U.S. patent application number 13/148641 was filed with the patent office on 2012-03-01 for foam laminate product and process for production thereof.
This patent application is currently assigned to PROPRIETECT L.P.. Invention is credited to Neil P. Gehani.
Application Number | 20120052283 13/148641 |
Document ID | / |
Family ID | 42561348 |
Filed Date | 2012-03-01 |
United States Patent
Application |
20120052283 |
Kind Code |
A1 |
Gehani; Neil P. |
March 1, 2012 |
FOAM LAMINATE PRODUCT AND PROCESS FOR PRODUCTION THEREOF
Abstract
A laminate product comprising a foam core having a pair of
opposed major surfaces and a cover layer secured with respect to
each major surface is described. The cover layer contains a fibrous
reinforcement layer that is substantially encapsulated by a
polymer. It has been found that the use of a fibrous polymer layer
(e.g., in place of conventional polyethylene film) results in a
laminate product having significantly lower resistance to air flow
resistance and significantly improved sound absorption
properties.
Inventors: |
Gehani; Neil P.;
(Mississauga, CA) |
Assignee: |
PROPRIETECT L.P.
Mississauga
CA
|
Family ID: |
42561348 |
Appl. No.: |
13/148641 |
Filed: |
February 9, 2010 |
PCT Filed: |
February 9, 2010 |
PCT NO: |
PCT/CA2010/000165 |
371 Date: |
November 16, 2011 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61202249 |
Feb 10, 2009 |
|
|
|
Current U.S.
Class: |
428/317.1 ;
264/257; 428/304.4 |
Current CPC
Class: |
Y10T 428/249953
20150401; B29K 2075/00 20130101; B29K 2105/128 20130101; B29L
2031/3023 20130101; B29C 44/5681 20130101; B29C 66/73182 20130101;
B32B 37/04 20130101; B32B 2605/003 20130101; B60R 13/0212 20130101;
B32B 2307/102 20130101; B32B 5/28 20130101; B32B 2305/20 20130101;
B29C 43/003 20130101; Y10T 428/249982 20150401; B32B 2305/022
20130101; B32B 5/18 20130101 |
Class at
Publication: |
428/317.1 ;
428/304.4; 264/257 |
International
Class: |
B32B 3/26 20060101
B32B003/26; B32B 7/12 20060101 B32B007/12; B32B 27/08 20060101
B32B027/08; B32B 27/12 20060101 B32B027/12 |
Claims
1. A laminate product comprising a foam core having a pair of
opposed major surfaces and a cover layer secured with respect to
each major surface, the cover layer comprising a fibrous
reinforcement layer that is substantially encapsulated by a
polymer, the laminate product having an air flow resistance as
measured in accordance with ASTM C522 of less than about 6,000 mks
Rayls.
2. (canceled)
3. (canceled)
4. (canceled)
5. (canceled)
6. The laminate product defined in claim 1, the laminate product
having an air flow resistance as measured in accordance with ASTM
C522 in the range of from about 500 to about 5,000 mks Rayls.
7. (canceled)
8. (canceled)
9. (canceled)
10. (canceled)
11. The laminate product defined in claim 1, the laminate product
having an air flow resistance as measured in accordance with ASTM
C522 in the range of from about 700 to about 1,500 mks Rayls.
12. The laminate product defined in claim 1, wherein a first cover
layer is adhered by the polymer to a first major surface of the
foam core and a second cover layer is adhered by the polymer to a
second major surface of the foam core.
13. (canceled)
14. (canceled)
15. The laminate product defined in claim 12, wherein at least one
of the first cover layer and the second cover layer comprises a
plurality of fibrous reinforcement layers.
16. (canceled)
17. (canceled)
18. (canceled)
19. (canceled)
20. (canceled)
21. The laminate product defined in claim 12, wherein each of the
first cover layer and the second cover layer independently
comprises from 1 to 15 fibrous reinforcement layers.
22. (canceled)
23. (canceled)
24. The laminate product defined in claim 12, wherein each of the
first cover layer and the second cover layer independently
comprises from 1 to 5 fibrous reinforcement layers.
25. (canceled)
26. (canceled)
27. (canceled)
28. (canceled)
29. (canceled)
30. The laminate product defined in claim 1, wherein the polymer
comprises a polyolefin.
31. The laminate defined in claim 30, wherein the polyolefin is
selected from the group consisting of a homopolymer, a copolymer
and a terpolymer derived from the polymerization of at least one
olefin monomer.
32. (canceled)
33. (canceled)
34. (canceled)
35. (canceled)
36. (canceled)
37. (canceled)
38. (canceled)
39. (canceled)
40. (canceled)
41. (canceled)
42. (canceled)
43. (canceled)
44. (canceled)
45. (canceled)
46. (canceled)
47. (canceled)
48. (canceled)
49. (canceled)
50. (canceled)
51. (canceled)
52. The laminate defined in claim 30, wherein the polyolefin is
polypropylene.
53. (canceled)
54. (canceled)
55. The laminate defined in claim 30, wherein the polyolefin has a
molecular weight (Mn) in the range of from about 40,000 to about
60,000.
56. (canceled)
57. (canceled)
58. The laminate product defined in claim 1, wherein the foam core
comprises an compression force deflection at 10% deflection in the
range of from about 10 psi to about 80 psi when measured pursuant
to ASTM 3574-D.
59. (canceled)
60. The laminate product defined in claim 1, wherein the foam core
comprises a polyurethane foam.
61. (canceled)
62. (canceled)
63. (canceled)
64. (canceled)
65. (canceled)
66. (canceled)
67. The laminate product defined in claim 1, wherein the foam core
comprises a thickness of greater than or equal to about 2 mm.
68. (canceled)
69. (canceled)
70. (canceled)
71. The laminate product defined in claim 1, wherein the foam core
comprises a thickness in the range of from about 3 mm to about 8
mm.
72. The laminate product defined in claim 1, wherein the foam core
comprises a thickness in the range of from about 3 mm to about 6
mm.
73. A vehicular headliner, a sunshade or a package tray comprising
the laminate product defined in claim 1.
74. A process for producing a laminate foam product having a
pre-determined shape, the process comprising the steps of:
positioning a blank in a heating device, the blank comprising a
foam core having a pair of opposed major surfaces and a cover layer
disposed on each major surface, each cover layer comprising at
least one fibrous reinforcing layer and at least one fibrous
polymer layer; heating the blank at temperature above the melting
point of the at least one fibrous polymer layer to cause polymer to
substantially encapsulate the at least one fibrous layer and adhere
each cover layer to the foam core.
75. (canceled)
76. (canceled)
77. (canceled)
78. (canceled)
79. (canceled)
80. (canceled)
81. (canceled)
82. (canceled)
83. (canceled)
84. (canceled)
85. (canceled)
86. (canceled)
87. (canceled)
88. (canceled)
89. (canceled)
90. (canceled)
91. (canceled)
92. (canceled)
93. (canceled)
94. (canceled)
95. (canceled)
96. (canceled)
97. (canceled)
98. (canceled)
99. (canceled)
100. (canceled)
101. (canceled)
102. (canceled)
103. (canceled)
104. (canceled)
105. (canceled)
106. (canceled)
107. (canceled)
108. (canceled)
109. (canceled)
110. (canceled)
111. (canceled)
112. (canceled)
113. (canceled)
114. (canceled)
115. (canceled)
116. (canceled)
117. (canceled)
118. (canceled)
119. (canceled)
120. (canceled)
121. (canceled)
122. (canceled)
123. (canceled)
124. (canceled)
125. (canceled)
126. (canceled)
127. (canceled)
128. (canceled)
129. (canceled)
130. (canceled)
131. (canceled)
132. (canceled)
133. (canceled)
134. (canceled)
135. (canceled)
136. (canceled)
137. (canceled)
138. (canceled)
139. (canceled)
140. (canceled)
141. (canceled)
142. (canceled)
143. (canceled)
144. (canceled)
145. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims the benefit under 35 U.S.C.
.sctn.119(e) of provisional patent application S. N. 61/202,249,
filed Feb. 10, 2010, the contents of which are hereby incorporated
by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] In one of aspects the present invention relates to a foam
laminate product, more particularly such a product adapted for use
in the interior of a vehicle. In another of its aspects, the
present invention relates to process for the production of a foam
laminate product. In a highly preferred embodiment, the present
invention relates to a headliner, more particularly a vehicular
headliner. In this preferred embodiment, an aspect of present
invention relates to process for the production of a headliner.
[0004] 2. Description of the Prior Art
[0005] Energy absorbing devices (also known as energy management
devices) and structural devices are known. Such devices can take
one of a variety of shapes and forms. Currently, one of the major
applications for energy absorbing devices and/or structural devices
is in vehicles, particularly automobiles. Such devices, when used
in vehicles, would be of great convenience if they could be
included in or substituted for trim panel and, indeed, are commonly
referred to as trim panels.
[0006] In recent years, one particularly useful application of such
energy absorbing devices and/or structural devices which has
developed is in vehicular headliners. Vehicular headliners are
generally known in the art. More particularly, automotive
headliners are generally known in the art. In many case an
automotive headliner will serve as a structural device and a device
which combines both structural and energy absorbing properties.
[0007] As is known such automotive headliners are used to line the
roof of the automobile. Conventionally, an automotive headliner is
a laminate structure comprising, for example, a foam or other
padded element having a cover material secured thereto. The cover
material comprises a finished outer surface that faces the interior
of the automobile and this the cover material is disposed adjacent
or is comprised in the so-called A-surface of the headliner. The
surface of the headliner adjacent the A-surface is the so-called
B-surface. The B-surface of the headliner may or may not comprise a
cover material.
[0008] Conventionally, foamed automotive headliners have made
produced from isocyanate-based foams such as polyurethane
foams.
[0009] When producing automotive headliners from polyurethane
foams, it is conventional to utilize the so-called free-rise or
slab polyurethane foams.
[0010] In a typical slab polyurethane foam production plant, the
resultant foam is usually produced by dispensing a foamable
composition into a trough having an open top (also known as a
tunnel) and a conveyor bottom to move the composition away from the
mixhead as the foam rises. Low pressure mixing is typically used
and involves metering the components for foam production into a
mixhead equipped with a stirrer (or other suitable agitation means)
at a pressure generally less than 500 psi (usually 200-350 psi).
The components are mixed in the mixhead and the foamable
composition is expanded to produce polyurethane foam. As is known
in the art, low pressure mixing is conventionally used to produce
slabstock foam. It is known to vary the properties of the resulting
foam by varying the nature and/or amount of one or more of the
metered components.
[0011] Commercial slabstock polyurethane foam plants produce foam
"buns" having dimensions such as 4 feet (height).times.6 feet
(width).times.100 feet (length). Each bun is then cut into a
plurality shorter length (e.g., 5 feet) buns, depending on the
specifications of the particular automotive headliner being
produced. The shorter length bun is then sliced into sheets of
appropriate thickness (e.g., 1/8 to 1/2 inches). Each sheet is then
covered, trimmed and secured in the automobile. It is also known in
the art to subject each sheet to further processing steps such as
thermoforming so to confer to the planar sheet a slightly contoured
appearance which more closely assumes the shape of the roof of the
automobile.
[0012] Thus, slabstock polyurethane foam conventionally used in the
production of automotive headliners is known as a foam (e.g., a
resilient foam) having at least one uncontoured surface (i.e., the
foam is a "free-rise" foam).
[0013] U.S. Pat. Nos. 5,683,796 and 5,721,038 [both to Kornylo et
al. (Kornylo)] teach a vehicular headliner made from molded
polyurethane foam. The headliner taught by Kornylo purportedly
comprises a substantially constant density while having central
sections with a greater cross-sectional thickness than peripheral
portions. The central sections must be relatively thick such that
the headliner possesses acceptable sound absorbing properties while
the peripheral portions must be relatively thin so as to facilitate
securing of the headliner to the roof of the automobile.
[0014] International Publication Number WO 02/42119 [Zolfaghari]
teaches an improvement to the headliner taught by Kornylo.
Specifically, Zolfaghari teaches a vehicular headliner comprising
energy management capabilities to improve vehicle occupant
safety.
[0015] Regardless of the precise mode of production, it is
conventional to reinforce the headliner using a fibrous
reinforcement layer such as fibreglass. Typically the fibreglass is
used in the form of a fibreglass mat or chopped fibreglass.
[0016] Conventionally, if the headliner is produced from slabstock
foam, it is conventional to initially form a blank comprising a
foam core, an adhesive layer consisting of polyethylene film on
both sides of the foam core and fibreglass mat layer or chopped
fibreglass on each adhesive layer (the blank may also comprise
other layers such as a trim cover and the like). The blank is then
subjected to a forming operation which serves to shape the foam
core and adhere the fibreglass mats to each surface of the shaped
foam core. Conventional forming operations include thermoforming
and thermocrushing (also known as "Cold Forming"). For more detail
on the production of vehicular headliners, see, for example,
"Polyurethane Foam as an Integral "Core" Component of Automotive
Headliner", Dolgopolsky et al., Polyurethanes Expo '99 (1999).
[0017] Polyethylene (or other polymer) film is conventionally used
as the adhesive in large part because it is readily available and
is relatively inexpensive. The polyethylene (or other polymer) is
in the form of an impermeable film that can selected from a variety
of thicknesses.
[0018] The use polyethylene (or other polymer) film as an adhesive
layer in the to production of laminate products such as vehicular
headliners gives rise to certain disadvantages. Specifically, in
recent years, vehicle manufacturers are mandating that trim parts
and panels used in the vehicles interior have improved acoustical
properties to reduce cabin noise in the vehicle. In essence, this
means that the trim parts and panels used in vehicles must have
improved sound absorption properties, preferably without adversely
affecting other properties of the trim parts and panels. This is
especially desirable in the case of a vehicular headliner owing to
its relatively large surface area.
[0019] When polyethylene (or other polymer) film is used as an
adhesive layer in the production of laminate products such as
vehicular headliners the resultant products have a relatively
impervious/impermeable polymer layer or layers. This results in
products that have relatively poor sound absorption properties. The
poor sound absorption properties are related to the air flow
resistance properties of the product. A product with high air flow
resistance (i.e., relatively impermeable to the passage of air)
tends to have relatively poor sound absorption properties whereas a
product with low air flow resistance (i.e., relatively permeable to
air) tends to have relatively good sound absorption properties.
[0020] Accordingly, there remains a need in the art for a laminate
product that has relatively low air flow resistance and improved
sound absorption properties. It would be advantageous if such a
product did not significantly compromise other properties and could
be readily produced using existing equipment. It would be further
advantageous if such a product could be use to produce a relatively
thin vehicular headliner having all requisite properties, together
with improved sound absorption properties.
SUMMARY OF THE INVENTION
[0021] It is an object of the present invention to obviate or
mitigate at least one of the above-mentioned disadvantages of the
prior art.
[0022] Accordingly, in one of its aspects, the present invention
provides a laminate product comprising a foam core having a pair of
opposed major surfaces and a cover layer secured with respect to
each major surface, the cover layer comprising a fibrous
reinforcement layer that is substantially encapsulated by a
polymer, the laminate product having an air flow resistance as
measured in accordance with ASTM C522 of less than about 6,000 mks
Rayls.
[0023] A process for producing a laminate foam product having a
pre-determined shape, the process comprising the steps of:
[0024] positioning a blank in a heating device, the blank
comprising a foam core having a pair of opposed major surfaces and
a cover layer disposed on each major surface, each cover layer
comprising at least one fibrous reinforcing layer and at least one
fibrous polymer layer;
[0025] heating the blank at temperature above the melting point of
the at least one fibrous polymer layer to cause polymer to
substantially encapsulate the at least one fibrous layer and adhere
each cover layer to the foam core.
[0026] Thus, the present inventor has discovered a novel laminate
product having a desirable combination of properties. While it has
been conventional to use fibrous polymeric materials in the
production of laminate products, this has typically been in the
form of the use of so-called non-woven scrim layer. When a scrim
layer has been conventionally used, it has been done so in a manner
which avoids melting of the scrim during production of the laminate
product. The present inventor has discovered a counter-intuitive
technique wherein the fibrous polymer layer (in the form of a scrim
or some other form) is actually used as a melt adhesive to
substantially encapsulate and adhere a fibrous reinforcing layer to
the foam core. The result is a laminate product having a very
desirable lower air flow resistance measured according to ASTM
C522. Such a laminate product has improved acoustical
properties.
[0027] The following additional advantages accrue from the present
invention: [0028] allows for the replacement of conventional
polyethylene film with, in a preferred embodiment, a polypropylene
scrim; [0029] the effect limited production availability of
conventional polyethylene film is reduced or avoided; [0030] the
preferred fibrous polymer layer is a non-woven polypropylene or a
polypropylene-based scrim--this is available from a number of
sources and is significantly less expensive than the conventional
polyethylene film; [0031] the fibrous polymer layer can be made
available in a number of different weights and colours; [0032] the
present invention allows for the production of thinner and/or
lighter laminate products (e.g., for use in vehicular headliners)
which have improved acoustical properties; and [0033] the present
laminate product has a relatively low air flow resistance when
measured within accordance with ASTM C522.
[0034] During the present process, a blank (as described herein) is
heated to a temperature above the melting point of the fibrous
polymeric layer. With or without applied pressure, the melted
fibrous polymer layer then substantially encapsulates the fibrous
reinforcement layer while maintain a porous structure that is
believed to result in relatively low air flow resistance and
improved sound absorption properties.
[0035] While a preferred embodiment of the present invention is
directed to application in vehicular foam parts, such as vehicular
headliners, it will be appreciated by those of skill in the art
that scope of the invention is not restricted to such applications.
Thus, it may be possible to use the invention in other applications
such as floorboards, cargo vehicle mats, Tonneau covers, and other
applications where it is desirable to have a relatively lightweight
article which has energy absorbing and/or structural properties
equivalent to articles made using fiberglass reinforcement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] Embodiments of the present invention will be described with
reference to the accompanying drawings, wherein like reference
numerals denote like parts, and in which:
[0037] FIG. 1 illustrates a schematic of a prior art foam laminate
product in the form a layered structure or blank prior to product
of the foam laminate product;
[0038] FIG. 2 illustrates a schematic of a preferred foam laminate
product in accordance with a preferred embodiment of the present
invention in the form a layered structure or blank prior to product
of the foam laminate product; and
[0039] FIGS. 3-6 the sound absorption properties of various foam
laminate products produced in the Examples.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] The preferred foam for use in the core portion of the
present laminate product is a foamed isocyanate-based polymer.
Preferably, the isocyanate-based polymer is selected from the group
comprising polyurethane, polyurea, polyisocyanurate, urea-modified
polyurethane, urethane-modified polyurea, urethane-modified
polyisocyanurate and urea-modified polyisocyanurate. As is known in
the art, the term "modified", when used in conjunction with a
polyurethane, polyurea or polyisocyanurate means that up to 50% of
the polymer backbone forming linkages have been substituted.
[0041] Typically, the foamed isocyanate-based polymer is produced
from a reaction mixture which comprises an isocyanate and an active
hydrogen-containing compound.
[0042] The isocyanate suitable for use in the reaction mixture is
not particularly restricted and the choice thereof is within the
purview of a person skilled in the art. Generally, the isocyanate
compound suitable for use may be represented by the general
formula:
Q(NCO).sub.i
[0043] wherein i is an integer of two or more and Q is an organic
radical having the valence of i. Q may be a substituted or
unsubstituted hydrocarbon group (e.g., an alkylene or arylene
group). Moreover, Q may be represented by the general formula:
Q.sup.1-Z-Q.sup.1
wherein Q.sup.1 is an alkylene or arylene group and Z is chosen
from the group comprising --O--, --O---Q.sup.1-, --CO--, --S--,
--S-Q.sup.1-S-- and --SO.sub.2--. Examples of isocyanate compounds
which fall within the scope of this definition include
hexamethylene diisocyanate, 1,8-diisocyanato-p-methane, xylyl
diisocyanate, (OCNCH.sub.2CH.sub.2CH.sub.2OCH.sub.2O).sub.2,
1-methyl-2,4-diisocyanatocyclohexane, phenylene diisocyanates,
tolylene diisocyanates, chlorophenylene diisocyanates,
diphenylmethane-4,4'-diisocyanate, naphthalene-1,5-diisocyanate,
triphenylmethane-4,4',4''-triisocyanate and
isopropylbenzene-alpha-4-diisocyanate.
[0044] In another embodiment, Q may also represent a polyurethane
radical having a valence of i. In this case Q(NCO).sub.i is a
compound which is commonly referred to in the art as a prepolymer.
Generally, a prepolymer may be prepared by reacting a
stoichiometric excess of an isocyanate compound (as defined
hereinabove) with an active hydrogen-containing compound (as
defined hereinafter), preferably the polyhydroxyl-containing
materials or polyols described below. In this embodiment, the
polyisocyanate may be, for example, used in proportions of from
about 30 percent to about 200 percent stoichiometric excess with
respect to the proportion of hydroxyl in the polyol. Since the
process of the present invention may relate to the production of
polyurea foams, it will be appreciated that in this embodiment, the
prepolymer could be used to prepare a polyurethane modified
polyurea.
[0045] In another embodiment, the isocyanate compound suitable for
use in the process of the present invention may be selected from
dimers and trimers of isocyanates and diisocyanates, and from
polymeric diisocyanates having the general formula:
Q'(NCO)d.sub.i].sub.j
[0046] wherein both i and j are integers having a value of 2 or
more, and Q' is a polyfunctional organic radical, and/or, as
additional components in the reaction mixture, compounds having the
general formula:
L(NCO).sub.i
[0047] wherein i is an integer having a value of 1 or more and L is
a monofunctional or polyfunctional atom or radical. Examples of
isocyanate compounds which fall with the scope of this definition
include ethylphosphonic diisocyanate, phenylphosphonic
diisocyanate, compounds which contain a .dbd.Si--NCO group,
isocyanate compounds derived from sulphonamides (QSO.sub.2NCO),
cyanic acid and thiocyanic acid.
[0048] See also for example, British patent number 1,453,258, for a
discussion of suitable isocyanates.
[0049] Non-limiting examples of suitable isocyanates include:
1,6-hexamethylene diisocyanate, 1,4-butylene diisocyanate,
furfurylidene diisocyanate, 2,4-toluene diisocyanate, 2,6-toluene
diisocyanate, 2,4'-diphenylmethane diisocyanate,
4,4'-diphenylmethane diisocyanate, 4,4'-diphenylpropane
diisocyanate, 4,4'-diphenyl-3,3'-dimethyl methane diisocyanate,
1,5-naphthalene diisocyanate,
1-methyl-2,4-diisocyanate-5-chlorobenzene,
2,4-diisocyanato-s-triazine, 1-methyl-2,4-diisocyanato cyclohexane,
p-phenylene diisocyanate, m-phenylene diisocyanate, 1,4-naphthalene
diisocyanate, dianisidine diisocyanate, bitolylene diisocyanate,
1,4-xylylene diisocyanate, 1,3-xylylene diisocyanate,
bis-(4-isocyanatophenyl)methane,
bis-(3-methyl-4-isocyanatophenyl)methane, polymethylene polyphenyl
polyisocyanates and mixtures thereof. A more preferred isocyanate
is selected from the group comprising 2,4-toluene diisocyanate,
2,6-toluene diisocyanate and mixtures thereof, for example, a
mixture comprising from about 75 to about 85 percent by weight
2,4-toluene diisocyanate and from about 15 to about 25 percent by
weight 2,6-toluene diisocyanate. Another more preferred isocyanate
is selected from the group comprising 2,4'-diphenylmethane
diisocyanate, 4,4'-diphenylmethane diisocyanate and mixtures
thereof. The most preferred isocyanate is a mixture comprising from
about 15 to about 25 percent by weight 2,4'-diphenylmethane
diisocyanate and from about 75 to about 85 percent by weight
4,4'-diphenylmethane diisocyanate.
[0050] If the process is utilized to produce a polyurethane foam,
the active hydrogen-containing compound is typically a polyol. The
choice of polyol is not particularly restricted and is within the
purview of a person skilled in the art. For example, the polyol may
be a hydroxyl-terminated backbone of a member selected from the
group comprising polyether, polyester, polycarbonate, polydiene and
polycaprolactone. Preferably, the polyol is selected from the group
comprising hydroxyl-terminated polyhydrocarbons,
hydroxyl-terminated polyformals, fatty acid triglycerides,
hydroxyl-terminated polyesters, hydroxymethyl-terminated
polyesters, hydroxymethyl-terminated perfluoromethylenes,
polyalkyleneether glycols, polyalkylenearyleneether glycols and
polyalkyleneether triols. More preferred polyols are selected from
the group comprising adipic acid-ethylene glycol polyester,
poly(butylene glycol), poly(propylene glycol) and
hydroxyl-terminated polybutadiene--see, for example, British patent
number 1,482,213, for a discussion of suitable polyols. Preferably,
such a polyether polyol has a molecular weight in the range of from
about 100 to about 10,000, more preferably from about 100 to about
4,000, most preferably from about 100 to about 3,500.
[0051] If the core portion is to comprise a polyurea foam, the
active hydrogen-containing compound comprises compounds wherein
hydrogen is bonded to nitrogen. Preferably such compounds are
selected from the group comprising polyamines, polyamides,
polyimines and polyolamines, more preferably polyamines.
Non-limiting examples of such compounds include primary and
secondary amine terminated polyethers. Preferably such polyethers
have a molecular weight of greater than about 100 and a
functionality of from 1 to 25. Such amine terminated polyethers are
typically made from an appropriate initiator to which a lower
alkylene oxide is added with the resulting hydroxyl terminated
polyol being subsequently aminated. If two or more alkylene oxides
are used, they may be present either as random mixtures or as
blocks of one or the other polyether. For ease of amination, it is
especially preferred that the hydroxyl groups of the polyol be
essentially all secondary hydroxyl groups. Typically, the amination
step replaces the majority but not all of the hydroxyl groups of
the polyol.
[0052] The reaction mixture used to produce the foamed
isocyanate-based polymer core portion typically will further
comprise a blowing agent. As is known in the art, water can be used
as an indirect or reactive blowing agent in the production of
foamed isocyanate-based polymers. Specifically, water reacts with
the isocyanate forming carbon dioxide which acts as the effective
blowing agent in the final foamed polymer product. Alternatively,
the carbon dioxide may be produced by other means such as unstable
compounds which yield carbon dioxide (e.g., carbamates and the
like). Optionally, direct organic blowing agents may be used in
conjunction with water although the use of such blowing agents is
generally being curtailed for environmental considerations. The
preferred blowing agent for use in the production of the present
foamed isocyanate-based polymer comprises water.
[0053] It is known in the art that the amount of water used as an
indirect blowing agent in the preparation of a foamed
isocyanate-based polymer is conventionally in the range of from
about 0.5 to as high as about 40 or more parts by weight,
preferably from about 1.0 to about 10 parts by weight, based on 100
parts by weight of the total active hydrogen-containing compound
content in the reaction mixture. As is known in the art, the amount
of water used in the production of a foamed isocyanate-based
polymer typically is limited by the fixed properties expected in
the foamed polymer and by the tolerance of the expanding foam
towards self structure formation.
[0054] To produce the core portion made from a foamed
isocyanate-based polymer, a catalyst is usually incorporated in the
reaction mixture. The catalyst used in the reaction mixture is a
compound capable of catalyzing the polymerization reaction. Such
catalysts are known, and the choice and concentration thereof in
the reaction mixture is within the purview of a person skilled in
the art. See, for example, U.S. Pat. Nos. 4,296,213 and 4,518,778
for a discussion of suitable catalyst compounds. Non-limiting
examples of suitable catalysts include tertiary amines and/or
organometallic compounds. Additionally, as is known in the art,
when the objective is to produce an isocyanurate, a Lewis acid must
be used as the catalyst, either alone or in conjunction with other
catalysts. Of course it will be understood by those skilled in the
art that a combination of two or more catalysts may be suitably
used.
[0055] Preferably, the foam core portion of the present laminate
product comprises an compression force deflection at 10% deflection
in the range of from about 2 psi to about 200 psi when measured
pursuant to ASTM 3574-D, more preferably in the range of from about
5 psi to about 100 psi when measured pursuant to ASTM 3574-D most
preferably, in the range of from about 10 psi to about 80 psi when
measured pursuant to ASTM 3574-D. Throughout this specification,
when reference is made to ASTM 3574-D, the test sample has the
following dimensions: 2 ft..times.2 ft..times.1 in. (last dimension
is the thickness).
[0056] Non-limiting and preferred examples of suitable polyurethane
foams for use in producing the present headliner are available from
Woodbridge Foam Corporation under the tradename Stratas.
[0057] Generally, the polyurethane foam suitable for use in the
present headliners and having desirable energy management and/or
structural characteristics may be produced from the following
general non-limiting formulation:
TABLE-US-00001 Component Amount Polymer Polyol 100-0 parts Polyol
0-100 parts Crosslinker 0-30 parts/100 parts total polyol Catalyst
0.05 to 3.5 parts/100 parts total polyol Silicone Surfactants 0-1.5
parts/100 parts total polyol H.sub.2O 0.5 to 25 parts/100 parts
total polyol Isocyanate Adequate quantity for an index of from
about 0.60 to 1.30 ratio of NCO equivalents to the equivalents of
NCO reactive sites.
[0058] Suitable crosslinkers, catalysts and silicone surfactants
are described in U.S. Pat. Nos. 4,107,106 and 4,190,712.
[0059] The preferred polyurethane foam suitable for use in the
present headliner may be produced from the following
formulation:
TABLE-US-00002 Component Amount Polymer Polyol 20-100 parts Polyol
0-80 parts Crosslinker 5-15 parts/100 parts total polyol Catalyst
0.5-1.2 parts/100 parts total polyol Silicone Surfactants 0.3-1.1
parts/100 parts total polyol H.sub.2O 1.75-2.75 parts/100 parts
total polyol Isocyanate Adequate quantity for an index of from
about 0.8 to 1.1 ratio of NCO equivalents to the equivalents of NCO
reactive sites.
[0060] Typically, the foamed isocyanate-based polymer is produced
from a reaction mixture which comprises an isocyanate and an active
hydrogen-containing compound. The foam core in the present laminate
product may have a substantially uniform density--this is typically
a characteristic of a molded foam (i.e., a foam produced by
constraining the expanding mass on all surfaces as it is converted
to the foam product). Alternatively, and preferably, the foam core
has a variable density--this is typically a characteristic of a
slab foam (i.e., a foam produced by a process in which at least one
surface of the expanding mass is unconstrained so that the mass may
"free rise" as it is converted to the foam product) after
conventional forming operations such as thermoforming and
thermocrushing (also known as "Cold Forming"). For more detail on
the production of vehicular headliners, see, for example,
"Polyurethane Foam as an Integral "Core" Component of Automotive
Headliner", Dolgopolsky et al., Polyurethanes Expo '99 (1999).
[0061] Preferably, the foam core in the present laminate product
has a density in the range of from about 0.5 to about 30 pounds per
cubic foot, more preferably in the range of from about 1 to about
20 pounds per cubic foot, even more preferably in the range of from
about 2 to about 15 pounds per cubic foot, most preferably in the
range of from about 2 to about 8 pounds per cubic foot.
[0062] Preferably, the foam core used in the present laminate
product comprises a thickness of greater than or equal to about 2
mm, more preferably from about 2 mm to about 20 mm, more preferably
from about 3 mm to about 15 mm, even more preferably from about 3
mm to about 12 mm, even more preferably from about 3 mm to about 8
mm, most preferably from about 3 mm to about 6 mm.
[0063] The present laminate product further comprises a cover layer
disposed on opposed surfaces of the foam core portion. The cover
layer comprising a fibrous reinforcement layer that is
substantially encapsulated by a polymer.
[0064] Preferably, a first cover layer is adhered by the polymer to
a first major surface of the foam core and a second cover layer is
adhered by the polymer to a second major surface of the foam core.
One or both of the first cover layer and the second cover layer may
comprise a single fibrous reinforcement layer. Alternatively, one
or both of the first cover layer and the second cover layer may
comprise a plurality of fibrous reinforcement layers.
[0065] Preferably, one or both of the first cover layer and the
second cover layer each independently comprise from 1 to 15 fibrous
reinforcement layers, more preferably from 1 to 12 fibrous
reinforcement layers, more preferably from 1 to 10 fibrous
reinforcement layers, most preferably from 1 to 5 fibrous
reinforcement layers.
[0066] Preferably, the polymer that substantially encapsulates the
at least one fibrous reinforcement layer comprises an organic
polymer. The organic polymer may be selected from a thermoplastic
polymer, an elastomeric material and a thermosetting material.
[0067] Preferably, the polymer is selected from the group
consisting of a polyolefin, a polyester, a nylon, poly(vinyl
choride), a polyurethane, a polyacrylate, a latex, a
styrene-butadiene polymer, a nitrile-butadiene polymer, a silicone
polymer, mixtures thereof, copolymers thereof and interpenetrating
networks thereof.
[0068] In a more preferred embodiment, the polymer comprises a
polyolefin.
[0069] The polyolefin may be selected from the group consisting of
a homopolymer, a copolymer and a terpolymer derived from the
polymerization of at least one olefin monomer.
[0070] Non-limiting examples of the olefin monomer may be selected
from the group comprising .alpha.-olefin monomers, diolefin
monomers and polymerizable monomers containing at least one
internal olefin linkage.
[0071] In one embodiment, the olefin monomer comprises an
.alpha.-olefin monomer. Non-limiting examples of the .alpha.-olefin
monomer may be selected from the group propylene, 1-butene,
isobutene, 1-pentene, 1-hexene, 1-octene, branched isomers thereof,
styrene, .alpha.-methylstyrene and mixtures thereof. Preferably,
the .alpha.-olefin monomer comprises propylene.
[0072] In another embodiment, the olefin monomer comprises a
diolefin monomer.
[0073] In one embodiment, the diolefin monomer comprises an
aliphatic compound. Non-limiting examples of such a diolefin
monomer may be selected from the group comprising 1,3-butadiene,
isoprene, 2,3-dimethyl-1,3-butadiene, 2-ethyl-1,3-butadiene,
piperylene, myrcene, allene, 1,2-butadiene, 1,4,9-decatrienes,
1,4-hexadiene, 1,6-octadiene, 1,5-hexadiene,
4-methyl-,1,4-hexadiene, 5-methyl-1,4-hexadiene,
7-methyl-octa-1,6-diene-1,6, phenylbutadiene, pentadiene and
mixtures thereof.
[0074] In another embodiment, the diolefin monomer comprises a
bicyclic compound. Non-limiting examples of such a diolefin monomer
may be selected from the group comprising norbornadiene, alkyl
derivatives thereof, 5-alkylidene-2-norbornene compounds,
5-alkenyl-2-norbornene compounds and mixtures thereof. More
preferred embodiments of such a diolefin monomer may be selected
from the group comprising 5-methylene-2-norbornene,
5-ethylidene-2-norbornene, 5-propenyl-2-norbornene
1,4-cyclohexadiene, 1,5-cyclooctadiene, 1,5-cyclododecadiene,
methyltetrahydroindene, dicyclopentadiene, bicyclo
[2.2.1]hepta-2,5-2,5-diene and mixtures thereof.
[0075] When the polyolefin is a copolymer, it may be derived from
polymerization of a mixture of ethylene and at least one
.alpha.-olefin, preferably from polymerization of a mixture of
ethylene and propylene. The mixture may comprise from about 30 to
about 75 ethylene and from about 25 to about 70 weight percent
.alpha.-olefin, preferably from about 35 to about 65 ethylene and
from about 35 to about 65 weight percent .alpha.-olefin, more
preferably from polymerization of a mixture of ethylene, at least
one .alpha.-olefin and at least one diolefin monomer.
[0076] When the polyolefin is a terpolymer derived from
polymerization of a mixture of ethylene, propylene and one or both
of 5-ethylidene-2-norbornene 1,5-hexadiene and 1,5-hexadiene. The
mixture may comprise from about 0.5 to about 15 weight percent of
the diolefin monomer, more preferably from about 1 to about 10
weight percent of the diolefin monomer.
[0077] In a more preferred embodiment the polyolefin is selected
from the group comprising polypropylene, ethylene-propylene
copolymers, polyethylene and mixtures thereof The most preferred
polyolefin is polypropylene.
[0078] The polyolefin may have a molecular weight (Mn) in the range
of from about 10,000 to about 100,000, more preferably from about
20,000 to about 80,000. most preferably from about 40,000 to about
60,000.
[0079] The present laminate product has an air flow resistance as
measured in accordance with ASTM C522 of less than about 6,000 mks
Rayls, more preferably less than about 5,750 mks Rayls, more
preferably less than about 5,500 mks Rayls, more preferably less
than about 5,250 mks Rayls, more preferably less than about 5,000
mks Rayls, more preferably from about 500 to about 5,000 mks Rayls,
more preferably, from about 500 to about 4,500 mks Rayls, more
preferably from about 500 to about 4,000 mks Rayls, more preferably
from about 500 to about 3,000 mks Rayls, more preferably from about
700 to about 2,700 mks Rayls, most preferably from about 500 to
about 1,500 mks Rayls.
[0080] The fibrous reinforcement layer may be made from nature
fibers or synthetic fibers. The melting point (if any) of the
fibers used in the fibrous reinforcement layer should be greater
than the melting point of the polymer used to substantially
encapsulate the fibrous reinforcement layer. The fibrous
reinforcement layer may be constructed from fibrous materials such
as fibreglass, natural fibers (e.g., hemp, burlap, etc), basalt
fibers, nylon fibers, composites of two or more of these and the
like.
[0081] The preferred method for producing the present laminate
product will now be discussed. Prior to this discussion, there will
be a brief discussion of the prior art approach to producing a
vehicular headliner.
[0082] Thus, with reference to FIG. 1, there is illustrated in
schematic form, the various layers of materials used in the
production of a conventional headliner product. These components
include a foam core 20 having its major surfaces covered by two
cover layers. Each cover layer consists of a single fibreglass mat
12 interposed between a pair of polyethylene film layers 10. One of
the cover layers also includes a scrim layer 15 while other cover
layer includes a coverstock material 17.
[0083] When it is desired to produce the vehicular headliner
material, a stack or blank containing the layers described above is
placed in a conventional thermoforming device (or other a shaping
device) after which the stack or blank is subjected to heat and
pressure (sequentially or concurrently) for a sufficient time such
that polyethylene film layers 10 serve to permeate into fibreglass
mat 12 and also serve to adhere the cover layers to foam core 20.
Thereafter, or concurrently, foam core 20 is shaped to the desired
shape of the vehicular headliner. The resulting product is
relatively impervious/impermeable to air flow since polyethylene
film layers 10 tend to remain impervious/impermeable even after
they have permeated into fibreglass mat 12.
[0084] With reference to FIG. 2, there is illustrated, in schematic
form, the layers used in a preferred embodiment of the present
laminate product. As shown, polyethylene film layers 10 used in the
conventional approach (FIG. 1) have been replaced with a a fibrous
polymer layer 25. A fibrous reinforcement layer 30 interposed
between a pair of Fibrous polymer layers 25. One of the cover
layers also includes a scrim layer 15 while other cover layer
includes a coverstock material 17.
[0085] Thus, the major surfaces of foam core 20 are covered by a
cover layer. In the illustrated embodiment, each cover layer
consists of a single fibrous reinforcement layer which is
interposed between a pair of fibrous polymer layers 25. Those of
skill in the art will appreciate that, for a given cover layer, it
is possible (and in some cases preferred) to have pairs of fibrous
polymer layer 25 and fibrous reinforcement layer 30 with an extra
fibrous polymer layer 25 to create a stack or blank having N
fibrous reinforcement layers and greater than N (N+1 or more)
fibrous polymer layers.
[0086] Foam core 20, fibrous polymer layers 25 and fibrous
reinforcement layers 30 may be selected from the materials
described hereinabove.
[0087] Fibrous reinforcement layer 30 may be used as one or more
sheet or mat-like materials. Alternatively, fibrous reinforcement
layer 30 may be used in the form of loose (e.g., chopped) fibres.
The fibrous mat-like material may contain polymer material, and/or
layers of fibrous polymer, to bind and/or to encapsulate the fibers
(prefabricated skin). This contemplates the case where a composite
skin containing layers of fibrous polymer and reinforcement fibers
is prefabricated and then used to make the product, or even as a
product on its own which can be used, for example, as a component
for wet process or dry process headliners.
[0088] It will be appreciated that the fibrous polymer layer may be
woven or non-woven. Further information on such materials may be
found on the following websites: http://www.nonwovens-group.com,
http://www.johnrstarr.com and http://www.inda.org. Preferably, the
fibrous polymer layer is non-woven and, more preferably, is
spun-bound. Alternatively, other non-woven fibrous polymer layers
such as staple-fiber, meltblown and blends thereof may be used.
Further, in some cases, it may be desirable to pre-treat the
fibrous polymer layer to enhance adhesion strength of that layer to
the foam core. For example, it may be desirable to subject the
fibrous polymer layer to a surface treatment such as corona
treatment, plasma treatment and the like.
[0089] The most preferred fibrous polymer layer for use in
producing the present laminate product is non-woven, spun-bound
polypropylene.
[0090] Preferably, the fibrous polymer layer has a basis weight of
from about 0.1 to about 4.0 oz/yd.sup.2, more preferably from about
0.5 to about 2.5 oz/yd.sup.2, more preferably from about 0.8 to
about 2.8 oz/yd.sup.2, most preferably from about 1.0 to about 2.3
oz/yd.sup.2.
[0091] One or both of each cover layer independently may comprise a
single fibrous reinforcement layer or a plurality of fibrous
reinforcement layers. Preferably, one or both of the first cover
layer and the second cover layer independently comprises from 1 to
15 fibrous reinforcement layers, more preferably from 2 to 12
fibrous reinforcement layers, more preferably from 2 to 10 fibrous
reinforcement layers, most preferably from 2 to 5 fibrous
reinforcement layers.
[0092] When it is desired to produce the present laminate product,
a stack or blank similar to the one shown in FIG. 2 is disposed in
a conventional forming or shaping device such as a device capable
of carry out forming operations such as thermoforming and
thermocrushing (also known as "Cold Forming"). For more detail on
the production of vehicular headliners, see, for example,
"Polyurethane Foam as an Integral "Core" Component of Automotive
Headliner", Dolgopolsky et al., Polyurethanes Expo '99 (1999).
[0093] The stack or blank is then subjected to a temperature that
exceeds the melting point of fibrous polymer layer 25 in the
shaping device at a pressure and for period of time sufficient to
cause fibrous polymer layers 25 to melt and substantially
encapsulate fibrous reinforcement layer 30. Thereafter or
concurrently, foam core 20 assumes the pre-determined shape
(contoured or planar) of the laminate product. Thus, during the
process, each of fibrous polymer layers 25 permeates into adjacent
fibrous reinforcement layers 30 with the result that the latter are
substantially completely encapsulated by the former and the
combination is adhered to foam core 20.
[0094] During the process, fibrous polymer layers 25 melt or
otherwise become flowable to wet out, fully permeate and/or
substantially encapsulate fibrous reinforcement layer(s) 30. By
using fibrous polymer layers 25 (instead of polyethylene film
layers 10 described above in connection with FIG. 1), the resulting
foam laminate product contains a polymer layer that maintains a
degree of porosity which allows for lower air flow resistance and
improved sound absorption properties.
[0095] The heating step in the present process is conducted at a
temperature greater than the melting point of the fibrous polymer
layer. For example, if the fibrous polymer layer is a polypropylene
scrim (the most preferred embodiment), the heating step may be
conducted at approximately 165.degree. C. Typically, the heating
step is conducted at a temperature of at least about 100.degree.
C., more preferably in the range of from about 100.degree. C. to
about 250.degree. C., even more preferably from about 110.degree.
C. to about 250.degree. C., most preferably from about 110.degree.
C. to about 200.degree. C.
[0096] It is possible to conduct the process using a two step
lamination approach. In this approach, the stack or blank is placed
in flat-bed laminator (e.g., a Meyer Laminator) and heated under
pressure to produce an initial laminate product. This initial
laminate product is then placed in a second laminator that heats
(e.g., infrared heat) and shapes the initial laminate product to
produce the final product. An example of the second laminator is
described in U.S. Pat. No. 5,928,597 [Van Ert], U.S. Pat. No.
6,146,578 [Van Ert el al.] and U.S. Pat. No. 6,338,618 [Van Ert et
al.].
[0097] Alternatively, in some applications for the present laminate
product, it is possible to conduct the process using a one step
approach--e.g., a flat bed laminator, a laminator that accomplishes
lamination and shaping in a single piece of equipment and the
like.
[0098] Embodiments of the present invention will now be described
with reference to the following Examples which are provided for
illustrative purposes only and should not be used to limit or
construe the invention.
[0099] In the Examples, the following materials were used:
[0100] CF--Core foam (thickness=5.5 mm)--polyurethane foam having a
density of 40 kg/m.sup.3 commercially available from Woodbridge
Foam Corporation under the tradename Stratas 1825.TM.;
[0101] PE--Polyethylene (HDPE) film having a thickness of 2 mil
corresponding to 1.5 oz/yd.sup.2 (47 g/m.sup.2) conventionally used
in the product of foam laminate products;
[0102] FPL#1--Fibrous polymer layer--spun-bound, non-woven
polypropylene scrim--1.0 oz/yd.sup.2 (33 g/m.sup.2);
[0103] FPL#2--Fibrous polymer layer--spun-bound, non-woven
polypropylene scrim--2.25 oz/yd.sup.2 (75 g/m.sup.2);
[0104] SCM--Scrim--spun-bound polyester scrim 1.0 oz/yd.sup.2;
and
[0105] FRL--Fibrous reinforcement layer--chopped strand fiberglass
mat--80 g/m.sup.2.
EXAMPLES 1-3
[0106] Example 1 was produced using a blank having the following
lay-up:
TABLE-US-00003 PE FRL PE FC PE FRL PE SCM
Example 1 is provided for comparative purposes only and is outside
the scope of the present invention.
[0107] Examples 2 and 3 were produced using blanks having the
following lay-ups:
TABLE-US-00004 FPL#1 FRL FPL#1 FC FPL#1 FRL FPL#1 SCM
TABLE-US-00005 FPL#2 FRL FPL#2 FC FPL#2 FRL FPL#2 SCM
[0108] Each blank or stack was manually passed through a flat bed
laminator, consisting of an adjacent heating zone and cooling zone.
The process parameters for lamination were as follows: [0109] line
speed: 9 m/min-12 m/min; [0110] hot Platens temp.: 175.degree.
C.-240.degree. C.; [0111] pressure roller offset: 1.8 mm; [0112]
plate height 5.2 mm; and [0113] cold platens temperature:
20.degree. C.-45.degree. C. The resulting samples were conditioned
for 24 hours.
[0114] Thereafter the samples were heated and shaped in a laminator
such as the one described in U.S. Pat. No. 5,928,597 [Van Ert],
U.S. Pat. No. 6,146,578 [Van Ert el al.] and U.S. Pat. No.
6,338,618 [Van Ert et al.] to produce the final form of the
samples. The process conditions for this part of the process were
as follows: [0115] infrared oven power: 75 to 90% of heater output;
[0116] infrared oven dwell time: 50 to 100 seconds; [0117]
substrate surface temperature: 185.degree. C.-200.degree. C.;
[0118] substrate core temperature: 185.degree. C.-200.degree. C.;
[0119] forming press pressure: 1-4 inches Hg; and [0120] forming
press time: 50-80 seconds.
[0121] The maximum load and stiffness (both at room temperature) of
the samples was measured according to Honda Specification
8302Z-S84-0000. The air flow resistance of the samples was measured
according to ASTM C522. The results of these physical tests are
reported in Table 1, together with the weight of each sample.
[0122] Quite surprisingly, in comparing the results for Examples 1
and 2, these results show that a lighter laminate product can be
made with significantly lower air flow resistance while maintaining
maximum load and stiffness properties. Such a product would present
a significant improvement to know laminate products.
[0123] A comparison of results for Examples 1 and 3 shows that the
laminate product of Example 3 is heavier, it has significantly
greater maximum load while still achieve a significant reduction in
air flow resistance compared to Example 1. Such a product would
have use in an application where the added weight is tolerable
given the maximum load that can be absorbed.
[0124] The sound absorption coefficient of the samples for Examples
1 and 2 was measured according to ASTM E1050 using a conventional
testing apparatus that provided an air gap of 5 mm or 10 mm. The
results are illustrated in FIGS. 3 (5 mm air gap) and 4 (10 mm air
gap). As illustrated, these results illustrate the sample produced
in Example 2 (invention) had relatively high sound absorption
coefficient at higher frequency when compared with the sample
produced in Example 1 (comparative). This high sound absorption
coefficient translates into improved sound absorption properties
for the sample produced in Example 2 (invention) compared to the
that produced in Example 1 (comparative).
Examples 4-5
[0125] Typically, the foamed isocyanate-based polymer is produced
from a reaction mixture which comprises an isocyanate and an active
hydrogen-containing compound.
[0126] Examples 4 and 5 were produced using the methodology used in
Examples 1-3 and blanks having the following lay-ups:
TABLE-US-00006 PE FRL PE PE FRL PE FC PE FRL PE SCM
TABLE-US-00007 FPL#1 FRL FPL#1 FPL#1 FRL FPL#1 FC FPL#1 FRL FPL#2
SCM
[0127] Example 4 is provided for comparative purposes only and is
outside the scope of the present invention.
[0128] The result samples were subjected to the same physical
testing reporting in connection with Examples 1-3 and the results
are reported in Table 2 (weight, maximum load, strength and air
flow resistance) and FIG. 4 (sound absorption). The same trends
reported in connected with the results for Examples 1-3 are seen in
the results for Examples 4-5.
Examples 6-7
[0129] Examples 6 and 7 were produced using the methodology used in
Examples 1-3 and blanks having the following lay-ups:
TABLE-US-00008 PE FRL PE FRL PE FC PE FRL PE SCM
TABLE-US-00009 FPL#1 FRL FPL#1 FRL FPL#1 FC FPL#1 FRL FPL#2 SCM
[0130] Example 6 is provided for comparative purposes only and is
outside the scope of the present invention.
[0131] The result samples were subjected to the same physical
testing reporting in connection with Examples 1-3 and the results
are reported in Table 3 (weight, maximum load, strength and air
flow resistance) and FIGS. 5 and 6 (sound absorption, air gap of 5
mm and 10 mm, respectively). The same trends reported in connected
with the results for Examples 1-3 are seen in the results for
Examples 6-7.
[0132] While this invention has been described with reference to
illustrative embodiments and examples, the description is not
intended to be construed in a limiting sense. Thus, various
modifications of the illustrative embodiments, as well as other
embodiments of the invention, will be apparent to persons skilled
in the art upon reference to this description. For example, if it
is desired to produce the present laminate product from a molded
foam core, this can be achieved by forming and shaping the cover
layers from the stacks referred to in FIG. 2 independently of the
foam core. The foam core could be molded independently of the cover
layers (i.e., the conversion of the foamable composition to the
foam core would be completed in a mold constraining all surfaces of
the foam core) and the formed elements can then be adhered to each
other with conventional adhesive. Further, it is possible to
include a finishing or trim cover on one major surface of the
present laminate product thereby producing a finished part. Still
further, it is possible to add other elements to the foam laminate
product during production thereof. For example, it is possible to
incorporate one or more of: (i) an electrically conduct layer in
the foam laminate product to provide a heating function, (ii) a
sound absorbing layer to further improve acoustical performance of
the foam laminate product, and/or (iii) a flame retardant layer to
improve flame retardant properties of the foam laminate. Still
further, while the Examples illustrate product of a preferred
embodiment of the present laminate product using a two-step
lamination approach (i.e., flat bed laminator followed heat/shaping
in a separate laminator), it will be apparent that, depending on
the final application for the laminate product to is possible to
use a one step lamination approach--e.g., using a flat bed
laminator, a laminator that accomplishes lamination, heating and
shaping in a single piece of equipment, and the like. It is
therefore contemplated that the appended claims will cover any such
modifications or embodiments.
[0133] All publications, patents, patent applications and subject
matter on Internet website referred to herein are incorporated by
reference in their entirety to the same extent as if each
individual publication, patent or patent application was
specifically and individually indicated to be incorporated by
reference in its entirety.
TABLE-US-00010 TABLE 1 Example 1 Example 2 Example 3 Weight
(g/m.sup.2) 601 545 710 Maximum load (N) 22.4 21.3 30.1 Stiffness
(N/mm) 10.7 11.3 12.7 Air flow resistance (mks Rayels) 21845 1566
5493
TABLE-US-00011 TABLE 2 Example 4 Example 5 Weight (g/m.sup.2) 775
691 Maximum load (N) 39.0 39.0 Stiffness (N/mm) 14.5 14.2 Air flow
resistance (mks Rayels) 6160 2427
TABLE-US-00012 TABLE 3 Example 6 Example 7 Weight (g/m.sup.2) 728
658 Maximum load (N) 38.3 35.5 Stiffness (N/mm) 14.9 14.2 Air flow
resistance (mks Rayels) 7037 2214
* * * * *
References