Composite panels including aesthetic edges

Abstract

To provide composite articles with aesthetic edges.SOLUTION: Certain configurations of composite panels are described that comprise at least one aesthetic edge. In some embodiments, the composite panel with aesthetic edges 1105, 1106 comprises a sandwich panel coupled to a shell layer 1150. The sandwich panel may comprise skin layers 1120, 1130 and a core layer 1110.SELECTED DRAWING: Figure 11

Description

[Technical field]

[0001] Related Applications This application is related to and claims priority to and the benefit of U.S. Provisional Application No. 62 / 830,260, filed April 5, 2019, the entire disclosure of which is incorporated herein by reference for all purposes.

[0002] Certain configurations described herein are directed to composite panels with aesthetic edges. More particularly, certain embodiments of composite panels are described that include a sandwich panel bonded to a shell layer to provide an aesthetic edge to the composite article. [Background technology]

[0003] Composite articles are often used in a variety of applications. The edges of the composite articles can often be unsightly as a result of the processes and / or materials used to make the composite article. Summary of the Invention [Means for solving the problem]

[0004] Specific aspects, configurations, and examples of composite articles with aesthetic edges are described. Composite panels can include two or more aesthetic edges, if desired. The composite articles can be used in many different end articles, including, but not limited to, vehicle load floors, structural panels, recreational vehicle tables, recreational vehicle storage doors or panels, and in other vehicular and non-vehicular applications.

[0005] In one embodiment, a composite article includes a sandwich panel including a first skin comprising a thermoplastic material and reinforcing fibers, a second skin comprising a thermoplastic material and reinforcing fibers, and a core layer positioned between the first skin and the second skin, and a shell layer bonded to the sandwich panel via the second skin, wherein the shell layer and sandwich panel together provide an aesthetic edge to the composite article.

[0006] In certain embodiments, the combined basis weight of the shell layer and second skin is the same or a different basis weight than the basis weight of the first skin. In some embodiments, the composite article includes four sides, a first side facing a third side and a second side facing a fourth side, the second skin disposed lengthwise from the first side to the third side, and the shell layer disposed lengthwise from the second side to the fourth side. In other examples, the composite article includes an air gap in the aesthetic edge, the air gap being between the shell layer and the second skin.

[0007] In some examples, the composite article includes at least two aesthetic edges each having an air gap, each of the air gaps being between the shell layer and the second skin.

[0008] In some configurations, the reinforcing fibers of each of the first and second skins include one or more of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers such as para-aramid and meta-aramid fibers, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool fibers, wollastonite, alumina silica, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In other examples, the thermoplastic material of each of the first and second skins includes a polyolefin material.

[0009] In some embodiments, the composite article includes a decorative layer bonded to the first skin of the sandwich panel. In other embodiments, the core layer includes a cellulosic or non-cellulosic material. In further embodiments, the composite article has a thickness of about 5 mm to about 100 mm.

[0010] In another aspect, a vehicle load floor sized and positioned to cover a rear interior section of a vehicle includes a decorative layer facing the interior of the vehicle and a load floor substrate bonded to the decorative layer, the load floor substrate including a sandwich panel bonded to the decorative layer, the sandwich panel including a first skin comprising a thermoplastic material and reinforcing fibers, a second skin comprising a thermoplastic material and reinforcing fibers, and a core layer positioned between the first skin and the second skin, a shell layer bonded to the sandwich panel via the second skin, and the vehicle load floor includes an aesthetic edge.

[0011] In certain embodiments, the combined basis weight of the shell layer and second skin is the same or a different basis weight than the basis weight of the first skin. In other embodiments, the load floor substrate includes four sides, a first side facing a third side and a second side facing a fourth side, the second skin being disposed longitudinally from the first side to the third side, and the shell layer being disposed longitudinally from the second side to the fourth side.

[0012] In some embodiments, the vehicle load floor includes at least one aesthetic edge having an air gap, the air gap being between the shell layer and the second skin. In some embodiments, the vehicle load floor includes at least two aesthetic edges, each having an air gap, the air gap being between the shell layer and the second skin.

[0013] In certain examples, the reinforcing fibers of each of the first and second skins include one or more of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers such as para- and meta-aramid fibers, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool fibers, wollastonite, alumina silica, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, the thermoplastic material of each of the first and second skins includes a polyolefin material.

[0014] In certain configurations, the load floor includes a second decorative layer bonded to the underside of the vehicle load floor. In some embodiments, the core layer includes a cellulosic or non-cellulosic material. In other embodiments, the vehicle load floor has a thickness of about 5 mm to about 30 mm.

[0015] In an additional aspect, a structural panel includes at least one interconnect, the structural panel includes a sandwich panel including a first skin including a thermoplastic material and reinforcing fibers, a second skin including a thermoplastic material and reinforcing fibers, and a core layer positioned between the first and second skins, and a shell layer bonded to the sandwich panel via the second skin, the structural panel including an aesthetic edge on one side of the structural panel. If desired, the structural panel can also include an air gap in the aesthetic edge, the air gap being between the shell layer and the second skin and configured to receive the interconnect.

[0016] In some examples, the interconnects comprise electrical wires. In other examples, the structural panel is configured as a table that is removable from the vehicle. In some embodiments, the interconnects include as a USB charging port. In other examples, the interconnects are electrically coupled to batteries in the structural panel. In additional examples, the interconnects are electrically coupled to photovoltaic cells in the structural panel.

[0017] In some examples, the reinforcing fibers of each of the first and second skins include one or more of 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, mineral fibers such as basalt, mineral wool fibers, wollastonite, alumina silica, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In certain embodiments, the thermoplastic material of each of the first and second skins includes a polyolefin material.

[0018] In another example, the structural panel includes a decorative layer bonded to the first skin of the sandwich panel. In some embodiments, each edge of the structural panel includes an aesthetic edge.

[0019] In another aspect, a method of manufacturing a composite panel having an aesthetic edge is provided. In some examples, the method includes bonding a preformed shell layer to a sandwich panel to provide the aesthetic edge, the sandwich panel including a first skin including a thermoplastic material and reinforcing fibers, a second skin including a thermoplastic material and reinforcing fibers, and a core layer positioned between the first skin and the second skin.

[0020] In certain embodiments, the preformed shell layer is bonded to a second skin of the sandwich panel. In other embodiments, the bond between the preformed layer and the second skin provides an air gap for an aesthetic edge between the second skin and the preformed shell layer. In some examples, the preformed shell layer includes a thermoplastic material and reinforcing fibers. In certain embodiments, the second skin includes a fiber orientation that is different from the fiber orientation of the reinforcing fibers of the shell layer. In some embodiments, each skin of the sandwich panel is manufactured using a wet-laid process. In other embodiments, each of the first and second skins includes a polyolefin and a glass reinforcing fiber, and the core includes a paper honeycomb. In additional examples, each of the first and second skins includes a polyolefin and a glass reinforcing fiber, and the core includes a non-cellulosic core.

[0021] Additional aspects, configurations, examples, and embodiments are described below. [Brief description of the drawings]

[0022] [Figure 1A] 1A-1C are diagrams of aesthetic edges on the sides of a composite panel according to some embodiments. [Figure 1B] 1A-1D are views of several aspects of an aesthetic edge according to several configurations. [Diagram 2]FIG. 2 is a diagram of a sandwich panel according to some embodiments. [Diagram 3] FIG. 1 illustrates an illustration of a sandwich panel, according to some embodiments. [Figure 4] FIG. 2 is a diagram of a shell layer, according to some embodiments. [Diagram 5] FIG. 1 is an illustration of a composite panel, in accordance with certain embodiments. [Figure 6] FIG. 2 is a diagram of a skin layer and a core layer comprising fibers of different orientations, according to some embodiments. [Figure 7] FIG. 2 is a diagram of a skin layer and a core layer comprising fibers of different orientations, according to some embodiments. [Figure 8] FIG. 2 is a diagram of a skin layer and a core layer comprising fibers of different orientations, according to some embodiments. [Figure 9] FIG. 2 is a diagram of a skin layer and a core layer comprising fibers of different orientations, according to some embodiments. [Figure 10] FIG. 2 is an illustration of a load floor, in accordance with certain embodiments; [Figure 11] FIG. 1 illustrates a composite article with an aesthetic edge on each side according to some embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] It will be recognized by those of ordinary skill in the art, given the benefit of this disclosure, that the dimensions of the various layers in the figures are not shown to scale. No layer thickness or dimensions are specifically intended or implied unless made clear from the specific description in relation to that particular layer or other component. The exact dimensions will vary depending on the final configuration of the article and / or its intended use.

[0024] A particular configuration of a composite panel having an aesthetic edge is described. The phrase "aesthetic edge" generally refers to an edge that includes a change in direction when viewed in cross section. For example, referring to FIG. 1A, a panel 100 with an aesthetic edge is shown that includes a first face 110 that is joined to a second face 120 via a rounded edge or low curvature bend 105. Although not required, the first face 110 may be generally perpendicular to the second face 120, but the faces 110, 120 can be disposed at other angles if desired. When viewed from the first face 110 or side of the panel 100, the second face 120 is generally not visible, but is shown as a dashed line in FIG. 1B for reference. In contrast to existing composite panels that have curved or sharp edges that are rough, uneven, or prone to bridging, aesthetic edges provide a more rounded edge that is generally not bridged and joins the faces of the panel. Aesthetic edges may generally be characterized by a change in edge direction, where the edge is configured as a rounded bend rather than a sharp edge or a generally curved edge from the top surface of the panel to the bottom surface of the panel.

[0025] In some examples, the aesthetic edge may be produced by bonding the sandwich panel to a shell layer, which may be preformed and manufactured separately from the composite panel or may be manufactured along with the composite panel. Referring to FIG. 2, a cross section of a sandwich panel 200 is shown. The sandwich panel 200 generally includes a first skin 220, a second skin 230, and a core layer 210 between the first skin 220 and the second skin 230. In some examples, the fibers of the skin layers 220, 230 may be arranged in similar or different directions, e.g., one of the skins 220, 230 may include fibers that are parallel to the longitudinal direction of the skins and the other skin may include fibers that are parallel to the cross direction of the skins. In certain examples, the skin layers 220, 230 may generally include the same material but have different amounts of material, e.g., different amounts of reinforcing fibers and / or different amounts of thermoplastic material. In other examples, the skin layers 220, 230 may include the same thermoplastic material but different reinforcing fibers. In additional configurations, the skin layers 220, 230 may include the same reinforcing fibers but different thermoplastic materials. In other examples, the skin layers 220, 230 may include the same reinforcing materials and thermoplastic materials but have different basis weights, different porosities, or other different physical properties. In some examples, the skin layers 220, 230 may include the same reinforcing fibers and the same thermoplastic materials but have different concentrations or amounts of lofting agents to provide various lofting capabilities.

[0026] In certain examples, each of the skin layers 220, 230, separately, may be constructed solely similar to the skin layer 120, e.g., each of the skin layers 220, 230 may be a glass mat thermoplastic (GMT) skin or a lightweight reinforced thermoplastic (LWRT) skin. For example, each of the skin layers 220, 230 may be constructed as an LWRT skin including one or more thermoplastic materials. In some examples, the thermoplastic material present in each of the layers 220, 230, separately, may include at least in part one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, as well as mixtures of these materials with each other or with other polymeric materials. Other suitable thermoplastics are , including, but not limited to, polyarylene ethers, polycarbonates, polyestercarbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, copolyamides, acrylonitrile-butylacrylate-styrene polymers, amorphous nylons, polyarylene ether ketones, polyphenylene sulfides, polyarylsulfones, polyethersulfones, liquid crystal polymers, poly(1,4-phenylene) compounds commercially known as PARMAX®, high heat polycarbonates such as Bayer's APEC® PC, high temperature nylons, and silicones, as well as copolymers, alloys, and mixtures of these materials with each other or with other polymeric materials. The thermoplastic materials used to form layers 220, 230 may be used in powder form, resin form, rosin form, particle form, fiber form, or other suitable form, and the forms used in different layers 220, 230 need not be the same. Exemplary thermoplastic materials in various forms are described herein, and are also described, for example, in U.S. Publication Nos. 2013 / 0244528 and US2012 / 0065283. The exact amount of thermoplastic material present in the skin layers 220, 230 can vary, with exemplary amounts ranging from about 20% to about 80% by weight, e.g., 30-70% or 35-65% by weight. As described herein, the amount of thermoplastic material present in the skins 220, 230 need not be the same.

[0027] In certain examples, the reinforcing fibers of the skin layers 220, 230 may include, separately, glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers such as para- and meta-aramid fibers, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool (e.g., rock wool or mineral wool), wollastonite, alumina silica, and the like, or mixtures thereof, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the aforementioned fibers may be chemically treated prior to use to provide desired functional groups or impart other physical properties to the fibers, for example, chemically treated to be capable of reacting with a thermoplastic material, a lofting agent, or both. In some examples, the fibers of one of the skin layers 220, 230 are chemically treated and the fibers of the other of the skin layers 220, 230 are not chemically treated. The fiber content of each of the layers 220, 230, separately, may 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 sandwich panel including the skin layers 220, 230 varies from about 20% to about 90% by weight of the assembly, more particularly, from about 30% to about 80% by weight, such as from about 40% to about 70% by weight. 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 skin layers 220, 230. 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 example, the fibers dispersed within the thermoplastic material and optionally the lofting agent to provide the skin layers 220, 230 may generally have a diameter greater than about 5 microns, more specifically, from about 5 microns to about 22 microns, and a length of from about 5 mm to about 200 mm, more specifically, 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.

[0028] In certain embodiments, the skin layers 220, 230 may include different fiber materials or different fiber blends. When different fiber materials are present, the fibers may be completely different fibers, e.g., fiberglass in one layer and carbon fiber in another layer, or may include the same substrate that has been modified, e.g., fiberglass in one layer and chemically treated glass fiber in another layer. In some examples, the fibers may be the same fiber material, but one or more physical properties of the fibers may be different. For example, the fiber materials of the layers 220, 230 may be the same or different, but the fibers of the layer 220 may have a first diameter that is different from the diameter of the fibers present in the layer 230. In other examples, the fiber materials present in the layers 220, 230 may be the same or different, but the length of the fibers in the layer 220 may be different from the length of the fibers present in the layer 230. In additional examples, the fiber materials present in layers 220, 230 may be the same or different, but both the length and diameter of the fibers in layer 220 may be different from the length and diameter of the fibers in layer 230. In still other examples, two or more different fibers may be used in one of layers 220, 230, and a single type of fiber may be present in the other layer. By selecting the amount and / or type and / or orientation of the fibers, the physical properties of the skin layers 220, 230 can be varied, for example, to provide different lofting capabilities for different skin layers of the assembly.

[0029] In some embodiments, the reinforcing fibers form a network that is held in place by the thermoplastic material of the skins 220, 230. The network is generally porous. In some examples, the pores of each skin 220, 230 may contain additives, including flame retardants, particles, or other materials. Exemplary basis weights of each of the skins 220, 230 include, but are not limited to, about 100 grams per square meter (gsm) to about 2000 gsm, more specifically, about 300 gsm to about 1500 gsm, or about 500 gsm to about 1200 gsm. The skins 220, 230 do not have to have the same basis weight in a composite article. In some examples, each skin layer 220, 230 may be formed first as a prepreg, which is generally a precursor to the skin and is not necessarily fully formed. The skins are typically porous to allow gas to flow through the skins. For example, the skins 220 and 230 are respectively 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%, 20-95%, 20-95%, 20-10%, 20-15%, 20-25%, 20-30%, 20-40%, 20-50%, 20-60%, 20-70%, 20-80%, 20-95 ... The skins 220, 230 may include a porosity or void content of 0%, 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 exemplary value within these exemplary ranges. In some examples, the skins 220, 230 include a porosity or void content of greater than 0%, e.g., completely unreinforced, up to about 95%.

[0030] In some examples, the core layer 210 can include a cellulosic or non-cellulosic material. For example, the core layer 210 can include a paper honeycomb or other core material that includes cellulosic fibers. The cellulosic fibers can be present with or without other materials, for example, in combination with a thermoplastic material. In other examples, the core layer 210 can include a foam, such as a polyurethane foam, which can be a closed cell foam or an open cell foam. When the core layer 210 is a closed cell foam, the closed cell foam of the core layer 210 can include a porosity of less than about 5%, 4%, 3%, 2%, or 1%.

[0031] In some embodiments, the core layer is not a sprayed or sprayable core layer, but instead is a solid planar layer that may be bonded to the skin layers 220, 230 after formation of the core layer 210. In some examples, the core layer 210 may include one or more of foam, cardboard, or paper honeycomb, or combinations thereof. In other examples, the core layer 210 may include or be polystyrene foam, expanded or extruded polyolefin foam (e.g., extruded polyethylene or expanded polypropylene), or other foam. In some examples, the core layer 210 may be devoid of any polyurethane material and / or devoid of any cellulosic material. Exemplary basis weights of the core layer 210 include, but are not limited to, from about 300 gsm to about 2000 gsm, more specifically, from about 500 gsm to about 1900 gsm, or from about 500 gsm to about 1500 gsm.

[0032] In some embodiments, the core layer 210 has greater compressive strength in the cross direction than in the machine direction. For example, the core layer 210 may include a foam having directional compressive strength, e.g., a foam having different compressive strengths in orthogonal directions, to impart higher stiffness to the entire article including the core layer 210 and the skin layers 220, 230. Foams capable of providing directional compressive strength are commercially available from Dow Corning and other manufacturers. The core layer 210 is typically first formed from a foam (or other material) and then bonded to the skin layers 220, 230. In some configurations, the material of the core layer 210 may be configured and arranged to allow for compression of the core layer 210 without substantial damage to the core layer 210. The material in the core layer 210 may also be selected to allow the article 200 to be thermoformed, e.g., compressed, molded, etc., without substantial damage to the core layer 210. Compared to a fibrous thermoplastic core layer, at a comparable basis weight, the presence of a core layer 210 including a closed cell foam (or a non-fiber reinforced thermoplastic material) may provide better performance and higher strength.

[0033] In certain examples, the core layer 210 itself may be configured as a GMT material or an LWRT material. For example, the core layer 210 may include reinforcing fibers and thermoplastic materials as described in connection with the skins 220, 230. The thickness of the core layer 210 is typically greater than the thickness of the skins 220, 230, although this arrangement is not required. In some examples where the core layer 210 is configured as an LWRT material, the thermoplastic material present in the core layer 210 may at least partially include one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, as well as mixtures of these materials with each other or with other polymeric materials. Other suitable thermoplastic materials include, but are not limited to, polyarylene ethers, polycarbonates, polyester carbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, copolyamides, acrylonitrile-butyl acrylate-styrene polymers, amorphous nylons, polyarylene ether ketones, polyphenylene sulfides, polyarylsulfones, polyethersulfones, liquid crystal polymers, poly(1,4-phenylene) compounds commercially known as PARMAX®, high heat polycarbonates such as Bayer's APEC® PC, high temperature nylons, and silicones, as well as copolymers, alloys, and mixtures of these materials with each other or with other polymeric materials. The thermoplastic materials used to form the core layer 210 may be used in powder, resin, rosin, particle, fiber, or other suitable form. Various forms of exemplary thermoplastic materials are described herein and also in, for example, U.S. Publication Nos. 2013 / 0244528 and US 2012 / 0065283. The exact amount of thermoplastic material present in the skin layers 220, 230 can vary, with exemplary amounts ranging from about 20% to about 80% by weight, such as 30-70% or 35-65% by weight.

[0034] In certain examples, the reinforcing fibers of the core layer 210 may include, separately, glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers such as para-aramid and meta-aramid fibers, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool (e.g., rock wool or mineral wool), wollastonite, alumina silica, and the like, or mixtures thereof, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the aforementioned fibers may be chemically treated prior to use to provide desired functional groups or impart other physical properties to the fibers, for example, chemically treated to be capable of reacting with a thermoplastic material, a lofting agent, or both. In some examples, the fibers in the core layer 210 may be chemically treated. The fiber content of the core layer 210 may 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 the core layer 210 is from about 20% to about 9% by weight of the core layer 210. 0% by weight, more particularly about 30% to about 80% by weight, for example, about 40% to about 70% by weight. The particular size and / or orientation of the fibers used may depend at least in part on the thermoplastic polymeric material used and / or the desired properties of the core layer 210. Suitable additional fiber types, fiber sizes and amounts will be readily selected by one of ordinary skill in the art given the benefit of this disclosure. In one non-limiting example, the fibers dispersed within the thermoplastic material and optionally the lofting agent to provide the core layer 210 may generally have a diameter greater than about 5 microns, more particularly about 5 microns to about 22 microns in diameter, and a length of about 5 mm to about 200 mm, more particularly, the fiber diameter may be about microns to about 22 microns, and the fiber length may be about 5 mm to about 75 mm.

[0035] In certain embodiments, the core layer 210 may first be formed as a prepreg, which is generally a precursor to the core layer 210 and is not necessarily fully formed. The core layer 210 is typically a porous structure that allows gas to flow through the core layer. For example, the core layer 210 may be formed in a range 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%, 20-80%, 20-95%, 20-95%, 20-10 ... The core layer 210 may include a porosity or void content of 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 exemplary value within these exemplary ranges. In some examples, the core layer 210 includes a porosity or void content of greater than 0%, e.g., completely unreinforced, up to about 95%.

[0036] In some configurations, the skin layers 220, 230 (and optionally the core layer 210) can be substantially halogen-free or halogen-free layers to meet the limits of hazardous materials requirements for a particular application. In other examples, one or more of the layers 210, 220, 230 can include halogenated flame retardants, such as, for example, one or more of F, Cl, Br, I, and At, or compounds that include such halogens, such as tetrabromobisphenol-A polycarbonate, or monohalo-, dihalo-, trihalo-, or tetrahalo-polycarbonates. In some examples, the thermoplastic material used in one or more of the skin layers 220, 230 can include one or more halogens to impart some flame retardancy without the addition of a separate flame retardant. If a halogenated flame retardant is present, it is desirable for the flame retardant to be present in a flame retardant amount that can vary depending on other ingredients present. For example, the halogenated flame retardant may be present at about 0.1% to about 15% by weight (based on the weight of the layer), more specifically, about 1% to about 13% by weight, e.g., about 5% to about 13% by weight. If desired, two different halogenated flame retardants may be added to the layer. In other examples, a non-halogenated flame retardant may be added, such as a flame retardant containing one or more of N, P, As, Sb, Bi, S, Se, and Te. In some embodiments, the non-halogenated flame retardant may include a phosphorylated material, thus making the layer more environmentally friendly. When a non-halogenated or substantially halogen-free flame retardant is present, it is desirable that the flame retardant be present in a flame retardant amount that may vary depending on other components present. For example, the substantially halogen-free flame retardant may be present at about 0.1% to about 15% by weight (based on the weight of the layer), more specifically, about 1% to about 13% by weight, e.g., about 5% to about 13% by weight, based on the weight of the layer. If desired, two substantially different halogen-free flame retardants may be added to one or more of layers 210, 220, and 230. In certain examples, one or more of layers 210, 220, and 230 may include one or more halogenated flame retardants in combination with one or more substantially halogen-free flame retardants.When two different flame retardants are present, the combination of the two flame retardants may be present in a flame retardant amount that may vary depending on the other ingredients present. For example, the total weight of flame retardants present may be about (based on the weight of the layer). The flame retardant content may be from 0.1% to about 20% by weight, more specifically, from about 1% to about 15% by weight, for example, from about 2% to about 14% by weight, based on the weight of the layer. The flame retardant used in the layers described herein may be added to the mixture including the thermoplastic material and the fibers (prior to disposing of the mixture on a wire screen or other processing component) or may be added after the layer is formed. In some examples, the flame retardant material may include one or more of expandable graphite material, magnesium hydroxide (MDH), and aluminum hydroxide (ATH).

[0037] In the configuration shown in FIG. 2, the lofting capabilities of the skin layers 220, 230 may be the same or different. The exact type of lofting agent used in the layers 220, 230 may depend on a number of factors including, for example, the desired lofting temperature, the degree of lofting desired, etc. In some examples, particulate lofting agents may be used, such as expandable particulates, that can increase their size upon exposure to convective heating. Exemplary commercially available lofting agents are available from Kureha Corp. (Japan). In other examples, a first lofting agent having a first average particle size and a second lofting agent having 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. The skin layers 220, 230 may be configured to provide the same lofting capabilities or different lofting capabilities. For example, upon exposure to heat or other lofting stimuli, the post-loft thickness of the layer 220 may be greater than the thickness of the layer 230. For example, the thickness of layer 220 before lofting may be about 1-2 mm, and after lofting may be about 10-15 mm. The thickness of layers 220, 230 before lofting may also be about 1-2 mm, and after lofting may be about 6-8 mm. These thickness variations may occur even in the absence of any added lofting agent. For example, without wishing to be bound by any particular theory, during lofting, the thermoplastic material may melt and release its hold on the reinforcing material, allowing the reinforcing material to occupy a larger volume. Subsequent cooling of the thermoplastic material may result in the reformation of an open-cell network having a larger volume than the pre-lofted network. The extent to which the volume of layer 220 can be increased by adjusting the level of thermoplastic and / or reinforcing material in layer 220 may be selected. In comparison, the amount of thermoplastic and / or reinforcing material present in layer 230 may be selected such that melting of the thermoplastic material during lofting does not result in a substantial increase in overall volume. As the network of layers 230 reforms after lofting, the volume of the resulting post-lofted network is not substantially different from the volume of the pre-lofted network.If desired, one or more of layers 220, 230 may include lofting agents added to further increase the overall volume. For example, layer 220 may include lofting agents added to further select the overall volume after lofting. In some examples, there is enough lofting agent present such that layer 220 after lofting (and / or layer 230 after lofting) has a thickness of about 20-25 mm. In some examples, layer 220 may include a polyolefin, a reinforcing fiber, and a lofting agent, and layer 230 may include a polyolefin (which may be the same or different from the polyolefin of layer 220) and a reinforcing material. In certain configurations, the polyolefin present in each of layers 220, 230 may be polypropylene or a polyolefin copolymer including polypropylene. In some embodiments, the reinforcing material of each of layers 220, 230 may include glass fibers, optionally in combination with other fibers. The exact weight percentages of thermoplastic and reinforcing materials in each of layers 220, 230 may vary, with exemplary weight percentages in layers 220, 230 being about 40-60 weight percent thermoplastic material, with the remainder being reinforcing material. If desired, skin layer 230 can be configured to have a higher lofting capability than layer 220.

[0038] In some embodiments, adhesive layers may be present between the various layers shown in FIG. For example, the layers may be bonded together without the use of an adhesive, or an adhesive layer may be present between the core layer 210 and the skin 220 and / or between the core layer 210 and the skin 230. If an adhesive layer is present, it may include thermoplastic adhesives including, but not limited to, pressure sensitive adhesives and hot melt adhesives, for example, polyamides, modified polyolefins, urethanes, and polyolefins. In some examples, the thermoplastic component of the adhesive layer may include separately thermoplastic polymers, for example, polyolefins, such as polyethylene or polypropylene. In other examples, the thermoplastic polymers of the adhesive layer may include separately polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, as well as mixtures of these materials with each other or with other polymeric materials. Other suitable thermoplastic polymers for use in the adhesive layer include, but are not limited to, polyarylene ethers, polycarbonates, polyester carbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, copolyamides, acrylonitrile-butyl acrylate-styrene polymers, amorphous nylons, polyarylene ether ketones, polyphenylene sulfides, polyarylsulfones, polyethersulfones, liquid crystal polymers, poly(1,4 phenylene) compounds commercially known as PARMAX®, high heat polycarbonates such as Bayer's APEC® PC, high temperature nylons, and silicones, as well as alloys and mixtures of these materials with each other or with other polymeric materials. If desired, the adhesive layer may also separately include any thermosetting material, including, but not limited to, epoxides, epoxy resins, polyesters, polyester resins, urethanes, polyurethanes, diallyl phthalates, polyimides, cyanate esters, polycyanurates, and combinations thereof.

[0039] In some examples, with reference to FIG. 3, one or more surface layers may be present on the surface of the sandwich panel. As described in more detail below, one skin layer of the sandwich panel is typically bonded to a shell layer, and the remaining skin layers may include a surface layer 340, as shown in FIG. 3. Layer 340 may take a number of forms and may typically be different from skin layer 230, e.g., a fiber-reinforced thermoplastic layer. In some embodiments, layer 340 may take the form of a skin. Skin 340 may include, for example, a film (e.g., a thermoplastic film or an elastomeric film), a flim, a scrim (e.g., a fiber-based scrim), a foil, a woven fabric, a nonwoven fabric, or may exist as an inorganic coating, an organic coating, or a thermosetting coating. In other examples, skin 340 may have a limiting oxygen index of greater than about 22, measured according to ISO 4589 of 1996. If a thermoplastic film is present as (or as part of) skin 340, the thermoplastic film may include at least one of poly(etherimide), poly(etherketone), poly(ether-etherketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ether sulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. If a fiber-based scrim is present as (or as part of) skin 340, the fiber-based scrim may include at least one of glass fiber, aramid fiber, graphite fiber, carbon fiber, inorganic mineral fiber, metal fiber, metallized synthetic fiber, and metallized inorganic fiber. If a thermosetting coating is present as (or as part of) skin 340, the coating may include at least one of unsaturated polyurethane, vinyl ester, phenolic, and epoxy. If an inorganic coating is present as skin 340 (or as part of skin 340), the inorganic coating may include minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or may include at least one of gypsum, calcium carbonate, and mortar.When a nonwoven is present as (or as part of) the skin 340, the nonwoven may include thermoplastic materials, thermosetting binders, inorganic fibers, metallic fibers, metallized inorganic fibers, and metallized synthetic fibers, as desired. 340 may also include a lofting agent. If desired, an adhesive layer (not shown) may be used to bond layer 340 to skin 230.

[0040] In a particular example, the layer 340 may be configured as a decorative layer. The decorative layer 340 may be formed from a thermoplastic film, such as, for example, polyvinyl chloride, polyolefin, thermoplastic polyester, thermoplastic elastomer, and the like. The decorative layer 340 may include carpet, rubber, or other aesthetic coverings. The decorative layer 340 may also be a multi-layer structure including a foam core, such as, for example, formed from polypropylene, polyethylene, polyvinyl chloride, polyurethane, and the like. Fabrics, such as woven fabrics made from natural and synthetic fibers, organic fiber nonwoven fabrics after needle punching or the like, raised fabrics, knitted goods, brushed fabrics, or other such materials, may be bonded to the foam core. Fabrics may also be bonded to the foam core with thermoplastic adhesives, including pressure sensitive adhesives and hot melt adhesives, such as polyamides, modified polyolefins, urethanes, and polyolefins. The decorative layer 340 may also be manufactured using spunbond, thermally bonded, spunlace, meltblown, wet-laid, and / or dry-laid processes. Although not shown, a skin, such as a scrim, film, decorative layer, etc., may also be bonded to layer 220 if desired.

[0041] In certain embodiments, the composite panel typically further includes a shell layer that may be bonded to the skin layer of the sandwich panel. In certain instances, the shell layer 400 is typically a single layer of material, although the shell layer may include two or more separate layers, if desired. A diagram of a shell layer is shown in FIG. 4. The shell layer 400 is typically a preformed or prefabricated layer that is bonded to the sandwich panel to provide an aesthetic edge to the composite panel. For example, the shell layer 410 may be molded to the exterior surface of the sandwich panel to hide the rough or raised surface of the sandwich panel from view. Although the panel 400 is shown to include aesthetic edges 405, 410, there may be only one aesthetic edge, or each edge of the composite panel may include an aesthetic edge, depending on the configuration and intended use of the composite panel.

[0042] In certain configurations, the shell layer 400 itself may include a GMT material or an LWRT material. For example, the shell layer 400 may be configured as an LWRT article that includes one or more thermoplastic materials and reinforcing fibers. In some examples, the thermoplastic material present in the shell layer 400 may at least partially include one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, as well as blends of these materials with each other or with other polymeric materials. Other suitable thermoplastic materials include, but are not limited to, polyarylene ethers, polycarbonates, polyester carbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, copolyamides, acrylonitrile-butyl acrylate-styrene polymers, amorphous nylons, polyarylene ether ketones, polyphenylene sulfides, polyarylsulfones, polyethersulfones, liquid crystal polymers, poly(1,4-phenylene) compounds commercially known as PARMAX®, high heat polycarbonates such as Bayer's APEC® PC, high temperature nylons, and silicones, as well as copolymers, alloys, and mixtures of these materials with each other or with other polymeric materials. The thermoplastic materials used to form layer 400 may be used in powder, resin, rosin, particle, fiber, or other suitable form. Various forms of exemplary thermoplastic materials are described herein and also in, for example, U.S. Publication Nos. 2013 / 0244528 and US2012 / 0065283. The exact amount of thermoplastic material present in layer 400 can vary, with exemplary amounts ranging from about 20% to about 80% by weight, such as 30-70% or 35-65% by weight.

[0043] In certain examples, the reinforcing fibers of layer 400 may include glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers such as para-aramid and meta-aramid fibers, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool (e.g., rock wool or mineral wool), wollastonite, alumina silica, and the like, or mixtures thereof, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof, separately. In some embodiments, any of the aforementioned fibers may be chemically treated prior to use to provide desired functional groups or impart other physical properties to the fibers, for example, chemically treated to be capable of reacting with a thermoplastic material, a lofting agent, or both. In some examples, the fibers in layer 400 are chemically treated. The fiber content of layer 400 may be about 20% to about 90% by weight of the layer, more particularly about 30% to about 70% by weight of the layer. The particular size and / or orientation of the fibers used may depend at least in part on the thermoplastic polymeric material used and / or the desired properties of layer 400. Suitable additional types of fibers, fiber sizes and amounts will be readily selected by one of ordinary skill in the art given the benefit of this disclosure. In one non-limiting example, the fibers dispersed within the thermoplastic material and optionally the lofting agent to provide skin layer 400 may generally have a diameter greater than about 5 microns, more specifically, a diameter of about 5 microns to about 22 microns, and a length of about 5 mm to about 200 mm, more specifically, the fiber diameter may be about microns to about 22 microns, and the fiber length may be about 5 mm to about 75 mm. In some embodiments, the reinforcing fibers form a network that is held in place by the thermoplastic material of layer 400. The network is generally porous, for example, comprising a porosity of 5% or more, and is permeable to gas. In some examples, the pores of layer 400 may contain additives, including flame retardants, particles, or other materials. Exemplary basis weights for layer 400 include, but are not limited to, from about 100 gsm to about 2000 gsm, and more specifically, from about 300 gsm to about 1500 gsm, or from about 500 gsm to about 1200 gsm.If desired, layer 400 may be halogen-free or may include halogenated materials or other materials such as lofting agents, flame retardants, and the like.

[0044] In a particular embodiment, a cross-section of a composite panel 500 including a shell layer is shown in FIG. 5. The composite panel 500 includes a core layer 510, skins 520, 530, and a shell layer 550. An aesthetic edge 505 is present on one side of the composite panel 500. If desired, an air gap 515 may be present between the skin 530 and the shell layer 550, or this air gap 515 may be filled with foam or other material. As described in more detail below, the presence of the air gap 515 provides a channel within which interconnects, cables, or other items may be located within the air gap 505 of the composite panel 500. Although not shown, another edge of the composite panel 500 may also include an aesthetic edge similar to edge 505.

[0045] In some embodiments, the basis weight of skin 520 can be approximately the same as the basis weight of the combination of skin 530 and core layer 550. For example, the basis weight of skin 530 can be selected to be less than the basis weight of skin 520, such that when shell layer 550 is bonded to skin 530, the combined basis weight of skin 530 and shell layer 550 is approximately the same as the basis weight of skin 520.

[0046] In other embodiments, the fiber blends and / or fiber orientations in the skins 520, 530 and shell layer 550 may be selected such that the fibers of different layers are present in different orientations. With reference to FIG. 6, a diagram is shown in which the shell layer 650 includes fibers oriented in a first direction and the skin 630 includes fibers oriented in a second direction. If desired, one of the layers 630, 650 may have randomly oriented fibers. The shell layer 650 and skin 630 are shown separated for ease of illustration. If desired, FIG. The fiber orientations shown can be swapped. In either case, bonding the skin 630 to the shell layer 650 provides a composite with fibers running in different directions.

[0047] In other embodiments, the shell layer may include bidirectional fibers and the skin layer may include a unidirectional or random fiber arrangement. With reference to Figure 7, the shell layer 750 includes bidirectional fibers and the skin 730 includes a unidirectional fiber arrangement, but the fibers within the skin 730 may be randomly oriented. The bidirectional fibers of the shell layer 750 need not be arranged in a 0 / 90 degree orientation as shown in Figure 7. Instead, the fibers may be arranged in an arrangement greater than 0 / 0 and less than or equal to 90 degrees, with some fibers being non-parallel to other fibers.

[0048] In other embodiments, the shell layer may include unidirectional fibers (or randomly distributed fibers) and the skin layer may include a bidirectional fiber arrangement. With reference to Figure 8, the shell layer 850 includes unidirectional fibers and the skin 830 includes a bidirectional fiber arrangement. The bidirectional fibers of the skin 830 need not be arranged in a 0 / 90 degree orientation as shown in Figure 8. Instead, the fibers may be arranged in an arrangement greater than 0 / 0 and less than or equal to 90 degrees, with some fibers being non-parallel to other fibers.

[0049] In some examples, the shell layer may include a bidirectional arrangement of fibers and the skin layer may include a bidirectional arrangement of fibers. With reference to Figure 9, the shell layer 950 includes bidirectional fibers and the skin 930 includes a bidirectional fiber arrangement. The bidirectional fibers of each of the skin 930 and layer 950 need not be arranged in a 0 / 90 degree orientation as shown in Figure 9. Instead, the fibers may be arranged in an arrangement greater than 0 / 0 and less than or equal to 90 degrees, with some fibers being non-parallel to other fibers.

[0050] In some examples, the composite articles described herein may be present in a vehicle load floor. One example is shown in FIG. 10. A side view of a depicted article 1000 that may be used as a vehicle load floor is shown. The article 1000 is typically positioned in the rear of a vehicle, for example, in the rear storage of a sports utility vehicle or minivan, and is designed to receive components, gear, luggage, spare tires, etc. for storage. A lid or cover (not shown) may also be present to enclose the components within the load floor 1000 of the vehicle and shield them from view. The load floor 1000 may include, for example, a composite article with aesthetic edges as described herein, or other similar articles with aesthetic edges that would be selected by one of ordinary skill in the art given the benefit of this disclosure. In some examples, the load floor 1000 provides sufficient weight-bearing capacity such that a support member underneath the vehicle does not need to be present to support it.

[0051] In some embodiments, the presence of the shell layer and sandwich panels in the load floor, as described herein, can provide an air gap through which one or more wires, interconnects, cables, or other devices can be routed. For example, the load floor air gap can include wiring that allows for USB charging using a port or other device present in the load floor or its lid. In other examples, the load floor can include a charging or power port that is electrically coupled to one or more wires routed through the air gap. The charging or power port can be used to charge or power a phone, pump, inflator, backup battery power source, or other device that may be present on or near the load floor or its lid.

[0052] In other examples, the composite panel may exist or be configured as a table that can be removed from a vehicle, such as a recreational vehicle (RV) van, truck, etc. For example, the composite panel may constitute or be part of a dinette table for the recreational vehicle. The table may be removed from the vehicle and placed on the exterior of the vehicle for use. In some examples, the table may include interconnects, an on-board battery or other power source, or other electronic media, some of which may reside within the air gaps of the composite panels. If desired, one or more surfaces of the table may also include photovoltaic cells, allowing the table to be moved outside of the RV and used as a solar cell to charge the RV's batteries or power the RV.

[0053] In other embodiments, the composite panels described herein may be used as structural panels. For example, the aesthetic edges of the panels allow them to be used as wall panels, cubicle panels, ceiling panels, ceiling tiles, or other applications of panels and tiles in the building industry. Other applications for structural panels that include aesthetic edges will be selected by those of ordinary skill in the art given the benefit of this disclosure.

[0054] In certain embodiments, the skin and shell layers described herein may generally be made using reinforcing fibers and thermoplastic materials, optionally in combination with flame retardant or other materials. To produce the layers, the thermoplastic material, reinforcing fibers, and optionally other materials may be added or metered into a dispersed 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 air pockets in the foam may aid in the dispersion of the reinforcing fibers, thermoplastic material, and any other materials. In some examples, the dispersed mixture of fibers and thermoplastic may be pumped through a distribution manifold to a headbox located above the wiring section of the paper making machine. The dispersed mixture may then be fed using pressure to a moving support such as a wire screen, which removes the foam, but not the fibers or thermoplastic, allowing the continuous production of a uniform fibrous wet network. The wet network may be passed through a dryer at a suitable temperature to reduce the moisture content and melt or soften the thermoplastic material. As the hot web exits the dryer, another layer, such as an optional film or other material, can be laminated onto the web by passing the web of reinforcing fibers, thermoplastic material, and film through the nip of a set of heated rollers. If desired, additional layers, such as, for example, another film layer, a scrim layer, and the like, can be attached to one or both sides of the web along with the film to facilitate handling of the produced layer or composite. The composite can then be passed through tension rolls and subsequently cut (guillotined) to the desired size for later formation into the final composite article.Further information regarding the preparation of such composites, including suitable materials and processing conditions used to form such composites, can be found, 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, and 5,609,966, as well as U.S. Patent Application Publication Nos. 2005 / 0082881, 2005 / 0228108, 2005 / 0217932, 2005 / 0215698, 2005 / 0164023, and 2005 / 0161865.

[0055] In some embodiments, the shell layer is first made as described above and molded to a shape and dimensions suitable for bonding to a sandwich panel. The sandwich panel may be made separately and then bonded to the shell layer via an adhesive, film, or other material. The entire bonded layer may be heated if desired. In other examples, the shell layer is made first and mating molded, and the skin is optionally added to the shell layer using an adhesive or film between the shell layer and the skin. The core layer may then be placed on the added skin with an optional adhesive or film between the core layer and the skin. A second skin may then be placed on the core layer with an optional adhesive or film between the core layer and the second skin. The resulting composite article may be heated to bond the various layers together. An optional decorative layer or other surface layer may then be added to one or more surfaces of the composite article as desired.

[0056] In certain embodiments, the panels described herein may include an aesthetic edge on each side of the panel. Referring to Figure 11, a panel 1100 is shown with aesthetic edges 1105, 1106. If desired, an air gap may be present between the second skin 1130 and the shell layer 1150 on each side of the panel 1100. The panel 1100 may also include a core layer 1110 and a skin 1120. An optional decorative layer (not shown) may further be present.

[0057] When incorporating elements of embodiments disclosed herein, the articles "a," "an," "the," and "said" are intended to mean that there are one or more 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 one of ordinary skill in the art, given the benefit of this disclosure, that various components of the embodiments may be interchanged or substituted for various components in other embodiments.

[0058] While particular aspects, examples, and embodiments have been described above, it will be recognized by those of ordinary skill in the art, given the benefit of this disclosure, that additions, substitutions, modifications, and variations of the disclosed exemplary aspects, examples, and embodiments are possible.

Claims

1. 1. A composite article comprising: a sandwich panel comprising a first skin comprising a thermoplastic material and reinforcing fibers, a second skin comprising a thermoplastic material and reinforcing fibers, and a core layer positioned between the first skin and the second skin; a shell layer bonded to the sandwich panel via the second skin, the shell layer and sandwich panel together providing an aesthetic edge to the composite article.

2. 10. The composite article of claim 1, wherein the combined basis weight of the shell layer and second skin is the same or a different basis weight than the basis weight of the first skin.

3. 2. The composite article of claim 1, wherein the composite article includes four sides, a first side facing a third side and a second side facing a fourth side, the second skin disposed longitudinally from the first side to the third side, and the shell layer disposed longitudinally from the second side to the fourth side.

4. 10. The composite article of claim 1, further comprising an air gap in said aesthetic edge, said air gap being between said shell layer and said second skin.

5. 5. The composite article of claim 4, wherein the composite article includes at least two aesthetic edges each having an air gap, each of the air gaps being between the shell layer and the second skin.

6. 2. The composite article of claim 1, wherein the reinforcing fibers of each of the first and second skins comprise one or more of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, in particular highly elastic organic fibers such as para- and meta-aramid fibers, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool fibers, wollastonite, alumina silica, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof.

7. The composite article of claim 6 , wherein the thermoplastic material of each of the first skin and the second skin comprises a polyolefin material.

8. The composite article of claim 1 , further comprising a decorative layer bonded to the first skin of the sandwich panel.

9. The composite article of claim 1 , wherein the core layer comprises a cellulosic or non-cellulosic material.

10. The composite article of claim 1, wherein the thickness of the composite article is from about 5 mm to about 100 mm.

11. A vehicle load floor sized and arranged to cover a rear interior section of a vehicle, said vehicle load floor comprising: A decorative layer facing the interior of the vehicle; a load floor substrate bonded to said decorative layer, A sandwich panel bonded to the decorative layer, the sandwich panel comprising a thermoplastic material and a reinforcing fiber. a sandwich panel comprising a first skin comprising a thermoplastic material and a reinforcing fiber, a second skin comprising a thermoplastic material and a reinforcing fiber, and a core layer positioned between the first skin and the second skin; a shell layer coupled to the sandwich panel via the second skin; and a load floor substrate comprising: A vehicle load floor, said vehicle load floor including an aesthetic edge.

12. 12. The vehicle load floor of claim 11, wherein the combined basis weight of the shell layer and second skin is the same or a different basis weight than the basis weight of the first skin.

13. 12. The vehicle load floor of claim 11, wherein the load floor substrate includes four sides, a first side facing a third side and a second side facing a fourth side, the second skin disposed longitudinally from the first side to the third side, and the shell layer disposed longitudinally from the second side to the fourth side.

14. 12. The vehicle load floor of claim 11, wherein said vehicle load floor further comprises an air gap in said aesthetic edge, said air gap being between said shell layer and said second skin.

15. 15. The vehicle load floor of claim 14, wherein the vehicle load floor includes at least two aesthetic edges each having an air gap therebetween, each of the air gaps being between the shell layer and the second skin.

16. 12. The vehicle load floor of claim 11, wherein the reinforcing fibers of each of the first and second skins comprise one or more of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, in particular highly elastic organic fibers such as, for example, para- and meta-aramid fibers, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool fibers, wollastonite, alumina silica, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof.

17. 17. The vehicle load floor of claim 16, wherein the thermoplastic material of each of the first skin and the second skin comprises a polyolefin material.

18. 12. The vehicle load floor of claim 11, further comprising a second decorative layer coupled to an underside of the vehicle load floor.

19. 12. The vehicle load floor of claim 11, wherein the core layer comprises a cellulosic or non-cellulosic material.

20. 12. The vehicle load floor of claim 11, wherein the vehicle load floor has a thickness of from about 5 mm to about 30 mm.

21. 1. A structural panel comprising at least one interconnect, a sandwich panel comprising a first skin comprising a thermoplastic material and reinforcing fibers, a second skin comprising a thermoplastic material and reinforcing fibers, and a core layer positioned between the first skin and the second skin; a shell layer coupled to the sandwich panel via the second skin, the structural panel including an aesthetic edge on one side of the structural panel; an air gap in the aesthetic edge, the air gap being between the shell layer and the second skin and configured to receive the interconnect; A structural panel comprising:

22. 22. The structural panel of claim 21 , wherein the interconnects comprise electrical wires.

23. 22. The structural panel of claim 21, wherein the structural panel is configured as a table that is removable from a vehicle.

24. 22. The structural panel of claim 21 , wherein the interconnect comprises a USB charging port.

25. 22. The structural panel of claim 21, wherein the interconnects are electrically coupled to batteries within the structural panel.

26. 22. The structural panel of claim 21 , wherein the interconnects are electrically coupled to photovoltaic cells within the structural panel.

27. 22. The structural panel of claim 21, wherein the reinforcing fibers of each of the first and second skins comprise one or more of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, in particular highly elastic organic fibers such as, for example, para- and meta-aramid fibers, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool fibers, wollastonite, alumina silica, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof.

28. 30. The structural panel of claim 27, wherein the thermoplastic material of each of the first skin and the second skin comprises a polyolefin material.

29. 30. The structural panel of claim 28, further comprising a decorative layer bonded to the first skin of the sandwich panel.

30. 30. The structural panel of claim 29, wherein each edge of the structural panel includes an aesthetic edge.

31. 1. A method for manufacturing a composite panel having an aesthetic edge, the method comprising bonding a preformed shell layer to a sandwich panel to provide the aesthetic edge, the sandwich panel comprising a first skin comprising a thermoplastic material and reinforcing fibers, a second skin comprising a thermoplastic material and reinforcing fibers, and a core layer positioned between the first skin and the second skin.

32. 33. The method of claim 32, wherein the preformed shell layer is bonded to the second skin of the sandwich panel.

33. 33. The method of claim 32, wherein the bonding of the preformed shell layer to the second skin provides an air gap at the aesthetic edge between the second skin and the preformed shell layer.

34. 32. The method of claim 31 , wherein the preformed shell layer comprises a thermoplastic material and reinforcing fibers.

35. 35. The method of claim 34, wherein the second skin includes a fiber orientation that is different than a fiber orientation of the reinforcing fibers of the shell layer.

36. 4. The method of claim 3, wherein each skin of the sandwich panel is manufactured using a wet laying process.

5. The method according to claim 4.

37. 32. The method of claim 31, wherein each of the first and second skins comprises polyolefin and glass reinforcing fibers and the core comprises a paper honeycomb.

38. 32. The method of claim 31, wherein each of the first and second skins comprises a polyolefin and glass reinforcing fibers, and the core comprises a non-cellulosic core.

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