Method and system for manufacturing lightweight reinforced thermoplastic articles

Abstract

Methods and systems for manufacturing lightweight, reinforced thermoplastic articles are described. [Solution] In some embodiments, the method includes heating and pressing a core layer, and then cooling and pressing the core layer to maintain its thickness during cooling. Automotive articles, building articles, and recreational vehicle articles that can be manufactured using this method and system are also described.

Description

[Technical Field]

[0001] Priority Claim This application claims priority to and benefits of U.S. Provisional Patent Application No. 62 / 982,406, filed on 27 February 2020, the entire disclosure of which is incorporated herein by reference.

[0002] Technical field The specific configurations described herein relate to methods for manufacturing lightweight reinforced thermoplastic articles. In some cases, the articles may be manufactured using two or more presses. [Background technology]

[0003] background Lightweight reinforced thermoplastic (LWRT) articles or composites are widely used in many industries as a result of being lightweight yet still possessing the desired mechanical properties. [Overview of the Initiative]

[0004] overview Specific aspects of a process for manufacturing LWRT articles using a first press and a second press are described. LWRT articles can be manufactured automatically using an in-line system designed to perform the process.

[0005] In one embodiment, an in-line process for manufacturing a lightweight thermoplastic composite article using an in-line system is described. In a particular configuration, the in-line process includes combining a reinforcing material and a thermoplastic material in a liquid to produce an aqueous foam, and depositing the aqueous foam onto a moving support of the in-line system. The process may also include removing the liquid from the deposited aqueous foam on the moving support to form a web of open-cell structure formed from the thermoplastic material and the reinforcing material. The method may also include providing the web formed on the moving support of the in-line system to a first press device of the in-line system at a first pressure and a first temperature, and using the first press device to apply heat and pressure to the formed web, the first temperature and first pressure being selected to melt the thermoplastic material of the formed web. This method may also include providing a heated web to a second press in an in-line system at a second temperature and a second pressure, and using the second press to cool the heated web, wherein the second temperature is below the melting point of the thermoplastic material of the heated web, and the second pressure is less than or equal to the first pressure, and by cooling the heated web using the second press, a cooled web having substantially the same thickness as the heated web is provided. This method may also include discharging the cooled web from the in-line system to provide a lightweight thermoplastic composite article.

[0006] In certain configurations, the first pressure is greater than 1.1 bar, or approximately 2 bar to approximately 30 bar, or approximately 3 bar to approximately 25 bar, or approximately 3 bar to approximately 15 bar. In other examples, the first temperature is approximately 170°C to approximately 250°C, or approximately 170°C to approximately 240°C, or approximately 170°C to approximately 230°C, or approximately 170°C to approximately 220°C, or approximately 170°C to approximately 210°C, or approximately 170°C to approximately 200°C. In some examples, the second temperature is below the melting temperature of the thermoplastic material, or below 170°C, or below 160°C, or below 150°C, or below 140°C, or below 130°C, or below 120°C, or below 110°C, or below 90°C, or below 80°C, or below 70°C, or below 60°C, or below 50°C, or below 45°C, or between 5°C and 45°C. In some embodiments, the method includes cutting a cooling web into individual lightweight thermoplastic composite articles using an in-line system and discharging the individual lightweight thermoplastic composite articles from the in-line system. In some configurations, a first press device is configured to apply pressure to the heating web at a first temperature and a first pressure by sandwiching the formed web between an upper plate and a lower plate. In other configurations, a second press device is configured to apply pressure to the heating web at a second temperature and a second pressure by sandwiching the heating web between an upper plate and a lower plate.

[0007] In some examples, the first press apparatus comprises an upper roller set and a lower roller set, with a space between the upper and lower roller sets of the first press apparatus, and each of the plurality of upper rollers and plurality of lower rollers of the first press apparatus is heated to a first temperature and used together to apply a first pressure to the formed web as the formed web passes between the upper and lower roller sets of the first press apparatus.

[0008] In another example, the second press device comprises an upper roller set and a lower roller set, with a space between the upper and lower roller sets of the second press device, and each of the multiple upper rollers and multiple lower rollers of the second press device is cooled to a second temperature and used together to apply a second pressure to the heated web received from the first press device as the heated web passes between the upper and lower roller sets of the second press device.

[0009] In some embodiments, the system includes at least one set of rollers for selecting the thickness of the formed web before providing the formed web to a first press device.

[0010] In another embodiment, an in-line process for manufacturing a lightweight thermoplastic composite article using an in-line system comprises: combining a reinforcing material and a thermoplastic material in a liquid to produce an aqueous foam; depositing the aqueous foam on a moving support of the in-line system; removing the liquid from the deposited aqueous foam on the moving support to form a web of open-cell structure formed from the thermoplastic material and the reinforcing material; placing a first skin on a first surface of the formed web; and providing the formed web and the placed first skin on the moving support of the in-line system to a first press device of the in-line system, and using the first press device to press the formed at a first temperature and a first pressure. The invention provides a method for providing a lightweight thermoplastic composite article by applying heat and pressure to a web and a placed first skin, wherein the first temperature and first pressure are selected to melt the thermoplastic material of the formed web; providing the heated web and the placed first skin to a second press device of an in-line system at a second temperature to cool the heated web and the placed skin; applying pressure to the heated web at a second pressure using the second press device to cool the heated web, thereby providing a cooled web having substantially the same thickness as the heated web, wherein the second pressure is less than or equal to the first pressure; and discharging the cooled web from the in-line system to provide a lightweight thermoplastic composite article.

[0011] In certain configurations, the first pressure is greater than 1.1 bar, or about 2 to 30 bar, or about 3 to 25 bar, or about 3 to 15 bar. In other examples, the first temperature is about 170°C to 250°C, or about 170°C to 240°C, or about 170°C to 230°C, or about 170°C to 220°C, or about 170°C to 210°C, or about 170°C to 200°C. In some examples, the second temperature is below the melting temperature of the thermoplastic material, or below 170°C, or below 160°C, or below 150°C, or below 140°C, or below 130°C, or below 120°C. The temperature is full, or less than 110°C, or less than 90°C, or less than 80°C, or less than 70°C, or less than 60°C, or less than 50°C, or less than 45°C, or between 5°C and 45°C. In some embodiments, the method includes cutting the cooling web into individual lightweight thermoplastic composite articles using an in-line system and discharging the individual lightweight thermoplastic composite articles from the in-line system. In some configurations, a first press device is configured to apply pressure to the heating web at a first temperature and a first pressure by sandwiching the formed web between an upper plate and a lower plate. In other configurations, a second press device is configured to apply pressure to the heating web at a second temperature and a second pressure by sandwiching the heating web between an upper plate and a lower plate.

[0012] In some examples, the first press apparatus comprises an upper roller set and a lower roller set, with a space between the upper and lower roller sets of the first press apparatus, and each of the plurality of upper rollers and plurality of lower rollers of the first press apparatus is heated to a first temperature and used together to apply a first pressure to the formed web as the formed web passes between the upper and lower roller sets of the first press apparatus.

[0013] In another example, the second press device comprises an upper roller set and a lower roller set, with a space between the upper and lower roller sets of the second press device, and each of the multiple upper rollers and multiple lower rollers of the second press device is cooled to a second temperature and used together to apply a second pressure to the heated web received from the first press device as the heated web passes between the upper and lower roller sets of the second press device.

[0014] In some embodiments, the system includes at least one set of rollers for selecting the thickness of the formed web before providing the formed web to a first press device.

[0015] In other configurations, the method includes placing a second skin on a second surface of a formed web before providing the formed web and the placed first skin to a first press device.

[0016] In some embodiments, the first pressure is greater than 1.1 bar, or is about 2 bar to about 30 bar, or is about 3 bar to about 25 bar, or is about 3 bar to about 15 bar. In other examples, the first temperature is about 170°C to about 250°C, or about 170°C to about 240°C, or about 170°C to about 230°C, or about 170°C to about 220°C, or about 170°C to about 210°C, or about 170°C to about 200°C. In some examples, the second temperature is less than the melting temperature of the thermoplastic material, or less than 170°C, or less than 160°C, or less than 150°C, or less than 140°C, or less than 130°C, or less than 120°C, or less than 110°C, or less than 90°C, or less than 80°C, or less than 70°C, or less than 60°C, or less than 50°C, or less than 45°C, or is 5°C to 45°C. In some embodiments, the method includes cutting a cooling web into individual lightweight thermoplastic composite articles using an in-line system and discharging the individual lightweight thermoplastic composite articles from the in-line system. In some configurations, the first press device is configured to apply pressure to the heated web at the first temperature and the first pressure by sandwiching the formed web between an upper plate and a lower plate. In other configurations, the second press device is configured to apply pressure to the heated web at the second temperature and the second pressure by sandwiching the heated web between an upper plate and a lower plate.

[0017] In some examples, the first press device includes an upper roller set and a lower roller set and there is a space between the upper roller set and the lower roller set of the first press device, and each of the plurality of upper rollers and the plurality of lower rollers of the first press device is heated to the first temperature and is used together to apply the first pressure to the formed web as the formed web passes between the upper roller set and the lower roller set of the first press device.

[0018] In other examples, the second pressing device includes an upper roller set and a lower roller set, there is a space between the upper roller set and the lower roller set of the second pressing device, and each of the plurality of upper rollers and the plurality of lower rollers of the second pressing device is cooled to a second temperature and is used together to apply a second pressure to the heated web received from the first pressing device when the heated web passes between the upper roller set and the lower roller set of the second pressing device.

[0019] In some embodiments, the system includes at least one roller set for selecting the thickness of the formed web before providing the web formed on the first pressing device.

[0020] In other configurations, the method includes disposing a second skin on a second surface of the formed web before providing the formed web and the disposed first skin to the first pressing device.

[0021] In another aspect, an in-line system for manufacturing lightweight thermoplastic materials includes a mixing reservoir configured to receive a thermoplastic material and a reinforcing material and provide a substantially homogeneous dispersion of the thermoplastic material and the reinforcing material. The system can also include a moving support fluidly coupled to the mixing reservoir and configured to receive the substantially homogeneous dispersion from the mixing reservoir. The system can also include a pressure device configured to remove liquid from the dispersion received by the moving support and provide a web of continuous cellular structure formed from the thermoplastic material and the reinforcing material. The system can also include a first pressing device configured to receive the formed web and provide heat and pressure to the formed web using a first temperature and a first pressure. The system can also include a second pressing device configured to receive the heated web from the first pressing device and cool the heated web using a second temperature and a second pressure.

[0022] In certain embodiments, the second press device is configured to cool the web at a second pressure to prevent any substantial change in the thickness of the heated web after it has been heated and pressed using the first press device.

[0023] In other embodiments, the first press apparatus comprises an upper roller set and a lower roller set, with a space between the upper and lower roller sets of the first press apparatus, and each of the plurality of upper rollers and the plurality of lower rollers of the first press apparatus is heated to a first temperature and used together to apply a first pressure to the formed web as the formed web passes between the upper and lower roller sets of the first press apparatus.

[0024] In some configurations, the second press and the second press are equipped with an upper roller set and a lower roller set, with a space between the upper and lower roller sets of the second press, and each of the multiple upper rollers and multiple lower rollers of the second press is cooled to a second temperature and used together to impart a second pressure to the heated web received from the first press as the heated web passes between the upper and lower roller sets of the second press.

[0025] In additional configurations, the first and second press devices are part of the belt feeder device. In some examples, the first press device comprises upper and lower plates that clamp the formed web on the belt feeder device. In additional examples, the second press device comprises upper and lower plates that clamp the heated web on the belt feeder device.

[0026] In some embodiments, the first and second pressing devices are configured to clamp the formed web in a direction parallel to the direction of movement of the moving support.

[0027] In certain embodiments, at least one of the first and second pressing devices is configured to clamp the formed web in a direction not parallel to the direction of movement of the moving support.

[0028] In another example, the system includes a roller set configured to select the thickness of the formed web before providing it to a first press device.

[0029] In some examples, a system for manufacturing lightweight thermoplastic composite articles comprises a first subsystem comprising a mixing reservoir configured to receive thermoplastic material and reinforcing material and provide a substantially homogeneous dispersion of the thermoplastic material and reinforcing material; a mobile support fluidly coupled to the mixing reservoir and configured to receive the substantially homogeneous dispersion from the mixing reservoir; and a pressure device configured to remove liquid from the dispersion received by the mobile support and provide a web of open-cell structure formed from the thermoplastic material and reinforcing material. A second subsystem comprises a first press device configured to receive the formed web from the first subsystem and to apply heat and pressure to the formed web using a first temperature and a first pressure; and a second press device configured to receive the heated web from the first press device and to cool the heated web using a second temperature and a second pressure.

[0030] In a particular configuration, the second press is configured to cool the web at a second pressure to prevent any substantial change in the thickness of the heated web after it has been heated and pressed using the first press. In other configurations, the first press comprises an upper roller set and a lower roller set, with a space between the upper and lower roller sets of the first press, and each of the multiple upper rollers and multiple lower rollers of the first press is heated to a first temperature and used together to apply a first pressure to the formed web as it passes between the upper and lower roller sets of the first press. In some embodiments, the second press apparatus comprises an upper roller set and a lower roller set, with a space between the upper and lower roller sets of the second press apparatus, and each of the plurality of upper rollers and plurality of lower rollers of the second press apparatus is cooled to a second temperature and used together to impart a second pressure to the heated web received from the first press apparatus as the heated web passes between the upper and lower roller sets of the second press apparatus.

[0031] In certain examples, the first and second presses are part of a belt feeder device. In some examples, the first presse comprises upper and lower plates that clamp the formed web on the belt feeder device. In other examples, the second presse comprises upper and lower plates that clamp the heated web on the belt feeder device. In some embodiments, the first and second presses are each configured to clamp the formed web in a direction parallel to the direction of movement of the moving support. In other embodiments, at least one of the first and second presses is configured to clamp the formed web The web is configured to be clamped in a direction not parallel to the direction of movement of the moving support. In some examples, the system includes a roller set configured to select the thickness of the formed web before providing the formed web to a second subsystem.

[0032] In an additional embodiment, a process for forming a lightweight thermoplastic composite article comprising a web having an open-cell structure formed from a reinforcing material held in place by a thermoplastic material comprises heating the web to a first temperature above the melting point of the thermoplastic material, applying a first pressure at the first temperature to provide a heated web having a first thickness, cooling the heated web to a second temperature below the melting point of the thermoplastic material, and applying a second pressure at the second temperature to cool the heated web and provide a lightweight thermoplastic composite article having a first thickness, wherein the second pressure is less than or equal to the first pressure.

[0033] In other embodiments, the lightweight reinforced thermoplastic composite article comprises a core layer manufactured using one of the processes described herein. In a particular configuration, the density of the core layer is 0.2 gm / cm³. 3 ~1.5 g / cm 3 In some examples, the thermoplastic material of the core layer includes polyolefin, polyetherimide, or both. In other examples, the reinforcing material of the core layer includes glass fibers, polymer fibers, binary fibers, and / or mixtures thereof. In certain embodiments, a lofting agent may be present in the core layer. In some cases, at least one skin layer is placed on the core layer.

[0034] In another embodiment, the automotive ceiling material comprises a core layer manufactured using the methods and systems described herein.

[0035] In an additional embodiment, the automotive underbody shield comprises a core layer manufactured using the methods and systems described herein.

[0036] In another embodiment, an automotive trim piece comprises a core layer manufactured using the methods and systems described herein.

[0037] In an additional embodiment, the ceiling tile comprises a core layer manufactured using the method and system described herein.

[0038] In another embodiment, the cubicle panel comprises a core layer manufactured using the methods and systems described herein.

[0039] In additional embodiments, the structural panel comprises a core layer manufactured using the methods and systems described herein.

[0040] In another embodiment, the wall panel comprises a core layer manufactured using the methods and systems described herein.

[0041] In an additional embodiment, the siding panel comprises a core layer manufactured using the methods and systems described herein.

[0042] In another embodiment, the roof panel comprises a core layer manufactured using the methods and systems described herein.

[0043] In an additional embodiment, the single roof panel comprises a core layer manufactured using the methods and systems described herein.

[0044] In an additional embodiment, the recreational vehicle comprises a core layer manufactured using the methods and systems described herein.

[0045] In an additional embodiment, an aerospace interior panel comprises a core layer manufactured using the methods and systems described herein.

[0046] In an additional embodiment, the exterior panel of a recreational vehicle comprises a core layer manufactured using the methods and systems described herein.

[0047] In an additional embodiment, an aerospace exterior panel comprises a core layer manufactured using the methods and systems described herein.

[0048] In an additional embodiment, the recreational vehicle comprises a core layer manufactured using the methods and systems described herein.

[0049] In an additional embodiment, the aerospace vehicle comprises a core layer manufactured using the methods and systems described herein.

[0050] In an additional embodiment, the automobile vehicle comprises a core layer manufactured using the methods and systems described herein.

[0051] In an additional embodiment, a recreational vehicle comprises a trim piece having a core layer manufactured using the method and system described herein.

[0052] In an additional embodiment, the aerospace vehicle comprises a trim piece having a core layer manufactured using the methods and systems described herein.

[0053] Additional aspects, embodiments, configurations, and features are described in more detail below.

[0054] A brief description of some views of the drawing. A specific configuration is described below with reference to the attached drawings. [Brief explanation of the drawing]

[0055] [Figure 1] These are diagrams of a first press apparatus and a second press apparatus, illustrating several examples. [Figure 2] This is a flowchart of one process that can be used to manufacture LWRT articles according to several embodiments. [Figure 3] This is another flowchart of one process that can be used to manufacture LWRT articles according to a specific embodiment. [Figure 4] This is another flowchart of a process that can be used to manufacture LWRT articles according to other embodiments. [Figure 5] This flowchart shows a process, according to several embodiments, in which a dry web can be heated and pressed, and then cooled and pressed. [Figure 6A] This figure shows core layers optionally combined with other layers according to several embodiments. [Figure 6B] This figure shows core layers optionally combined with other layers according to several embodiments. [Figure 6C] This figure shows core layers optionally combined with other layers according to several embodiments. [Figure 6D] This figure shows core layers optionally combined with other layers according to several embodiments. [Figure 6E] This figure shows core layers optionally combined with other layers according to several embodiments. [Figure 7] This is a diagram of a system comprising a first press device and a second press device according to a specific embodiment. [Figure 8] This is a diagram of a system comprising a first press device and a second press device according to a specific embodiment. [Figure 9] This is a diagram of a system comprising a first press device and a second press device according to a specific embodiment. [Figure 10] This is a diagram of a system comprising a first press device and a second press device according to a specific embodiment. [Figure 11] This is a diagram of a system comprising two subsystems according to a specific embodiment. [Figure 12] These are diagrams of vehicle ceiling materials, showing several examples. [Figure 13A] This is a diagram of an underbody shield according to several embodiments. [Figure 13B] This is a diagram of a trim piece according to several embodiments. [Figure 14] Here are some examples of ceiling tiles. [Figure 15] Here are some examples of cubicle panel diagrams. [Figure 16A] These are diagrams of structural panels, illustrating several examples. [Figure 16B]These are diagrams of structural panels, illustrating several examples. [Figure 17] This is a diagram of a wall panel according to a specific embodiment. [Figure 18] This is a diagram of a siding panel according to several embodiments. [Figure 19] Here are some examples of roof panel diagrams. [Figure 20] Here are some examples of shingle roofing panels. [Figure 21A] This is a diagram of an interior panel according to several embodiments. [Figure 21B] This is a diagram of an exterior panel according to several embodiments. [Figure 22A] This is a diagram of a vehicle that may include a core layer manufactured as described herein, according to a particular embodiment. [Figure 22B] This is a diagram of a vehicle that may include a core layer manufactured as described herein, according to a particular embodiment. [Figure 22C] This is a diagram of a vehicle that may include a core layer manufactured as described herein, according to a particular embodiment. [Figure 22D] This is a diagram of a vehicle that may include a core layer manufactured as described herein, according to a particular embodiment. [Figure 23] This is a diagram of interior trim according to a specific embodiment. [Figure 24A] This figure shows various core layers based on a specific example. [Figure 24B] This figure shows various core layers based on a specific example. [Figure 24C] This figure shows various core layers based on a specific example. [Figure 24D] This figure shows various core layers based on a specific example. [Figure 24E] This figure shows various core layers based on a specific example. [Figure 25] This is a diagram of a core layer bonded to a scrim and film, according to several embodiments. [Figure 26A]This figure shows various surface morphologies of the test samples, illustrated by several examples. [Figure 26B] This figure shows various surface morphologies of the test samples, illustrated by several examples. [Figure 27A] This figure shows various surface morphologies of the test samples, illustrated by several examples. [Figure 27B] This figure shows various surface morphologies of the test samples, illustrated by several examples. [Figure 28A] This figure shows various surface morphologies of the test samples, illustrated by several examples. [Figure 28B] This figure shows various surface morphologies of the test samples, illustrated by several examples. [Figure 29A] This figure shows various mechanical properties of a test sample according to a specific embodiment. [Figure 29B] This figure shows various mechanical properties of a test sample according to a specific embodiment. [Figure 30A] This figure shows various mechanical properties of a test sample according to a specific embodiment. [Figure 30B] This figure shows various mechanical properties of a test sample according to a specific embodiment. [Figure 31A] This figure shows various mechanical properties of a test sample according to a specific embodiment. [Figure 31B] This figure shows various mechanical properties of a test sample according to a specific embodiment. [Figure 32A] This figure shows various tensile properties of the test sample according to several embodiments. [Figure 32B] This figure shows various tensile properties of the test sample according to several embodiments. [Figure 33A] This figure shows various tensile properties of the test sample according to several embodiments. [Figure 33B] This figure shows various tensile properties of the test sample according to several embodiments. [Figure 34A]This figure shows various tensile properties of the test sample according to several embodiments. [Figure 34B] This figure shows various tensile properties of the test sample according to several embodiments. [Modes for carrying out the invention]

[0056] Given the advantages of this disclosure, it will be recognized by those skilled in the art that the dimensions, sizes, shading, arrangement configurations, and other features of the drawings are provided for illustrative purposes only and are not intended to limit the art to any one configuration.

[0057] Detailed explanation Specific configurations and embodiments of steps and methods that can be used to manufacture LWRT articles are described below, but additional steps and other processing conditions, temperatures and pressures may be selected by those skilled in the art, given the interests of this disclosure.

[0058] In certain embodiments, the in-line method described herein can produce a lightweight thermoplastic composite article comprising a web with an open-cell structure formed from a reinforcing material held in place by a thermoplastic material. Exemplary reinforcing and thermoplastic materials are described in more detail below. While specific steps may vary depending on the properties of the LWRT article to be produced, the method may include heating the formed web to a first temperature higher than the melting point of the thermoplastic material within the formed web, applying a first pressure at the first temperature to provide a heated web having a first thickness, cooling the heated web to a second temperature lower than the melting point of the first temperature, and cooling the heated web at the second temperature by applying a first pressure (or a pressure lower than the first pressure) to provide a lightweight thermoplastic composite article having a first thickness.

[0059] In some cases, the heated web is removed from the heated press without any intermediate processing steps. The formed web is then directly transferred to a cooling press. For example, the formed web can be provided to a first press, such as a hydraulic press, a mechanical press, a set of upper and lower rollers, or other suitable press and apparatus, which can apply pressure and heat to the surface of the formed web. The pressure can be used to press the web to a desired thickness, which can vary, for example, from about 100 microns to about 10 mm. The first press is typically held at a first temperature higher than the melting temperature of the thermoplastic material of the formed web, allowing the reinforcing material of the formed web to wet out by the thermoplastic material. The heated web of the desired thickness can then be transferred to a second press at a lower temperature, typically lower than the melting temperature of the thermoplastic material of the heated web, to allow the heated web to solidify. The second press can apply a pressure typically less than or equal to the pressure applied by the first press to maintain substantially the same thickness as selected using the first press. For example, the thickness of an LWRT article produced using the first and second presses can vary by up to about 5% after heating and cooling of the LWRT article.

[0060] In some embodiments, as described in more detail below, the first press device can heat the LWRT article to a temperature sufficient to melt the thermoplastic material but not high enough to loft any lofting agents that may be present in the LWRT. The exact temperature may vary depending on the material present in the LWRT article, but exemplary temperatures used by the first press device may range from about 170°C to about 240°C or from about 180°C to about 220°C. The pressure supplied by the first press device may range from about 2 bar to about 20 bar, more specifically from about 3 bar to about 15 bar. The temperature of the second press device is typically lower than that of the first press device to allow the heating web to cool. For example, the temperature of the second press device may be less than 180°C, less than 150°C, less than 125°C, or even closer to room temperature, for example, from about 5°C to about 45°C. The pressure supplied by the second press device is typically less than or equal to the pressure supplied by the first press device. While we do not wish to be bound to any single configuration, it may be desirable to use the lowest possible pressure in the second press while still maintaining approximately the same thickness for the heated web. By using the lowest possible second pressure in the second press while maintaining approximately the same thickness for the heated web, a simpler and less expensive device can be used as the second press.

[0061] In certain cases, the formed web exiting the second press device may undergo further processing steps, including lofting, compaction, lamination, cutting, or other steps, as desired. In some cases, one or more skins may be applied to one or more surfaces of the formed web after it exits the second press device, while in other cases, one or more skins may be applied to the formed web before it is heated and pressed using the first press device. The process of heating and pressing the web, and optionally other post-processing steps, can be carried out offline or in an in-line process that can be automated to increase the production of LWRT articles.

[0062] In the offline process, heating and pressing can be performed by transferring the formed web (or formed LWRT article) to a first press and a second press, as shown in Figure 1. For example, the first press 100 may comprise an upper plate 102 and a lower plate 104, and the second press 110 may comprise an upper plate 112 and a lower plate 114. A rotating belt 120 moving around pulleys or rollers 130, 140 can advance the heated web 150 from the first press 100 to the second press 110. The temperature provided by the plates 102, 104 is typically higher than the melting temperature of the thermoplastic material in the formed web, for example, 170-240°C. After pressing and cooling, the cooled web 160 is carried on belt 12 The webs are released from the press and collected in containers, which can be stacked or placed on pallets as desired. The first press device 100 can press the web 150 to a desired thickness between the upper plate 102, the belt 120, and the lower plate 104 using a first pressure, for example, 2 bar to about 20 bar. Similarly, the second press device 110 can press the web between the upper plate 112, the belt 120, and the lower plate 104 to cool the web to a second temperature and maintain the web thickness, for example, the second press device 110 can apply a second pressure less than the first pressure, for example, 2 bar to 20 bar. The temperature of the plates 112,114 of the second press device 110 is typically lower than the melting point of the thermoplastic material in the heated web in order to allow the web to solidify. The rotation of the belt 120 can be stopped during the pressing step as desired.

[0063] In an alternative configuration, the belt 120 can be completely omitted, and the operator can manually position the formed web between plates 102, 104 and heat and press the formed web using a first temperature and a first pressure. Once the web is heated, plates 102, 104 can be moved away from each other, and the heated web can be removed from the first press unit 100 and transferred to the second press unit 110 using preferably non-stick peeling means, paddles, or other transfer devices. Using plates 112, 114, the transferred web can be cooled at a second pressure, typically less than the first pressure provided by the first press unit 100, and pressure can be applied to cool the web while maintaining substantially the same thickness. Once the web is cooled, plates 112, 114 can be moved away from each other, and the resulting formed LWRT can be removed from the second press unit 110 and stacked or placed on a pallet as desired. Although not shown, a release liner can be placed on the surfaces of plates 102, 104, 112, and 114 that come into contact with the formed web to prevent the formed web from adhering to the plates 102, 104, 112, and 114. Alternatively, a release liner can be added to one or both sides of the formed web before pressing and heating.

[0064] In a specific embodiment, Figure 2 shows a flowchart of the process for manufacturing an LWRT article. In step 210, the thermoplastic material (TP) and the reinforcing material (RM) are combined together in a liquid. Then, in step 220, the combined material can be deposited onto a moving support, such as a wire screen or mesh. In step 230, the liquid, rather than the TP or RM, can be removed from the moving support, for example, using vacuum pressure, leaving a web formed from the TP and RM. In step 240, the formed web can be heated and pressed using a first press device at a first temperature and a first pressure to form a heated web. The first temperature can be selected to be higher than the melting temperature of the TP in the formed web, for example, between approximately 170°C and 240°C. The first pressure can be selected to press the heated web to a desired overall thickness, for example, between approximately 100 microns and 10 mm. Heating the formed web in the first press device can melt the TP material and improve the wet-out of the reinforcing material. Next, in step 250, the heated web can be transferred to a second press at a second temperature lower than the first temperature to cool the heated web and form a cooled web. The second press can apply a second pressure, which can be less than or equal to the first pressure, to maintain the thickness of the heated web during the cooling process. Once cooled, the cooled web can be discharged as a cooled web treatment in step 260. As described herein, this process can be performed as an inline process using an inline system, or one or more steps can be performed offline.

[0065] In a specific embodiment, another flowchart of the process for manufacturing LWRT articles is shown. As shown in 3, in step 310, the thermoplastic material (TP) and the reinforcing material (RM) are combined together in a liquid. Then, in step 320, the combined material can be deposited onto a mobile support, such as a wire screen or mesh. In step 330, the liquid, rather than the TP or RM, can be removed from the mobile support, for example using vacuum pressure, leaving a web formed from the TP and RM. Then, a skin, such as a scrim, film, or other skin discussed herein, can be added to one surface of the core in step 335. The formed web and skin can be heated and pressed in step 340 using a first press device at a first temperature and a first pressure to form a heated web and skin. The first temperature can be selected to be higher than the melting temperature of the TP in the formed web, for example, from about 170°C to about 240°C. The first pressure can be selected to press the heated web and skin to a desired overall thickness, for example, from about 100 microns to about 10 mm. Heating the formed web and skin in the first press device can melt the TP material and improve the wet-out of the reinforcing material. Then, in step 350, the heated web and skin can be transferred to a second press device at a second temperature lower than the first temperature to cool the heated web and skin and form a cooled web. The second press can apply a second pressure, which can be less than or equal to the first pressure, to maintain the thickness of the heated web and skin during the cooling process. Once cooled, the cooled web and skin can be discharged as LWRT articles in step 360. As described herein, this process can be performed as an inline process using an inline system, or one or more steps can be performed offline.

[0066] In another embodiment, an additional flowchart of the process for manufacturing an LWRT article is shown in Figure 4. In step 410, the thermoplastic material (TP) and the reinforcing material (RM) are combined together in a liquid. Then, in step 420, the combined material can be deposited onto a moving support, such as a wire screen or mesh. In step 430, the liquid, rather than the TP or RM, can be removed from the moving support, for example, using vacuum pressure, to leave a web formed from the TP and RM. Then, a skin, such as a scrim, film, or other skin discussed herein, can be added to each side or surface of the core in step 435. The two skins may be the same or different, as will be discussed later. The formed web and skin can be heated and pressed in step 440 using a first press device at a first temperature and a first pressure to form a heated web and skin. The first temperature can be selected to be higher than the melting temperature of the TP in the formed web, for example, between about 170°C and about 240°C. A first pressure can be selected to press the heated web and skin to a desired overall thickness, for example, about 100 microns to about 10 mm. Heating the formed web and skin in the first press can melt the TP material and improve the wet-out of the reinforcing material. Then, in step 450, the heated web and skin can be transferred to a second press at a second temperature lower than the first temperature to cool the heated web and skin and form a cooled web. The second press can apply a second pressure, which can be less than or equal to the first pressure, to maintain the thickness of the heated web and skin during the cooling process. Once cooled, the cooled web and skin can be discharged as LWRT articles in step 460. As described herein, this process can be performed as an inline process using an inline system, or one or more steps can be performed offline.

[0067] In certain embodiments, the formed web can be dried or treated before being offered to the first press. For example, referring to Figure 5, in step 520, the formed web The web 510 can be dried to provide a dry web. Water or other liquids can be removed using heat, pressure, suction, rollers, airflow or other devices or materials. If desired, the dry web can be placed between rollers to remove any excess liquid, or the dry web can be pre-pressed. Then, in step 530, the dry web can be provided to a first press device, heated and pressed to form a heated web. The heated web can then be transferred to a second press device, cooled and pressed to maintain its thickness and form a cooled web 540. In step 550, the cooled web can be discharged to form the LWRT.

[0068] The exact composition and materials of an LWRT article may vary depending on the materials used, the intended application of the LWRT article, and / or the desired properties of the LWRT article. In a particular example, a thermoplastic composite article may include reinforcing materials such as powders, whiskers, or fibers, and a thermoplastic material. A simplified diagram is shown in Figure 6A, in which article 600 includes a porous core layer containing reinforcing fibers and a thermoplastic material. The reinforcing fibers and thermoplastic material can form a web with an open-cell structure in which the reinforcing fibers are held in place by the thermoplastic material. The web can be porous as a result of the formed open-cell structure. For example, the porosity or void ratio of the porous core layer is 0-30%, 10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10-90%, 10-95%, 20-60%, 20-70%, 20-80%, 20-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95%, 40-80%, 40-90%, 40-95%, 50-90%, 50-95%, 60-95%. The void percentages may be 70-80%, 70-90%, 70-95%, 80-90%, 80-95%, or any exemplary value within these exemplary ranges. In some examples, porous core layers may have void percentages of up to approximately 95%, exceeding 0%, e.g., not fully compacted. Unless otherwise specified, references to core layers with specific void percentages or void percentages are based on the total volume of the core layer and not necessarily on the total volume of the core layer and any other materials or layers bonded to it. Post-compaction of core 600 using a hot press can reduce the void percentage compared to the same core layer that is not compacted, although this is not necessarily true in all cases. Even when compaction is performed using a hot press or cold press, the resulting void percentage of the compacted core may still remain above 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, or even 65%, based on the total volume of the core layer 600.In other examples, the core layer 600 can be completely consolidated to achieve a porosity of 0%, with minimal or no void space present within the core layer 600.

[0069] In certain embodiments, the thermoplastic material present in the core layer 600 may include, but not be limited to, different forms including, fibrous form, granular form, resin form or other suitable forms. In some examples, the thermoplastic material may include polyolefins or other thermoplastic materials. For example, the thermoplastic material may include one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, and may include both plasticized and unplasticized forms, as well as blends of these materials with each other or with other polymer materials. Other suitable thermoplastic materials include polyarylene ethers, polycarbonates, polyester carbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, acrylonitrile-butyl acrylate-styrene polymers, amorphous nylons, polyarylene ether ketones, polyphenylene sulfides, polyarylsulfones, polyethersulfones, liquid crystal polymers, poly(1,4-phenylene) compounds marketed as PARMAX®, high-temperature polycarbonates such as Bayer's APPEC® PC, high-temperature nylons, and silica. This includes, but is not limited to, these materials, as well as alloys and blends of these materials with each other or with other polymer materials. In some cases, the resin may be a polyetherimide resin such as Ultem® resin. Ultem® resin may or may not be filled and can be selected to be low-smoke KPSI FDA, USDA, USP Class VI and NSF approved UL 94 V-0 rating. If desired, Ultem® resin may be a glass-reinforced material such as 30% glass-filled (Ultem 2300), 20% glass-filled (Ultem 2200), or 10% glass-filled (Ultem 2100). If desired, a thermoplastic blend, which may be a blend containing a thermoplastic or thermosetting material, may be present in the core layer 600. The exact amount of thermoplastic material in the core layer 600 may vary, including, but is not limited to, about 10% to about 90% by weight of the core layer 600, for example, about 20% to about 80% by weight or about 30% to about 70% by weight or about 40% to about 60% by weight based on the total weight of the core layer 600.

[0070] In some examples, the exact amount of reinforcing material, such as reinforcing fibers, present in the core layer 600 may vary. For example, the content of reinforcing material or fibers in the core layer 600 may be greater than 0% to about 90% by weight of the core layer 600, for example, about 1% to about 80% by weight, more specifically about 2% to about 80% by weight of the core layer 600, or about 20% to about 80% by weight of the core layer 600. The specific size and / or orientation of the hydrophilic fibers used may depend at least in part on the polymer material used and / or the desired properties of the resulting prepreg or core. Suitable additional types of reinforcing materials include, but are not limited to, particles, powders, fibers, etc. If reinforcing fibers are present in the core 600, the reinforcing fibers may include one or more of the following: glass fibers, polymer fibers, polymer bicomponent fibers, carbon fibers, graphite fibers, synthetic organic fibers, in particular high modulus organic fibers such as para- and meta-aramid fibers, nylon fibers, polyester fibers, or high melt flow index resins as specified herein that are suitable for use as fibers, natural fibers such as hemp, sisal, jute, flax, coir, and kenaf, mineral fibers such as 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, hydrophilic fibers, hydrophobic fibers of other types of fibers. In a non-limiting example, reinforcing fibers dispersed in a thermoplastic material to provide a prepreg or core generally have a diameter greater than about 5 microns, more specifically about 5 to about 22 microns, and a length of about 5 mm to about 200 mm, and more specifically, the diameter of hydrophilic fibers may be about 3 nanometers to about 22 microns, and the fiber length may be about 5 mm to about 75 mm.

[0071] In some embodiments, the core layer 600 can be used with an adhesive layer, for example, one that is compatible with the adhesive layer. Referring to Figure 6B, the adhesive layer 610 is shown as being present on one surface of the core layer 600. The adhesive layer 610 may contain one or more aqueous adhesives, non-aqueous adhesives, and / or a mixture of aqueous and non-aqueous adhesives. If desired, the adhesive layer 610 can be used to bond the skin layer 620 to the core layer 600 (see Figure 6C), but if desired, the skin layer 620 can be placed in direct contact with the core 600 without an adhesive layer (or other layer) between the skin 620 and the core 600. In some cases, a blend of several different adhesives can also be used. If desired, individual adhesive strips can also be used.

[0072] In certain examples, the skin layer 620 may include a film (e.g., a thermoplastic film or elastomer film), frim, scrim (e.g., a fibrous scrim, or a scrim containing hydrophilic fibers such as cellulose fibers), foil, woven fabric, nonwoven fabric, or an inorganic coating, organic coating, or thermosetting coating placed on the prepreg or core 600. It may exist as a chemical coating. In other examples, the skin layer 620 may contain a limiting oxygen index greater than about 22, as measured according to ISO 4589 1996. If a thermoplastic film is present as (or as part of) the skin layer 620, 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 layer 620, 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 layer 620, the coating may contain at least one of unsaturated polyurethanes, vinyl esters, phenols, and epoxy. If an inorganic coating is present as (or as part of) the skin layer 620, 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 layer 620, the nonwoven fabric may contain thermoplastic materials, thermosetting binders, inorganic fibers, metal fibers, metallized inorganic fibers, and metallized synthetic fibers. Optionally, the skin layer 620 may contain expandable graphite materials, flame retardant materials, cellulose fibers, or hydrophilic fibers.

[0073] In certain configurations, a second skin layer 630 may be present on the opposite surface of the core 600, as shown in Figure 6D. Optionally, an optional adhesive layer (not shown) may be present between the core 600 and the skin layer 630. In some cases, the skin layer 630 may include a film (e.g., a thermoplastic film or elastomer film), frim, scrim (e.g., a fibrous scrim, or a scrim containing hydrophilic fibers such as cellulose fibers), foil, woven fabric, nonwoven fabric, or exist as an inorganic coating, organic coating, or thermosetting coating placed on the prepreg or core 600. In other examples, the skin layer 630 may contain a limiting oxygen index greater than approximately 22, as measured according to ISO 4589 1996. If a thermoplastic film is present as (or as part of) the skin layer 630, 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 layer 630, 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 layer 630, the coating may contain at least one of unsaturated polyurethane, vinyl esters, phenols, and epoxy. If an inorganic coating is present as (or as part of) the skin layer 630, 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 layer 630, the nonwoven fabric may contain thermoplastic materials, thermosetting binders, inorganic fibers, metal fibers, metallized inorganic fibers, and metallized synthetic fibers.Optionally, the skin layer 630 may contain an expandable graphite material, a flame retardant material, cellulose fibers, or hydrophilic fibers.

[0074] In other configurations, the decorative layer 650 is located on either or both of the skin layers 620 and 630. This is possible. Referring to Figure 6E, the decorative layer 650 is shown as being placed on the skin layer 620. An optional adhesive layer (not shown) may be present between the decorative layer 650 and the skin layer 620. The decorative layer 650 can be a thermoplastic film such as polyvinyl chloride, polyolefin, thermoplastic polyester, or thermoplastic elastomer. The decorative layer 650 can be a multilayer structure including a foam core formed from, for example, polypropylene, polyethylene, polyvinyl chloride, or polyurethane. Fabrics such as woven fabrics made of natural and synthetic fibers, nonwoven fabrics of organic fibers after needle punching, napped fabrics, knitted fabrics, flocked fabrics, or other such materials may be bonded to the foam core. The fabrics may also be bonded to the foam core by thermoplastic adhesives including pressure-sensitive adhesives and hot-melt adhesives such as polyamide, modified polyolefin, urethane, and polyolefin. The decorative layer 650 can be manufactured using spunbond, thermal bonding, spunlace, meltblown, wet-laid, and / or dry-laid processes. In some configurations, the decorative layer 650 may include an open-cell structure or a closed-cell structure.

[0075] In certain embodiments, two or more core layers can be stacked on top of each other to increase the overall thickness of the core. Optionally, the formed core layers can be laminated and then subjected to a hot press to bond them together. The resulting core layers can then be pressed to a desired thickness using appropriate pressure. When a laminate of core layers is used, the laminate may include any of these materials, such as an adhesive layer, a skin layer, or a decorative layer, as shown in Figures 6B to 6E.

[0076] In certain embodiments, the various core layers described herein may optionally contain other materials, including additives, fragrances, perfumes, dyes, colorants, antioxidants, or other materials. In some configurations, the prepreg or core may be substantially halogen-free or halogen-free to meet the limitations of hazardous substance requirements for a particular application. In other examples, the prepreg or core may contain halogenated flame retardants (which may be present in or added to the flame retardant material), for example, halogenated flame retardants containing one or more of F, Cl, Br, I, and At, or compounds containing such halogens, for example, tetrabromobisphenol-A polycarbonate or monohalo-, dihalo-, trihalo- or tetrahalo-polycarbonate. In some examples, the thermoplastic material used in the prepreg and core may contain one or more halogens to impart some degree of flame retardancy without the addition of another flame retardant. Where a halogenated flame retardant is present, the flame retardant is preferably present in an amount that may vary depending on other components present. For example, if halogenated flame retardants are present, they may be present in amounts of about 0.1% to about 15% by weight (based on the weight of the prepreg or core), more specifically about 1% to about 13% by weight, for example, about 5% to about 13% by weight. Two different halogenated flame retardants may be added to the prepreg or core as desired. In other examples, non-halogenated flame retardants may be added, such as flame retardants containing one or more of N, P, As, Sb, Bi, S, Se, and Te. In some embodiments, the non-halogenated flame retardants may include phosphorus-added materials so that the prepreg may be more environmentally friendly. If non-halogenated or substantially halogen-free flame retardants are present, the flame retardants are preferably present in amounts that 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 prepreg or core), more specifically, about 1% to about 13% by weight, for example, about 5% to about 13% by weight, based on the weight of the prepreg or core. If desired, two different substantially halogen-free flame retardants may be added to the prepreg or core. In specific cases, the prepreg or core described herein may be combined with one or more substantially halogen-free flame retardants to contain one or more halogens. Flame retardants may be included. If two different flame retardants are present, the combination of the two flame retardants may be present in amounts that vary depending on the other components present. For example, the total weight of the flame retardants present (excluding any compounded flame retardants) may be about 0.1% to about 20% by weight (based on the weight of the prepreg or core), more specifically, about 1% to about 15% by weight, for example, about 2% to about 14% by weight, based on the weight of the prepreg or core. The flame retardants used in prepregs or cores described herein may be added to a mixture containing thermoplastic material and fibers (before removing the mixture onto a wire screen or other processing component) or after the prepreg or core has been formed.

[0077] In other examples, the prepreg or core may contain one or more scavenging agents. Exemplary scavenging agents include, but are not limited to, metal stearates and metal oxides, such as calcium stearate, zinc stearate, zinc oxide, calcium lactate, or dihydrotalcite. These or other suitable scavenging agents can be used to prevent discoloration of the prepregs and cores described herein. Alternatively, if discoloration is desired, the prepreg or core may not contain scavenging agents, for example, metal stearates or metal oxides, such as calcium stearate, zinc stearate, zinc oxide, or calcium lactate, or may be substantially free of them.

[0078] In some cases, phenolic antioxidants may be present and used to manipulate the color of the composite article. For example, a thermoplastic composite article may include a porous core containing reinforcing fibers and a thermoplastic material, the porous core further containing a metal hydroxide flame retardant and an antioxidant, the porous core including a web formed from reinforcing fibers held in place by the thermoplastic material, the antioxidant in the porous core containing the metal hydroxide flame retardant changes color from a first color to a second color when exposed to an oxidizing agent, and changes color from the second color to the first color when the oxidizing agent is removed. The reaction in which phenolic antioxidants change color can be reversed, so that the color can be preferred or suppressed depending on the specific environmental conditions present.

[0079] In some configurations, the prepreg or core layer may contain other materials such as lofting agents, expandable microspheres, expandable graphite materials, hydroxides such as aluminum hydroxide or magnesium hydroxide, or other materials. For example, the lofting agent may be present in the core layer and may be present in a non-covalent or covalent manner. The application of heat or other perturbations may act to increase the volume of the lofting agent, which increases the overall thickness of the layer, for example, as the size of the lofting agent increases and / or additional air is trapped in the layer, causing the layer to expand. Furthermore, even in the absence of added lofting agents, some lofting can be achieved by heating the prepreg or core layer. As described herein, a hot press can be used to press a heated web to a desired thickness. A cool press can be used to maintain the thickness of the web while it cools. Post-treatment of the cooled web may result in lofting or an increase in the thickness of the prepreg or core layer. By maintaining the pressed thickness of the prepreg or core layer during cooling, an enhanced lofting capacity can be present in the prepreg or core layer.

[0080] In certain embodiments, the surface density of the prepreg or core of any manufactured LWRT article may range from about 300 grams per square meter (gsm) to about 4000 gsm, although the surface density may be less than 300 gsm or more than 4000 gsm depending on the requirements of the particular application. In some examples, the overall thickness of the prepreg, core, or LWRT may range from about 100 microns to about 10 mm in the pre-lofting state. As described herein, lofting can reduce the overall thickness of the core layer to, for example, about 35 mm or less after lofting. The thickness can be increased to 20mm or less after lofting, more than 3mm before lofting, or more than 6mm before lofting. In some cases, the thickness before lofting may be approximately 1mm to 10mm, and the thickness after lofting may be approximately 5mm to 30mm.

[0081] In manufacturing the prepregs and cores described herein, it may be desirable to use a wet-laid process and additional materials. For example, a liquid or fluid medium containing dispersed material, such as a thermoplastic material, and one or more types of reinforcing materials, such as fibers containing any one or more additives described herein (e.g., other flame retardants), can be agitated or stirred in the presence of a gas, such as air or other gas. The dispersion can then be deposited onto a moving support, such as a wire screen or other support material, to provide a substantially uniform distribution of the material in the deposited material. To enhance material dispersion and / or uniformity, the agitated dispersion may contain, for example, anionic, cationic, or nonionic activators, such as 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. These agents can help disperse air in the dispersion. These components can be added to a mixing tank, flotation cell, or other suitable apparatus in the presence of air to provide a dispersion. While aqueous dispersions are preferred, one or more non-aqueous fluids may also be present to aid dispersion, alter the viscosity of the fluid, or otherwise impart desired physical or chemical properties to the dispersion or prepreg, core, or article.

[0082] In certain cases, after a dispersion has been mixed for a sufficient period of time, the fluid containing the suspended material can be placed on a screen, movable wire, or other suitable support structure to provide a web of deposited material. Suction or reduced pressure can be applied to the web to remove any liquid from the deposited material, leaving the thermoplastic material and any other materials present, such as fibers, additives, etc. The resulting web can be dried and optionally compacted or pressed to a desired thickness before being fully formed to provide the desired prepreg or core. Depending on the properties of the thermoplastic and reinforcing materials, a wet-laid process may be used, but it may be preferable to use an air-laid process, dry-blend process, carding and needle process, or other known processes used to manufacture nonwoven products. In some cases, after the prepreg or core has partially cured, flame retardant material, additional fibers, or other materials can be sprayed onto the surface of the prepreg or core by passing the substrate under multiple coating jets configured to spray the material at an angle of approximately 90 degrees to the surface of the prepreg or core. Furthermore, one or more skins, adhesive layers, decorative layers, etc., can be added to the formed core to provide the article. As described herein, these additional layers may be added before heating or pressing, or after heating and pressing have been performed.

[0083] In certain embodiments, the cores, prepregs, and LWRT articles described herein can be manufactured using an in-line process and / or an in-line system. A diagram of an in-line system is shown in Figure 7. The system 700 includes a headbox 710 that can be used to mix materials and deposit a liquid containing thermoplastic material (TP) and reinforcing material (RM) onto a moving support 705. The moving support 705 is moved using pulleys or rollers 702, 704 which can be coupled to motors. A vacuum device 720 may be present to remove the liquid, rather than the TP or RM, from the deposited material on the moving support 705 to form a web. The web can be allowed to solidify or dry for at least a certain period of time before being supplied to a first press device 740. A moving belt 735 can receive the dried web from the moving support 705. The gap between the moving support 705 and the belt can be made small to prevent the dried web from falling. Using the first press device 740, the dried web can be heated and pressed by bringing the two plated parts close together, using a first temperature of, for example, 170-240°C and a first pressure. The exact time used to heat the web in the first press device 740 can vary from about 2 seconds to about 1 minute, depending on the overall thickness of the dried web. The first press device 740 can also compress the heated web within the first press device 740 to a desired thickness by applying a first pressure. During pressing by the first press device 740, the movement of the belt 735 may be stopped as desired. Optionally, a release liner can be placed between the plate of the first press device 740 and the web to prevent the web from adhering to the plate. The exact pressure applied by the first press device 740 can vary from about 2 bar to about 30 bar, for example, from about 3 bar to about 15 bar. Once the web is heated to a first temperature, the pressure can be released, and the heated web can then be fed between the plates of the second press device 750 to cool. The second press device 750 can press the heated web using a second pressure, which is less than or equal to the first pressure provided by the first press device 740. For example, the exact pressure applied by the second press device 750 can vary from about 2 bar to about 30 bar, for example, from about 3 bar to about 15 bar. The second temperature provided by the second press device 750 is typically lower than the melting temperature of the TP in the web. In some examples, the second temperature may be about 0°C to about 50°C, for example, from 5°C to 45°C. Once the web has cooled, it can be moved along the moving belt 735, collected, stacked, or placed on a pallet.

[0084] In some embodiments, the inline system may include one or more rollers or roller sets that can be used to heat the web and / or apply pressure to the web. An illustration of system 800 having a roller set comprising an upper roller 840 and a lower roller 842 is shown in Figure 8. Optionally, the rollers or pulleys 732 and 734 may be omitted, and the moving belt 735 can be driven using only the rollers 840 and 842. The height of each roller in the roller sets 840, 842 may be adjusted independently or simultaneously, as desired. The rollers 840, 842 are typically held at the same temperature, but may be held at different temperatures, as desired. The exact number of rollers present may vary from about two to more than ten, depending on the dimensions of the web and / or the speed of the moving belt. When rollers are used, the moving belt 735 can continue to move while the web is being pressed and heated. Rollers 840, 842 are typically used as a first pressing device to heat the web and press it to a desired thickness, allowing the reinforcing material to wet out with the thermoplastic material. The exact time used to heat the web in rollers 840, 842 can vary from about 2 seconds to about 1 minute, depending on the overall thickness of the dry web. The temperature of rollers 840, 842 is typically higher than the melting temperature of the TP material, for example, 170°C to 240°C. Rollers 840, 842 can also provide a first pressure to the heated web, compressing it to a desired thickness. The exact pressure applied by rollers 840, 842 can vary from about 2 bar to about 30 bar, for example, from about 3 bar to about 15 bar. Once the web has been heated and pressed using rollers 840, 842, it may be supplied to a second pressing device 750 comprising an upper plate and a lower plate. The second press device 750 can press the heated web received from the rollers 840,842 using a second pressure which is less than or equal to the first pressure provided by the rollers 840,842. For example, the exact pressure applied by the second press device 750 can vary from about 2 bar to about 30 bar, for example, from about 3 bar to about 15 bar.The second temperature provided by the second press device 750 is typically lower than the melting temperature of the TP in the web. In some examples, the second temperature can be about 0°C to about 50°C, for example, 5°C to 45°C, while the web is cooled. The web then moves along the moving belt 735, can be collected, stacked, or placed on a pallet.

[0085] In certain examples, a roller or roller set can be used instead as a cool press device. Referring to Figure 9, system 900 includes a roller set comprising an upper roller 950 and a lower roller 952. The rollers 950, 952 can be used to cool the heated web from the first press device 740 and to apply appropriate pressure to the heated web to maintain its thickness during cooling. For example, the rollers 950, 952 can be used to apply a second pressure which is less than or equal to the first pressure provided by the first press device 740. In some cases, the exact pressure applied by the rollers 950, 952 may vary from about 2 bar to about 30 bar, for example, from about 3 bar to about 15 bar. The second temperature provided by the rollers 950, 952 is typically lower than the melting temperature of the TP in the web. In some examples, the second temperature may be about 0°C to about 50°C, for example, from 5°C to 45°C. Once the web is cooled using rollers 950 and 952, it moves along the moving belt 735, where it can be collected, stacked, or placed on a pallet.

[0086] In other configurations, the rollers can be used as both a first and a second press. For example, referring to Figure 10, rollers 1040, 1042 form the first press, and rollers 1050, 1052 form the second press. The temperature of rollers 1040, 1042 is typically higher than the melting temperature of the TP material, for example, 170°C to 240°C. Rollers 1040, 1042 can also provide a first pressure to the heated web to compress it to a desired thickness. The exact pressure applied by rollers 1040, 1042 can vary from about 2 bar to about 30 bar, for example, from about 3 bar to about 15 bar. Once the web has been heated and pressed using rollers 1040, 1042, the web can be fed to rollers 1050, 1052 to cool and press the heated web. In certain examples, the exact pressure applied by rollers 1050, 1052 can vary from about 2 bar to about 30 bar, for example, from about 3 bar to about 15 bar. The second temperature provided by rollers 1050, 1052 is typically lower than the melting temperature of the TP in the web. In some examples, the second temperature can be from about 0°C to about 50°C, for example, from 5°C to 45°C. Once the web is cooled using rollers 1050, 1052, the web can move along the moving belt 735, be collected, stacked, or placed on a pallet.

[0087] In certain embodiments, the press apparatus may reside in a subsystem separate from the subsystem used to manufacture the web. An example is shown in Figure 11, which shows a first subsystem 1110 comprising a moving support 1125 that moves in a general direction indicated by arrow 1112. The moving support can receive a liquid containing thermoplastic and reinforcing materials to form the web. The formed web can be dried and cut into individual pieces using subsystem 1110. The individual web pieces can then be provided in a second subsystem 1150 comprising a moving belt or support that moves the individual web pieces in a general direction indicated by arrow 1152. The individual pieces can then be provided to the first press apparatus 1160 to heat and press the formed web at a first temperature and a first pressure, as described herein. The heated web pieces can then be fed to a second press 1170 to cool and press the heated web to maintain its thickness during cooling. The cooled web can then be discharged from the subsystem, collected, stacked, or placed on a pallet. Although the plates are shown inside the first press unit 1160 and the second press unit 1170, rollers, roller sets, or other devices can be used instead to heat and cool individual web fragments received from subsystem 1110.

[0088] The methods and systems described herein can be used to manufacture LWRT articles, including automotive articles, building materials, recreational vehicle articles, and other articles where high mechanical and lightweight properties are desired. Some of the many possible LWRT articles are described below.

[0089] In certain configurations, vehicle ceiling materials can be provided using the prepregs or cores described herein. Exemplary vehicles include, but are not limited to, automobiles, trucks, trains, subways, recreational vehicles, aircraft, ships, submarines, spacecraft, and other vehicles capable of transporting people or cargo. In some examples, the ceiling material typically comprises at least one prepreg or core layer and a decorative layer, such as decorative fabric, placed on the core layer. The decorative layer may also enhance sound absorption in addition to being aesthetically and / or visually pleasing, and may optionally include foam, thermal insulation, or other materials. A top view of the ceiling material is shown in Figure 12. The ceiling material 1200 comprises a body 1210 and openings 1220 for, for example, a sunroof, moonroof, etc., although multiple openings may be present as desired. The body of the ceiling material 1210 can be manufactured by first heating and pressing the prepreg or core layer using a first press device, and then cooling the heated prepreg or core layer under pressure. Next, the cooled prepreg or core layer can be moved to a press machine having a suitable male and female die half, where the decorative fabric is placed and pressed with the desired die to convert the article into a ceiling material. The opening 1220 can then be provided by trimming the ceiling material 1200. The "C" side or roof side of the ceiling material typically consists of a PET nonwoven scrim layer for handling purposes. The overall shape and geometric shape of the ceiling material 1200 can be selected based on the area of ​​the vehicle to which the ceiling material is joined. For example, the length of the ceiling material can be sized and positioned to span from the windshield to the rear window, and the width of the ceiling material can be sized and positioned to span from the left side to the right side of the vehicle.

[0090] In certain cases, similar methods can be used to manufacture underbody shields and rear window trim pieces or components from prepreg or core layers that are heated and pressed to maintain their thickness, and then cooled and pressed. An illustration of the underbody shield 1300 is shown in Figure 13A, and a top view of the rear window trim 1350 is shown in Figure 13B. The specific outer layers used for the underbody shield 1300 and rear window trim 1350 may differ from those of the ceiling material. For example, the underbody shield may include scrim or other outer layers to enhance its durability and / or acoustic properties. For example, the inner surface of an underbody shield located adjacent to the bottom of the engine may have one or more layers designed to absorb and / or retain automotive fluids such as lubricating oil, antifreeze, and brake fluid. Various openings are shown in the rear window trim 1350, but the location and geometric shape of these openings may vary. Furthermore, typical rear window trim decorative materials may include unbacked PET or PP carpet.

[0091] In certain examples, prepregs or core layers manufactured as described herein can be used in composite articles configured for interior use in recreational vehicle panels, wall panels, building panels, roofs, floors, or other applications. As described herein, composite articles are generally used as-manufactured and not molded. In certain examples, articles described herein can be configured as ceiling tiles. Referring to Figure 14, a grid of ceiling tiles 1400 is shown, which comprises support structures 1402, 1403, 1404, and 1405 in which multiple ceiling tiles, such as tile 1410, are arranged within a grid formed by the support structures. In some examples, the ceiling tiles include a porous core layer comprising a web of open-cell structure containing a random arrangement configuration of multiple reinforcing fibers held together by a thermoplastic material. In some examples, ceiling tile 1410 is open-cell ski This may include a porous decorative layer placed on top of the layer, such as cloth, fabric, or other layers.

[0092] In certain examples, LWRT articles can be configured as cubicle panels. Referring to Figure 15, a top view of a cubicle 1500 is shown, comprising lateral panels 1510, 1530 and a central panel 1520. One or more of the panels 1510–1530 may include one of the porous core layers manufactured as described herein. The cubicle panels may also include one or more skin layers. In some examples, the cubicle wall panels are sized and arranged in a way that allows them to be joined to another cubicle wall panel, and include a porous core layer comprising a web of open-cell structure containing a random arrangement of multiple reinforcing fibers held together by a thermoplastic material.

[0093] In certain embodiments, LWRT articles can be configured as structural panels. Structural panels can be used, for example, as subflooring, wall cladding, roof cladding, as structural support for cabinets, countertops, etc., as step boards, as a substitute for plywood and other applications. Optionally, structural panels can be bonded to other substrates, such as plywood, oriented strand board, or other building panels commonly used in residential and commercial environments. Referring to Figure 16A, a top view of a structural panel 1610 is shown. Panel 1610 may include any one of the core layers manufactured as described herein. Optionally, two or more structural panels can be sandwiched with one skin facing the interior of the space and the other skin of the structural panel facing outward from the interior of the space. In some examples, the structural panel may also comprise a structural substrate 1620, as shown in Figure 16B. For example, the structural panel may include a porous core layer comprising a web of open-cell structure containing a random arrangement configuration of multiple reinforcing fibers held together by a thermoplastic material. The exact properties of the structural substrate 1620 may vary and include, but are not limited to, plywood, gypsum board, wood board, wood tile, cement board, oriented strand board, polymer or vinyl or plastic panel. In some examples, the structural substrate includes plywood panel, gypsum board, wood tile, ceramic tile, metal tile, wood panel, concrete panel, concrete board or brick. Optionally, the structural panel may further include a second structural panel bonded to the skin layer of the first structural panel, the second structural panel being a porous structural panel.

[0094] In certain examples, LWRT articles can be configured as wall panels or wall boards. Wall panels can be used, for example, to cover studs or structural members within a building, or to cover ceiling beams or trusses. Optionally, wall panels can be bonded to other substrates, such as tiles, wood panels, plaster, concrete support boards, or other wall panel substrates commonly used in residential and commercial environments. Referring to Figure 17, a side view of wall panel 1700 is shown. Panel 1700 may include one of the porous core layers manufactured as described herein. As described herein, panels may also include one or more skins on their surface. Optionally, two or more wall panels can be sandwiched with one open-cell skin facing the interior of the space and the open-cell skin of the other wall panel facing outward from the interior of the space. Wall panel 1700 may also include at least one skin 1720 bonded to a first surface of the porous core layer 1710. Although not shown, a second skin may be located on a second surface of the core layer 1710. An optional wall substrate can be bonded to the second surface of the porous core layer 1710 and configured to support the porous core layer 1710 when the wall panel 1700 is bonded to the wall surface. In certain configurations, the wall panel 1700 further comprises a porous decorative layer disposed on the skin 1720. In certain embodiments, a second wall panel can be bonded to the skin 1720, and the second wall panel is a porous wall panel.

[0095] In some cases, LWRTs are installed on buildings such as residential or commercial buildings. It can be configured as a siding panel. Siding panels can be used, for example, to cover house wraps, retaining walls, or other materials commonly used on the exterior surfaces of buildings. If desired, siding panels can be bonded to another substrate, such as vinyl, concrete board, wood siding, brick, or other substrates commonly placed on the exterior of buildings. Referring to Figure 18, a side view of siding panel 1800 is shown. Panel 1800 may include either a core layer or an article manufactured as described herein, for example, a core layer 1810 and a skin 1820. If desired, two or more siding panels can be sandwiched with one open-cell skin facing the interior of the building and the open-cell skin of the other wall panel facing outward from the interior of the building. The substrate 1830 can be made of many different materials, including but not limited to vinyl, wood, brick, and concrete. For example, a vinyl substrate can be bonded to a first surface of a flame-retardant noise-reducing layer, and the siding can be bonded to a non-horizontal surface of the building to hold the siding panel to the non-horizontal surface of the building. In some examples, the siding panel further comprises a weather-resistant barrier, such as a house wrap or membrane, bonded to a second surface of the flame-retardant noise-reducing layer. In some embodiments, the substrate comprises a nailing flange for enabling the siding to be bonded to the side of a building. In some examples, the flame retardant is homogeneously dispersed in a porous core layer. In some examples, the siding panel may further include a second siding panel that can be bonded to the second substrate. In some cases, there may be butt joints, overlapping joints, etc., that allow the two siding panels to lock together horizontally.

[0096] In some cases, LWRT articles can be configured as roof panels attached to structures such as residential or commercial buildings. Roof panels can be used, for example, to cover attic spaces, to be attached to roof trusses, or to cover flat roofs, such as those commonly found on commercial buildings. Optionally, roof panels can be bonded to other substrates, such as oriented strand boards, plywood, or even solar cells, which adhere to and function as roof coverings. Referring to Figure 19, a perspective view of a roof panel 1910 attached to a house 1900 is shown. The roof panel 1910 may include either a core layer or an article manufactured as described herein. Optionally, two or more roof panels can be sandwiched or otherwise used together. The roof panel may also comprise a roof substrate bonded to a first surface of the core layer, which can be bonded to the roof of the building to hold the roof panel to the roof. In some examples, the roof panel may comprise or be used with a weather barrier, such as a membrane, house wrap, tar paper, plastic film, etc. In other examples, the roof substrate comprises a cellulosic material. In certain cases, the roof panel may be fitted with a second roof panel, or it may overlap or be joined with a second roof panel to prevent moisture from entering the house 1900.

[0097] In certain configurations, LWRT articles can be configured as shingles to be attached to buildings such as residential or commercial buildings to absorb sound and provide flame retardancy. Shingleles can be used, for example, to cover roofs commonly found on residential and commercial buildings. Optionally, shingles can be bonded to other substrates such as asphalt, ceramic, clay tile, aluminum, copper, wood such as cedar, and other materials commonly found or used as shingles. Referring to Figure 20, an exploded view of a shingle 2000 is shown. The shingle 2000 may include any one of the core layers or articles described herein. Optionally, two or more shingles can be sandwiched. In some examples, the shingle 2000 may comprise a core layer 2010. Optionally, the weather-resistant shingle substrate 2030 may be bonded to a first surface of the article and bonded to the roof panel of a building. It may be configured to provide weather-resistant and flame-retardant roof panels. In certain examples, the weather-resistant barrier can be bonded to the shingle roofing panels. In other examples, the shingle roofing panels include asphalt. An intermediate layer 2020, such as a skin, insulation, or other material, may be present between the outer layer 2030 and the base material 2010.

[0098] In certain configurations, one or more of the core layers or articles described herein may constitute interior panels or walls of a recreational vehicle (RV), or interior panels of an aircraft or aerospace vehicle, such as a rocket, satellite, shuttle, or other aviation or spacecraft. The panels or walls may, for example, be used to cover the internal skeletal structure of a recreational vehicle or aerospace vehicle and may be bonded between the interior and exterior of the vehicle with foam or other insulating material. In some examples, the core layers or articles may be part of a sandwich structure formed from the core layers or articles and other layers. Optionally, the interior panels may be bonded to another substrate, such as cloth, plastic, or tile. Referring to Figure 21A, a side view of a recreational vehicle 2100 is shown. The interior panel 2110 may include one of the core layers or articles manufactured as described herein. Optionally, two or more RV panels may be sandwiched or bonded together. In some examples, the RV panels may include interior wall substrates configured as decorative layers, such as cloth, plastic, tile, metal, or wood. In additional examples, the RV panel may include a second RV interior panel, which may be the same as or different from the RV panel. Optionally, the RV panel may also include a third RV interior panel, which may also be the same as or different from the RV panel. Although not illustrated, similar interior panels may exist in aerospace applications / vehicles and may be positioned against and / or bonded to an exterior skin, such as a metal or metal alloy skin or structure, e.g., aluminum, magnesium, titanium, or other external structure.

[0099] In certain configurations, one or more of the core layers or articles described herein may be configured as exterior panels or walls of an aircraft, aerospace vehicle, or recreational vehicle. The panels or walls may, for example, be used to cover the exterior skeletal structure of a vehicle and may be bonded between the interior and exterior of the vehicle with foam or other insulating material. In some examples, the core layers or articles may be part of a sandwich structure formed from the core layers or articles and other layers. Optionally, the exterior panels may be bonded to another substrate, such as metal, metal alloy, or fiberglass. Referring to Figure 21B, a side view is shown of a recreational vehicle 2150 having an exterior panel 2160 which may be configured as one of the core layers or articles manufactured as described herein. Optionally, two or more RV panels may be sandwiched with one open-cell skin facing the interior of the RV and the other RV panel's open-cell skin facing outward from the interior of the RV. In certain configurations, the exterior wall substrate may contain fiberglass or be configured as a metal panel, such as aluminum or other metallic material. In additional examples, the RV panel may include a second RV exterior panel, which may be the same as or different from the RV panel. Optionally, the RV panel may also include a third RV exterior panel, which may also be the same as or different from the RV panel. Although not illustrated, similar exterior panels may be present in aerospace applications / vehicles and may be positioned against an internal skin or structure such as an internal metal or metal alloy skin, e.g., aluminum, magnesium, titanium, or other internal structures, and / or bonded to an external skin.

[0100] In certain examples, the core layers and LWRT articles described herein include automobiles (Figure 22A), recreational vehicles (Figure 22B), airplanes (Figure 22C), shuttles or spacecraft (Figure 22D), rockets, satellites, or vehicles with one or more wheels, engines, motors, turbines, rockets, fuel cells, batteries, and are powered by solar energy, wind energy, gas, and Alternatively, it can be used within another vehicle having a power source that can be used to propel the vehicle. However, as shown in Figure 22B, the vehicle having the core layer and LWRT described herein may be towed or coupled behind another vehicle as desired and may not have an independent motor or engine to propel them.

[0101] In some examples, similar structures can be used for interior trim applications, such as RV interior trim, building or automotive interior trim. For example, an interior trim can be used for interior trim applications that includes a porous core layer containing a web of open-cell structure containing a random arrangement configuration of multiple reinforcing fibers held together by a thermoplastic material. The interior trim base material can be bonded to other materials, such as wood, PVC, vinyl, plastic, leather or other materials. A side view of a trim piece that can be used as a baseboard trim is shown in Figure 23. The trim piece 2300 comprises a trim base material 2320. The trim piece 2300 may be nailed to a stud or wall panel 2310 as desired, or otherwise attached. The base material 2320 is outward-facing and visible from the interior. The trim piece 2300 may be curved or may take on a two-dimensional or three-dimensional shape as desired.

[0102] In certain embodiments, two or more individual web fragments can be edge-joined to one another using the methods and systems described herein. Figures 24A, 24B, and 24C show how a first core layer 2410 is edge-joined to a second core layer 2420 to form an LWRT article 2430. Edges 2412 and 2422 can be positioned adjacent to each other horizontally or vertically within a first press apparatus. For example, the first press apparatus can edge-join machine-direction edges, cross-direction edges, or join the machine-direction edge of one core layer to the cross-direction edge of another core layer. The edges may be positioned adjacent to each other (Figure 24D) or vertically overlapping (Figure 24E). The positioned core layers 2410 and 2420 can then be heated and pressed using the first press apparatus. As a result of heating and pressing the core layers 2410 and 2420, the two core layers are joined to each other at their edges. Next, the resulting composite core layer 2430 can be provided to a second press apparatus for cooling and pressing, maintaining its overall thickness during cooling. Optionally, three or more core layers can be edge-bonded to provide an LWRT having the same or variable base weight across the surface of the edge-bonded core layers.

[0103] In certain cases, the methods and systems described herein may be used to improve the mechanical properties of LWRT articles, particularly those with a core layer of 1500 gsm or less. For example, when a core layer is manufactured using the methods described herein, for example, when the core layer is subjected to first and second presses, the mechanical properties can be increased by 10% or more. In one example, the peak load in the mechanical direction (MD) or the cross direction (CD), or both, can be increased by at least 5% (1200 core gsm, MD, hot press for 5 seconds), at least 25% (1000 core gsm, MD, hot press for 5 seconds), or at least 35% (450 gsm, MD, hot press for 5 seconds). In another example, the stiffness in the mechanical direction or the cross direction, or both, can be increased by at least 5% (1200 core gsm, both MD and CD directions), at least 15% (1000 core gsm, MD, hot press for 10 seconds), or at least 45% (450 core gsm, CD, hot press for 5 seconds). In some cases, the tensile strength can be increased by at least 5% (1200 core gsm, MD, hot press for 10 seconds), at least 5% (1000 core gsm, CD, hot press for 5 seconds), or at least 5% (450 core gsm, CD, hot press for 5 seconds) in the mechanical direction, the intersecting direction, or both. In some cases, the modulus of elasticity can be increased by at least 1% (1200 core gsm, MD, hot press for 10 seconds), at least 5% (1000 core gsm, MD, hot press for 20 seconds) in the mechanical direction, the intersecting direction, or both. Alternatively, it can be increased by at least 7.5% (450 core gsm, CD, hot press 5 seconds). These characteristics can be measured using, for example, one or more of ASTM D790 dated 2017 and ASTM D5034 dated 2009.

[0104] In certain embodiments, the density of the core layer of the LWRT article is approximately 0.1 g / cm³. 3 ~Approx. 1.5g / cm 3 It can vary. In some configurations, the density is approximately 0.1 g / cm³. 3 ~about 0.8gm / cm 3 Or approximately 0.2 g / cm³3 ~ about 0.7 g / cm 3 or about 0.3 g / cm 3 ~ about 0.6 g / cm 3 or about 0.3 g / cm 3 ~ about 0.5 g / cm 3 and may vary. In other cases, the density is about 0.6 g / cm 3 ~ about 1.3 g / cm 3 or about 0.7 g / cm 3 ~ about 1.2 g / cm 3 or about 0.8 g / cm 3 ~ about 1.1 g / cm 3 or about 0.8 g / cm 3 ~ about 1.0 g / cm 3 and may vary. The exact density selected may depend on the intended and / or final use of the article including the core layer or LWRT article. For example, in aerospace applications, it may be desirable to use a board having a core layer with a higher density, such as about 0.6 g / cm 3 ~ about 1.3 g / cm 3 but in certain automotive applications, a core layer with a lower density, such as about 0.3 g / cm 3 ~ about 0.6 g / cm 3 can be used.

[0105] In certain configurations, by using the methods described herein, the wet-out of reinforcing material or reinforcing fibers may increase after post-compaction. An indirect measure of the increase in fiber wet-out is the ratio of 1 / thickness after compaction to 1 / thickness before compaction, which is also referred to herein as the density ratio. For example, using the press apparatus described herein, the thickness of the core layer can be reduced by 50% or more. The exact change in thickness may depend at least in part on the base weight of the core layer. As a non-limiting example, for a 1000gsm core, the as-manufactured thickness may be approximately 3.5 mm, and the thickness after compaction may be approximately 1.1 mm. These values ​​provide a density ratio of (1 / 1.1) / (1 / 3.5) = 3.2. In contrast, an uncompactioned board has a density ratio of 1. In some embodiments described herein, the density ratio of the core layer is at least 1.5 or at least 2.0 or at least 2.25, at least 2.5, at least 2.75, at least 3.0 or at least 3.25. While not always the case, heavier core layers tend to have a higher density ratio because they tend to be thicker before compaction. [Examples]

[0106] To illustrate some of the novel and inventive aspects, embodiments, and feature elements of the technology described herein, specific configurations are described.

[0107] Example 1 LWRT cores were manufactured using a wet-laid process. Polypropylene powder, shredded glass fibers, and other additives were dispersed in water. The aqueous slurry was transferred to the web-forming section of a mobile support. The resulting liquid was removed, leaving the web. The web was dewatered and then heated above the melting point of the polypropylene resin. Depending on the final application, surface materials (a nonwoven scrim or woven frim 2530 on the top and a polymer film 2520 on the bottom) were laminated to both sides of the LWRT core 2510, as shown in Figure 25. Finally, the materials were compacted to produce a flat LWRT composite sheet. By adjusting the manufacturing parameters, materials with various base weights (surface density) can be produced.

[0108] Three samples with different base weights (gsm or grams per square meter) were prepared as shown in Table 1.

[0109] [Table 1]

[0110] Each LWRT article was post-consolidated using a hot press and a cold press. The as-manufactured LWRT composite substrates were pressed in a hot press at selected pressures and residence times. In this example, the hot press was heated and maintained at 195°C, and a pressure of 3.8 bar was applied to the LWRT substrate. Three residence times in the hot press were examined, including 5 seconds, 10 seconds, and 20 seconds. After heating in the hot press, the substrates were transferred to a cold press and cooled using the same pressures and residence times as in the hot press. The cold press was used to maintain the thickness of the hot-pressed substrates and to prevent lofting during cooling. After consolidation, the substrates could be lofted and formed to the target thickness by a thermoforming process. For comparison, a control of each sample was directly lofted and formed to the target thickness without post-consolidation using a hot press and a cold press. The post-consolidation settings and target formed thicknesses are listed in Table 2.

[0111] [Table 2]

[0112] The surface morphology of the scrim side of molded LWRT substrates was investigated using a scanning electron microscope, both with and without post-compression. Small rectangular specimens were cut from the molded panel, coated with a thin layer of gold on the surface of interest (scrim side), and the surface morphology was examined under vacuum.

[0113] Mechanical tests were also performed to evaluate the effects of the post-consolidation process. Test specimens were cut from the molded LWRT substrate. The bending properties of all specimens were evaluated according to ASTM D790 dated 2017. Tensile tests were also performed according to ASTM D5034 dated 2009.

[0114] Example 2 In the case of LWRT composites, mechanical performance largely depends on the "wet-out" of the resin against the glass fiber surface. An additional post-densification process was used to improve adhesion between the glass fibers and the polypropylene (PP) resin. Surface morphology from SEM micrographs is a direct indicator of the degree of "wet-out" in the LWRT composite. Comparisons between molded samples with and without post-densification, using a 20-second residence time and checking the surface morphology on the scrim side, are shown in Figures 26A, 26B, 27A, 27B, and 28A and 28B. Figures 26A (without post-densification) and 26B (with post-densification) show a 450 gsm core, Figures 27A (without post-densification) and 27B (with post-densification) show a 1000 gsm core, and Figures 28A (without post-densification) and 28B (with post-densification) show a 1000 gsm core.

[0115] For all molded samples (450, 1000, and 1200 core gsm), the additional post-densification process significantly altered the surface morphology of the scrim side. Without post-densification, the scrim side is highly porous, but the porosity is significantly reduced by the post-densification process. This indicates that the additional pressure and heating during post-densification promote the expansion of the resin between fibers within the core.

[0116] Example 3 Bending properties are crucial for handling LWRT sheets during the thermoforming process, when the sheets are formed into articles such as ceiling materials and attached to fabric surfaces or other materials. If the LWRT sheet does not have sufficient rigidity or strength, bending deformation during handling can cause wrinkles to appear on the surface, and may even lead to catastrophic failure of the sheet.

[0117] The bending properties of all specimens were evaluated. The bending peak load and stiffness of the control and post-consolidated specimens of the 450gsm core are shown in Figures 29A (peak load) and 29B (stiffness). The bending peak load and stiffness of the control and post-consolidated specimens of the 1000gsm core are shown in Figures 30A (peak load) and 30B (stiffness). The bending peak load and stiffness of the control and post-consolidated specimens of the 1200gsm core are shown in Figures 31A (peak load) and 31B (stiffness). The rightmost bar in each graph represents the control specimen, and the remainder represents the post-consolidated specimen.

[0118] All samples show significantly better results in the mechanical direction (MD) than in the cross-mechanical direction (CD). Fiber alignment primarily occurs within the headbox during the web-forming phase of the wet-laid process and is generally favorable in the mechanical direction. The flow within the headbox is a mixture of both shear and extensional flows. There is a strong shear flow near the walls and an extensional flow towards the mechanical direction. As a result, the fibers align strongly in the flow direction, leading to better mechanical performance in the MD.

[0119] For the lightest 450gsm core material, post-consolidation improved both peak load and stiffness for all three residence times. Longer residence times resulted in better bending performance. The shortest residence time (5 seconds) improved bending properties from approximately 39% to 60%. The longest residence time (20 seconds) showed a minimum improvement of 65% in stiffness for the CD (consolidation) and a maximum improvement of 89% in peak load for the MD (consolidation) layer.

[0120] For 1000gsm core materials, residence time is considered to have a much less significant impact on mechanical properties. According to the t-test results, both the peak load and stiffness of the post-consolidated specimens were still improved by 14% (stiffness at CD) to 44% (peak load at CD) compared to the control.

[0121] For the heaviest 1200gsm core material, only the peak load determined by the t-test is considered. Improvements have been achieved, and there is no substantial increase in stiffness due to the use of post-compaction. Increasing the hot-press temperature of higher GSM substrates is thought to improve peak load and stiffness due to better wet-out at higher temperatures.

[0122] Example 4 Tensile properties were also investigated. Tensile properties can depend heavily on the bonding between the resin and the fibers. Figures 32A and 32B show the tensile strength (Figure 32A) and modulus (Figure 32B) of a 450 gsm core. Figures 33A and 33B show the tensile strength (Figure 33A) and modulus (Figure 33B) of a 1000 gsm core. Figures 34A and 34B show the tensile strength (Figure 34A) and modulus (Figure 34B) of a 1200 gsm core.

[0123] The measurement results were very similar to those for the bending properties. Residence time affected the properties of the lightest 450gsm core more than heavier cores. As the base weight increased, the improvement due to post-consolidation decreased. For the 1200gsm core, the tensile strength in MD and the properties in CD improved slightly with a residence time of 20 seconds, but there was no or minimal enhancement for other residence times. At a hot-press temperature of 195°C, the post-consolidation process was favorable to lighter cores, resulting in improved properties. It is thought that the tensile properties of heavier cores would improve by using higher temperatures and / or pressures to promote better wet-out.

[0124] When introducing elements of the examples disclosed herein, the articles “a,” “an,” “the,” and “said” are intended to mean that there is one or more elements. The terms “comprising,” “including,” and “having” are intended to be open-ended, meaning that additional elements other than those enumerated may exist. In light of the merits of this disclosure, it will be recognized by those skilled in the art that various components of the examples can be interchanged or substituted with various components of other examples.

[0125] While specific aspects, configurations, examples, and embodiments have been described above, those skilled in the art will recognize that, in consideration of the interests of this disclosure, additions, substitutions, modifications, and changes are possible to the disclosed exemplary aspects, configurations, examples, and embodiments.

Claims

1. An in-line process for manufacturing lightweight thermoplastic composite articles using an in-line system, The process involves combining reinforcing materials and thermoplastic materials in a liquid to produce an aqueous foam, The aqueous foam is deposited onto the moving support of the in-line system, The liquid is removed from the deposited aqueous foam on the movable support to form a web of open-cell structure formed from the thermoplastic material and the reinforcing material, Providing the formed web on the moving support of the inline system to a first press device of the inline system at a first pressure and a first temperature, and using the first press device to apply heat and pressure to the formed web, wherein the first temperature and the first pressure are selected to melt the thermoplastic material of the formed web, Providing the heated web to a second press device of the inline system at a second temperature and a second pressure, and cooling the heated web using the second press device, wherein the second temperature is lower than the melting point of the thermoplastic material of the heated web, and the second pressure is less than or equal to the first pressure, by cooling the heated web using the second press device, a cooled web having substantially the same thickness as the heated web is provided. To provide the lightweight thermoplastic composite article by discharging the cooling web from the in-line system. An inline process, including

2. The inline process according to claim 1, wherein the first pressure is greater than 1.1 bar, or about 2 bar to about 30 bar, or about 3 bar to about 25 bar, or about 3 bar to about 15 bar.

3. The inline process according to claim 1, wherein the first temperature is approximately 170°C to approximately 250°C, or approximately 170°C to approximately 240°C, or approximately 170°C to approximately 230°C, or approximately 170°C to approximately 220°C, or approximately 170°C to approximately 210°C, or approximately 170°C to approximately 200°C.

4. The inline process according to claim 1, wherein the second temperature is less than the melting temperature of the thermoplastic material, or less than 170°C, or less than 160°C, or less than 150°C, or less than 140°C, or less than 130°C, or less than 120°C, or less than 110°C, or less than 90°C, or less than 80°C, or less than 70°C, or less than 60°C, or less than 50°C, or less than 45°C, or between 5°C and 45°C.

5. The inline process according to claim 1, further comprising using the inline system to cut the cooling web into individual lightweight thermoplastic composite articles, and discharging the individual lightweight thermoplastic composite articles from the inline system.

6. The inline process according to claim 1, wherein the first press apparatus is configured to apply pressure to the heated web at a first temperature and a first pressure by sandwiching the formed web between an upper plate and a lower plate.

7. The inline process according to claim 1, wherein the second press apparatus is configured to apply pressure to the heating web at the second temperature and the second pressure by sandwiching the heating web between an upper plate and a lower plate.

8. The first press device comprises an upper roller set and a lower roller set, and the first The inline process according to claim 1, wherein there is a space between the upper roller set and the lower roller set of the press apparatus, and each of the plurality of upper rollers and the plurality of lower rollers of the first press apparatus is heated to the first temperature and used together to apply the first pressure to the formed web as the formed web passes between the upper roller set and the lower roller set of the first press apparatus.

9. The inline process according to claim 1, wherein the second press apparatus comprises an upper roller set and a lower roller set, with a space between the upper roller set and the lower roller set of the second press apparatus, and each of the plurality of upper rollers and the plurality of lower rollers of the second press apparatus is cooled to the second temperature and used together to apply the second pressure to the heated web received from the first press apparatus as the heated web passes between the upper roller set and the lower roller set of the second press apparatus.

10. The inline process according to claim 1, wherein the system comprises at least one set of rollers for selecting the thickness of the formed web before providing the formed web to the first press device.

11. An in-line process for manufacturing lightweight thermoplastic composite articles using an in-line system, The process involves combining reinforcing materials and thermoplastic materials in a liquid to produce an aqueous foam, The aqueous foam is deposited onto the moving support of the in-line system, The liquid is removed from the aqueous foam deposited on the movable support to form a web of open-cell structure formed from the thermoplastic material and the reinforcing material, Placing a first skin on the first surface of the formed web, To provide the formed web and positioned first skin on the moving support of the inline system to a first press device of the inline system, and to use the first press device to apply heat and pressure to the formed web and positioned first skin at a first temperature and a first pressure, wherein the first temperature and first pressure are selected to melt the thermoplastic material of the formed web, Providing the heating web and the positioned first skin to a second press device of the inline system at a second temperature to cool the heating web and the positioned skin, and applying pressure to the heating web at a second pressure using the second press device to cool the heating web, thereby providing a cooled web having substantially the same thickness as the heating web, wherein the second pressure is less than or equal to the first pressure, To provide the lightweight thermoplastic composite article by discharging the cooling web from the in-line system. An inline process, including

12. The inline process according to claim 11, wherein the first pressure is greater than 1.1 bar, or about 2 bar to about 30 bar, or about 3 bar to about 25 bar, or about 3 bar to about 15 bar.

13. The inline process according to claim 11, wherein the first temperature is about 170°C to about 250°C, or about 170°C to about 240°C, or about 170°C to about 230°C, or about 170°C to about 220°C, or about 170°C to about 210°C, or about 170°C to about 200°C.

14. The second temperature is less than the melting temperature of the thermoplastic material, or less than 170°C, or 1 The inline process according to claim 11, wherein the temperature is less than 60°C, or less than 150°C, or less than 140°C, or less than 130°C, or less than 120°C, or less than 110°C, or less than 90°C, or less than 80°C, or less than 70°C, or less than 60°C, or less than 50°C, or less than 45°C, or between 5°C and 45°C.

15. The inline process according to claim 11, further comprising using the inline system to cut the cooling web into individual lightweight thermoplastic composite articles, and discharging the individual lightweight thermoplastic composite articles from the inline system.

16. The inline process according to claim 11, wherein the first press apparatus is configured to apply pressure to the heated web at a first temperature and a first pressure by sandwiching the formed web between an upper plate and a lower plate.

17. The inline process according to claim 11, wherein the second press apparatus is configured to apply pressure to the heating web at the second temperature and the second pressure by sandwiching the heating web between an upper plate and a lower plate.

18. The inline process according to claim 11, wherein the first press apparatus comprises an upper roller set and a lower roller set, with a space between the upper roller set and the lower roller set of the first press apparatus, and each of the plurality of upper rollers and the plurality of lower rollers of the first press apparatus is heated to a first temperature and used together to apply a first pressure to the formed web as the formed web passes between the upper roller set and the lower roller set of the first press apparatus.

19. The inline process according to claim 11, wherein the second press apparatus comprises an upper roller set and a lower roller set, with a space between the upper roller set and the lower roller set of the second press apparatus, and each of the plurality of upper rollers and the plurality of lower rollers of the second press apparatus is cooled to the second temperature and used together to apply the second pressure to the heated web received from the first press apparatus as the heated web passes between the upper roller set and the lower roller set of the second press apparatus.

20. The inline process according to claim 11, wherein the system comprises at least one set of rollers for selecting the thickness of the formed web before providing the formed web to the first press device.

21. The inline process according to claim 11, further comprising placing a second skin on a second surface of the formed web before providing the formed web and the placed first skin to the first press device.

22. The inline process according to claim 21, wherein the first pressure is greater than 1.1 bar, or is about 2 bar to about 30 bar, or about 3 bar to about 25 bar, or about 3 bar to about 15 bar.

23. The inline process according to claim 21, wherein the first temperature is about 170°C to about 250°C, or about 170°C to about 240°C, or about 170°C to about 230°C, or about 170°C to about 220°C, or about 170°C to about 210°C, or about 170°C to about 200°C.

24. The second temperature is less than the melting temperature of the thermoplastic material, or less than 170°C, or less than 160°C, or less than 150°C, or less than 140°C, or less than 130°C, or 1 The inline process according to claim 21, wherein the temperature is less than 20°C, or less than 110°C, or less than 90°C, or less than 80°C, or less than 70°C, or less than 60°C, or less than 50°C, or less than 45°C, or between 5°C and 45°C.

25. The inline process according to claim 21, further comprising using the inline system to cut the cooling web into individual lightweight thermoplastic composite articles, and discharging the individual lightweight thermoplastic composite articles from the inline system.

26. The inline process according to claim 21, wherein the first press apparatus is configured to apply pressure to the heated web at a first temperature and a first pressure by sandwiching the formed web between an upper plate and a lower plate.

27. The inline process according to claim 21, wherein the second press apparatus is configured to apply pressure to the heating web at the second temperature and the second pressure by sandwiching the heating web between an upper plate and a lower plate.

28. The inline process according to claim 21, wherein the first press apparatus comprises an upper roller set and a lower roller set, with a space between the upper roller set and the lower roller set of the first press apparatus, and each of the plurality of upper rollers and the plurality of lower rollers of the first press apparatus is heated to a first temperature and used together to apply a first pressure to the formed web as the formed web passes between the upper roller set and the lower roller set of the first press apparatus.

29. The inline process according to claim 21, wherein the second press apparatus comprises an upper roller set and a lower roller set, with a space between the upper roller set and the lower roller set of the second press apparatus, and each of the plurality of upper rollers and the plurality of lower rollers of the second press apparatus is cooled to the second temperature and used together to apply the second pressure to the heated web received from the first press apparatus as the heated web passes between the upper roller set and the lower roller set of the second press apparatus.

30. The inline process according to claim 21, wherein the system comprises at least one set of rollers for selecting the thickness of the formed web before providing the formed web to the first press device.

31. An in-line system for manufacturing lightweight thermoplastic composite articles, A mixing reservoir configured to receive a thermoplastic material and a reinforcing material and to provide a substantially homogeneous dispersion of the thermoplastic material and the reinforcing material, A mobile support fluidly coupled to the mixing reservoir and configured to receive the substantially homogeneous dispersion from the mixing reservoir, A pressure device configured to remove liquid from the dispersion received by the moving support to provide a web of open-cell structure formed from the thermoplastic material and the reinforcing material, A first press device configured to receive the formed web and to apply heat and pressure to the formed web using a first temperature and a first pressure, A second press device configured to receive the heated web from the first press device and to cool the heated web using a second temperature and a second pressure, An inline system equipped with this feature.

32. The second press device is used after heating and pressing using the first press device. The inline system according to claim 31, configured to cool the web at the second pressure in order to prevent any substantial change in the thickness of the heated web.

33. The inline system according to claim 31, wherein the first press apparatus comprises an upper roller set and a lower roller set, with a space between the upper roller set and the lower roller set of the first press apparatus, and each of the plurality of upper rollers and the plurality of lower rollers of the first press apparatus is heated to a first temperature and used together to provide the formed web with a first pressure as the formed web passes between the upper roller set and the lower roller set of the first press apparatus.

34. The inline system according to claim 31, wherein the second press apparatus comprises an upper roller set and a lower roller set, with a space between the upper roller set and the lower roller set of the second press apparatus, and each of the plurality of upper rollers and the plurality of lower rollers of the second press apparatus is cooled to the second temperature and used together to provide the second pressure to the heated web received from the first press apparatus as the heated web passes between the upper roller set and the lower roller set of the second press apparatus.

35. The inline system according to claim 31, wherein the first press device and the second press device are part of a belt feeder device.

36. The inline system according to claim 35, wherein the first press device comprises an upper plate and a lower plate that sandwich the formed web on the belt feeder device.

37. The inline system according to claim 26, wherein the second press device comprises an upper plate and a lower plate that sandwich the heated web on the belt feeder device.

38. The inline system according to claim 31, wherein the first press device and the second press device are each configured to clamp the formed web in a direction parallel to the direction of movement of the moving support.

39. The inline system according to claim 31, wherein at least one of the first press device and the second press device is configured to clamp the formed web in a direction not parallel to the direction of movement of the moving support.

40. The inline system according to claim 31, further comprising a roller set configured to select the thickness of the formed web before providing the formed web to the first press device.

41. A system for manufacturing lightweight thermoplastic composite articles, The first subsystem, A mixing reservoir configured to receive a thermoplastic material and a reinforcing material and to provide a substantially homogeneous dispersion of the thermoplastic material and the reinforcing material, A mobile support fluidly coupled to the mixing reservoir and configured to receive the substantially homogeneous dispersion from the mixing reservoir, A pressure device configured to remove liquid from the dispersion received by the moving support, thereby providing a web of open-cell structures formed from the thermoplastic material and the reinforcing material. A first subsystem comprising, It is the second subsystem, A first press device configured to receive the formed web from the first subsystem and to apply heat and pressure to the formed web using a first temperature and a first pressure, and A second press device configured to receive the heated web from the first press device and to cool the heated web using a second temperature and a second pressure. A second subsystem comprising An inline system equipped with this feature.

42. The system according to claim 41, wherein the second press device is configured to cool the web at the second pressure in order to prevent any substantial change in the thickness of the heated web after it has been heated and pressed using the first press device.

43. The system according to claim 41, wherein the first press apparatus comprises an upper roller set and a lower roller set, there is a space between the upper roller set and the lower roller set of the first press apparatus, and each of the plurality of upper rollers and the plurality of lower rollers of the first press apparatus is heated to a first temperature and used together to provide the formed web with a first pressure as the formed web passes between the upper roller set and the lower roller set of the first press apparatus.

44. The system according to claim 41, wherein the second press apparatus comprises an upper roller set and a lower roller set, the space between the upper roller set and the lower roller set of the second press apparatus, and each of the plurality of upper rollers and the plurality of lower rollers of the second press apparatus is cooled to the second temperature and used together to provide the second pressure to the heated web received from the first press apparatus as the heated web passes between the upper roller set and the lower roller set of the second press apparatus.

45. The system according to claim 41, wherein the first press device and the second press device are part of a belt feeder device.

46. The system according to claim 45, wherein the first press device comprises an upper plate and a lower plate that sandwich the formed web on the belt feeder device.

47. The system according to claim 46, wherein the second press device comprises an upper plate and a lower plate that sandwich the heated web on the belt feeder device.

48. The system according to claim 41, wherein the first press device and the second press device are each configured to clamp the formed web in a direction parallel to the direction of movement of the moving support.

49. The system according to claim 41, wherein at least one of the first press device and the second press device is configured to clamp the formed web in a direction not parallel to the direction of movement of the moving support.

50. The system according to claim 41, further comprising a roller set configured to select the thickness of the formed web before providing the formed web to the second subsystem.

51. A process for forming a lightweight thermoplastic composite article comprising a web of open-cell structure formed from a reinforcing material held in place by a thermoplastic material, Heating the web to a first temperature higher than the melting point of the thermoplastic material, To provide a heated web having a first thickness by applying a first pressure at the first temperature, The heating web is cooled to a second temperature lower than the melting point of the first temperature, To provide a lightweight thermoplastic composite article having the first thickness by applying a second pressure at the second temperature to cool the heated web, wherein the second pressure is less than or equal to the first pressure. A process that includes this.

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