Reinforced polyester structural components

1 . A polyester composite produced by consolidating a polyester prepreg comprising an article which comprises a polyester composition,

wherein the article has, as measured by differential scanning calorimetry with a heating rate of 20° C. per minute on first heating according to ASTM D3418,

at least two different crystalline melting temperatures, wherein a first crystalline melting temperature and a second crystalline melting temperature are each independently 200-290° C.; and

a first heat of fusion and a second heat of fusion that are each independently at least 3 J/g, and

wherein the polyester composition comprises, based on the total weight of the polyester composition,

20 to 50 weight percent of a first polyester having a phosphorous content of greater than or equal to 20 ppm by weight, based on the total weight of the polyester composition,

20 to 60 weight percent of a second polyester,

5 to 50 weight percent of a plurality of fibers, based on the total weight of the polyester composition, wherein the plurality of fibers have a diameter of 5 to 25 micrometers,

0.01 to 0.3 weight percent of a stabilizer, the stabilizer comprising a hindered phenol, phosphite, phosphonite, thioester, or a combination thereof,

0.05 to 5 weight percent of a nucleant, the nucleant comprising talc, silica, siloxane, clay, alkaline carboxylate salt, or a combination thereof,

0.1 to 0.8 weight percent of a mold release agent, the mold release agent comprising a fatty acid ester, a wax, a polyolefin, or a combination thereof, and

0.1 to 5 weight percent of a colorant, the colorant comprising carbon black, a dye, a pigment, or a combination thereof,

wherein the polyester composite is produced by consolidating the polyester prepreg in the form of a laminate produced by consolidating at least two layers of the polyester prepreg under heat and pressure,

wherein each of the layers of the polyester prepreg comprises a continuous unidirectional fiber-reinforced polyester tape comprising the plurality of fibers or a polyester tape comprising woven glass fabric comprising the plurality of fibers,

wherein the first polyester comprises a poly(ethylene terephthalate) and the first polyester has

a weight-average molecular weight of 15,000-80,000 grams per mole, as measured by gel permeation chromatography using polystyrene standards;

a carboxylic COOH end group content of 20 to 60 millimole equivalents per kilogram;

a hydroxy OH end group content of 20 to 60 millimole equivalents per kilogram;

a ratio of hydroxy end groups to carboxylic end groups of at least 1.3:1; and

a metal content of greater than 10 ppm by weight but less than 200 ppm by weight, wherein the metal is titanium, zirconium, zinc, antimony, germanium, cobalt, tin, or a combination thereof; and

wherein the second polyester comprises a first poly(butylene terephthalate) and a second poly(butylene terephthalate), and wherein

an intrinsic viscosity of the first poly(butylene terephthalate) is different than an intrinsic viscosity of the second poly(butylene terephthalate); or

a weight average molecular weight of the first poly(butylene terephthalate) is different than a weight average molecular weight of the second poly(butylene terephthalate); or

both the intrinsic viscosity and the weight average molecular weight are different.

2 . The polyester composite of claim 1 , wherein the plurality of fibers comprises a plurality of chopped glass fiber, long glass fiber, glass filament, woven glass fiber, carbon fiber, ceramic fiber, or a combination thereof.

3 . The polyester composite of claim 1 , wherein the polyester composition further comprises 1 to 30 weight percent of an impact modifier, based on the total weight of the polyester composition.

4 . The polyester composite of claim 1 , wherein each of the layers of the polyester prepreg comprises the continuous unidirectional fiber-reinforced polyester tape.

5 . The polyester composite of claim 1 , each of the layers of the polyester prepreg comprises the polyester tape comprising woven glass fabric.

6 . A method of manufacturing the polyester composite of claim 1 , the method comprising

coating a substrate with a blend comprising the first polyester and the second polyester to form a coated substrate, wherein the substrate comprises the plurality of fibers;

heating the coated substrate at a first temperature to form a polyester prepreg;

layering a plurality of polyester prepregs; and

heating the plurality of polyester prepregs at a second temperature under pressure to form the polyester composite.

7 . A method of producing the polyester composite of claim 1 , the method comprising:

forming a prepreg by laminating at least two prepreg layers in the form of continuous unidirectional fiber-reinforced polyester tapes;

heating the at least two prepreg layers at a first temperature to form the polyester prepreg;

layering one or more polyester prepregs to form the article; and

consolidating the article at a second temperature under pressure to form a polyester composite,

wherein the continuous unidirectional fiber-reinforced polyester tapes are oriented in the same direction.

8 . A method of producing the polyester composite of claim 1 , the method comprising:

forming a prepreg by laminating at least two prepreg layers in the form of polyester tapes comprising woven glass fabric;

heating the at least two prepreg layers at a first temperature to form the polyester prepreg;

layering one or more polyester prepregs to form the article; and

consolidating the article at a second temperature under pressure to form a polyester composite.