Long‐fiber‐reinforced thermoplastic matrix composites by slurry deposition

A process for producing long‐fiber‐reinforced thermoplastic matrix composites is described. This process, based on papermaking technology, consists of depositing a mixture of a polymeric powder and reinforcing fibers from an aqueous slurry. The degree of homogeneity of the mixture and the subsequent ability to handle the dried sheet have been significantly improved by the addition of less than 5% pulp fibers, based on solids concentration, to the slurry. The dried sheet is then consolidated into a composite sheet with a continuous matrix phase by the application of heat and then pressure. Tensile properties and the degree of reinforcement efficiency of composites produced by this process have been shown to be comparable to those produced by melt impregnation techniques.