Multilayer assembly including reinforced thermoplastic surface layer and core layer

Abstract

This invention provides a multi-layer assembly that offers excellent sound insulation and water resistance, possesses high strength, and can be used as a vehicle loading floor, wall panel, flooring panel, and the like. [Solution] The multilayer assembly comprises: a core layer containing a closed-cell material; a first reinforced thermoplastic layer disposed on a first surface of the core layer, wherein the first fiber-reinforced thermoplastic layer includes a web of open-cell structure formed by a plurality of reinforcing materials joined together with a thermoplastic material; and a second reinforced thermoplastic layer disposed on a second surface of the core layer, wherein the second fiber-reinforced thermoplastic layer includes a web of open-cell structure formed by a plurality of reinforcing materials joined together with a thermoplastic material.

Description

Technical Field

[0001] Priority Application This application claims the benefit of and priority to U.S. Provisional Application No. 62 / 470,691, filed Mar. 13, 2017, the entire disclosure of which is incorporated herein by reference for all purposes.

Background Art

[0002] This application relates to reinforced thermoplastic composites and their use in vehicles. More specifically, certain embodiments described herein relate to multilayer assemblies that include a reinforced thermoplastic surface layer combined with a core layer, and their use in vehicles and other applications.

[0003] Articles for automotive and construction material applications are typically designed to meet a number of competing and stringent performance specifications.

Summary of the Invention

Means for Solving the Problems

[0004] Specific configurations are described herein for multilayer assemblies and their components that can include one or more porous reinforced thermoplastic surface layers in combination with a core layer that is not a substantially non-porous core layer or a reinforced thermoplastic layer. Specific, particular configurations are described in detail below, but the exact materials present in the surface layer and core layer can vary depending on the intended use of the multilayer assembly.

[0005] In one aspect, a multilayer assembly includes a core layer that includes a closed-cell material, a first reinforced thermoplastic layer disposed on a first surface of the core layer, the first fiber-reinforced thermoplastic layer including a web of a continuous-cell structure formed by a plurality of reinforcing materials joined together with a thermoplastic material, a second reinforced thermoplastic layer disposed on a second surface of the core layer, the second fiber-reinforced thermoplastic layer including a web of a continuous-cell structure formed by a plurality of reinforcing materials joined together with a thermoplastic material.

[0006] In certain configurations, the closed-cell material is not polyurethane foam, or the core layer does not contain cellulose. In other configurations, the core layer includes polyurethane material, e.g., polyurethane foam, or cellulosic material, e.g., paper, honeycomb. In certain embodiments, the basis weight of the first reinforced thermoplastic layer is substantially the same as that of the second reinforced thermoplastic layer. In some embodiments, the basis weight of the first reinforced thermoplastic layer is different from that of the second reinforced thermoplastic layer. In certain embodiments, the provided first reinforced thermoplastic layer includes at least one reinforcing material different from that of the provided second reinforced thermoplastic layer. In other embodiments, the closed-cell material of the core layer includes a directional compression foam selected from the group consisting of directional compression expandable polystyrene foam, directional compression extruded polyethylene foam, and directional compression expandable polypropylene foam. In some embodiments, the thermoplastic material of the first reinforced thermoplastic layer is different from that of the second reinforced thermoplastic layer. In further embodiments, the thermoplastic materials of the first and second reinforced thermoplastic layers are the same. In some embodiments, the reinforcing materials of the first and second reinforced thermoplastic layers are the same. In other cases, the reinforcing material of the first and second reinforced thermoplastic layers each includes reinforcing fibers. In some configurations, the first fiber-reinforced thermoplastic layer includes at least one reinforcing fiber that is different from the reinforcing fibers of the second fiber-reinforced thermoplastic layer. In other configurations, one or both of the first and second fiber-reinforced thermoplastic layers are The lofting agent is included. In some embodiments, the lofting agent includes at least one of expandable microspheres and expandable graphite material. In additional embodiments, the lofting agent is absent in the core layer. In other embodiments, the thermoplastic and reinforcing materials of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer are selected to allow lofting of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer without the presence of a lofting agent. In some embodiments, the multilayer assembly further comprises a first adhesive layer disposed on a first surface of the core layer between the first reinforcing thermoplastic layer and the core layer. In additional embodiments, the multilayer assembly further comprises a second adhesive layer disposed on a second surface of the core layer between the second reinforcing thermoplastic layer and the core layer. In some configurations, the multilayer assembly comprises a decorative layer disposed on one of the first reinforcing thermoplastic layer and the second reinforcing thermoplastic layer. In some embodiments, the closed-cell material of the core layer comprises a directional compressible and expandable polystyrene foam, the first fiber-reinforced thermoplastic layer comprises polypropylene and glass fibers, the second fiber-reinforced thermoplastic layer comprises polypropylene and glass fibers, and the first and second adhesive layers each comprise a copolyamide. In some embodiments, at least one of the core layer, the first reinforced thermoplastic layer, and the second reinforced thermoplastic layer comprises a flame-retardant material. In certain cases, the flame-retardant material comprises one or more of an expandable graphite material, magnesium hydroxide, and aluminum hydroxide.

[0007] In another embodiment, the multilayer assembly comprises: a core layer comprising a closed-cell material having no polyurethane or cellulose material, wherein the closed-cell material is substantially non-porous and provides directional compressive strength to the multilayer assembly; a first adhesive layer disposed on a first surface of the core layer; a second adhesive layer disposed on a second surface of the core layer; a first fiber-reinforced thermoplastic layer disposed on the first adhesive layer, wherein the first fiber-reinforced thermoplastic layer comprises a web of open-cell structure formed by a plurality of reinforcing fibers joined together with a thermoplastic material; and a second fiber-reinforced thermoplastic layer disposed on the second adhesive layer, wherein the second fiber-reinforced thermoplastic layer comprises a web of open-cell structure formed by a plurality of reinforcing fibers joined together with a thermoplastic material.

[0008] In certain embodiments, the core layer includes a directional compression foam. In other embodiments, the directional compression foam is selected from the group consisting of directional compression expandable polystyrene foam, directional compression extruded polyethylene foam, and directional compression expandable polypropylene foam, or alternatively, polyurethane foam or cellulosic material. In some embodiments, the basis weight of the first fiber-reinforced thermoplastic layer is substantially the same as that of the second fiber-reinforced thermoplastic layer. In some embodiments, the basis weight of the first fiber-reinforced thermoplastic layer is different from that of the second fiber-reinforced thermoplastic layer. In other embodiments, the provided first fiber-reinforced thermoplastic layer includes at least one reinforcing fiber material different from that of the provided second fiber-reinforced thermoplastic layer. In certain cases, the thermoplastic material of the first fiber-reinforced thermoplastic layer is different from that of the second fiber-reinforced thermoplastic layer. In some embodiments, the thermoplastic material of the first and second reinforced thermoplastic layers is the same. In further embodiments, the reinforcing fibers of the first and second fiber-reinforced thermoplastic layers are the same. In some embodiments, the first fiber-reinforced thermoplastic layer further includes at least one reinforcing fiber different from the reinforcing fibers of the second fiber-reinforced thermoplastic layer. In other embodiments, one or both of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer include a lofting agent. In some embodiments, the lofting agent includes at least one of expandable microspheres and expandable graphite material. In certain embodiments, no lofting agent is present in the core layer. In certain configurations, the thermoplastic and reinforcing materials of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer are selected to allow lofting of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer without the presence of a lofting agent. In other configurations, the multilayer assembly is distributed between one of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer. The assembly comprises a surface layer, the surface layer including cloth, scrim, film, and combinations thereof. In some cases, the multilayer assembly comprises a decorative layer bonded to one of a first fiber-reinforced thermoplastic layer and a second reinforced thermoplastic layer. In certain embodiments, the thermoplastic material of each of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer is independently selected from the group consisting of polyolefin materials, thermoplastic polyolefin blend materials, polyvinyl polymer materials, butadiene polymer materials, acrylic polymer materials, polyamide materials, polyester materials, polycarbonate materials, polyester carbonate materials, polystyrene materials, acrylonitrile styrene polymer materials, acrylonitrile-butyl acrylate-styrene polymer materials, polyetherimide materials, polyphenylene ether materials, polyphenylene oxide materials, polyphenylene sulfide materials, polyether materials, polyether ketone materials, polyacetal materials, polyurethane materials, polybenzimidazole materials, and copolymers and mixtures thereof. In other embodiments, the reinforcing material of each of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer is independently selected from the group consisting of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, inorganic fibers, natural fibers, mineral fibers, metal fibers, metallized inorganic fibers, metallized synthetic fibers, ceramic fibers, and combinations thereof. In some embodiments, the fibers present in each of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer independently include a diameter greater than about 5 microns and a length of about 5 mm to about 200 mm. In other embodiments, the directional compression foam is a directional compression expandable polystyrene foam, each of the first and second fiber-reinforced thermoplastic layers includes polypropylene and glass fibers, the multilayer assembly further includes a skin bonded to the second fiber-reinforced thermoplastic layer, and the multilayer assembly further includes a decorative layer bonded to the skin. In some embodiments, at least one of the core layer, the first reinforced thermoplastic layer, and the second reinforced thermoplastic layer includes a flame-retardant material. In certain cases, the flame-retardant material includes one or more of the following: expansive graphite material, magnesium hydroxide, and aluminum hydroxide. If desired, the adhesive layer may also include the flame-retardant material.

[0009] In another embodiment, a vehicle loading floor providing structural reinforcement comprises a core layer containing a closed-cell material; a first reinforcing thermoplastic layer disposed on a first surface of the core layer, wherein the first fiber-reinforced thermoplastic layer includes a web of open-cell structure formed by a plurality of reinforcing materials joined together by a thermoplastic material; and a second reinforcing thermoplastic layer disposed on a second surface of the core layer, wherein the second fiber-reinforced thermoplastic layer includes a web of open-cell structure formed by a plurality of reinforcing materials joined together by a thermoplastic material, wherein the core layer, the first reinforcing thermoplastic layer, and the second reinforcing thermoplastic layer together provide a vehicle loading floor that flexes by less than about 25 mm under a weight of 220 kg or less.

[0010] In certain configurations, the vehicle loading floor comprises a decorative layer bonded to a first reinforced thermoplastic layer. In some embodiments, the decorative layer includes carpet. In certain cases, the vehicle loading floor comprises an adhesive layer between the decorative layer and the first reinforced thermoplastic layer. In other embodiments, the vehicle loading floor comprises a second decorative layer bonded to a second reinforced thermoplastic layer. In some embodiments, the second decorative layer includes carpet. In other embodiments, the vehicle loading floor comprises an adhesive layer between the second decorative layer and the second reinforced thermoplastic layer. In further embodiments, the vehicle loading floor flexes by less than 15 mm at a weight of 100 kg, or less than 15 mm at a weight of 150 kg, or less than 10 mm at a weight of 100 kg, or less than 5 mm at a weight of 220 kg. In some configurations, the thermoplastic material of the first reinforced thermoplastic layer comprises at least one thermoplastic material similar to or different from the thermoplastic material present in the second reinforced thermoplastic layer. In other configurations, the closed-cell material of the core layer includes a directional compression foam selected from the group consisting of directional compression-expandable polystyrene foam, directional compression-extruded polyethylene foam, and directional compression-expandable polypropylene foam, or alternatively, polyurethane foam or cellulosic material. In some cases, the thermoplastic material of the first fiber-reinforced layer and the second fiber-reinforced layer, respectively, is independently a polyolefin material, a thermoplastic polyolefin blend material, or polyvinyl poly The materials are selected from the group consisting of remer materials, butadiene polymer materials, acrylic polymer materials, polyamide materials, polyester materials, polycarbonate materials, polyester carbonate materials, polystyrene materials, acrylonitrile styrene polymer materials, acrylonitrile-butyl acrylate-styrene polymer materials, polyetherimide materials, polyphenylene ether materials, polyphenylene oxide materials, polyphenylene sulfide materials, polyether materials, polyether ketone materials, polyacetal materials, polyurethane materials, polybenzimidazole materials, and copolymers and mixtures thereof. In other configurations, the thermoplastic material of each of the first fiber-reinforced layer and the second fiber-reinforced layer is independently a resin or a fiber. In some embodiments, the reinforcing material of each of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer is independently selected from the group consisting of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, inorganic fibers, natural fibers, mineral fibers, metal fibers, metallized inorganic fibers, metallized synthetic fibers, ceramic fibers, and combinations thereof. In other embodiments, the fibers present in each of the first and second fiber-reinforced layers include a diameter greater than about 5 microns and a length of about 5 mm to about 200 mm. In some embodiments, the thermoplastic material present in each of the first and second fiber-reinforced layers includes polypropylene, and the reinforcing material present in each of the first and second fiber-reinforced layers is glass fiber. In certain cases, the basis weight of each of the first and second fiber-reinforced layers is about 500 gsm to about 3000 gsm, and the basis weight of the core layer is about 300 gsm to about 2000 gsm. In some embodiments, at least one of the first and second fiber-reinforced layers includes a lofting agent. In further embodiments, the vehicle loading floor comprises a carpet layer disposed on top of at least one of the first and second fiber-reinforced layers. In some embodiments, the first fiber-reinforced layer is bonded to the core layer via a first adhesive layer, and the second fiber-reinforced layer is bonded to the core layer via a second adhesive layer.In other embodiments, the first and second fiber-reinforced layers do not contain any lofting agents, and the thermoplastic and reinforcing materials of the first and second fiber-reinforced layers are selected, respectively, to enable lofting of the first and second fiber-reinforced layers in the absence of lofting agents. In some embodiments, at least one of the core layer, the first reinforced thermoplastic layer, and the second reinforced thermoplastic layer includes a flame-retardant material. In certain cases, the flame-retardant material includes one or more of an expandable graphite material, magnesium hydroxide, and aluminum hydroxide. If desired, the adhesive layer may also include a flame-retardant material.

[0011] In an additional embodiment, a kit for manufacturing a vehicle loading floor comprises a core layer and a first reinforced thermoplastic layer separated from the core layer, wherein the core layer comprises a closed-cell material and the first reinforced thermoplastic layer comprises a web of open-cell structure formed by a plurality of reinforcing materials bonded together by the thermoplastic material. The kit may also include instructions for bonding the first reinforced thermoplastic core layer to a first surface of the core layer.

[0012] In some embodiments, the kit comprises a second reinforced thermoplastic layer separate from the core layer and the first reinforced thermoplastic layer. In other embodiments, the first reinforced thermoplastic layer of the kit is the same as the second reinforced thermoplastic layer of the kit. In some cases, the basis weight of the first reinforced thermoplastic layer of the kit is different from that of the second reinforced thermoplastic layer of the kit. In other embodiments, the kit comprises a decorative layer separate from the core layer and the first reinforced thermoplastic layer. In some embodiments, the kit comprises an adhesive material effective for bonding the first reinforced thermoplastic layer to the core layer. In some embodiments, the kit comprises a skin layer. In some cases, the skin layer is selected from the group consisting of cloth, scrim, film, and combinations thereof. In other embodiments, the closed-cell material of the core layer includes a directional compression foam selected from the group consisting of directional compression expandable polystyrene foam, directional compression extruded polyethylene foam, and directional compression expandable polypropylene foam. In certain cases, the core layer is configured as a planar sheet.

[0013] In another embodiment, a method for forming a multilayer assembly includes forming a reinforced thermoplastic layer by mixing a thermoplastic polymer, reinforcing fibers, and a lofting agent in an aqueous solution; mixing the aqueous solution containing the thermoplastic polymer, reinforcing fibers, and lofting agent to disperse the reinforcing fibers and lofting agent in the thermoplastic polymer to provide an aqueous foam dispersion; arranging the aqueous foam dispersion on a forming element; and removing the liquid from the arranged aqueous foam to provide a reinforced thermoplastic layer comprising a web containing the thermoplastic polymer, reinforcing fibers, and lofting agent; and arranging the provided reinforced thermoplastic layer on a first surface of a core layer comprising a closed-cell material. In some embodiments, at least one of the core layer, the first reinforced thermoplastic layer, and the second reinforced thermoplastic layer comprises a flame-retardant material. In certain cases, the flame-retardant material comprises one or more of an expandable graphite material, magnesium hydroxide, and aluminum hydroxide. If desired, the adhesive material may also comprise a flame-retardant material.

[0014] In certain configurations, the method includes heating the provided reinforced thermoplastic layer to a temperature above the softening temperature of the thermoplastic polymer in the web of the provided reinforced thermoplastic layer before distributing the provided reinforced thermoplastic layer onto a first surface of the core layer. In other cases, the method includes distributing an adhesive layer onto the first surface of the core layer before distributing the provided reinforced thermoplastic layer onto the first surface of the core layer. In some embodiments, the method includes distributing an adhesive layer onto the surface of the provided reinforced thermoplastic layer before distributing the provided reinforced thermoplastic layer onto the first surface of the core layer. In some embodiments, the method includes distributing a second adhesive layer onto a second surface of the core layer. In other configurations, the method includes distributing another reinforced thermoplastic layer on the disposed second adhesive layer. In some embodiments, the method includes distributing a second adhesive layer onto the surface of another reinforced thermoplastic layer. In certain embodiments, the method includes distributing another reinforced thermoplastic layer onto the core layer to bond the core layer to the other reinforced thermoplastic layer via the second adhesive layer. In other embodiments, the method includes heating the provided reinforced thermoplastic sheet to loft the provided reinforced thermoplastic sheet. In certain embodiments, the method includes configuring the core layer to include a directional compression foam selected from the group consisting of directional compression expandable polystyrene foam, directional compression extruded polyethylene foam, and directional compression expandable polypropylene foam.

[0015] In another embodiment, the wall of a recreational vehicle includes one or more of the multilayer assemblies described herein.

[0016] In additional embodiments, the roof of a recreational vehicle includes one or more of the multilayer assemblies described herein.

[0017] In another embodiment, a slide-out assembly for a recreational vehicle, for example, one that includes a dinette, bathroom, or other feature in the recreational vehicle, comprises one or more of the multilayer assemblies described herein. Any or all of the walls, ceiling, floor, or structural components of a slide-out assembly may comprise one or more of the multilayer assemblies described herein.

[0018] In additional embodiments, the sleeping bed of a sleeper cab includes one or more of the multilayer assemblies described herein.

[0019] In another embodiment, the exterior panel includes one or more of the multilayer assemblies described herein. For example, roofing panels, floor panels, wall panels, and interior or exterior panels used in residential or commercial structures may include one or more of the multilayer assemblies described herein.

[0020] In additional embodiments, the roofing panel comprises one or more multilayer assemblies described herein.

[0021] In another embodiment, the flooring panel comprises one or more of the multilayer assemblies described herein.

[0022] In additional embodiments, the vehicle loading floor includes one or more of the multilayer assemblies described herein.

[0023] In another embodiment, a vehicle is described having a vehicle loading bed that includes one or more multi-layer assemblies described herein.

[0024] In additional embodiments, a vehicle having a vehicle loading platform as described herein is provided. In another embodiment, the tire cover includes one or more of the multilayer assemblies described herein.

[0025] In an additional aspect, the deck includes one or more of the multilayer assemblies described herein. For example, the deck can be attached to a residential or commercial structure or a recreational vehicle, if desired.

[0026] Additional features, aspects, examples, configurations, and embodiments are described in more detail below. Certain embodiments are described with reference to the accompanying drawings.

Brief Description of the Drawings

[0027] [Figure 1] FIG. 1 is a diagram of a multilayer assembly including a surface layer and a core layer according to a particular example. [Figure 2] FIG. 2 is a diagram of a multilayer assembly including two surface layers and a core layer according to a particular configuration. [Figure 3A] FIG. 3A is a diagram of a multilayer assembly including a core layer, an adhesive layer, and a surface layer according to a particular configuration. [Figure 3B] FIG. 3B is a diagram showing the assembly of FIG. 3A combined with an outer skin layer or a decorative layer according to a particular configuration. ! [Figure 4A] FIG. 4A is a diagram of a multilayer assembly including a core layer, two adhesive layers, and two surface layers according to a particular configuration. [Figure 4B] FIG. 4B is a diagram showing the assembly of FIG. 4A combined with an outer skin layer or a decorative layer according to a particular configuration. [Figure 5A] FIG. 5A is a diagram of a multilayer assembly including two core layers and one surface layer according to a particular configuration. [Figure 5B] FIG. 5B is a diagram showing the assembly of FIG. 5A combined with another surface layer. [Figure 5C] FIG. 5C is a diagram showing the assembly of FIG. 5B combined with an outer skin layer or a decorative layer according to a particular configuration. [Figure 6A] FIG. 6A is a diagram of a multilayer assembly including two core layers and two surface layers according to a particular configuration. [Figure 6B] Figure 6B shows the assembly of Figure 6A combined with another surface layer. [Figure 6C] Figure 6C shows the assembly of Figure 6B combined with a skin layer or decorative layer in a specific configuration. [Figure 7] Figure 7 shows a vehicle floor according to a specific embodiment. [Figure 8] Figure 8 shows a loading platform with a specific configuration. [Modes for carrying out the invention]

[0028] Those skilled in the art will recognize that, in order to provide drawings in a more usable format, taking into account the interests of this disclosure, certain dimensions or features in the drawings may be enlarged, distorted, or otherwise shown in an unconventional or disproportionate manner. Specific thicknesses, widths, or lengths are not intended by the depiction in the drawings, and relative sizes within the elements of the drawings are not intended to limit the size of any of the elements of the drawings. Where dimensions or values ​​are specified in the following description, they are provided for illustrative purposes only. In addition, shading in any particular part of the drawings is not intended to require any specific material or arrangement, and although different elements in the drawings may include shading for distinction, different elements may include the same or similar material, if desired.

[0029] To provide a more accessible description of the technology disclosed herein, specific embodiments are described below with reference to singular and plural terms. These terms are used for convenience only and are not intended to limit layers, assemblies, articles, methods, and other subject matter to include or exclude specific features, unless otherwise stated as being present in or excluded from the specific embodiments described herein.

[0030] In certain cases, the materials described herein can be used together to provide sheets, panels, floor pans, loading floors, vehicle walls, ceilings, or floors, for example, walls, ceilings, or floors for recreational vehicles, and other articles. For example, a multilayer assembly can be used as a wall or ceiling panel, as flooring, as a subfloor, or in automotive applications, such as a vehicle loading floor or underbody floor of a vehicle. When an assembly is used as a vehicle loading floor, the loading floor may exist as an underbody assembly within the vehicle's interior, or as one or more different components or areas of the vehicle, for example, as a loading floor retracted into a vehicle storage compartment at the rear of the vehicle. In some cases, a multilayer assembly can be used as a vehicle loading floor without any supporting structural support from any vehicle, for example, the loading floor may be constructed and positioned to support a load of a selected weight without requiring the provision of structural support or reinforcement beneath the loading floor. As described herein, some components of a multilayer assembly may be manufactured using a fiber-reinforced thermoplastic surface layer and / or without any fiber-reinforced thermoplastic core layer. In other cases, the multilayer assembly may be manufactured without using any polyurethane core component, or without using any polyurethane at all. In other configurations, the multilayer assembly may be manufactured without using any cellulosic material, such as honeycomb or paper. However, if desired, one or more of the layers may contain polyurethane, polyurethane foam, or a cellulosic material, such as paper or honeycomb.

[0031] In some embodiments described herein, the core layer may include a directional compression material, such as a directional compression foam. Directionally compressible materials generally have greater compressive strength in the transverse direction than in the longitudinal direction (or vice versa, if desired). For example, the core layer may include a material having directional compressive strength, such as a material having different compressive strengths in the orthogonal direction, in order to impart more rigidity to the entire article containing the core layer. The core layer is typically used with one or more surface layers or skins and can take many forms. In some embodiments, the surface layer is a non-extruded surface layer to provide increased porosity and / or to reduce the overall weight of the article.

[0032] In certain configurations, a multilayer assembly may have two or more different layers bonded together. Good. Referring to Figure 1, the two-layer assembly 100 includes a surface layer 120 bonded to a core layer 110. The surface layer 120 can be configured as a porous reinforced thermoplastic surface layer, as described in more detail below. The core layer 110 is not typically a porous reinforced thermoplastic layer, but may be a closed-cell or substantially non-porous core layer to avoid the intrusion of water or other fluids. Exemplary core layers are described in more detail below, but in some configurations, the core layer may be a foam such as a closed-cell foam, a cellulose-based product, such as paper honeycomb or other material. In some configurations, the core layer 110 can be configured as a non-cellulose core layer or a non-polyurethane core layer. The combination of the surface layer 120 and the core layer 110 can provide a lightweight panel or structural wall that provides sufficient load-bearing capacity for use in floors, walls, and ceilings, for example.

[0033] In certain embodiments, the reinforced surface layer 120 may be composed of (or used in) a glass mat thermoplastic composite (GMT) or a lightweight reinforced thermoplastic material (LWRT). One such LWRT is manufactured by HANWHA AZDEL, Inc. and marketed under the trademark SUPERLITE® mat. The surface density of such a GMT or LWRT may range from about 400 grams per square meter (gsm) to about 4000 gsm, although the surface density may be less than 400 gsm or greater than 4000 gsm, depending on the needs of the particular application. In some embodiments, the upper density may be less than about 4000 gsm. In certain cases, the GMT or LWRT may include one or more lofting agent materials disposed in the void spaces or pores of the GMT or LWRT.

[0034] In certain embodiments where LWRT is used as a surface layer, the LWRT typically comprises a thermoplastic material and multiple reinforcing fibers that together form a web of open-cell structure. For example, the surface layer 120 typically contains a considerable amount of open-cell structure so that void spaces exist within the layer. In some cases, the surface layer 120 is composed 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%, and 20-80%. Porosity may include %, 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 cases, surface layer 120 contains a porosity or void content greater than 0%, and is not completely solidified to, for example, about 95%. Unless otherwise specified, references to surface layers containing a particular void content or void content are based on the total volume of that surface layer and not necessarily on the total volume of the multilayer assembly.

[0035] In certain embodiments, the surface layer 120 can be manufactured in the form of a glass mat. In certain cases, the glass mat can generally be made using woven or nonwoven fabrics made of chopped glass fibers, thermoplastic material, optionally a lofting agent, and any thermoplastic polymer film(s), and / or glass fiber or thermoplastic resin fiber, e.g., polypropylene (PP), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycarbonate (PC), PC / PBT blends, or PC / PET blends. In some embodiments, PP, PBT, PET, PC / PET blends, or PC / PBT blends can be used as the resin. To manufacture the glass mat, the thermoplastic material and reinforcing material can be added to or weighed into a dispersed foam placed in an open-top mixing tank equipped with a paddle. While not wishing to be bound by any particular theory, the presence of trapped air pockets in the foam may help in the dispersion of the glass fibers, thermoplastic material, and lofting agent. It is possible. In some embodiments, the dispersion mixture of fibers and thermoplastic material may be pumped via a dispersion manifold to a headbox located above the wire section of the paper machine. As the dispersion mixture is fed to a movable wire screen using vacuum to continuously produce a uniform fibrous wet web, foam can be removed instead of fibers and thermoplastic resin. The wet web can be passed through a dryer at a suitable temperature to reduce the moisture content and melt or soften the thermoplastic material.

[0036] In certain embodiments, the high porosity present in the surface layer 120 can reduce the overall weight of the layer and allow for the inclusion of agents within the void spaces. For example, lofting agents may be present in the void spaces in a non-covalent bonding manner. The application of heat or other perturbations can act to increase the volume of the non-covalently bonded lofting agents, resulting in an increase in the overall thickness of the layer, for example, as the size of the lofting agents increases and / or as additional air is trapped in the layer. Flame retardants, colorants, smoke suppressants, and other materials may be included in the void spaces of the surface layer 120 if desired. Prior to lofting, the surface layer 120 can be compressed to reduce its overall thickness, for example, before or after it is bonded to one or more other layers.

[0037] In certain embodiments, the thermoplastic material of the surface layer 120 may comprise, at least partially, one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, as well as blends of these materials with each other or with other polymer materials. Other suitable thermoplastic resins include, but are not limited to, polyarylene ethers, polycarbonates, polyester carbonates, 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-temperature polycarbonates such as Bayer's APEC® PC, high-temperature nylons, silicones, and copolymers, alloys, and blends of these materials with each other or with other polymer materials. The thermoplastic material used to form layer 120 can be used in powder form, resin form, rosin form, particle form, fiber form, or other preferred form. Various exemplary forms of thermoplastic materials are described herein and, for example, in U.S. Patent Application Publications 20130244528 and US20120065283. The exact amount of thermoplastic material present in the surface layer 120 may vary, with exemplary amounts ranging from about 20% to about 80% by weight, for example, 30 to 70% by weight or 35 to 65% by weight.

[0038] In certain embodiments, the reinforcing fibers of the surface layer 120 may include glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, in particular high modulus organic fibers (e.g., para- and meta-aramid fibers, nylon fibers, polyester fibers, or any high melt flow index resin described herein that is suitable for use as a fiber), mineral fibers (basalt), mineral wool (e.g., rock wool or slag wool), wollastonite, alumina silica, 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 before use to provide the fibers with desired functional groups or to impart other physical properties, for example, they may be chemically treated so that they can react with thermoplastic materials, lofting agents, or both. The fiber content of layer 120 may independently be about 20% to about 90% by weight of the layer, more specifically about 30% to about 70% by weight of the layer. Typically, the fiber content of a multilayer assembly including the surface layer 120 The amount of the fibers varies between approximately 20% to approximately 90% by weight of the assembly, more specifically between approximately 30% to approximately 80% by weight, for example between approximately 40% to approximately 70% by weight. The specific size and / or orientation of the fibers used may vary, at least in part, depending on the desired properties of the thermoplastic polymer material and / or surface layer 120 used. Suitable additional fiber types, fiber sizes, and quantities will be readily selected by those skilled in the art, taking into account the interests of this disclosure. In a non-limiting example, the fibers dispersed in the thermoplastic material and optionally the lofting agent for providing the surface layer 120 generally have a diameter greater than approximately 5 microns, more specifically between approximately 5 microns and approximately 22 microns, and a length of approximately 5 mm to approximately 200 mm, more specifically, the fiber diameter may be approximately 5 microns to approximately 22 microns, and the fiber length may be approximately 5 mm to approximately 75 mm.

[0039] In some embodiments, the lofting ability of the surface layer 120 can be further adjusted by including one or more additional lofting agents. The exact type of lofting agent used in layer 120 may vary depending on a number of factors, including, for example, a desired lofting temperature and a desired degree of lofting. In some cases, microsphere lofting agents, such as expandable microspheres that can increase in size when exposed to convective heating, may be used. Exemplary commercially available lofting agents are available from Kureha Corp. (Japan). In other cases, 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 layer 120. In other embodiments, the lofting agent may be an expandable graphite material.

[0040] In some embodiments, the core layer 110 may include materials other than closed-cell foam or porous fiber-reinforced thermoplastic layers, for example, closed-cell foams may have porosity of about 5%, 4%, 3%, 2%, or less than 1%. In some embodiments, the core layer is not a sprayed or sprayable core layer, but instead a solid planar layer that can be bonded to the surface layer 120 after the formation of the core layer 110. In some embodiments, the core layer 110 may include one or more of foam, cardboard, paper honeycomb, or a combination thereof. In other embodiments, the core layer 110 includes, or may include, polystyrene foam, expandable or extruded polyolefin foam (e.g., extruded polyethylene or expandable polypropylene) or other foams. In some cases, the core layer may lack any polyurethane material and / or any cellulose material. While we do not wish to be bound by any particular theory, the presence of certain materials such as polyurethane and / or cellulose may result in edge deformation and / or allow mold growth if moisture penetrates the core layer. By using a foam core layer made of a specific material, clean edges can be achieved, mold growth problems can be avoided, and higher compressive strength can be obtained with a lighter area weight. Exemplary basis weights of the core layer 110 are, but are not limited to, approximately 300 gsm to 2000 gsm, more specifically, approximately 500 gsm to 1900 gsm, or approximately 500 gsm to 1500 gsm.

[0041] In some embodiments, the core layer 110 may include a foam with greater transverse compressive strength than longitudinal compressive strength. For example, the core layer 110 may include a foam with directional compressive strength, such as a foam with different compressive strengths in orthogonal directions, to impart more rigidity to the entire article including the core layer 110 and the surface layer 120. Foams capable of providing directional compressive strength are commercially available from Dow Corning and other suppliers. The core layer 110 is typically formed first from a foam (or other material) and then bonded to the surface layer 120. In some configurations, the material of the core layer 110 can be constructed and arranged to allow compression of the core layer 110 without substantial damage to the core layer 110. The material of the core layer 110 can also be used to bond the article 100 without substantial damage to the core layer 110. It can be selected to allow thermoforming, such as compression or molding. Compared to a fiber thermoplastic core layer, the presence of a core layer 110 containing closed-cell foam (or non-fiber-reinforced thermoplastic material) can provide better performance and higher strength at the same basis weight.

[0042] In some configurations, the surface layer 120 (and optionally the core layer 110) may be substantially halogen-free or halogen-free to meet regulations regarding hazardous substance requirements for a particular application. In other cases, one or more of layers 110, 120 may contain halogenated flame retardants, such as halogenated flame retardants containing more of one of F, Cl, Br, I, and At, or compounds containing such halogens, such as tetrabromobisphenol-A polycarbonate or monohalo-, dihalo-, trihalo-, or tetrahalo-polycarbonate. In some cases, the thermoplastic material used in the surface layer 120 may contain one or more halogens to impart some flame retardancy without the addition of another flame retardant. Where a halogenated flame retardant is present, the flame retardant is preferably present in a flame retardant amount, which may vary depending on other components present. For example, halogenated flame retardants may be present in amounts of about 0.1% to about 15% by weight (based on the weight of the layer), more specifically, about 1% to about 13% by weight, for example, about 5% to about 13% by weight. If desired, two different halogenated flame retardants may be added to the layer. In other cases, non-halogenated flame retardants, such as flame retardants containing one or more of N, P, As, Sb, Bi, S, Se, and Te, may be added. In some embodiments, the non-halogenated flame retardants may also contain phosphorylated materials, so that the layer may be more environmentally friendly. If non-halogenated flame retardants or substantially halogen-free flame retardants are present, the flame retardants are present in preferably a flame retardant amount, which may vary depending on other components present. For example, a substantially halogen-free flame retardant may be present in an amount of about 0.1% to about 15% by weight (based on the weight of the layer), more specifically, about 1% to about 13% by weight, for example, 5% to about 13% by weight, based on the weight of the layer. If desired, two different substantially halogen-free flame retardants may be added to one or more of layers 110, 120.In certain cases, one or more of the layers 110, 120 described herein may contain one or more halogenated flame retardants in combination with one or more substantially halogen-free flame retardants. If two different flame retardants are present, the combination of the two flame retardants may be present in amounts that vary depending on other components present. For example, the total weight of the flame retardants may be about 0.1 weight percent to about 20 weight percent (based on the weight of the layer), more specifically, about 1 weight percent to about 15 weight percent, for example, about 2 weight percent to about 14 weight percent, based on the weight of the layer. The flame retardants used in the layers described herein can be added to a mixture containing thermoplastic material and fibers (before the mixture is placed on a wire screen or other processing component), or they can be added after the layer is formed. In some embodiments, the flame retardant material may include one or more of the following: expandable graphite material, magnesium hydroxide (MDH), and aluminum hydroxide (ATH).

[0043] Referring to Figure 2 in a particular configuration, the multilayer assembly 200 may include surface layers 220, 230 on each surface of the core layer 210. The surface layers 220, 230 may be the same or they may be different. In a particular case, the surface layers 220, 230 may generally contain the same material, but may have different amounts of material, e.g., different amounts of reinforcing fibers and / or different amounts of thermoplastic material. In other embodiments, the surface layers 220, 230 may contain the same thermoplastic material, but may contain different reinforcing fibers. In an additional configuration, the surface layers 220, 230 may contain the same reinforcing fibers, but may contain different thermoplastic materials. In other embodiments, the surface layers 220, 230 may contain the same reinforcing material and thermoplastic material, but may have different basis weights, different porosity, or other different physical properties. In some embodiments, the surface layers 220, 230 may contain the same reinforcing fibers and the same thermoplastic material. The material may contain a plastic material, but may also have different thicknesses or different amounts of lofting agent to provide variable lofting capability.

[0044] In certain embodiments, each of the surface layers 220 and 230 may be constructed independently, similar to the surface layer 120, and for example, each of the surface layers 220 and 230 may be a GMT or LWRT. For example, each of the surface layers 220 and 230 may be constructed as an LWRT comprising one or more thermoplastic materials. In some embodiments, the thermoplastic materials present in each of the layers 220 and 230 may independently, at least partially, comprise one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, as well as blends of these materials with each other or with other polymer materials. Other suitable thermoplastic resins 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-temperature polycarbonates such as Bayer's APEC® PC, high-temperature nylons, silicones, and copolymers, alloys, and blends of these materials with each other or with other polymer materials. The thermoplastic material used to form layers 220 and 230 may be in powder form, resin form, rosin form, particle form, fiber form, or other suitable form, and the form used in different layers 220 and 230 does not need to be the same. Various exemplary forms of thermoplastic materials are described herein, for example, in U.S. Patent Application Publications 20130244528 and US20120065283. The exact amount of thermoplastic material present in surface layers 220, 230 may vary, with exemplary amounts ranging from about 20% by weight to about 80% by weight, for example, 30 to 70% by weight or 35 to 65% by weight.As described herein, the amounts of thermoplastic material present in the surface layers 220 and 230 do not need to be the same.

[0045] In certain embodiments, the reinforcing fibers of surface layers 220, 230 may independently include glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, in particular high modulus organic fibers (e.g., para- and meta-aramid fibers, nylon fibers, polyester fibers, or any high melt flow index resin described herein that is suitable for use as a fiber), mineral fibers (e.g., basalt), mineral wool (e.g., rock wool or slag wool), wollastonite, alumina silica, 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 before use to provide the fibers with desired functional groups or to impart other physical properties, for example, they may be chemically treated so that they can react with thermoplastic materials, lofting agents, or both. In some cases, one of the fibers of surface layers 220, 230 is chemically treated, while the other of the fibers of surface layers 220, 230 is not chemically treated. The fiber content of each of layers 220 and 230 may independently range from about 20% to about 90% by weight of the layer, more specifically, from about 30% to about 70% by weight of the layer. Typically, the fiber content of a multilayer assembly including surface layers 220 and 230 varies between about 20% to about 90% by weight of the assembly, more specifically, from about 30% to about 80% by weight, for example, from about 40% to about 70% by weight. The specific 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 surface layers 220 and 230. Suitable additional fiber types, fiber sizes, and quantities will be readily selected by those skilled in the art, taking into account the interests of this disclosure. In a non-limiting example, surface layers 220 and 230 may be used. The fibers dispersed in the thermoplastic material and optionally in the lofting agent for providing 30 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 diameter of the fibers may be about 5 microns to about 22 microns, and the length of the fibers may be about 5 mm to about 75 mm.

[0046] In certain embodiments, the surface layers 220 and 230 may contain different fibrous materials or different fibrous fillers. If different fibrous materials are present, the fibers may be completely different fibers, for example, glass fibers in one layer and carbon fibers in another layer, or they may contain the same chemically treated substrate, for example, glass fibers in one layer and chemically treated glass fibers in another layer. In some cases, the fibers may be the same fibrous material, but one or more physical properties of the fibers may differ. For example, the fibers of layer 220 may have a first diameter different from the diameter of the fibers present in layer 230, even if the fibrous materials of layers 220 and 230 are the same or different. In other cases, the length of the fibers of layer 220 may differ from the length of the fibers present in layer 230, even if the fibrous materials present in layers 220 and 230 are the same or different. In additional embodiments, both the length and diameter of the fibers of layer 220 may differ from the length and diameter of the fibers of layer 230, even if the fibrous materials present in layers 220 and 230 are the same or different. In further embodiments, two or more different fibers may be used in one of the layers 220, 230, or a single type of fiber may be present in the other layer. As described herein, by selecting the amount and / or type of fibers, it is possible to change the physical properties of the surface layers 220, 230, for example, to provide different lofting capacities to different surface layers of the assembly.

[0047] In some embodiments, the core layer 210 may include a closed-cell foam or other material that is not a fiber-reinforced thermoplastic layer, for example, the closed-cell foam of the core layer 210 may have a porosity of about 5%, 4%, 3%, 2%, or less than 1%. In some embodiments, the core layer is not a sprayed or sprayable core layer, but instead a solid planar layer that can be bonded to the surface layers 220, 230 after the formation of the core layer 210. In some embodiments, the core layer 210 may include one or more of the following: foam, cardboard, paper honeycomb, or a combination thereof. In other embodiments, the core layer 210 includes, or may include, polystyrene foam, expandable or extruded polyolefin foam (e.g., extruded polyethylene or expandable polypropylene) or other foams. In some cases, the core layer may lack any polyurethane material and / or any cellulose material. By using a specific foam material for the core layer 210, clean edges can be achieved, mold growth problems can be avoided, and higher compressive strength can be obtained with a lighter area weight. Exemplary basis weights for the core layer 210 are not limited to but include approximately 300 gsm to 2000 gsm, more specifically, approximately 500 gsm to 1900 gsm, or approximately 500 gsm to 1500 gsm.

[0048] In some embodiments, the core layer 210 may include a foam with greater transverse compressive strength than longitudinal compressive strength. For example, the core layer 210 may include a foam with directional compressive strength, such as a foam with different compressive strengths in orthogonal directions, to impart more rigidity to the entire article including the core layer 210 and surface layers 220, 230. Foams capable of providing directional compressive strength are commercially available from Dow Corning and other suppliers. The core layer 210 is typically formed first from a foam (or other material) and then bonded to the surface layers 220, 230. In some configurations, the material of the core layer 210 can be constructed and arranged to allow compression of the core layer 210 without substantial damage to the core layer 210. The material of the core layer 210 can also be selected to allow thermoforming, e.g., compression, molding, etc., of the article 200 without substantial damage to the core layer 210. Compared to a fiber thermoplastic core layer, closed-cell foam (or non-fiber-reinforced thermoplastic) can be used at equivalent basis weight. The presence of a core layer 210 containing a plastic material can provide better performance and higher strength.

[0049] In some configurations, the surface layers 220, 230 (and optionally the core layer 210) may be substantially halogen-free or halogen-free layers to meet regulations regarding hazardous substance requirements for a particular application. In other cases, one or more of the layers 210, 220, 230 may contain halogenated flame retardants, such as halogenated flame retardants containing more of one of F, Cl, Br, I, and At, or compounds containing such halogens, such as tetrabromobisphenol-A polycarbonate or monohalo-, dihalo-, trihalo-, or tetrahalo-polycarbonate. In some cases, the thermoplastic material used in one or more of the surface layers 220, 230 may contain one or more halogens to impart some flame retardancy without the addition of another flame retardant. Where halogenated flame retardants are present, the flame retardants are preferably present in a flame retardant amount, which may vary depending on other components present. For example, halogenated flame retardants may be present in amounts of about 0.1% to about 15% by weight (based on the weight of the layer), more specifically, about 1% to about 13% by weight, for example, about 5% to about 13% by weight. If desired, two different halogenated flame retardants may be added to the layer. In other cases, non-halogenated flame retardants, such as flame retardants containing one or more of N, P, As, Sb, Bi, S, Se, and Te, may be added. In some embodiments, the non-halogenated flame retardants may also contain phosphorylated materials, so that the layer may be more environmentally friendly. If non-halogenated flame retardants or substantially halogen-free flame retardants are present, the flame retardants are present in preferably a flame retardant amount, which may vary depending on other components present. For example, a substantially halogen-free flame retardant may be present in an amount of about 0.1% to about 15% by weight (based on the weight of the layer), more specifically, about 1% to about 13% by weight, for example, 5% to about 13% by weight, based on the weight of the layer. If desired, two different substantially halogen-free flame retardants may be added to one or more of layers 210, 220, and 230.In certain cases, one or more of layers 210, 220, and 230 may contain one or more halogenated flame retardants in combination with one or more substantially halogen-free flame retardants. If two different flame retardants are present, the combination of the two flame retardants may be present in amounts that vary depending on other components present. For example, the total weight of the flame retardants may be about 0.1 weight percent to about 20 weight percent (based on the weight of the layer), more specifically, about 1 weight percent to about 15 weight percent, for example, about 2 weight percent to about 14 weight percent, based on the weight of the layer. The flame retardants used in the layers described herein can be added to a mixture containing thermoplastic material and fibers (before the mixture is placed on a wire screen or other processing component) or can be added after the layer is formed. In some embodiments, the flame retardant material may contain one or more of expansive graphite material, magnesium hydroxide (MDH), and aluminum hydroxide (ATH).

[0050] In the configuration shown in Figure 2, the lofting capacity of the surface layers 220 and 230 can be further adjusted by including one or more additional lofting agents. The exact type of lofting agent used in layers 220 and 230 may vary depending on a number of factors, including, for example, the desired lofting temperature and the desired degree of lofting. In some cases, microsphere lofting agents, such as expandable microspheres that can increase in size when exposed to convective heating, may be used. Exemplary commercially available lofting agents are available from Kureha Corp. (Japan). In other cases, 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 embodiments, the lofting agent may be an expandable graphite material. Surface layers 220 and 230 can have the same lofting capacity or different lofting capacities. It can be configured to provide lofting capabilities. For example, when exposed to heat or other lofting stimuli, the thickness of layer 220 after lofting may be greater than the thickness of layer 230. For example, the thickness of layer 220 before lofting may be about 1-2 mm, and after lofting it may be about 10-15 mm. The thicknesses of layers 220 and 230 before lofting may also be about 1-2 mm, and after lofting they may be about 6-8 mm. These thickness changes can occur without the addition of any lofting agent. For example, although we do not wish to be bound by any particular theory, during lofting the thermoplastic material may melt, releasing the reinforcing material and allowing the reinforcing material to occupy a larger volume. Subsequent cooling of the thermoplastic material may result in the reformation of a web with an open-cell structure that has a larger volume than the pre-lofted web. By adjusting the levels of thermoplastic material and / or reinforcing material within layer 220, the extent to which the volume of layer 220 can be increased may be selected. In contrast, the amount of thermoplastic material and / or reinforcing material present in layer 230 can be selected such that the melting of the thermoplastic material during lofting does not result in a substantial increase in the overall volume. When the web of layer 230 is reformed after lofting, the resulting post-lofted web volume is substantially the same as the pre-lofted web volume. If desired, one or more of layers 220, 230 may contain additional lofting agents to further increase the overall volume. For example, layer 220 may contain additional lofting agents to further select the overall volume after lofting. In some cases, there is enough lofting agent so that the post-lofted layer 220 (and / or post-lofted layer 230) has a thickness of about 20–25 mm. In some embodiments, layer 220 may contain polyolefin, reinforcing fibers, and a lofting agent, and layer 230 may contain polyolefin (which may be the same as or different from the polyolefin in layer 220) and reinforcing material. In certain configurations, the polyolefin present in layers 220 and 230 may be polypropylene or a polyolefin copolymer containing polypropylene.In some embodiments, the reinforcing material in each of layers 220 and 230 may optionally include glass fibers combined with other fibers. The exact weight percentages of thermoplastic and reinforcing materials in each of layers 220 and 230 may vary, with exemplary weight percentages in layers 220 and 230 being approximately 40–60 weight percent thermoplastic material and the remainder being reinforcing material. If desired, the surface layer 230 may be configured to have a higher lofting capacity than layer 220.

[0051] To further illustrate some of the possible configurations of multilayer assemblies including a reinforced thermoplastic surface layer in combination with one or more core layers, several different exemplary layer assemblies are described herein. Given the benefits of this disclosure, additional configurations will be recognizable to those skilled in the art. Referring to Figure 3A, a composite article 300 is shown, including a core layer 310 and a surface layer 320 bonded to each other via an adhesive layer 315. The surface layer 320 may be configured similarly to any of the surface layers 120, 220, or 230, and may be a porous fiber-reinforced thermoplastic layer such as GMT or LWRT, for example. Although not shown, additional surface layers may be bonded to the opposite surface of the core layer 310.

[0052] In certain embodiments, the surface layer 320 may include or be composed of (or used in) a glass mat thermoplastic composite (GMT) or a lightweight reinforced thermoplastic (LWRT). The surface density of such a GMT or LWRT may range from about 400 grams per square meter (gsm) to about 4000 gsm, but the surface density may be less than 400 gsm or greater than 4000 gsm, depending on the needs of the particular application. In some embodiments, the upper density may be less than about 4000 gsm. In certain cases, the GMT or LWRT may include one or more lofting agent materials disposed in the void spaces or pores of the GMT or LWRT. In certain embodiments in which LWRT is used as the surface layer 320, the LWRT is typically continuous It includes a thermoplastic material and multiple reinforcing fibers that together form a web of buoyant structures. For example, the surface layer 320 typically contains a considerable amount of open-cell structure so that void spaces exist within the layer. In some cases, the surface layer 320 is composed 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%, and 20-80% buoyant. Porosity may include %, 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 cases, the surface layer 320 contains a porosity or void content greater than 0%, and is not completely solidified to, for example, about 95%. Unless otherwise specified, references to surface layers containing a particular void content or void content are based on the total volume of that surface layer and not necessarily on the total volume of the multilayer assembly.

[0053] In certain embodiments, the surface layer 320 can be manufactured in the form of a glass mat. In certain cases, the glass mat can generally be made using woven or nonwoven fabrics made of chopped glass fibers, thermoplastic material, optionally a lofting agent, and any thermoplastic polymer film(s), and / or glass fiber or thermoplastic resin fiber, e.g., polypropylene (PP), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycarbonate (PC), PC / PBT blends, or PC / PET blends. In some embodiments, PP, PBT, PET, PC / PET blends, or PC / PBT blends can be used as the resin. To manufacture the glass mat, the thermoplastic material and reinforcing material can be added to or weighed into a dispersed foam placed in an open-top mixing tank equipped with an impeller. While we do not wish to be bound by any particular theory, the presence of trapped air pockets in the foam may aid in the dispersion of the glass fibers, thermoplastic material, and lofting agent. In some embodiments, the dispersion mixture of fibers and thermoplastic material may be pumped via a dispersion manifold to a headbox located above the wire section of the paper machine. As the dispersion mixture is fed to a movable wire screen using vacuum, a uniform fibrous wet web is continuously produced, allowing for the removal of foam rather than fibers and thermoplastic resin. The wet web can be passed through a dryer at a suitable temperature to reduce the moisture content and melt or soften the thermoplastic material.

[0054] In certain embodiments, the high porosity present in the surface layer 320 can reduce the overall weight of the article 300 and allow for the inclusion of agents within the void spaces. For example, lofting agents may be present in the void spaces in a non-covalent bonding manner. The application of heat or other perturbations can act to increase the volume of the non-covalent lofting agents, resulting in an increase in the overall thickness of the layer, for example, as the size of the lofting agents increases and / or as additional air is trapped in the layer. Flame retardants, colorants, smoke suppressants, and other materials may be included in the void spaces of the surface layer 320 if desired. Prior to lofting, the surface layer 320 can be compressed to reduce its overall thickness, for example, before or after it is bonded to one or more other layers.

[0055] In certain embodiments, the thermoplastic material of the surface layer 320 may comprise, at least partially, one or more of the following: polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, as well as blends of these materials with each other or with other polymer materials. Other suitable thermoplastic resins include, but are not limited to, polyarylene. Examples include ethers, polycarbonates, polyester carbonates, 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-temperature polycarbonates such as Bayer's APEC® PC, high-temperature nylons, silicones, and copolymers, alloys, and blends of these materials with each other or with other polymer materials. The thermoplastic material used to form layer 320 can be used in powder form, resin form, rosin form, particle form, fiber form, or other preferred form. Various exemplary forms of thermoplastic materials are described herein and, for example, in U.S. Patent Application Publications 20130244528 and US20120065283. The exact amount of thermoplastic material present in the surface layer 320 may vary, with exemplary amounts ranging from about 20% by weight to about 80% by weight, for example, in the range of 30-70% by weight or 35-65% by weight.

[0056] In certain embodiments, the reinforcing fibers of the surface layer 320 may include glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, in particular high modulus organic fibers (e.g., para- and meta-aramid fibers, nylon fibers, polyester fibers, or any high melt flow index resin described herein that is suitable for use as a fiber), mineral fibers (basalt), mineral wool (e.g., rock wool or slag wool), wollastonite, alumina silica, 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 before use to provide the fibers with desired functional groups or to impart other physical properties, for example, they may be chemically treated so that they can react with thermoplastic materials, lofting agents, or both. The fiber content of layer 320 may independently be about 20% to about 90% by weight of the layer, more specifically, about 30% to about 70% by weight of the layer. Typically, the fiber content of a multilayer assembly including the surface layer 320 varies between about 20% to about 90% by weight of the assembly, more specifically between about 30% to about 80% by weight, for example, between about 40% to about 70% by weight. The specific size and / or orientation of the fibers used may depend, at least in part, on the desired properties of the thermoplastic polymer material and / or surface layer 320 used. Suitable additional fiber types, fiber sizes, and quantities will be readily selected by those skilled in the art, taking into account the interests of this disclosure. In a non-limiting example, the fibers dispersed in the thermoplastic material and optionally in the lofting agent for providing the surface layer 320 generally have a diameter greater than about 5 microns, more specifically between about 5 microns and about 22 microns, and a length of about 5 mm to about 200 mm, more specifically, the fiber diameter may be about 5 microns to about 22 microns, and the fiber length may be about 5 mm to about 75 mm.

[0057] In some embodiments, the lofting ability of the surface layer 320 can be further adjusted by including one or more additional lofting agents. The exact type of lofting agent used in layer 320 may vary depending on a number of factors, including, for example, a desired lofting temperature and a desired degree of lofting. In some cases, microsphere lofting agents, such as expandable microspheres that can increase in size when exposed to convective heating, may be used. Exemplary commercially available lofting agents are available from Kureha Corp. (Japan). In other cases, 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 layer 320. In other embodiments, the lofting agent may be an expandable graphite material.

[0058] In a specific example, the core layer 310 is configured similarly to the core layers 110 and 210 described herein. It may be, for example, not a porous fiber-reinforced thermoplastic layer, or it may be a closed-cell foam. In certain configurations, the core layer 310 may include a closed-cell foam or other material that is not a fiber-reinforced thermoplastic layer, for example, the closed-cell foam of the core layer 310 may have a porosity of about 5%, 4%, 3%, 2%, or less than 1%. In some embodiments, the core layer is not a sprayed or sprayable core layer, but instead a solid planar layer that can be bonded to an adhesive layer 315 after the formation of the core layer 310, for example, the adhesive layer 315 can be disposed on the surface of the core layer 310 after the formation of the core layer, or otherwise added. In some embodiments, the core layer 310 may include one or more of the following: foam, cardboard, paper honeycomb, or a combination thereof. In other embodiments, the core layer 310 includes, or may include, polystyrene foam, expandable or extruded polyolefin foam (e.g., extruded polyethylene or expandable polypropylene) or other foams. In some cases, the core layer may lack any polyurethane material and / or any cellulose material. By using a specific foam material for the core layer 310, clean edges can be present, mold growth problems can be avoided, and higher compressive strength can be obtained with a lighter area weight. Exemplary basis weights of the core layer 310 include, but are not limited to, about 300 gsm to about 2000 gsm, more specifically about 500 gsm to about 1900 gsm, or about 500 gsm to about 1500 gsm.

[0059] In some embodiments, the core layer 310 may include a foam with greater transverse compressive strength than longitudinal compressive strength. For example, the core layer 310 may include a foam with directional compressive strength, such as a foam with different compressive strengths in orthogonal directions, to impart more rigidity to the entire article including the core layer 210 and the surface layer 320. Foams capable of providing directional compressive strength are commercially available from Dow Corning and other suppliers. The core layer 310 is typically formed first from a foam (or other material) and then bonded to the surface layer 320 via an adhesive layer 315. In some configurations, the material of the core layer 310 can be constructed and arranged to allow compression of the core layer 310 without substantial damage to the core layer 310. The material of the core layer 310 can also be selected to allow thermoforming, e.g., compression, molding, etc., of the article 300 without substantial damage to the core layer 310. Compared to a fiber-reinforced thermoplastic core layer, the presence of a core layer 310 containing closed-cell foam (or non-fiber-reinforced thermoplastic material) can provide better performance and higher strength at the same basis weight.

[0060] In some configurations, the adhesive layer 315 can act to bond the surface layer 320 to the underlying core layer 310, preventing the separation of the surface layer 320 from the core layer 310. Suitable adhesives, though not limited to those mentioned above, include thermoplastic adhesives, such as pressure-sensitive adhesives and hot-melt adhesives, including polyamides, modified polyolefins, urethanes, and polyolefins. In some embodiments, the thermoplastic component of the adhesive layer 315 may include thermoplastic polymers, such as polyolefins like polyethylene or polypropylene. In other instances, the thermoplastic polymer of the adhesive layer may include both plasticized and unplasticized polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, as well as blends of these materials with each other or with other polymer materials. Other thermoplastic polymers suitable for use in adhesive layer 315 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®, and Bayer Examples include high-temperature polycarbonates such as APEC® PC, high-temperature nylon, silicone, and alloys and blends of these materials with each other or with other polymer materials. If desired, the adhesive layer 315 may also include, but is not limited to, several thermosetting materials, including epoxides, epoxy resins, polyesters, polyester resins, urethanes, polyurethanes, diallyl phthalates, polyimides, cyanate esters, polycyanurates, and combinations thereof.

[0061] In certain configurations, the core layer 310 may be bonded to an additional layer on its opposite surface. Referring to Figure 3B, article 350 is shown as including a core layer 310 bonded to a surface layer 320 via an adhesive layer 315. The opposite surface of the core layer 310 is bonded to layer 360. Layer 360 can take many forms and is usually different from the surface layer 320, and may not be, for example, a fiber-reinforced thermoplastic layer. In some embodiments, layer 360 may take the form of a skin. The skin 360 may include, for example, a film (e.g., a thermoplastic film or elastomer film), a frim, a scrim (e.g., a fibrous scrim), a foil, a woven fabric, a nonwoven fabric, or it may exist as an inorganic coating, an organic coating, or a thermosetting coating. In other cases, the skin 360 may contain a critical oxygen index greater than about 22 when measured according to ISO 4589 dated 1996. If a thermoplastic film is present as (or as part of) the skin 360, the thermoplastic film may contain at least one of poly(etherimide), poly(etherketone), poly(ether-etherketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ethersulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. If a fibrous scrim is present as (or as part of) the skin 360, the fibrous scrim may contain at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallated synthetic fibers, and metallated inorganic fibers. If a thermosetting coating is present as (or as part of) the skin 360, the thermosetting coating may contain at least one of unsaturated polyurethane, vinyl ester, phenolic, and epoxy. If an inorganic coating is present as (or as part of) the skin 360, the inorganic coating may contain minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or it may contain at least one of gypsum, calcium carbonate, and mortar.If a nonwoven fabric is present as (or as part of) the surface 360, the nonwoven fabric may include thermoplastic materials, thermosetting bonding agents, inorganic fibers, metallic fibers, metallized inorganic fibers, and metallized synthetic fibers. If desired, the surface 360 ​​may also include lofting agents.

[0062] In certain cases, layer 360 may be configured as a decorative layer. The decorative layer 360 may be formed from a thermoplastic film such as polyvinyl chloride, polyolefin, thermoplastic polyester, or thermoplastic elastomer. The decorative layer 360 may include carpet, rubber, or other aesthetic coverings. The decorative layer 360 may also be a multilayer structure including a foam core formed from, for example, polypropylene, polyethylene, polyvinyl chloride, or polyurethane. Fabrics such as woven fabrics made from natural and synthetic fibers, organic fiber nonwovens after needle punching, napped fabrics, knitted products, flocked fabrics, or other such materials may be bonded to the foam core. The fabrics may also be bonded to the foam core with thermoplastic adhesives such as pressure-sensitive adhesives and hot-melt adhesives, such as polyamide, modified polyolefin, urethane, or polyolefin. The decorative layer 360 may also be manufactured using spunbond, heat bonding, spunlace, meltblown, wet-laid, and / or dry-laid processes. Although not shown in the diagram, if desired, a skin, such as a scrim, film, or decorative layer, can also be bonded to layer 320.

[0063] Referring to Figures 4A and 4B in a specific configuration, the multilayer assembly 400 (or Figure 4B(450) may include surface layers 420, 430 on each surface of the core layer 410. The surface layers 420, 430 may be the same or they may be different. In certain cases, the surface layers 420, 430 may generally contain the same material but may have different amounts of material, e.g., different amounts of reinforcing fibers and / or different amounts of thermoplastic material. In other embodiments, the surface layers 420, 430 may contain the same thermoplastic material but may contain different reinforcing fibers. In additional configurations, the surface layers 420, 430 may contain the same reinforcing fibers but may contain different thermoplastic materials. In other embodiments, the surface layers 420, 430 may contain the same reinforcing material and thermoplastic material but may have different basis weights, different porosity, or other different physical properties. In some embodiments, the surface layers 420, 430 may contain the same reinforcing fibers and the same thermoplastic material but may have different thicknesses or different amounts of lofting agent to provide variable lofting ability.

[0064] In certain configurations, the surface layer 420 is bonded to the core layer 410 via an adhesive layer 415, and the surface layer 430 is bonded to the core layer 410 via an adhesive layer 425. The adhesive layers 415 and 425 can act to bond the surface layers 420 and 430 to the underlying core layer 410, respectively, and prevent separation of the surface layers 420 and 430 from the core layer 410. The adhesive layers 415 and 425 do not need to be made of the same material, thickness, etc. Exemplary adhesives that can be independently included in the adhesive layers 415 and 425 include, but are not limited to, polyamides, modified polyolefins, urethanes, and polyolefins, and thermoplastic adhesives including, but are not limited to, pressure-sensitive adhesives and hot-melt adhesives. In some embodiments, the thermoplastic component of the adhesive layers 415 and 425 may independently include thermoplastic polymers, such as polyethylene or polyolefins such as polypropylene. In other cases, the thermoplastic polymers of adhesive layers 415, 425 may independently include both plasticized and unplasticized polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, as well as blends of these materials with each other or with other polymer materials. Other thermoplastic resins suitable for use in adhesive layers 415 and 425 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-temperature polycarbonates such as Bayer's APEC® PC, high-temperature nylons, silicones, and alloys and blends of these materials with each other or with other polymer materials.If desired, the adhesive layers 415 and 425 may also independently contain, but not limited to, several thermosetting materials, including epoxides, epoxy resins, polyesters, polyester resins, urethanes, polyurethanes, diallyl phthalates, polyimides, cyanate esters, polycyanurates, and combinations thereof.

[0065] In certain embodiments, each of the surface layers 420 and 430 may be constructed independently, similar to the surface layer 120, and for example, each of the surface layers 420 and 430 may be a GMT or LWRT. For example, each of the surface layers 420 and 430 may be constructed as an LWRT comprising one or more thermoplastic materials. In some embodiments, the thermoplastic materials present in each of the layers 420 and 430 may independently, at least partially, comprise one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, as well as blends of these materials with each other or with other polymer materials. Other suitable thermoplastic resins include, but are not limited to, polyarylene ethers and polycarbonates. Examples include 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-temperature polycarbonates such as Bayer's APEC® PC, high-temperature nylons, silicones, and copolymers, alloys, and blends of these materials with each other or with other polymer materials. The thermoplastic materials used to form layers 420 and 430 may be in powder form, resin form, rosin form, particle form, fiber form, or other suitable form, and the form used in different layers 420 and 430 does not have to be the same. Various exemplary forms of thermoplastic materials are described herein and, for example, in U.S. Patent Application Publications 20130244528 and US20120065283. The exact amount of thermoplastic material present in surface layers 420 and 430 may vary, with exemplary amounts ranging from about 20% to about 80% by weight, for example, 30 to 70% by weight or 35 to 65% by weight. As described herein, the amounts of thermoplastic material present in surface layers 420 and 430 do not need to be the same.

[0066] In certain embodiments, the reinforcing fibers of surface layers 420, 430 may independently include glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, in particular high modulus organic fibers (e.g., para- and meta-aramid fibers, nylon fibers, polyester fibers, or any high melt flow index resin described herein suitable for use as a fiber), mineral fibers (e.g., basalt), mineral wool (e.g., rock wool or slag wool), wollastonite, alumina silica, 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 before use to provide the fibers with desired functional groups or to impart other physical properties, for example, they may be chemically treated so that they can react with thermoplastic materials, lofting agents, or both. In some cases, one of the fibers of surface layers 420, 430 is chemically treated, while the other of the fibers of surface layers 420, 430 is not chemically treated. The fiber content of each of layers 420 and 430 may independently range from about 20% to about 90% by weight of the layer, more specifically, from about 30% to about 70% by weight of the layer. Typically, the fiber content of a multilayer assembly including surface layers 420 and 430 varies between about 20% to about 90% by weight of the assembly, more specifically, from about 30% to about 80% by weight, for example, from about 40% to about 70% by weight. The specific 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 surface layers 420 and 430. Suitable additional fiber types, fiber sizes, and quantities will be readily selected by those skilled in the art, taking into account the interests of this disclosure. In a non-limiting example, the fibers dispersed in the thermoplastic material and optionally in the lofting agent for providing the surface layers 420, 430 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 5 microns to about 22 microns, and the fiber length may be about 5 mm to about 75 mm.

[0067] In certain embodiments, the surface layers 420 and 430 may contain different fibrous materials or different fibrous fillers. If different fibrous materials are present, the fibers may be completely different fibers, for example, glass fibers in one layer and carbon fibers in another layer, or they may contain the same chemically treated substrate, for example, glass fibers in one layer and chemically treated glass fibers in another layer. In some cases, the fibers may be the same fibrous material, but one or more physical properties of the fibers may differ. For example, the fibers in layer 420 may have a different diameter than the fibers present in layer 430, even if the fibrous materials of layers 420 and 430 are the same or different. It may have a first diameter. In other examples, the length of the fibers in layer 420 may differ from the length of the fibers in layer 430, even if the fiber materials present in layers 420 and 430 are the same or different. In additional embodiments, both the length and diameter of the fibers in layer 420 may differ from the length and diameter of the fibers in layer 430, even if the fiber materials present in layers 420 and 430 are the same or different. In yet another embodiment, two or more different fibers may be used in one of layers 420 and 430, and a single type of fiber may be present in the other layer. By selecting the amount and / or type of fibers as described herein, it is possible to change the physical properties of the surface layers 420 and 430, for example, to provide different lofting capacities to different surface layers of an assembly.

[0068] In some embodiments, the core layer 410 may include a closed-cell foam or other material that is not a fiber-reinforced thermoplastic layer, for example, the closed-cell foam of the core layer 410 may have a porosity of about 5%, 4%, 3%, 2%, or less than 1%. In some embodiments, the core layer is not a sprayed or sprayable core layer, but instead a solid planar layer that can be bonded to the surface layers 420, 430 after the formation of the core layer 410. In some embodiments, the core layer 410 may include one or more of the following: foam, cardboard, paper honeycomb, or a combination thereof. In other embodiments, the core layer 410 includes, or may include, polystyrene foam, expandable or extruded polyolefin foam (e.g., extruded polyethylene or expandable polypropylene) or other foams. In some cases, the core layer may lack any polyurethane material and / or any cellulose material. By using a specific foam material for the core layer 410, clean edges can be provided, mold growth problems can be avoided, and higher compressive strength can be obtained with a lighter area weight. While not limiting, an example basis weight for the core layer 410 is approximately 300 gsm to 2000 gsm, more specifically, approximately 500 gsm to 1900 gsm, or approximately 500 gsm to 1500 gsm.

[0069] In some embodiments, the core layer 410 may include a foam with greater transverse compressive strength than longitudinal compressive strength. For example, the core layer 410 may include a foam with directional compressive strength, such as a foam with different compressive strengths in orthogonal directions, in order to impart more rigidity to the entire article, which includes the core layer 410 and the surface layers 420, 430. Foams capable of providing directional compressive strength are commercially available from Dow Corning and other suppliers. The core layer 410 is typically formed first from a foam (or other material) and then bonded to the surface layers 420, 430. In some configurations, the material of the core layer 410 can be constructed and arranged to allow compression of the core layer 410 without substantial damage to the core layer 410. The material of the core layer 410 can also be selected to allow thermoforming, e.g., compression, molding, etc., of the article 400 (or article 450) without substantial damage to the core layer 410. Compared to a fiber-reinforced thermoplastic core layer, the presence of a core layer 410 containing closed-cell foam (or non-fiber-reinforced thermoplastic material) can provide better performance and higher strength at the same basis weight.

[0070] In some configurations, the surface layers 420, 430 (and optionally the core layer 410 and adhesive layers 415, 425) may be substantially halogen-free or halogen-free layers to meet regulations regarding hazardous substance requirements for a particular application. In other cases, one or more of the layers 410, 415, 420, 425, 430 may contain halogenated flame retardants, such as halogenated flame retardants containing more of one of F, Cl, Br, I, and At, or compounds containing such halogens, such as tetrabromobisphenol-A polycarbonate or monohalo-, dihalo-, trihalo-, or tetrahalo-polycarbonate. In some cases, the thermoplastic material used in one or more of the surface layers 420, 430 may contain one or more halogens to impart some flame retardancy without the addition of another flame retardant. In addition, flame retardants are present, preferably in a flame retardant amount, which may vary depending on other components present. For example, halogenated flame retardants may be present in an amount of about 0.1% to about 15% by weight (based on the weight of the layer), more specifically, about 1% to about 13% by weight, for example, about 5% to about 13% by weight. If desired, two different halogenated flame retardants may be added to the layer. In other cases, non-halogenated flame retardants, such as flame retardants containing one or more of N, P, As, Sb, Bi, S, Se, and Te, may be added. In some embodiments, the non-halogenated flame retardants may also contain phosphorylated materials, so that the layer may be more environmentally friendly. If non-halogenated flame retardants or substantially halogen-free flame retardants are present, the flame retardants are present, preferably in a flame retardant amount, which may vary depending on other components present. For example, substantially halogen-free flame retardants may be present in amounts of approximately 0.1% to 15% by weight (based on the weight of the layer), more specifically, approximately 1% to 13% by weight, for example, 5% to 13% by weight, based on the weight of the layer. If desired, two different substantially halogen-free flame retardants may be added to one or more of layers 410, 415, 420, 425, and 430. In certain cases, one or more of layers 410, 415, 420, 425, and 430 may contain one or more halogenated flame retardants in combination with one or more substantially halogen-free flame retardants. If two different flame retardants are present, the combination of the two flame retardants may be present in amounts that vary depending on other components present. For example, the total weight of the flame retardant may be about 0.1 weight percent to about 20 weight percent (based on the weight of the layer), more specifically, about 1 weight percent to about 15 weight percent (based on the weight of the layer), for example, about 2 weight percent to about 14 weight percent. The flame retardants used in the layers described herein can be added to a mixture containing thermoplastic material and fibers (before the mixture is placed on a wire screen or other processing component), or they can be added after the layer has been formed.In some embodiments, the flame retardant material may include one or more of the following: an expandable graphite material, magnesium hydroxide (MDH), and aluminum hydroxide (ATH).

[0071] In the configuration shown in Figure 4A (and / or Figure 4B), the lofting capacity of the surface layers 420, 430 can be further adjusted by including one or more additional lofting agents. The exact type of lofting agent used in layers 420, 430 can vary depending on a number of factors, including, for example, the desired lofting temperature and the desired degree of lofting. In some cases, microsphere lofting agents, such as expandable microspheres that can increase in size when exposed to convective heating, may be used. Exemplary commercially available lofting agents are available from Kureha Corp. (Japan). In other cases, 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 embodiments, the lofting agent may be an expandable graphite material. The surface layers 420, 430 can be configured to provide the same or different lofting capacities. For example, when exposed to heat or other lofting stimuli, the thickness of layer 420 after lofting may be greater than the thickness of layer 430. For example, the thickness of layer 420 before lofting may be about 1-2 mm, and after lofting it may be about 10-15 mm. Similarly, the thickness of layer 430 before lofting may also be about 1-2 mm, and after lofting it may be about 6-8 mm. These thickness changes can occur without the addition of any lofting agent. For example, while we do not wish to be bound by any particular theory, during lofting the thermoplastic material may melt, releasing the reinforcing material and allowing it to occupy a larger volume. Subsequent cooling of the thermoplastic material may result in the reformation of a web with an open-cell structure that has a larger volume than the pre-lofted web. By adjusting the levels of thermoplastic material and / or reinforcing material in layer 420, the extent to which the volume of layer 420 can be increased may be selected. In contrast, the thermoplastic material present in layer 430 The amounts of the material and / or reinforcing material can be selected such that the melting of the thermoplastic material during lofting does not result in a substantial increase in the overall volume. When the web of layer 430 is reformed after lofting, the resulting post-lofted web volume is substantially the same as the pre-lofted web volume. If desired, one or more of layers 420, 430 may contain additional lofting agents to further increase the overall volume. For example, layer 420 may contain additional lofting agents to further select the overall volume after lofting. In some cases, there is enough lofting agent so that the post-lofted layer 420 (and / or post-lofted layer 430) has a thickness of about 20-25 mm. In some embodiments, layer 420 may contain polyolefin, reinforcing fibers, and lofting agents, and layer 430 may contain polyolefin (which may be the same as or different from the polyolefin in layer 420) and reinforcing material. In certain configurations, the polyolefin present in each of layers 420 and 430 may be polypropylene or a polyolefin copolymer containing polypropylene. In some embodiments, the reinforcing material in each of layers 420 and 430 may optionally include glass fibers combined with other fibers. The exact weight percentages of thermoplastic and reinforcing materials in each of layers 420 and 430 may vary, with exemplary weight percentages in layers 420 and 430 being approximately 40–60 weight percent thermoplastic material and the remainder being reinforcing material. If desired, the surface layer 430 may be configured to have a higher lofting capacity than layer 420.

[0072] In certain configurations, one or both of the surface layers 420, 430 can be bonded to an additional layer or material. Referring to Figure 4B, article 450 is shown as including a surface layer 430 bonded to layer 460. Layer 460 can take many forms and is usually different from the surface layers 420, 430, and may not be, for example, a fiber-reinforced thermoplastic layer. In some embodiments, layer 460 may take the form of a skin. The skin 460 may include, for example, a film (e.g., a thermoplastic film or elastomer film), a frim, a scrim (e.g., a fibrous scrim), a foil, a woven fabric, a nonwoven fabric, or it may exist as an inorganic coating, an organic coating, or a thermosetting coating. In other cases, the skin 460 may contain a limiting oxygen index greater than about 22 when measured according to ISO 4589 dated 1996. If a thermoplastic film is present as (or as part of) the skin 460, the thermoplastic film may contain at least one of poly(etherimide), poly(etherketone), poly(ether-etherketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ethersulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. If a fibrous scrim is present as (or as part of) the skin 460, the fibrous scrim may contain at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallated synthetic fibers, and metallated inorganic fibers. If a thermosetting coating is present as (or as part of) the skin 460, the thermosetting coating may contain at least one of unsaturated polyurethane, vinyl ester, phenolic, and epoxy. If an inorganic coating is present as (or as part of) the skin 460, the inorganic coating may contain minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or it may contain at least one of gypsum, calcium carbonate, and mortar.If a nonwoven fabric is present as (or as part of) the surface 460, the nonwoven fabric may include thermoplastic materials, thermosetting bonding agents, inorganic fibers, metallic fibers, metallized inorganic fibers, and metallized synthetic fibers. If desired, the surface 460 may also include lofting agents.

[0073] In certain cases, layer 460 may be configured as a decorative layer. The decorative layer 460 may be, for example, polyvinyl chloride, polyolefin, thermoplastic polyester, thermoplastic elastomer, etc. It may be formed from any thermoplastic film. The decorative layer 460 may include carpet, rubber, or other aesthetic coverings. The decorative layer 460 may also be a multilayer structure including a foam core formed from, for example, polypropylene, polyethylene, polyvinyl chloride, polyurethane, etc. Fabrics such as woven fabrics made from natural and synthetic fibers, organic fiber nonwovens after needle punching, napped fabrics, knitted products, flocked fabrics, or other such materials may be bonded to the foam core. The fabrics may also be bonded to the foam core with thermoplastic adhesives including pressure-sensitive adhesives and hot-melt adhesives such as polyamide, modified polyolefin, urethane, and polyolefin. The decorative layer 460 may also be manufactured using spunbond, heat bonding, spunlace, meltblown, wet-laid, and / or dry-laid processes. Although not shown, if desired, a skin, e.g., scrim, film, decorative layer, etc., may also be bonded to layer 420.

[0074] Referring to Figures 5A, 5B, and 5C in a particular configuration, the multilayer assembly 500 (or 525 in Figure 5B or 450 in Figure 5C) may include a surface layer 520 and two or more core layers 510, 512 bonded to each other. The core layers 510, 512 may be the same or different, as described below. In some embodiments, the core layers 510, 512 may include closed-cell foam or other materials that are not fiber-reinforced thermoplastic layers, for example, the core layers 510, 512 or both closed-cell foams may have porosity of about 5%, 4%, 3%, 2%, or less than 1%. In some embodiments, one or both of the core layers 510, 512 are solid planar layers that are not sprayed or sprayable core layers, but instead can be bonded to the surface layer 520 after the formation of the core layers 510, 512. In some embodiments, each of the core layers 510, 512 may independently contain one or more of the following: foam, cardboard, paper honeycomb, or a combination thereof. In other embodiments, each of the core layers 510, 512 may contain, or be, polystyrene foam, expandable or extruded polyolefin foam (e.g., extruded polyethylene or expandable polypropylene) or other foams. In some cases, one or both of the core layers 510, 512 may lack any polyurethane material and / or any cellulose material. By using a specific foam material in one or both of the core layers 510, 512, clean edges can be present, mold growth problems can be avoided, and higher compressive strength can be obtained with a lighter area weight. While not limiting, the typical basis weights of core layers 510 and 512 are approximately 300 gsm to 2000 gsm, more specifically, approximately 500 gsm to 1900 gsm, or approximately 500 gsm to 1500 gsm. The basis weights of core layers 510 and 512 may be the same or different.

[0075] In some embodiments, each of the core layers 510, 512 may contain a foam with greater transverse compressive strength than longitudinal compressive strength. For example, one or both of the core layers 510, 512 may contain a foam with directional compressive strength, such as a foam with different compressive strengths in orthogonal directions, to impart more rigidity to the entire article including the core layers 510, 512 and the surface layer 520. Foams capable of providing directional compressive strength are commercially available from Dow Corning and other suppliers. Each of the core layers 510, 512 is typically formed first from a foam (or other material) and then bonded to each other and to the surface layer 520. In some configurations, the material of one or both of the core layers 510, 512 can be constructed and positioned to allow compression of the core layers 510, 512 without substantially damaging the core layers 510, 512. The materials of the core layers 510 and 512 can also be selected to allow thermoforming, for example, compression, molding, etc., of article 500 (or articles 525 and 550) without substantial damage to the core layers 510 and 512. Compared to fiber thermoplastic core layers, the presence of core layers 510 and 512 containing closed-cell foam (or non-fiber-reinforced thermoplastic material) can provide better performance and higher strength at equivalent basis weight. The core layers 510 and 512 are directly bonded to each other without any intervening layers or materials. They can be joined together, or, for example, using an adhesive layer (not shown).

[0076] In certain embodiments, the surface layer 520 (and / or surface layer 530, if present) may be composed of (or used in) a glass mat thermoplastic composite (GMT) or a lightweight reinforced thermoplastic material (LWRT). One such LWRT is manufactured by HANWHA AZDEL, Inc. and marketed under the trademark SUPERLITE® mat. The surface density of such a GMT or LWRT may range from about 400 grams per square meter (gsm) to about 4000 gsm, although the surface density may be less than 400 gsm or greater than 4000 gsm, depending on the needs of the particular application. In some embodiments, the upper density may be less than about 4000 gsm. In certain cases, the GMT or LWRT may include one or more lofting agent materials disposed in the void spaces or pores of the GMT or LWRT.

[0077] In certain embodiments where LWRT is used as the surface layer 520 (and / or surface layer 530, if present), the LWRT typically comprises a thermoplastic material and multiple reinforcing fibers that together form a web of open-cell structure. For example, the surface layer 520 (and / or layer 530) typically contains a considerable amount of open-cell structure so that void spaces exist within the layer. In some cases, the surface layer 520 is composed 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% Porosity may include %, 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 cases, surface layer 520 (and / or layer 530) contains a porosity or void content greater than 0%, and is not completely solidified to, for example, about 95%. Unless otherwise specified, references to surface layers containing a particular void content or void content are based on the total volume of that surface layer and not necessarily on the total volume of the multilayer assembly.

[0078] In certain embodiments, the surface layer 520 (and / or layer 530) can be manufactured in the form of a glass mat. In certain cases, the glass mat can generally be manufactured using woven or nonwoven fabrics made of chopped glass fibers, thermoplastic material, optionally a lofting agent, and any thermoplastic polymer film(s), and / or glass fiber or thermoplastic resin fiber, e.g., polypropylene (PP), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycarbonate (PC), PC / PBT blends, or PC / PET blends. In some embodiments, PP, PBT, PET, PC / PET blends, or PC / PBT blends can be used as the resin. To manufacture the glass mat, the thermoplastic material and reinforcing material can be added to or weighed into a dispersed foam placed in an open-top mixing tank equipped with a paddle. While we do not wish to be bound by any particular theory, the presence of trapped air pockets in the foam may aid in the dispersion of the glass fibers, thermoplastic material, and lofting agent. In some embodiments, the dispersion mixture of fibers and thermoplastic material may be pumped via a dispersion manifold to a headbox located above the wire section of the paper machine. As the dispersion mixture is fed to a movable wire screen using vacuum to continuously produce a uniform fibrous wet web, foam can be removed instead of fibers and thermoplastic resin. This reduces the water content and thermoplastic material. To melt or soften it, the wet web can be passed through a dryer at a suitable temperature.

[0079] In certain embodiments, the high porosity present in the surface layer 520 (and / or layer 530) can reduce the overall weight of the layer and allow for the inclusion of agents within the void spaces. For example, lofting agents may be present in the void spaces in a non-covalent bonding manner. The application of heat or other perturbations can act to increase the volume of the non-covalent lofting agents, resulting in an increase in the overall thickness of the layer, for example, as the size of the lofting agents increases and / or as additional air is trapped in the layer. If desired, flame retardants, colorants, smoke suppressants, and other materials may be included in the void spaces of the surface layer 520 (and / or layer 530). Prior to lofting, the surface layer 520 (and / or layer 530) can be compressed to reduce its overall thickness, for example, before or after it is bonded to one or more other layers.

[0080] In certain embodiments, the thermoplastic material of the surface layer 520 (and / or layer 530) may comprise at least partially one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, as well as blends of these materials with each other or with other polymer materials. Other suitable thermoplastic resins 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-temperature polycarbonates such as Bayer's APEC® PC, high-temperature nylons, silicones, and copolymers, alloys, and blends of these materials with each other or with other polymer materials. The thermoplastic material used to form layer 520 (and / or layer 530) can be used in powder form, resin form, rosin form, particle form, fiber form, or other suitable form. Various exemplary forms of thermoplastic materials are described herein and, for example, in U.S. Patent Application Publications 20130244528 and US20120065283. The exact amount of thermoplastic material present in surface layer 520 (and / or layer 530) may vary, with exemplary amounts ranging from about 20% by weight to about 80% by weight, for example, in the range of 30–70% by weight or 35–65% by weight.

[0081] In certain embodiments, the reinforcing fibers of the surface layer 520 (and / or layer 530) may include glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, in particular high modulus organic fibers (e.g., para- and meta-aramid fibers, nylon fibers, polyester fibers, or any high melt flow index resin described herein that is suitable for use as a fiber), mineral fibers (basalt), mineral wool (e.g., rock wool or slag wool), wollastonite, alumina silica, 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 before use to provide the fibers with desired functional groups or to impart other physical properties, for example, they may be chemically treated so that they can react with thermoplastic materials, lofting agents, or both. The fiber content of layer 520 (and / or layer 530) may independently be about 20% to about 90% by weight of the layer, more specifically, about 30% to about 70% by weight of the layer. Typically, the fiber content of a multilayer assembly including the surface layer 520 (and / or layer 530) is about 20% to 90% by weight of the assembly, more specifically, about 30% to 80% by weight. The amount varies in percent, for example, between about 40% by weight and about 70% by weight. The specific 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 surface layer 520 (and / or layer 530). Suitable additional fiber types, fiber sizes, and quantities will be readily selected by those skilled in the art, taking into account the interests of this disclosure. In a non-limiting example, the thermoplastic material for providing the surface layer 520 (and / or layer 530) and the fibers optionally dispersed in the lofting agent generally have a diameter greater than about 5 microns, more specifically, 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 5 microns to about 22 microns, and the fiber length may be about 5 mm to about 75 mm.

[0082] In some embodiments, the lofting ability of the surface layer 520 (and / or layer 530) can be further adjusted by including one or more additional lofting agents. The exact type of lofting agent used in layer 520 (and / or layer 530) may vary depending on a number of factors, including, for example, the desired lofting temperature and the desired degree of lofting. In some cases, microsphere lofting agents, such as expandable microspheres that can increase in size when exposed to convective heating, may be used. Exemplary commercially available lofting agents are available from Kureha Corp. (Japan). In other cases, 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 layer 520 (and / or layer 530). In other embodiments, the lofting agent may be an expandable graphite material.

[0083] Referring to Figure 5B in a particular embodiment, the surface layers 520 and 530 may be the same or they may be different. In a particular case, the surface layers 520 and 530 may generally contain the same material, but may have different amounts of material, e.g., different amounts of reinforcing fibers and / or different amounts of thermoplastic material. In another embodiment, the surface layers 520 and 530 may contain the same thermoplastic material, but may contain different reinforcing fibers. In an additional configuration, the surface layers 520 and 530 may contain the same reinforcing fibers, but may contain different thermoplastic materials. In another example, the surface layers 520 and 530 may contain the same reinforcing material and thermoplastic material, but may have different basis weights, different porosity, or other different physical properties. In some embodiments, the surface layers 520 and 530 may contain the same reinforcing fibers and the same thermoplastic material, but may have different thicknesses or different amounts of lofting agent to provide variable lofting ability.

[0084] In certain configurations, the surface layer 520 may be bonded to the core layer 510 via an adhesive layer (not shown), and the surface layer 540 may be bonded to the core layer 512 via an adhesive layer (not shown). The adhesive layer (if present) can act to bond the surface layers 520 and 530 to the underlying core layers 510 and 512, respectively, preventing separation of the surface layers 520 and 530 from the core layers 510 and 512. The adhesive layer does not need to be made of the same material, thickness, etc. Exemplary adhesives that can be independently included in the adhesive layer include, but are not limited to, polyamides, modified polyolefins, urethanes, and polyolefins, and thermoplastic adhesives including, but are not limited to, pressure-sensitive adhesives and hot-melt adhesives. In some embodiments, the thermoplastic component of the adhesive layer may independently include thermoplastic polymers, such as polyethylene or polyolefins such as polypropylene. In other cases, the thermoplastic polymer of the adhesive layer may independently include both plasticized and unplasticized polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, as well as blends of these materials with each other or with other polymer materials. Other thermoplastic resins suitable for use in the adhesive layer are not limited to... Examples 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, polyaryl sulfones, polyether sulfones, liquid crystal polymers, poly(1,4-phenylene) compounds commercially known as PARMAX®, high-temperature polycarbonates such as Bayer's APEC® PC, high-temperature nylons, silicones, and alloys and blends of these materials with each other or with other polymer materials. If desired, the adhesive layer may also independently include, but is not limited to, several thermosetting materials, including epoxides, epoxy resins, polyesters, polyester resins, urethanes, polyurethanes, diallyl phthalates, polyimides, cyanate esters, polycyanurates, and combinations thereof.

[0085] In certain embodiments, the surface layers 520 and 530 may contain different fibrous materials or different fibrous fillers. If different fibrous materials are present, the fibers may be completely different fibers, for example, glass fibers in one layer and carbon fibers in another layer, or they may contain the same chemically treated substrate, for example, glass fibers in one layer and chemically treated glass fibers in another layer. In some cases, the fibers may be the same fibrous material, but one or more physical properties of the fibers may differ. For example, the fibers of layer 520 may have a first diameter different from the diameter of the fibers present in layer 530, even if the fibrous materials of layers 520 and 530 are the same or different. In other cases, the length of the fibers of layer 520 may differ from the length of the fibers present in layer 530, even if the fibrous materials present in layers 520 and 530 are the same or different. In additional embodiments, both the length and diameter of the fibers of layer 520 may differ from the length and diameter of the fibers of layer 530, even if the fibrous materials present in layers 520 and 530 are the same or different. In further embodiments, two or more different fibers may be used in one of the layers 520, 530, or a single type of fiber may be present in the other layer. As described herein, by selecting the amount and / or type of fibers, it is possible to change the physical properties of the surface layers 520, 530, for example, to provide different lofting capacities to different surface layers of the assembly.

[0086] In some configurations, the surface layers 520, 530 (and optionally the core layers 510, 512) may be substantially halogen-free or halogen-free layers to meet regulations regarding hazardous substance requirements for a particular application. In other cases, one or more of the layers 510, 512, 520, and 530 may contain halogenated flame retardants, such as halogenated flame retardants containing more of one of F, Cl, Br, I, and At, or compounds containing such halogens, such as tetrabromobisphenol-A polycarbonate or monohalo-, dihalo-, trihalo-, or tetrahalo-polycarbonate. In some cases, the thermoplastic material used in one or more of the surface layers 520, 530 may contain one or more halogens to impart some flame retardancy without the addition of another flame retardant. Where halogenated flame retardants are present, the flame retardants are preferably present in a flame retardant amount, which may vary depending on other components present. For example, halogenated flame retardants may be present in amounts of about 0.1% to about 15% by weight (based on the weight of the layer), more specifically, about 1% to about 13% by weight, for example, about 5% to about 13% by weight. If desired, two different halogenated flame retardants may be added to the layer. In other cases, non-halogenated flame retardants, such as flame retardants containing one or more of N, P, As, Sb, Bi, S, Se, and Te, may be added. In some embodiments, the non-halogenated flame retardants may also contain phosphorylated materials, so that the layer may be more environmentally friendly. If non-halogenated or substantially halogen-free flame retardants are present, the flame retardants are present in preferably a flame retardant amount, which may vary depending on other components present. For example, substantially halogen-free flame retardants The agent may be present in an amount of about 0.1% to about 15% by weight (based on the weight of the layer), more specifically, about 1% to about 13% by weight, for example, 5% to about 13% by weight, based on the weight of the layer. If desired, two different substantially halogen-free flame retardants may be added to one or more of layers 510, 512, 520, and 530. In certain cases, one or more of layers 510, 512, 520, and 530 may contain one or more halogenated flame retardants in combination with one or more substantially halogen-free flame retardants. If two different flame retardants are present, the combination of the two flame retardants may be present in a flame retardant amount, which may vary depending on other components present. For example, this total weight may be about 0.1% to about 20% by weight (based on the weight of the layer), more specifically, about 1% to about 15% by weight, for example, about 2% to about 14% by weight, based on the weight of the layer. The flame retardants used in the layers described herein can be added to a mixture containing thermoplastic material and fibers (before the mixture is placed on a wire screen or other processing component) or after the layer has been formed. In some embodiments, the flame retardant material may include one or more of the following: an expandable graphite material, magnesium hydroxide (MDH), and aluminum hydroxide (ATH).

[0087] In the configuration shown in Figure 5A (and / or Figures 5B and 5C), the lofting capacity of the surface layers 520, 530 can be further adjusted by including one or more additional lofting agents. The exact type of lofting agent used in layers 520, 530 may vary depending on a number of factors, including, for example, the desired lofting temperature and the desired degree of lofting. In some cases, microsphere lofting agents, such as expandable microspheres that can increase in size when exposed to convective heating, may be used. Exemplary commercially available lofting agents are available from Kureha Corp. (Japan). In other cases, 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 embodiments, the lofting agent may be an expandable graphite material. The surface layers 520, 530 can be configured to provide the same or different lofting capacities. For example, when exposed to heat or other lofting stimuli, the thickness of layer 520 after lofting may be greater than the thickness of layer 530. For example, the thickness of layer 520 before lofting may be about 1-2 mm, and after lofting it may be about 10-15 mm. Similarly, the thickness of layer 530 before lofting may also be about 1-2 mm, and after lofting it may be about 6-8 mm. These set of thickness changes can occur without the addition of any lofting agent. For example, while we do not wish to be bound by any particular theory, during lofting the thermoplastic material may melt, releasing the reinforcing material and allowing it to occupy a larger volume. Subsequent cooling of the thermoplastic material may result in the reformation of a web with an open-cell structure that has a larger volume than the pre-lofted web. By adjusting the levels of thermoplastic material and / or reinforcing material within layer 520, the extent to which the volume of layer 520 can be increased may be chosen. In contrast, the amount of thermoplastic material and / or reinforcing material present in layer 530 can be selected such that the melting of the thermoplastic material during lofting does not result in a substantial increase in the overall volume.When the web of layer 530 is reformed after lofting, the resulting post-lofted web volume is substantially the same as the pre-lofted web volume. If desired, one or more of layers 520, 530 may contain additional lofting agents to further increase the overall volume. For example, layer 520 may contain additional lofting agents to further select the overall volume after lofting. In some cases, there is enough lofting agent so that the post-lofted layer 520 (and / or post-lofted layer 530) has a thickness of about 20-25 mm. In some embodiments, layer 520 may contain polyolefin, reinforcing fibers, and a lofting agent, and layer 530 may contain polyolefin (which may be the same as or different from the polyolefin in layer 520). The layers may also contain reinforcing materials. In certain configurations, the polyolefin present in each of layers 520 and 530 may be polypropylene or a polyolefin copolymer containing polypropylene. In some embodiments, the reinforcing material in each of layers 520 and 530 may optionally include glass fibers combined with other fibers. The exact weight percentages of thermoplastic and reinforcing materials in each of layers 520 and 530 may vary, with exemplary weight percentages in layers 520 and 530 being about 40–60 weight percent thermoplastic material and the remainder being reinforcing material. If desired, the surface layer 530 may be configured to have a higher lofting capacity than layer 520.

[0088] In certain configurations, one or both of the surface layers 520, 530 can be bonded to an additional layer or material. Referring to Figure 5C, article 550 is shown as including a surface layer 530 bonded to layer 560. Layer 560 can take many forms and is usually different from the surface layers 520, 530, and may not be, for example, a fiber-reinforced thermoplastic layer. In some embodiments, layer 560 may take the form of a skin. The skin 560 may include, for example, a film (e.g., a thermoplastic film or elastomer film), a frim, a scrim (e.g., a fibrous scrim), a foil, a woven fabric, a nonwoven fabric, or it may exist as an inorganic coating, an organic coating, or a thermosetting coating. In other cases, the skin 560 may contain a limiting oxygen index greater than about 22 when measured according to ISO 4589 dated 1996. If a thermoplastic film is present as (or as part of) the skin 560, the thermoplastic film may contain at least one of poly(etherimide), poly(etherketone), poly(ether-etherketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ethersulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. If a fibrous scrim is present as (or as part of) the skin 560, the fibrous scrim may contain at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallated synthetic fibers, and metallated inorganic fibers. If a thermosetting coating is present as (or as part of) the skin 560, the thermosetting coating may contain at least one of unsaturated polyurethane, vinyl ester, phenolic, and epoxy. If an inorganic coating is present as (or as part of) the skin 560, the inorganic coating may contain minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or it may contain at least one of gypsum, calcium carbonate, and mortar.If a nonwoven fabric is present as (or as part of) the surface 560, the nonwoven fabric may include thermoplastic materials, thermosetting bonding agents, inorganic fibers, metallic fibers, metallized inorganic fibers, and metallized synthetic fibers. If desired, the surface 560 may also include lofting agents.

[0089] In certain cases, layer 560 may be configured as a decorative layer. The decorative layer 560 may be formed from a thermoplastic film such as polyvinyl chloride, polyolefin, thermoplastic polyester, or thermoplastic elastomer. The decorative layer 560 may include carpet, rubber, or other aesthetic coverings. The decorative layer 560 may also be a multilayer structure including a foam core formed from, for example, polypropylene, polyethylene, polyvinyl chloride, or polyurethane. Fabrics such as woven fabrics made from natural and synthetic fibers, organic fiber nonwovens after needle punching, napped fabrics, knitted products, flocked fabrics, or other such materials may be bonded to the foam core. The fabrics may also be bonded to the foam core with thermoplastic adhesives including pressure-sensitive adhesives and hot-melt adhesives such as polyamide, modified polyolefin, urethane, and polyolefin. The decorative layer 560 may also be manufactured using spunbond, heat bonding, spunlace, meltblown, wet-laid, and / or dry-laid processes. Although not shown in the diagram, if desired, a skin, such as a scrim, film, or decorative layer, can also be bonded to layer 520.

[0090] Referring to Figures 6A, 6B, and 6C in certain embodiments, the multilayer assembly 600 (or 625 in Figure 6B or 650 in Figure 6C) may include two or more core layers 610, 612 bonded to each other via a fiber-reinforced thermoplastic layer 620. An optional surface layer 630 may also be present on articles 600, 625, and 650. In certain embodiments, the core layers 610, 612 may be the same or different. In some embodiments, the core layers 610, 612 may include closed-cell foam or other materials that are not fiber-reinforced thermoplastic layers, for example, the core layers 610, 612 or both closed-cell foams may have porosity of about 5%, 4%, 3%, 2%, or less than 1%. In some embodiments, one or both of the core layers 610, 612 are not sprayed or sprayable core layers, but instead are solid planar layers that can be bonded to layers 620 and surface layer 630 after the formation of the core layers 610, 612. In some embodiments, each of the core layers 610, 612 may independently contain one or more of the following: foam, cardboard, paper honeycomb, or a combination thereof. In other embodiments, each of the core layers 610, 612 may contain, or may contain, polystyrene foam, expandable or extruded polyolefin foam (e.g., extruded polyethylene or expandable polypropylene) or other foams. In some cases, one or both of the core layers 610, 612 may lack any polyurethane material and / or any cellulose material. By using a specific foam material for one or both of the core layers 610, 612, clean edges can be present, mold growth problems can be avoided, and higher compressive strength can be obtained with a lighter area weight. While not limiting, the typical basis weights of core layers 610 and 612 are approximately 300 gsm to 2000 gsm, more specifically, approximately 500 gsm to 1900 gsm, or approximately 500 gsm to 1500 gsm. The basis weights of core layers 610 and 612 may be the same or different.

[0091] In some embodiments, each of the core layers 610, 612 may contain a foam with greater transverse compressive strength than longitudinal compressive strength. For example, one or both of the core layers 610, 612 may contain a foam with directional compressive strength, such as a foam with different compressive strengths in orthogonal directions, to impart more rigidity to the core layers 610, 612 and the entire article including layer 620 and any surface layer 630. Foams capable of providing directional compressive strength are commercially available from Dow Corning and other suppliers. Each of the core layers 610, 612 is typically first formed from a foam (or other material) and then bonded to each other via layer 620 and optionally one or more adhesive layers (not shown). In some configurations, the material of one or both of the core layers 610, 612 can be constructed and positioned to allow compression of the core layers 610, 612 without substantially damaging the core layers 610, 612. The materials of the core layers 610, 612 can also be selected to allow thermoforming, for example, compression, molding, etc., of article 600 (or articles 625, 650) without substantial damage to the core layers 610, 612. Compared to fiber thermoplastic core layers, the presence of core layers 610, 612 containing closed-cell foam (or non-fiber-reinforced thermoplastic material) can provide better performance and higher strength at equivalent basis weight. The core layer 610 can be bonded directly to any surface layer 630 without any intervening layers or materials, or it can be bonded to the layer 630 using, for example, an adhesive layer (not shown).

[0092] In certain embodiments, layer 620 (and / or surface layer 630, if present) may be constructed (or used in such) as a glass mat thermoplastic composite (GMT) or a lightweight reinforced thermoplastic material (LWRT). One such LWRT is manufactured by HANWHA AZDEL, Inc. and marketed under the trademark SUPERLITE® mat. The surface density of such a GMT or LWRT can range from about 400 grams per square meter (gsm) to about 4000 gsm, although the surface density may be less than 400 gsm depending on the needs of the particular application. The density may be greater than 4000 gsm. In some embodiments, the upper density may be less than approximately 4000 gsm. In certain cases, the GMT or LWRT may include one or more lofting agent materials disposed in the void spaces or pores of the GMT or LWRT.

[0093] In certain embodiments where LWRT is used as the surface layer 620 (and / or surface layer 630, if present), the LWRT typically comprises a thermoplastic material and multiple reinforcing fibers that together form a web of open-cell structure. For example, the surface layer 620 (and / or layer 630) typically contains a considerable amount of open-cell structure so that void spaces exist within the layer. In some cases, the surface layer 620 is composed 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% Porosity may include %, 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 cases, surface layer 620 (and / or layer 630) contains porosity or void content greater than 0%, and is not completely solidified to, for example, about 95%. Unless otherwise specified, references to surface layers containing a particular void content or void content are based on the total volume of that surface layer and not necessarily on the total volume of the multilayer assembly.

[0094] In certain embodiments, layer 620 (and / or layer 630) can be manufactured in the form of a glass mat. In certain cases, the glass mat can generally be manufactured using woven or nonwoven fabrics made of chopped glass fibers, thermoplastic material, optionally a lofting agent, and any thermoplastic polymer film(s), and / or glass fiber or thermoplastic resin fiber, e.g., polypropylene (PP), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycarbonate (PC), PC / PBT blends, or PC / PET blends. In some embodiments, PP, PBT, PET, PC / PET blends, or PC / PBT blends can be used as the resin. To manufacture the glass mat, the thermoplastic material and reinforcing material can be added to or weighed into a dispersed foam placed in an open-top mixing tank equipped with a paddle. While we do not wish to be bound by any particular theory, the presence of trapped air pockets in the foam may aid in the dispersion of the glass fibers, thermoplastic material, and lofting agent. In some embodiments, the dispersion mixture of fibers and thermoplastic material may be pumped via a dispersion manifold to a headbox located above the wire section of the paper machine. As the dispersion mixture is fed to a movable wire screen using vacuum, a uniform fibrous wet web is continuously produced, allowing for the removal of foam rather than fibers and thermoplastic resin. The wet web can be passed through a dryer at a suitable temperature to reduce the moisture content and melt or soften the thermoplastic material.

[0095] In certain embodiments, the high porosity present in layer 620 (and / or layer 630) can reduce the overall weight of the layer and allow for the inclusion of agents within the void spaces. For example, lofting agents may be present in the void spaces in a non-covalent bonding manner. The application of heat or other perturbations can act to increase the volume of the non-covalently bonded lofting agents, resulting in an increase in the overall thickness of the layer, for example, as the size of the lofting agents increases and / or as additional air is trapped in the layer. Flame retardants, colorants, smoke suppressants, and other materials may be added to layer 620 (and / or layer 630) if desired. 30) may be included in the void space. Before lofting, layer 620 (and / or layer 630) can be compressed to reduce its overall thickness, for example, before or after it is joined to one or more other layers.

[0096] In certain embodiments, the thermoplastic material of layer 620 (and / or layer 630) may comprise at least partially one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, as well as blends of these materials with each other or with other polymer materials. Other suitable thermoplastic resins 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-temperature polycarbonates such as Bayer's APEC® PC, high-temperature nylons, silicones, and copolymers, alloys, and blends of these materials with each other or with other polymer materials. The thermoplastic material used to form layer 620 (and / or layer 630) can be used in powder form, resin form, rosin form, particle form, fiber form, or other suitable form. Various exemplary forms of thermoplastic materials are described herein and, for example, in U.S. Patent Application Publications 20130244528 and US20120065283. The exact amount of thermoplastic material present in layer 620 (and / or layer 630) may vary, with exemplary amounts ranging from about 20% by weight to about 80% by weight, for example, in the range of 30–70% by weight or 35–65% by weight.

[0097] In certain embodiments, the reinforcing fibers of layer 620 (and / or layer 630) may include glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, in particular high modulus organic fibers (e.g., para- and meta-aramid fibers, nylon fibers, polyester fibers, or any high melt flow index resin described herein that is suitable for use as a fiber), mineral fibers (basalt), mineral wool (e.g., rock wool or slag wool), wollastonite, alumina silica, 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 before use to provide the fibers with desired functional groups or to impart other physical properties, for example, they may be chemically treated so that they can react with thermoplastic materials, lofting agents, or both. The fiber content of layer 620 (and / or layer 630) may independently be about 20% to about 90% by weight of the layer, more specifically about 30% to about 70% by weight of the layer. Typically, the fiber content of a multilayer assembly including layer 620 (and / or layer 630) varies between about 20% to about 90% by weight of the assembly, more specifically between about 30% to about 80% by weight, for example, between about 40% to about 70% by weight. The specific 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 layer 620 (and / or layer 630). Suitable additional fiber types, fiber sizes, and quantities will be readily selected by those skilled in the art, taking into account the interests of this disclosure. In a non-limiting example, the fibers dispersed in the thermoplastic material and optionally in the lofting agent for providing layer 620 (and / or layer 630) generally have a diameter greater than about 5 microns, more specifically between about 5 microns and about 22 microns, and a length of about 5 mm to about 200 mm, more specifically, the fiber diameter may be about 5 microns to about 22 microns, and the fiber length may be about 5 mm to about 75 mm.

[0098] In some embodiments, the lofting ability of layer 620 (and / or layer 630) can be further adjusted by including one or more additional lofting agents. The exact type of lofting agent used in layer 620 (and / or layer 630) may vary depending on a number of factors, including, for example, the desired lofting temperature and the desired degree of lofting. In some cases, microsphere lofting agents, such as expandable microspheres that can increase in size when exposed to convective heating, may be used. Exemplary commercially available lofting agents are available from Kureha Corp. (Japan). In other cases, 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 layer 620 (and / or layer 630). In other embodiments, the lofting agent may be an expandable graphite material.

[0099] In certain embodiments, layers 620 and 630 may be the same or they may be different. In certain cases, the surface layers 620 and 630 may generally contain the same material, but may have different amounts of material, e.g., different amounts of reinforcing fibers and / or different amounts of thermoplastic material. In other embodiments, layers 620 and 630 may contain the same thermoplastic material, but may contain different reinforcing fibers. In additional configurations, layers 620 and 630 may contain the same reinforcing fibers, but may contain different thermoplastic materials. In other embodiments, layers 620 and 630 may contain the same reinforcing material and thermoplastic material, but may have different basis weights, different porosity, or other different physical properties. In some embodiments, layers 620 and 630 may contain the same reinforcing fibers and the same thermoplastic material, but may have different thicknesses or different amounts of lofting agent to provide variable lofting ability.

[0100] In certain configurations, layer 620 is bonded to core layers 610, 612 via an adhesive layer (not shown), and surface layer 630 may be bonded to core layer 610 via an adhesive layer (not shown). If desired, another surface layer 640 can be bonded to core layer 612 via an adhesive layer, as shown in Figure 6B. The adhesive layer (if present) can act to bond the various layers to the underlying core layers 610, 612, preventing the separation of layers 620, 630, 640 from the core layers 610, 612. The adhesive layer does not need to be made of the same material, thickness, etc. Exemplary adhesives that can be independently included in the adhesive layer include, but are not limited to, polyamides, modified polyolefins, urethanes, and polyolefins, and thermoplastic adhesives including, but are not limited to, pressure-sensitive adhesives and hot-melt adhesives. In some embodiments, the thermoplastic component of the adhesive layer may independently include thermoplastic polymers, such as polyethylene or polyolefins such as polypropylene. In other cases, the thermoplastic polymer in the adhesive layer may independently include 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 polymer materials. Other thermoplastic polymers suitable for use in the adhesive layer include, but are not limited to, polyarylene ethers, polycarbonates, polyester carbonates, 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-temperature polycarbonates such as Bayer's APEC® PC, high-temperature nylons, silicones, as well as alloys and blends of these materials with each other or with other polymer materials. If desired, the adhesive layer may also be independently applied, but is not limited to these, epoxides, epoxy resins, etc. The material may include several thermosetting materials, including fats, polyesters, polyester resins, urethanes, polyurethanes, diallyl phthalates, polyimides, cyanate esters, polycyanurates, and combinations thereof.

[0101] In certain embodiments, surface layers 620 and 640 may contain different fibrous materials or different fibrous fillers. If different fibrous materials are present, the fibers may be completely different fibers, for example, glass fibers in one layer and carbon fibers in another, or they may contain the same chemically treated substrate, for example, glass fibers in one layer and chemically treated glass fibers in another. In some cases, the fibers may be the same fibrous material, but one or more physical properties of the fibers may differ. For example, the fibers of layer 630 may have a first diameter different from the diameter of the fibers present in layer 640, even if the fibrous materials of layers 630 and 640 are the same or different. In other cases, the length of the fibers of layer 630 may differ from the length of the fibers present in layer 640, even if the fibrous materials present in layers 630 and 640 are the same or different. In additional embodiments, both the length and diameter of the fibers of layer 630 may differ from the length and diameter of the fibers of layer 640, even if the fibrous materials present in layers 630 and 640 are the same or different. In further embodiments, two or more different fibers may be used in one of the layers 630, 640, or a single type of fiber may be present in the other layer. As described herein, by selecting the amount and / or type of fibers, it is possible to change the physical properties of the surface layers 630, 640, for example, to provide different lofting capacities to different surface layers of the assembly.

[0102] In some configurations, surface layers 630, 640 (and optionally core layers 610, 612, and 620) may be substantially halogen-free or halogen-free layers to meet regulations regarding hazardous substance requirements for specific applications. In other cases, one or more of layers 610, 612, 620, 630, and 640 may contain halogenated flame retardants, such as halogenated flame retardants containing more of one of F, Cl, Br, I, and At, or compounds containing such halogens, such as tetrabromobisphenol-A polycarbonate or monohalo-, dihalo-, trihalo-, or tetrahalo-polycarbonate. In some cases, the thermoplastic material used in one or more of surface layers 630, 640 may contain one or more halogens to impart some flame retardancy without the addition of another flame retardant. Where halogenated flame retardants are present, the flame retardants are preferably present in a flame retardant amount, which may vary depending on other components present. For example, halogenated flame retardants may be present in amounts of about 0.1% to about 15% by weight (based on the weight of the layer), more specifically, about 1% to about 13% by weight, for example, about 5% to about 13% by weight. If desired, two different halogenated flame retardants may be added to the layer. In other cases, non-halogenated flame retardants, such as flame retardants containing one or more of N, P, As, Sb, Bi, S, Se, and Te, may be added. In some embodiments, the non-halogenated flame retardants may also contain phosphorylated materials, so that the layer may be more environmentally friendly. If non-halogenated flame retardants or substantially halogen-free flame retardants are present, the flame retardants are present in preferably a flame retardant amount, which may vary depending on other components present. For example, a substantially halogen-free flame retardant may be present in an amount of about 0.1% to about 15% by weight (based on the weight of the layer), more specifically, about 1% to about 13% by weight, for example, 5% to about 13% by weight, based on the weight of the layer. If desired, two different substantially halogen-free flame retardants may be added to one or more of layers 610, 612, 620, 630, and 640.In certain cases, one or more of layers 610, 612, 620, 630, and 640 may contain one or more halogenated flame retardants in combination with one or more substantially halogen-free flame retardants. If two different flame retardants are present, the combination of the two flame retardants may be present in terms of the amount of flame retardants, which may vary depending on other components present, for example, the total weight of the flame retardants. The amount may be about 0.1 weight percent to about 20 weight percent (based on the weight of the layer), more specifically, about 1 weight percent to about 15 weight percent, for example, about 2 weight percent to about 14 weight percent, based on the weight of the layer. The flame retardants used in the layers described herein can be added to the mixture containing the thermoplastic material and fibers (before the mixture is placed on a wire screen or other processing component), or they can be added after the layer is formed. In some embodiments, the flame retardant material may include one or more of the following: an expandable graphite material, magnesium hydroxide (MDH), and aluminum hydroxide (ATH).

[0103] In the configuration shown in Figure 6A (and / or Figures 6B and 6C), the lofting capabilities of layers 620, 630, and 640 can be further adjusted by including one or more additional lofting agents. The exact type of lofting agent used in layers 620, 630, and 640 can vary depending on a number of factors, including, for example, the desired lofting temperature and the desired degree of lofting. In some cases, microspherical lofting agents, such as expandable microspheres that can increase in size when exposed to convective heating, may be used in one or more of layers 620, 630, and 640. Exemplary commercially available lofting agents are available from Kureha Corp. (Japan). In other cases, 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 embodiments, the lofting agent may be an expandable graphite material. Layers 620, 630, and 640 can be configured to provide the same or different lofting capabilities. For example, when exposed to heat or other lofting stimuli, the thickness of layer 620 after lofting may be greater than the thickness of layer 630. For example, the thickness of layer 620 before lofting may be about 1-2 mm, and after lofting it may be about 10-15 mm. The thickness of layer 630 before lofting may also be about 1-2 mm, and after lofting it may be about 6-8 mm. These thickness changes can occur without the addition of any lofting agent. For example, although we do not wish to be bound by any particular theory, during lofting the thermoplastic material may melt, releasing the reinforcing material and allowing it to occupy a larger volume. Subsequent cooling of the thermoplastic material may result in the reformation of a web with a continuous cell structure that has a larger volume than the pre-lofted web. By adjusting the levels of the thermoplastic material and / or reinforcing material within layer 620, the extent to which the volume of layer 620 can be increased may be selected. In contrast, the amount of thermoplastic material and / or reinforcing material present in layer 630 can be selected such that the melting of the thermoplastic material during lofting does not result in a substantial increase in the overall volume.When the web of layer 630 is reformed after lofting, the resulting post-loft web volume is substantially the same as the pre-loft web volume. If desired, one or more of layers 620, 630, and 640 may contain additional lofting agents to further increase the overall volume. For example, layer 620 may contain additional lofting agents to further select the overall volume after lofting. In some cases, there is enough lofting agent so that the post-loft layer 620 (and / or post-loft layers 630, 640) has a thickness of about 20–25 mm. In some embodiments, layer 620 may contain polyolefin, reinforcing fibers, and a lofting agent, and layers 630 and 640 may each contain polyolefin (which may be the same as or different from the polyolefin in layer 620) and reinforcing material. In certain configurations, the polyolefin present in each of layers 620, 630, and 640 may be polypropylene or a polyolefin copolymer containing polypropylene. In some embodiments, the reinforcing material in each of layers 620, 630, and 640 may optionally include glass fibers combined with other fibers. The exact weight percentages of thermoplastic and reinforcing materials in each of layers 620, 630, and 640 may vary, with exemplary weight percentages in layers 620, 630, and 640 being approximately 40 to 60 weight percent thermoplastic. The material is the main component, and the remainder is the reinforcing material. If desired, the surface layers 630 and 640 can be configured to have a higher lofting capacity than layer 620.

[0104] In certain configurations, one or both of the surface layers 630, 640 can be bonded to an additional layer or material. Referring to Figure 6C, article 650 is shown as including a surface layer 640 bonded to layer 660. Layer 660 can take many forms and is usually different from the surface layers 630, 640, and may not be, for example, a fiber-reinforced thermoplastic layer. In some embodiments, layer 660 may take the form of a skin. The skin 660 may include, for example, a film (e.g., a thermoplastic film or elastomer film), a frim, a scrim (e.g., a fibrous scrim), a foil, a woven fabric, a nonwoven fabric, or it may exist as an inorganic coating, an organic coating, or a thermosetting coating. In other cases, the skin 660 may contain a limiting oxygen index greater than about 22 when measured according to ISO 4589 dated 1996. If a thermoplastic film is present as (or as part of) the skin 660, the thermoplastic film may contain at least one of poly(etherimide), poly(etherketone), poly(ether-etherketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ethersulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. If a fibrous scrim is present as (or as part of) the skin 660, the fibrous scrim may contain at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallated synthetic fibers, and metallated inorganic fibers. If a thermosetting coating is present as (or as part of) the skin 660, the thermosetting coating may contain at least one of unsaturated polyurethane, vinyl ester, phenolic, and epoxy. If an inorganic coating is present as (or as part of) the skin 660, the inorganic coating may contain minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or it may contain at least one of gypsum, calcium carbonate, and mortar.If a nonwoven fabric is present as (or as part of) the skin 660, the nonwoven fabric may include thermoplastic materials, thermosetting bonding agents, inorganic fibers, metallic fibers, metallized inorganic fibers, and metallized synthetic fibers. If desired, the skin 660 may also include lofting agents.

[0105] In certain cases, layer 660 may be configured as a decorative layer. The decorative layer 660 may be formed from a thermoplastic film such as polyvinyl chloride, polyolefin, thermoplastic polyester, or thermoplastic elastomer. The decorative layer 560 may include carpet, rubber, or other aesthetic coverings. The decorative layer 660 may also be a multilayer structure including a foam core formed from, for example, polypropylene, polyethylene, polyvinyl chloride, or polyurethane. Fabrics such as woven fabrics made from natural and synthetic fibers, organic fiber nonwovens after needle punching, napped fabrics, knitted products, flocked fabrics, or other such materials may be bonded to the foam core. The fabrics may also be bonded to the foam core with thermoplastic adhesives including pressure-sensitive adhesives and hot-melt adhesives such as polyamide, modified polyolefin, urethane, and polyolefin. The decorative layer 660 may also be manufactured using spunbond, heat bonding, spunlace, meltblown, wet-laid, and / or dry-laid processes. Although not shown in the diagram, if desired, a skin, such as a scrim, film, or decorative layer, can also be bonded to layer 630.

[0106] In some embodiments, the fiber-reinforced thermoplastic layers described herein may include additional materials or additives to impart desired physical or chemical properties. For example, one or more dyes, texture modifiers, colorants, viscosity modifiers, fume suppressants, synergistic materials, lofting agents, particles, powders, biocides, foams, or other materials may be mixed with or added to the layer. In some cases, the layer may contain about 0.2% to about 10% by weight. The material may contain one or more smoke-blocking compositions in amounts of .Example smoke-blocking compositions include, but are not limited to, stanates, zinc borate, zinc molybdate, magnesium silicate, zinc calcium molybdate, calcium silicate, calcium hydroxide, and mixtures thereof. If desired, synergistic materials may be present to enhance the physical properties of the layer. If desired, synergistic materials may be present to enhance the lofting function.Example synergistic materials include, but are not limited to, sodium potassium trichlorobenzenesulfonate, diphenyl sulfon-3-sulfonate, and mixtures thereof.

[0107] In certain embodiments, each layer of a multilayer assembly may be manufactured individually and then assembled together to form the multilayer assembly. For example, each layer may be manufactured separately by wet-laid or other processes and then assembled together to provide the multilayer assembly. In the manufacture of the various fiber-reinforced thermoplastic layers described herein, it may be desirable to use a wet-laid process. For example, a liquid or fluid medium containing dispersed materials, e.g., thermoplastic material, fibers, and optionally lofting agent material together with any one or more additives described herein (e.g., other lofting agents or flame retardants), may be stirred or agitated in the presence of a gas, e.g., air or other gas. The dispersion may then be placed on a support, e.g., a wire screen or other support material. The stirred dispersion may contain one or more activators, such as anionic, cationic, or nonionic activators, e.g., those sold by Industrial Soaps Ltd. under the name ACE Liquid, those sold by Glover Chemicals Ltd. as TEXOFOR® FN 15 material, and those sold by Float-Ore Ltd. as AMINE Fb 19 material. The components may be added in the presence of air to a mixing tank, flotation cell, or other suitable apparatus to provide the dispersion. While the use of an aqueous dispersion is preferred, one or more non-aqueous fluids may also be present to aid dispersion, alter the viscosity of the fluid, or impart any desired physical or chemical properties to the dispersion or layer.

[0108] In certain cases, after the dispersion has been mixed for a sufficient period of time, the material-dispersed fluid can be placed on a screen, and a wire or other suitable support structure can be moved to provide a web of the material on top. The web may be subjected to suction or reduced pressure to remove any liquid from the material on top, leaving the thermoplastic material, lofting agent, and any other materials present, such as fibers, additives, etc. The resulting web can be dried, solidified, pressed, lofted, laminated, sized, or otherwise further processed to provide the desired layer or article. In some cases, additives or additional lofting agent materials can be added before drying, solidifying, pressing, lofting, laminating, sizing, or otherwise further processed to provide the desired layer or article. In other cases, the lofting agent can be added to the web after drying, solidifying, pressing, lofting, laminating, sizing, or otherwise further processed to provide the desired layer or article. While a wet-laid process can be used, depending on the properties of the thermoplastic material, lofting agent material, and other materials present, it may be preferable to use an air-laid process, dry-blending process, curging and needleing process, or other known processes used in the production of nonwovens instead.

[0109] In some configurations, the fiber-reinforced thermoplastic layers described herein can be produced by mixing a thermoplastic material, fibers, and an optional microsphere lofting agent in an aqueous solution or foam in the presence of a surfactant. By mixing or stirring the mixed components for a sufficient amount of time, the various materials can be dispersed, providing a substantially homogeneous aqueous mixture of the materials. The dispersed mixture can then be used to support any suitable support structure, for example, a desired multilayer structure. The material is placed on a wire mesh or other mesh or support having porosity. Water can then be drained through the wire mesh to form a web. The web is dried and heated above the softening point of the thermoplastic powder. The web is then cooled and pressed to a predetermined thickness to produce a composite sheet having a porosity of about 1 percent to about 95 percent. In alternative embodiments, the aqueous foam also includes a bonding material. In some configurations, after heating the web above the softening point of the thermoplastic powder, an adhesive layer containing a thermoplastic polymer and a thermosetting material can be placed on the web.

[0110] In certain embodiments, one or more of the fiber-reinforced thermoplastic layers can be manufactured in the form of GMT. In certain cases, GMT can generally be manufactured using chopped glass fibers, thermoplastic material, lofting agent, and any thermoplastic polymer film(s), and / or glass fiber or thermoplastic resin fiber, such as woven or nonwoven fabrics made from polypropylene (PP), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycarbonate (PC), PC / PBT blends, or PC / PET blends. In some embodiments, PP, PBT, PET, PC / PET blends, or PC / PBT blends can be used as the resin. To manufacture a glass mat, the thermoplastic material, reinforcing material, lofting agent, and / or other additives can be added to or weighed into a dispersed foam placed in an open-top mixing tank equipped with an impeller. While we do not wish to be bound by any particular theory, the presence of trapped air pockets in the foam may aid in the dispersion of the glass fibers, thermoplastic material, and lofting agent. In some embodiments, the dispersion mixture of glass and resin may be pumped via a dispersion manifold to a headbox located above the wire section of the paper machine. As the dispersion mixture is fed to a movable wire screen using vacuum to continuously produce a uniform fibrous wet web, foams rather than glass fibers, lofting agents, or thermoplastics can be removed. To reduce the moisture content and melt or soften the thermoplastic material, the wet web can be passed through a dryer at a suitable temperature. Once the hot web has emerged from the dryer, a surface layer, such as an adhesive layer containing a thermoplastic polymer and a thermosetting material, can be applied to the web by passing the web of glass fibers, lofting agents, thermoplastics, and film through the nip of a heated set of rollers, followed by spraying an adhesive onto the web surface. If desired, additional layers, such as nonwoven and / or woven or skin layers, can also be attached to one or both sides of the web to facilitate handling of the glass fiber reinforced mat.Next, the composite can be passed through a tension roll and then continuously cut (guillotine cut) to the desired size to form the final product. Further information relating to the manufacture of such GMT composites, including preferred materials and processing conditions used to form such composites, is described, for example, in U.S. Patent Nos. 6,923,494, 4,978,489, 4,944,843, 4,964,935, 4,734,321, 5,053,449, 4,925,615, 5,609,966, as well as U.S. Patent Application Publications US 2005 / 0082881, US 2005 / 0228108, US 2005 / 0217932, US 2005 / 0215698, US 2005 / 0164023, and US 2005 / 0161865.

[0111] In some cases, each fiber-reinforced thermoplastic layer can be formed separately as a sheet, and then the sheets are used to provide a multilayer article. For example, a first fiber-reinforced thermoplastic sheet having low lofting capacity can be produced using a wet-laid process. A second fiber-reinforced thermoplastic sheet having higher lofting capacity than the first sheet can also be produced using a wet-laid process. Each sheet may be treated before being joined together. For example, each sheet may be compressed to provide a desired thickness. One or more of the manufactured fiber-reinforced thermoplastic sheets are then used. These can be bonded to the core layer of the multilayer assembly described herein. The bonding process can vary, but in some cases, a single first fiber-reinforced thermoplastic sheet is heated to a temperature at which the thermoplastic component softens. The heated fiber-reinforced thermoplastic sheet can then be bonded to the core layer. If desired, a second fiber-reinforced thermoplastic sheet, which may be the same as or different from the first fiber-reinforced thermoplastic, is placed on the other surface of the core layer. Any additional heating is applied to soften the placed second fiber-reinforced thermoplastic sheet. The bonded two or three layers can then be compressed or further processed. Processes such as molding, thermoforming, etc., may be used to apply pressure and / or heat to help bond the sheets together and / or impart a desired shape to the article.

[0112] Articles described herein can be processed using preferred processes to achieve a desired configuration or shape, such processes include, but are not limited to, casting, thermoforming, deep drawing, or other forming processes. In some cases, such processes are used to impart a desired configuration and / or to loft various layers of the article. For example, if an article is designed to function as a vehicle floor, the floor can be shaped and / or cut in a desired manner. Referring to Figure 7, the vehicle floor 700 is shown as being disposed on and coupled to a vehicle frame, which includes components 705a, 705b. The floor 700 is generally a flat structure comprising one or more multilayer assemblies described herein, e.g., those illustrated and described in relation to Figures 1 to 6C, or other similar multilayer assemblies that would be selected by a person skilled in the art in consideration of the interests of this disclosure. The floor 700 can be bonded to the frame via preferred fasteners such as bolts, screws, etc., and optionally with one or more adhesives. In some cases, vehicle doors, roof assemblies, and other components may be disposed on the floor 700 to provide a passenger compartment. If desired, carpets, foam padding, or the like may be combined with the floor 700 for aesthetic or other reasons.

[0113] In some embodiments, a loading floor for a rear storage compartment may be manufactured using the articles described herein. Referring to Figure 8, a side view of a deep-drawn article 800 that can be used as a loading floor is shown. The article 800 is typically positioned at the rear of a vehicle, for example, in the rear storage compartment of a sports utility vehicle or minivan, and is designed to accommodate components, tools, luggage, a spare tire, etc. A lid or cover (not shown) may also be present to enclose the components within the loading floor 800 and conceal them from view. The loading floor 800 may include, for example, a multilayer assembly described herein, for example, those illustrated and described in relation to Figures 1 to 6C, or any other similar multilayer assembly that would be selected by a person skilled in the art in consideration of the interests of this disclosure. In some cases, the loading floor 800 provides sufficient weight-bearing capacity, and therefore there is no need for any underlying support members to support the vehicle.

[0114] In some embodiments, the loading floor may include structural members or slats to provide additional strength, if desired. For example, one, two, three, or more metal rods or members can be positioned within the loading floor, e.g., within the core layer or any other layer, to provide additional strength. A particular configuration of the loading floor may provide deflection not exceeding a desired amount when tested under a selected weight, e.g., using ASTM D790-10 dated April 1, 2010. If a particular loading floor configuration deflects by a desired amount, e.g., more than 10 mm under a 100 kg load, the core layer or other layers can be modified, e.g., by changing the material and / or by including structural members, to provide a loading floor that meets the desired specifications.

[0115] In some embodiments, the articles described herein are vehicle exteriors or ship hulls, for example, The panels may be configured in the form of exterior panels for creation vehicles, boat hulls, or other structural panels that may need to withstand some weight or force. The panels are particularly desirable for use in humid environments because the core layer is generally not sensitive to contact with water, and its properties do not change to a substantial degree when it comes into contact with water.

[0116] In certain embodiments, the articles described herein may be in the form of interior wall, ceiling, or floor panels of a vehicle, for example, interior wall, ceiling, or floor panels of a recreational vehicle that may need to withstand some weight or force. The panels are particularly desirable for use in humid environments, because the core layer is generally not sensitive to contact with water and its properties do not change substantially when in contact with water.

[0117] In other configurations, the articles described herein can be used as structural components of a vehicle. For example, the articles may be present in the cabin berths of road vehicles and recreational vehicles, and can be used in folding beds, folding or configurable dinettes that can form a bed, and other uses where a person can sleep. In some embodiments, the articles can be present in slide-out structures of recreational vehicles (RVs) designed to provide increased interior space away from the exterior of the RV. The lightweight nature of the articles can reduce the overall weight of the slide-out structure and reduce stress on the gears and motors used to extend and retract the slide-out structure. In addition, the water resistance of the articles can provide a sliding ceiling that can withstand warping and mold growth.

[0118] In certain embodiments, the exact properties of the core layer and other selected layers may vary, at least in part, depending on the desired acoustic properties of the article comprising the various layers. For example, a particular configuration of the core layer described herein may provide excellent sound absorption but may not have the desired sound insulation properties. By selecting the skin or other layers such that their acoustic properties complement those of the core layer, a composite structure with good sound absorption and sound insulation can be provided.

[0119] In some embodiments, the core layer of the articles described herein can be water-resistant. For example, in many configurations of loading beds, the core layer can be made of a paper-based material. Contact with water can significantly reduce the strength of the core layer and may promote mold growth. By using the core layer described herein, contact with water does not alter the overall strength of the article.

[0120] In describing elements of the embodiments disclosed herein, the articles “a,” “an,” “the,” and “the” are intended to mean that there are one or more elements. The terms “comprising, including” and “having” are intended to be non-restrictive and mean that there may be additional elements other than those listed. In light of the interests of this disclosure, it will be recognized by those skilled in the art that various components of the embodiments can be interchanged or substituted with various components of other embodiments.

[0121] While specific aspects, examples, and embodiments have been described above, those skilled in the art will recognize that additions, substitutions, modifications, and changes are possible to the exemplary aspects, examples, and embodiments disclosed, in accordance with the interests of this disclosure.

Claims

1. It is a multilayer assembly, A core layer containing closed-cell material, A first reinforced thermoplastic layer disposed on the first surface of the core layer, wherein the first fiber-reinforced thermoplastic layer includes a web with an open-cell structure formed by a plurality of reinforcing materials joined together by a thermoplastic material, A multilayer assembly comprising: a second reinforced thermoplastic layer disposed on a second surface of the core layer, wherein the second fiber-reinforced thermoplastic layer includes a web of open-cell structure formed by a plurality of reinforcing materials joined together by a thermoplastic material.

2. The multilayer assembly according to claim 1, wherein the closed-cell material is not a polyurethane foam, or the core layer does not contain cellulose.

3. The multilayer assembly according to claim 1, wherein the core layer comprises a polyurethane material or a cellulosic material.

4. The multilayer assembly according to claim 1, wherein the basis weight of the first reinforced thermoplastic layer is substantially the same as the basis weight of the second reinforced thermoplastic layer.

5. The multilayer assembly according to claim 1, wherein the basis weight of the first reinforced thermoplastic layer is different from the basis weight of the second reinforced thermoplastic layer.

6. The multilayer assembly according to claim 1, wherein the disposed first reinforced thermoplastic layer comprises at least one reinforcing material different from the reinforcing material of the disposed second reinforced thermoplastic layer.

7. The multilayer assembly according to claim 1, wherein the closed-cell material of the core layer includes a directional compression foam selected from the group consisting of directional compression expandable polystyrene foam, directional compression extruded polyethylene foam, and directional compression expandable polypropylene foam.

8. The multilayer assembly according to claim 1, wherein the thermoplastic material of the first reinforced thermoplastic layer is different from the thermoplastic material of the second reinforced thermoplastic layer.

9. The multilayer assembly according to claim 1, wherein the thermoplastic material of the first reinforced thermoplastic layer and the second reinforced thermoplastic layer are the same.

10. The multilayer assembly according to claim 9, wherein the reinforcing material of the first reinforcing thermoplastic layer and the second reinforcing thermoplastic layer are the same.

11. The multilayer assembly according to claim 10, wherein the reinforcing material of the first reinforcing thermoplastic layer and the second reinforcing thermoplastic layer each comprises reinforcing fibers.

12. The multilayer assembly according to claim 11, wherein the first fiber-reinforced thermoplastic layer includes at least one reinforcing fiber different from the reinforcing fibers of the second fiber-reinforced thermoplastic layer.

13. The multilayer assembly according to claim 11, wherein one or both of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer contain a lofting agent.

14. The lofting agent comprises at least one of the expandable microspheres and expandable graphite material. A multilayer assembly according to claim 13, including the multilayer assembly described in claim 13.

15. The multilayer assembly according to claim 14, wherein no lofting agent is present in the core layer.

16. The multilayer assembly according to claim 11, wherein the thermoplastic material and reinforcing material of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer are selected to enable lofting of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer without the presence of a lofting agent.

17. The multilayer assembly according to claim 1, further comprising a first adhesive layer disposed on the first surface of the core layer between the first reinforced thermoplastic layer and the core layer.

18. The multilayer assembly according to claim 17, further comprising a second adhesive layer disposed on the second surface of the core layer between the second reinforced thermoplastic layer and the core layer.

19. The multilayer assembly according to claim 18, further comprising a decorative layer disposed on one of the first reinforced thermoplastic layer and the second reinforced thermoplastic layer.

20. The multilayer assembly according to claim 18, wherein the closed-cell material of the core layer comprises a directional compressible polystyrene foam, the first fiber-reinforced thermoplastic layer comprises polypropylene and glass fibers, the second fiber-reinforced thermoplastic layer comprises polypropylene and glass fibers, and the first and second adhesive layers each comprise a copolyamide.

21. It is a multilayer assembly, A core layer comprising a closed-cell material that does not contain any polyurethane or cellulose material, wherein the closed-cell material is substantially non-porous and provides directional compressive strength to the multilayer assembly, A first adhesive layer disposed on the first surface of the core layer, A second adhesive layer disposed on the second surface of the core layer, A first fiber-reinforced thermoplastic layer disposed on the first adhesive layer, wherein the first fiber-reinforced thermoplastic layer includes a web with an open-cell structure formed by a plurality of reinforcing fibers joined together with a thermoplastic material, A multilayer assembly comprising: a second fiber-reinforced thermoplastic layer disposed on the second adhesive layer, wherein the second fiber-reinforced thermoplastic layer includes a web of open-cell structure formed by a plurality of reinforcing fibers joined together with a thermoplastic material.

22. The multilayer assembly according to claim 21, wherein the core layer includes a directional compression foam.

23. The multilayer assembly according to claim 22, wherein the directional compression foam is selected from the group consisting of directional compression expandable polystyrene foam, directional compression extruded polyethylene foam, and directional compression expandable polypropylene foam.

24. The multilayer assembly according to claim 22, wherein the basis weight of the first fiber-reinforced thermoplastic layer is substantially the same as the basis weight of the second fiber-reinforced thermoplastic layer.

25. The multilayer assembly according to claim 22, wherein the basis weight of the first fiber-reinforced thermoplastic layer is different from the basis weight of the second fiber-reinforced thermoplastic layer.

26. The first fiber-reinforced thermoplastic layer provided is the second fiber-reinforced thermoplastic layer provided. The multilayer assembly according to claim 22, comprising at least one reinforcing fiber material different from the reinforcing fiber material of the layer.

27. The multilayer assembly according to claim 22, wherein the thermoplastic material of the first fiber-reinforced thermoplastic layer is different from the thermoplastic material of the second fiber-reinforced thermoplastic layer.

28. The multilayer assembly according to claim 22, wherein the thermoplastic material of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer are the same.

29. The multilayer assembly according to claim 28, wherein the reinforcing fibers of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer are the same.

30. The multilayer assembly according to claim 29, wherein the first fiber-reinforced thermoplastic layer further comprises at least one reinforcing fiber different from the reinforcing fibers of the second fiber-reinforced thermoplastic layer.

31. The multilayer assembly according to claim 30, wherein one or both of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer contain a lofting agent.

32. The multilayer assembly according to claim 31, wherein the lofting agent comprises at least one of expandable microspheres and expandable graphite material.

33. The multilayer assembly according to claim 32, wherein no lofting agent is present in the core layer.

34. The multilayer assembly according to claim 22, wherein the thermoplastic material and reinforcing material of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer are selected to enable lofting of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer without the presence of a lofting agent.

35. The multilayer assembly according to claim 22, further comprising a skin layer disposed on one of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer, wherein the skin layer includes cloth, scrim, film, and combinations thereof.

36. The multilayer assembly according to claim 22, further comprising a decorative layer bonded to one of the first fiber-reinforced thermoplastic layer and the second reinforced thermoplastic layer.

37. The multilayer assembly according to claim 21, wherein the thermoplastic material of each of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer is independently selected from the group consisting of polyolefin materials, thermoplastic polyolefin blend materials, polyvinyl polymer materials, butadiene polymer materials, acrylic polymer materials, polyamide materials, polyester materials, polycarbonate materials, polyester carbonate materials, polystyrene materials, acrylonitrile styrene polymer materials, acrylonitrile-butyl acrylate-styrene polymer materials, polyetherimide materials, polyphenylene ether materials, polyphenylene oxide materials, polyphenylene sulfide materials, polyether materials, polyether ketone materials, polyacetal materials, polyurethane materials, polybenzimidazole materials, and copolymers and mixtures thereof.

38. The multilayer assembly according to claim 37, wherein the reinforcing material of each of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer is independently selected from the group consisting of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, inorganic fibers, natural fibers, mineral fibers, metal fibers, metallized inorganic fibers, metallized synthetic fibers, ceramic fibers, and combinations thereof.

39. The multilayer assembly according to claim 38, wherein the fibers present in each of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer independently include a diameter greater than about 5 microns and a length of about 5 mm to about 200 mm.

40. The multilayer assembly according to claim 22, wherein the directional compression foam is a directional compression expandable polystyrene foam, each of the first and second fiber-reinforced thermoplastic layers comprises polypropylene and glass fibers, the multilayer assembly further comprises a skin bonded to the second fiber-reinforced thermoplastic layer, and the multilayer assembly further comprises a decorative layer bonded to the skin.

41. A vehicle loading platform that provides structural reinforcement, A core layer containing closed-cell material, A first reinforced thermoplastic layer disposed on the first surface of the core layer, wherein the first fiber-reinforced thermoplastic layer includes a web with an open-cell structure formed by a plurality of reinforcing materials joined together by a thermoplastic material, A second reinforced thermoplastic layer disposed on the second surface of the core layer, wherein the second fiber-reinforced thermoplastic layer includes a web of open-cell structure formed by a plurality of reinforcing materials joined together by a thermoplastic material, A vehicle loading floor in which the core layer, the first reinforced thermoplastic layer, and the second reinforced thermoplastic layer together provide a vehicle loading floor that flexes by less than approximately 25 mm when weighing 220 kg or less.

42. The vehicle loading floor according to claim 41, further comprising a decorative layer bonded to the first reinforced thermoplastic layer.

43. The vehicle loading floor according to claim 42, wherein the decorative layer includes a carpet.

44. The vehicle loading floor according to claim 42, further comprising an adhesive layer between the decorative layer and the first reinforced thermoplastic layer.

45. The vehicle loading floor according to claim 42, further comprising a second decorative layer bonded to the second reinforced thermoplastic layer.

46. The vehicle loading floor according to claim 45, wherein the second decorative layer includes a carpet.

47. The vehicle loading floor according to claim 45, further comprising an adhesive layer between the second decorative layer and the second reinforcing thermoplastic layer.

48. The vehicle loading floor according to claim 41, wherein the loading floor flexes by less than approximately 15 mm with a weight of 100 kg, or less than approximately 15 mm with a weight of 150 kg, or less than approximately 10 mm with a weight of 100 kg, or less than approximately 5 mm with a weight of 220 kg.

49. The vehicle loading bed according to claim 41, wherein the thermoplastic material of the first reinforced thermoplastic layer comprises at least one thermoplastic material that is the same as or different from the thermoplastic material present in the second reinforced thermoplastic layer.

50. The vehicle loading bed according to claim 41, wherein the closed-cell material of the core layer comprises a directional compression foam selected from the group consisting of directional compression expandable polystyrene foam, directional compression extruded polyethylene foam, and directional compression expandable polypropylene foam.

51. The vehicle loading bed according to claim 50, wherein the thermoplastic material of each of the first fiber-reinforced layer and the second fiber-reinforced layer is independently selected from the group consisting of polyolefin materials, thermoplastic polyolefin blend materials, polyvinyl polymer materials, butadiene polymer materials, acrylic polymer materials, polyamide materials, polyester materials, polycarbonate materials, polyester carbonate materials, polystyrene materials, acrylonitrile styrene polymer materials, acrylonitrile-butyl acrylate-styrene polymer materials, polyetherimide materials, polyphenylene ether materials, polyphenylene oxide materials, polyphenylene sulfide materials, polyether materials, polyether ketone materials, polyacetal materials, polyurethane materials, polybenzimidazole materials, and copolymers and mixtures thereof.

52. The vehicle loading bed according to claim 51, wherein the thermoplastic material of each of the first fiber-reinforced layer and the second fiber-reinforced layer is independently a resin or a fiber.

53. The vehicle loading bed according to claim 51, wherein the reinforcing material of each of the first fiber-reinforced layer and the second fiber-reinforced layer is independently selected from the group consisting of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, inorganic fibers, natural fibers, mineral fibers, metal fibers, metallized inorganic fibers, metallized synthetic fibers, ceramic fibers, and combinations thereof.

54. The vehicle loading bed according to claim 53, wherein the fibers present in each of the first fiber-reinforced layer and the second fiber-reinforced layer include a diameter greater than about 5 microns and a length of about 5 mm to about 200 mm.

55. The vehicle loading floor according to claim 41, wherein the thermoplastic material present in each of the first fiber-reinforced layer and the second fiber-reinforced layer includes polypropylene, and the reinforcing material present in each of the first fiber-reinforced layer and the second fiber-reinforced layer is glass fiber.

56. The vehicle loading bed according to claim 55, wherein the basis weight of each of the first and second fiber-reinforced layers is approximately 500 gsm to approximately 3000 gsm, and the basis weight of the core layer is approximately 300 gsm to approximately 2000 gsm.

57. The vehicle loading floor according to claim 56, wherein at least one of the first and second fiber-reinforced layers comprises a lofting agent.

58. The vehicle loading floor according to claim 55, further comprising a carpet layer disposed on at least one of the first fiber-reinforced layer and the second fiber-reinforced layer.

59. The vehicle loading bed according to claim 55, wherein the first fiber-reinforced layer is bonded to the core layer via a first adhesive layer, and the second fiber-reinforced layer is bonded to the core layer via a second adhesive layer.

60. The vehicle loading bed according to claim 545, wherein the first fiber-reinforced layer and the second fiber-reinforced layer do not contain any lofting agent, and the thermoplastic material and reinforcing material of the first fiber-reinforced layer and the second fiber-reinforced layer are selected to enable lofting of the first fiber-reinforced layer and the second fiber-reinforced layer in the absence of a lofting agent in the first fiber-reinforced layer and the second fiber-reinforced layer.

61. A kit for manufacturing a vehicle loading platform, wherein the kit is A core layer, and a first reinforced thermoplastic layer separated from the core layer. 、 The core layer comprises a closed-cell material, The first reinforced thermoplastic layer comprises a core layer and a first reinforced thermoplastic layer, which includes a web of open-cell structure formed by a plurality of reinforcing materials joined together by a thermoplastic material. A kit comprising instructions for bonding the first reinforced thermoplastic core layer to the first surface of the core layer.

62. The kit according to claim 61, further comprising a second reinforcing thermoplastic layer separate from the core layer and the first reinforcing thermoplastic layer.

63. The kit according to claim 62, wherein the first reinforced thermoplastic layer of the kit is the same as the second reinforced thermoplastic layer of the kit.

64. The kit according to claim 62, wherein the basis weight of the first reinforced thermoplastic layer of the kit is different from the basis weight of the second reinforced thermoplastic layer of the kit.

65. The kit according to claim 61, further comprising a decorative layer separate from the core layer and the first reinforced thermoplastic layer.

66. The kit according to claim 61, further comprising an adhesive material effective for bonding the first reinforced thermoplastic layer to the core layer.

67. The kit according to claim 61, further comprising an epidermal layer.

68. The kit according to claim 67, wherein the surface layer is selected from the group consisting of cloth, scrim, film, and combinations thereof.

69. The kit according to claim 61, wherein the closed-cell material of the core layer comprises a directional compression foam selected from the group consisting of directional compression expandable polystyrene foam, directional compression extruded polyethylene foam, and directional compression expandable polypropylene foam.

70. The kit according to claim 69, wherein the core layer is configured as a planar sheet.

71. A method for forming a multilayer assembly, The process involves forming a reinforced thermoplastic layer, Mixing thermoplastic polymers, reinforcing fibers, and lofting agents in an aqueous solution. The aqueous solution containing the thermoplastic polymer, reinforcing fibers, and lofting agent is mixed to disperse the reinforcing fibers and lofting agent in the thermoplastic polymer, thereby providing an aqueous foam dispersion. Distributing the aqueous foam dispersion on the forming element, The liquid is removed from the aqueous foam provided, and a reinforced thermoplastic layer is formed by providing a web containing the thermoplastic polymer, the reinforcing fibers, and the lofting agent. A method comprising distributing the provided reinforced thermoplastic layer on a first surface of a core layer containing a closed-cell material.

72. Before distributing the provided reinforced thermoplastic layer on the first surface of the core layer, the softening temperature of the thermoplastic polymer in the web of the provided reinforced thermoplastic layer is exceeded. The method according to claim 71, further comprising heating the provided reinforced thermoplastic layer.

73. The method according to claim 71, further comprising distributing an adhesive layer on the first surface of the core layer before distributing the provided reinforced thermoplastic layer on the first surface of the core layer.

74. The method according to claim 71, further comprising distributing an adhesive layer on the surface of the provided reinforced thermoplastic layer before distributing the provided reinforced thermoplastic layer on the first surface of the core layer.

75. The method according to claim 74, further comprising disposing a second adhesive layer on the second surface of the core layer.

76. The method according to claim 75, further comprising disposing another reinforced thermoplastic layer on the disposed second adhesive layer.

77. The method according to claim 74, further comprising disposing a second adhesive layer on the surface of another reinforced thermoplastic layer.

78. The method according to claim 77, further comprising arranging the other reinforced thermoplastic layer on the core layer and bonding the core layer to the other reinforced thermoplastic layer via the second adhesive layer.

79. The method according to claim 71, further comprising heating the provided reinforced thermoplastic sheet to loft the provided reinforced thermoplastic sheet.

80. The method according to claim 71, further comprising configuring the core layer to include a directional compression foam selected from the group consisting of directional compression expandable polystyrene foam, directional compression extruded polyethylene foam, and directional compression expandable polypropylene foam.

81. A wall for a recreational vehicle comprising a multi-layer assembly according to any one of claims 1 to 50 or 93 to 96.

82. A ceiling for a recreational vehicle comprising a multilayer assembly according to any one of claims 1 to 50 or 93 to 96.

83. A slide-out assembly for a recreational vehicle comprising a multilayer assembly according to any one of claims 1 to 50 or 93 to 96.

84. A sleeper cab bed comprising a multilayer assembly according to any one of claims 1 to 50 or 93 to 96.

85. An exterior panel comprising a multilayer assembly according to any one of claims 1 to 50 or 93 to 96.

86. A roofing panel comprising a multilayer assembly according to any one of claims 1 to 50 or 93 to 96.

87. A flooring panel comprising a multilayer assembly according to any one of claims 1 to 50 or 93 to 96.

88. A loading floor for an automobile comprising a multi-layer assembly according to any one of claims 1 to 50 or 93 to 96.

89. A vehicle having an automobile loading floor comprising a multi-layer assembly according to any one of claims 1 to 50 or 93 to 96.

90. A vehicle having a vehicle loading bed according to any one of claims 51 to 60 or 97 or 98.

91. A tire cover comprising a multilayer assembly according to any one of claims 1 to 50 or 93 to 96.

92. A deck comprising a multilayer assembly according to any one of claims 1 to 50.

93. The multilayer assembly according to claim 1, wherein at least one of the core layer, the first reinforced thermoplastic layer, and the second reinforced thermoplastic layer includes a flame-retardant material.

94. The multilayer assembly according to claim 93, wherein the flame retardant material comprises one or more of an expandable graphite material, magnesium hydroxide, and aluminum hydroxide.

95. The multilayer assembly according to claim 21, wherein at least one of the core layer, the first reinforced thermoplastic layer, and the second reinforced thermoplastic layer includes a flame-retardant material.

96. The multilayer assembly according to claim 95, wherein the flame-retardant material comprises one or more of an expandable graphite material, magnesium hydroxide, and aluminum hydroxide.

97. The vehicle loading bed according to claim 41, wherein at least one of the core layer, the first reinforced thermoplastic layer, and the second reinforced thermoplastic layer comprises a flame-retardant material.

98. The vehicle loading bed according to claim 97, wherein the flame-retardant material comprises one or more of an expandable graphite material, magnesium hydroxide, and aluminum hydroxide.

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