U.S. patent application number 15/223725 was filed with the patent office on 2017-02-23 for thermoplastic sheets and articles with variable lofting capacity.
The applicant listed for this patent is Anthony J. Messina, Yune Seo Park. Invention is credited to Anthony J. Messina, Yune Seo Park.
Application Number | 20170050408 15/223725 |
Document ID | / |
Family ID | 57944009 |
Filed Date | 2017-02-23 |
United States Patent
Application |
20170050408 |
Kind Code |
A1 |
Park; Yune Seo ; et
al. |
February 23, 2017 |
THERMOPLASTIC SHEETS AND ARTICLES WITH VARIABLE LOFTING
CAPACITY
Abstract
Certain configurations are described herein of a thermoplastic
sheet or article comprising a plurality of porous layers coupled to
each other. In one configuration, the thermoplastic article may
comprise a core layer, a first layer disposed on one surface of the
core layer and a second layer disposed on another surface of the
core layer. In some instances, each of the core layer, the first
layer and the second layer may comprises a web of open celled
structures formed by a plurality of reinforcing materials bonded
together with a thermoplastic material and optionally may also
include a lofting agent. The lofting capacity in different layers
can be selected or tuned to provide desired properties.
Inventors: |
Park; Yune Seo; (Fenton,
MI) ; Messina; Anthony J.; (Macomb, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Park; Yune Seo
Messina; Anthony J. |
Fenton
Macomb |
MI
MI |
US
US |
|
|
Family ID: |
57944009 |
Appl. No.: |
15/223725 |
Filed: |
July 29, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62199767 |
Jul 31, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 70/02 20130101;
B32B 29/007 20130101; B32B 2250/03 20130101; B32B 2605/00 20130101;
B29K 2309/08 20130101; B32B 2307/718 20130101; B32B 2307/738
20130101; B29C 44/569 20130101; B32B 37/12 20130101; B29C 65/02
20130101; B32B 2398/20 20130101; B29K 2075/00 20130101; B32B
2255/02 20130101; B29K 2105/128 20130101; B32B 7/02 20130101; B32B
2307/102 20130101; B32B 2250/40 20130101; B32B 2255/26 20130101;
B32B 2250/05 20130101; B32B 27/40 20130101; B29C 44/02 20130101;
B32B 2270/00 20130101; B32B 7/12 20130101; B29K 2023/14 20130101;
B32B 37/06 20130101; B32B 5/022 20130101; B32B 2419/00 20130101;
B32B 2307/732 20130101; B32B 2307/546 20130101; B32B 2607/00
20130101; B29K 2995/0078 20130101; B32B 2262/10 20130101; B32B
2255/12 20130101; B32B 5/32 20130101; B29C 65/48 20130101; B32B
27/24 20130101; B32B 29/02 20130101; B32B 3/26 20130101; B32B
2305/08 20130101; B32B 2305/022 20130101; B32B 5/18 20130101; D21H
13/50 20130101; B32B 2307/3065 20130101; D21H 13/14 20130101; B32B
2255/20 20130101; B32B 2264/108 20130101; B29C 66/7212 20130101;
B32B 2307/7265 20130101; B32B 27/12 20130101; B32B 2262/02
20130101; B32B 27/10 20130101; B32B 2262/101 20130101; B29L
2031/3017 20130101; B32B 5/024 20130101; D21H 13/36 20130101; B32B
2266/0278 20130101; B32B 5/245 20130101; D21H 13/20 20130101 |
International
Class: |
B32B 3/26 20060101
B32B003/26; B29C 44/56 20060101 B29C044/56; B29C 65/48 20060101
B29C065/48; B29C 65/02 20060101 B29C065/02; B32B 27/24 20060101
B32B027/24; B32B 5/32 20060101 B32B005/32; B32B 7/12 20060101
B32B007/12; B32B 37/12 20060101 B32B037/12; B32B 37/06 20060101
B32B037/06; B29C 44/02 20060101 B29C044/02; B29C 65/00 20060101
B29C065/00 |
Claims
1. A thermoplastic sheet comprising: a core layer comprising a web
of open celled structures formed by a plurality of reinforcing
materials bonded together with a thermoplastic material, the core
layer further comprising a lofting agent, the core layer also
comprising a first surface and a second surface opposite the first
surface; a first layer disposed on the first surface of the core
layer, the first layer comprising a web of open celled structures
formed by a plurality of reinforcing materials bonded together with
a thermoplastic material; and a second layer disposed on the second
surface of the core layer, the second layer comprising a web of
open celled structures formed by a plurality of reinforcing
materials bonded together with a thermoplastic material.
2. The thermoplastic sheet of claim 1, in which a basis weight of
the first layer is substantially the same as a basis weight of the
second layer.
3. The thermoplastic sheet of claim 2, in which a basis weight of
the core layer is greater than the basis weight of the first layer
and greater than the basis weight of the second layer.
4. The thermoplastic sheet of claim 1, in which the reinforcing
materials of the first layer, the second layer and the core layer
each comprise reinforcing fibers.
5. The thermoplastic sheet of claim 4, in which the first layer
comprises at least one different reinforcing fiber material than
the reinforcing fiber materials of the core layer.
6. The thermoplastic sheet of claim 4, in which the reinforcing
fibers of the first layer, the second layer and the core layer
comprise at least one common reinforcing fiber material.
7. The thermoplastic sheet of claim 1, in which the thermoplastic
material in the core layer is different than the thermoplastic
material in the first layer.
8. The thermoplastic sheet of claim 1, in which the thermoplastic
material in the first layer and the second layer are the same.
9. The thermoplastic sheet of claim 8, in which the reinforcing
materials in the first layer and the second layer are the same.
10. The thermoplastic sheet of claim 8, in which the reinforcing
materials in the first layer and the second layer are the
different.
11. The thermoplastic sheet of claim 6, in which the reinforcing
materials of the first layer, the second layer and the core layer
each comprise reinforcing fibers.
12. The thermoplastic sheet of claim 11, in which the first layer
comprises at least one different reinforcing fiber than the
reinforcing fibers of the core layer.
13. The thermoplastic sheet of claim 11, in which the reinforcing
fibers of the first layer, the second layer and the core layer
comprise at least one common reinforcing fiber type.
14. The thermoplastic sheet of claim 1, in which the lofting agent
of the core layer comprises at least one of expandable microspheres
and expandable graphite materials.
15. The thermoplastic sheet of claim 14, in which no lofting agent
is present in the first layer or in the second layer.
16. The thermoplastic sheet of claim 15, in which the thermoplastic
material and reinforcing materials of the first layer and the
second layer are selected to permit lofting of the first layer and
the second layer.
17. The thermoplastic sheet of claim 16, in which the thermoplastic
material and reinforcing materials of the first layer and second
layer permit lofting of the first layer and the second layer at a
different lofting temperature than a lofting temperature used to
loft the core layer.
18. The thermoplastic sheet of claim 1, further comprising a first
adhesive layer disposed on the first surface of the core layer
between the first layer and the core layer.
19. The thermoplastic sheet of claim 18, further comprising a
second adhesive layer disposed on the second surface of the core
layer between the second layer and the core layer.
20. The thermoplastic sheet of claim 19, in which the first layer
is directly disposed on the first adhesive layer and the second
layer is directly disposed on the second adhesive layer, in which
the first adhesive layer is directly disposed on the first surface
of the core layer and in which the second adhesive layer is
directly disposed on the second surface of the core layer.
21-120. (canceled)
Description
PRIORITY APPLICATION
[0001] This application is related to, and claims priority to and
the benefit of, U.S. Application No. 62/199,767 filed on Jul. 31,
2015, the entire disclosure of which is hereby incorporated herein
by reference for all purposes.
TECHNOLOGICAL FIELD
[0002] This application is related to thermoplastic sheets and
articles with variable lofting capacity. More particularly, certain
embodiments described herein are directed to multi-layer articles
with different lofting capacities in different layers.
BACKGROUND
[0003] Articles for automotive and construction materials
applications typically are designed to meet a number of competing
and stringent performance specifications.
SUMMARY
[0004] Certain configurations are described herein that are
directed to multi-layer assemblies, and components thereof, that
provide for variable lofting capacity in different layers. While
certain specific configurations are described in detail below, the
variable lofting capacity may arise from one or more of a
thermoplastic material and/or reinforcing materials. In some
instances, lofting capacity can be further tuned or selected by
including an added lofting agent in addition to the thermoplastic
material and/or reinforcing materials present in the layer.
[0005] In one aspect, a thermoplastic sheet comprising a core layer
comprising a web of open celled structures formed by a plurality of
reinforcing materials bonded together with a thermoplastic
material, the core layer further comprising a lofting agent, the
core layer also comprising a first surface and a second surface
opposite the first surface, a first layer disposed on the first
surface of the core layer, the first layer comprising a web of open
celled structures formed by a plurality of reinforcing materials
bonded together with a thermoplastic material, and a second layer
disposed on the second surface of the core layer, the second layer
comprising a web of open celled structures formed by a plurality of
reinforcing materials bonded together with a thermoplastic material
is provided.
[0006] In certain embodiments, a basis weight of the first layer is
substantially the same (or different) as a basis weight of the
second layer. In other configurations, a basis weight of the core
layer is greater than the basis weight of the first layer and
greater than the basis weight of the second layer. In certain
instances, the reinforcing materials of the first layer, the second
layer and the core layer each comprise reinforcing fibers. In some
examples, the first layer comprises at least one different
reinforcing fiber material than the reinforcing fiber materials of
the core layer. In other examples, the reinforcing fibers of the
first layer, the second layer and the core layer comprise at least
one common reinforcing fiber material. In certain embodiments, the
thermoplastic material in the core layer is different than the
thermoplastic material in the first layer. In some examples, the
thermoplastic material in the first layer and the second layer are
the same. In other examples, the reinforcing materials in the first
layer and the second layer are the same. In some instances, the
reinforcing materials in the first layer and the second layer are
the different. In certain examples, the reinforcing materials of
the first layer, the second layer and the core layer each comprise
reinforcing fibers. In some examples, the first layer comprises at
least one different reinforcing fiber than the reinforcing fibers
of the core layer. In certain embodiments, the reinforcing fibers
of the first layer, the second layer and the core layer comprise at
least one common reinforcing fiber type. In other embodiments, the
lofting agent of the core layer comprises at least one of
expandable microspheres and expandable graphite materials. In some
examples, no lofting agent is present in the first layer or in the
second layer. In other examples, the thermoplastic material and
reinforcing materials of the first layer and the second layer are
selected to permit lofting of the first layer and the second layer.
In certain embodiments, the thermoplastic material and reinforcing
materials of the first layer and second layer permit lofting of the
first layer and the second layer at a different lofting temperature
than a lofting temperature used to loft the core layer. In some
examples, the sheet further comprises a first adhesive layer
disposed on the first surface of the core layer between the first
layer and the core layer. In other examples, the sheet further
comprises a second adhesive layer disposed on the second surface of
the core layer between the second layer and the core layer. In some
embodiments, the first layer is directly disposed on the first
adhesive layer and the second layer is directly disposed on the
second adhesive layer, in which the first adhesive layer is
directly disposed on the first surface of the core layer and in
which the second adhesive layer is directly disposed on the second
surface of the core layer. In certain configurations, the
thermoplastic material of each of the core layer, the first layer
and the second layer is independently selected from the group
consisting of a polyolefin material, a thermoplastic polyolefin
blend material, a polyvinyl polymer material, a butadiene polymer
material, an acrylic polymer material, a polyamide material, a
polyester material, a polycarbonate material, a polyestercarbonate
material, a polystyrene material, an acrylonitrylstyrene polymer
material, an acrylonitrile-butylacrylate-styrene polymer material,
a polyether imide material, a polyphenylene ether material, a
polyphenylene oxide material, a polyphenylenesulphide material, a
polyether material, a polyetherketone material, a polyacetal
material, a polyurethane material, a polybenzimidazole material,
and copolymers and mixtures thereof. In some embodiments, the
thermoplastic material in each of the core layer, the first layer
and the second layer is independently a resin or a fiber. In other
embodiments, the reinforcing materials of each of the core layer,
the first layer and the second layer is independently selected from
the group consisting of glass fibers, carbon fibers, graphite
fibers, synthetic organic fibers, inorganic fibers, natural fibers,
mineral fibers, metal fibers, metalized inorganic fibers, metalized
synthetic fibers, ceramic fibers, and combinations thereof. In
certain examples, the fibers present in each of the core layer, the
first layer and the second layer comprise a diameter greater than
about 5 microns and a length from about 5 mm to about 200 mm. In
other examples, the sheet comprises a skin layer disposed on the
first layer. In some examples, the skin layer comprises a fabric, a
scrim, a film and combinations thereof. In other examples, the
sheet comprises an additional skin layer disposed on the second
layer. In certain configurations, the additional skin layer
comprises a fabric, a scrim, a film and combinations thereof. In
some configurations, the thermoplastic material present in each of
the core layer, the first layer and the second layer comprises a
polypropylene, the reinforcing materials present in each of the
core layer, the first layer and the second layer are glass fibers
and the lofting agent of the core layer comprises expandable
microspheres. In other configurations, the basis weight of each of
the first and second layers is about 500 gsm to about 3000 gsm and
the basis weight of the core layer is about 500 gsm to about 1600
gsm.
[0007] In an additional aspect, a vehicle load floor that provides
structural reinforcement is provided. In certain configurations,
the vehicle load floor comprises a core layer comprising a web of
open celled structures formed by a plurality of reinforcing
materials bonded together with a thermoplastic material, the core
layer further comprising a lofting agent, the core layer also
comprising a first surface and a second surface opposite the first
surface, a first layer disposed on the first surface of the core
layer, the first layer comprising a web of open celled structures
formed by a plurality of reinforcing materials bonded together with
a thermoplastic material, and a second layer disposed on the second
surface of the core layer, the second layer comprising a web of
open celled structures formed by a plurality of reinforcing
materials bonded together with a thermoplastic material, in which
the core layer, the first layer and the second layer together
provide a vehicle load floor that deflects less than about 25 mm at
a weight of no more than 220 kg, e.g., 200-200 kg.
[0008] In certain embodiments, the load floor comprises a
decorative layer coupled to the first layer. In some examples, the
decorative layer comprises a carpet. In certain examples, the load
floor comprises an adhesive layer between the decorative layer and
the first layer. In additional examples, the load floor comprises a
second decorative layer coupled to the second layer. In some
examples, the second decorative layer comprises a carpet. In
certain examples, the load floor comprises an adhesive layer
between the second decorative layer and the second layer. In
certain examples, the load floor deflects less than about 15 mm at
100 kg weight, or less than about 15 mm at 150 kg weight, or less
than about 10 mm at 100 kg weight, or less than about 5 mm at 220
kg weight. In some embodiments, the thermoplastic material of the
core layer comprises at least one similar or different
thermoplastic material than the thermoplastic material present in
the first layer. In certain examples, the core layer, the first
layer and the second layer each comprises a void content of at
least 5%. In some embodiments, the thermoplastic material of each
of the core layer, the first layer and the second layer is
independently selected from the group consisting of a polyolefin
material, a thermoplastic polyolefin blend material, a polyvinyl
polymer material, a butadiene polymer material, an acrylic polymer
material, a polyamide material, a polyester material, a
polycarbonate material, a polyestercarbonate material, a
polystyrene material, an acrylonitrylstyrene polymer material, an
acrylonitrile-butylacrylate-styrene polymer material, a polyether
imide material, a polyphenylene ether material, a polyphenylene
oxide material, a polyphenylenesulphide material, a polyether
material, a polyetherketone material, a polyacetal material, a
polyurethane material, a polybenzimidazole material, and copolymers
and mixtures thereof. In certain examples, the thermoplastic
material in each of the core layer, the first layer and the second
layer is independently a resin or a fiber. In some embodiments, the
reinforcing materials of each of the core layer, the first layer
and the second layer is independently selected from the group
consisting of glass fibers, carbon fibers, graphite fibers,
synthetic organic fibers, inorganic fibers, natural fibers, mineral
fibers, metal fibers, metalized inorganic fibers, metalized
synthetic fibers, ceramic fibers, and combinations thereof. In
certain examples, the fibers present in each of the core layer, the
first layer and the second layer comprise a diameter greater than
about 5 microns and a length from about 5 mm to about 200 mm. In
some embodiments, the thermoplastic material present in each of the
core layer, the first layer and the second layer comprises a
polypropylene, and the reinforcing materials present in each of the
core layer, the first layer and the second layer are glass fibers.
In certain examples, the basis weight of each of the first and
second layers is about 500 gsm to about 3000 gsm and the basis
weight of the core layer is about 500 gsm to about 1600 gsm. In
some examples, the lofting agent of the core layer comprises
expandable microspheres or expandable graphite materials. In
certain embodiments, the load floor comprises a carpet layer
disposed on at least one of the first layer and the second layer.
In some examples, the first layer is coupled to the core layer
through an adhesive layer and the second layer is coupled to the
core layer through an adhesive layer. In other examples, the first
layer and the second layer do not include any lofting agent, and
wherein the thermoplastic material and reinforcing materials of the
first layer and the second layer are each selected to permit
lofting of the first layer and the second layer in the absence of
lofting agent in the first layer and the second layer.
[0009] In another aspect, a kit for producing a vehicle load floor,
the kit comprising a core layer comprising a web of open celled
structures formed by a plurality of reinforcing materials bonded
together with a thermoplastic material, the core layer further
comprising a lofting agent, the core layer also comprising a first
surface and a second surface opposite the first surface, a first
layer separate from the core layer and comprising a web of open
celled structures formed by a plurality of reinforcing materials
bonded together with a thermoplastic material, and a second layer
separate from the core layer and the first layer and comprising a
web of open celled structures formed by a plurality of reinforcing
materials bonded together with a thermoplastic material, and
instructions for coupling the first layer to the first surface of
the core layer and for coupling the second layer to the second
surface of the core layer is described.
[0010] In certain embodiments, the kit comprises a decorative layer
separate from the core layer, the first layer, and the second
layer. In some examples, the kit comprises an adhesive material
effective to bond the first layer to the core layer. In certain
examples, the first layer of the kit is the same as the second
layer of the kit. In some examples, the kit comprises a skin layer.
In some examples, the skin layer is selected from the group
consisting of a fabric, a scrim, a film and combinations thereof.
In certain embodiments, the kit comprises a second core layer, in
which the second core layer comprises a web of open celled
structures formed by a plurality of reinforcing materials bonded
together with a thermoplastic material, the core layer further
comprising a lofting agent, the core layer also comprising a first
surface and a second surface opposite the first surface. In some
examples, the lofting agent of the core layer is different than the
lofting agent of the second core layer. In certain examples, the
first core layer and the second core layer comprise the same
thermoplastic material, reinforcing materials and lofting agent. In
other embodiments, the basis weight of the core layer is different
than the basis weight of the second core layer.
[0011] In another aspect, a method of forming a thermoplastic sheet
comprising forming a core layer by combining a thermoplastic
polymer, reinforcing fibers and a lofting agent in an aqueous
solution, mixing the aqueous solution comprising the thermoplastic
polymer, reinforcing fibers and lofting agent to disperse the
reinforcing fibers and the lofting agent in the thermoplastic
polymer to provide an aqueous foam dispersion, disposing the
aqueous foam dispersion onto a forming element, removing liquid
from the disposed aqueous foam to provide a core layer comprising a
web comprising the thermoplastic polymer, the reinforcing fibers
and the lofting agent, forming a first layer by combining a
thermoplastic polymer, reinforcing fibers and a lofting agent in an
aqueous solution, mixing the aqueous solution comprising the
thermoplastic polymer, reinforcing fibers and lofting agent to
disperse the reinforcing fibers and the lofting agent in the
thermoplastic polymer to provide an aqueous foam dispersion,
disposing the aqueous foam dispersion onto a forming element,
removing liquid from the disposed aqueous foam to provide a first
layer comprising a web comprising the thermoplastic polymer, the
reinforcing fibers and the lofting agent, disposing the formed
first layer on a first surface of the core layer, and disposing
another first layer on a second surface of the core layer to
provide a thermoplastic sheet is disclosed.
[0012] In certain embodiments, the method comprises heating the
core layer above a softening temperature of the thermoplastic
polymer of the web of the core layer prior to disposing the first
layer on the first surface of the core layer. In other embodiments,
the method comprises heating the core layer above a softening
temperature of the thermoplastic polymer of the web of the core
layer prior to disposing the first layer on the second surface of
the core layer. In some examples, the method comprises disposing an
adhesive layer on the first surface of the core layer prior to
disposing the first layer on the first surface. In certain
embodiments, the method comprises disposing an adhesive layer on
the first layer prior to disposing the first layer on the first
surface. In some examples, the method comprises disposing an
adhesive layer on the second surface of the core layer prior to
disposing the first layer on the second surface. In certain
examples, the method comprises disposing an adhesive layer on the
first layer prior to disposing the first layer on the second
surface. In some examples, the method comprises heating the
thermoplastic sheet to loft each of the core layer and the first
layers. In certain embodiments, the method comprises selecting a
first loft temperature to loft the first layers where the first
layer lacks any lofting agent. In some examples, the method
comprises selecting a second loft temperature to loft the core
layer. In certain embodiments, the method comprises selecting the
first loft temperature to loft the first layer without any
substantial loft of the core layer. In other embodiments, the
method comprises disposing a decorative layer on one of the first
layers. In certain examples, the method comprises lofting the first
layers disposed on the core layer using radiant heating or
conduction heating. In certain embodiments, the method comprises
lofting the core layer using infrared heating. In some examples,
the method comprises compressing the thermoplastic sheet to reduce
its overall thickness. In some embodiments, the method comprises
molding the compressed thermoplastic sheet. In certain examples,
the method comprises compressing the core layer prior to disposing
the first layers on the core layer. In certain examples, the method
comprises compressing the first layers prior to disposing the first
layers on the core layer. In some examples, the method comprises
disposing a skin layer on the first layer disposed on the first
surface of the core layer. In certain embodiments, the method
comprises disposing an additional skin layer on the first layer
disposed on the second surface of the core layer.
[0013] In an additional aspect, a method of forming a thermoplastic
sheet comprising forming a core layer by combining a thermoplastic
polymer, reinforcing fibers and a lofting agent in an aqueous
solution, mixing the aqueous solution comprising the thermoplastic
polymer, reinforcing fibers and lofting agent to disperse the
reinforcing fibers and the lofting agent in the thermoplastic
polymer to provide an aqueous foam dispersion, disposing the
aqueous foam dispersion onto a forming element, removing liquid
from the disposed aqueous foam to provide a core layer comprising a
web comprising the thermoplastic polymer, the reinforcing fibers
and the lofting agent, forming each of a first layer and a second
layer by combining a thermoplastic polymer, reinforcing fibers and
a lofting agent in an aqueous solution, mixing the aqueous solution
comprising the thermoplastic polymer, reinforcing fibers and
lofting agent to disperse the reinforcing fibers and the lofting
agent in the thermoplastic polymer to provide an aqueous foam
dispersion, disposing the aqueous foam dispersion onto a forming
element, removing liquid from the disposed aqueous foam to provide
a first layer comprising a web comprising the thermoplastic
polymer, the reinforcing fibers and the lofting agent, disposing
the formed first layer on a first surface of the core layer, and
disposing the formed second layer on a second surface of the core
layer to provide a thermoplastic sheet is provided.
[0014] In certain embodiments, the method comprises heating the
core layer above a softening temperature of the thermoplastic
polymer of the web of the core layer prior to disposing the first
layer on the first surface of the core layer. In some examples, the
method comprises heating the core layer above a softening
temperature of the thermoplastic polymer of the web of the core
layer prior to disposing the second layer on the second surface of
the core layer. In certain examples, the method comprises disposing
an adhesive layer on the first surface of the core layer prior to
disposing the first layer on the first surface. In some
embodiments, the method comprises disposing an adhesive layer on
the first layer prior to disposing the first layer on the first
surface. In some embodiments, the method comprises disposing an
adhesive layer on the second surface of the core layer prior to
disposing the second layer on the second surface. In some examples,
the method comprises disposing an adhesive layer on the second
layer prior to disposing the second layer on the second surface. In
certain examples, the method comprises heating the thermoplastic
sheet to loft each of the core layer and the first layers. In some
embodiments, the method comprises selecting a first loft
temperature to loft the first layers where the first layer lacks
any lofting agent. In certain examples, the method comprises
selecting a second loft temperature to loft the core layer.
[0015] In another aspect, a method of forming a thermoplastic sheet
comprising forming a core layer by combining a thermoplastic
polymer, reinforcing fibers and a lofting agent in an aqueous
solution, mixing the aqueous solution comprising the thermoplastic
polymer, reinforcing fibers and lofting agent to disperse the
reinforcing fibers and the lofting agent in the thermoplastic
polymer to provide an aqueous foam dispersion, disposing the
aqueous foam dispersion onto a forming element, removing liquid
from the disposed aqueous foam to provide a core layer comprising a
web comprising the thermoplastic polymer, the reinforcing fibers
and the lofting agent, disposing a first layer on a first surface
of the core layer, the first layer comprising a web of open celled
structures formed by a plurality of reinforcing materials bonded
together with a thermoplastic material, and disposing a second
layer on a second surface of the core layer, the second layer
comprising a web of open celled structures formed by a plurality of
reinforcing materials bonded together with a thermoplastic material
is disclosed.
[0016] In certain embodiments, the method comprises heating the
core layer above a softening temperature of the thermoplastic
polymer of the web of the core layer prior to disposing the first
layer on the first surface of the core layer. In some embodiments,
the method comprises heating the core layer above a softening
temperature of the thermoplastic polymer of the web of the core
layer prior to disposing the second layer on the second surface of
the core layer. In some examples, the method comprises disposing an
adhesive layer on the first surface of the core layer prior to
disposing the first layer on the first surface. In certain
examples, the method comprises disposing an adhesive layer on the
first layer prior to disposing the first layer on the first
surface. In some embodiments, the method comprises disposing an
adhesive layer on the second surface of the core layer prior to
disposing the second layer on the second surface. In certain
examples, disposing an adhesive layer on the second layer prior to
disposing the second layer on the second surface. In certain
embodiments, the method comprises heating the thermoplastic sheet
to loft each of the core layer and the first layers. In some
examples, the method comprises selecting a first loft temperature
to loft the first layers where the first layer lacks any lofting
agent. In certain embodiments, the method comprises selecting a
second loft temperature to loft the core layer.
[0017] Additional features, aspect, examples, configurations and
embodiments are described in more detail below.
BRIEF DESCRIPTION OF THE FIGURES
[0018] Certain embodiments are described with reference to the
accompanying figures in which:
[0019] FIG. 1 is an illustration of a multi-layer assembly, in
accordance with certain examples;
[0020] FIG. 2 is an illustration of a multi-layer assembly
including a core layer with a high lofting capacity, in accordance
with certain examples;
[0021] FIG. 3 is an illustration of a multi-layer assembly
including a core layer with a low lofting capacity, in accordance
with certain examples;
[0022] FIG. 4 is an illustration of a multi-layer assembly
including three layers each with a different lofting capacity, in
accordance with certain examples;
[0023] FIG. 5A is an illustration of a multi-layer assembly
comprising a skin on one surface, in accordance with certain
configurations;
[0024] FIG. 5B is an illustration of a multi-layer assembly
comprising a skin on each surface, in accordance with certain
configurations;
[0025] FIG. 6 is an illustration of a multi-layer assembly
comprising a decorative layer on an outer surface, in accordance
with certain examples;
[0026] FIG. 7 is an illustration of an article comprising four
layers, in accordance with certain examples;
[0027] FIG. 8 is an illustration of another article comprising four
layers, in accordance with certain examples;
[0028] FIG. 9 is an illustration of an article comprising five
layers, in accordance with certain configurations;
[0029] FIG. 10 is an illustration of a vehicle floor, in accordance
with certain examples; and
[0030] FIG. 11 is an illustration of a load floor, in accordance
with certain configurations.
[0031] It will be recognized by the person of ordinary skill in the
art, given the benefit of this disclosure, that certain dimensions
or features in the figures may have been enlarged, distorted or
shown in an otherwise unconventional or non-proportional manner to
provide a more user friendly version of the figures. No particular
thickness, width or length is intended by the depictions in the
figures, and relative sizes of the figure components are not
intended to limit the sizes of any of the components in the
figures. Where dimensions or values are specified in the
description below, the dimensions or values are provided for
illustrative purposes only. In addition, no particular material or
arrangement is intended to be required by virtue of shading of
certain portions of the figures, and even though different
components in the figures may include shading for purposes of
distinction, the different components can include the same or
similar materials, if desired.
DETAILED DESCRIPTION
[0032] Certain embodiments are described below with reference to
singular and plural terms in order to provide a more user friendly
description of the technology disclosed herein. These terms are
used for convenience purposes only and are not intended to limit
the layers, assemblies, articles, methods and other subject matter
as including or excluding certain features unless otherwise noted
as being present in a particular embodiment described herein.
[0033] In certain instances, the materials described herein can be
used together to provide sheets, panels, floor pans, load floors
and other articles. For example, the multi-layer assembly can be
used as a wall or ceiling panel, as flooring, a sub-floor or in
automotive applications such as, for example, vehicle load floors
or underbody floors of a vehicle. Where the assembly is used as a
vehicle load floor, the load floor may be present as an underbody
assembly within the vehicle cabin or may be present as or in one or
more different components or areas of the vehicle, e.g., as a drawn
load floor in a vehicle storage compartment in the rear of a
vehicle. As noted herein, some configurations of the multi-layer
assembly may be produced without the use of any cellulose or paper
based materials. In other instances, the multi-layer assembly may
be produced without the use of any polyurethane core component or
without the use of any polyurethane whatsoever.
[0034] In certain configurations, the multi-layer assembly may
comprise three or more different layers coupled to each other with
one of the layers comprising a different lofting capacity than the
other layers. Referring to FIG. 1, a three layer assembly 100 is
shown that comprises layers 110, 120, and 130. The layer 110 is
referred to in certain instances as a "core layer" as it is present
between the two layers 120, 130. Various physical properties of the
layers 110-130 may be the same or may be different. For example,
the basis weight of any two of the layers 110-130 may be the same
or may be different. In other instances, the overall thickness of
the layers 110-130 may be the same or may be different. As
described in more detail below, each of the layers 110-130 may
comprise a thermoplastic material and/or a plurality of reinforcing
materials, e.g., reinforcing fibers. By selecting the amount and/or
nature of these materials to be different in two or more of the
layers 110-130, the lofting capacity of the layers can be varied in
the different layers, e.g., the assembly 100 has a variable lofting
capacity in different layers. As used herein, lofting capacity
refers to the ability to increase the overall thickness of the
layer after application of a suitable stimulus such as heating. The
ability to control or select the lofting capacity in each layer can
provide for an assembly with reduced weight and with suitable
structural rigidity and mechanical properties that can be used as
panels, floor assemblies or sub floor assemblies.
[0035] In certain embodiments, any one or more of the layers
110-130 may be configured as (or used in) a glass mat thermoplastic
composite (GMT) or a light weight reinforced thermoplastic (LWRT).
One such LWRT is prepared by HANWHA AZDEL, Inc. and sold under the
trademark SUPERLITE.RTM. mat. The areal density of such a GMT or
LWRT can range from about 400 grams per square meter (gsm) of the
GMT or LWRT to about 4000 gsm, although the areal density may be
less than 400 gsm or greater than 4000 gsm depending on the
specific application needs. In some embodiments, the upper density
can be less than about 4000 gsm. In certain instances, the GMT or
the LWRT may comprise lofting agent material disposed in void space
of the GMT or the LWRT.
[0036] In certain examples, the LWRT typically includes a
thermoplastic material and a plurality of reinforcing fibers which
together form a web of open celled structures. For example, each of
the layers 110-130 typically comprises a substantial amount of open
cell structure such that void space is present in the layers. For
example, each of the layers may independently comprise a void
content or porosity of 0-30%, 10-40%, 20-50%, 30-60%, 40-70%,
50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%,
10-60%, 10-70%, 10-80%, 10-90%, 10-95%, 20-60%, 20-70%, 20-80%,
20-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95%, 40-80%, 40-90%,
40-95%, 50-90%, 50-95%, 60-95% 70-80%, 70-90%, 70-95%, 80-90%,
80-95% or any illustrative value within these exemplary ranges. In
some instances, each of the layers 110-130 comprises a porosity or
void content of greater than 0%, e.g., is not fully consolidated,
up to about 95%. Unless otherwise stated, the reference to the
layer comprising a certain void content or porosity is based on the
total volume of the layer and not necessarily the total volume of
the multi-layer assembly.
[0037] In certain examples, one or more of the layers 110-130 can
be produced in the form of a GMT. In certain instances, the GMT can
be generally prepared using chopped glass fibers, a thermoplastic
material, optionally a lofting agent and an optional thermoplastic
polymer film or films and/or woven or non-woven fabrics made with
glass fibers or thermoplastic resin fibers such as, for example,
polypropylene (PP), polybutylene terephthalate (PBT), polyethylene
terephthalate (PET), polycarbonate (PC), a blend of PC/PBT, or a
blend of PC/PET. In some embodiments, a PP, a PBT, a PET, a PC/PET
blend or a PC/PBT blend can be used as a resin. To produce the
glass mat, a thermoplastic material and reinforcing materials can
be added or metered into a dispersing foam contained in an open top
mixing tank fitted with an impeller. Without wishing to be bound by
any particular theory, the presence of trapped pockets of air of
the foam can assist in dispersing the glass fibers, the
thermoplastic material and the lofting agent. In some examples, the
dispersed mixture of fibers and thermoplastic material can be
pumped to a head-box located above a wire section of a paper
machine via a distribution manifold. The foam, not the fibers and
thermoplastic, can then be removed as the dispersed mixture is
provided to a moving wire screen using a vacuum, continuously
producing a uniform, fibrous wet web. The wet web can be passed
through a dryer at a suitable temperature to reduce moisture
content and to melt or soften the thermoplastic material.
[0038] In certain embodiments, the high porosity present in the
layers 110-130 can reduce the overall weight of the layers and can
permit the inclusion of agents within the void space. For example,
lofting agents can reside in the void space in a non-covalently
bonded manner. Application of heat or other perturbations can act
to increase the volume of the non-covalently bonded lofting agent
which in turn increases the overall thickness of the layer, e.g.,
the layer increases as the size of the lofting agent increases
and/or additional air becomes trapped in the prepreg. If desired,
flame retardants, colorants, smoke suppressants and other materials
may be included in the void space of the layers 110-130. Prior to
lofting, any one or more of the layers 110-130 can be compressed to
reduce its overall thickness, e.g., compressed before or after the
layer is coupled to one or more other layers.
[0039] In certain embodiments, the thermoplastic material of the
layers described herein may comprise, at least in part, one or more
of polyethylene, polypropylene, polystyrene, acrylonitrylstyrene,
butadiene, polyethyleneterephthalate, polybutyleneterephthalate,
polybutylenetetrachlorate, and polyvinyl chloride, both plasticized
and unplasticized, and blends of these materials with each other or
other polymeric materials. Other suitable thermoplastics include,
but are not limited to, polyarylene ethers, polycarbonates,
polyestercarbonates, thermoplastic polyesters, polyimides,
polyetherimides, polyamides, acrylonitrile-butylacrylate-styrene
polymers, amorphous nylon, polyarylene ether ketone, polyphenylene
sulfide, polyaryl sulfone, polyether sulfone, liquid crystalline
polymers, poly(1,4 phenylene) compounds commercially known as
PARMAX.RTM., high heat polycarbonate such as Bayer's APEC.RTM. PC,
high temperature nylon, and silicones, as well as copolymers,
alloys and blends of these materials with each other or other
polymeric materials. The thermoplastic material used to form the
layers 110-130 can be used in powder form, resin form, rosin form,
fiber form or other suitable forms. Illustrative thermoplastic
materials in various forms are described herein and are also
described, for example in U.S. Publication Nos. 20130244528 and
US20120065283. The exact amount of thermoplastic material present
in the layers 110-130 can vary and illustrative amounts range from
about 20% by weight to about 80% by weight, e.g., 30-70 percent by
weight or 35-65 percent by weight. As noted in more detail herein,
by varying the chemical composition (and/or amount) of the
thermoplastic material in the different layers 110-130, the
different layers 110-130 may provide for different lofting
capacities even where no added lofting agent is present in the
layers 110-130.
[0040] In certain embodiments, a thermoplastic material used in one
of the layers 110-130 differs chemically from a thermoplastic
material used in the other layers. For example, the thermoplastic
material present in the layer 110 may differ chemically than the
thermoplastic material present in the layer 120 or the layer 130 or
both. In some instances, the thermoplastic material present in the
layers 120, 130 may be the same, and the thermoplastic material
present in the layer 110 may be different. In certain
configurations, the thermoplastic material present in the layers
110-130 each may be chemically different. By selecting the
thermoplastic material present in the layers 110-130, it is
possible to provide layers with differing lofting capacities. Even
though a different thermoplastic material may be present in one or
more of the layers 110-130, one or more common materials may also
be present in the layers 110-130. For example, the layers 110-130
may each comprise a first polyolefin and the layers 120, 130 may
also comprise a second polyolefin not present in the first layer
110.
[0041] In other embodiments, a thermoplastic material used in one
of the layers 110-130 may be chemically the same as a thermoplastic
material present in another one of the layers, but the amount of
the thermoplastic material may be different. For example, the layer
110 may comprise a first thermoplastic material present in a first
amount (by weight) that is different than the amount of the first
thermoplastic material present in one of the other layers 120, 130.
The balance of the materials in the layers may comprise reinforcing
fibers (as discussed below) or may comprise other materials such
as, for example, another thermoplastic material, a lofting agent, a
flame retardant or other materials as desired. Without wishing to
be bound by any particular theory, by selecting the amount of a
particular thermoplastic material present in a layer, the overall
volume of the web of open celled structures can be changed.
[0042] In certain examples, the reinforcing materials of the layers
110-130 described herein can independently comprise glass fibers,
carbon fibers, graphite fibers, synthetic organic fibers,
particularly high modulus organic fibers such as, for example,
para- and meta-aramid fibers, nylon fibers, polyester fibers, or
any of the high melt flow index resins described herein that are
suitable for use as fibers, mineral fibers such as basalt, mineral
wool (e.g., rock or slag wool), wollastonite, alumina silica, and
the like, or mixtures thereof, metal fibers, metalized natural
and/or synthetic fibers, ceramic fibers, yarn fibers, or mixtures
thereof. In some embodiments, any of the aforementioned fibers can
be chemically treated prior to use to provide desired functional
groups or to impart other physical properties to the fibers, e.g.,
may be chemically treated so that they can react with the
thermoplastic material, the lofting agent or both. The fiber
content in each of the layers 110-130 may independently be from
about 20% to about 90% by weight of the layer, more particularly
from about 30% to about 70%, by weight of the layer. Typically, the
fiber content of a multi-layer assembly comprising the layers
110-130 varies between about 20% to about 90% by weight, more
particularly about 30% by weight to about 80% by weight, e.g.,
about 40% to about 70% by weight of the assembly. The particular
size and/or orientation of the fibers used may depend, at least in
part, on the thermoplastic polymer material used and/or the desired
properties of the resulting layers 110-130. Suitable additional
types of fibers, fiber sizes and amounts will be readily selected
by the person of ordinary skill in the art, given the benefit of
this disclosure. In one non-limiting illustration, fibers dispersed
within a thermoplastic material and lofting agent to provide a
layer can generally have a diameter of greater than about 5
microns, more particularly from about 5 microns to about 22
microns, and a length of from about 5 mm to about 200 mm; more
particularly, the fiber diameter may be from about microns to about
22 microns and the fiber length may be from about 5 mm to about 75
mm.
[0043] In certain embodiments, at least two of the layers 110-130
may comprise a different fiber material or a different fiber
loading. Where different fiber materials are present, the fibers
may be different fibers entirely, e.g., glass fibers in one layer
and carbon fibers in another layer, or may comprise the same base
material that has been modified, e.g., glass fibers in one layer
and chemically treated glass fibers in another layer. In some
instances, the fibers may be the same fiber material but one or
more physical properties of the fibers may differ. For example, the
fibers of the layer 110 may have a first diameter that differs from
a diameter of the fibers present in the layer 120 even though the
fiber material in the layers 110, 120 may be the same or different.
In other instances, the length of the fibers in the layer 110 may
differ from a length of the fibers present in the layer 120 even
though the fiber material present in the layers 110, 120 may be the
same or different. In additional examples, both the length and
diameter of the fiber in the layer 110 may differ from a length and
diameter of the fibers in the layer 120 even though the fiber
material present in the layers 110, 120 may be the same or
different. In yet other examples, two or more fiber types may be
used in one of the layers 110, 120 and a single type of fibers may
be present in the other layer. As noted herein, by selecting the
amount and/or type of fibers, it is possible to provide a different
lofting capacity for different layers of the assembly.
[0044] In certain embodiments, two or more of the layers 110-130
may have a different lofting profile. For example, in some
instances, the layer 110 may loft at a different temperature than
the layer 120. In other examples, the layer 110 may loft at a
different temperature than the layer 130. In further
configurations, two or more of the layers 110-130 may loft at the
same temperature but the degree to which they loft may be
different, e.g., the post-loft thickness of one of the layers
110-130 may be different than a post-loft thickness of one of the
other layers even though all the layers are subjected to the same
lofting temperature.
[0045] In some embodiments, the lofting capacity of the various
layers 110-130 can be further tuned by including one or more added
lofting agents. The exact type of lofting agent used in the layer
can depend on numerous factors including, for example, the desired
lofting temperature, the desired degree of loft, etc. In some
instances, microsphere lofting agents, e.g., expandable
microspheres, which can increase their size upon exposure to
convection heating may be used. Illustrative commercially available
lofting agents are available from Kureha Corp. (Japan). In other
instances, a first lofting agent with a first average particle size
and a second lofting agent with a second average particle size,
different from the first average particle size, may be used. In
other examples, the lofting agent may be an expandable graphite
material.
[0046] In some configurations, each of the layers 110-130 may be a
substantially halogen free or halogen free layer to meet the
restrictions on hazardous substances requirements for certain
applications. In other instances, one or more of the layers 110-130
may comprise a halogenated flame retardant agent such as, for
example, a halogenated flame retardant that comprises one of more
of F, Cl, Br, I, and At or compounds that including such halogens,
e.g., tetrabromo bisphenol-A polycarbonate or monohalo-, dihalo-,
trihalo- or tetrahalo-polycarbonates. In some instances, the
thermoplastic material used in one or more of the layers 110-130
may comprise one or more halogens to impart some flame retardancy
without the addition of another flame retardant agent. Where
halogenated flame retardants are present, the flame retardant is
desirably present in a flame retardant amount, which can vary
depending on the other components which are present. For example,
the halogenated flame retardant may be present in about 0.1 weight
percent to about 15 weight percent (based on the weight of the
layer), more particularly about 1 weight percent to about 13 weight
percent, e.g., about 5 weight percent to about 13 weight percent.
If desired, two different halogenated flame retardants may be added
to the layers. In other instances, a non-halogenated flame
retardant agent such as, for example, a flame retardant agent
comprising one or more of N, P, As, Sb, Bi, S, Se, and Te can be
added. In some embodiments, the non-halogenated flame retardant may
comprise a phosphorated material so the layers may be more
environmentally friendly. Where non-halogenated or substantially
halogen free flame retardants are present, the flame retardant is
desirably present in a flame retardant amount, which can vary
depending on the other components which are present. For example,
the substantially halogen free flame retardant may be present in
about 0.1 weight percent to about 15 weight percent (based on the
weight of the layer), more particularly about 1 weight percent to
about 13 weight percent, e.g., about 5 weight percent to about 13
weight percent based on the weight of the layer. If desired, two
different substantially halogen free flame retardants may be added
to one or more of the layers 110-130. In certain instances, one or
more of the layers 110-130 described herein may comprise one or
more halogenated flame retardants in combination with one or more
substantially halogen free flame retardants. Where two different
flame retardants are present, the combination of the two flame
retardants may be present in a flame retardant amount, which can
vary depending on the other components which are present. For
example, the total weight of flame retardants present may be about
0.1 weight percent to about 20 weight percent (based on the weight
of the layer), more particularly about 1 weight percent to about 15
weight percent, e.g., about 2 weight percent to about 14 weight
percent based on the weight of the layer. The flame retardant
agents used in the layers described herein can be added to the
mixture comprising the thermoplastic material and fibers (prior to
disposal of the mixture on a wire screen or other processing
component) or can be added after the layer is formed.
[0047] Several different illustrative layer assemblies are now
described to illustrate further some of the possible configurations
of a multi-layer assembly with variable lofting capacity.
Additional configurations will be recognized by the person of
ordinary skill in the art, given the benefit of this disclosure.
Referring to FIG. 2, a composite article 200 is shown comprising
layers 210, 220 and 230. In this examples, layers 220 and 230 are
selected to be the same with a respective one of the layers 220,
230 disposed on a surface of the layer 210. In the configuration
shown in FIG. 2, the core layer 210 is selected such that it has a
higher lofting capacity than the layers 220, 230. Upon exposure to
heat or other lofting stimulus, the post-loft thickness of the
layer 210 will be greater than that of the layers 220, 230. For
example, the thickness of the layer 210 prior to lofting may be
about 1-2 mm and after lofting may be about 10-15 mm. The thickness
of the layers 220, 230 prior to lofting may also be about 1-2 mm
and after lofting may be about 6-8 mm. These thickness changes may
occur even in the absence of any added lofting agent. For example
and without wishing to be bound by any particular theory, during
lofting the thermoplastic material may melt and release their hold
on the reinforcing materials to permit the reinforcing materials to
occupy more volume. Subsequent cooling of the thermoplastic
material can result in reformation of a web of open celled
structures with a larger volume than the pre-lofted web. By tuning
the level of thermoplastic material and/or reinforcing materials in
the layer 210, the degree to which the volume of the layer 210 can
increase may be selected. In comparison, the amount of
thermoplastic material and/or reinforcing materials present in the
layers 220, 230 can be selected such that melting of the
thermoplastic material during lofting does not result in a
substantial increase in the overall volume. As the web of the
layers 220, 230 reforms after lofting, the resulting post-lofted
web volume is not substantially different from the pre-lofted web
volume. If desired, one or more of the layers 210-230 may include
an added lofting agent to further increase the overall volume. For
example, the layer 210 may comprise an added lofting agent to
further select the overall post-lofted volume. In some instances,
enough lofting agent is present so the post-lofted layer 210 has a
thickness of about 20-25 mm. In some examples, the layer 210 may
comprise a polyolefin, reinforcing fibers and a lofting agent, and
the layers 220, 230 may comprise a polyolefin (which can be the
same or different than the polyolefin in the layer 210) and a
reinforcing material. In certain configurations, the polyolefin
present in each of the layers 210-230 may be polypropylene or a
polyolefin copolymer comprising polypropylene. In some embodiments,
the reinforcing material of each of the layers 210-230 may comprise
glass fibers optionally in combination with other fibers. The exact
weight percentages of the thermoplastic material and reinforcing
materials in each of the layers 210-230 may vary, and illustrative
weight percentages in the layers 220, 230 are about 40-60 weight
percent thermoplastic material with the balance being reinforcing
material. The weight percentages of materials present in the layer
210 can vary and illustrative ranges include, but are not limited
to, about 45-65 weight percent thermoplastic material with the
balance being reinforcing material and optionally lofting agent
(which is typically present from 0.1 up to about 15 weight
percent).
[0048] In certain examples, another configuration of a multi-layer
assembly is shown in FIG. 3. An article 300 is shown as comprising
layers 310, 320 and 330. In this example, layers 320 and 330 are
selected to be the same with a respective one of the layers 320,
330 disposed on a surface of the layer 310. In the configuration
shown in FIG. 3, the core layer 310 is selected such that it has a
lower lofting capacity than the layers 320, 330. Upon exposure to
heat or other lofting stimulus, the post-loft thickness of the
layer 310 will be less than that of the layers 320, 330. For
example, the thickness of the layer 310 prior to lofting may be
about 1-2 mm and after lofting may be about 6-8 mm. The thickness
of the layers 320, 330 prior to lofting may also be about 1-2 mm
and after lofting may be about 10-15 mm. These thickness changes in
the layers 320, 330 may occur even in the absence of any added
lofting agent. For example and without wishing to be bound by any
particular theory, during lofting the thermoplastic material of the
layers 320, 330 may melt and release their hold on the reinforcing
materials to permit the reinforcing materials to occupy more
volume. Subsequent cooling of the thermoplastic material can result
in reformation of a web of open celled structures with a larger
volume than the pre-lofted web. By tuning the level of
thermoplastic material and/or reinforcing materials in the layers
320, 330, the degree to which the volume of the layers 320, 330 can
increase may be selected. In comparison, the amount of
thermoplastic material and/or reinforcing materials present in the
layer 310 can be selected such that melting of the thermoplastic
material during lofting does not result in a substantial increase
in the overall volume. As the web of the layer 310 reforms after
lofting, the resulting post-lofted web volume is not substantially
different from the pre-lofted web volume. If desired, one or more
of the layers 310-330 may include an added lofting agent to further
increase the overall volume. For example, one or both of the layers
320, 330 may comprise an added lofting agent to further select the
overall post-lofted volume. In some instances, enough lofting agent
is present so the post-lofted layers 320, 330 each have a thickness
of about 20-25 mm. In some examples, the layer 310 may comprise a
polyolefin, and reinforcing fibers, and the layers 320, 330 may
comprise a polyolefin (which can be the same or different than the
polyolefin in the layer 310), a reinforcing material and a lofting
agent. In some instances, only one of the layers 320, 330 comprises
a lofting agent. In certain configurations, the polyolefin present
in each of the layers 310-330 may be polypropylene or a polyolefin
copolymer comprising polypropylene. In some embodiments, the
reinforcing material of each of the layers 310-330 may comprise
glass fibers optionally in combination with other fibers. The exact
weight percentages of the thermoplastic material and reinforcing
materials in each of the layers 310-330 may vary, and illustrative
weight percentages in the layers 320, 330 are about 45-65 weight %
thermoplastic material with the balance being reinforcing material
and optionally lofting agent (which is typically present from 0.1
up to about 15 weight percent). The weight percentages of materials
present in the layer 310 can vary and illustrative ranges include,
but are not limited to, about 35-60 weight percent thermoplastic
material with the balance being reinforcing material.
[0049] In certain embodiments, an additional configuration of a
multi-layer assembly is shown in FIG. 4. An article 400 is shown as
comprising layers 410, 420 and 430. In this example, each of the
layers 410-430 has a different lofting capacity. In one
configuration of the illustration shown in FIG. 4, the core layer
410 has the highest lofting capacity followed by the layer 420 and
then the layer 430. In a different configuration, the core layer
410 has the highest lofting capacity followed by the layer 430 and
then the layer 420. In other configurations, the layer 420 has the
highest lofting capacity followed by the layer 410 and then the
layer 430. In a different configuration, the layer 420 has the
highest lofting capacity followed by the layer 430 and then the
layer 410. In some configurations, the layer 430 has the highest
lofting capacity followed by the layer 410 and then the layer 420.
In a different configuration, the layer 430 has the highest lofting
capacity followed by the layer 420 and then the layer 410. Upon
exposure to heat or other lofting stimulus, the post-loft thickness
of the layer with the highest lofting capacity will be greater than
the other layers. For example, the thickness of the layer with the
highest lofting capacity may be about 1-2 mm and after lofting may
be about 10-15 mm or 20-25 mm where a lofting agent is present. The
thickness of the layer with the second highest lofting capacity
prior to lofting may also be about 1-2 mm and after lofting may be
about 6-8 mm. The thickness of the layer with the lowest highest
lofting capacity prior to lofting may also be about 1-2 mm and
after lofting may be about 3-5 mm. By tuning the level of
thermoplastic material and/or reinforcing materials in the various
layers 410-440, the degree to which the volume of the layers can
increase may be selected. In some examples, each of the layers
410-430 may comprise a polyolefin and reinforcing fibers. In
certain configurations, the layer with the highest lofting capacity
may also comprise a lofting agent. In some examples, the
thermoplastic material of each layer may be a polyolefin such as
polypropylene, but the amount of polypropylene in each of the
layers 410-430 may be different. In some embodiments, the
reinforcing material of each of the layers 410-430 may comprise
glass fibers optionally in combination with other fibers. The exact
weight percentages of the thermoplastic material and reinforcing
materials in each of the layers 410-430 may vary to provide the
desired lofting capacity in each of the layers 410-430.
[0050] In certain configurations, any one or more of the
multi-layer assemblies described herein may comprise a skin layer
disposed on one of the other layers. Referring to FIG. 5A, an
illustration is shown of an article 500 that comprises layers
510-530 and a skin 540 disposed on the layer 520. If desired the
skin could instead be disposed on the layer 530. For illustration
purposes, the layers 510-520 are shown as being configured similar
to those layers described in reference to FIG. 2, though any of the
other multi-layered configurations described herein may also be
used with a skin. If desired, an adhesive layer (not shown) may be
present between the layer 520 and the skin 540. The skin 540 may
comprise, for example, a film (e.g., thermoplastic film or
elastomeric film), a frim, a scrim (e.g., fiber based scrim), a
foil, a woven fabric, a non-woven fabric or be present as an
inorganic coating, an organic coating, or a thermoset coating. In
other instances, the skin 540 may comprise a limiting oxygen index
greater than about 22, as measured per ISO 4589 dated 1996. Where a
thermoplastic film is present as (or as part of) the skin 540, the
thermoplastic film may comprise at least one of poly(ether imide),
poly(ether ketone), poly(ether-ether ketone), poly(phenylene
sulfide), poly(arylene sulfone), poly(ether sulfone),
poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and
silicone. Where a fiber based scrim is present as (or as part of)
the skin 540, the fiber based scrim may comprise at least one of
glass fibers, aramid fibers, graphite fibers, carbon fibers,
inorganic mineral fibers, metal fibers, metalized synthetic fibers,
and metalized inorganic fibers. Where a thermoset coating is
present as (or as part of) the skin 540, the coating may comprise
at least one of unsaturated polyurethanes, vinyl esters, phenolics
and epoxies. Where an inorganic coating is present as (or as part
of) the skin 540, the inorganic coating may comprise minerals
containing cations selected from Ca, Mg, Ba, Si, Zn, Ti and Al or
may comprise at least one of gypsum, calcium carbonate and mortar.
Where a non-woven fabric is present as (or as part of) the skin
540, the non-woven fabric may comprise a thermoplastic material, a
thermal setting binder, inorganic fibers, metal fibers, metallized
inorganic fibers and metallized synthetic fibers. If desired, the
skin 540 may also comprise a lofting agent as well.
[0051] In some examples, a second skin may be present on an
opposite surface of the multi-layer assembly. Referring to FIG. 5B,
a second skin 560 is shown as being present on the article 550. If
desired, an adhesive layer (not shown) may be present between the
layer 530 and the skin 560. The skins 540, 560 may independently
comprise, for example, a film (e.g., thermoplastic film or
elastomeric film), a frim, a scrim (e.g., fiber based scrim), a
foil, a woven fabric, a non-woven fabric or be present as an
inorganic coating, an organic coating, or a thermoset coating. In
other instances, the skins 540, 560 may independently comprise a
limiting oxygen index greater than about 22, as measured per ISO
4589 dated 1996. Where a thermoplastic film is present as (or as
part of) the skin 540, the thermoplastic film may comprise at least
one of poly(ether imide), poly(ether ketone), poly(ether-ether
ketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ether
sulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate,
nylon, and silicone. Where a fiber based scrim is present as (or as
part of) one or both of the skins 540, 560, the fiber based scrim
may comprise at least one of glass fibers, aramid fibers, graphite
fibers, carbon fibers, inorganic mineral fibers, metal fibers,
metalized synthetic fibers, and metalized inorganic fibers. Where a
thermoset coating is present as (or as part of) one or both of the
skins 540, 560, the coating may comprise at least one of
unsaturated polyurethanes, vinyl esters, phenolics and epoxies.
Where an inorganic coating is present as (or as part of) one or
both of the skins 540, 560 the inorganic coating may comprise
minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti
and Al or may comprise at least one of gypsum, calcium carbonate
and mortar. Where a non-woven fabric is present as (or as part of)
one or both of the skins 540, 560 the non-woven fabric may comprise
a thermoplastic material, a thermal setting binder, inorganic
fibers, metal fibers, metallized inorganic fibers and metallized
synthetic fibers. If desired, one or both of the skins 540, 560 may
also comprise a lofting agent as well.
[0052] In certain instances, a multi-layer assembly can comprise a
decorative layer disposed on a skin present in the multi-layer
assembly. Referring to FIG. 6, an article 600 comprises layers
610-630, a skin 640 disposed on the layer 620 and a decorative
layer 650 disposed on the skin 640. As described herein, one or
more of the layers 610-630 may have a variable lofting capacity,
e.g., different amounts of materials and/or the presence of a
lofting agent. The skin 640 may be any of the skins described in
connection with the skin 540 of FIGS. 5A and 5B, e.g., films,
scrims, frims, foils, a woven fabric, a coating, etc. The
decorative layer 650 may be formed, e.g., from a thermoplastic film
of polyvinyl chloride, polyolefins, thermoplastic polyesters,
thermoplastic elastomers, or the like. The decorative layer 650 may
comprise a carpet, rubber or other aesthetic covering. The
decorative layer 650 may also be a multi-layered structure that
includes a foam core formed from, e.g., polypropylene,
polyethylene, polyvinyl chloride, polyurethane, and the like. A
fabric may be bonded to the foam core, such as woven fabrics made
from natural and synthetic fibers, organic fiber non-woven fabric
after needle punching or the like, raised fabric, knitted goods,
flocked fabric, or other such materials. The fabric may also be
bonded to the foam core with a thermoplastic adhesive, including
pressure sensitive adhesives and hot melt adhesives, such as
polyamides, modified polyolefins, urethanes and polyolefins. The
decorative layer 650 may also be produced using spunbond, thermal
bonded, spun lace, melt-blown, wet-laid, and/or dry-laid
processes.
[0053] In some embodiments, the various layers and components
described herein may be disposed directly onto each other without
any intervening layer or material to couple the components. For
example, the layers may be adjacent to each other without the use
of any adhesive to couple the layers to each other. In instances
where an adhesive is desirable, one or more thermoplastic polymer
adhesives may be used. For example, it may be desirable to couple
the skin layer or the decorative layer to the assembly using an
adhesive. In some examples, the thermoplastic component of the
adhesive layer may comprise a thermoplastic polymer such as, for
example, a polyolefin such as a polyethylene or a polypropylene. In
other instances, the thermoplastic polymer of the adhesive layer
may comprise, polystyrene, acrylonitrylstyrene, butadiene,
polyethyleneterephthalate, polybutyleneterephthalate,
polybutylenetetrachlorate, and polyvinyl chloride, both plasticized
and unplasticized, and blends of these materials with each other or
other polymeric materials. Other suitable thermoplastic polymers
for use in the adhesive layer include, but are not limited to,
polyarylene ethers, polycarbonates, polyestercarbonates,
thermoplastic polyesters, polyimides, polyetherimides, polyamides,
acrylonitrile-butylacrylate-styrene polymers, amorphous nylon,
polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone,
polyether sulfone, liquid crystalline polymers, poly(1,4 phenylene)
compounds commercially known as PARMAX.RTM., high heat
polycarbonate such as Bayer's APEC.RTM. PC, high temperature nylon,
and silicones, as well as alloys and blends of these materials with
each other or other polymeric materials. If desired, the adhesive
may also comprise some thermosetting material including, but not
limited to, epoxides, epoxy resins, polyesters, polyester resins,
urethanes, polyurethanes, diallyl-phthalates, polymides, cyanate
esters, polycyanurates and combinations thereof.
[0054] In certain examples, the multi-layer assemblies described
herein can include more than three layers, e.g., may include, four,
five, six or more layers which can be lofted where at least one of
the layers has a different lofting capacity than another layer.
Referring to FIG. 7, an article 700 comprises layers 710-740 with
layers 710, 740 being the same and layers 720, 730 being the same.
In some instances, the lofting capacity of the layers 710, 740 is
higher than that of the layers 720, 730, whereas in other
configurations the lofting capacity of the layers 720, 730 is
higher than that of the layers 710, 740. Each of the layers 710-740
can include a thermoplastic material and a reinforcing material as
noted herein in connection with other layers. If desired, the
layers with a higher lofting capacity may include a lofting agent
or more lofting agent than the layers with a lower lofting
capacity. While not shown a skin may be present on one or both
surfaces of the article 700, and a decorative layer may also be
present if desired.
[0055] Referring to FIG. 8, another configuration of an article 800
is shown that comprises layers 810-840 with layers 810, 820 being
the same and layers 830, 840 being the same. In some instances, the
lofting capacity of the layers 810, 820 is higher than that of the
layers 830, 840, whereas in other configurations the lofting
capacity of the layers 830, 840 is higher than that of the layers
810, 820. Each of the layers 810-840 can include a thermoplastic
material and a reinforcing material as noted herein in connection
with other layers. If desired, the layers with a higher lofting
capacity may include a lofting agent or more lofting agent than the
layers with a lower lofting capacity. While not shown a skin may be
present on one or both surfaces of the article 800, and a
decorative layer may also be present if desired.
[0056] Referring to FIG. 9, another configuration of an article 800
is shown that comprises layers 810-850 with layers 910, 940 being
the same and layers 920, 930, 950 being the same. In some
instances, the lofting capacity of the layers 910, 940 is higher
than that of the layers 920, 930, 950, whereas in other
configurations the lofting capacity of the layers 920, 930, 950 is
higher than that of the layers 910, 920. Each of the layers 910-940
can include a thermoplastic material and a reinforcing material as
noted herein in connection with other layers. If desired, the
layers with a higher lofting capacity may include a lofting agent
or more lofting agent than the layers with a lower lofting
capacity. While not shown a skin may be present on one or both
surfaces of the article 900, and a decorative layer may also be
present if desired.
[0057] In some embodiments, the layers may include additional
materials or additives to impart desired physical or chemical
properties. For example, one or more dyes, texturizing agents,
colorants, viscosity modifiers, smoke suppressants, synergistic
materials, lofting agents, particles, powders, biocidal agents,
foams or other materials can be mixed with or added to the prepregs
or the cores. In some instances, the layers may comprise one or
more smoke suppressant compositions in the amount of about 0.2
weight percent to about 10 weight percent. Illustrative smoke
suppressant compositions include, but are not limited to,
stannates, zinc borates, zinc molybdate, magnesium silicates,
calcium zinc molybdate, calcium silicates, calcium hydroxides, and
mixtures thereof. If desired, a synergist material can be present
to enhance the physical properties of the prepregs or cores. If
desired, a synergist material that enhances lofting ability may be
present. Illustrative synergist materials include, but are not
limited to, sodium trichlorobenzene sulfonate potassium, diphenyl
sulfone-3-sulfonate, and mixtures thereof.
[0058] In certain examples, each of the layers of the multi-layer
assembly can be separately produced and then combined together to
form the multi-layer assembly or layers may be formed on each other
to build up a multi-layer assembly. For example, each of the layers
may be separately produced in a wet laid or other process and then
combined together to provide the multi-layer assembly. In producing
the various layers described herein, it may be desirable to use a
wet-laid process. For example, a liquid or fluid medium comprising
dispersed material, e.g., thermoplastic materials, fibers and
optionally lofting agent material optionally with any one or more
additives described herein (e.g., other lofting agents or flame
retardant agents), may be stirred or agitated in the presence of a
gas, e.g., air or other gas. The dispersion may then be laid onto a
support, e.g., a wire screen or other support material. The stirred
dispersion may comprise one or more active agents, e.g., anionic,
cationic, or non-ionic such as, for example, those sold under the
name ACE liquid by Industrial Soaps Ltd., that sold as TEXOFOR.RTM.
FN 15 material, by Glover Chemicals Ltd., and those sold as AMINE
Fb 19 material by Float-Ore Ltd. These agents can assist in
dispersal of air in the liquid dispersion. The components can be
added to a mixing tank, flotation cell or other suitable devices in
the presence of air to provide the dispersion. While an aqueous
dispersion is desirably used, one or more non-aqueous fluids may
also be present to assist in dispersion, alter the viscosity of the
fluid or otherwise impart a desired physical or chemical property
to the dispersion or the layer.
[0059] In certain instances, after the dispersion has been mixed
for a sufficient period, the fluid with the suspended materials can
be disposed onto a screen, moving wire or other suitable support
structure to provide a web of laid down material. Suction or
reduced pressure may be provided to the web to remove any liquid
from laid down material to leave behind the thermoplastic material,
lofting agent and any other materials that are present, e.g.,
fibers, additives, etc. The resulting web can be dried,
consolidated, pressed, lofted, laminated, sized or otherwise
processed further to provide a desired layer or article. In some
instances, an additive or additional lofting agent material can be
added to the web prior to drying, consolidation, pressing, lofting,
laminating, sizing or other further processing to provide a desired
layer or article. In other instances, the lofting agent may be
added to the web subsequent to drying, consolidation, pressing,
lofting, laminating, sizing or other further processing to provide
a desired layer or article. While wet laid processes may be used,
depending on the nature of the thermoplastic material, the lofting
agent material and other materials present, it may be desirable to
instead use an air laid process, a dry blend process, a carding and
needle process, or other known process that are employed for making
non-woven products.
[0060] In some configurations, the layers described herein can be
produced by combining a thermoplastic material, fibers, and an
optional microsphere lofting agent in the presence of a surfactant
in an aqueous solution or foam. The combined components can be
mixed or agitated for a sufficient time to disperse the various
materials and provide a substantially homogeneous aqueous mixture
of the materials. The dispersed mixture is then laid down on any
suitable support structure, for example, a wire mesh or other mesh
or support having a desired porosity. Water can then be evacuated
through the wire mesh forming a web. The web is dried and heated
above the softening temperature of the thermoplastic powder. The
web is then cooled and pressed to a predetermined thickness to
produce a composite sheet having a void content of between about 1
percent to about 95 percent. In an alternate embodiment, the
aqueous foam also includes a binder material. In some
configurations, after the web is heated above the softening
temperature of the thermoplastic powder, an adhesive layer
comprising a thermoplastic polymer and a thermosetting material can
then be disposed on the web.
[0061] In certain examples, one or more of the layers can be
produced in the form of a GMT. In certain instances, the GMT can be
generally prepared using chopped glass fibers, a thermoplastic
material, lofting agent and an optional thermoplastic polymer film
or films and/or woven or non-woven fabrics made with glass fibers
or thermoplastic resin fibers such as, for example, polypropylene
(PP), polybutylene terephthalate (PBT), polyethylene terephthalate
(PET), polycarbonate (PC), a blend of PC/PBT, or a blend of PC/PET.
In some embodiments, a PP, a PBT, a PET, a PC/PET blend or a PC/PBT
blend can be used as a resin. To produce the glass mat, a
thermoplastic material, reinforcing materials, lofting agent and/or
other additives can be added or metered into a dispersing foam
contained in an open top mixing tank fitted with an impeller.
Without wishing to be bound by any particular theory, the presence
of trapped pockets of air of the foam can assist in dispersing the
glass fibers, the thermoplastic material and the lofting agent. In
some examples, the dispersed mixture of glass and resin can be
pumped to a head-box located above a wire section of a paper
machine via a distribution manifold. The foam, not the glass fiber,
lofting agent or thermoplastic, can then be removed as the
dispersed mixture is provided to a moving wire screen using a
vacuum, continuously producing a uniform, fibrous wet web. The wet
web can be passed through a dryer at a suitable temperature to
reduce moisture content and to melt or soften the thermoplastic
material. When the hot web exits the dryer, a surface layer such
as, for example, an adhesive layer comprising a thermoplastic
polymer and a thermosetting material may be laid onto the web by
passing the web of glass fiber, lofting agent, thermoplastic
material and film through the nip of a set of heated rollers
followed by spraying of the adhesive onto the surface of the web.
If desired, additional layers such as, for example, a non-woven
and/or woven fabric layer or skin layer may also be attached to one
side or to both sides of the web to facilitate ease of handling the
glass fiber-reinforced mat. The composite can then be passed
through tension rolls and continuously cut (guillotined) into the
desired size for later forming into an end product article. Further
information concerning the preparation of such GMT composites,
including suitable materials and processing conditions used in
forming such composites, are described, for example, in U.S. Pat.
Nos. 6,923,494, 4,978,489, 4,944,843, 4,964,935, 4,734,321,
5,053,449, 4,925,615, 5,609,966 and U.S. Patent Application
Publication Nos. US 2005/0082881, US2005/0228108, US 2005/0217932,
US 2005/0215698, US 2005/0164023, and US 2005/0161865.
[0062] In some instances, each of the layers may be formed
separately as a sheet which is then used to provide a multi-layer
article. For example, a wet laid process can be used to produce a
first sheet with a low lofting capacity. A wet laid process can
also be used to produce a second sheet with a higher lofting
capacity than the first sheet. Each sheet may be processed prior to
coupling to each other. For example, each sheet may be compressed
to provide for a desired thickness. Two of the first sheets can be
coupled to the second sheet to provide a 3-layer assembly similar
to that shown in FIG. 2. While the coupling process may vary, in
some instances, one first sheet is heated to a temperature where
the thermoplastic component softens. The second sheet is then
disposed on the heated first sheet and additional heating is
applied to soften the disposed second sheet. Another first sheet is
then disposed on the heated, disposed second sheet with heating.
The three layers "melt" together to couple the layers to each
other. Pressure and/or temperature may be applied using processed
such as molding, thermoforming, etc. to assist in coupling the
sheets to each other. In other instances, one sheet may be formed
onto another sheet by disposing the material onto the sheet in a
liquid slurry form and permitting the water to evaporate leaving
behind the thermoplastic material and reinforcing materials. Once
the slurry cures, an additional sheet may be formed on top of the
cured sheet using similar methods.
[0063] The articles described herein can be processed into a
desired configuration or shape using suitable processes including,
but not limited to, molding, thermoforming, drawing or other
forming processes. In some instances, such processes are used to
impart a desired configuration and/or to loft the various layers of
the article. For example, where the article is designed to function
as a vehicle floor, the floor may be shaped and/or cut in a desired
manner. Referring to FIG. 10, a vehicle floor 1000 is shown as
being disposed and coupled to a vehicle frame comprising components
1005a, 1005b. The floor 1000 is a generally planar structure
comprising one or more of the multi-layer assemblies described
herein, e.g., those shown and described in connection with FIGS.
1-9, or other similar multi-layer assemblies that will be selected
by the person of ordinary skill in the art, given the benefit of
this disclosure. The floor 1000 may be coupled to the frame through
suitable fasteners such as bolts, screws and the like and
optionally with one or more adhesives. In some instances, doors, a
roof assembly and other components of the vehicle may be disposed
onto the floor 1000 to provide a user cabin. If desired, a carpet,
foam padding, and the like may be coupled to the floor 1000 for
aesthetic or other reasons.
[0064] In some embodiments, a load floor for a rear storage
compartment may be produced using the articles described herein.
Referring to FIG. 11, a side view of a deep drawn article 1100 that
can be used as a load floor is shown. The article 1100 is typically
positioned in the rear portion of the vehicle, e.g., a rear storage
portion of a sport utility vehicle or minivan, and is designed to
receive components, gear, luggage, a spare tire, etc. for storage.
A lid or covering (not shown) may also be present to enclose the
components within the load floor 1100 and shield them from view.
The load floor 1100 may comprise, for example, any of the
multi-layer assemblies described herein, e.g., those shown and
described in connection with FIGS. 1-9, or other similar
multi-layer assemblies that will be selected by the person of
ordinary skill in the art, given the benefit of this
disclosure.
[0065] In some embodiments, the load floor can include structural
members or slats to provide additional strength if desired. For
example, one, two, three or more metal bars or members can be
positioned within the load floor, e.g., in the core layer or in any
other layer, to provide for additional strength. As described in
more detail in the examples below, certain configurations of a load
floor may provide no more than a desired amount of deflection under
a selected weight, e.g., as tested using ASTM D790-10 dated Apr. 1,
2010. If a particular load floor construction deflects more than a
desired amount, e.g., no more than 10 mm of deflection under a 100
kg load, then the core layer or the other layers can be altered,
e.g., by altering the materials and/or by including structural
members, to provide a load floor that meet a desired
specification.
[0066] In some embodiments, the articles described herein may be
configured in the form of a vehicle exterior or hull, e.g., a
recreational vehicle exterior panel, a boat hull or other
structural panels that may need to withstand some weight or force.
The panels are particular desirable for use in higher humidity
environments as the core layers are not generally sensitive to
water exposure and the properties do not change to a substantial
degree upon exposure to water.
[0067] In certain examples, the exact nature of the core layer and
the other layers selected may depend, at least in part, on the
desired acoustic properties of the article including the various
layers. For example, certain configurations of the core layers
described herein can provide excellent sound absorption but may not
have desired sound barrier properties. A skin or other layer can be
selected whose acoustic properties complement that of the core
layer to provide a composite structure with good sound absorption
and sound barrier properties.
[0068] In some embodiments, the core layer of the articles
described herein can be water resistant. For example, in many
configurations of a load floor, the core layer may be a paper based
material. Exposure of the paper based material to water can greatly
reduce the core layer strength and can promote mold growth. By
using a core layer as described herein, water exposure does not
alter the overall strength of the article.
[0069] Certain examples are described below to illustrate better
some of the novel aspects and configurations described herein.
Example 1
[0070] A vehicle load floor was produced using a Superlite.TM.
material (available from Hanwha Azdel, Inc.) as a skin and a
polyurethane foam block (6 pounds per cubic feet). The
Superlite.TM. material was present on both side of the polyurethane
foam block. The overall panel thickness was 21.5 mm, the panel
weight was about 5332 gsm and the panel density was 0.24
g/cm.sup.3. Under a 45 kg load (using a support width of 815 mm and
a support length of 380 mm), a deflection of 1.8 mm was observed
(or 0.34 mm/1000 gsm mass). At a 60 kg load, the deflection was
2.39 mm. In this Example 1 and the examples below, a coupon of the
load floor was placed onto the support of specified dimensions, and
a weight was placed on the span. The distance of deflection was
then measured.
Example 2
[0071] Deflection values for several comparative load floors were
measured to compare to Example 1. A first load floor and a second
load floor each included a glass fiber reinforced polyurethane skin
material and a paper honeycomb core layer. The first load floor
(Comparative Load Floor #1) was 20 mm thick, weighed about 3235 gsm
and had a board density of about 0.14 g/cm.sup.3. The second load
floor (Comparative Load Floor #2) was about 16.6 mm thick, weighed
about 3950 gsm and had a board density of about 0.25 g/cm.sup.3. A
third load floor was also produced using a polypropylene blow
molding process to produce a skin. The third load floor
(Comparative Load Floor #3) was hollow and included a thickness of
18.6 mm, a weight of 5520 gsm and a board density of 0.3
g/cm.sup.3. The deflection results under the same 45 kg load, 60 kg
load and load conditions of Example 1 are shown in Table 1.
TABLE-US-00001 TABLE 1 Deflection Deflection Deflection under per
1000 gsm under 60 kg Load Floor 45 kg (mm) Mass (mm) (mm)
Comparative Load 2.8 0.87 3.35 Floor #1 Comparative Load 2.31 0.51
2.9 Floor #2 Comparative Load 11.5 2.1 14.5 Floor #3
[0072] In comparing the results in Table 1 to those of Example 1,
less deflection was observed in the Example 1 load floor compared
to any of the comparative load floors. In addition, the
deflection/1000 gsm mass of the Example 1 load floor was about over
30% less than the next best comparative load floor
Example 3
[0073] Heat cycling was performed on coupons (3 inches in width and
14 inches in length) cut from each of three of the loads floors of
Example 1 and 2 (Example 1 load floor and Comparative Load Floors
#1 and #2). The test conditions used were 95+/-3% relative humidity
at 40+/-2 deg. C. for 18 hours. A 10 kg weight was then placed on
each coupon. The coupon from the load floor of Example 1 withstood
the 10 kg weight with minimal deflection. The coupons from
comparative load floors #2 and #3 both failed (broke) under the 10
kg weight.
Example 4
[0074] The coupon from load floor of Example 1 was tested under
heavier weight to measure the deflection. At 220 kg, the deflection
was measured to be 3.1 mm. After removal of the 220 kg weight, the
coupon of the load floor exhibited a permanent deflection of about
0.1 mm (similar to the permanent deflection that occurred using the
other weights in Examples 1-3).
Example 5
[0075] A composite panel is produced by combining two Superlite.TM.
skins with an XL4 core (a polypropylene/glass fiber material), each
of which is commercially available from Hanwha Azdel, Inc. (Forest,
Va.). The weight of the Superlite.TM. skins varies from about 500
gsm to about 3000 gsm, and the weight of the XL4 core layer varies
from about 500 gsm to about 1600 gsm. The weight of the
Superlite.TM. skins on each side of the XL4 core layer is about the
same. The exact dimensions may vary and illustrative overall
dimensions include a length of about 18 inches to about 36 inches,
a width of about 8 inches to about 22 inches and a thickness of
about 6 mm to about 50 mm.
Example 6
[0076] A composite panel is produced by combining two Superlite.TM.
skins with an XL4 core (all commercially available from Hanwha
Azdel, Inc.). The weight of the Superlite.TM. skins varies from
about 500 gsm to about 3000 gsm, and the weight of the XL4 core
layer varies from about 500 gsm to about 1600 gsm. The weight of
one Superlite.TM. skin on one side of the XL4 core is different
than a weight of the other Superlite.TM. skin on the other side of
the XL4 core layer. The exact dimensions may vary and illustrative
overall dimensions include a length of about 18 inches to about 36
inches, a width of about 8 inches to about 22 inches and a
thickness of about 6 mm to about 50 mm.
Example 7
[0077] A composite panel is produced by combining two Superlite.TM.
skins with an XL4 core (all commercially available from Hanwha
Azdel, Inc.). The weight of the Superlite.TM. skins varies from
about 500 gsm to about 3000 gsm, and the weight of the XL4 core
layer varies from about 500 gsm to about 1600 gsm. The weight of
one Superlite.TM. skin on one side of the XL4 core is the same or
different than a weight of the other Superlite.TM. skin on the
other side of the XL4 core layer. A decorative layer, e.g., a
non-woven fabric, is added to at least one of the Superlite.TM.
skins. The exact dimensions may vary and illustrative overall
dimensions include a length of about 18 inches to about 36 inches,
a width of about 8 inches to about 22 inches and a thickness of
about 6 mm to about 50 mm.
Example 8
[0078] A composite panel is produced by combining two Superlite.TM.
skins with an XL4 core comprising expandable microsphere lofting
agents, each of which is commercially available from Hanwha Azdel,
Inc. (Forest, Va.). The weight of the Superlite.TM. skins varies
from about 500 gsm to about 3000 gsm, and the weight of the XL4
core layer varies from about 500 gsm to about 1600 gsm. The weight
of the Superlite.TM. skins on each side of the XL4 core layer is
about the same. The exact dimensions may vary and illustrative
overall dimensions include a length of about 18 inches to about 36
inches, a width of about 8 inches to about 22 inches and a
thickness of about 6 mm to about 50 mm.
Example 9
[0079] A composite panel is produced by combining two Superlite.TM.
skins with an XL4 core comprising expandable microsphere lofting
agents (all commercially available from Hanwha Azdel, Inc.). The
weight of the Superlite.TM. skins varies from about 500 gsm to
about 3000 gsm, and the weight of the XL4 core layer varies from
about 500 gsm to about 1600 gsm. The weight of one Superlite.TM.
skin on one side of the XL4 core is different than a weight of the
other Superlite.TM. skin on the other side of the XL4 core layer.
The exact dimensions may vary and illustrative overall dimensions
include a length of about 18 inches to about 36 inches, a width of
about 8 inches to about 22 inches and a thickness of about 6 mm to
about 50 mm.
Example 10
[0080] A composite panel is produced by combining two Superlite.TM.
skins with an XL4 core comprising expandable microsphere lofting
agents (all commercially available from Hanwha Azdel, Inc.). The
weight of the Superlite.TM. skins varies from about 500 gsm to
about 3000 gsm, and the weight of the XL4 core layer varies from
about 500 gsm to about 1600 gsm. The weight of one Superlite.TM.
skin on one side of the XL4 core is the same or different than a
weight of the other Superlite.TM. skin on the other side of the XL4
core layer. A decorative layer, e.g., a non-woven fabric, is added
to at least one of the Superlite.TM. skins. The exact dimensions
may vary and illustrative overall dimensions include a length of
about 18 inches to about 36 inches, a width of about 8 inches to
about 22 inches and a thickness of about 6 mm to about 50 mm.
[0081] When introducing elements of the examples disclosed herein,
the articles "a," "an," "the" and "said" are intended to mean that
there are one or more of the elements. The terms "comprising,"
"including" and "having" are intended to be open-ended and mean
that there may be additional elements other than the listed
elements. It will be recognized by the person of ordinary skill in
the art, given the benefit of this disclosure, that various
components of the examples can be interchanged or substituted with
various components in other examples.
[0082] Although certain aspects, examples and embodiments have been
described above, it will be recognized by the person of ordinary
skill in the art, given the benefit of this disclosure, that
additions, substitutions, modifications, and alterations of the
disclosed illustrative aspects, examples and embodiments are
possible.
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