Process for molding a fiberglass reinforced article

A process for producing fiberglass reinforced molded articles of superior surface quality involves preparation of a mat of glass fiber comprised of a majority of fibers having a diameter of less than one micron and a minority of fibers having a diameter greater than one micron. A sizing is applied to the fibers. The sizing includes a coupling agent preselected to be compatible with the moldable material, e.g. nylon. The glass fiber mat is comminuted into pieces shaped and dimensioned for combination with the moldable material to form a composite having a range of to 50% of glass fiber by weight. The composite is then molded by a conventional process to yield a fiberglass reinforced article with superior surface quality.

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Claims

4. The process of claim 1 wherein the smaller diameter glass fibers have diameters in the range of 0.2 to 1 micron.

5. The process of claim 1 wherein the article is injection molded.

6. The process of claim 1 wherein the moldable.Iadd.plastic.Iaddend.material is a thermoplastic resin.

7. The process of claim 1 wherein the moldable.Iadd.plastic.Iaddend.material is a thermosetting resin.

11. An article made in accordance with the process of claims 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10.

14. The process as defined in claim 13 wherein said sizing comprises an aqueous emulsion.

Referenced Cited
U.S. Patent Documents
3932573 January 13, 1976 Kucsma et al.
4666645 May 19, 1987 Prewo et al.
4801626 January 31, 1989 Auerbach et al.
4886701 December 12, 1989 Ehnert et al.
4892695 January 9, 1990 Bainbridge et al.
4913956 April 3, 1990 Fay et al.
4927579 May 22, 1990 Moore
4946738 August 7, 1990 Chenoweth et al.
4957415 September 18, 1990 Paul et al.
Patent History
Patent number: RE35984
Type: Grant
Filed: Nov 1, 1994
Date of Patent: Dec 8, 1998
Assignee: Johns Manville International, Inc. (Denver, CO)
Inventors: James A. Fadell (Toledo, OH), Stephen E. Gross (Littleton, CO)
Primary Examiner: Christopher W. Raimund
Attorney: Robert D. Touslee
Application Number: 8/332,675