公开(公告)号：US12070933B2

公开(公告)日：2024-08-27

申请号：US17533333

申请日：2021-11-23

申请人： JOHNS MANVILLE

发明人： Mingfu Zhang ,  Jawed Asrar

IPC分类号： B32B5/28 ,  B29C70/12 ,  B29C70/50 ,  B32B27/12

CPC分类号： B32B5/28 ,  B29C70/12 ,  B29C70/506 ,  B29C70/508 ,  B32B27/12 ,  B32B2260/021 ,  B32B2260/046 ,  B32B2262/101

摘要： A chopped roving thermoplastic composite sheet includes a web or mesh of chopped rovings and a thermoplastic resin that fully saturates the web or mesh of chopped rovings. The web or mesh of chopped rovings is not mechanically bonded and does not include a binder that bonds or adheres the chopped rovings together other than thermoplastic resin. As such, the thermoplastic resin and the web or mesh of chopped rovings are able to flow and conform to a mold or cavity when the chopped roving thermoplastic composite sheet is pressed within the mold or cavity and when the chopped roving thermoplastic composite sheet is heated to above the melting temperature of the thermoplastic resin.

公开(公告)号：US11952689B2

公开(公告)日：2024-04-09

申请号：US17012471

申请日：2020-09-04

申请人： JOHNS MANVILLE

发明人： Zhihua Guo ,  Uranchimeg Lester ,  Jawed Asrar ,  Kiarash Alavi ,  Mingfu Zhang

IPC分类号： D04H1/64 ,  C08K7/14 ,  C08L3/02 ,  C08L61/20 ,  C08L61/24 ,  C08L61/32 ,  C09J101/28 ,  C09J103/02 ,  C09J105/00 ,  D04H1/4218 ,  D04H1/4242 ,  D04H1/587 ,  D04H13/00 ,  D21H13/40 ,  D21H17/20 ,  D21H23/48

CPC分类号： D04H13/008 ,  C08K7/14 ,  C08L3/02 ,  C08L61/20 ,  C08L61/24 ,  C08L61/32 ,  C09J101/28 ,  C09J101/286 ,  C09J103/02 ,  C09J105/00 ,  D04H1/4218 ,  D04H1/4242 ,  D04H1/587 ,  D04H1/64 ,  D21H13/40 ,  D21H17/20 ,  D21H23/48 ,  Y10T442/604 ,  C09J105/00 ,  C08K7/14 ,  C09J103/02 ,  C08K7/14 ,  C09J101/28 ,  C08K7/14 ,  C09J101/286 ,  C08K7/14 ,  C09J101/286 ,  C08K7/14 ,  C08L61/32 ,  C09J103/02 ,  C08K7/14 ,  C08L61/32 ,  C09J105/00 ,  C08K7/14 ,  C08L61/32 ,  C09J101/28 ,  C08K7/14 ,  C08L61/32

摘要： Processes of making a non-woven glass fiber mat are described. The process may include forming an aqueous dispersion of fibers. The process may also include passing the dispersion through a mat forming screen to form a wet mat. The process may further include applying a carbohydrate binder composition to the wet mat to form a binder-containing wet mat. The binder compositions may include a carbohydrate, a nitrogen-containing compound, and a thickening agent. The binder compositions may have a Brookfield viscosity of 7 to 50 centipoise at 20° C. The thickening agents may include modified celluloses such as hydroxyethyl cellulose (HEC) and carboxymethyl cellulose (CMC), and polysaccharides such as xanthan gum, guar gum, and starches. The process may include curing the binder-containing wet mat to form the non-woven glass fiber mat.

公开(公告)号：US11850809B2

公开(公告)日：2023-12-26

申请号：US17524561

申请日：2021-11-11

申请人： JOHNS MANVILLE

发明人： Mingfu Zhang ,  Klaus Friedrich Gleich ,  Asheber Yohannes ,  Michael John Block ,  Jawed Asrar ,  Derek Cooper Bristol ,  Christopher P Sandoval ,  Matthew Walp ,  Edwing Chaparro-Chavez ,  Stanislav O Kukatin ,  Albert Patrick Faulkinbury ,  Christopher McBride ,  Bradley Ray Lockwood ,  Nicholas Gene Fitzpatrick

IPC分类号： B29C70/50 ,  B05C5/02 ,  B05C9/12 ,  B05C9/14 ,  B05C11/02 ,  B29B15/12 ,  B32B5/28 ,  B05C9/10 ,  B05D1/40 ,  B05D3/02 ,  B29B11/12 ,  B29B11/16 ,  B29B13/02 ,  B29B13/06 ,  B29B15/14 ,  B29C70/06 ,  C08J3/24 ,  C08J5/24 ,  C08K7/14 ,  C08L77/02 ,  D06M15/51 ,  D06M15/61 ,  D06M15/71 ,  B29K33/00 ,  B29K105/08 ,  B29K105/00 ,  B29L7/00 ,  B29L9/00 ,  D06M15/705

CPC分类号： B29C70/50 ,  B05C5/0245 ,  B05C5/0254 ,  B05C9/10 ,  B05C9/12 ,  B05C9/14 ,  B05C11/021 ,  B05D1/40 ,  B05D3/0227 ,  B05D3/0272 ,  B29B11/12 ,  B29B11/16 ,  B29B13/02 ,  B29B13/06 ,  B29B15/12 ,  B29B15/122 ,  B29B15/14 ,  B29C70/06 ,  B29C70/504 ,  B32B5/28 ,  C08J3/242 ,  C08J3/247 ,  C08J5/24 ,  C08K7/14 ,  C08L77/02 ,  D06M15/51 ,  D06M15/61 ,  D06M15/71 ,  B29K2033/12 ,  B29K2105/089 ,  B29K2105/0872 ,  B29K2105/256 ,  B29L2007/002 ,  B29L2009/00 ,  D06M15/705 ,  Y10T442/2992

摘要： According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.

公开(公告)号：US20230405877A1

公开(公告)日：2023-12-21

申请号：US18239418

申请日：2023-08-29

申请人： JOHNS MANVILLE

发明人： Mingfu Zhang ,  Jawed Asrar

IPC分类号： B29B11/16 ,  B29B11/12

CPC分类号： B29B11/16 ,  B29B11/12 ,  B29K2101/12

摘要： A thermoplastic composite sheet may be composed of a polymer material matrix and a lightweight material that is disposed throughout the polymer material matrix. The polymer material matrix may extend continuously throughout a length, width, and thickness of the thermoplastic composite sheet. The polymer material matrix may be a fully polymerized thermoplastic material. The lightweight material may be fully saturated by the thermoplastic material of the polymer material matrix. The thermoplastic composite sheet may include between 50 and 99 weight percent of the thermoplastic material and between 1 and 50 weight percent of the lightweight material. The thermoplastic composite sheet may be free of reinforcing fibers.

公开(公告)号：US11820044B2

公开(公告)日：2023-11-21

申请号：US17369025

申请日：2021-07-07

申请人： JOHNS MANVILLE

发明人： Mingfu Zhang ,  Jawed Asrar

IPC分类号： C08J9/32 ,  B29B11/16 ,  B29B11/12 ,  B29K101/12 ,  B29K509/08

CPC分类号： B29B11/16 ,  B29B11/12 ,  B29K2101/12 ,  B29K2509/08 ,  B29K2995/0063

摘要： A thermoplastic composite sheet may be composed of a polymer material matrix and a lightweight material that is disposed throughout the polymer material matrix. The polymer material matrix may extend continuously throughout a length, width, and thickness of the thermoplastic composite sheet. The polymer material matrix may be a fully polymerized thermoplastic material. The lightweight material may be fully saturated by the thermoplastic material of the polymer material matrix. The thermoplastic composite sheet may include between 50 and 99 weight percent of the thermoplastic material and between 1 and 50 weight percent of the lightweight material. The thermoplastic composite sheet may be free of reinforcing fibers.

公开(公告)号：US20230027108A1

公开(公告)日：2023-01-26

申请号：US17901117

申请日：2022-09-01

申请人： JOHNS MANVILLE

发明人： Mingfu Zhang ,  Jawed Asrar

IPC分类号： B29C70/50 ,  B05C9/12 ,  B05C9/14 ,  B05C11/02 ,  B05D1/40 ,  B05D3/02 ,  B29B11/12 ,  B29B11/16 ,  B29B13/02 ,  B29B13/06 ,  B29B15/12 ,  B29B15/14 ,  B29C70/06 ,  C08J5/04 ,  C08K7/04 ,  D06M15/71 ,  D06M15/705 ,  D06M15/61 ,  D06M15/51 ,  B05C9/10 ,  B29C48/285 ,  C08J5/24

摘要： A thermoplastic prepreg includes a mat, web, or fabric of fibers and hollow glass microspheres that are positioned atop the mat, web, or fabric of fibers or dispersed therein. The thermoplastic prepreg also includes a thermoplastic polymer that is fully impregnated through the mat, web, or fabric of fibers and the hollow glass microspheres so that the thermoplastic prepreg has a void content of less than 3% by volume of the thermoplastic prepreg. The thermoplastic material is polymerized monomers and oligomers in which greater than 90% by weight of the monomers or oligomers react to form the thermoplastic material.

公开(公告)号：US20210402730A1

公开(公告)日：2021-12-30

申请号：US17470480

申请日：2021-09-09

申请人： JOHNS MANVILLE

发明人： Mingfu Zhang ,  Jawed Asrar

IPC分类号： B32B1/08 ,  B32B5/12 ,  B32B27/12 ,  B29C70/32 ,  B29C65/00 ,  B29C70/38 ,  B29C53/56 ,  F03D1/06

摘要： A thermoplastic product includes a fabric-based reinforcing sheet and a polymerized thermoplastic material. The fabric-based reinforcing sheet is wound about a mandrel to form a plurality of layers having a cross-sectional shape that corresponds to the mandrel. The fabric-based reinforcing sheet includes a plurality of fiber bundles, which may have a bidirectional orientation or configuration. A polymerized thermoplastic material is disposed within each layer of the fabric-based reinforcing sheet. The polymerized thermoplastic material bonds each layer of the fabric-based reinforcing sheet to an adjacent layer.

公开(公告)号：US20210299978A1

公开(公告)日：2021-09-30

申请号：US16833794

申请日：2020-03-30

申请人： JOHNS MANVILLE

发明人： Malay Nandi ,  Mingfu Zhang ,  Lance Wang ,  Jawed Asrar

IPC分类号： B29C70/50 ,  B29B15/12 ,  B32B5/18 ,  B32B5/24 ,  B29B11/16

摘要： A system for manufacturing a thermoplastic prepreg product includes a belt or conveyor, a prepreg applicator that positions a thermoplastic prepreg atop the belt or conveyor, a foam applicator that applies a foam mixture atop the thermoplastic prepreg, a heating mechanism that heats the thermoplastic prepreg and the foam mixture to cause the foam mixture to react atop the thermoplastic prepreg, and a laminator that is configured to press the thermoplastic prepreg and foam mixture to control a thickness of the resulting thermoplastic prepreg product. The thermoplastic prepreg includes a fabric, mat, or web of fibers and a thermoplastic material that is impregnated within the fabric, mat, or web of fibers. The thermoplastic material is formed from in situ polymerization of monomers and oligomers. The foam mixture includes an isocyanate, a polyol blend, and a blowing agent.

公开(公告)号：US20210001599A1

公开(公告)日：2021-01-07

申请号：US16460603

申请日：2019-07-02

申请人： JOHNS MANVILLE

发明人： Mingfu Zhang ,  Jawed Asrar

IPC分类号： B32B5/28 ,  B32B27/12

摘要： A chopped roving thermoplastic composite sheet includes a web or mesh of chopped rovings and a thermoplastic resin that fully saturates the web or mesh of chopped rovings. The web or mesh of chopped rovings is not mechanically bonded and does not include a binder that bonds or adheres the chopped rovings together other than thermoplastic resin. As such, the thermoplastic resin and the web or mesh of chopped rovings are able to flow and conform to a mold or cavity when the chopped roving thermoplastic composite sheet is pressed within the mold or cavity and when the chopped roving thermoplastic composite sheet is heated to above the melting temperature of the thermoplastic resin.

公开(公告)号：US20200368979A1

公开(公告)日：2020-11-26

申请号：US16990723

申请日：2020-08-11

申请人： JOHNS MANVILLE

发明人： Mingfu Zhang ,  Klaus Friedrich Gleich ,  Asheber Yohannes ,  Michael John Block ,  Jawed Asrar ,  Derek Cooper Bristol ,  Christopher P. Sandoval

IPC分类号： B29C70/50 ,  D06M15/51 ,  D06M15/61 ,  D06M15/71 ,  C08K7/14 ,  C08J3/24 ,  C08J5/24 ,  C08L77/02 ,  B05C9/10 ,  B05C9/12 ,  B05C9/14 ,  B05C11/02 ,  B05D1/40 ,  B05D3/02 ,  B29B13/02 ,  B29B13/06 ,  B29B15/12 ,  B29B15/14 ,  B29C70/06 ,  B29B11/12 ,  B29B11/16

摘要： According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.