Composite article comprising a surface layer providing enhanced formability

Abstract

To provide a thermoplastic composite article having improved formability.SOLUTION: There are provided a prepreg, a composite and an article, which comprise a porous core layer and a surface layer comprising a bi-components fiber which can enhance formability of the article without breakthrough. The enhanced formability can permit forming or drawing of the article to increase depths without breakthrough. There are also provided interior and exterior automotive components including the articles.SELECTED DRAWING: Figure 1A

Description

Technical Field

[0001] Priority Application This application claims the benefit and priority of U.S. Provisional Application No. 62 / 433,154, filed Dec. 12, 2016, and U.S. Provisional Application No. 62 / 537,296, filed Jul. 26, 2017, the entire disclosure of each of which is hereby incorporated by reference herein for all purposes.

[0002] This application relates to thermoplastic composite articles having improved formability. More specifically, a particular configuration of a composite article that provides enhanced formability to enable deep drawing of the composite article is described below.

Background Art

[0003] Articles for automotive and structural applications are typically designed to meet many competing and stringent performance specifications. In many cases, the formation of the article may result in breakthroughs in one or more regions being formed.

Summary of the Invention

[0004] The particular configurations of the prepregs, cores, and composite articles described herein provide desirable attributes, including the ability to provide enhanced formability to a composite article, e.g., one or more surface layers including bicomponent fibers that can prevent or inhibit breakthrough during the forming process, e.g., lightweight materials that can include a fiber-based scrim including bicomponent fibers, but are not limited thereto.

[0005] In one aspect, a composite article includes a thermoplastic fiber-reinforced porous core layer and a surface layer. For example, the porous core layer can include a web formed from a plurality of reinforcing fibers and a thermoplastic material. The surface layer can include a plurality of bicomponent fibers, e.g., a plurality of sheath-core fibers or shell-core fibers. The surface layer is typically bonded to the porous core layer at one or more surfaces of the porous core layer.

[0006] In certain examples, at least 95% of the fibers in the surface layer are bicomponent fibers, such as core - sheath fibers, bicomponent fibers, coated fibers, etc. In other examples, the bicomponent fibers include fibers containing a polyethylene sheath or fibers containing a polypropylene sheath. In some examples, the bicomponent fibers can include polyester core fibers, such as polyethylene terephthalate core fibers having a polyethylene sheath or polyethylene terephthalate core fibers having a polypropylene sheath, or nylon core fibers having a polyethylene sheath or nylon core fibers having a polypropylene sheath. In some examples, the porous core layer includes a flame - retardant material, such as an expandable graphite material, magnesium hydroxide, aluminum hydroxide, or a combination thereof.

[0007] In one aspect, the composite article includes a thermoplastic fiber - reinforced porous core layer comprising a web formed from a plurality of reinforcing fibers and a thermoplastic material, and a surface layer, such as a non - woven scrim, bonded to the core layer at a first surface of the core layer, wherein the surface layer, such as the non - woven scrim, includes a plurality of sheath - core fibers, the sheath being a polyolefin, and for example, an article having a particular surface layer can provide enhanced formability without blow - through when the article is subjected to a deep drawing molding process.

[0008] In certain examples, at least 95 wt% of the fibers of the non - woven scrim are bicomponent fibers . For example, 95% by weight of the fibers in the surface layer can include polyolefin sheaths or core fibers including another material as a sheath. In some examples, the fibers of the scrim include polyethylene sheath fibers or polypropylene sheath fibers. In certain embodiments, the scrim includes polyester core fibers, such as polyethylene terephthalate core fibers. In other examples, the polyester fibers of the scrim include polyester core fibers including a polyethylene sheath, or polyester terephthalate core fibers including a polypropylene sheath, or combinations thereof. In some examples, the thermoplastic material of the core layer includes one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachloride, polyvinyl chloride, polyarylene ether, polycarbonate, polyester carbonate, thermoplastic polyester, polyimide, polyetherimide, polyamide, acrylonitrile-butyl acrylate-styrene polymer, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone, polyether sulfone, liquid crystal polymer, poly(1,4 phenylene) compound, high heat polycarbonate, high temperature nylon, silicone, or blends of these materials with each other. In other cases, the reinforcing fibers of the core layer include one or more of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, and metallized inorganic fibers, fibers, or combinations thereof. In some examples, the article includes a skin bonded to the second surface of the core layer. In certain cases, the skin is selected from the group consisting of a thermoplastic film, an elastomeric film, a flim (film + scrim), a scrim, a foil, a woven fabric, a non-woven fabric, a two-component fiber scrim (e.g., a two-component fiber scrim including sheath-core fibers), or exists as an inorganic coating, an organic coating, a thermoplastic coating, or a thermosetting coating. In some embodiments, the porous core further includes a lofting agent. In some examples, the porosity of the porous core layer is at least 20%.In other examples, based on the weight of the porous core layer, the thermoplastic material is present in an amount of about 20 wt% to about 80 wt%, and the reinforcing fibers are present in an amount of about 20 wt% to about 80 wt%. In certain embodiments, the thermoplastic material includes a polyolefin, the reinforcing fibers include glass fibers, the lofting agent includes microspheres, the surface layer includes sheath-core fibers, the sheath material is a polyolefin, and the core fibers are thermoplastic fibers or polyester fibers. In some examples, the article includes at least one deep draw region having a depth of at least 10 cm, at least 20 cm, at least 30 cm, or at least 40 cm. In some examples, the basis weight of the surface layer is at least 10 gsm, or about 10 gsm to about 300 gsm, or about 15 gsm to about 50 gsm. In other examples, the article includes a decorative layer bonded to the article. In certain embodiments, the porous core layer has a basis weight of about 300 gsm to about 3500 gsm.

[0009] In another aspect, a fiber reinforced thermoplastic composite article includes a thermoplastic fiber reinforced porous core layer including a web formed from a plurality of reinforcing fibers and a thermoplastic material, and a surface layer bonded to the core layer at a first surface of the core layer, the surface layer including a bicomponent thermoplastic fiber including a plurality of two-component thermoplastic fibers, such as sheath-core fibers, the sheath including a polyolefin, and the article including at least one deep draw region having a depth of at least 1 cm (or 5 cm, or 10 cm) without break-through in at least one deep draw.

[0010] In certain examples, at least 95 wt% of the fibers of the surface layer include sheath-core fibers. In some embodiments, the thermoplastic fibers of the surface layer include polyethylene sheath fibers or polypropylene sheath fibers. In other examples, the surface layer includes polyester core fibers, such as polyethylene terephthalate core fibers. In some embodiments, the polyester core fibers of the surface layer include a polyethylene sheath, or a polypropylene sheath, or a combination thereof. In certain examples, the thermoplastic material of the core layer is polyeth Ren, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachloride, polyvinyl chloride, polyarylene ether, polycarbonate, polyester carbonate, thermoplastic polyester, polyimide, polyetherimide, polyamide, acrylonitrile-butyl acrylate-styrene polymer, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone, polyether sulfone, liquid crystal polymer, poly(1,4 phenylene) compound, high heat polycarbonate, high temperature nylon, silicone, or a blend of these materials with each other, including one or more of them. In other cases, the reinforcing fibers of the core layer include one or more of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, and metallized inorganic fibers, fibers, or combinations thereof. In some examples, the article includes a skin bonded to the second surface of the core layer. In certain examples, the skin is selected from the group consisting of a thermoplastic film, an elastomeric film, a frim, a scrim, a foil, a woven fabric, a non-woven fabric, a sheath-core fiber scrim, or exists as an inorganic coating, an organic coating, a thermoplastic coating, or a thermosetting coating. In some embodiments, the porous core further includes a lofting agent. In a further case, the porosity of the porous core layer is at least 20%. In a specific example, based on the weight of the porous core layer, the thermoplastic material is present in an amount of about 20% to about 80% by weight, and the reinforcing fibers are present in an amount of about 20% to about 80% by weight. In some embodiments, the thermoplastic material includes a polyolefin, the reinforcing fibers include glass fibers, the lofting agent includes microspheres, the surface layer includes a scrim containing sheath-core fibers, the sheath material includes a polyolefin, and the core includes thermoplastic fibers or polyester fibers. In a specific example, the article includes at least one deep draw region having a depth of at least 20 cm. In some examples, the article includes at least one deep draw region having a depth of at least 40 cm. In other examples, the article includes at least one deep draw region having a depth of at least 45 cm.In certain embodiments, the surface layer is a scrim having a basis weight of at least 10 gsm, or from about 10 gsm to about 300 gsm, or from about 15 gsm to about 50 gsm. In some examples, the scrim is composed of a sheath-core fiber nonwoven arrangement, the sheath contains a polyolefin, the core contains a thermoplastic fiber or a polyester fiber, and at least 95% by weight of the fibers are sheath-core fibers. In further examples, the article includes a decorative layer bonded to the article. In certain embodiments, the porous core layer has a basis weight of from about 300 gsm to about 3500 gsm.

[0011] In additional aspects, the thermoplastic composite article includes a thermoplastic fiber reinforced porous core layer including a web formed from a plurality of reinforcing fibers and a thermoplastic material, and a surface layer bonded to the core layer at a first surface of the core layer, the surface layer including bicomponent fibers such that the composite article has improved formability and can be subjected to a deep drawing forming process without blow-through. For example, the surface layer can be selected for use in the composite article based on having increased elongation prior to bonding the surface layer to the core layer. In some cases, the elongation of the surface layer can be at least 20% greater in the machine direction and in the cross direction when tested by ASTM test method D5304-09(2013) as compared to a similar surface layer including only single component fibers, for example, a surface layer including single component fibers without a sheath.

[0012] In certain embodiments, at least 95% by weight of the fibers of the surface layer are bicomponent fibers. For example, 95% by weight of the fibers within the surface layer can include sheath-core fibers, the sheath containing a polyolefin. In other embodiments, the bicomponent fibers of the surface layer include polyethylene sheath fibers or polypropylene sheath fibers. In some examples, the surface layer includes polyester core fibers. In certain cases, the polyester core fibers of the surface layer include a polyethylene sheath, or a polypropylene sheath, or a combination thereof . In some embodiments, the thermoplastic material of the core layer includes one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachloride, polyvinyl chloride, polyarylene ether, polycarbonate, polyester carbonate, thermoplastic polyester, polyimide, polyetherimide, polyamide, acrylonitrile-butyl acrylate-styrene polymer, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyarylsulfone, polyethersulfone, liquid crystal polymer, poly(1,4 phenylene) compound, high heat polycarbonate, high temperature nylon, silicone, or blends of these materials with each other. In other embodiments, the reinforcing fibers of the core layer include one or more of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, and metallized inorganic fibers, or combinations thereof. In certain examples, the article includes a skin bonded to a second surface of the core layer. In some embodiments, the skin is selected from the group consisting of a thermoplastic film, an elastomeric film, a film, a scrim, a foil, a woven fabric, a non-woven fabric, a sheath-core fiber scrim, or is present as an inorganic coating, an organic coating, a thermoplastic coating, or a thermosetting coating. In certain examples, the porous core further includes a lofting agent. In some embodiments, the porosity of the porous core layer is at least 20%. In other examples, based on the weight of the porous core layer, the thermoplastic material is present in an amount of about 20 wt% to about 80 wt%, and the reinforcing fibers are present in an amount of about 20 wt% to about 80 wt%. In certain cases, the thermoplastic material includes a polyolefin, the reinforcing fibers include glass fibers, the lofting agent includes microspheres, and the surface layer includes a scrim including sheath-core thermoplastic fibers. In other examples, the article includes at least one deep draw region having a depth of at least 20 cm, at least 30 cm, or at least 40 cm, or at least 45 cm. In certain examples, the surface layer is a scrim having a basis weight of at least 10 gsm, or from about 10 gsm to about 300 gsm, or from about 15 gsm to about 50 gsm.In some embodiments, the scrim is composed of a non-woven arrangement of thermoplastic core fibers having a polyolefin sheath, and at least 95% of the thermoplastic core fibers contain a polyolefin sheath. In certain embodiments, the article includes a decorative layer bonded to the article. In certain examples, the porous core layer has a basis weight of from about 300 gsm to about 3500 gsm.

[0013] In another aspect, a method of producing a thermoplastic composite article includes disposing a surface layer comprising sheath-core thermoplastic fibers over a thermoplastic fiber reinforced porous core layer comprising a web formed from a plurality of reinforcing fibers and a thermoplastic material.

[0014] In some examples, the method includes combining a thermoplastic material and fibers to form agitated aqueous foam, disposing the agitated aqueous foam over a wire support, draining the water to form a web of fibers held together by the thermoplastic material, heating the web to a first temperature above the melting temperature of the thermoplastic material, and compressing the web to a first thickness, to form a porous core layer. In certain examples, the method includes forming a surface layer by disposing a surface layer comprising a plurality of sheath-core fibers over the core layer. In some cases, the method includes forming a surface layer by forming a non-woven scrim comprising a plurality of sheath-core fibers after disposing the surface layer over the core layer. In other examples, the method includes forming a surface layer by providing aqueous foam to the core fibers of the surface layer and disposing the foam over the core fibers of the surface layer. In certain embodiments, the method includes spraying aqueous foam over the core fibers of the surface layer. In some examples, the method includes immersing the surface layer in the aqueous foam. In other examples, the method includes heating the article to melt the sheath material of the surface layer. In certain cases, the method includes subjecting the article to a forming process to deep draw at least one region to a depth of 10 cm or more without break-through. In other examples, the method includes bonding a decorative layer to the core layer.

[0015] In another aspect, a method of producing a thermoplastic composite article includes combining a thermoplastic material and fibers to form agitated aqueous bubbles, disposing the agitated aqueous bubbles onto a wire support, draining the water to form a web of fibers held together by the thermoplastic material, heating the web to a first temperature above the melting temperature of the thermoplastic material, disposing a surface layer including sheath-core fibers onto the heated web to provide a composite article, and compressing the composite article to a first thickness.

[0016] In certain embodiments, the method includes selecting the thermoplastic material of the porous core layer to include a polyolefin. In other examples, the method includes selecting the fibers to include one or more of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, and metallized inorganic fibers, fibers, or combinations thereof. In some examples, the method includes forming a thermoplastic article to include at least one deep draw region without break-through in the deep draw region. In certain embodiments, the method includes deep drawing the region to a depth of at least 1 cm without break-through, at least 10 cm without break-through, at least 20 cm without break-through, at least 30 cm without break-through, or at least 40 cm without break-through. As described in more detail below, the exact draw depth achievable without break-through can depend, at least in part, on the width or diameter of the draw region. In some examples, the method includes heating the composite article to melt or soften the sheath material of the sheath-core fibers of the surface layer to at least some extent to increase the adhesion between the surface layer and the core layer. In other examples, the method includes compressing the composite article after melting or softening the sheath material of the sheath-core fibers to at least some extent.

[0017] In another aspect, a method of producing a thermoplastic composite article includes combining a thermoplastic material and fibers to form agitated aqueous foam, disposing the agitated aqueous foam onto a wire support, draining water to form a web of fibers held together by the thermoplastic material, heating the web to a first temperature above the melting temperature of the thermoplastic material, compressing the article to a first thickness, and disposing a surface layer including sheath-core fibers onto the compressed web to provide a composite article.

[0018] In certain embodiments, the method includes selecting the thermoplastic material of the porous core layer to include a polyolefin. In other examples, the method includes selecting the fibers to include one or more of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, and metallized inorganic fibers, fibers, or combinations thereof. In some examples, the method includes forming a thermoplastic article to include at least one deep draw region without break-through in a deep draw region. In certain examples, the method includes deep drawing a region to a depth of at least 1 cm without break-through, or at least 5 cm without break-through, or at least 10 cm without break-through. In other examples, the method includes deep drawing a region to a depth of at least 20 cm without break-through, or a minimum of 30 cm without break-through, or a minimum of 30 cm without break-through. In some examples, the method includes heating the composite article to melt or soften the sheath material of the sheath-core fibers of the surface layer to at least some extent to increase the adhesion between the surface layer and the core layer. In certain examples, the method includes compressing the composite article after melting or softening the sheath material of the sheath-core fibers to at least some extent.

[0019] In another aspect, the thermoplastic article includes a thermoplastic fiber reinforced porous core layer that includes a web formed from a plurality of reinforcing fibers and a thermoplastic material, and a nonwoven scrim bonded to the core layer at a first surface of the core layer. The nonwoven scrim includes a plurality of bicomponent fibers, such as sheath-core fibers, and includes a polyolefin to increase the peel strength between the nonwoven scrim and the core layer as compared to the peel strength provided by a corresponding nonwoven scrim that includes a plurality of single-component fibers, such as fibers without a sheath material.

[0020] Additional features, aspects, examples, configurations, and embodiments are described in further detail below. Specific embodiments are described with reference to the accompanying drawings.

Brief Description of the Drawings

[0021]

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DETAILED DESCRIPTION OF THE INVENTION

[0022] One of ordinary skill in the art will recognize that, in light of the benefits of the present disclosure, in order to provide more user-friendly forms of the drawings, certain dimensions or features in the drawings may be enlarged, distorted, or otherwise presented in a manner that is not bound by or otherwise proportional to other conventions. Specific thicknesses, widths, or lengths are not intended by the drawing depictions, nor are they intended to limit the relative sizes of the components of the drawings or the size of any of the components of the drawings. When dimensions or values are specified in the following description, the dimensions or values are provided for illustrative purposes only. Additionally, shading of specific portions of the drawings is not intended to require a specific material or arrangement, and even if different components of the drawings may include shading for differentiation, the different components may include the same or similar materials if desired. In some cases, a core layer comprising fibers, a thermoplastic material, and optionally a lofting agent is shown as including stubs or dots for illustrative purposes. The arrangement of stubs and dots does not suggest a specific distribution, unless otherwise specified, in the context of describing a particular drawing.

[0023] Certain embodiments are described below with reference to singular and plural terms to more clearly explain the technology disclosed herein to the user. These terms are used for convenience only and are not intended to limit prepregs, cores, articles, composites, and other objects to include or exclude specific features, unless otherwise noted, as being present in or excluded from the particular embodiments described herein.

[0024] In certain cases, thermoplastic composite articles are often formed into various shapes, e.g., molded or processed, to provide a final formed part or article. In some cases, the article is formed into parts used in the automotive industry, including, but not limited to, ceilings, rear window trims, trunk trims, door trims, seat backs, pillars, and compartment covers. During the forming process, the forming or drawing of one or more regions of the thermoplastic region can result in breakthroughs, e.g., cracks, slits, holes, etc., such that the material can become unacceptable in the case of deep drawing. In certain examples described herein, the presence of a surface layer containing a two-component fiber can allow for increasing the draw depth of the composite article, e.g., to 10 cm, 20 cm, 30 cm, 40 cm, or more, without breakthrough of the article in the draw region. The exact forming or draw depth of the thermoplastic article can depend on the dimensional width of the forming or draw region. While not wishing to be bound by any particular measurement method, one useful measurement method is to compare the draw depth ratio. As used herein, the draw depth ratio refers to the cavity depth divided by the maximum horizontal dimension of the cavity. For example, in the case of a frustum of a cone, e.g., a frustum or a conical frustum having a truncated body, for a base diameter of about 40 mm and a draw depth or height of about 20 mm, the draw depth ratio is about 0.5 (20 mm / 40 mm). By using the surface layer having a two-component fiber described herein, a higher draw depth ratio can be achieved without breakthrough compared to the draw depth ratio achievable without breakthrough when using a surface layer containing a single-component fiber. The various examples below are with respect to the draw depth ratio for purposes of comparison.

[0025] In some cases, the surface layers described herein can be used to increase the draw depth ratio by 10%, 20%, 30%, 40%, or 50% in the draw region without break-through. As a control or reference, the increase in the draw depth ratio can be compared to a similar composite article that includes a surface layer containing single-component fibers of a similar composition. For example, the control or reference can include a surface layer containing polyethylene fibers, and the surface layer of the composite article having enhanced formability can include sheath-core fibers, where the core fibers include polyethylene and the sheath includes a thermoplastic material. In some examples, the draw depth ratio of at least one draw region of the composite article having enhanced formability is at least 0.8 without break-through in the draw region, or at least 1.0 without break-through, or at least 1.25 without break-through, or at least 1.4 or 1.5 without break-through. In some cases, the surface layers described herein can be used to increase the draw depth ratio by 10%, 20%, 30%, 40%, or 50% in the draw region without break-through. As a control or reference, the increase in the draw depth ratio can be compared to a similar composite article that includes a surface layer containing single-component fibers of a similar composition. For example, the control or reference can include a surface layer containing polyethylene fibers, and the surface layer of the composite article having enhanced formability can include sheath-core fibers, where the core fibers include polyethylene and the sheath includes a thermoplastic material. In some examples, the draw depth ratio of at least one draw region of the composite article having enhanced formability is at least 0.8 without break-through in the draw region, or at least 1.0 without break-through, or at least 1.25 without break-through, or at least 1.4 or 1.5 without break-through.

[0026] In certain configurations, the articles described herein can include a prepreg or a core layer. Without wishing to be bound by any particular theory, a prepreg is generally not the fully formed or processed version of the core. For example, a partially cured layer that includes a thermoplastic material, a plurality of reinforcing fibers, and optionally a lofting agent is generally referred to as a prepreg, while a fully cured layer that includes a thermoplastic material, a plurality of reinforcing fibers, and optionally a lofting agent is generally referred to as a core or a core layer. As described herein, even when the core can be considered cured, the core can still be combined with one or more surface layers (or other layers) to change the overall properties of the composite article that includes the core layer. The following description refers to both prepregs and cores, and the materials (as well as their amounts and properties) used with prepregs can also be used or present in the core as desired.

[0027] As described in further detail below, the articles described herein are generally porous and can generally permit the passage of fluids, such as gases, through the articles. In some instances, the various components of the article can be selected such that the article does not function as a barrier to fluid flow. In other instances, the prepreg or core of the article can be porous and the article can include one or more surface layers that can function as a barrier or can be non-barrier. In some instances, extrusion can reduce the porosity to about 0% and can affect the lofting ability of the articles described herein, and thus the prepregs and cores of the articles described herein are not extruded articles.

[0028] In certain embodiments, the enhanced formability of the articles described herein can allow for a reduction in the basis weight of the prepreg or core layer while still allowing for deep drawing of the article to a desired depth. In some instances, when using a surface layer that includes bicomponent fibers, the core basis weight can be reduced by 5%, 10%, 15%, 20%, 25%, 30%, or even 35% compared to, for example, the same scrim that includes the same core fibers without a sheath material, when compared to a conventional surface layer.

[0029] Referring to FIG. 1A, article 100 includes a surface layer 110 containing two-component fibers on surface 104, such as a prepreg 105 bonded to a scrim. Optionally, surface layer 110 can be bonded to surface 102 instead, or as described below, the scrim can be bonded to each of surfaces 102, 104. Optionally, each scrim bonded to surfaces 102, 104 can contain two-component fibers. Prepreg 105 includes a thermoplastic material and a plurality of reinforcing fibers. As described in more detail below, the reinforcing fibers of the prepreg can be single-component fibers or two-component fibers, as desired. Prepreg 105 also optionally includes a lofting agent dispersed through prepreg 105. In some cases, the materials of prepreg 100 can be dispersed substantially homogeneously or substantially uniformly from the first surface 102 to the second surface 102 of prepreg 105. As described in more detail herein, to achieve such a substantially homogeneous or substantially uniform distribution of materials within prepreg 105, the components of prepreg 105 can be mixed together to form a dispersion. The mixing can be carried out until the dispersion contains a substantially homogeneous or substantially uniform mixture of reinforcing fibers and optional lofting agent within the dispersion. Then, for example, using an appropriate laying process or other appropriate The prepreg 105 can be formed as described herein by using a technique to place the dispersion onto the wire screen. In other configurations, it may be desirable to provide a gradient distribution of either, or both, of the reinforcing fibers or lofting agent such that one of the materials is present more towards one of the surfaces 102, 104 than the other surface. The gradient of the reinforcing fibers or lofting agent can be generated, for example, by spraying or coating the surface of the prepreg 105 with additional reinforcing fibers or lofting agent. The prepreg 105 can also include fibers of a second type different from the first type. The fibers of the second type can be hydrophilic fibers such as glass fibers, thermoplastic fibers, etc. Further, the fibers of the second type can be of the same general type as the first, for example, both fibers can be reinforcing fibers of the same composition, but the fibers can be configured with different lengths, different diameters, etc.

[0030] In certain configurations, the thermoplastic material of the prepreg can be present in fiber form, particle form, resin form, or other suitable forms. In some cases, the thermoplastic material used in the prepreg can be present in particle form. For example, the thermoplastic particles can be mixed with reinforcing fibers, lofting agents, and any other particles or materials present to provide a dispersion of the materials. The dispersion can be used to provide the prepreg 105 by forming a substantially planar structure or board that allows the sheet to solidify or cure. In certain embodiments, the prepreg 105 generally includes a significant amount of open cell structure such that void spaces are present within the prepreg. For example, the prepreg layer 105 can be configured with a void content or porosity of 0 to 30%, 10 to 40%, 20 to 50%, 30 to 60%, 40 to 70%, 50 to 80%, 60 to 90%, 0 to 40%, 0 to 50%, 0 to 60%, 0 to 70%, 0 to 80%, 0 to 90%, 10 to 50%, 10 to 60%, 10 to 70%, 10 to 80%, 10 to 90%, 10 to 95%, 20 to 60%, 20 to 70%, 20 to 80%, 20 to 90%, 20 to 95%, 30 to 70%, 30 to 80%, 30 to 90%, 30 to 95%, 40 to 80%, 40 to 90%, 40 to 95%, 50 to 90%, 50 to 95%, 60 to 95%, 70 to 80%, 70 to 90%, 70 to 95%, 80 to 90%, 80 to 95%, or any exemplary value within these exemplary ranges. In some cases, the prepreg is configured with a porosity or void content of greater than 0%, for example up to about 95% porosity or void content that is not fully consolidated. Unless otherwise indicated, references to a prepreg configured with a particular void content or porosity are based on the total volume of the prepreg and do not necessarily include the total volume of any other materials or layers bonded to the prepreg in forming the final article. The exact porosity can vary, but prepregs produced using reinforcing fibers and a thermoplastic material, such as reinforcing fibers combined with a polyolefin thermoplastic material, can have a porosity of about 5% to about 90%, or about 10% to about 75%, or about 15% to about 60%, or about 20% to about 55%.

[0031] In certain embodiments, the thermoplastic material of the prepreg described herein can at least partially include one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachloride, and polyvinyl chloride (plasticized and unplasticized), as well as blends of these materials with each other or blends with other polymeric materials. Other suitable thermoplastics include polyarylene ether, polycarbonate, polyester carbonate, thermoplastic polyester, polyimide, polyetherimide, polyamide, acrylonitrile-butyl acrylate-styrene polymer, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone, polyether sulfone, liquid crystal polymer, poly(1,4 phenylene) compounds commercially known as PARMAX®, high heat polycarbonates such as Bayer's APEC® PC, high temperature nylons, and silicones, as well as alloys and blends of these materials with each other, or other polymeric materials having a processing temperature lower than the thermal degradation temperature of the reinforcing fibers, but are not limited thereto. The thermoplastic material used to form the prepreg can be used in powder form, resin form, rosin form, fiber form, combinations thereof, or other suitable forms. Exemplary thermoplastic materials in various forms are described herein, and are also described, for example, in U.S. Patent Application Publication Nos. 2013 / 0244528 and 2012 / 0065283. The exact amount of thermoplastic material present in the prepreg can vary, but exemplary amounts range from about 20 wt% to about 80 wt%. As described in more detail below, any one or more of these thermoplastic materials can be coated onto the fibers of a non-prepreg layer, such as a scrim, or can be present on the fibers themselves prior to forming the non-prepreg layer. Examples include, but are not limited to, alloys and blends of these materials with each other, or other polymeric materials having a processing temperature lower than the thermal degradation temperature of the reinforcing fibers. The thermoplastic material used to form the prepreg can be used in powder form, resin form, rosin form, fiber form, combinations thereof, or other suitable forms. Exemplary thermoplastic materials in various forms are described herein, and are also described, for example, in U.S. Patent Application Publication Nos. 2013 / 0244528 and 2012 / 0065283. The exact amount of thermoplastic material present in the prepreg can vary, but exemplary amounts range from about 20 wt% to about 80 wt%. As described in more detail below, any one or more of these thermoplastic materials can be coated onto the fibers of a non-prepreg layer, such as a scrim, or can be present on the fibers themselves prior to forming the non-prepreg layer.

[0032] In certain examples, the reinforcing fibers present within the prepreg 105 can include numerous types of fibers or mixtures thereof. For example, the prepreg 105 can include glass fibers, carbon fibers, graphite fibers, synthetic organic fibers such as para and meta aramid fibers, nylon fibers, polyester fibers, or other particularly high modulus organic fibers such as materials described herein suitable for use as fibers, natural fibers such as hemp, sisal, jute, linen, coir, kenaf, and cellulose-based fibers, mineral fibers such as basalt, mineral wool (e.g., rock wool or slag wool), wollastonite, alumina silica, and the like, or mixtures thereof, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. The total fiber content within the prepreg can be from about 20 wt% to about 80 wt% of the prepreg, more specifically from about 30 wt% to about 70 wt% of the prepreg. Typically, the fiber content of a composite article including the prepreg varies between about 20% and about 60 wt%.

[0033] In certain examples, the specific size and / or orientation of the fibers used can depend, at least in part, on the polymer material used and / or the desired properties of the resulting prepreg 105. Exemplary reinforcing fibers dispersed within a thermoplastic material can be configured with a diameter greater than about 5 microns, more specifically a diameter from about 5 microns to about 22 microns, and a length from about 5 mm to about 200 mm, or from about 5 mm to about 100 mm, or from about 5 mm to about 50 mm, or from about 5 mm to about 20 mm. In some cases, the fiber diameter can be from about 5 microns to about 22 microns and the fiber length can be from about 5 mm to about 75 mm. In other instances, the fiber diameter can be from about 10 microns to about 20 microns and the length can be from about 5 mm to about 15 mm.

[0034] In some cases, the reinforcing fibers present in the prepreg can be sheath-core reinforcing fibers. For example, as described below, the two-component fibers present in a surface layer such as a scrim can include a sheath-core structure. Optionally, the reinforcing fibers present in the prepreg can also include one or more sheath-core fibers. In some examples, the sheath material present in the core reinforcing fibers of the prepreg can be the same material as the material present as the sheath material of the fibers present in the surface layer. In other examples, the sheath material present in the core reinforcing fibers of the prepreg can be a different sheath material than the sheath material present in the core fibers present in the surface layer. In some cases, the reinforcing fibers of the prepreg can include a polyolefin sheath, such as polyethylene, polypropylene, etc. The polyolefin can be a low-density polyolefin, a high-density polyolefin, or a combination thereof. In some examples, the sheath material, the reinforcing fibers, can be selected such that it melts or flows during the processing of the prepreg, whereas the underlying core fiber material generally does not melt or flow during the processing of the prepreg.

[0035] In some configurations, the prepreg 105 can be substantially halogen-free or halogen-free to meet the regulations regarding the requirements of harmful substances for specific applications. In other cases, the prepreg 105 can contain a halogenated flame retardant, which can include, for example, one or more of F, Cl, Br, I, and At, or a compound containing such a halogen, such as tetrabromobisphenol-A polycarbonate, or mono-halo-, di-halo-, tri-halo-, or tetra-halo-polycarbonate. In some cases, the thermoplastic material used within the prepreg and the core can contain one or more halogens to impart a certain degree of flame retardancy without the addition of another flame retardant. When a halogenated flame retardant is present, the flame retardant is desirably present in an amount of the flame retardant that can vary depending on the other components present. For example, the halogenated flame retardant can be present at about 0.1 wt% to about 15 wt%, more specifically about 1 wt% to about 13 wt%, such as about 5 wt% to about 13 wt% (based on the weight of the prepreg 105). Optionally, two different halogenated flame retardants can be added to the prepreg. In other cases, a non-halogenated flame retardant, such as a flame retardant containing one or more of N, P, As, Sb, Bi, S, Se, and Te, can be added. In some embodiments, the non-halogenated flame retardant can contain a phosphorus-containing material, thus making the prepreg more environmentally friendly. When a non-halogenated flame retardant or a substantially halogen-free flame retardant is present, the flame retardant is desirably present in an amount of the flame retardant that can vary depending on the other components present. For example, the substantially halogen-free flame retardant can be present at about 0.1 wt% to about 15 wt%, more specifically, based on the weight of the prepreg 105, about 1 wt% to about 13 wt%, such as about 5 wt% to about 13 wt%. Optionally, two different substantially halogen-free flame retardancies can be added to the prepreg 105.In certain cases, the prepregs described herein can include one or more halogenated flame retardants in combination with one or more substantially halogen-free flame retardants. When two different flame retardants are present, the combination of the two flame retardants can be present in amounts of flame retardant that can vary depending on the other components present. For example, the total weight of the flame retardant present can be from about 0.1 wt% to about 20 wt% (based on the weight of the prepreg 105), more specifically, from about 1 wt% to about 15 wt% based on the weight of the prepreg 105, such as from about 2 wt% to about 14 wt%. The flame retardants used in the prepregs described herein can be added to the mixture containing the thermoplastic material and the reinforcing fibers, or can be added after the prepreg 105 is formed. In some examples, the prepreg can include carbon black, an expandable graphite material, or an inorganic flame retardant such as magnesium hydroxide or aluminum hydroxide.

[0036] In certain embodiments, when a lofting agent is present within the prepreg 105, the lofting agent can be used to increase (or decrease) the overall size of the prepreg 105, such as the thickness, by varying the temperature. In some cases, heating the prepreg 105 containing the lofting agent increases the overall thickness of the prepreg 105. The exact lofting temperature used can be varied and is typically selected such that the temperature is lower than the thermal degradation temperature of the reinforcing fibers and exceeds the melting / softening point of the thermoplastic material. Further, the amount of the lofting agent can be varied as desired. In some examples, the prepreg 105 can be compressed to its pre-lofting thickness and further processed, such as thermoformed, molded, etc., to allow the thickness of the prepreg 105 to be increased to a desired thickness. Further, softening the prepreg can also serve to enable processes such as deep drawing or other processes that can form a multi-dimensional structure from the prepreg 105. In some examples, the lofting agent can be a microsphere-based lofting agent, an expandable graphite material, a chemical foaming agent, or a combination thereof. The amount of the lofting agent present within the prepreg 105 can be varied, for example, from about 1 wt% to about 10 wt% based on the weight of the prepreg 105. Based on the weight of the prepreg 105, it can be varied, for example, from about 1 wt% to about 10 wt%.

[0037] In certain configurations, the surface layer 110 can include a plurality of fibers, such as a plurality of bicomponent fibers. The exact configuration of the bicomponent fibers can vary, but in some examples, the fibers can be sheath-core, shell-core, or coated in order to enhance the formability of the article 100 during processing. For example, the surface layer 110 can include fibers produced from a first core material having a sheath or shell of a second different material such that the bonding of the prepreg 105 (or core) of the surface layer 110 provides an increased elongation of the article 100 compared to the elongation provided when a corresponding surface layer without sheath or shell material is present. In some examples, a scrim having bicomponent fibers can have an elongation of at least 30%, 40%, 50%, 60%, or 70% in one or both of the machine direction and the cross direction when compared to a control scrim, such as a scrim including fibers of a first composition without a sheath material. The increased elongation of the scrim enables, at least in part, increasing the draw depth of the article without break-through, e.g., without tears (at least in certain regions). The elongation of the scrim or surface layer can be measured in a number of ways, including using, for example, the ASTM 5304-09(2013) test entitled "Breaking Strength and Elongation of Textile Fabrics (Grab Test)". In certain embodiments, the presence of the surface layer 110 enables an increase in the draw depth ratio of at least 10% or more without break-through compared to the draw depth ratio of a corresponding article without sheath-core fibers in the surface layer. In some embodiments, the presence of the surface layer 110 enables an increase in the draw depth ratio of at least 20% or more without break-through compared to the draw depth ratio of a corresponding article without sheath-core fibers in the surface layer. In other embodiments, the presence of the surface layer 110 enables an increase in the draw depth ratio of at least 30% without break-through compared to the draw depth ratio of a corresponding article without sheath-core fibers in the surface layer.In some embodiments, the presence of the surface layer 110 enables an increase in the draw depth ratio of at least 40% or more without breakthrough, compared to the draw depth ratio of a corresponding article that does not contain sheath-core fibers within the surface layer. In certain embodiments, the presence of the surface layer 110 enables an increase in the draw depth ratio of at least 50% or more without breakthrough, compared to the draw depth ratio of a corresponding article that does not contain sheath-core fibers within the surface layer and does not experience breakthrough. In some embodiments, the basis weight of the surface layer can be from about 10 gsm to about 100 gsm, such as 10 gsm, 20 gsm, 30 gsm, 40 gsm, 50 gsm, 60 gsm, 70 gsm, 80 gsm, 90 gsm, 100 gsm, 40 - 60 gsm, or other basis weights, but still be effective in providing enhanced formability when used in a composite article. In other embodiments, the two-component fibers may not necessarily include a coating, but can include two different materials used together to provide the fibers, for example, the sheath material can surround the core material. Additionally, three-component, four-component, and other multi-component fibers can also be used. For example, the base fiber material can be coated with or include two different materials such that it can provide a three-component fiber that can be used in the surface layer of an article that includes a porous core layer. An example of a two-component fiber is shown in FIG. 1B, where the two-component fiber 150 includes a core fiber 155 and a sheath or shell material 160 that surrounds the core fiber 155. The two-component fiber 150 can be considered to have a sheath-core or a shell-core with the core being the fiber 155 and the sheath or shell being the material 160. For example, a sheath-core fiber can be considered to be a fiber within a fiber. For illustrative purposes, the sheath 160 is shown surrounding the entire side of the core fiber 155, but the sheath material 160 does not need to be uniform over the entire surface of the core fiber 155. Additionally, other sheath materials or coatings can be disposed over the sheath material 160 to provide a multi-component fiber for use in the surface layer.

[0038] In some examples, the sheath material of the fibers of the surface layer 110 can include the same material as the thermoplastic material present in the prepreg 105. In other examples, the sheath material of the fibers of the surface layer 110 can include a material different from the thermoplastic material present in the prepreg 105. In still other embodiments, the sheath material of the fibers of the surface layer 110 can include the same general class as the thermoplastic material of the prepreg 105, such as polyolefin. For example, both materials can be thermoplastic materials, but the specific materials used can be different. For example, the prepreg 105 can include polypropylene, and the sheath material of the fibers of the surface layer 110 can include polyethylene. The exact type of core fibers present in the scrim can vary, and exemplary fibers include, but are not limited to, glass fibers, nylon fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, metallized inorganic fibers, polyester fibers, and thermoplastic fibers. When polyester fibers are used within the core fibers, the polyester material can be one or more of polyethylene terephthalate, polyethylene terephthalate, polypropylene terephthalate, polybutylene terephthalate, or other materials containing two or more ester groups. Although many different fiber types can be used, still, in some configurations, the fibers used in the surface layer 110 preferably have a melting point higher than the thermoplastic material present in the prepreg 105. This configuration allows the prepreg 105 to be softened or melted by heating that does not significantly soften or melt the core fibers within the surface layer 110. The sheath material of the fibers of the surface layer 110 can have a softening point / melting point lower than, the same as, or higher than the thermoplastic material of the prepreg 105. For example, in some cases, the coating of the fibers of the surface layer 110 can be softened / melted (at least to some extent) during the formation of the article 100.In some configurations, the sheath material of the fibers of the surface layer 110 can be a polyolefin, such as polyethylene, polypropylene, etc., and the fibers used in the surface layer can include thermoplastic fibers, such as polyethylene terephthalate or other fibers.

[0039] In certain examples, the exact proportion of sheath-core fibers present within the surface layer 110 can vary from at least 80 wt%, to at least 90 wt%, at least 95 wt%, at least 99 wt%, and even up to 100 wt% based on the total weight of the fibers present within the surface layer 110. In some examples, to provide enhanced formability to the article, substantially all of the fibers present within the surface layer 110 are bicomponent fibers, such as sheath-core fibers. As described in more detail below, the surface layer 110 can be produced in a number of ways including preforming the surface layer 110 by forming the surface layer of sheath-core fibers into a desired structure. In some examples, the core fibers are used to form the surface layer 110, and then the formed surface layer 110 is dipped, immersed, sprayed, or otherwise provided with a coating in a number of ways to provide a coating to the formed surface layer 110 to provide a surface layer that includes sheath-core fibers. In further examples, the sheath material can be applied to the surface layer 110 either before the surface layer 110 is bonded to the prepreg 105 or after the surface layer 110 is bonded to the prepreg 105. In some cases, the formed article, such as a surface layer that includes core + core fibers, is dipped or immersed in a coating of sheath material applied to the core fibers of the surface layer, and the resulting article is dried, heated, or otherwise processed as desired to form the article into a desired shape or component, such as a vehicle trim or other interior or exterior part of an automobile. The surface layer 110 is typically composed of a non-woven arrangement of sheath-core fibers, although other arrangements and configurations are possible depending on the technique used to produce the surface layer 110.

[0040] In certain configurations, the articles described herein can include a porous core. In a specific example, the porous core includes one or more thermoplastic materials and a plurality of reinforcing fibers, and the reinforcing fibers are adapted within a web or network structure by the formed thermoplastic material It can be held in a place to provide a plurality of open cells, voids, or webs within the core. In certain configurations, a core similar to the prepreg of FIG. 1 can be produced. The core includes reinforcing fibers and, optionally, a lofting agent dispersed throughout the core. In some cases, the distribution of the reinforcing fibers and / or the lofting agent within the core can be substantially homogeneous or substantially uniform from a first surface of the core to a second surface. As described in more detail herein, to achieve such a substantially homogeneous or substantially uniform distribution of materials within the core, the components within the core can be mixed together to form a dispersion. The mixing can be carried out until the dispersion contains a substantially homogeneous or substantially uniform mixture of the materials in the dispersion. The core can then be formed as described herein, for example, by placing the dispersion onto a wire screen using a suitable laying process, followed by compressing and / or curing the thermoplastic material of the core. In other configurations, it may be desirable to provide a gradient distribution of reinforcing fibers, lofting agents, etc. from one surface of the core to the other surface of the core. In some configurations, a substantially uniform distribution of materials can be present within the core, and then additional fibers, lofting agents, or other materials can be added to one side of the core to provide a gradient distribution. Such additional materials can be added directly to the core, for example, by spraying or coating a solution containing fibers or lofting agents, or can be added by bonding a skin, additional prepreg or core, or other component containing the core. For example, referring to FIG. 2, a first core 210 and a second core 220 disposed on top of the first core 210 can provide a composite article. Each core 210, 220 can include a substantially uniform distribution of materials, but the amount and / or type of fibers present within the two cores 210, 220 can be different. For example, the loading rates can be different, or the materials themselves can be different.However, if desired, only one of the cores can contain two or more different types of thermoplastic materials, two or more different types of reinforcing fibers, and / or two or more different types of lofting agents. The thermoplastic materials of cores 210, 220 can be melted to provide a single combined core containing the materials from the two cores, for example a combined core without any substantial interface between the original cores 210, 220. Melting the cores results in a composite core having a mixture of materials from the two different cores 210, 220.

[0041] In certain configurations, the core thermoplastic material can be used in the core in fiber form, particle form, resin form, or other suitable forms. In some examples, the thermoplastic material used in the core can be present in particle form. In certain embodiments, the core generally includes a substantial amount of open-cell structure such that voids are present within the core. For example, the core layer can be configured with a void content or porosity of 0 - 30%, 10 - 40%, 20 - 50%, 30 - 60%, 40 - 70%, 50 - 80%, 60 - 90%, 0 - 40%, 0 - 50%, 0 - 60%, 0 - 70%, 0 - 80%, 0 - 90%, 5 - 30%, 5 - 40%, 5 - 50%, 5 - 60%, 5 - 70%, 5 - 80%, 5 - 90%, 5 - 95%, 10 - 50%, 10 - 60%, 10 - 70%, 10 - 80%, 10 - 90%, 10 - 95%, 20 - 60%, 20 - 70%, 20 - 80%, 20 - 90%, 20 - 95%, 30 - 70%, 30 - 80%, 30 - 90%, 30 - 95%, 40 - 80%, 40 - 90%, 40 - 95%, 50 - 90%, 50 - 95%, 60 - 95%, 70 - 80%, 70 - 90%, 70 - 95%, 80 - 90%, 80 - 95%, or any exemplary value within these exemplary ranges. In some cases, the core is configured with a porosity or void content of greater than 0%, for example up to about 95% porosity or void content where it is not fully consolidated. For example, the core can include a porosity greater than 5% or 10% but less than 90% or 95%. Unless otherwise indicated, references to a core configured with a particular void content or porosity are based on the total volume of the core and not necessarily the total volume including any other materials or layers bonded to the core. Compared to the prepreg, the porosity of the core may be the same or different. For example, in many cases, the prep The prepeg is formed into the core by passing the prepeg through a set of rollers or by compressing one or more surfaces of the prepeg. In such cases, the porosity of the core may be different from the porosity of the prepeg. For example, the porosity of the core can be made smaller than the prepeg used to provide the final core. In some cases, the porosity of the core is intentionally selected to be smaller than the corresponding prepeg to provide increased lofting ability to enable the use of the core (and any bonded layers) in the ultimately formed article or product.

[0042] In certain embodiments, the core thermoplastic material described herein can at least partially include one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachloride, and polyvinyl chloride (plasticized and unplasticized), as well as blends of these materials with each other or blends with other polymeric materials. Other suitable thermoplastics include polyarylene ether, polycarbonate, polyester carbonate, thermoplastic polyester, polyimide, polyetherimide, polyamide, acrylonitrile - butyl acrylate - styrene polymer, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyarylsulfone, polyethersulfone, liquid crystal polymer, poly(1,4 - phenylene) compounds commercially known as PARMAX®, high heat polycarbonates such as Bayer's APEC® PC, high temperature nylon, and silicone, as well as alloys and blends of these materials with each other or with other polymeric materials, but are not limited thereto. The thermoplastic material used to form the core can be used in powder form, resin form, rosin form, fiber form, or other suitable form. Exemplary thermoplastic materials in various forms are described herein and are also described, for example, in U.S. Patent Application Publication Nos. 2013 / 0244528 and 2012 / 0065283. The exact amount of the thermoplastic material present within the core can vary, but exemplary amounts range from about 20 wt% to about 80 wt% or from about 40 wt% to about 75 wt%, for example, from about 55 wt% to about 65 wt%. As described in more detail below, any one or more of these thermoplastic materials can be coated onto a non - core layer, such as the fibers of a scrim, or can be present on the fibers themselves prior to forming the non - core layer.

[0043] In certain examples, the core fibers described herein can include one or more of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers such as para and meta aramid fibers, nylon fibers, polyester fibers, or other organic fibers of particularly high elastic modulus such as those described herein suitable for use as fibers, natural fibers such as hemp, sisal, jute, flax, coir, kenaf, and cellulose-based fibers, mineral fibers such as basalt, mineral wool (e.g., rock wool or slag wool), wollastonite, alumina silica, and the like, or mixtures thereof, metal fibers, metalized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, fibers other than the reinforcing fibers can also be present within the core. The fiber content within the core can be from about 20 wt% to about 90 wt% of the core, more specifically from about 30 wt% to about 70 wt% of the core, for example from about 35 wt% to about 55 wt% based on the weight of the core. The specific size and / or orientation of the fibers used can depend, at least in part, on other materials present within the core and / or the desired properties of the resulting core. In some cases, the fibers used to provide the core generally have a diameter greater than about 5 microns, more specifically from about 5 microns to about 22 microns, and a length from about 5 mm to about 200 mm, more specifically the fiber diameter can be from about 5 microns to about 20 microns and the fiber length can be from about 5 mm to about 75 mm. In other cases, the fiber diameter can be from about 10 microns to about 20 microns and the length can be from about 5 mm to about 15 mm.

[0044] In some cases, the core can be substantially halogen-free or halogen-free to meet the regulations regarding the requirements of hazardous substances for specific applications. In other cases, the core can contain a halogenated flame retardant, which can include, for example, one or more of F, Cl, Br, I, and At, or a compound containing such a halogen, such as tetrabromobisphenol-A polycarbonate, or a mono-halo-, di-halo-, tri-halo-, or tetra-halo-polycarbonate. In some cases, the thermoplastic material used within the core can contain one or more halogens to impart a certain degree of flame retardancy without the addition of another flame retardant. When a halogenated flame retardant is present, the flame retardant preferably is present in an amount of the flame retardant that can vary depending on the other components present. For example, the halogenated flame retardant can be present at about 0.1 wt% to about 15 wt% (based on the weight of the core), more specifically about 1 wt% to about 13 wt%, such as about 5 wt% to about 13 wt%. Optionally, two different halogenated flame retardants can be added to the core. In other cases, a non-halogenated flame retardant, such as a flame retardant containing one or more of N, P, As, Sb, Bi, S, Se, and Te, can be added. In some embodiments, the non-halogenated flame retardancy can include a phosphorus-containing material, thus making the core more environmentally friendly. When a non-halogenated flame retardant or a substantially halogen-free flame retardant is present, the flame retardant preferably is present in an amount of the flame retardant that can vary depending on the other components present. For example, the substantially halogen-free flame retardant can be present at about 0.1 wt% to about 15 wt% (based on the weight of the core), more specifically, based on the weight of the core, about 1 wt% to about 13 wt%, such as about 5 wt% to about 13 wt%. Optionally, two different substantially halogen-free flame retardancies can be added to the core. In certain cases, the core described herein can contain one or more halogenated flame retardants in combination with one or more substantially halogen-free flame retardants.When two different flame retardants are present, the combination of the two flame retardants can be present in amounts of the flame retardant that can vary depending on the other components present. For example, the total weight of the flame retardant present can be from about 0.1 wt% to about 20 wt% (based on the weight of the core), more specifically from about 1 wt% to about 15 wt% based on the weight of the core, such as from about 2 wt% to about 14 wt%. The flame retardants used in the cores described herein can be added to a mixture containing reinforcing fibers, a thermoplastic material, and optionally a lofting agent (before placing the mixture onto the wire screen or other processing components), or can be added after the core has cured, for example by dipping the core in the flame retardant or spraying the flame retardant onto the core. Further, the flame retardant can be sprayed onto the reinforcing fibers, thermoplastic material, lofting agent, etc. before combining the components within the mixture used to form the prepreg or core.

[0045] In certain embodiments, the prepregs or cores described herein can include one of the layers, such as a skin, disposed on the surface of the prepreg or core to provide an article. Referring to FIG. 3, article 300 includes prepreg or core 310 and surface layer 320 includes sheath-core fibers, such as a scrim including two-component fibers, e.g., sheath-core fibers. When sheath-core fibers are present within surface layer 320, the exact sheath material present within the fibers of surface layer 320 can vary and exemplary coatings include polyolefins such as polyethylene, polypropylene, and other materials that can be softened or melted to some extent during processing, but are not limited thereto. Additionally, the core fibers of surface layer 320 can vary and can include, for example, one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, metallized inorganic fibers, polyethylene terephthalate fibers (PET), and thermoplastic fibers. In some cases, surface layer 320 can include a fiber-based scrim including sheath-core fibers and the sheath material can be a polyolefin material It includes PET fibers, aramid fibers, or glass fibers having a sheath material of a material, for example, polyethylene, polypropylene, or a combination thereof. The article 300 also includes a layer 330 disposed on the prepreg or core 310. The layer or skin 330 can include, for example, a film (e.g., a thermoplastic film or an elastomeric film), a flim, a scrim (e.g., a fiber-based scrim), a foil, a woven fabric, a non-woven fabric, or can be present as an inorganic coating, an organic coating, or a thermosetting coating disposed on the prepreg or core 310. In some examples, the layers 320, 330 can be the same, but in other cases, the layers are different. For example, the layer 320 can include a scrim containing two-component fibers, and the layer 330 can include one or more of a film (e.g., a thermoplastic film or an elastomeric film), a flim, a scrim (e.g., a fiber-based scrim), a foil, a woven fabric, a non-woven fabric, or can be present as an inorganic coating, an organic coating, or a thermosetting coating. In other cases, the layer 320 can include a scrim containing two-component fibers, and the layer 330 can include a scrim without any two-component fibers. In some configurations, each of the layers 320, 330 can include a scrim containing two-component fibers, but the scrim coatings can be the same or different. For example, when the two-component fibers are sheath-core fibers, the materials can have different compositions, or the compositions can be the same, but the amounts of the sheath-core fibers in the different layers 320, 330 can be different. In other cases, the layer 330 can include a limiting oxygen index greater than about 22 when measured according to ISO 4589 of 1996. When a thermoplastic film is present as the skin 330 (or as part thereof), the thermoplastic film can include at least one of poly(etherimide), poly(etherketone), poly(ether-etherketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ether sulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone.When a fiber-based scrim is present as skin 330 (or as part thereof), the fiber-based scrim can include at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, metallized inorganic fibers, and fibers. When a thermosetting coating is present as skin 330 (or as part thereof), the coating can include at least one of unsaturated polyester, polyurethane, vinyl ester, phenolic resin, and epoxy. When an inorganic coating is present as skin 330 (or as part thereof), the inorganic coating can include a mineral containing a cation selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or can include at least one of gypsum, calcium carbonate, and mortar. When a non-woven fabric is present as skin 330 (or as part thereof), the non-woven fabric can include a thermoplastic material, a thermosetting binder, inorganic fibers, metal fibers, metallized inorganic fibers, and metallized synthetic fibers. The prepreg or core 310 can include any of the materials described herein in connection with prepregs and cores, such as a thermoplastic material, reinforcing fibers, and a lofting agent dispersed within the prepreg or core 310. For example, the prepreg or core 310 can include a polyolefin combined with reinforcing fibers, such as glass fibers, and optionally one or more lofting agents such as microspheres.

[0046] In a particular configuration, the prepregs and cores described herein can be used to provide an article having two or more layers on either side of the prepreg or core and including a skin on each side of the prepreg or core. Referring to FIG. 4, the article 400 shown includes a prepreg or core 410, a surface layer 420 disposed on a first surface of the prepreg or core 410, a layer 430 disposed on a second surface of the prepreg or core 410, and a surface layer 440 disposed on the layer 430. The prepreg or core 410 can include any of the materials described herein in connection with prepregs and cores, such as thermoplastic materials, reinforcing fibers, and any lofting agents. The surface layer 420 is To enhance the formability of the article 400, it can include a scrim comprising a two-component fiber, such as a sheath-core fiber. When the sheath-core fiber is used within the surface layer 420, the exact sheath materials present within the fibers of the surface layer 420 can vary and exemplary sheath materials include polyolefins such as polyethylene, polypropylene, and other materials that can be softened or melted to some extent during processing, but are not limited thereto. Additionally, the core fibers of the surface layer 420 can vary and can include, for example, one of glass fiber, aramid fiber, graphite fiber, carbon fiber, inorganic mineral fiber, metal fiber, metallized synthetic fiber, metallized inorganic fiber, polyethylene terephthalate fiber (PET), and thermoplastic fiber. In some cases, the surface layer 420 can include a fiber-based scrim comprising sheath-core fibers, and the sheath material has a sheath material including a polyolefin material, such as polyethylene, polypropylene, or a combination thereof, and includes PET fibers, aramid fibers, or glass fibers. Each of the layers 430, 440 can include, for example, a film (e.g., a thermoplastic film or an elastomeric film), a flim, a scrim (e.g., a fiber-based scrim), a foil, a woven fabric, a non-woven fabric, or can be present as an inorganic coating, an organic coating, or a thermosetting coating disposed on the prepreg or the core 410. In some examples, the layer 420, and one or both of the layers 430, 440 can be the same, but in other cases, the layers are different. For example, the layer 420 can include a scrim comprising a two-component fiber, and each of the layers 430, 440 can include any one or more of a film (e.g., a thermoplastic film or an elastomeric film), a flim, a scrim (e.g., a fiber-based scrim), a foil, a woven fabric, a non-woven fabric, or can be present as an inorganic coating, an organic coating, or a thermosetting coating. In other cases, the layer 420 can include a scrim comprising a two-component fiber, and one or both of the layers 430, 440 can include a scrim without any two-component fiber.In some configurations, each of layers 420, 430, 440 can include a scrim comprising bicomponent fibers, but the sheath material of the scrim can vary. For example, if the bicomponent fibers are sheath-core fibers, the sheath material can have a different composition, or the composition can be the same but the amount of sheath-core fibers in different layers 430, 430, 440 can vary. In other cases, each of layers 430, 440 can include a limiting oxygen index greater than about 22 when measured by ISO 4589 of 1996. When a thermoplastic film is present as one or both (or as part thereof) of layers 430, 440, the thermoplastic film can include at least one of poly(etherimide), poly(etherketone), poly(ether-etherketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ether sulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. When a fiber-based scrim is present as one or both (or as part thereof) of layers 430, 440, the fiber-based scrim can include at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, metallized inorganic fibers, and fibers. When a thermoset coating is present as one or both (or as part thereof) of layers 430, 440, the coating can include at least one of unsaturated polyester, polyurethane, vinyl ester, phenolic resin, and epoxy. When an inorganic coating is present as one or both (or as part thereof) of layers 430, 440, the inorganic coating can include a mineral containing a cation selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or can include at least one of gypsum, calcium carbonate, and mortar. When a nonwoven fabric is present as one or both (or as part thereof) of layers 430, 440, the nonwoven fabric can include a thermoplastic material, a thermoset binder, inorganic fibers, metal fibers, metallized inorganic fibers, and metallized synthetic fibers.The prepreg or core 410 can include any of the materials described herein in connection with prepregs and cores, such as thermoplastic materials, reinforcing fibers, and lofting agents dispersed within the prepreg or core 410. For example, the prep. The leg or core 410 can include a polyolefin combined with reinforcing fibers, such as glass fibers, and optionally one or more lofting agents such as microspheres.

[0047] In certain cases, the article can include a prepreg or core, at least one skin disposed on the prepreg or core, and a decorative layer or cover layer disposed on the skin. Referring to FIG. 5, the article 500 shown includes a prepreg or core 510, a surface layer 520 disposed on a first surface of the prepreg or core 510, and a decorative layer 530 disposed on a second surface of the prepreg or core 510. The prepreg or core 510 can include any of the materials described herein in connection with prepregs and cores, such as thermoplastic materials, reinforcing fibers, and any lofting agents. The surface layer 520 can include a scrim that includes two-component fibers, such as sheath-core fibers, to enhance the formability of the article 500. When sheath-core fibers are used, the exact sheath materials present in the core fibers of the surface layer 520 can vary and exemplary sheath materials include polyolefins such as polyethylene, polypropylene, and other materials that can be softened or melted to some extent during processing, but are not limited thereto. Additionally, the core fibers of the surface layer 520 can vary and can include, for example, one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, metallized inorganic fibers, polyethylene terephthalate fibers (PET), and thermoplastic fibers. In some cases, the surface layer 520 can include a fiber-based scrim that includes sheath-core fibers, and the sheath material has a sheath material that includes a polyolefin material, such as polyethylene, polypropylene, or a combination thereof, and includes PET fibers, aramid fibers, or glass fibers. The decorative layer 530 can be formed, for example, from a thermoplastic film of polyvinyl chloride, polyolefin, thermoplastic polyester, thermoplastic elastomer, or the like. The decorative layer 530 can also be a multi-layer structure that includes, for example, a foam core formed from polypropylene, polyethylene, polyvinyl chloride, polyurethane, and the like. Optionally, the decorative layer 530 can also include one or more types of reinforcing fibers.The fabric can be adhered to the foam core, such as natural fibers and synthetic fibers, organic fiber nonwoven fabrics after needle punching or similar processes, fleece fabrics, knitted goods, flocked fabrics, or woven fabrics made from other such materials. The fabric can also be bonded to the foam core with pressure-sensitive adhesives and thermoplastic adhesives including hot melt adhesives such as polyamides, modified polyolefins, urethanes, and polyolefins. The decorative layer 530 can also be produced using spunbond, thermal bonding, spunlace, meltblowing, wet laying processes, and / or dry laying processes. Optionally, one or more layers can be positioned between the decorative layer 530 and the prepreg or core 510. For example, an intermediate layer or skin can be present between the layer 530 and the prepreg or core 510. The intermediate layer can include, for example, an adhesive layer, a film (e.g., a thermoplastic film or an elastomeric film), a fleece, a scrim (e.g., a fiber-based scrim), a foil, a woven fabric, a nonwoven fabric, or can be present as an inorganic coating, an organic coating, or a thermosetting coating disposed on the prepreg or core 510. In other cases, the intermediate layer can include a limiting oxygen index greater than about 22 when measured by ISO 4589 in 1996. When a thermoplastic film is present as the intermediate layer, the thermoplastic film can include at least one of poly(etherimide), poly(ether ketone), poly(ether-ether ketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ether sulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. When a fiber-based scrim is present as the intermediate layer, the fiber-based scrim can include at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, metallized inorganic fibers, and fibers. When a thermosetting coating is present, the coating is an unsaturated polyester, a polyurethane, a vinyl ester, a phenolic resin, and an epoxy. can include at least one of them. When the inorganic coating exists as an intermediate layer, the inorganic coating can include a mineral containing a cation selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or can include at least one of gypsum, calcium carbonate, and mortar. When the nonwoven fabric exists as an intermediate layer, the nonwoven fabric can include a thermoplastic material, a thermosetting binder, inorganic fibers, metal fibers, metallized inorganic fibers, and metallized synthetic fibers.

[0048] In certain configurations, two or more prepregs or cores can be joined to each other through an intervening layer or intermediate layer, such as a skin. Referring to FIG. 6, article 600 includes a first prepreg or core 610 joined to a prepreg or core 630 through an intermediate layer 620. Article 600 also includes a surface layer 615 disposed on a first surface of prepreg or core 610. Surface layer 615 can include a scrim comprising two-component fibers, such as sheath-core fibers, to enhance the formability of article 600 during the forming operation. When sheath-core fibers are used, the exact sheath material present in the sheath-core fibers of surface layer 615 can vary and can include polyolefins such as polyethylene, polypropylene, and other materials that can be softened or melted to some extent during processing, but are not limited thereto. Additionally, the core fibers of surface layer 615 can vary and can include, for example, one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, metallized inorganic fibers, polyethylene terephthalate fibers (PET), and thermoplastic fibers. In some cases, surface layer 615 can include a fiber-based scrim comprising sheath-core fibers, and the sheath material can have a sheath material of a polyolefin material, such as polyethylene, polypropylene, or a combination thereof, and include PET fibers, aramid fibers, or glass fibers. Each of prepregs or cores 610, 630 can be the same or different. In some cases, the thermoplastic materials and lofting agents of prepregs or cores 610, 630 are the same, but the type and amount of fibers present within prepregs or cores 610, 630 are different. In other cases, the type and / or amount of fibers within prepregs or cores 610, 630 can be the same, and one or both of the thermoplastic material and / or lofting agent can be different, for example, chemically different or present in different amounts. Optionally, one or more suitable flame retardants, such as halogenated or non-halogenated flame retardants, can be present in one or both of cores 610, 630.In FIG. 6, the thicknesses of the prepregs or cores 610, 630 are shown to be approximately the same, but the thicknesses of the prepregs or cores 610, 630 can be varied. If a "thick" core is desired, it may be desirable to bond two "thin" core layers together through layer 620 to keep the core layers 610, 630 in proximity to each other and still provide a composite having the desired final thickness. The intermediate layer 620 can take the form of a skin as described herein, for example, in the form having fibers. The layer 620 can include an open cell structure to enhance adhesion to the core layers 610, 630. The intermediate layer 620 can include, for example, an adhesive layer, a film (e.g., a thermoplastic film or an elastomeric film), a frim, a scrim (e.g., a fiber-based scrim), a foil, a woven fabric, a non-woven fabric, or can be present as an inorganic coating, an organic coating, or a thermosetting coating disposed on the prepreg or core 610. In other cases, the layer 620 can include a limiting oxygen index greater than about 22 when measured by ISO 4589 of 1996. When a thermoplastic film is present, the thermoplastic film can include at least one of poly(etherimide), poly(ether ketone), poly(ether-ether ketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ether sulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. When a fiber-based scrim is present as or in the layer 620, the fiber-based scrim can include glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers. It can include at least one of fibers, metal fibers, metallized synthetic fibers, metallized inorganic fibers, and thermoplastic fibers. When a thermosetting coating is present as layer 620 or therein, the coating can include at least one of unsaturated polyester, polyurethane, vinyl ester, phenolic resin, and epoxy. When an inorganic coating is present as layer 620 or therein, the inorganic coating can include a mineral containing a cation selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or can include at least one of gypsum, calcium carbonate, and mortar. When a non-woven fabric is present as layer 620 or therein, the non-woven fabric can include a thermoplastic material, a thermosetting binder, inorganic fibers, metal fibers, metallized inorganic fibers, metallized synthetic fibers, or fibers. Although not shown, the decorative layer can be bonded to the prepreg or core 630 and / or to the surface layer 615 as desired. As described herein, the decorative layer can be formed from a thermoplastic film such as, for example, polyvinyl chloride, polyolefin, thermoplastic polyester, thermoplastic elastomer, or the like. The decorative layer can also be a multi-layer structure including, for example, a foam core formed from polypropylene, polyethylene, polyvinyl chloride, polyurethane, and the like. The fabric can be adhered to the foam core, such as a natural fiber and synthetic fiber (a part of which can be a fiber), a needle-punched or similar processed organic fiber non-woven fabric, a fleece fabric, a knitted product, a flocked fabric, or a woven fabric made from other such materials. The fabric can also be bonded to the foam core with a pressure-sensitive adhesive and a thermoplastic adhesive including hot melt adhesives such as polyamide, modified polyolefin, urethane, and polyolefin. The decorative layer can also be produced using a spunbond, heat bond, spunlace, meltblown, wet laid process, and / or dry laid process. As desired, the decorative layer can be configured with a closed cell structure or an open cell structure.

[0049] In certain embodiments, two or more prepregs or cores can be joined together, and then a skin can be disposed on one surface of the prepreg or core. Referring to FIG. 7, article 700 includes a prepreg or core 710 joined to a prepreg or core 730, and a surface layer 715 disposed on a first surface of prepreg or core 710. The article also includes a surface layer 720 disposed on prepreg or core 730. Surface layer 715 can include a scrim comprising a two-component fiber, such as a sheath-core fiber, to enhance the formability of article 700, e.g., deep drawing during a forming operation. When sheath-core fibers are used, the exact sheath material present within the fibers of surface layer 715 can vary and exemplary sheath materials include polyolefins such as polyethylene, polypropylene, and other materials that can be softened or melted to some extent during processing, but are not limited thereto. Additionally, the core fibers of surface layer 715 can vary and can include, for example, one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, metallized inorganic fibers, polyethylene terephthalate fibers (PET), and thermoplastic fibers. In some cases, surface layer 715 can include a fiber-based scrim comprising sheath-core fibers, and the sheath material can have a sheath material of a polyolefin material, e.g., polyethylene, polypropylene, or a combination thereof, with PET fibers, aramid fibers, or glass fibers. Each of prepregs or cores 710, 730 can be the same or different. In some cases, the thermoplastic materials and lofting agents of cores 710, 730 are the same, but the fiber loading or type within cores 710, 730 is different. In other cases, the type and / or amount of fibers within cores 710, 730 can be the same, and one or both of the thermoplastic material and / or lofting agent can be different. Optionally, one or more suitable flame retardants, such as halogenated flame retardants or non-halogenated flame retardants, can be present in one or both of prepregs or cores 710, 730.In FIG. 7, the thicknesses of the prepregs or cores 710, 730 are shown to be approximately the same, but the thicknesses of the prepregs or cores 710, 730 can be varied. The desired overall... In order to provide a core thickness of a certain nature, it may be desirable to construct a composite article using a continuous thin core layer. For example, in order to facilitate the production of a thicker core layer, instead of using a 4 mm lofted core layer, it may be desired to bond two or more thin core layers having a thickness of, for example, 2 mm or less to each other. The layer or skin 720 can include, for example, a film (e.g., a thermoplastic film or an elastomeric film), a flim, a scrim (e.g., a fiber-based scrim), a foil, a woven fabric, a non-woven fabric, or can be present as an inorganic coating, an organic coating, or a thermosetting coating disposed on the prepreg or core 730. In other cases, the skin 720 can include a limiting oxygen index greater than about 22 when measured by ISO 4589 of 1996. When a thermoplastic film is present as or within the skin 720, the thermoplastic film can include at least one of poly(etherimide), poly(etherketone), poly(ether-ether-ketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ether sulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. When a fiber-based scrim is present as or within the skin 720, the fiber-based scrim can include at least one of glass fiber, aramid fiber, graphite fiber, carbon fiber, inorganic mineral fiber, metal fiber, metallized synthetic fiber, metallized inorganic fiber, and thermoplastic fiber. When a thermosetting coating is present as or within the skin 720, the coating can include at least one of unsaturated polyester, polyurethane, vinyl ester, phenolic resin, and epoxy. When an inorganic coating is present as or within the skin 720, the inorganic coating can include a mineral containing a cation selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or can include at least one of gypsum, calcium carbonate, and mortar.When the nonwoven fabric is present as or within the skin 720, the nonwoven fabric can include a thermoplastic material, a thermosetting binder, inorganic fibers, metal fibers, metallized inorganic fibers, and metallized synthetic fibers. Depending on the final configuration of the article 700, the skin 720 can be an open-cell skin or a closed-cell skin. Although not shown, the decorative layer can be bonded to the skin 720, or to the surface layer 715, or to both. As described herein, the decorative layer can be formed, for example, from a thermoplastic film of polyvinyl chloride, polyolefin, thermoplastic polyester, thermoplastic elastomer, or the like. The decorative layer can also be a multilayer structure including, for example, a foam core formed from polypropylene, polyethylene, polyvinyl chloride, polyurethane, and the like. The fabric can be adhered to the foam core, such as natural and synthetic fibers (some of which can be fibers), organic fiber nonwoven fabrics after needlepunching or the like, fleece fabrics, knitted goods, flocked fabrics, or woven fabrics made from other such materials. The fabric can also be bonded to the foam core with a pressure-sensitive adhesive and with thermoplastic adhesives including hot melt adhesives such as polyamide, modified polyolefin, urethane, and polyolefin. The decorative layer can also be produced using spunbond, thermal bonding, spunlace, meltblowing, wet laying processes, and / or dry laying processes. Depending on the positioning of the decorative layer with respect to the incident sound energy, the decorative layer can include an open-cell structure or a closed-cell structure.

[0050] In certain embodiments, two or more prepregs or cores can be joined together, and then skins can be disposed on each surface of the prepreg or core. Referring to FIG. 8, an article 800 is shown that includes a prepreg or core 810 joined to a prepreg or core 830, a first skin 820 disposed on core 830, and a second skin 840 disposed on core 810. A surface layer 815 is shown as being disposed on skin 840. The surface layer 815 can include a scrim comprising two-component fibers, such as sheath-core fibers, to enhance the formability of the article 800, e.g., deep drawing during a forming operation. When sheath-core fibers are used, the exact sheath material present within the fibers of the surface layer 815 can vary Yes, exemplary sheath materials include, but are not limited to, polyolefins such as polyethylene and polypropylene, and other materials that can be softened or melted to some extent during processing. In addition, the core fibers of the surface layer 815 can be various, for example, one of glass fiber, aramid fiber, graphite fiber, carbon fiber, inorganic mineral fiber, metal fiber, metallized synthetic fiber, metallized inorganic fiber, polyethylene terephthalate fiber (PET), and thermoplastic fiber can be included. In some cases, the surface layer 815 can include a fiber-based scrim containing sheath-core fibers, and the sheath material can be a polyolefin material, for example, a sheath material of polyethylene, polypropylene, or a combination thereof, including PET fibers, aramid fibers, or glass fibers. Each of the prepregs or cores 810, 830 can be the same or different. In some cases, the thermoplastic materials and lofting agents of the prepregs or cores 810, 830 are the same, but the fiber filling amount or fiber type in the prepregs or cores 810, 830 is different. In other cases, the fiber type and / or amount in the prepregs or cores 810, 830 can be the same, and one or both of the thermoplastic material and / or lofting agent may be different, for example, chemically different or present in different amounts. Optionally, one or more suitable flame retardants, such as halogenated flame retardants or non-halogenated flame retardants, can be present in one or both of the prepregs or cores 810, 830. In FIG. 8, the thicknesses of the prepregs or cores 810, 830 are shown to be approximately the same, but the thicknesses of the prepregs or cores 810, 830 can be varied. As described herein, it may be desirable to use two or more core layers bonded to each other instead of a single core layer with an increased thickness.The layers or skins 820, 840 can independently include, for example, films (e.g., thermoplastic films or elastomeric films), felts, scrims (e.g., fiber-based scrims), foils, woven fabrics, non-woven fabrics, or can be present as inorganic coatings, organic coatings, or thermosetting coatings disposed on the prepreg or core 830. In other cases, the skins 820, 840 can independently include a limiting oxygen index greater than about 22 when measured by ISO 4589 of 1996. When a thermoplastic film is present as the skin 820 or skin 840 (or both) or within it, the thermoplastic film can include at least one of poly(etherimide), poly(etherketone), poly(ether-etherketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ether sulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. When a fiber-based scrim is present as the skin 820 or skin 840 (or both) or within it, the fiber-based scrim can include at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, metallized inorganic fibers, and thermoplastic fibers. When a thermosetting coating is present as the skin 820 or skin 840 (or both) or within it, the coating can include at least one of unsaturated polyester, polyurethane, vinyl ester, phenolic resin, and epoxy. When an inorganic coating is present as the skin 820 or skin 840 (or both) or within it, the inorganic coating can include minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or can include at least one of gypsum, calcium carbonate, and mortar. When a non-woven fabric is present as the skin 820 or skin 840 (or both) or within it, the non-woven fabric can include thermoplastic materials, thermosetting binders, inorganic fibers, metal fibers, metallized inorganic fibers, and metallized synthetic fibers.Depending on the desire, one of the skins 820, 840 can include an open cell structure, and the other skin can include a closed cell structure. Alternatively, each of the skins 820, 840 can include an open cell structure or a closed cell structure. Although not shown, the decorative layer can be bonded to the skin 820, or to the layer 815 (or both). As described herein, the decorative layer is, for example. For example, it can be formed from a thermoplastic film of polyvinyl chloride, polyolefin, thermoplastic polyester, thermoplastic elastomer, or the like. The decorative layer can also be a multilayer structure including, for example, a foam core formed from polypropylene, polyethylene, polyvinyl chloride, polyurethane, and the like. The fabric can be adhered to the foam core, such as natural and synthetic fibers (some of which can be fibers), organic fiber non-woven fabric after needle punching or the like, raised fabric, knitted goods, flocked fabric, or woven fabric made from other such materials. The fabric can also be bonded to the foam core with a pressure-sensitive adhesive and a thermoplastic adhesive including hot melt adhesives such as polyamide, modified polyolefin, urethane, and polyolefin. The decorative layer can also be produced using spunbond, thermal bond, spunlace, meltblown, wet laid process, and / or dry laid process.

[0051] In certain embodiments, two or more prepregs or cores can be joined to each other through one or more skin layers. Referring to FIG. 9, an article 900 is shown that includes a prepreg or core 910 joined to a prepreg or core 930 through an intermediate layer 920, and a skin 940 disposed on a surface layer 915 that includes bicomponent fibers. The surface layer 915 can include a scrim that includes bicomponent fibers, such as sheath-core fibers, to enhance the formability of the article 900. When sheath-core fibers are used, the exact sheath materials present within the fibers of the surface layer 915 can vary and exemplary sheath materials include polyolefins such as polyethylene, polypropylene, and other materials that can be softened or melted to some extent during processing, but are not limited thereto. Additionally, the core fibers of the surface layer 915 can vary and can include, for example, one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, metallized inorganic fibers, polyethylene terephthalate fibers (PET), and thermoplastic fibers. In some cases, the surface layer 915 can include a fiber-based scrim that includes sheath-core fibers, and the sheath material can have a sheath material of a polyolefin material, such as polyethylene, polypropylene, or a combination thereof, and includes PET fibers, aramid fibers, or glass fibers. Optionally, another skin can be disposed on the prepreg or core 930. Each of the prepregs or cores 910, 930 can be the same or different. In some cases, the thermoplastic materials and lofting agents of the prepregs or cores 910, 930 are the same, but the fiber loading or fiber type present within the prepregs or cores 910, 930 is different. In other cases, the fiber type and / or amount within the prepregs or cores 910, 930 can be the same, and one or both of the thermoplastic material and / or lofting agent can be different, for example, chemically different or present in different amounts. Optionally, one or more suitable flame retardants, such as halogenated flame retardants or non-halogenated flame retardants, can be present in one or both of the prepregs or cores 910, 930.In FIG. 9, the thicknesses of the prepregs or cores 910, 930 are shown to be approximately the same, but the thicknesses of the prepregs or cores 910, 930 can be varied. For example, instead of using a single, equally thick core layer that is lofted to some extent, two thin core layers can be bonded together. The layer 920 and the skin 940 can independently include, for example, a film (e.g., a thermoplastic film or an elastomeric film), a film, a scrim (e.g., a fiber-based scrim), a foil, a woven fabric, a non-woven fabric, or can be present as an inorganic coating, an organic coating, or a thermosetting coating. In other cases, the layer 920 and the skin 940 can independently include a limiting oxygen index greater than about 22 when measured according to ISO 4589 of 1996. When a thermoplastic film is present as or in the layer 920 or the skin 940 (or both), the thermoplastic film is poly(etherimide), poly(etherketone), poly(ether-etherketone), poly(phenylene sulfide), poly(arylene sulfone), poly(ether sulfone), poly(amide-imide), poly(1,4-phenylene), poly. It can include at least one of carbonate, nylon, and silicone. When a fiber-based scrim is present as layer 920 or skin 940 (or both), or within them, the fiber-based scrim can include at least one of glass fiber, aramid fiber, graphite fiber, carbon fiber, inorganic mineral fiber, metal fiber, metallized synthetic fiber, metallized inorganic fiber, and thermoplastic fiber. When a thermosetting coating is present as layer 920 or skin 940 (or both), or within them, the coating can include at least one of unsaturated polyester, polyurethane, vinyl ester, phenolic resin, and epoxy. When an inorganic coating is present as layer 920 or skin 940 (or both), or within them, the inorganic coating can include a mineral containing a cation selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or can include at least one of gypsum, calcium carbonate, and mortar. When a non-woven fabric is present as layer 920 or skin 940 (or both), or within them, the non-woven fabric can include a thermoplastic material, a thermosetting binder, inorganic fibers, metal fibers, metallized inorganic fibers, and metallized synthetic fibers. In some cases, layer 920 preferably includes an open-cell structure or a closed-cell structure. Similarly, skin 940 can include an open-cell structure or a closed-cell structure. Although not shown, the decorative layer can be bonded to layer 915, or prepreg or core 930 (or both). As described herein, the decorative layer can be formed from a thermoplastic film such as, for example, polyvinyl chloride, polyolefin, thermoplastic polyester, thermoplastic elastomer, or the like. The decorative layer can also be a multi-layer structure including, for example, a foam core formed from polypropylene, polyethylene, polyvinyl chloride, polyurethane, and the like. The fabric can be adhered to the foam core, such as natural and synthetic fibers (some of which can be fibers), organic fiber non-woven fabric after needlepunching or the like, raised fabric, knitted goods, flocked fabric, or woven fabric made from other such materials.Budi can also be bonded to the foam core with a pressure-sensitive adhesive and a thermoplastic adhesive including hot melt adhesives such as polyamides, modified polyolefins, urethanes, and polyolefins. The decorative layer can also be produced using spunbond, thermal bonding, spunlace, meltblowing, wet laying processes, and / or dry laying processes.

[0052] In certain embodiments, strips of material containing bicomponent fibers can be placed on the prepreg or core layer. Referring to FIG. 10, an article 1000 is shown including a prepreg or core 1010 having strips 1020, 1030 disposed in different regions of the prepreg or core 1010. Optionally, such strips can be present in any of the exemplary embodiments shown in FIGS. 1-9. Strips 1020, 1030 can be the same or different. In some cases, one or more of strips 1020, 1030 can include sheath-core fibers that can enhance formability in the region where the strip is placed. For example, strips 1020, 1030 containing bicomponent fibers can be placed in the region to be subjected to the drawing process to increase the overall depth of that particular region without break-through. Optionally, strips 1020, 1030 can also be placed on a surface layer that also contains bicomponent fibers. The prepreg or core 1010 can include any of the prepregs or cores described herein. Strips 1020, 1030 can include the same or different compositions. In some examples, at least one of strips 1020, 1030 includes a scrim strip containing bicomponent fibers, such as sheath-core fibers, to enhance the formability of article 1000. When sheath-core fibers are present within the strip, the exact sheath materials present within the fibers of strips 1020, 1030 vary and exemplary coatings include, but are not limited to, polyolefins such as polyethylene, polypropylene, and other materials that can be softened or melted to some extent during processing. Additionally, the core fibers of strips 1020, 1030 vary and for example Alternatively, it can include one of glass fiber, aramid fiber, graphite fiber, carbon fiber, inorganic mineral fiber, metal fiber, metallized synthetic fiber, metallized inorganic fiber, polyethylene terephthalate fiber (PET), and thermoplastic fiber. In some cases, the strips 1020, 1030 can include a fiber-based scrim strip including sheath-core fibers, the sheath material includes a polyolefin material, for example, PET fibers, aramid fibers, or glass fibers having the sheath material include polyethylene, polypropylene, or a combination thereof. In some cases, one of the strips 1020, 1030 includes sheath-core fibers and the other of the strips 1020, 1030 includes single-component fibers.

[0053] In certain embodiments, any of the exemplary articles shown in FIGS. 1A and 2-10 can include two or more surface layers including bicomponent fibers. For example, a first surface layer including bicomponent fibers can be present on a first surface of a prepreg or core layer (optionally having one or more intermediate layers between the prepreg or core layer and the first surface layer of the first surface), and a second surface layer including bicomponent fibers can be present on a second surface of a prepreg or core layer (optionally having one or more intermediate layers between the prepreg or core layer and the second surface layer of the second surface). The surface layers can have similar or different compositions. In some cases, the bicomponent fibers of different surface layers can include at least one common material, for example, the core fiber, the sheath material, or both can be the same. In other cases, the bicomponent fibers of different surface layers are the same or substantially the same.

[0054] In some embodiments, the prepreg and core can include additional materials or additives to provide desired physical or chemical properties. For example, one or more dyes, texturizing agents, colorants, viscosity modifiers, smoke suppressants, synergistic materials, lofting agents, particles, powders, biocides, foams, or other materials can be mixed with or added to the prepreg or core. In some cases, the prepreg or core can include one or more smoke suppressant compositions in an amount of from about 0.2 wt% to about 10 wt%. Exemplary smoke suppressant compositions include, but are not limited to, stannates, zinc borate, zinc molybdate, magnesium silicate, calcium zinc molybdate, calcium silicate, calcium hydroxide, and mixtures thereof. Optionally, synergistic materials can be present to enhance the physical properties of the prepreg or core. For example, synergistic agents that enhance flame retardancy can be present.

[0055] In other cases, the prepregs or cores described herein can include a desired amount, e.g., less than about 50 wt%, of a small amount of a thermosetting material, based on the total amount of the prepreg or core, to provide desired properties to the core. The thermosetting material can be mixed with the thermoplastic material or added as a coating on one or more surfaces of the prepreg or core.

[0056] In certain embodiments, the prepregs or cores described herein can be configured as (or used within) glass mat thermoplastic composites (GMTs) or lightweight reinforced thermoplastics (LWRTs). One such LWRT is prepared by HANWHA AZDEL, Inc. and sold under the trademark of SUPERLITE® materials. The fiber-filled SUPERLITE® mat can provide desired attributes, including, for example, enhanced processing capabilities. The areal density of such GMTs or LWRTs can be in the range of about 300 grams per square meter (gsm) to about 4,000 gsm, although the areal density can be less than 300 gsm or greater than 4,000 gsm depending on the needs of a particular application. In some embodiments, the upper density limit can be less than about 4,000 gsm. In some examples, the overall thickness of the GMT or LWRT can be 4 mm or less, more specifically 3 mm or less, for example, 2 mm or less, or even 1 mm or less.

[0057] When generating the prepregs and cores described herein, it may be desirable to use a wet laying process. For example, a liquid or fluid medium containing a dispersing material, such as a thermoplastic material, fibers, and optionally a lofting agent having any one or more additives (e.g., flame retardants) described herein, can be stirred (stirred or agitated) in the presence of a gas, (e.g., air or other gas) and optionally a surfactant or dispersant. The dispersion can then be spread onto a support, such as a wire screen or other support material, to provide a substantially uniform distribution of the materials within the laid material. To increase the dispersion and / or uniformity of the materials, the stirred dispersion can include one or more activators, such as anionic, cationic, or nonionic activators, e.g., those sold under the name ACE liquid by Industrial Soaps Ltd., those sold as TEXOFOR® FN15 material by Glover Chemicals Ltd., and those sold as AMINE Fb19 by Float-Ore Ltd. These agents can assist in the dispersion of air and / or the dispersion of hydrophobic components within the liquid dispersion. These components can be added to a mixing tank, flotation cell, or other suitable apparatus in the presence of air to provide the dispersion. Preferably an aqueous dispersion is used, but one or more non-aqueous fluids can also be present to assist in the dispersion, change the viscosity of the fluid, or otherwise impart desired physical or chemical properties to the dispersion, or the prepreg, core, or article.

[0058] In certain cases, after mixing the dispersion for a sufficient period of time, a fluid having a suspension material can be placed onto a screen, moving wire, or other suitable support structure to provide a web of the laid material. Suction or reduced pressure can be provided to the web to remove any liquid from the laid material, leaving behind the thermoplastic material, fibers, and any other materials present, such as fibers, additives, etc. The resulting web can be dried, optionally densified or compressed to a desired thickness, and then fully cured to provide the desired prepreg, core, or article. In some cases, additional materials can be added to the web and then dried, fully cured, and / or densified or compressed to provide the desired prepreg, core, or article. In other cases, additional materials can be added to the web and then dried, cured, etc. to provide the desired prepreg, core, or article. Depending on the nature of the thermoplastic material, fibers, and other materials present, a wet laydown process can be used, but alternatively, an air laydown process, dry blending process, carding and needling process, or other known processes utilized to make nonwoven products may be desirable in some cases. In some cases, after the prepreg or core has been somewhat cured, additional fibers, lofting agents, or thermoplastic material can be sprayed onto the surface of the prepreg or core by passing a board under a plurality of coating jets configured to spray the material onto the prepreg or core surface at an angle of about 90 degrees.

[0059] In some configurations, the prepregs and cores described herein can be produced by combining a thermoplastic material, reinforcing fibers, and a lofting agent in an aqueous solution or in the presence of a surfactant within a foam. The combined components can be mixed or agitated for a sufficient time to disperse the various materials and provide a substantially homogeneous aqueous mixture of materials. Additionally, the materials can be left in the dispersion for a sufficient period of time to allow the fibers to react with or otherwise bond to a masking or sizing agent present in the dispersion, enabling reduction of the overall hydrophilicity of the reinforcing fibers. The dispersion mixture is then laid onto any suitable support structure, for example, onto a wire mesh or other mesh or support having a desired porosity rate. Water can then be drained through the wire mesh forming the web. The web is dried and heated to a temperature above the softening temperature of the thermoplastic powder. The web is then cooled and compressed to a predetermined thickness to produce a composite sheet. In an alternative embodiment, the aqueous foam also includes a binder material.

[0060] In certain examples, a prepreg or core in a form similar to a porous GMT can be produced. In certain cases, the GMT-like core generally comprises short fibers, a thermoplastic material, a lofting agent, and optionally a thermoplastic polymer film(s) and / or woven or non-woven fibers made of fibers or thermoplastic resin fibers such as, for example, polypropylene (PP), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycarbonate (PC), a PC / PBT blend, or a PC / PET blend. In some embodiments, PP, PBT, PET, a PC / PET blend, or a PC / PBT blend can be used as a high melt flow index resin. To produce a glass mat, a thermoplastic material, a reinforcing material, and a lofting agent, and / or other additives can be added to or metered into the dispersed foam contained within an open-top mixing tank equipped with an impeller. Without wishing to be bound by any particular theory, the presence of air entrapment pockets in the foam can assist in the dispersion of the fibers, thermoplastic material, and lofting agent. In some examples, the dispersed mixture of fibers and resin can be pumped through a distribution manifold to a headbox positioned above the wire section of a papermaking machine. Then, when using a vacuum to provide the dispersed mixture to a moving wire screen, the foam can be removed rather than the fibers or thermoplastic plastic to continuously produce a uniform fibrous wet web. The wet web can be passed through a dryer at a suitable temperature to reduce the water content and melt or soften the thermoplastic material. When the hot web exits the dryer, a surface layer such as, for example, a film can be laminated onto the web by passing the web of fiber material and thermoplastic material and film through the nip of a set of heated rollers. Optionally, additional layers such as, for example, non-woven and / or woven layers can also be attached to one or both sides of the web along with the film to facilitate handling of the glass fiber reinforced mat.Next, the composite can be passed through a tension roll and then continuously cut (severed) to the desired size for later formation into the final product. Further information regarding the preparation of GMT composites, including suitable materials and processing conditions used in forming such composites, is described, for example, in U.S. Patent Nos. 6,923,494; 4,978,489; 4,944,843; 4,964,935; 4,734,321; 5,053,449; 4,925,615; 5,609,966; and U.S. Patent Application Publication Nos. US2005 / 0082881; US2005 / 0228108; US2005 / 0217932; US2005 / 0215698; US2005 / 0164023; and US2005 / 0161865.

[0061] In some examples, a dispersion of a thermoplastic material can be used to provide a coating onto a surface layer that is bonded to the resulting prepreg or core that is partially formed using the thermoplastic material. An example of one of the particular process steps is shown in FIG. 11. In step 1110, a thermoplastic material is provided to a mixing tank to provide an aqueous dispersion of the thermoplastic material. A dispersant, surfactant, etc. can be added to the mixing tank, or the mixing tank can contain a dispersion or solution of the thermoplastic material in an aqueous solvent or carrier without using any dispersant or surfactant. In step 1120, the dispersion is provided to a surface layer that includes core fibers to place a sheath material over the fibers having the dispersed thermoplastic material, and in step 1130, a coated surface layer can be provided. For example, at least about 75% of the fibers present within the surface layer, such as at least 80%, 85%, 90%, or 95 In some embodiments for providing a sheath material such that the % constitutes the sheath material, the dispersion can be sprayed onto the core fibers of the surface layer, the core fibers of the surface layer can be immersed in the dispersion, or the dispersion can be otherwise provided to the core fibers of the surface layer. In step 1130, a prepreg dispersion can be formed by adding reinforcing fibers, an optional lofting agent, and other additives to an aqueous dispersion containing a thermoplastic material. In step 1140, various processes such as a wet laying process, an air laying process, etc. can be used to form bubbles using the prepreg dispersion. Then, the coated surface layer from step 1120 is placed on the formed core to provide a composite article comprising a porous core formed from a thermoplastic material and reinforcing fibers (and optionally a lofting agent) having a surface layer comprising coated fibers, which can increase the elongation of the formed article and enable the forming operation by the formed article without break-through in the deep drawing region.

[0062] In other cases, a process similar to the process of FIG. 11 can be used, but a surface layer containing sheath-core fibers can be pre-formed and added to the formed core. For example, the sheath material and the core fiber material can be co-extruded to provide sheath-core fibers that can be formed into a surface layer, such as a non-woven scrim. Referring to FIG. 12, in step 1210, a thermoplastic material is provided to a mixing tank to provide an aqueous dispersion of the thermoplastic material. Dispersants, surfactants, etc. can be added to the mixing tank, or the mixing tank can contain a dispersion or solution of the thermoplastic material in an aqueous solvent or carrier without using any dispersant or surfactant. In step 1220, a prepreg dispersion can be formed by adding reinforcing fibers, an optional lofting agent, and other additives to the aqueous dispersion containing the thermoplastic material. In step 1230, various processes, such as a wet laying process, an air laying process, etc., can be used to form bubbles using the prepreg dispersion. In step 1240, a pre-formed coated surface layer is placed on the formed core to provide a composite article comprising a porous core formed from the thermoplastic material and the reinforcing fibers (and optionally a lofting agent) having a surface layer containing sheath-core fibers, enhancing the elongation of the formed article and enabling the forming operation by the formed article without break-through in the deep drawing region.

[0063] In some examples, the core fibers of the surface layer can be coated with a prepreg dispersion. Referring to FIG. 13, in process 1310, a thermoplastic material is provided to a mixing tank to provide an aqueous dispersion of the thermoplastic material. A dispersant, surfactant, etc. can be added to the mixing tank, or the mixing tank can contain a dispersion or solution of the thermoplastic material in an aqueous solvent or carrier without using any dispersant or surfactant. In process 1320, a prepreg dispersion can be formed by adding reinforcing fibers, an optional lofting agent, and other additives to the aqueous dispersion containing the thermoplastic material. In process 1330, the prepreg dispersion can be provided to the surface layer containing the core fibers to place the prepreg dispersion into the core fibers. For example, in some manners for placing the prepreg dispersion onto the core fibers, such as in some manners where at least about 75%, 80%, 85%, 90%, or 95% of the core fibers present in the surface layer can contain the placed prepreg dispersion, the prepreg dispersion can be sprayed onto the core fibers of the surface layer, the core fibers of the surface layer can be immersed in the prepreg dispersion, or the prepreg dispersion can be provided to the core fibers of the surface layer in other ways. In some examples, after providing the prepreg dispersion to the core fibers of the surface layer, the surface layer can be heated to melt the thermoplastic material present in the core fibers of the surface layer. The surface layer can be cooled, and after the surface layer has cooled, the reinforcing fibers and lofting agent can be washed away, leaving the thermoplastic material disposed on the core fibers intact. In process 1340, various processes such as a wet laying process, an air laying process, etc. can also be used to form bubbles using the prepreg dispersion. The formed surface layer can be bonded to the formed core to provide a composite article (in process 1350) containing a porous core formed from the thermoplastic material and the reinforcing fibers (and optionally the lofting agent) having a surface layer containing sheath-core fibers, increasing the elongation of the formed article without break-through in the deep drawing region and enabling the forming operation by the formed article. It is possible to provide a composite article comprising a porous core formed from a thermoplastic material, and reinforcing fibers (and optionally a lofting agent) having a surface layer containing sheath-core fibers, enhancing the elongation of the formed article without break-through in the deep drawing region and enabling the forming operation by the formed article.

[0064] In some embodiments, the core can be formed on the surface layer by spraying, coating, or otherwise disposing the core components on the surface layer. The surface layer can be pre-formed by sheath-core fibers, or the sheath-core fibers can be formed using one or more materials during the manufacturing process. In some examples, a thermoplastic material and a reinforcing fiber dispersion (optionally with any lofting agent) can be sprayed onto the surface layer including the sheath-core fibers to form a prepreg on top of the surface layer. The composite of the prepreg and the surface layer can be further processed by heating, compression, dicing, cutting, etc. to provide an article having a desired thickness and / or shape. The formed article can then be subjected to one or more forming processes such as molding, deep drawing, and similar processes.

[0065] In certain examples, the articles described herein can optionally include an adhesive layer between the core layer and one or more other layers. For example, in certain automotive applications, it may be desirable to staple, adhere, or otherwise attach a fabric or cover to the article to provide a more aesthetically pleasing article, such as an aesthetically pleasing headliner or cargo compartment side trim, vehicle headlight, trunk trim, pillar trim, or compartment cover, or other automotive interior components. In other cases, the articles described herein can be used in architectural applications, including but not limited to wall coverings, ceiling panels, cubicle partition panels, or other similar products.

[0066] In other cases, the articles described herein can be configured as external automotive parts, including, but not limited to, wheel well liners, underbody shields, spare tire covers, or other automotive components that are attached to a vehicle and remain outside the passenger compartment. In some examples, the articles described herein can be configured as interior automotive parts, including, but not limited to, headliners, trunk trim panels, seatback panels, floor liners, or other interior automotive parts.

[0067] In other configurations, the composite articles described herein can be used in architectural applications such as tiles, ceiling panels, cubicle walls, roofing materials, wallboards, and other uses, particularly where it is desirable to have three-dimensional structural panels or three-dimensional aesthetic or cover panels. The ability to deep draw the composite articles described herein enables structures with shapes and features that are typically not achievable with conventional architectural panels.

[0068] In additional configurations, the composite articles described herein can be used in interior RV applications such as wall coverings, table coverings, floor coverings, cabinets, ceiling tiles or panels, countertops, or other interior RV components.

[0069] To better illustrate the novel aspects and configurations described herein, specific examples are set forth below. In a specific example, various scrims, and the elongation ability of articles containing the scrims, are tested.

[0070] Examples 1 - 9 Various different scrims (before bonding to any core layer) were tested to determine whether the scrims are suitable for use in the composite articles described herein to enhance formability. The scrims are listed below in Table 1.

[0071] [Table 1]

[0072] The elongation measurements of the articles of Examples 1 to 9 were carried out at room temperature (RT). Table 2 shows the results of the elongation measurements in the machine direction (MD) and the cross direction (CD). Using a test system by MTS Systems Corporation, the measurements were carried out in accordance with the ASTM 5304-09(2013) test entitled "Breaking Strength and Elongation of Textile Fabrics (Grab Test)".

[0073] [Table 2]

[0074] The scrums of Examples 8 and 9 provided high elongation in both the machine direction and the cross direction. In particular, the scrums of Examples 8 and 9 achieved an elongation of 50% or more in both the machine direction and the cross direction.

[0075] Example 10 The elongation measurements of the surface layer materials tested in Examples 1 to 9 were carried out at 200 degrees Celsius. Table 3 shows the results of the elongation measurements in the machine direction (MD) and the cross direction (CD). Using a test system by MTS Sy stems Corporation, the measurements were carried out in accordance with the ASTM 5304-09(2013) test entitled "Breaking Strength and Elongation of Textile Fabrics (Grab Test)".

[0076] [Table 3]

[0077] At 200 degrees Celsius, the scrims having sheath-core fibers (Examples 8 and 9) showed the highest elongation in both the machine direction and the transverse direction. Since the scrims did not tear at the chamber limit, the elongation values are likely to be even higher than those of Examples 8 and 9.

[0078] Example 11 Certain articles were subjected to a deep drawing molding process. Photographs showing the formed parts are shown in Fig. 14 (nylon scrim) and Fig. 15 (polyethylene (PE) sheath material and PET core fiber scrim). At a certain draw depth and geometry, when an article containing a nylon scrim was deep drawn, cracks were observed. At the same certain draw depth and geometry, when a polyethylene (PE)-PET sheath-core fiber scrim was molded (Fig. 15), no cracks were observed. No wrinkles were observed in any of the molded samples, and thus, no problems due to high shrinkage occurred during molding.

[0079] Example 12 The physical values of three LWRT boards including a control board (PET scrim), Sample A (PE-PET sheath-core fiber), and Sample B (PE-PET sheath-core fiber) were measured. The values are shown in Table 4 below.

[0080]

Table 4

[0081] Each of the control, Sample A, and Sample B boards was subjected to the deep drawing process and ranked. The ranking is shown in Table 5 below for each of the tested boards. The ranking numbers correspond to the following criteria. Rank 1: The cup is not fully formed. Rank 2: The cup is fully formed with a hole through the core. Rank 3: The cup is fully formed with a soft spot or a reduction in structural integrity. Rank 4: The cup is fully formed and maintains its structural integrity. Rank 5: The cup is fully formed without any scrim tears and maintains its structural integrity. Each rank was the average ranking of the three molding parts.

[0082]

Table 5

[0083] Example 13 Using the control and sample articles, "cupcakes" or frustum shapes were formed at various sites and depths. The die included five regions of different depths: Site 1 corresponding to a depth of 15 mm, Site 2 corresponding to a depth of 30 mm, Site 3 corresponding to a depth of 45 mm, and Sites 4 and 5 corresponding to a depth of 50 mm. The die cavity opening or width dimension was 36 mm for all formed regions. The calculated draw depth ratios for each cavity site are shown in Table 6.

[0084]

Table 6

[0085] The control article was a 600 gsm LWRT article with a PET fiber nonwoven scrim. Sample 1 was a 600 gsm LWRT article with a PE sheath material - PET core fiber nonwoven scrim. Sample 2 was a 500 gsm LWRT article with a PE sheath material - PET core fiber nonwoven scrim.

[0086] The results at cavity site 1 (depth 15 mm) for each of the samples are shown.

[0087]

Table 7

[0088] The results at each cavity site 2 (30 mm depth) of the samples are shown in Table 8.

[0089]

Table 8

[0090] These results are consistent with articles containing a two-component fiber scrim that provide a greater draw depth without breakthrough.

[0091] When introducing elements of the embodiments disclosed herein, the articles "a," "an," "the," and "said" are intended to mean that there are one or more elements. The terms "including" and "having" are open-ended and are intended to mean that additional elements other than the recited elements may exist. Those skilled in the art will recognize that, in view of the advantages of the present disclosure, the various components of the embodiments may be interchanged or substituted with the various components in other embodiments.

[0092] While specific aspects, examples, and embodiments have been described above, those skilled in the art will recognize that, in view of the advantages of the present disclosure, additions, substitutions, modifications, and changes to the exemplary aspects, examples, and embodiments disclosed are possible.

Claims

1. A composite article comprising: a thermoplastic fiber-reinforced porous core layer formed from a plurality of reinforcing fibers and a web formed from a thermoplastic material; a nonwoven scrim bonded to the thermoplastic fiber-reinforced porous core layer at a first surface of the thermoplastic fiber-reinforced porous core layer, the nonwoven scrim comprising a plurality of bicomponent sheath-core fibers, wherein a sheath material of the bicomponent sheath-core fibers surrounds an entire side portion of a core material of the sheath-core fibers; wherein the sheath material of the sheath-core fibers comprises a polyolefin, the core material of the sheath-core fibers comprises a polyester or nylon, and the composite article comprises at least one deep draw region having a draw depth ratio of at least 0.25 without break-through in the at least one deep draw region.

2. The composite article according to claim 1, wherein at least 95% by weight of the fibers of the nonwoven scrim are the bicomponent sheath-core fibers.

3. The composite article according to claim 1, wherein the sheath material of the sheath-core fibers comprises polypropylene and the core material of the sheath-core fibers comprises a polyester.

4. The composite article according to claim 3, wherein the polyester comprises polyethylene terephthalate.

5. The composite article according to claim 1, wherein the thermoplastic material of the thermoplastic fiber-reinforced porous core layer comprises one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachloride, polyvinyl chloride, polyarylene ether, polycarbonate, polyester carbonate, thermoplastic polyester, polyimide, polyetherimide, polyamide, acrylonitrile-butyl acrylate-styrene polymer, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone, polyether sulfone, liquid crystal polymer, poly(1,4 phenylene) compound, high heat polycarbonate, high temperature nylon, silicone, or a blend of these materials with each other.

6. The composite article according to claim 1, wherein the reinforcing fibers of the thermoplastic fiber-reinforced porous core layer include one or more of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, and metallized inorganic fibers, fibers, or combinations thereof.

7. The composite article according to claim 1, further comprising a skin bonded to a second surface of the thermoplastic fiber-reinforced porous core layer.

8. The composite article according to claim 7, wherein the skin is selected from the group consisting of a thermoplastic film, an elastomeric film, a flim, a scrim, a foil, a woven fabric, a non-woven fabric, a sheath-core fiber scrim, or is present as an inorganic coating, an organic coating, a thermoplastic coating, or a thermosetting coating.

9. The composite article according to claim 8, wherein the thermoplastic fiber-reinforced porous core layer further comprises a lofting agent.

10. The composite article according to claim 8, wherein the porosity of the thermoplastic fiber-reinforced porous core layer is at least 20%.

11. The composite article according to claim 10, wherein based on the weight of the thermoplastic fiber-reinforced porous core layer, about 20 wt% to about 80 wt% of the thermoplastic material is present, and about 20 wt% to about 80 wt% of the reinforcing fibers is present.

12. The composite article according to claim 11, wherein the thermoplastic material includes a polyolefin, the reinforcing fibers include glass fibers, the lofting agent includes microspheres, and the non-woven scrim includes sheath-core fibers.

13. The composite article according to claim 1, comprising at least one deep drawing region having a draw depth ratio of at least 0.8 without break-through in the at least one deep drawing region.

14. The composite article according to claim 1, comprising at least one deep drawing region having a draw depth ratio of at least 1.0 without break-through in the at least one deep drawing region.

15. The composite article according to claim 1, comprising at least one deep drawing region having a draw depth ratio of at least 1.25 without break-through in the at least one deep drawing region.

16. The composite article according to claim 1, wherein the basis weight of the nonwoven scrim is from 10 gsm to 300 gsm.

17. The composite article according to claim 1, further comprising a decorative layer bonded to the composite article.

18. The composite article according to claim 1, wherein the thermoplastic fiber reinforced porous core layer has a basis weight of from 300 gsm to 3500 gsm.

19. The composite article according to claim 1, wherein the reinforcing fibers of the thermoplastic fiber reinforced porous core layer include sheath-core fibers, and the sheath material of the sheath-core fibers of the thermoplastic fiber reinforced porous core layer is a sheath material different from the sheath material of the two-component sheath-core fibers of the nonwoven scrim.

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