Method of preparing fiber-reinforced polymer composites and fiber-reinforced polymer composites prepared thereof

Abstract

A method of preparing a fiber-reinforced polymer composite is provided. The method includes (a) providing a swollen clay material; (b) chemically modifying a surface of the swollen clay material with an organosilane to form a silane-modified clay material; (c) intercalating the silane-modified clay material with a binder to form an intercalated clay material; and (d) melt compounding the intercalated clay material with a mixture comprising a polymer and fiber to form the fiber-reinforced polymer composite. A fiber-reinforced polymer composite is also provided.

1 - 23 . (canceled) 
     
     
         24 . A fiber-reinforced polymer composite comprising discrete, elongated pieces of fiber and an intercalated clay material comprising a silane-modified clay material that is intercalated with a binder, wherein the intercalated clay material is dispersed along with the fiber in a polyamide polymer and wherein an amount of clay in the fiber-reinforced polymer composite is in the range of 1 wt % to 5 wt %. 
     
     
         25 . The fiber-reinforced polymer composite according to  claim 24 , wherein clay in the silane-modified clay material comprises montmorillonite clay. 
     
     
         26 . The fiber-reinforced polymer composite according to  claim 24 , wherein amount of silane in the silane-modified clay material is in the range of about 1 wt % to about 25 wt % of clay. 
     
     
         27 . The fiber-reinforced polymer composite according to  claim 24 , wherein the binder comprises an epoxy resin. 
     
     
         28 . The fiber-reinforced polymer composite according to  claim 24 , wherein amount of binder in the silane-modified clay material is in the range of about 30 wt % to about 90 wt % of clay. 
     
     
         29 . The fiber-reinforced polymer composite according to  claim 24 , wherein fiber in the fiber-reinforced polymer composite comprises glass. 
     
     
         30 . The fiber-reinforced polymer composite according to  claim 24 , wherein amount of clay in the fiber-reinforced polymer composite is in the range of about 1 wt % to about 5 wt %. 
     
     
         31 . The fiber-reinforced polymer composite according to  claim 24 , wherein amount of fiber in the fiber-reinforced polymer composite is in the range of about 10 wt % to about 20 wt %.