Fiber Reinforced Polymeric Composites and Methods of Making the Same

Abstract

The present invention provides sizing compositions and methods of using the same for glass fibers used in reinforced polymeric composites produced by reactive processing techniques.

That which is claimed is: 
     
         1 - 27 . (canceled) 
     
     
         28 . A method of making a glass fiber reinforced composite comprising:
 providing at least one glass fiber at least partially coated with a sizing composition, the sizing composition comprising a polymerization activator, a polymerization activator precursor or a combination thereof;   at least partially contacting the at least one coated glass fiber with a composition comprising polymer precursors; and   polymerizing the polymer precursors to produce a polymeric material in which the at least one glass fiber is disposed.   
     
     
         29 . The method of  claim 28 , wherein the polymerization activator or polymerization activator precursor comprises a blocked isocyanate. 
     
     
         30 . The method of  claim 28 , wherein the sizing composition further comprises a silane. 
     
     
         31 . The method of  claim 28 , wherein the sizing composition further comprises a protective component. 
     
     
         32 . The method of  claim 31 , wherein the protective component comprises a film former, a lubricant or a combination thereof. 
     
     
         33 . The method of  claim 28 , wherein polymerizing the polymer precursors to produce a polymeric material comprises anionically polymerizing lactams to produce an anionically polymerized polyamide. 
     
     
         34 . The method of  claim 28 , wherein polymerizing the polymer precursors to produce a polymeric material comprises polymerizing polyurethane precursors to produce a polyurethane. 
     
     
         35 . A method of making a glass fiber reinforced composite comprising:
 providing at least one glass fiber at least partially coated with a sizing composition, the sizing composition comprising a polymerization activator, a polymerization activator precursor or a combination thereof;   at least partially contacting the at least one coated glass fiber with polyamide precursors; and   polymerizing the polyamide precursors to produce a polymeric material in which the at least one glass fiber is disposed.   
     
     
         36 . The method of  claim 35 , wherein the polyamide precursors comprise one or more lactams. 
     
     
         37 . The method of  claim 35 , wherein the polymerization activator or polymerization activator precursor comprises a blocked isocyanate. 
     
     
         38 . The method of  claim 35 , wherein the sizing composition further comprises a silane. 
     
     
         39 . A method of producing a fiber reinforced polyamide composite comprising:
 providing at least one glass fiber at least partially coated with a sizing composition comprising a silane and a protective component;   at least partially contacting the at least one coated glass fiber with polyamide precursors; and   anionically polymerizing the polyamide precursors to produce a polyamide in which the at least one glass fiber is disposed.   
     
     
         40 . The method of  claim 39 , wherein the polyamide precursors comprise one or more lactams. 
     
     
         41 . The method of  claim 39 , wherein the silane is present in the sizing composition in an amount of at least about 2 weight percent on a total solids basis. 
     
     
         42 . The method of  claim 39 , wherein the protective component comprises a film former, a lubricant or a combination thereof. 
     
     
         43 . The method of  claim 39 , wherein the sizing composition further comprises a polymerization activator or polymerization activator precursor comprising a blocked isocyanate.