U.S. patent application number 10/630875 was filed with the patent office on 2004-05-20 for laminated composition for a headliner and other applications.
Invention is credited to Balthes, Garry E., Eggers, Darrell R., Hickey, Harry R..
Application Number | 20040097159 10/630875 |
Document ID | / |
Family ID | 31997603 |
Filed Date | 2004-05-20 |
United States Patent
Application |
20040097159 |
Kind Code |
A1 |
Balthes, Garry E. ; et
al. |
May 20, 2004 |
Laminated composition for a headliner and other applications
Abstract
A vehicle headliner panel is provided which has a core layer
having a binding resin, randomly-oriented sisal fibers, and
randomly-oriented natural filler fibers.
Inventors: |
Balthes, Garry E.; (Elkhart,
IN) ; Eggers, Darrell R.; (Bristol, IN) ;
Hickey, Harry R.; (Macomb, MI) |
Correspondence
Address: |
BARNES & THORNBURG
600 One Summit Square
Fort Wayne
IN
46802
US
|
Family ID: |
31997603 |
Appl. No.: |
10/630875 |
Filed: |
July 30, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10630875 |
Jul 30, 2003 |
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10287250 |
Nov 4, 2002 |
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60347858 |
Nov 7, 2001 |
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60349541 |
Jan 18, 2002 |
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60358857 |
Feb 22, 2002 |
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60359017 |
Feb 22, 2002 |
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60359602 |
Feb 26, 2002 |
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60400173 |
Jul 31, 2002 |
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Current U.S.
Class: |
442/415 ;
442/416 |
Current CPC
Class: |
B32B 37/146 20130101;
B32B 2305/188 20130101; B32B 9/02 20130101; B32B 38/105 20130101;
Y10T 442/697 20150401; B32B 27/20 20130101; B32B 5/024 20130101;
B32B 27/36 20130101; B29C 43/021 20130101; B32B 2323/10 20130101;
B32B 2605/00 20130101; B29C 43/222 20130101; B29K 2311/10 20130101;
B32B 27/32 20130101; B32B 37/08 20130101; B32B 2307/724 20130101;
B32B 39/00 20130101; B32B 5/26 20130101; B32B 5/28 20130101; B32B
37/20 20130101; B32B 2262/0276 20130101; B29C 2043/483 20130101;
B32B 27/34 20130101; B32B 2307/7265 20130101; Y10T 442/698
20150401; B32B 2262/062 20130101; B32B 2367/00 20130101; B32B
2377/00 20130101; B29C 70/081 20130101; B32B 29/002 20130101; B32B
37/1027 20130101; B32B 2605/08 20130101; B32B 2037/243 20130101;
B29C 70/504 20130101; B32B 17/04 20130101; B32B 38/164 20130101;
B32B 2038/002 20130101 |
Class at
Publication: |
442/415 ;
442/416 |
International
Class: |
D04H 001/00 |
Claims
What is claimed is:
1. A vehicle headliner panel comprising: a core layer having first
and second surfaces, and comprising a binding resin,
randomly-oriented sisal fibers, and randomly-oriented natural
filler fibers; a first permeability-resistance layer located on the
first surface of the core; and a second permeability-resistance
layer located on the second surface of the core.
2. The vehicle headliner panel of claim 1, wherein the binding
resin is polypropylene.
3. The vehicle headliner panel of claim 1, wherein the
permeability-resistance layer is a film.
4. The vehicle headliner panel of claim 3, wherein the
permeability-resistance layer is a polypropylene film.
5. The vehicle headliner panel of claim 1, wherein the natural
filler fibers are selected from a group consisting of flax, jute,
kenaf and hemp.
6. The vehicle headliner panel of claim 1, wherein the binding
resin are present in an amount ranging from about 25 to about 35
weight percent.
7. The vehicle headliner panel of claim 1, wherein the sisal fibers
are present in an amount ranging from about 35 to about 45 weight
percent.
8. The vehicle headliner panel of claim 1, wherein the natural
filler fibers are present in an amount ranging from about 25 to
about 35 weight percent.
9. The vehicle headliner panel of claim 1, wherein the binding
resin is present in an amount of about 30 weight percent, the sisal
is present in an amount of about 40 weight percent, and the natural
filler fibers are present in an amount of about 30 weight
percent.
10. The vehicle headliner panel of claim 2, wherein the
polypropylene comprises about 5 weight percent maleic anhydride and
about 95 weight percent generic polypropylene.
11. A vehicle headliner comprising: a core layer having first and
second surfaces, and comprising a binding resin, randomly-oriented
sisal fibers, and randomly-oriented natural filler fibers; a
permeability-resistance film layer located on the first surface of
the core; and a fiberglass layer located on the
permeability-resistance film layer opposite the core layer.
12. The vehicle headliner panel of claim 11, wherein a film layer
is located over the fiberglass layer, and a second fiberglass layer
is located on the permeability-resistance film layer opposite the
fiberglass layer.
13. The vehicle headliner panel of claim 11, wherein a second
permeability-resistance film layer is located on the second surface
of the core.
14. The vehicle headliner panel of claim 13, wherein a fiberglass
layer is located on the second permeability-resistance film layer
opposite the core layer.
15. The vehicle headliner panel of claim 14, wherein a film layer
is located over the fiberglass layer located on the second
permeability-resistance film layer, and a second fiberglass layer
is located on the film layer opposite the fiberglass layer.
16. The vehicle headliner panel of claim 11, wherein the binding
resin of the core layer is present in an amount of about 30 weight
percent, the sisal is present in an amount of about 40 weight
percent, and the natural filler fibers are present in an amount of
about 30 weight percent.
17. The vehicle headliner panel of claim 11, wherein the binding
resin is polypropylene.
18. The vehicle headliner panel of claim 12, wherein the
polypropylene comprises about 5 weight percent maleic anhydride and
about 95 weight percent generic polypropylene.
19. A vehicle headliner comprising: a core layer having first and
second surfaces, and comprising a binding resin, randomly-oriented
sisal fibers, and randomly-oriented natural filler fibers; a
permeability-resistance film layer located on the first surface of
the core; a woven fiber layer located on the second surface of the
core; and a film layer located over the woven fiber layer opposite
the core layer.
20. The vehicle headliner panel of claim 19, wherein the binding
resin of the core layer is a polypropylene and is present in an
amount of about 25 to about 35 weight percent, the sisal is present
in an amount of about 35 to about 45 weight percent, and the
natural filler fibers are present in an amount of about 25 to about
35 weight percent.
21. The vehicle headliner panel of claim 19, wherein the woven
fiber layer is a polyester woven fiber layer.
22. The vehicle headliner panel of claim 19, wherein the woven
fiber layer is a polypropylene/cellulous woven fiber layer.
23. The vehicle headliner panel of claim 19, wherein the film layer
is a polypropylene film.
24. The vehicle headliner panel of claim 19, further comprising a 4
mil polypropylene film layer.
25. The vehicle headliner panel of claim 19, wherein the binding
resin is a nylon film layer.
26. The vehicle headliner panel of claim 19, further comprising a 4
mil layer.
27. A vehicle headliner comprising: a core layer having first and
second surfaces, and comprising a binding resin, randomly-oriented
sisal fibers, and randomly-oriented natural filler fibers; a first
permeability-resistance film layer located on the first surface of
the core; a second permeability-resistance film layer located on
the second surface of the core; and a paper layer located over the
second permeability-resistance film layer and opposite the core
layer.
28. The vehicle headliner panel of claim 27, wherein the binding
resin of the core layer is a polypropylene and is present in an
amount of about 25 to about 35 weight percent, the sisal is present
in an amount of about 35 to about 45 weight percent, and the
natural filler fibers are present in an amount of about 25 to about
35 weight percent.
29. The vehicle headliner panel of claim 27, wherein the paper is a
creped paper.
30. The vehicle headliner panel of claim 27, further comprising a
woven fiber layer located over the first permeability-resistance
film layer opposite the core layer.
31. The vehicle headliner panel of claim 30, wherein the woven
fiber layer is a polyester woven fiber layer.
32. The vehicle headliner panel of claim 30, wherein the woven
fiber layer is a polypropylene/cellulous woven fiber layer.
33. The vehicle headliner panel of claim 27, wherein the first
permeability-resistance film layer is a nylon film layer.
34. A vehicle headliner comprising: a core layer having first and
second surfaces, and comprising a binding resin, randomly-oriented
sisal fibers, and randomly-oriented natural filler fibers; a first
permeability-resistance film layer located on the first surface of
the core; a second permeability-resistance film layer located on
the second surface of the core; a first woven fiber layer located
on the first permeability-resistance film layer opposite the core;
and a second woven fiber layer located on the second
permeability-resistance film layer opposite the core.
35. The vehicle headliner panel of claim 34, wherein the binding
resin of the core layer is a polypropylene and is present in an
amount of about 25 to about 35 weight percent, the sisal is present
in an amount of about 35 to about 45 weight percent, and the
natural filler fibers are present in an amount of about 25 to about
35 weight percent.
36. The vehicle headliner panel of claim 34, wherein the woven
fiber layer is a polyester woven fiber layer.
37. The vehicle headliner panel of claim 34, wherein the woven
fiber layer is a polypropylene/cellulous woven fiber layer.
38. A vehicle headliner comprising: a core layer having first and
second surfaces, and comprising a binding resin, randomly-oriented
sisal fibers, and randomly-oriented natural filler fibers; a first
permeability-resistance film layer located on the first surface of
the core; a second permeability-resistance film layer located on
the second surface of the core; a first paper layer located on the
first permeability-resistance film layer opposite the core; and a
second paper layer located on the second permeability-resistance
film layer opposite the core.
39. The vehicle headliner panel of claim 38, wherein the binding
resin of the core layer is a polypropylene and is present in an
amount of about 25 to about 35 weight percent, the sisal is present
in an amount of about 35 to about 45 weight percent, and the
natural filler fibers are present in an amount of about 25 to about
35 weight percent.
40. The vehicle headliner panel of claim 38, wherein the paper is a
creped paper.
41. A vehicle headliner comprising: a core layer having first and
second surfaces, and comprising a binding resin, randomly-oriented
sisal fibers, and randomly-oriented natural filler fibers; a first
permeability-resistance film layer located on the first surface of
the core; a second permeability-resistance film layer located on
the second surface of the core; a first paper layer located on the
first permeability-resistance film layer opposite the core; and a
second paper layer located on the second permeability-resistance
film layer opposite the core.
Description
RELATED APPLICATIONS
[0001] The present application is a Continuation-in-Part of U.S.
patent application, Ser. No. 10/287,250, filed on Nov. 4, 2002,
entitled Process, Composition and Coating of Laminate Material,
which is related to and claims priority to U.S. Provisional Patent
Applications: Serial No. 60/347,858, filed on Nov. 7, 2001,
entitled Laminated Panels and Processes; Serial No. 60/349,541,
filed on Jan. 18, 2002, entitled Truss Panel; Serial No.
60/358,857, filed on Feb. 22, 2002, entitled Compression Molded
Visor; Serial No. 60/359,017, filed on Feb. 22, 2002, entitled
Assemblies and Tooling for Work Surfaces; Serial No. 60/359,602,
filed on Feb. 26, 2002, entitled Compression Molded Visor, and
Serial No. 60/400,173, filed on Jul. 31, 2002, entitled Composite
Material. To the extent not included below, the subject matter
disclosed in those applications is hereby expressly incorporated
into the present application.
TECHNICAL FIELD
[0002] The present disclosure relates generally to vehicle
headliners, and more particularly to laminated panel and core
compositions, illustratively for use therein.
BACKGROUND AND SUMMARY
[0003] Vehicle headliners are known in the art. Such headliners are
typically used to provide sound absorption, padding, and aesthetics
to the ceiling of a vehicle. Conventionally, vehicle headliners
have sufficient impact absorption and sound absorption, as well as
the ability to receive any variety of aesthetically pleasing
coverings. Because of the varied environments that vehicle
headliners are exposed to, however, heat stability can also be a
relevant factor to consider. Since vehicle headliners, for the most
part, are located at the uppermost portion of a vehicle passenger
compartment, any heat that is generated in that compartment would
rise to that upper location and possibly affect the headliner.
Consequently, vehicle headliners that are located in, or are
subject to, prolonged elevated temperature environments should be
dimensionally heat stable.
[0004] It would, thus, be desirable to provide a composition of
material that has dimensional stability in high temperature
environments.
[0005] Accordingly, an illustrative embodiment of a vehicle
headliner panel is provided. The headliner comprises a core layer
having first and second surfaces, and first and second
permeability-resistance layers. The core layer comprises a binding
resin, randomly-oriented sisal fibers, and randomly-oriented
natural filler fibers. The first permeability-resistance layer is
located on the first surface of the core, and the second
permeability-resistance layer is located on the second surface of
the core.
[0006] In the above and other illustrative embodiments, the
headliner panel may also provide: the binding resin being
polypropylene; the permeability-resistance layer being a film; the
permeability-resistance layer being a polypropylene film; the
natural filler fibers being selected from a group consisting of
flax, jute, kenaf and hemp; the binding resin being present in an
amount ranging from about 25 to about 35 weight percent; the sisal
fibers being present in an amount ranging from about 35 to about 45
weight percent; the natural filler fibers being present in an
amount ranging from about 25 to about 35 weight percent; the
binding resin being present in an amount of about 30 weight
percent, the sisal being present in an amount of about 40 weight
percent, and the natural filler fibers being present in an amount
of about 30 weight percent; and polypropylene comprising about 5
weight percent maleic anhydride and about 95 weight percent generic
polypropylene.
[0007] Another illustrative embodiment provides a vehicle headliner
which comprises a core layer, a permeability-resistance film layer,
and a fiberglass layer. The core layer has first and second
surfaces and comprises a binding resin, randomly-oriented sisal
fibers, and randomly-oriented natural filler fibers. The
permeability-resistance film layer is located on the first surface
of the core. The fiberglass layer is located on the
permeability-resistance film layer opposite the core layer.
[0008] In the above and other illustrative embodiments, the
headliner panel may also provide: a film layer being located over
the fiberglass layer, and a second fiberglass layer being located
on the permeability-resistance film layer opposite the fiberglass
layer; a second permeability-resistance film layer being located on
the second surface of the core; a fiberglass layer being located on
a second permeability-resistance film layer opposite the core
layer; and a film layer being located over the fiberglass layer
which is located on the second permeability-resistance film layer,
and a second fiberglass layer being located on the film layer
opposite the fiberglass layer.
[0009] Another illustrative embodiment provides a vehicle headliner
which comprises a core layer, a permeability-resistance film layer,
a woven fiber layer, and a film layer. The core layer has first and
second surfaces, and comprises a binding resin, randomly-oriented
sisal fibers, and randomly-oriented natural filler fibers. The
permeability-resistance film layer is located on the first surface
of the core. The woven fiber layer is located on the second surface
of the core. The film layer is located over the woven fiber layer
opposite the core layer.
[0010] In the above and other illustrative embodiments, the
headliner panel may also provide: the woven fiber layer being a
polyester woven fiber layer; the woven fiber layer being a
polypropylene/cellulous woven fiber layer; a film layer being a
polypropylene film; the polypropylene film layer being a 4 mil
layer; the binding resin being a nylon film layer; and the nylon
film layer being an about 4 mil layer.
[0011] Another illustrative embodiment provides a vehicle headliner
which comprises a core layer, a first permeability-resistance film
layer, a second permeability-resistance film layer, and a paper
layer. The core layer has first and second surfaces, and comprises
a binding resin, randomly-oriented sisal fibers, and
randomly-oriented natural filler fibers. The first
permeability-resistance film layer is located on the first surface
of the core. The second permeability-resistance film layer is
located on the second surface of the core. The paper layer is
located over the second permeability-resistance film layer and
opposite the core layer.
[0012] In the above and other illustrative embodiments, the
headliner panel may also provide: the paper being a creped paper; a
woven fiber layer located over the first permeability-resistance
film layer opposite the core layer; the woven fiber layer being a
polyester woven fiber layer; a woven fiber layer being a
polypropylene/cellulous woven fiber layer; the first
permeability-resistance film layer being a 4 mil nylon film
layer.
[0013] Another illustrative embodiment provides a vehicle headliner
which comprises a core layer, a first permeability-resistance film
layer, a second permeability-resistance film layer, a first woven
fiber layer, and a second woven fiber layer. The core layer has
first and second surfaces, and comprises a binding resin,
randomly-oriented sisal fibers, and randomly-oriented natural
filler fibers. The first permeability-resistance film layer is
located on the first surface of the core. The second
permeability-resistance film layer is located on the second surface
of the core. The first woven fiber layer is located on the first
permeability-resistance film layer opposite the core. The second
woven fiber layer is located on the second permeability-resistance
film layer opposite the core.
[0014] Another illustrative embodiment provides a vehicle headliner
which comprises a core layer, a first permeability-resistance film
layer, a second permeability-resistance film layer, a first paper
layer and a second paper layer. The core layer has first and second
surfaces, and comprises a binding resin, randomly-oriented sisal
fibers, and randomly-oriented natural filler fibers. The first
permeability-resistance film layer is located on the first surface
of the core. The second permeability-resistance film layer is
located on the second surface of the core. The first paper layer is
located on the first permeability-resistance film layer opposite
the core. The second paper layer is located on the second
permeability-resistance film layer opposite the core.
[0015] Additional features and advantages of this disclosure will
become apparent to those skilled in the art upon consideration of
the following detailed description of illustrated embodiments
exemplifying the best mode of carrying out such embodiments as
presently perceived.
BRIEF DESCRIPTION OF DRAWINGS
[0016] The present disclosure will be described hereafter with
reference to the attached drawings which are given as non-limiting
examples only, in which:
[0017] FIG. 1 is a sectional view in panel form of a core
material;
[0018] FIG. 2 is a sectional view in panel form of another
illustrative embodiment of a laminated composite;
[0019] FIG. 3 is a sectional view in panel form of another
illustrative embodiment of a laminated composite;
[0020] FIG. 4 is a sectional view in panel form of another
illustrative embodiment of a laminated composite;
[0021] FIG. 5 is a sectional view in panel form of another
illustrative embodiment of a laminated composite;
[0022] FIG. 6 is a sectional view in panel form of another
illustrative embodiment of a laminated composite;
[0023] FIG. 7 is a sectional view in panel form of another
illustrative embodiment of a laminated composite;
[0024] FIG. 8 is a sectional view in panel form of another
illustrative embodiment of a laminated composite;
[0025] FIG. 9 is a sectional view in panel form of another
illustrative embodiment of a laminated composite; and
[0026] FIG. 10 is a sectional view in panel form of another
illustrative embodiment of a laminated composite.
[0027] Corresponding reference characters indicate corresponding
parts throughout the several views. The exemplification set out
herein illustrates several embodiments, and such exemplification is
not to be construed as limiting the scope of this disclosure in any
manner.
DETAILED DESCRIPTION OF THE DRAWINGS
[0028] A sectional view in panel form of a core layer 2 is shown in
FIG. 1. The core layer 2 can serve as the base for any variety of
laminated composite panels. One particular use of such panels is
for the vehicle headliner application. In one illustrative
embodiment, the core layer 2 comprises a formulation including
about 30 percent polypropylene containing about 5 percent is maleic
anhydride. The maleic anhydride is a coupling agent, and helps
distribute the polypropylene and all the materials in the
composition. The core layer 2 also comprises about 30 percent sisal
fiber which provides stiffness as well as loft and standoff in high
temperature environments. Also included is about 40 percent natural
fibers which may be hemp, kenaf, or jute, for example. These
natural fibers serve as a filler in combination with the sisal
fiber. The natural fibers are non-directionally disbursed in the
layer. The core layer 2 has an illustrative density of about 800
grams per meter square. It is appreciated, however, that the
density of this composition may vary from about 400 grams per meter
square to up above 1000 grams per meter square, for example. Other
densities may work as well. The amounts of polypropylene, sisal
fibers, and other natural fibers may too vary. In the case of
polypropylene, there can be about a 5 percent or more variation in
range. This will depend on the particular application, keeping in
mind any bonding requirements for that application. The variation
of the sisal and other natural fibers may too vary by about 5
percent or more. Such variation could be greater, but cost factors
between the sisal or like fibers, and the other natural fibers may
be an influencing factor when deriving the actual formulation. As
an illustrative range, the amount of polypropylene can vary from
about 25 to about 35 weight percent, the sisal can vary from about
35 to about 45 weight percent, and the amount of natural fibers may
vary from about 25 to about 35 weight percent.
[0029] The laminated compositions described herein are
characterized as panels. These panels can be formed by any variety
of lamination methods, including for example, the methods described
in U.S. patent application, Ser. No. 10/287,250, filed on Nov. 4,
2002, entitled Process, Composition and Coating of Laminate
Material, the disclosure of which has been incorporated herein by
reference.
[0030] It is appreciated that panels in their pre-formed state are
layered mats, which are, too, contemplated within the scope of this
invention. With respect to the layers themselves, for the purpose
of context, the film and layer thicknesses disclosed herein are
done so at the pre-formed stage. For example, the 2, 3 or 4 mil
film layers are identified as such even though their thicknesses
may be reduced during manufacture into panels. These thicknesses
are identified to teach the illustrative components used to create
the resulting panel.
[0031] Another illustrative embodiment of this base material may
comprise the formulation of about 30 percent polypropylene, about
30 percent sisal fiber, and about 40 percent other natural fibers.
In addition, a core layer of any embodiment may comprise a top
surface 3 and a bottom surface 5, wherein each receives a thin film
layer 4, illustratively of polypropylene. This film layer 4 can
provide adhesiveness to other composite layers, as well as provide
water and air permeability resistance to the core layer 2. This
permeability resistance inhibits exposure of the natural fibers to
air and water, for example, to prevent the natural fibers from
creating odors or mildewing.
[0032] In another illustrative embodiment, core layer 2 may
comprise about 10 percent by weight polypropylene fibers,
illustratively comprising about 95 percent total weight generic
polypropylene, and about 5 percent maleic anhydride, about 15
percent by weight kenaf or similar natural fibers, such as hemp,
flax, or jute, about 45 percent by weight bi-component polyester
fiber that is low melt (about 240 to 300 degrees F.), and about 30
percent by weight single component polyester fiber that is high
melt (440 degrees F.). In an illustrative embodiment, the
bi-component polyester may be a blend of about 50 percent high melt
(440 degree F.) polyester with about 50 percent low melt polyester
(240 to 300 degrees F.). This blend can assist in permitting
control of the polypropylene movement during the heat phase of the
laminating process. In another illustrative embodiment, the high
melt polyester fibers in the layers described herein may comprise
an outer sheath of low melt polyester (240 to 347 degrees F.). It
is appreciated that for these embodiments, other couplers may be
substituted in place of maleic anhydride. In addition, the natural
fibers can be pretreated with an anti-fungal/anti-micro bacterial
agent. This is illustratively done prior to blending.
[0033] Another illustrative embodiment of core layer 2 may comprise
about 30 percent by weight polypropylene fibers which itself
illustratively comprises about 95 percent generic polypropylene and
about 5 percent maleic anhydride. The core may also comprise about
40 percent natural fiber, including kenaf, hemp, flax, or jute, and
about 30 percent by weight bi-component polyester. The natural
fibers can be pretreated with anti-fungal/anti-micro bacterial
agent. Again, the bi-component polyester may be a 50/50 high
melt/low melt blend.
[0034] Another illustrative embodiment of a laminated panel 6 is
shown in FIG. 2. Laminated panel 6 includes core layer 2 with 2 mil
(0.002 inch) thick polypropylene film layers 4 bounding the top and
bottom surfaces 3 and 5, respectively, of core layer 2. Formed on
one of the polypropylene layers 4, opposite the core layer 2, is a
fiberglass layer 8. The fiberglass layer is, illustratively, a 40
grams per meter square chopped strand glass. Bounding the surface
of fiberglass layer 8, opposite the 2 mil polypropylene layer 4, is
another polypropylene layer 10. This layer 10 is illustratively a 1
ounce per yard square polypropylene layer. Another 40 gram
fiberglass layer 8 is located over the polypropylene layer 10. An
illustrative example of such a system is an Owens-Corning.RTM.
brand fiberglass product. This glass layer is one 40 gram layer of
chopped glass fiber (e glass), one layer of polypropylene spun bond
and one additional layer of 40 gram chopped glass. The combined
layers are then hot calendared causing consolidation of the three
layers into one. It is appreciated that the spun bond polypropylene
layer can be substituted with a 2 mil polypropylene film layer. It
is appreciated that the specific densities and material types
recited with respect to this embodiment are illustrative.
[0035] A sectional view of another illustrative embodiment of a
laminated composite panel 12 is shown in FIG. 3. The illustrative
panel 12 is similar to the illustrative panel 6 shown in FIG. 2,
with the addition of the glass layers 8 and the polypropylene layer
10 located therebetween, and positioned on the underside of core
layer 2, adjacent film layer 4. The embodiments shown in FIGS. 2
and 3 provide high strength composite panels with the temperature
stability of the core layer 2 to prevent substantial dimensional
fluctuations as a result of high temperature environments. Again,
the film layers 4 that sandwich core layer 2 assist in preventing
water or air from entering the surfaces of the core layer 2 and
affecting the natural fibers therein.
[0036] FIG. 4 is another illustrative embodiment of a laminated
composite panel 14 which comprises the core layer 2 with a 2 mil
polypropylene film layer 4 on top surface 3, and a 50 gram per
meter squared polyester weave layer 16 on the bottom surface 5. The
particular density of this layer is illustrative and can be varied,
depending on the application, for example. A 4 mil polypropylene
film layer 18 is located on the lower surface of polyester weave
layer 16, opposite core layer 2. This polypropylene layer 18 serves
to seal the polyester weave layer 16 as well as the core layer 2.
This illustrative embodiment has shown to be quite rigid under
environmental testing conditions. For example, in one such test,
the laminated composite panel 14 was subjected to a temperature of
95 degrees C. After the panel was allowed to cool for one hour to
an ambient temperature of 23 degrees C., a cantilever test was
conducted revealing a sag of about 1.27 millimeters. This is within
a target deflection range of about 10 millimeters for a headliner
application. Other panel or headliner applications may not require
such a limited deflection range. It is appreciated that the
polyester weave layer 16 can be substituted with a cellulous fiber
and polypropylene weave layer. In an illustrative embodiment of the
cellulous fiber weave, the density of the layer may be about 67
grams per meter squared.
[0037] Another illustrative embodiment of a laminated panel 20 is
shown in FIG. 5. This embodiment includes core layer 2 bounded on
both the top and bottom surfaces 3 and 5, respectively, by a
polypropylene film layer 4. Laminated on the lower surface of the
polypropylene film layer 4, opposite surface 5, is a
multi-directional creped paper material 22 having an illustrative
density of about 130 grams per meter square. A cantilever test,
like that described with respect to panel 14 in FIG. 4, showed that
after cooling for about one hour, a deflection of only about 1.27
millimeters resulted. It is appreciated that, in this embodiment,
the densities of the paper, as well as the core, may vary depending
on the desired application.
[0038] A sectional view of another illustrative embodiment of a
laminated panel 24 is shown in FIG. 6. Panel 24 comprises a core
layer 2 bounded on the upper and lower surfaces 3 and 5,
respectively, by a 2 mil polypropylene film layer 4. The surfaces
of film layer 4, opposite core layer 2, receive a 50 gram polyester
weave layer 16. It is appreciated that the specific density of the
polyester weave layer 16 may vary depending on the desired
application. Conducting an environmental cantilever test on this
embodiment produced a deflection of about 15.69 millimeters which
is above the desired range of maximum deflection of 10 millimeters
for a headliner application, but would be within tolerance for
other uses that may not require such high temperature
resistance.
[0039] A sectional view of another illustrative embodiment of a
composite panel 26 is shown in FIG. 7. Panel 26 comprises a core
layer 2 bounded on both the upper and lower surfaces 3 and 5,
respectively, by 2 mil polypropylene film layers 4, which are
themselves bounded on their outer surfaces by 130 gram creped paper
22. Similar to the previous embodiment shown in FIG. 6, panel 26
demonstrated a deflection of about 12.7 millimeters in an
environmental cantilever test. This is above the desired maximum
deflection of 10 millimeters for headliner applications. Panel 26,
similar to panel 24, however, may be used in applications where the
temperature resistance is not as critical.
[0040] A sectional view of another illustrative embodiment of a
laminated composite panel 28 is shown in FIG. 8. Panel 28 comprises
a core layer bounded on upper and lower surfaces 3 and 5,
respectively, by 2 mil polypropylene film layers 4. The top surface
of film layer 4, opposite surface 3 of core layer 2, receives a 50
gram polyester weave layer 16. The lowermost surface of film layer
4, opposite surface 5 of core layer 2, receives a 130 gram creped
paper layer 22. Again, similar to previous embodiments, the
specific densities of layers 16 and 22, can be varied depending on
the desired application. In addition, an environmental cantilever
test of panel 28 has shown a deflection of about 3.81 millimeters
which is within the range of the 10 millimeters for the headliner
application.
[0041] A sectional view of another illustrative embodiment of a
laminated composite panel 30 is shown in FIG. 9. Panel 30 comprises
a core layer 2 with its upper surface 3 bounded by a layer of about
3 mil nylon film 32. On the lower surface 5 of core layer 2 is a 50
gram polyester weave layer 16. In this particular embodiment, the
density of core layer 2 is about 1000 grams per meter square. It is
appreciated, however, that the densities can be varied for any
particular application. The lowermost layer applied to the surface
of polyester weave layer 16, opposite surface 5 of core layer 2, is
a 4 mil polypropylene film layer 34. It is appreciated that, in
this embodiment, the polypropylene film layer 34 serves as the
lower barrier to resist moisture and air from contacting both weave
layer 16 and core layer 2, whereas the upper nylon film layer 32
serves the same purpose for the upper surface 3 of core layer 2. In
addition, when panel 30 is subjected to an environmental cantilever
test, it was shown to deflect about 10.16 millimeters,
approximately the maximum for a particular headliner
application.
[0042] A sectional view of another illustrative embodiment of a
laminated composite panel 36 is shown in FIG. 10. The illustrative
panel 36 comprises a core layer 2, illustratively having about a
1000 grams per meter square density with an about 3 mil nylon film
32 bounding the core layer's 2 upper surface 3, and a 2 mil
polypropylene film layer 4 bounding the core layer's 2 lower
surface 5. Bounding the upper surface of the nylon film's 32 upper
surface, opposite surface 5 of core layer 2, is a 50 gram polyester
weave 16. The lowermost surface of film layer 4, opposite core
layer 2, is a 130 grams per millimeter square creped paper layer
22. An environmental cantilever test conducted on panel 36 showed a
deflection of about 10.16 millimeters. It is appreciated that the
film thickness of this embodiment, as well as the other
embodiments, are approximations. The thicknesses may vary depending
on the composition of the film, as well as its permeability
resistance.
[0043] Although the present disclosure has been described with
reference to particular means, materials and embodiments, from the
foregoing description, one skilled in the art can easily ascertain
the essential characteristics thereof and various changes and
modifications may be made to adapt the various uses and
characteristics without departing from the spirit and scope of the
present invention as set forth in the following claims.
* * * * *