in the shape of a spacecraft structural component.
- 10. The composite article of claim 2, wherein the composite article is in the shape of an airplane structural component.
- 11. The composite article of claim 2, wherein the composite article is in the shape of an automobile structural component.
- 12. A consolidated filament-wound composite formed at least in part from a continuous, linearly intermixed fiber tow comprising an intimately, uniformly and continuously intermixed blend of (i) about 90 to about 30% by volume, based on the total fiber content, of spun, continuous, individual, thermoplastic polymer fibers having a melting point of at least 50° C. and (ii) about 10 to about 70% by volume, based on the total fiber content, of continuous, individual, carbon fibers wherein there is substantially uniform distribution of the thermoplastic fibers and the carbon fibers within the intermixed tow.
- 13. A woven fabric formed at least in part from a continuous, linearly intermixed fiber tow comprising an intimately, uniformly and continuously intermixed blend of (i) about 90 to about 30% by volume, based on the total fiber content, of spun, continuous, individual, thermoplastic polymer fibers having a melting point of at least 50° C. and (ii) about 10 to about 70% by volume based on the total fiber content, of continuous, individual, carbon fibers wherein there is substantially uniform distribution of the thermoplastic fibers and the carbon fibers within the intermixed tow.
- 14. A composite article formed by:(a)placing in a mold a woven fabric formed at least in part from a continuous, linearly intermixed fiber tow comprising an intimately, uniformly and continuously intermixed blend of (i) about 90 to about 30% by volume, based on the total fiber content, of spun, continuous, individual, thermoplastic polymer fibers having a melting point of at least 50° C. and (ii) about 10 to about 70% by volume, based on the total fiber content, of continuous, individual, carbon fibers wherein there is substantially uniform distribution of the thermoplastic fibers and the carbon fibers within the intermixed tow; and (b) heating the woven fabric under pressure to the flow temperature of the thermoplastic polymer fibers.
Parent Case Info
This is a division of application Ser. No. 07/975,141, filed Nov. 12, 1992, now U.S. Pat. No. 6,045,906, which is a continuation of application Ser. No. 07/657,348, filed Feb. 15, 1991, now abandoned, which, in turn, is a continuation of application Ser. No. 06/770,376, filed Aug. 29, 1985, now abandoned, which, in turn, is a continuation of application Ser. No. 06/589,825, filed Mar. 15, 1984, now abandoned.
US Referenced Citations (95)
Foreign Referenced Citations (22)
Number |
Date |
Country |
828935 |
Nov 1975 |
BE |
828936 |
Nov 1975 |
BE |
894875 |
Feb 1983 |
BE |
2204119 |
Jan 1972 |
DE |
2166629 |
Dec 1974 |
DE |
2520819 |
Nov 1975 |
DE |
2520820 |
Nov 1975 |
DE |
2722120 |
Dec 1977 |
DE |
2834535 |
Feb 1979 |
DE |
2834536 |
Feb 1979 |
DE |
2834533 |
Feb 1980 |
DE |
2834537 |
Sep 1989 |
DE |
0033244 |
May 1981 |
EP |
2446336 |
Sep 1980 |
FR |
1200342 |
Jul 1970 |
GB |
1228573 |
Mar 1971 |
GB |
2090882 |
Jul 1982 |
GB |
2093768 |
Sep 1982 |
GB |
31-10871 |
Jan 1976 |
JP |
02-132116 |
May 1990 |
JP |
03-021293 |
Jan 1991 |
JP |
7505551 |
Nov 1975 |
NL |
Non-Patent Literature Citations (4)
Entry |
Robert M. Baucom, “Solventless Fabrication of Reinforced Composites”; NASA Technology Briefs, Fall 1982 LAR-12856. |
Bier, “Polyarylates . . . bisphenols”; Polymer, vol. 15, Aug. 1974, 527-535. |
Modern Plastics, Jul. 1975, vol. 52, No. 7, pp. 62-63. |
Storm et al., “Poly . . . Molding”; Coatings and Plastics, Preprint, L.A. Mtg. Apr. 1974, vol. 34, No. 1; pp. 194-197. |
Continuations (3)
|
Number |
Date |
Country |
Parent |
07/657348 |
Feb 1991 |
US |
Child |
07/975141 |
|
US |
Parent |
06/770376 |
Aug 1985 |
US |
Child |
07/657348 |
|
US |
Parent |
06/589825 |
Mar 1984 |
US |
Child |
06/770376 |
|
US |