Fiber-reinforced film processes and films
Cast-film process for making a fiber-reinforced film is disclosed. The process includes providing at least a first thermoplastic resin, melting the at least first thermoplastic resin, extruding the at least first thermoplastic resin through a first extension die to form a first thermoplastic film, providing at least a second thermoplastic resin, melting the at least second thermoplastic resin, extruding the at least second thermoplastic resin through a second extension die to form a second thermoplastic film, transporting the first and second thermoplastic films along respective casting rollers, and introducing a plurality of fibers between the first and second thermoplastic films so as to form a fiber-reinforced film having a thickness between about 0.2 mil to about 2.0 mils and having a first thermoplastic layer, a second thermoplastic layer, and a plurality of fibers dispersed therebetween. Cast-film process for making a fiber-reinforced bag is also disclosed.
1. A cast-film process for making a fiber-reinforced film, comprising:
providing at least a first thermoplastic resin;
melting the at least first thermoplastic resin;
extruding the at least first thermoplastic resin through a first extension die to form a first thermoplastic film;
providing at least a second thermoplastic resin;
melting the at least second thermoplastic resin;
extruding the at least second thermoplastic resin through a second extension die to form a second thermoplastic film;
transporting the first and second thermoplastic films along respective casting rollers; and
introducing a plurality of fibers between the first and second thermoplastic films so as to form a fiber-reinforced film, the fiber-reinforced film having a thickness between about 0.2 mil to about 2.0 mils and having a first thermoplastic layer, a second thermoplastic layer, and a plurality of fibers dispersed therebetween.
2. The process of claim 1 , wherein the plurality of fibers is in a continuous sheet.
3. The process of claim 1 , wherein the first thermoplastic resin and the second thermoplastic resin are the same.
4. The process of claim 1 , wherein the at least one thermoplastic resin is selected from the group consisting of polyolefins, polyesters, nylons, alkenyl aromatic polymers, polyvinyl chlorides, and combinations thereof.
5. The process of claim 1 , wherein the plurality of fibers is a thermoplastic material.
6. A cast-film process for making a fiber-reinforced bag, comprising:
providing at least a first thermoplastic resin;
melting the at least first thermoplastic resin;
extruding the at least first thermoplastic resin through a first extension die to form a first thermoplastic film;
providing at least a second thermoplastic resin;
melting the at least second thermoplastic resin;
extruding the at least second thermoplastic resin through a second extension die to form a second thermoplastic film;
transporting the first and second thermoplastic films along respective casting rollers;
introducing a plurality of fibers between the first and second thermoplastic films so as to form a fiber-reinforced film, the fiber-reinforced film having a first thermoplastic layer, a second thermoplastic layer, and a plurality of fibers dispersed therebetween;
forming a first and a second body panel from the fiber-reinforced film; and
closing the first and second body panels along two opposing sides and a bottom to form a bag.
7. The process of claim 6 wherein the plurality of fibers is in a continuous sheet.
8. The process of claim 6 , wherein the first thermoplastic resin and the second thermoplastic resin are the same.
9. The process of claim 6 , wherein the at least one thermoplastic resin is selected from the group consisting of polyolefins, polyesters, nylons, alkenyl aromatic polymers, polyvinyl chlorides, and combinations thereof.
10. The process of claim 6 , wherein the plurality of fibers is a thermoplastic material.