U.S. patent application number 17/385591 was filed with the patent office on 2022-05-26 for laminate facing for fiber reinforced materials and composite materials formed therefrom.
The applicant listed for this patent is Timothy Johnson, Thomas S. Miller. Invention is credited to Timothy Johnson, Thomas S. Miller.
Application Number | 20220161530 17/385591 |
Document ID | / |
Family ID | |
Filed Date | 2022-05-26 |
United States Patent
Application |
20220161530 |
Kind Code |
A1 |
Miller; Thomas S. ; et
al. |
May 26, 2022 |
Laminate Facing for Fiber Reinforced Materials And Composite
Materials Formed Therefrom
Abstract
The present invention provides a laminate material having a
polyester film and a web of polyester fibers cohesively bonded
directly thereto, such that portions of the fibers are bonded to
the polyester film and portions of the fibers are free from the
polyester film. The invention may also include a glass reinforced
polymer layer formed on the laminated facer where the polymer of
the glass reinforced polymer layer is commingled with the nonwoven
of the laminated facer. The laminate may further include a second
polymer layer having a thickness joined to the fiber layer and/or a
layer of hot melt adhesive applied to the polyester fibers. Also
presented is a composite material having a polyester film, a layer
of polyester fibers bonded to the second polymer layer; a second
polymer layer joined to the polyester film; and a glass reinforced
polymer layer formed on the laminated facer, where the polymer of
the class reinforced polymer layer is commingled with the nonwoven
of the laminated facer.
Inventors: |
Miller; Thomas S.;
(Granville, OH) ; Johnson; Timothy; (Dayton,
OH) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Miller; Thomas S.
Johnson; Timothy |
Granville
Dayton |
OH
OH |
US
US |
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|
Appl. No.: |
17/385591 |
Filed: |
July 26, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16247029 |
Jan 14, 2019 |
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17385591 |
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15353299 |
Nov 16, 2016 |
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16247029 |
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13851662 |
Mar 27, 2013 |
9505196 |
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15353299 |
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61616863 |
Mar 28, 2012 |
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International
Class: |
B32B 27/12 20060101
B32B027/12; B32B 7/05 20060101 B32B007/05; B32B 5/02 20060101
B32B005/02; B32B 7/14 20060101 B32B007/14; B32B 27/36 20060101
B32B027/36 |
Claims
1. A laminate material comprising: a base layer of a polymer film a
heat sealable polymer film having a thickness of 0.5-5 mil, and a
bonded fiber web having a density of 17-100 GSM and including
polymer fibers cohesively bonded directly thereto, such that
portions of the fibers are bonded to the polymer film and portions
of the fibers are free from the polymer film.
2. The laminate material of claim 1, wherein the polymer tint is a
polyester film.
3. The laminate material of claim 1, wherein the polymer film is a
polyethylene terephthalate film.
4. The laminate material of claim 1, wherein the polymer fibers
comprise polyester.
5. The laminate material of claim 1, wherein the polymer
polyethylene terephthalate.
6. The laminate material of claim 1, wherein the polymer is
selected from the group consisting of polyethylene, polyvinylidene
fluoride, poly(methyl methacrylate), polycarbonate, acrylonitrile
butadiene styrene, polyvinyl fluoride, polyester, polyurethane,
polypropylene, polyethylene terephthalate, polyurea, polyvinyl
chloride, EMA, or EVA.
7. The laminate material of claim 1, wherein the polymer fibers are
selected from the group consisting of polyethylene, polyvinylidene
fluoride, poly(methyl methacrylate), polycarbonate, acrylonitrile
butadiene styrene, polyvinyl fluoride, polyester, polyurethane,
polypropylene, polyethylene terephthalate, polyurea, polyvinyl
chloride, EMA, or EVA.
8. The laminate material of claim 1, wherein the base layer has a
softening point T1 and the and the heat sealable layer has a
softening point T2, such that T2<T1.
9. The laminate material of claim 1, wherein the monocomponent
fibers have a softening point T3 such that T3>T2.
10. The laminate material of claim 1 wherein a polymer in the
multicomponent fibers has a softening point T4 such that
T4<T1.
11. The laminate of claim 1, wherein the bonded fiber web includes
a mixture of monocomponent fibers and multicomponent fibers.
12. The laminate of claim 1, wherein the bonded fiber has a density
of 20-50 GSM and the web includes staple fibers.
13. The laminate of claim 1, wherein the bonded fiber has a density
of 20-50 GSM and the web includes continuous fibers.
14. The laminate of claim 1, wherein the cohesive bond is selected
from the group consisting of melt bonding, point bonding and roll
bonding.
15. The laminate of claim 1, further comprising: a layer selected
from the group consisting of a metal layer, an ink layer, a polymer
layer deposited on at least one surface of the laminate.
16. The laminate of claim 1, further comprising: a layer applied to
the base layer opposite heat sealable layer, the layer se polymers
(polyethylene, low melt PET, acrylic, polyurethane, ink, polyester,
polypropylene, polyethylene terephthalate, polyurea or polyvinyl
chloride) or a vapor deposited metals.
17. The laminate of claim 1, wherein the polyester film has a
thickness of 0.5-3.0 MIL.
18. The laminate of claim 1, wherein the polyester film has a
thickness of 0.5-3.0 MIL and the nonwoven has a density of 30-65
GSM.
19. The laminate of claim 1, wherein the polyester film has a
thickness of 0.5-1.5 MIL and the nonwoven has a density of 17-35
GSM.
20. The laminate of claim 1, further comprising: an extrusion
coated polymer layer having a thickness of 30-260 GSM joined to the
nonwoven.
21. The laminate of claim 20, wherein the extrusion coated polymer
layer is selected from the group consisting of polyethylene,
polyester, polyurethane, polypropylene, polyethylene terephthalate,
polyurea, polyvinyl chloride, EMA, or EVA.
22. A composite material, comprising: a laminated facer having a
polymer film having a thickness of 0.5-5 mil and a bonded fiber web
having a density of 17-100 GSM fibers being cohesively bonded
directly to the polymer film, such that portions of the fibers are
bonded to the polymer film and portions of the fibers are free from
the polymer film; and a fiber reinforced polymer layer formed on
die laminated facer; whereby, the polymer of the reinforced polymer
layer is commingled with the nonwoven of the laminated facer.
23. The composite material of claim 22, wherein the polymer film is
a polyester film.
24. The composite material of claim 22, wherein the polymer film is
a polyethylene terephthalate film.
25. The composite material of claim 22, wherein the polymer fibers
comprise polyester.
26. The composite material of claim 22, wherein the polymer
polyethylene terephthalate.
27. The composite material of claim 22, wherein the polymer film is
selected from the group consisting of polyethylene, polyvinylidene
fluoride, poly(methyl methacrylate), polycarbonate, acrylonitrile
butadiene styrene, polyvinyl fluoride, polyester, polyurethane,
polypropylene, polyethylene terephthalate, polyurea, polyvinyl
chloride, EMA or EVA.
28. The composite material of claim 22, wherein the polymer fibers
are selected from the group consisting of polyethylene,
polyvinylidene fluoride, poly(ra ethyl methacrylate),
polycarbonate, acrylonitrile butadiene styrene, polyvinyl fluoride,
polyester, polyurethane, polypropylene, polyethylene terephthalate,
polyurea, polyvinyl chloride, EMA, or EVA.
29. The material of claim 22, further comprising: a layer selected
from the group consisting of a metal layer, an ink layer, a polymer
layer deposited on at least one surface of the laminate.
30. The laminate of claim 21, wherein the polyester film has a
thickness of 0.5-3.0 MIL and the nonwoven has a density of 17-50
GSM.
31. A laminate material comprising: a polyester film having a
thickness of 0.5-2 mil, a bonded fiber web having a density of
17-100 GSM and including 20% PET fibers and 80% PET bicomponent
fibers cohesively bonded directly to the polyester film, such that
portions of the fibers are bonded to the polyester film and
portions of the fibers are free from the polyester film; and
Description
PRIORITY
[0001] This application is a Continuation-In-Part of U.S.
application Ser. No. 13/851,662, filed Mar. 27, 2013, which is a
Utility application based upon Provisional Application Ser. No.
61/616,863, filed Mar. 28, 20012, entitled, "Laminate Facing for
Fiber Reinforced Materials and Composite Materials Formed
Therefrom" with inventor: Thomas Miller. All aspects of Provisional
Application Ser. No. 61/616,863 are hereby incorporated by
reference.
BACKGROUND
[0002] Polypropylene films are often used as surface materials for
laminates and composite materials, are known for use in lining
tucks, refrigerated shipping containers and other industrial and
construction materials. Typically, a film such as polypropylene or
other substrate such as PET is bonded to a nonwoven. The
polypropylene face layer is not a suitably durable, temperature
resistant or chemically inert surface. The polypropylene facers are
generally not suitable for use with a thermoset composite due to
adherence issues and temperature resistance. Polypropylene is
typically porous and difficult to clean and is therefore generally
not suitable for use for a number of applications. The
polypropylene laminate is formed with a film of polypropylene, to
which a layer of polypropylene is extruded, and the extruded
polypropylene adheres to the film and the nonwoven material. The
three-step process increases material costs, processing expense and
material waste.
SUMMARY
[0003] In accordance with embodiments, the present invention
relates to laminate facings for
fiber reinforced or composite materials and materials formed
therefrom. The laminate facings are generally formed of a polyester
film layer bonded directly to a nonwoven fibrous layer. The facings
are cohesively bonded to a nonwoven, typically roll beaded, point
bonded or bonded by any other suitable method, including coforming
of the fiber layer on the film or the film layer on the fibrous
layer directly such that the fibers and the polyester film facing
are integrally joined without the use of a subsequently applied
layer of adhesive or other polymer. The composite materials may be
formed by applying the laminate to a surface and depositing fiber
reinforced resin to the laminate or applying the laminate to the
surface of a fiber-reinforced resin during manufacture. The
laminate provides a rugged outer layer for composite materials and
may reduce volatile organic compound emissions by replacing a gel
coat fryer. The laminate may also include a metalized layer such as
aluminum, molybdenum, tantalum, titanium, nickel, and tungsten. The
metalized layer improves thermal properties by forming a radiant
barrier and also improves opacity of the facing and provides an
aesthetically pleasing appearance.
[0004] In accordance with embodiments of the present invention the
films may be produced by conventional forming such as casting,
blowing, and extrusion or coextrusion processes. The extruded films
are created with a single base layer made from an extrudable
thermoplastic polymer and may include one or more exterior layers.
One suitable exterior layer includes a relatively low melting point
heat sealable polymer to improve the bonding of the film to the
fibrous layer. The bonding material of the film is a heat sealable
polymer layer designed to melt bond to the polymer of the fiber
layer. In an alternate embodiment of the present invention, a
metalized or ink layer may be deposited on one surface or both
surfaces of the laminate.
[0005] Bicomponent fibers may be incorporated into nonwovens by
several processes. The spunbond process may be adapted to create
bicomponent fibers of a sheath/core type and lay these fibers
continuously onto a conveyor wherein they can be consolidated into
a nonwoven web and wound into a roll. Consolidation may be provided
by heated rolls either of a pattern including point bonding, or
more preferably in this case of smooth surfaces to provide more
uniform bonding over the entire surface of the nonwoven web of
continuous fibers.
[0006] Alternatively, Bicomponent fibers may be produced and then
cut and crimped into staple fibers. Staple fibers may then be
blended and mixed with other fiber types and dimensions, then
carded and run onto a conveyor wherein they can be consolidated
into a nonwoven web and wound into a roll. Consolidation may be
provided by heated rolls either of a pattern including point
bonding, or more preferably in this case of smooth surfaces to
provide more uniform bonding over the entire surface of the
nonwoven web of continuous fibers.
[0007] There are several advantages for using staples fiber blends
for processing, performance, and cost. A notable difference between
the two described methods is that a nonwoven web formed of
continuous fibers is formed of layers of superimposed fibers,
whereas a nonwoven web of staple fibers has substantial
interleaving of the fibers such that each fiber may be present in
part on both top and bottom surfaces. While a spunbond line adapted
for the production of bicomponent fibers may only provide a
singular specification of fiber for a given layer of the nonwoven,
a production line using staple fibers may blend several types of
fibers throughout the nonwoven web. Staple fiber blending is common
and easily controlled, and the benefits of blending can provide
enhancements of performance and cost. In addition, a production
line using staple fibers may be more easily controlled for speed to
provide greater flexibility of the weight of nonwoven achieved as
well as the introduction of films into the process.
[0008] In accordance with an alternate embodiment of the present
invention is presented having a composite material of a laminated
facer having a polyester film with a thickness of 0.5-5 mil and a
layer of polyester fibers having a density of 17-100 GSM bonded
thereto; and a glass reinforced polymer layer formed on the
laminated facer where the polymer of the glass reinforced polymer
layer is commingled with the nonwoven of the laminated facer.
[0009] In accordance with an alternate embodiment of the present
invention is presented having a laminate material having a
polyester film having a thickness of 0.5-2 mil, a layer of
polyester fibers having a density of 17-70 GSM bonded to the
polyester film and a second polymer layer having a thickness of
0.5-5 mil joined to the polyester fibers.
[0010] In accordance with an alternate embodiment of the present
invention is presented having a composite material having a
polyester film having a thickness of 0.5-2 mil, a layer of
polyester fibers having a density of 17-70 GSM bonded to the film,
a second polymer layer having a thickness of 0.5-5.5 mil joined to
the polyester fibers and a glass reinforced polymer layer formed on
the laminated facer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A more complete appreciation of the invention and the many
embodiments thereof will be readily obtained as the same becomes
better understood by reference to the following detailed
description when considered in connection with the accompanying
drawings, wherein:
[0012] FIG. 1A illustrates a plan view of the formation of the
laminate material in accordance with one aspect of the present
invention.
[0013] FIG. 1B illustrates a plan view of the formation of the
laminate material in accordance with another aspect of the present
invention.
[0014] FIG. 2A illustrates a plan view of the metallization of the
laminate material in accordance with one aspect of the present
invention.
[0015] FIG. 2B illustrates a plan view of the metallization of the
laminate material in accordance with one aspect of the present
invention.
[0016] FIG. 3 illustrates a plan view of the composite material of
the present invention with a laminate layer and a non-woven
included.
[0017] FIG. 4A is a schematic top view of the laminate of the
present invention.
[0018] FIG. 4B is a schematic cross-sectional view of the laminate
of the present invention.
[0019] FIG. 5 is a schematic cross-sectional view of another
laminate of the present invention including an adhesive layer or
filler layer applied to the nonwoven layer.
[0020] FIG. 6A is a cross-sectional schematic view of a preform
(prior to consolidation) of a laminate in accordance with one
aspect of the present invention with a single fiber of a
monocomponent fiber web on a laminated polymer film.
[0021] FIG. 6B is a cross-sectional schematic view of a laminate in
accordance with one aspect of the present invention with a single
fiber of a monocomponent fiber web consolidated with a laminated
polymer film.
[0022] FIG. 6C is a cross-sectional schematic view of a laminate in
accordance with one aspect of the present invention with a single
fiber of a monocomponent fiber web consolidated with a laminated
polymer film with a film applied to the fiber side of the
laminate.
[0023] FIG. 6D is a cross-sectional schematic view of a preform
(prior to consolidation) of a laminate in accordance with one
aspect of the present invention with a single fiber of a
bicomponent fiber web on a laminated polymer film.
[0024] FIG. 6E is a cross-sectional schematic view of a laminate in
accordance with one aspect of the present invention with a single
fiber of a bicomponent fiber web consolidated with a laminated
polymer film such that the polymer of the polymer layer and the
polymer of the bicomponent fiber are merged.
[0025] FIG. 6F is a cross-sectional schematic view of a laminate in
accordance with one aspect of the present invention with a single
fiber of a bicomponent fiber web consolidated with a laminated
polymer film with a film applied to the fiber side of the
laminate.
[0026] FIG. 7A is a cross-sectional schematic view of a laminate in
accordance with one aspect of the present invention with a fiber
web of mixed monocomponent and bicomponent fiber web consolidated
with a laminated polymer.
[0027] FIG. 7B is a cross-sectional schematic view of a laminate in
accordance with one aspect of the present invention with a fiber
web of mixed monocomponent and bicomponent fiber web consolidated
with a laminated polymer film with a film applied to the fiber side
of the laminate.
[0028] FIG. 7C is a cross-sectional schematic view of a laminate in
accordance with one aspect of the present invention with a fiber of
a mixed monocomponent and bicomponent fiber web consolidated with a
laminated polymer film and having a subsequent polymer layer
deposited over the fiber web.
[0029] FIG. 8A is a cross-sectional schematic view of a laminate in
accordance with one aspect of the present invention with a fiber of
a mixed monocomponent and bicomponent fiber web consolidated with a
laminated polymer film and having a subsequent polymer layer
deposited over the fiber web and an additional layer deposited on
the laminated polymer film.
[0030] FIG. 8B is a cross-sectional schematic view of a laminate in
accordance with one aspect of the present invention with a fiber of
a mixed monocomponent and bicomponent fiber web consolidated with a
laminated polymer film and having a subsequent polymer layer
deposited over the fiber web and an additional layer deposited on
the laminated polymer film and a building material layer, such as
stucco applied over the laminate.
[0031] FIG. 8C is a cross-sectional schematic view of a laminate in
accordance with one aspect of the present invention with a fiber of
a mixed monocomponent and bicomponent fiber web consolidated with a
laminated polymer film and having a number of subsequent polymer
layers deposited over the fiber web.
DETAILED DESCRIPTION
[0032] The present invention will now be described with occasional
reference to the specific embodiments of the invention. This
invention may, however, be embodied in different forms and should
not be construed as limited to the embodiments set forth herein.
Rather, these embodiments are provided so that this disclosure will
be thorough and complete, and will fully convey the scope of the
invention to those skilled in the art.
[0033] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
terminology used in the description of the invention herein is for
describing particular embodiments only and is not intended to be
limiting of the invention. As used in the description of the
invention and the appended claims, the singular forms "a," "an,"
and "the" are intended to include the plural forms as well, unless
the context clearly indicates otherwise.
[0034] Unless otherwise indicated, all numbers expressing
quantities of ingredients, properties such as molecular weight,
reaction, conditions, and so forth as used in the specification and
claims are to be understood as being modified in all instances by
the term "about". Accordingly, unless otherwise indicated, the
numerical properties set forth in the specification and claims are
approximations that may vary depending on the desired properties
sought to be obtained in embodiments of the present invention.
Notwithstanding that the numerical ranges and parameters setting
forth the broad scope of the invention are approximations, the
numerical values set forth in the specific examples are reported as
precisely as possible. Any numerical values, however, inherently
contain certain errors necessarily resulting from error found in
their respective measurements.
[0035] Fibrous nonwoven webs provide an improved bonding surface
between a polymer film layer and a fiber reinforced polymer
composite material. Preferred nonwoven webs are formed with staple
fibers that are carded and then may be bonded with a heat and/or
pressure process such as hot calendering, including area bonding,
point bonding and embossing; belt calendaring; through-air thermal
bonding; ultrasonic bonding; or radiant-heat bonding. The web may
be additionally, or alternatively, chemically bonded to improve
mechanical properties. Many bonding methods are available including
powder bonding using a powdered adhesive added to the web and then
typically heated. In a preferred embodiment, point or pattern
bonding using heated calender rolls or ultrasonic bonding equipment
is used to bond the fibers together. Point bonding provides for a
secure bonding of the nonwoven to the polyester film while leaving
unbonded fibers available to commingle with the composite laminate
or other coating resin. Roll bonding may be used to bond the web
across its entire surface. Bicomponent or multicomponent staple
fibers may be used in the process as well and generally, a blend of
single component fibers and bicomponent fibers is preferred.
[0036] As seen in FIG. 1A, roll 16 of polymer film 18 and roll 12
of nonwoven 14 is laminated by calender rolls 20, 22. The resulting
laminate 24 is taken up roll 26. The polymer film is preferably
0.5-5.0 mil thick. A polyester film such as polyethylene
terephthalate sold under the trade names Mylar, Skyrol, Melinex or
Hostaphan may be used. Generally, the bonding temperature is
130-180.degree. C. Preferably, a temperature of about
140-170.degree. C. is to be used in the bonding process. The fibers
and the polyester film facing are cohesively bound, that is,
integrally joined without the use of an intermediate layer of
adhesive or other polymer. As shown in TABLE 1, a layer of
polypropylene or another polymer or a lower grade of polyester may
be applied to the nonwoven. The use of lower coat polymers may
substantially decrease the overall cost of the material without
substantially altering the properties.
[0037] In FIG. 1B, the polymer film 18 in taken off roll and fed
into nonwoven fiber deposition device 10 such that nonwoven 12 is
applied to film 18 and the nonwoven 12 and film 18 are laminated by
calender rolls 20, 22. The resulting laminate 24 is taken up roll
26. FIG. 2A shows the printing process in which laminate 24 is
unrolled from roll 26 fed through a printing device to form a
printed laminate 30 that is rolled onto take-up roll 32.
[0038] FIG. 2B shows the vapor deposition of metallic compounds in
which laminate 24 is unrolled from roll 26 fed through a deposition
device to form a metalized laminate 30, which is rolled onto
take-up roll 32. Various deposition methods may be used including
chemical vapor deposition, physical vapor deposition. Metals such
as molybdenum, tantalum, titanium, nickel, and tungsten are
generally applied by CVD. For the deposition of aluminum, CVD may
be used with tri-isobutyl aluminum, tri ethyl/methyl aluminum, or
dimethyl aluminum hydride precursors or a physical deposition
process may be used. Electrostatic spray assisted vapor deposition,
plasma and electron-beam deposition may also be used. The metalized
layer may be formed on either the polyester film layer or the
non-woven layer. It may also be advantageous to deposit a metallic
coating on both sides of the laminate for improved coverage,
durability, and aesthetics.
[0039] FIG. 3 shows a composite material 38 including a resin layer
36 including fibers 40 and laminate 24. Laminate 24 induces polymer
film layer 18 bonded to nonwoven 14. The resin 36 infuses into the
fibers of the nonwoven layer to provide an integrated mechanical
bond. The mechanical bond formed between the resin 36 and the
fibers of nonwoven layer 14 is substantially stronger than the
chemical bond formed between the resin and the surface of the
polymer layer 18. Any resin infusion technology, such as liquid
molding, resin transfer molding, vacuum assisted resin transfer
molding, vacuum infusion processing and composite infusion molding
processing as well as vacuum bag molding, open molding, press
molding, may be used to form composite member 38. Other processes
such as hot calendering of the laminate onto the resin layer or use
of the laminate as a surface film in pulltrusion may be used to
form composite member 38.
[0040] FIG. 4A and FIG. 4B show the point bonded laminate of the
present invention including a non-woven layer 14 positioned on poly
film 18. The point bonding sites 14' are formed by rollers 20, 22
(as shown in FIG. 1). The point bond sites 14' are substantially
compressed such that the polymer of the fiber in the nonwoven 14 is
integrally joined with the polymer of the film 18. One or both of
the rollers 20, 22 may be heated to melt the fibers to bond with
film 14.
[0041] FIG. 5 shows another embodiment of the laminate 44 including
a polymer film 18, a fibrous layer 24 and a polymer layer 46
applied to the nonwoven layer with bonding sites 14' bonding film
18 to fibers 24. The laminate may be formed as described above to
form a laminate material having a polyester film having a thickness
of 0.5-2 mil; a layer of polyester fibers having a density of 17-70
GSM bonded polyester film and a polymer layer of polyethylene,
polyvinylidene fluoride, poly(methyl methacrylate), polycarbonate,
acrylonitrile butadiene styrene, polyvinyl fluoride, polyester,
polyurethane, polypropylene, polyethylene terephthalate, polyurea,
polyvinyl chloride, EMA, or EVA. A second polymer 46 may also be a
hot melt adhesive applied to the fibers. The hotmelt adhesives may
be any known including Ethylene-vinyl acetate (EVA) copolymers,
Ethylene-acrylate copolymers such as ethylene n-butyl acrylate
(EnBA), ethylene-acrylic acid (EAA) and ethylene-ethyl acetate
(EEA), Polyolefins such as low or high density polyethylene,
atactic polypropylene, polybutene-1, and oxidized polyethylene,
Polybutene-1 and its copolymers, Amorphous polyolefin polymers,
Polyamides and polyesters, Polyurethanes, Thermoplastic
polyurethane, reactive urethanes, Styrene block copolymers such as
Styrene-butadiene-styrene such as Styrene-isoprene-styrene,
Styrene-ethylene/butylene-styrene, and Styrene-ethylene/propylene.
Other hotmelt adhesives may include Polycaprolactone
Polycarbonates, Fluoropolymers, Silicone rubbers, thermoplastic
elastomers and Polypyrrole may also be used.
[0042] FIG. 6A is a cross-sectional schematic view of a preform of
a laminate formed with a film having base layer 110 and heat
sealable layer 112 with a single monocomponent fiber 114 of a
monocomponent fiber web. At the junction of fiber 114 and layer 112
recesses 114', 114'' are formed.
[0043] FIG. 6B is a cross-sectional schematic view of a laminate
formed with layers, 110, 112 with a single monocomponent fiber 114
of a monocomponent fiber web consolidated thereto. Heat sealable
polymer layer 112 is formed of a lower melting point material than
fiber that when the fiber 114 and layer 112 are consolidated by
heat and pressure, heat sealable layer 112 Recesses 114', 114''
formed at the junction of fiber 114 and layer 112, remain after
consolidation of the fiber 114 and layer 112.
[0044] FIG. 6C is a cross-sectional schematic view of a laminate
formed with layers, 110, 112 with a single monocomponent fiber 114
of a monocomponent fiber web consolidated thereto. Preferably,
polymer layer 112 and fiber 114 are formed of a compatible or
miscible material such that when the fiber 114 and layer 112 are
consolidated by heat and pressure there is no substantial variation
in the material. An additional layer 122 is shown over layer 112
and fiber 114. Layer 122 maybe any suitable material, such as an
additional polymer layer or a metallization layer a printing ink,
or successive combination thereof. Junctions of fiber 114 and layer
112 form along the length of fiber 114 such that fiber 114 is
anchored in areas and free from layer 112 in areas. The unanchored
areas of fiber 114 may be completely surrounded by subsequent
polymer layers to form a strong mechanical bond.
[0045] FIG. 6D is a cross-sectional schematic view of a preform of
a laminate formed with layers, 110, 112 with a single
multicomponent fiber 116 of a fiber web. Multicomponent fiber 116
may include core 118 and clad layer 120 or may be and other
suitable multicomponent fiber structure. At the junction of fiber
116 and layer 112 recesses 116', 116'' are formed. As with fiber
114, junctions of fiber 116 and layer 112 form along the length of
fiber 116 such that fiber 116 is anchored in areas and free from
layer 112 in areas. The unanchored areas of fiber 116 may be
completely surrounded by subsequent polymer layers to form a strong
mechanical bond.
[0046] FIG. 6E is a cross-sectional schematic view of a laminate
formed with a film having layers, 110, 112 with a single
multicomponent fiber 116 of a filer web consolidated thereto.
Preferably, polymer layer 112 and sheath layer 120 are formed of a
compatible or miscible material such that when the fiber sheath 120
and layer 112 are consolidated by heat and pressure there is no
substantial variation in the material. Typically, with a core clad
fiber the clad layer 120 would be compatible with layer 112.
Recesses 116', 116'' formed at the junction of fiber 116 and layer
112, remain after consolidation of the fiber 116 and layer 112.
[0047] FIG. 6F is a cross-sectional schematic view of a laminate
formed with layers, 110, 112 with a single multicomponent fiber 114
of a fiber web consolidated thereto. An additional layer 122 is
shown over layer 112 and fiber 114. Layer 122 maybe any suitable
material, such as an additional polymer layer, a metallization
layer, printing ink, or a combination thereof. Recesses 116', 116''
formed at the junction of fiber 116 and layer 112, remain after
consolidation of the fiber 116 and layer 112 and the subsequent
deposition of layer 122.
[0048] FIG. 7A is a cross-sectional schematic view of a preform of
a laminate formed with film layers, 110, 112 with monocomponent
fibers 114, 130 and multicomponent fiber 116, shown with core 118
and clad layer 120 or may be another suitable multicomponent fiber
structure. At the junction of fiber 114 and layer 112 recesses
114', 114'' are formed and at the junction of fiber 116 and layer
112 recesses 116', 116'' are formed. Fibers 130 and 114 are
generally the same blended and carded fibers diameter as fed into
the web processing steps.
[0049] FIG. 7B is a cross-sectional schematic view of a laminate
formed with layers, 110, 112 with a single monocomponent fiber 114
and a single multicomponent fiber 120 of a mixed fiber web
consolidated thereto. Preferably, polymer layer 112, fiber 114 and
a portion of fiber 116 are formed of a compatible or miscible
material such that when the fibers 114, 116 and layer 112 are
consolidated by heat and pressure there is no substantial variation
in the material. Typically, with a core clad fiber the clad layer
123 would be compatible with layer 112. Recesses 114', 114'' formed
at the junction of fiber 114 and layer 112 and recesses 116', 116''
formed at the junction of fiber 116 and layer 112 and remain after
consolidation of the fiber 114 and layer 112. An additional layer
122 is shown over layer 112 and fiber 114. Layer 122 maybe any
suitable material, such as an additional polymer layer or a
metallization layer.
[0050] FIG. 7C is a cross-sectional schematic view of a preform of
a laminate formed with layers, 110, 112 with monocomponent fiber
114, and multicomponent fibers 116, 132, shown with core 118 and
clad layer 120 and core 136 and clad layer 134 or may be and other
suitable multicomponent fiber structure. At the junction of fiber
114, and layer 112 recesses 114', 114'' are formed and at the
junction of fiber 116 and layer 112 recesses 116', 116'' are
formed. Additional polymer layer 138 is applied to fibers 114, 116,
132 such that a chemical bond is formed therebetween and a
mechanical bond is formed when polymer layer 138 surrounds a
portion of the fiber at recesses 114' and 116' as well as the
circumference of fibers 114, 116 where the fibers are not joined to
layer 112 or to fiber 132.
[0051] FIG. 8A is a cross-sectional schematic view of a composite
material including a laminate formed with layers, 110, 112, 158
with a single monocomponent fiber 114 and a single multicomponent
fiber 120 of a mixed fiber web consolidated thereto. Alternatively,
layer 158 may be applied in a post-processing step to include.
Preferably, polymer layer 112 and a clad layer 118 of fiber 116 are
formed of a compatible or miscible material such that when the
fibers 116 and layer 112 are consolidated by heat and pressure
there is no substantial variation in the material. Typically, with
a core clad fiber the layer 120 would be compatible with layer 112.
Recesses 114', 114'' formed at the junction of fiber 114 and, layer
112 and recesses 116', 116'' formed at the junction of fiber 116
and layer 112 and remain after consolidation of the fiber 114 and
layer 112. An additional layer 122 is shown over layer 112 and
fiber 114. Layer 122 maybe any suitable material, such as an
additional polymer layer or a metallization layer. Additional layer
138 such as a fiber reinforced composite material is applied to
fibers 114, 116, 132 such that a mechanical bond is formed with the
recesses 114' and 116 and around the circumference of unbonded
regions of fiber 114, 116.
[0052] FIG. 8B is a cross-sectional schematic view of a laminate
formed with layers, 110, 112 and additional layer 160 with a single
monocomponent fiber 114 and a single multicomponent fiber 120 of a
mixed fiber web consolidated thereto. Preferably, polymer layer
112, fiber 114 and a portion of fiber 116 are formed of a
compatible or miscible material such that when the fibers 114, 116
and layer 112 are consolidated by heat and pressure there is no
substantial variation in the material. Typically, with a core clad
fiber the clad layer 120 would be compatible with layer 112.
Recesses 114', 114'' formed at the junction of fiber 114 and layer
112 and recesses 116', 116'' formed at the junction of fiber 116
and layer 112 and remain after consolidation of the fiber 114 and
layer 112. An additional layer 122 is shown over layer 112 and
fiber 114. Layer 122 maybe any suitable material, such as an
additional polymer layer or a metallization layer. Additional
polymer layer 138, such as a fiber reinforced polymer, is applied
to fibers 114, 116, 132 such that a chemical bond is formed
therebetween and a mechanical bond is formed with the recesses 114'
and 116' as well as the circumference of fibers 114, 116 where the
fibers are not joined to layer 112. Exterior layer 160 such as a
building material, for example, a foamed polymer, and adhesive
layer or a cementitious stucco may be applied after the laminate is
mounted to a wall.
[0053] FIG. 8C is a cross-sectional schematic view of a preform of
a laminate formed with layers, 110, 112 with monocomponent fiber
114, and multicomponent fitters 116, 132, shown with core 118 and
clad layer 120 and core 136 and clad layer 134 or may be and other
suitable multicomponent fiber structure. Additional layers fiber of
reinforced composite material may be applied such that the polymer
matrix of the composite saturates the fiber layer of the Film/Fiber
Laminate 150, 152, 154, 156 may be added to form a composite such
as a four-ply structure with fiber alignment of 0/90/90/0.
[0054] The laminate and composite material of the present invention
is suitable for use in any composite structures including truck and
trailer liners, refrigerated shipping container liners, ladder
rails, tool handles, window lineals, structural materials, wall
panels for use in food preparation, health care or sanitary
applications, wall panels for recreational vehicles, polls and
cross arms, pilings or other infrastructure applications, and
signage; or electronic materials such as substrates for electronic
boards, laminates for solar panels, integrated circuits, industrial
switching, capacitors, and electrical boards; and insulation such
as foam facers, glass or mineral wool facers, and radiant heat
barriers.
EXAMPLES
[0055] Generally, polyester layers are combined with nonwoven
layers a wide range of potential laminates is shown in TABLE 1. The
polyester film used in each trial ranged from 48 to 200 gauge
thickness. The spunbond nonwoven ranges from 34.50 GSM. The
PP/Glass composite fiber is 50% glass fibers and 50% polypropylene
fibers.
[0056] The examples cited in Table 1 include spunbond continuous
monocomponent fibers, (examples IA, 1B, 2), spunbond continuous
bicomponent fibers, (examples 3, 4), and staple (discontinuous)
bicomponent fibers blended with monocomponent fibers (examples 5,
6, 7, 8).
[0057] Examples 1A and 1B were produced at the same time, and
example 1B had the additional process of application of a coating
of Polypropylene applied to the fiber side. They were each then
laminated to a similar composite of Fiberglass and Polypropylene.
The tests demonstrated an improvement is shear performance with the
coating of example 1B.
[0058] Example 2 was produced analogous to examples 1 and then
additional processed by ultrasonic bonding. Subsequent tests
confirmed an increase of peel strength.
[0059] Examples 3 and 4 demonstrated improved peel strength when
using the continuous bicomponent fibers.
[0060] Examples 5, 6, 7, 8 demonstrated further improved peel
strength when using the staple (discontinuous) bicomponent fibers
blended with monocomponent fibers, and substantially higher shear
strength. This was confirmed for a range of film thickness and
fiber weights.
[0061] In Examples, 3-8 bicomponent fibers having a 50/50 ratio of
core to sheath are used. Any suitable multicomponent fiber may be
used provided that a relatively low melting point polymer is
available at the surface of the fiber for bonding.
[0062] The polypropylene layer of example 1B is applied at 108 GSM
(.about.3.5 mils thick). The use of a second polymer layer improves
the strength of the final bond to the composite board, improving
the shear strength from 175 PSI to 235 PSI. The use of sheath/core
fibers substantially increased the peel and shear strengths.
TABLE-US-00001 TABLE 1 Polymer Film and Polymer Fiber Surface
Laminates Applied to Fiberglass/Polypropylene Composite Material
Example Number 1A 1B 2 3 4 5 6 7 8 Film Type Extrusion with Biaxial
Orientation Base Polymer PET PET PET PET PET PET PET PET PET UV
Additives Yes Yes Yes Yes Yes No Yes Yes No PET PET PET PET PET PET
PET PET PET Heat Sealable Layer CoPolymer CoPolymer CoPolymer
CoPolymer CoPolymer CoPolymer CoPolymer CoPolymer CoPolymer
Adhesion Coating No No No No No Yes No No No Thickness Gauge 80 80
80 80 80 48 80 100 200 Fiber Layer Fiber Type Continuous Continuous
Continuous Continuous Continuous Staple Staple Staple Staple Fiber
Polymer 100% PET 100% PET 100% PET 100% PET 10% PET 10% PET 10% PET
10% PET 10% PET BiCo BiCo 20% BiCo 20% BiCo 20% BiCo 20% BiCo 20%
PET PET PET PET PET Bonding Type Pointbond Pointbond Ulrasonic
Flatbond Flatbond Flatbond Flatbond Flatbond Flatbond Weight, gsm
34 34 34 17 34 20 20 20 50 PP Coating gsm 108 Composite Type
Fiberglass/ Fiberglass/ Fiberglass/ Fiberglass/ Fiberglass/
Fiberglass/ Fiberglass/ Fiberglass/ Fiberglass/ pp pp pp pp pp pp
pp pp pp Weight Percent 65/35 65/35 65/35 65/35 65/35 65/35 63/35
65/35 65/35/ Ply Thickness, mils 15 15 15 15 15 15 15 15 15 Ply
Orientation 0/90/90/0 0/90/90/0 0/90/90/0 0/90/90/0 0/90/90/0
0/90/90/0 0/90/90/0 0/90/90/0 0/90/90/0 Total Thk, mils 60 60 60 60
60 60 60 60 60 Test Data Peel Strength, 28 28 60 37 62 71 77 83 71
N/50 mm Lap Shear 175 215 351 351 391 421 Strength, psi
[0063] The present invention should not be considered limited to
the specific examples described herein, but rather should be
understood to cover all aspects of the invention. Various
modifications, equivalent processes, as well as numerous structures
and devices to which the present invention may be applicable will
be readily apparent to those of skill in the art. Those skilled in
the art will understand that various changes may be made without
departing from the scope of the invention, which is not to be
considered limited to what is described in the specification.
* * * * *