Multilayer assemblies with one or more mesh layers

Abstract

To provide reinforced thermoplastic composites and their use in vehicles and / or in the building industry.SOLUTION: The present invention provides a multi-layer assembly that comprises: a mesh layer; and a first thermoplastic fiber reinforced thermoplastic layer disposed on a first surface of mesh layer. The multi-layer assembly may comprise two fiber reinforced thermoplastic layers coupled to each other through the mesh layer.SELECTED DRAWING: Figure 1A

Description

[Technical Field]

[0001] Priority application This application is related to and claims priority to and the benefit of U.S. Provisional Application No. 62 / 473,048, filed March 17, 2017, the entire disclosure of which is incorporated herein by reference for all purposes.

[0002] This application relates to reinforced thermoplastic composites and their use in the vehicle and / or building industries. More specifically, certain configurations described herein relate to a mesh layer combined with one or more thermoplastic fiber reinforced layers. [Background technology]

[0003] Automobiles are typically manufactured using steel or other materials to provide strength and / or structural reinforcement. The inclusion of steel can increase the overall weight of the vehicle, which can decrease fuel economy and increase operating costs. Summary of the Invention [Means for solving the problem]

[0004] Specific aspects, embodiments, configurations, and examples of multi-layer assemblies including one or more mesh layers and one or more thermoplastic fiber reinforced layers are described below.

[0005] In one aspect, the multi-layer assembly includes a mesh layer and a first fiber-reinforced thermoplastic layer. In some examples, the mesh layer includes reinforcing fibers held in place by a thermoplastic material; for example, the mesh layer may include a substantially non-porous tape layer or tape layer. In particular examples, the first fiber-reinforced thermoplastic layer is disposed on a first surface of the mesh layer. The first fiber-reinforced thermoplastic layer may include an open-cell web formed by multiple reinforcing materials bonded together with the thermoplastic material; for example, the fiber-reinforced thermoplastic layer may be configured as a porous layer that can be directly bonded to the mesh layer.

[0006] In certain embodiments, the first reinforcing thermoplastic layer is bonded directly to the mesh layer without any intervening layers or materials. In other embodiments, the multi-layer assembly includes a second reinforcing thermoplastic layer disposed on a second surface of the mesh layer, the second fiber-reinforced thermoplastic layer including an open-cell web formed by a plurality of reinforcing materials bonded together with a thermoplastic material. In some embodiments, the second reinforcing thermoplastic layer is bonded directly to the mesh layer without any intervening layers or materials.

[0007] In other instances, the multi-layer assembly comprises a first skin layer disposed on the first toughened thermoplastic layer. In some embodiments, the multi-layer assembly comprises a second skin layer disposed on the second toughened thermoplastic layer.

[0008] In certain embodiments, the mesh layer comprises fiberglass and polypropylene and is configured as a woven tape layer, and the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer each comprise polypropylene and fiberglass and have a basis weight of about 800 gsm to about 1000 gsm.

[0009] In some embodiments, the multi-layer assembly includes a decorative layer bonded to one of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer, hi other examples, the decorative layer includes foam bonded to a fabric.

[0010] In some cases, the thermoplastic material of the first fiber reinforced thermoplastic layer includes one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, 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.

[0011] In certain examples, the reinforcing fibers of the first fiber reinforced thermoplastic 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.

[0012] In some configurations, the multi-layer assembly includes a skin bonded to a surface of the first fiber-reinforced thermoplastic layer. In certain embodiments, 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 nonwoven fabric, a fibrous scrim, or is present as an inorganic coating, an organic coating, a thermoplastic coating, or a thermoset coating.

[0013] In some embodiments, the first fiber reinforced thermoplastic layer further comprises a lofting agent. In another embodiment, the multi-layer assembly includes a decorative layer bonded to the first fiber reinforced thermoplastic layer.

[0014] In another aspect, a multi-layer assembly includes a mesh layer, a first fiber-reinforced thermoplastic layer, and a second fiber-reinforced thermoplastic layer. The mesh layer may include a first tape layer and a second tape layer, the first and second tape layers being in a woven arrangement, each including reinforcing fibers held in place by a thermoplastic material. The first fiber-reinforced thermoplastic layer may be disposed on a first surface of the mesh layer. The first fiber-reinforced thermoplastic layer includes an open-celled web formed by a plurality of reinforcing materials bonded together with a thermoplastic material. The second fiber-reinforced thermoplastic layer may be disposed on a second surface of the mesh layer. The second reinforcing thermoplastic layer includes an open-celled web formed by a plurality of reinforcing materials bonded together with a thermoplastic material. Each of the first fiber-reinforced thermoplastic layer and the second fiber-reinforced thermoplastic layer may be directly bonded to the mesh layer without any intervening layers or materials.

[0015] In certain embodiments, the multi-layer assembly includes a second mesh layer disposed on a surface of the second fiber reinforced thermoplastic layer.

[0016] In some embodiments, the thermoplastic material of the first fiber reinforced layer is different from the thermoplastic material of the second fiber reinforced layer. In other embodiments, the thermoplastic material of the first fiber reinforced layer comprises a common material with the thermoplastic material of the second fiber reinforced layer. In particular cases, the thermoplastic material of the first fiber reinforced layer and the thermoplastic material of the second fiber reinforced layer each comprise polypropylene. In some embodiments, the reinforcing fibers of the first fiber reinforced layer are different from the reinforcing fibers of the second fiber reinforced layer. In other embodiments, the reinforcing fibers of the first fiber reinforced layer comprise a common material with the reinforcing fibers of the second fiber reinforced layer. In some embodiments, the reinforcing fibers of the first fiber reinforced layer and the reinforcing fibers of the second fiber reinforced layer comprise glass fibers.

[0017] In some embodiments, the multi-layer assembly may include a first reinforced thermoplastic layer disposed on a first reinforced thermoplastic layer. In some configurations, 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 nonwoven fabric, a fibrous scrim, or is present as an inorganic coating, an organic coating, a thermoplastic coating, or a thermoset coating. In other examples, the multilayer assembly includes a second skin disposed on the second toughened thermoplastic layer.

[0018] In a particular example, the mesh layer comprises fiberglass and polypropylene, and the first fiber reinforced thermoplastic layer and the second fiber reinforced thermoplastic layer each comprise polypropylene and fiberglass and have a basis weight of about 800 gsm to about 1000 gsm.

[0019] In certain configurations, the thermoplastic material of the first fiber reinforced thermoplastic layer and the thermoplastic material of the second fiber reinforced thermoplastic layer are independently selected from the group consisting of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, polyvinyl chloride, polyarylene ether, polycarbonate, polyester carbonate, thermoplastic polyester, polyimide, polyetherimide, polyamide, acrylonitrile-butyl acrylate-styrene polymer, amorphous and wherein the reinforcing fibers of the first fiber reinforced thermoplastic layer and the reinforcing fibers of the second fiber reinforced thermoplastic layer comprise 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.

[0020] In some embodiments, the first fiber reinforced thermoplastic layer and the second fiber reinforced thermoplastic layer each further comprise a lofting agent.

[0021] In other embodiments, the multi-layer assembly comprises a decorative layer bonded to the first fiber reinforced thermoplastic layer or the second fiber reinforced thermoplastic layer or both.

[0022] In an additional aspect, a divider wall configured to separate a passenger compartment of a vehicle from a cargo compartment of the vehicle is described. In some configurations, the divider wall includes: a mesh layer including reinforcing fibers held in place by a thermoplastic material; a first fiber-reinforced thermoplastic layer disposed on a first surface of the mesh layer, the first fiber-reinforced thermoplastic layer including an open-cell web formed by a plurality of reinforcing materials bonded together with a thermoplastic material; and a second fiber-reinforced thermoplastic layer disposed on a second surface of the mesh layer, the second fiber-reinforced thermoplastic layer including an open-cell web formed by a plurality of reinforcing materials bonded together with a thermoplastic material.

[0023] In some embodiments, the partition wall includes an opening between the passenger compartment and the cargo compartment. In certain embodiments of the partition wall, the first reinforced thermoplastic layer is bonded directly to the mesh layer without any intervening layers or materials. In some cases, the mesh layer comprises fiberglass and polypropylene and is configured as a woven tape layer, and the first and second fiber reinforced thermoplastic layers each comprise polypropylene and fiberglass and have a basis weight of about 800 gsm to about 1000 gsm.

[0024] In another embodiment, the partition wall further comprises a decorative layer coupled to one of the first fiber reinforced thermoplastic layer and the second fiber reinforced thermoplastic layer.

[0025] In certain embodiments, the thermoplastic first fiber reinforced thermoplastic layer and the thermoplastic second fiber reinforced thermoplastic layer The plastic materials each independently comprise one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, 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 some examples, the reinforcing fibers of the first fiber reinforced thermoplastic layer and the reinforcing fibers of the second fiber reinforced thermoplastic layer each independently comprise 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.

[0026] In certain cases, the partition wall further comprises a skin bonded to a surface of the first fiber-reinforced thermoplastic layer. In some examples, 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 nonwoven fabric, a fibrous scrim, or is present as an inorganic coating, an organic coating, a thermoplastic coating, or a thermoset coating. In other examples, the partition wall comprises a skin bonded to a surface of the second fiber-reinforced thermoplastic layer.

[0027] In another aspect, a vehicle includes a passenger compartment and a cargo compartment separated by a wall panel. In some configurations, the wall panel includes: a mesh layer including reinforcing fibers held in place by a thermoplastic material; a first fiber-reinforced thermoplastic layer disposed on a first surface of the mesh layer, the first fiber-reinforced thermoplastic layer including an open-cell web formed by a plurality of reinforcing materials bonded together with a thermoplastic material; and a second fiber-reinforced thermoplastic layer disposed on a second surface of the mesh layer, the second fiber-reinforced thermoplastic layer including an open-cell web formed by a plurality of reinforcing materials bonded together with a thermoplastic material.

[0028] In certain embodiments, the vehicle wall panel includes an opening between the passenger area and the cargo area. In other embodiments of the vehicle wall panel, the first reinforcing thermoplastic layer is bonded directly to the mesh layer without any intervening layers or materials.

[0029] In some embodiments of the vehicle wall panel, the mesh layer comprises fiberglass and polypropylene and is configured as a woven tape layer, and the first fiber reinforced thermoplastic layer and the second fiber reinforced thermoplastic layer each comprise polypropylene and fiberglass and have a basis weight of about 800 gsm to about 1000 gsm.

[0030] In an additional embodiment, the vehicle wall panel further includes a decorative layer bonded to one of the first fiber reinforced thermoplastic layer and the second fiber reinforced thermoplastic layer.

[0031] In some embodiments, the thermoplastic materials of the first fiber reinforced thermoplastic layer and the second fiber reinforced thermoplastic layer are each independently polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, 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 any of these materials. with one another.

[0032] In certain examples, the reinforcing fibers of the first fiber reinforced thermoplastic layer and the reinforcing fibers of the second fiber reinforced thermoplastic layer each independently comprise 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.

[0033] In other examples, the vehicle wall panel further includes a skin bonded to a surface of the first fiber-reinforced thermoplastic layer. In some embodiments, 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 nonwoven fabric, a fibrous scrim, or is present as an inorganic coating, an organic coating, a thermoplastic coating, or a thermoset coating. In other examples, the vehicle wall panel further includes a skin bonded to a surface of the second fiber-reinforced thermoplastic layer.

[0034] In another aspect, a method for manufacturing a multi-layer assembly includes forming a first fiber-reinforced thermoplastic layer by adding reinforcing fibers and a first thermoplastic material to an agitated liquid-containing foam to form a dispersed mixture of the first thermoplastic material and the reinforcing fibers, depositing the dispersed mixture of the reinforcing fibers and the first thermoplastic material on a forming support element, draining the liquid to form a web, heating the web above the softening temperature of the first thermoplastic material, and compressing the heated web to a predetermined thickness to form the first fiber-reinforced thermoplastic layer. The method may also include disposing a mesh layer on a first surface of the formed first fiber-reinforced thermoplastic layer to provide the multi-layer assembly. For example, the mesh layer may include fibers and a thermoplastic material.

[0035] In certain examples, the method includes forming a second fiber-reinforced thermoplastic layer by adding reinforcing fibers and a second thermoplastic material to an agitated liquid-containing foam to form a dispersed mixture of the second thermoplastic material and the reinforcing fibers, depositing the dispersed mixture of the reinforcing fibers and the second thermoplastic material onto a forming support element, draining the liquid to form a web, heating the web above a softening temperature of the second thermoplastic material, and compressing the heated web to a predetermined thickness to form the second fiber-reinforced thermoplastic layer. The method may also include disposing the formed second fiber-reinforced thermoplastic layer on a mesh layer.

[0036] In some embodiments, the first thermoplastic material and the second thermoplastic material comprise a common material.

[0037] In another embodiment, the method includes forming a mesh layer by weaving together two or more tape layers, each tape layer including a fiber and a thermoplastic material.

[0038] In some instances, the method includes sizing the mesh layer to contact substantially all of the first surface of the first fiber-reinforced layer, while in other instances, the method includes sizing the mesh layer to be smaller than the first surface of the first fiber-reinforced layer.

[0039] In another embodiment, the method includes configuring the first thermoplastic material to include polypropylene, configuring the reinforcing fibers to include glass fibers, and configuring the mesh layer to include polypropylene and glass fibers.

[0040] In some examples, the method includes bonding a skin to the first fiber reinforced thermoplastic layer. In certain embodiments, the method includes bonding the skin as a thermoplastic film, an elastomeric film, a flim, a scrim, a foil, a woven fabric, a nonwoven fabric, a fibrous scrim, or as an inorganic coating. In another embodiment, the method includes selecting the skin to be a decorative layer.

[0041] Specific embodiments will now be described with reference to the accompanying drawings. [Brief explanation of the drawings]

[0042] [Figure 1A] FIG. 1A is a diagram of a multi-layer assembly including a thermoplastic fiber reinforced layer and a mesh layer, according to certain embodiments. [Figure 1B] FIG. 1B is a diagram of a multi-layer assembly including a thermoplastic fiber reinforced layer, a mesh layer, and a surface layer, according to certain embodiments. [Figure 1C] FIG. 1C is a diagram of a multi-layer assembly including two thermoplastic fiber reinforced layers and a mesh layer, according to certain embodiments. [Figure 1D] FIG. 1D is a diagram of a multi-layer assembly including two layers: a thermoplastic fiber reinforced layer, a surface layer, and a mesh layer, according to certain embodiments. [Figure 1E]FIG. 1E is a diagram of a multi-layer assembly including two thermoplastic fiber reinforced layers, two surface layers, and a mesh layer, according to certain embodiments. [Figure 2] FIG. 2 is a diagram of a multi-layer assembly including a thermoplastic fiber reinforced layer and two mesh layers, according to some embodiments. [Figure 3] FIG. 3 is a diagram of a multi-layer assembly including a thermoplastic fiber reinforced layer, a mesh layer, and a surface layer bonded to the mesh layer, according to some embodiments. [Figure 4] FIG. 4 is a diagram of a multi-layer assembly comprising two mesh layers bonded together with a thermoplastic fiber reinforced layer, according to some embodiments. [Figure 5] FIG. 5 is a diagram of a multi-layer assembly comprising two thermoplastic fiber reinforced layers separated by a mesh layer and a skin layer on one side of the two thermoplastic fiber reinforced layers, according to some embodiments. [Figure 6A] FIG. 6A is an illustration of a partition wall according to some embodiments. [Figure 6B] FIG. 6B is an illustration of a partition wall according to some embodiments. [Figure 6C] FIG. 6C is an illustration of a partition wall according to some embodiments. [Figure 7A] FIG. 7A is a diagram of a multi-layer assembly comprising a tape mesh layer disposed on a thermoplastic fiber reinforced layer, according to certain embodiments. [Figure 7B] FIG. 7B is an illustration of a multi-layer assembly comprising a tape mesh layer disposed on a thermoplastic fiber reinforced layer, according to certain embodiments. [Figure 8] FIG. 8 is an illustration of tape layers woven together to form a mesh layer disposed on a thermoplastic fiber reinforced layer, according to certain embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0043] Those skilled in the art will recognize, with the benefit of this disclosure, that certain dimensions or features in the drawings may be shown enlarged, distorted, or in other non-conventional or non-proportional manners to provide a more accessible view of the drawings. No specific thickness, width, or length is intended by the depictions in the drawings, and the relative sizes among the components in the drawings are not intended to limit the size of any of the components in the drawings. Where dimensions or values ​​are specified in the following description, the dimensions or values ​​are provided for illustrative purposes only. Additionally, the shading of particular portions of the drawings is not intended to require specific materials or arrangements, and although different components in the drawings may include shading for distinction, the different components may comprise the same or similar materials if desired.

[0044] In order to provide a more readily accessible description of the technology disclosed herein, certain embodiments are described below with reference to singular and plural terms. These terms are used for convenience only. The descriptions are merely illustrative and are not intended to limit layers, assemblies, articles, methods, and other subject matter as including or excluding particular features unless otherwise specified as being present in or excluded from specific embodiments described herein.

[0045] In certain instances, the materials described herein can be used together to provide sheets, panels, floor pans, load floors, vehicle walls, divider panels, vehicle dividers, ceilings, or floors, e.g., recreational vehicle walls, ceilings, or floors, and other articles. For example, the multi-layer assemblies can be used as wall or ceiling panels, as flooring, subfloors, or in automotive applications, such as vehicle load floors or vehicle underbody floors. In some examples, the multi-layer assemblies can be used as dividers to separate the passenger compartment of a vehicle from other areas of the vehicle. In other examples, the assemblies can be used in architectural applications such as exterior cladding, roofing, floors, wall panels, and the like. Use of the multi-layer assemblies described herein can provide desirable attributes, including, for example, reduced weight and increased impact resistance.

[0046] In some examples, the multilayer assemblies described herein may include one or more thermoplastic fiber-reinforced layers bonded to a mesh layer. The term thermoplastic fiber-reinforced (TFR) layer is used interchangeably herein with the term “fiber-reinforced thermoplastic layer.” If desired, the thermoplastic fiber-reinforced layer can be bonded directly to the mesh layer without any intervening components or layers, e.g., without the use of an adhesive or other layer between the mesh layer and the thermoplastic fiber-reinforced layer. FIG. 1A shows a multilayer assembly including a thermoplastic fiber-reinforced (TFR) layer 120 and a mesh layer 110. As described herein, the thermoplastic fiber-reinforced layer 120 can be bonded directly to the mesh layer 110 without any intervening components or layers, and the properties of the mesh layer 110 can be selected so that the mesh layer and the reinforcement layer 120 adhere to each other to at least some degree. However, if desired, an adhesive or other material can be present between the layers 110 and 120.

[0047] In some embodiments, mesh layer 110 may generally comprise an arrangement of fibers and, optionally, one or more thermoplastic materials, such as polyolefin materials. In certain instances, mesh layer 110 may comprise an arrangement of thermoplastic fibers, optionally combined with one or more non-thermoplastic fibers, such as glass fibers, carbon fibers, etc. In some configurations, mesh layer 110 may comprise an arrangement of polyolefin fibers, optionally combined with one or more non-thermoplastic fibers. For example, polyethylene fibers or polypropylene fibers, or both, may be present in combination with glass fibers in mesh layer 110. If desired, one or more thermoplastic materials may also be present in combination with thermoplastic fibers and / or any non-thermoplastic fibers. In some examples, the fibers of the mesh layer may be arranged in a non-woven pattern, a woven pattern, or other pattern. In some examples, the fibers of the mesh layer may be arranged so that they intersect or cross the mesh layer. In other examples, the fibers or specific sections of the fibers may be arranged so that they do not intersect or overlap in some sections. While not wishing to be bound to any one configuration, mesh layer 110 can function as a bonding layer that allows bonding of TFR layer 120 to another layer or structure. In some cases, mesh layer 110 is effective to bond TFR layer 120 to another layer without the use of any adhesive. However, if desired, an adhesive layer or material can be present between TFR layer 120 and mesh layer 110 or added onto mesh layer 110.

[0048] In certain configurations, the exact thickness of the mesh layer may vary, and may be a thickness and / or basis weight that is less than the thickness or basis weight of the thermoplastic reinforcing fiber layer, or may be a thickness and / or basis weight that is less than the thickness or basis weight of the thermoplastic reinforcing fiber layer. The mesh layer 110 may have a thickness and / or basis weight similar to, or even greater than, the thickness or basis weight of the thermoplastic reinforcing fiber layer. In some embodiments, the mesh layer 110 may be configured as a strip or tape layer having a selected number of tapes per 10 cm of length and width. For example, there may be 1-6 tapes per 10 cm of length (1-6 tapes per 10 cm) and / or there may be 1-6 tapes per 10 cm of width (1-6 tapes per 10 cm). In some embodiments, there may be 3-5 tapes per 10 cm of length (3-5 tapes per 10 cm) and / or there may be 3-5 tapes per 10 cm of width (3-5 tapes per 10 cm). For example, the mesh layer may be configured as a 4 / 4 mesh layer per 10 cm, with 4 tapes per 10 cm of width and 4 tapes per 10 cm of length.

[0049] In other cases, the overall width of the mesh layer can vary from about 10 mm to about 200 cm. If the width of the mesh layer is smaller than the desired width, different mesh layers can be placed next to each other on the surface of the TFR layer 120 to provide the desired level of coverage across the surface of the TFR layer 120. As described in more detail below, the mesh layer 110 may be composed of two or more different tape layers woven together to provide the mesh layer 110. In some cases, the basis weight of the mesh layer 110 may be from about 400 grams per square meter (gsm) to about 1000 gsm, more specifically, from about 500 gsm to about 900 gsm, or from about 600 to 850 gsm. In some examples, the porosity of the mesh layer 110 may be less than 10%, or less than 5%, or even near 0%, or 0%. When mesh layer 110 is constructed as a woven material including two or more tape layers woven together, holes or openings at the intersections of the tape layer weave may provide some overall porosity to mesh layer 110.

[0050] In certain embodiments, the mesh layer 110 may comprise a fiber-reinforced thermoplastic, which is typically much thinner than the TFR layer. For example, the layer 110 may be configured as a fiber-reinforced mesh tape, which may have a unidirectional fiber orientation, a bidirectional fiber orientation, or other fiber orientation. The thermoplastic and reinforcing fibers of the mesh layer may be any of those described in connection with the TFR layer, e.g., polyolefins such as polypropylene, fiberglass, etc. For example, long strands of unidirectional glass fiber may be held together in mesh / tape form with polypropylene. In some embodiments, cut sheets of fiber may be woven to provide the mesh layer. If desired, fibers of different directions may be woven together to provide a bidirectional fiber orientation in the mesh layer 110. In certain examples, the reinforcing fibers of mesh layer 110 may include glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers (e.g., para- and meta-aramid fibers, nylon fibers, polyester fibers, or any of the high melt flow index resins described herein suitable for use as fibers), mineral fibers (e.g., basalt), mineral wool (e.g., rock wool or slag wool), wollastonite, alumina silica, or the like, or mixtures thereof, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the foregoing fibers may be chemically treated prior to use to provide the fibers with desired functional groups or to impart other physical properties, for example, to render them reactive with thermoplastic materials, lofting agents, or both. If a thermoplastic material is present in mesh layer 110, the thermoplastic material of mesh layer 110 may comprise, at least in part, one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, and blends of these materials with each other or with other polymeric materials.Other suitable thermoplastic resins include, but are not limited to, polyarylene ethers, polycarbonates, polyester carbonates, thermoplastic polyesters. Included are polyimides, polyetherimides, polyamides, copolyamides, acrylonitrile-butyl acrylate-styrene polymers, amorphous nylons, polyarylene ether ketones, polyphenylene sulfides, polyarylsulfones, polyethersulfones, liquid crystal polymers, poly(1,4 phenylene) compounds commercially known as PARMAX®, high heat polycarbonates such as Bayer's APEC® PC, high temperature nylons, silicones, and copolymers, alloys, and blends of these materials with each other or with other polymeric materials.

[0051] Referring now to FIG. 1B, a diagram of a multilayer assembly is shown including a thermoplastic fiber reinforced layer 120, a mesh layer 110, and a face layer 120. As described herein, the thermoplastic fiber reinforced (TFR) layer 120 can be bonded directly to the mesh layer 110 without any intervening components or layers, and if desired, the TFR layer 120 can be bonded directly to the skin or face layer 130. FIG. 1C shows a diagram of a multilayer assembly including two thermoplastic fiber reinforced layers 120, 160 and a mesh layer 110 between the two layers 120, 160. The thermoplastic fiber reinforced layers 120, 160 can each be bonded directly to the mesh layer 110 without any intervening components or layers, e.g., without the use of an adhesive layer. The TFR layers 120, 160 can be the same or different, e.g., can include different thicknesses of different basis weights. FIG. 1D shows a multilayer assembly including two thermoplastic fiber reinforced layers 120, 160, a surface layer 170, and a mesh layer 110 between the layers 120, 160. The thermoplastic fiber reinforced layers 120, 160 can each be bonded directly to the mesh layer 110 without any intervening components or layers, e.g., without any adhesive layer between the mesh layer 110 and the other layer 120, 160. If desired, the TFR layer 120 can be bonded directly to the surface layer 170. FIG. 1E shows a multilayer assembly including two thermoplastic fiber reinforced layers 120, 160, two surface layers 170, 180, and the mesh layer 110. If desired, the TFR layer 120 can be bonded directly to the surface layer 170, and the TFR layer 160 can be bonded directly to the surface layer 180, e.g., without any adhesive layer between the layers.

[0052] In certain examples, the TFR layers described herein may be configured as (or used in) a glass mat thermoplastic composite (GMT) or lightweight reinforced thermoplastic (LWRT). One such LWRT is made by HANWHA AZDEL, Inc. and sold under the trademark SUPERLITE® material. The areal density of such GMT or LWRT can range from about 400 grams per square meter (gsm) to about 4000 gsm, although the areal density may be less than 400 gsm or greater than 4000 gsm, depending on the needs of a particular application. In some embodiments, the upper density limit may be less than about 4000 gsm. In certain cases, the GMT or LWRT may include one or more lofting agent materials disposed in the void spaces or pores of the GMT or LWRT. When two or more GMT or LWRT layers are present, the GMT or LWRT layers may be the same or different.

[0053] In certain embodiments where LWRT is used as a surface layer, the LWRT typically includes a thermoplastic material and a plurality of reinforcing fibers that together form an open-celled web. For example, a TFR layer typically includes a significant amount of open-celled structure such that void space exists within the layer. In some instances, TFR layer 120 (and / or TFR layer 160) may be 0-30%, 10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10-90%, 10-120%, 10-140%, 10-160%, 10-180%, 10-200%, 10-220%, 10-240%, 10-260%, 10-280%, 10-300%, 10-320%, 10-340%, 10-400%, 10-500%, 10-600%, 10-700%, 10-240%, 10-32 ... 0-80%, 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 The TFR layer may include a void content or porosity of ∼95%, 80-90%, 80-95%, or any exemplary value within these exemplary ranges. In some cases, the TFR layer includes a porosity or void content greater than 0%, e.g., is not fully consolidated to about 95%. Unless otherwise specified, references to a TFR layer including a particular void content or porosity are based on the total volume of that TFR layer, and not necessarily the total volume of the multilayer assembly.

[0054] In certain examples, the TFR layer can be produced in the form of a GMT or LWRT sheet. In certain cases, the sheet can generally be made using chopped glass fiber, a thermoplastic material, optionally a lofting agent, and any thermoplastic polymer film(s), and / or a woven or nonwoven fabric made of glass fiber or thermoplastic resin fibers, such as 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 the resin. To produce the sheet, the thermoplastic material and reinforcing material can be added or metered into a dispersed foam placed in an open-top mixing tank equipped with an impeller. Without wishing to be bound by any particular theory, the presence of trapped air pockets in the foam may aid in the dispersion of the glass fiber, thermoplastic material, and lofting agent. In some embodiments, the dispersed mixture of fibers and thermoplastic material may be pumped through a dispersion manifold to a headbox located above the wire section of a papermaking machine. The dispersed mixture may be fed to a moving wire screen using a vacuum to continuously produce a uniform, fibrous wet web, removing the foam but not the fibers and thermoplastic resin. The wet web may be passed through a dryer at a suitable temperature to reduce the moisture content and melt or soften the thermoplastic material. The resulting product may be pressed or compressed, for example, using nip rollers or other techniques, to form a sheet, which may then be bonded to a mesh layer and, optionally, another GMT or LWRT sheet.

[0055] In certain embodiments, the high porosity present in the TFR layer can reduce the overall weight of the layer and allow for the inclusion of agents within the void spaces. For example, a lofting agent can be present in the void spaces in a non-covalently bonded manner. The application of heat or other perturbation can act to increase the volume of the non-covalently bonded lofting agent, resulting in an increase in the overall thickness of the layer, for example, as the size of the lofting agent increases and / or as additional air is trapped within the layer. If desired, flame retardants, colorants, smoke suppressants, and other materials can be included in the void spaces of the TFR layer. Prior to lofting, the TFR layer can be compressed to reduce its overall thickness, for example, before or after it is bonded to one or more other layers.

[0056] In certain embodiments, the thermoplastic material of the TFR layer may comprise, at least in part, one or more of polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, as well as blends of these materials with each other or with other polymeric materials. Other suitable thermoplastics include, but are not limited to, polyarylene ethers, polycarbonates, polyester carbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, copolyamides, acrylonitrile-butyl acrylate-styrene polymers, amorphous nylons, polyarylene ether ketones, polyphenylene sulfides, polyarylsulfones, polyethersulfones, liquid crystal polymers, and poly(1,4-phenylene) copolymers commercially known as PARMAX®. Examples of suitable thermoplastic materials include polycarbonates, high-heat polycarbonates such as Bayer's APEC® PC, high-temperature nylons, silicones, and copolymers, alloys, and blends of these materials with each other or with other polymeric materials. The thermoplastic material used to form the TFR layer can be used in powder form, resin form, rosin form, particle form, fiber form, or other suitable form. Various forms of exemplary thermoplastic materials are described herein and are also described, for example, in U.S. Patent Application Publication Nos. 20130244528 and US20120065283. The exact amount of thermoplastic material present in the TFR layer 120 can vary, with exemplary amounts ranging from about 20% to about 80% by weight, e.g., 30 to 70 weight percent or 35 to 65 weight percent.

[0057] In particular examples, the reinforcing fibers of the TFR layers 120, 160 may include glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers (e.g., para- and meta-aramid fibers, nylon fibers, polyester fibers, or any of the high melt flow index resins described herein suitable for use as fibers), mineral fibers (e.g., basalt), mineral wool (e.g., rock wool or slag wool), wollastonite, alumina-silica, or mixtures thereof, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the foregoing fibers may be chemically treated prior to use to provide the fibers with desired functional groups or to impart other physical properties, e.g., to enable them to react with thermoplastic materials, lofting agents, or both. The fiber content of the TFR layers 120, 160 may independently be from about 20% to about 90% by weight of the layer, more specifically, from about 30% to about 70% by weight of the layer. Typically, the fiber content of a multilayer assembly including the TFR layer 120 varies between about 20% and about 90% by weight of the assembly, more specifically, between about 30% and about 80% by weight, e.g., between about 40% and about 70% by weight. The specific size and / or orientation of the fibers used may depend, at least in part, on the desired properties of the thermoplastic polymer material and / or TFR layer used. Suitable additional fiber types, fiber sizes, and amounts will be readily selected by one of ordinary skill in the art given the benefit of this disclosure. In one non-limiting example, the fibers dispersed in the thermoplastic material and optional lofting agent to provide the TFR layer generally have a diameter greater than about 5 microns, more specifically, between about 5 microns and about 22 microns, and a length between about 5 mm and about 200 mm. More specifically, the fiber diameter may be between about 100 microns and about 22 microns, and the fiber length may be between about 5 mm and about 75 mm.

[0058] In some embodiments, the lofting capability of the TFR layer can be further tailored by including one or more additional lofting agents. The exact type of lofting agent used in the TFR layer can vary depending on numerous factors, including, for example, the desired lofting temperature, the desired degree of lofting, etc. In some cases, microsphere lofting agents, such as expandable microspheres that can increase in size when exposed to convection heating, may be used. Exemplary commercially available lofting agents are available from Kureha Corp. (Japan). In other cases, a first lofting agent having a first average particle size and a second lofting agent having a second average particle size different from the first average particle size may be used in the TFR layer 120. In another example, the lofting agent may be an expandable graphite material, which can also impart some flame retardancy to the multilayer assembly.

[0059] In some configurations, the TFR layer may be substantially halogen-free or halogen-free to meet regulatory requirements for hazardous materials for a particular application. In other cases, one or more of the layers may contain a halogenated flame retardant, such as a halogenated flame retardant containing more of one of F, Cl, Br, I, and At, or a compound containing such a halogen, such as tetrabromobisphenol-A polycarbonate or a monohalo-, dihalo-, trihalo-, or tetrahalo-polycarbonate. In some cases, the thermoplastic material used in the TFR layer may contain one or more halogens to impart some flame retardancy without the addition of a separate flame retardant. When a halogenated flame retardant is present, it is desirably present in a flame retardant amount, which may vary depending on the other components present. For example, the halogenated flame retardant may be present in an amount of about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), more specifically, about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent. If desired, two different halogenated flame retardants may be added to the layer. In other cases, a non-halogenated flame retardant may be added, such as a flame retardant containing one or more of N, P, As, Sb, Bi, S, Se, and Te. In some embodiments, the non-halogenated flame retardant may include a phosphorylated material, which may make the layer more environmentally friendly. When a non-halogenated or substantially halogen-free flame retardant is present, the flame retardant is desirably present in a flame retardant amount, which may vary depending on the other components present. For example, the substantially halogen-free flame retardant may be present in an amount of from about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), more specifically, from about 1 weight percent to about 13 weight percent, e.g., from 5 weight percent to about 13 weight percent, based on the weight of the layer. If desired, two different substantially halogen-free flame retardants may be added to one or more layers shown in Figures 1A-1E. In certain cases, one or more of the layers described herein may include one or more halogenated flame retardants in combination with one or more substantially halogen-free flame retardants. When two different flame retardants are present, the combination of the two flame retardants may be present in a flame retardant amount, which may vary depending on the other components present. For example, the total weight of the flame retardant may be from about 0.1 weight percent to about 20 weight percent (based on the weight of the layer), more specifically, from about 1 weight percent to about 15 weight percent, e.g., from about 2 weight percent to about 14 weight percent, based on the weight of the layer.The flame retardant used in the layers described herein can be added to the mixture containing the thermoplastic material and the fibers (before disposing the mixture on the wire screen or other processing component) or can be added after the layer is formed. In some examples, the flame retardant material can include one or more of expandable graphite material, magnesium hydroxide (MDH), and aluminum hydroxide (ATH).

[0060] In certain embodiments where two TFR layers sandwich a mesh layer (see FIG. 1C ), the two TFR layers may be the same or different. TFR layer 160 may include any of these materials described in connection with TFR layer 120. In some embodiments, the reinforcing fibers and thermoplastic material of TFR layers 120, 160 may be the same material, but the basis weight or thickness of TFR layers 120, 160 may be different. In other embodiments, the basis weight and thickness of TFR layers 120, 160 may be the same, but the reinforcing fibers or thermoplastic material, or both, may be different. In some cases, the basis weight and thickness of TFR layers 120, 160 may be different, and the reinforcing fibers or thermoplastic material, or both, may also be different.

[0061] In certain embodiments, the surface layers 130, 170, 180 can each independently take on a number of forms, typically distinct from the TFR and mesh layers. In some embodiments, layers 130, 170, and 180 can each take the form of a skin. The skins 130, 170, and 180 can each comprise, for example, a film (e.g., a thermoplastic film or an elastomeric film), a flim, a scrim (e.g., a fibrous scrim), a foil, a woven fabric, a nonwoven fabric, or can exist as an inorganic coating, an organic coating, or a thermoset coating. In other cases, the skins 130, 170, and 180 can each comprise a limiting oxygen index greater than about 22, as measured according to ISO 4589, dated 1996. When a thermoplastic film is present as (or as part of) the skins 130, 170, or 180, the thermoplastic film can be selected from the group consisting of poly(etherimide), poly(etherketone), poly(ether-etherketone), poly(phenylene sulfide ... The surface layer 130, 170, or 180 may comprise at least one of: poly(arylene sulfone), poly(ether sulfone), poly(amide-imide), poly(1,4-phenylene), polycarbonate, nylon, and silicone. If a fiber-based scrim is present as (or as part of) the skin 130, 170, or 180, the fiber-based scrim may comprise at least one of: glass fiber, aramid fiber, graphite fiber, carbon fiber, inorganic mineral fiber, metal fiber, metallized synthetic fiber, and metallized inorganic fiber. If a thermoset coating is present as (or as part of) the skin 130, 170, or 180, the thermoset coating may comprise at least one of: unsaturated polyurethane, vinyl ester, phenolic, and epoxy. If an inorganic coating is present as (or as part of) the skin 130, 170, or 180, the inorganic coating may include a mineral containing a cation selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or may include at least one of gypsum, calcium carbonate, and mortar. If a nonwoven fabric is present as (or as part of) the skin 130, 170, or 180, the nonwoven fabric may include a thermoplastic material, a thermosetting binder, inorganic fibers, metal fibers, metallized inorganic fibers, and metallized synthetic fibers. If desired, the skin may also include a lofting agent.

[0062] In certain cases, one or more of layers 130, 170, and 180 may be configured as a decorative layer. The decorative layer may be formed from a thermoplastic film, such as polyvinyl chloride, polyolefin, thermoplastic polyester, or thermoplastic elastomer. The decorative layer 130, 170, or 180 may include carpet, rubber, or other aesthetic coverings. The decorative layer 130, 170, or 180 may also be a multilayer structure including a foam core formed from, for example, polypropylene, polyethylene, polyvinyl chloride, polyurethane, or the like. Fabrics such as woven fabrics made from natural and synthetic fibers, organic fiber nonwoven fabrics after needle-punching or the like, raised fabrics, knitted products, flocked fabrics, or other such materials may be bonded to the foam core. Fabrics may also be bonded to the foam core with thermoplastic adhesives, including pressure-sensitive adhesives and hot-melt adhesives such as polyamides, modified polyolefins, urethanes, and polyolefins. The decorative layer may also be manufactured using spunbond, thermal bonding, spunlace, meltblown, wet-laid, and / or dry-laid processes.

[0063] In certain examples, each of the layers of the multilayer assembly can be manufactured separately and then combined together to form the multilayer assembly. For example, each of the layers can be manufactured separately by wet-laid or other processes and then combined together to provide the multilayer assembly. It may be desirable to use a wet-laid process in manufacturing the various fiber-reinforced thermoplastic layers described herein. For example, a liquid or fluid medium containing dispersed materials, e.g., thermoplastic material, fiber, and optionally a lofting agent material, optionally with any one or more additives described herein (e.g., other lofting agents or flame retardants), can be stirred or agitated in the presence of a gas, e.g., air or other gas. The dispersion can then be placed on a support, e.g., a wire screen or other support material. The stirred dispersion can include one or more active agents, such as anionic, cationic, or nonionic active agents, such as those sold under the name ACE Liquid by Industrial Soaps Ltd., those sold as TEXOFOR® FN 15 material by Glover Chemicals Ltd., and those sold as AMINE Fb 19 material by Float-Ore Ltd. The ingredients can be added to a mixing tank, flotation cell, or other suitable device in the presence of air to provide the dispersion. While the use of an aqueous dispersion is preferred, one or more non-aqueous fluids can also be present to aid dispersion, modify the viscosity of the fluid, or impart some desired physical or chemical property to the dispersion or layer.

[0064] In certain cases, after the dispersion has been mixed for a sufficient period of time, the fluid containing the dispersed material can be placed on a screen and moved over a wire or other suitable support structure to provide a web of the entrained material. Suction or reduced pressure can be applied to the web to remove any liquid from the entrained material, leaving behind the thermoplastic material, the lofting agent, and any other materials present, such as fibers, additives, etc. The resulting web can be dried, consolidated, pressed, lofted, laminated, sized, or otherwise further processed to provide the desired layer or article. In some cases, additives or additional lofting agent materials can be added before drying, consolidating, pressing, lofting, laminating, sizing, or otherwise further processed to provide the desired layer or article. In other cases, the lofting agent can be added to the web following drying, consolidating, pressing, lofting, laminating, sizing, or otherwise further processed to provide the desired layer or article. While a wet-laid process can be used, depending on the nature of the thermoplastic, lofting agent, and other materials present, it may be desirable to instead use an air-laid process, a dry blend process, a carding and needling process, or other known processes used to make nonwoven products.

[0065] In some configurations, the fiber-reinforced thermoplastic layer described herein can be produced by combining a thermoplastic material, fiber, and an optional microsphere lofting agent in an aqueous solution or foam in the presence of a surfactant. The combined components can be mixed or stirred for a sufficient time to disperse the various materials and provide a substantially homogeneous aqueous mixture of materials. The dispersed mixture can then be placed on any suitable support structure, such as a wire mesh or other mesh or support having the desired porosity. The water can then be drained through the wire mesh to form a web. The web is dried and heated above the softening point of the thermoplastic powder. The web is then cooled and pressed to a predetermined thickness to produce a composite sheet having a porosity of about 1 percent to about 95 percent. In an alternative embodiment, the aqueous foam also includes a binder material. In some configurations, after the web is heated above the softening point of the thermoplastic powder, an adhesive layer comprising a thermoplastic polymer and a thermosetting material can be disposed on the web.

[0066] In certain examples, one or more of the fiber-reinforced thermoplastic layers can be manufactured in the form of a glass mat. In certain cases, the glass mat can generally be made using chopped glass fibers, a thermoplastic material, a lofting agent, and any thermoplastic polymer film(s), and / or a woven or nonwoven fabric made of glass fibers or thermoplastic resin fibers, such as 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 the resin. To manufacture the glass mat, the thermoplastic material, the reinforcing material, the lofting agent, and / or other additives can be added or metered into a dispersed foam placed in an open-top mixing vessel equipped with an impeller. Without wishing to be bound by any particular theory, the presence of trapped air pockets in the foam may aid in the dispersion of the glass fibers, the thermoplastic material, and the lofting agent. In some embodiments, the dispersed mixture of glass and resin may be pumped through a dispersion manifold to a headbox located above the wire section of the paper machine. The dispersed mixture may be fed to a moving wire screen using a vacuum to continuously produce a uniform fibrous wet web, removing the foam but not the glass fibers, lofting agent, or thermoplastic material. The wet web may be passed through a dryer at a suitable temperature to reduce the moisture content and melt or soften the thermoplastic material. Once the hot web exits the dryer, the web of glass fibers, lofting agent, thermoplastic material, and film may be heated and melted. A surface layer, such as an adhesive layer including a thermoplastic polymer and a thermosetting material, can be applied to the web by passing it through the nip of a set of rollers, followed by spraying an adhesive onto the surface of the web. If desired, additional layers, such as a nonwoven and / or woven fabric layer or a skin layer, can also be attached to one or both sides of the web to facilitate handling of the glass fiber reinforced mat. The composite can then be passed through tension rolls and subsequently continuously cut (guillotine cut) to the desired size to form the final product. Further information regarding the preparation of such GMT composites, including suitable materials and processing conditions used to form such composites, is described, for example, in U.S. Pat. Nos. 6,923,494, 4,978,489, 4,944,843, 4,964,935, 4,734,321, 5,053,449, 4,925,615, and 5,609,966, as well as U.S. Patent Application Publication Nos. US 2005 / 0082881, US 2005 / 0228108, US 2005 / 0217932, US 2005 / 0215698, US 2005 / 0164023, and US 2005 / 0161865.

[0067] In some cases, each fiber-reinforced thermoplastic layer can be formed separately as a sheet, which can then be used to provide a multilayer article or assembly. For example, a wet-laid process can be used to produce a first fiber-reinforced thermoplastic sheet with low lofting capacity. A wet-laid process can also be used to produce a second fiber-reinforced thermoplastic sheet with higher lofting capacity than the first sheet. Each sheet can be processed before being bonded to each other via the mesh layer. For example, each sheet can be compressed to provide the desired thickness. Any one or more of the fabricated fiber-reinforced thermoplastic sheets can be bonded to a mesh layer to provide the multilayer assembly described herein. While the bonding process can vary, in some cases, a single first fiber-reinforced thermoplastic sheet is heated to a temperature at which the thermoplastic component softens. The heated fiber-reinforced thermoplastic sheet can then be bonded to the mesh layer. If desired, a second fiber-reinforced thermoplastic sheet, which can be the same or different from the first fiber-reinforced thermoplastic, is disposed on the other surface of the mesh layer. Optionally, additional heat can be applied to soften the second fiber-reinforced thermoplastic sheet. The bonded two or three layers can then be compressed or further processed. For example, processes such as molding, thermoforming, etc. may be used to apply pressure and / or temperature to help bond the sheets together and / or impart a desired shape to the article. In some embodiments, the assembly can be formed into the desired shape of an automotive interior vehicle part, a building product, or other final article. For example, the articles described herein can be processed into a desired configuration or shape using a suitable process, including, but not limited to, cast molding, thermoforming, drawing, or other forming processes. In some cases, such processes are used to impart a desired configuration, thickness, and / or loft the various layers of the article.

[0068] Referring now to FIG. 2 , a diagram of a multi-layer assembly is shown including a thermoplastic fiber reinforced layer 120 and two mesh layers 110, 115. The mesh layers 110, 115 may be the same or different. In some examples, the mesh layers 110, 115 are made of the same material, but have different basis weights or thicknesses. In other cases, the mesh layers 110, 115 are made of different materials, but have the same basis weights or thicknesses. In additional configurations, the mesh layers 110, 115 are made of different materials, but have different basis weights or thicknesses. If desired, one or more additional mesh layers can be bonded to the mesh layers 110, 115 to provide a stack of mesh layers on one side of the TFR layer 120. The stacked mesh layers can be bonded to each other before or after the stacked mesh layers are added to the TFR layer 120. If desired, a TFR layer and mesh There may be no adhesive or other material between layers 110, 115. In some cases, an adhesive layer may be present between one of mesh layers 110, 115 and TFR layer 120. In additional cases, an adhesive layer may be present between each of mesh layers 110, 115 and TFR layer 120. In some cases, mesh layers 110, 115 need not extend across the entire surface of TFR layer 120, but may be present on one side or area of ​​TFR layer 120 if desired. If desired, additional TFR layers (not shown) can be bonded to mesh layer 115 or mesh layer 110 to provide a stack of TFR layers separated by mesh layers. Additionally, decorative layers, skins, or other layers can be bonded to mesh layer 115 or mesh layer 110 if desired.

[0069] In certain examples, referring to FIG. 3 , a multi-layer assembly is shown including a mesh layer 115 bonded to a TFR layer 120 on one surface and a skin layer 130 on the opposite surface. Although not shown, another mesh layer, TFR layer, decorative layer, or skin layer can be bonded to the TFR layer 120 on the surface opposite to where the mesh layer 115 is bonded. In some cases, the skin 130 can be a fabric, scrim, or other material described above with respect to the skin 130. The mesh layer 110 can be any mesh layer described with reference to the mesh layer 110. In some examples, the mesh layer 115 and the skin 130 can be bonded to each other before being bonded to the TFR layer 120. In other cases, the mesh layer 115 can be bonded to the TFR layer 120 first, and then the skin 130 can be added to the surface of the mesh layer 115. In some embodiments, the mesh layer 115 can be bonded to the TFR layer 120 without any other layers between the layers 115 and 120, for example, without the use of an adhesive layer. Similarly, skin 130 can be bonded to mesh layer 115 without any other layer between layers 115, 130, for example, without the use of an adhesive layer, although adhesive or other materials may be present between any of the layers shown in FIG. 3 if desired.

[0070] Referring to FIG. 4 , in a specific configuration, a multi-layer assembly is shown including a mesh layer 110 bonded on one surface to a TFR layer 120 and another mesh layer 115 bonded on a second surface. The mesh layers 110, 115 may be the same or different. In some examples, the mesh layers 110, 115 are made of the same material, but the basis weights or thicknesses of the mesh layers 110, 115 are different. In other cases, the mesh layers 110, 115 are made of different materials, but the basis weights or thicknesses of the mesh layers 110, 115 are the same. In additional configurations, the mesh layers 110, 115 are made of different materials, and the basis weights or thicknesses of the mesh layers 110, 115 are also different. If desired, one or more additional mesh layers can be bonded to the mesh layers 110, 115 to provide a stack of mesh layers on one side of the TFR layer 120. Alternatively, another mesh layer or other layer can be bonded to the opposite surface of the TFR layer 120. The stacked mesh layers 110, 115 can be bonded to each other before adding the stacked mesh layers to the TFR layer 120, or they can be bonded to each other after adding the stacked mesh layers to the TFR layer 120. If desired, there may be no adhesive or other material between the TFR layers and the mesh layers 110, 115. In some cases, there may be an adhesive layer between the mesh layer 110 and the TFR layer 120. In additional cases, there may be an adhesive layer between each of the mesh layers 110 and 115. In some cases, the mesh layers 110, 115 need not extend across the entire surface of the TFR layer 120, but may be present in one area of ​​the TFR layer 120 if desired. If desired, an additional TFR layer (not shown) can be bonded to the mesh layer 115 to provide a stack of TFR layers separated by two mesh layers 110, 115. In addition, a decorative layer, skin, or other layer can be bonded to the mesh layer 115 if desired.

[0071] In a specific embodiment, referring to Figure 5, a multi-layer assembly is shown including TFR layers 120, 160 separated by a mesh layer 110. The skin 130 is The skin 135 is located on the opposite surface of the TFR layer 160. The TFR layers 120, 160 can each be directly bonded to the mesh layer 110 without any intervening components or layers, e.g., without the use of an adhesive layer. The TFR layers 120, 160 can be the same or different and can include different thicknesses of, e.g., basis weight. Similarly, the skin layers 130, 135 can be the same or different and can be bonded to the TFR layers 120, 160, respectively, with or without an adhesive layer. In some cases, the skin layers 130, 135 can include the same material but different thicknesses or basis weights. In other cases, the skin layers 130, 135 can include different and the same material but the same basis weight or thickness. In additional examples, the skin layers 130, 135 can include different and the same material and can also include different basis weights or thicknesses. Skins 130, 135 may each comprise, for example, a film (e.g., a thermoplastic film or an elastomeric film), a flim, a scrim (e.g., a fibrous scrim), a foil, a woven fabric, a nonwoven fabric, or may be present as an inorganic coating, an organic coating, or a thermoset coating. In other cases, skins 130, 135 may each independently comprise a limiting oxygen index greater than about 22 as measured according to ISO 4589, dated 1996. When a thermoplastic film is present as (or as part of) skins 130, 135, the thermoplastic film may comprise 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 (or as part of) the skins 130, 135, the fiber-based scrim may include at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metallized synthetic fibers, and metallized inorganic fibers.When a thermosetting coating is present as (or as part of) the skins 130, 135, the thermosetting coating may include at least one of unsaturated polyurethane, vinyl ester, phenolic, and epoxy. When an inorganic coating is present as (or as part of) the skins 130, 135, the inorganic coating may include a mineral containing a cation selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or may include at least one of gypsum, calcium carbonate, and mortar. When a nonwoven fabric is present as (or as part of) the skins 130, 135, the nonwoven fabric may include a thermoplastic material, a thermosetting binder, inorganic fibers, metal fibers, metallized inorganic fibers, and metallized synthetic fibers. If desired, the skins 130, 135 may also include a lofting agent. In some embodiments, one or both of the skins 130, 135 may take the form of a decorative layer. The decorative layer may be formed from a thermoplastic film, such as polyvinyl chloride, polyolefin, thermoplastic polyester, or thermoplastic elastomer. The decorative layers 130, 135 may independently comprise carpet, rubber, or other aesthetic coverings. The decorative layers 130, 135 may also independently comprise a multi-layer structure including a foam core formed from, for example, polypropylene, polyethylene, polyvinyl chloride, polyurethane, or the like. Fabrics such as woven fabrics made from natural and synthetic fibers, organic fiber nonwoven fabrics after needle punching or the like, brushed fabrics, knitted products, flocked fabrics, or other such materials may be bonded to the foam core. Fabrics may also be bonded to the foam core with thermoplastic adhesives, including pressure-sensitive adhesives and hot-melt adhesives, such as polyamides, modified polyolefins, urethanes, and polyolefins. The decorative layers 130, 135 may also independently be manufactured using spunbond, thermal bonding, spunlace, meltblown, wet-laid, and / or dry-laid processes.

[0072] In some embodiments, the multilayer assemblies described herein can be used in many different articles, including partition panels, ceiling panels, building substrates (e.g., walls, flooring, etc.), automotive walls or partitions, recreational vehicle panels, recreational vehicle ceilings, recreational vehicle floors, recreational vehicle compartments or doors, etc. Referring to FIG. 6A, an example of a multi-layer assembly 600 is shown including two TFR layers 620, 660 separated by a mesh layer 610. Each of the TFR layers 620, 660 may be independently constructed similarly to the TFR layer 120 described herein. In some embodiments, each of the TFR layers is constructed as a LWRT sheet including polypropylene and fiberglass and having a basis weight of approximately 800 gsm to 1000 gsm. The mesh layer 610 may be constructed similarly to the mesh layer 110. In one example, the mesh layer 610 may include fiberglass and polypropylene and have a basis weight of approximately 500 gsm to 1000 gsm. The multi-layer assembly can be used, for example, as a divider wall to separate a cargo area from a passenger area of ​​a vehicle. Referring to FIGS. 6B and 6C, a divider wall 675 including the multi-layer assembly 600 is shown. The overall weight of the divider wall 675 can be substantially less than conventional steel divider panels; for example, when a multi-layer assembly is used, the divider wall weight can be 25%, 30%, or 40% less than the weight if steel were present. The divider wall need not be continuous or solid from one side of the vehicle to the other. For example, there may be a passageway that allows occupants in the passenger compartment to move to the cargo compartment. Such a passageway may be particularly useful when the divider wall is used in commercial trucks that include a sleeping area separate from the area where the driver sits to operate the vehicle.

[0073] Referring to FIG. 7A , in a particular embodiment, a multi-layer assembly 700 may include a fiber-reinforced thermoplastic layer 720 and a mesh layer 710 disposed on portions of a first surface of the first TFR layer 720. The mesh layer 710 may be configured similarly to mesh layer 110, and the TFR layer 720 may be configured similarly to TFR layer 120. In FIG. 7A , the mesh layer 710 is configured as a tape layer disposed on top of the TFR layer 720. If desired, additional tape layers 711-714 (see FIG. 7B ) may be disposed adjacent to the tape layer 710, such that the tape layers span the entire first surface of the TFR layer 720. The additional tape layers 711-714 need not be parallel to the tape layer 710, but may instead be positioned transversely or in other directions. Additionally, the additional tape layers 711-714 need not have the same composition as the tape layer 710 or each other. Additionally, tape layers 710-714 may have different basis weights, fibers, thermoplastic materials, thicknesses, etc., if desired.

[0074] In some embodiments, two or more tape layers may be woven together before being placed on the surface of the TFR layer. Referring to FIG. 8, mesh layer 800 is shown including multiple tape layers 810-810j woven with tape layers 811a-811f. The exact number of different tape layers present in mesh layer 800 can vary from approximately 1-10 tape layers per 10 cm in the width direction to approximately 1-10 tape layers per 10 cm in the length direction. However, fewer or more tape layers can be present in either direction if desired. The overall width and length of mesh layer 800 can vary from approximately 10 mm to approximately 200 cm wide and from approximately 10 mm to approximately 400 cm long. If desired, the dimensions of mesh layer 800 can be sized so that the entire mesh layer covers substantially all of the surface of the TFR layer. Alternatively, two or more of mesh layers 800 can be disposed on the surface of the TFR layer to cover the entire surface of the TFR layer. Tape layers 810a-810j and 811a-811f may independently be the same or different, if desired. In some embodiments, each of tape layers 810a-810j includes substantially the same composition, and each of tape layers 811a-811j includes substantially the same composition, which may be different from the composition of tape layers 811a-811j. The basis weight of each of the tape layers may vary from about 50 gsm to about 1000 gsm. In some embodiments, mesh layer 800 as a whole may include a basis weight of about 100 gsm to about 1000 gsm. As shown in FIG. 8, the mesh layer may have some porosity provided by the openings formed from weaving the tape layers together, even though each tape layer itself may be substantially non-porous or porous, if desired.

[0075] The articles "a," "an," "the," and "said," when introducing elements of the embodiments disclosed herein, are intended to mean that there are one or more elements. The terms "comprising," "including," and "having" are intended to be open-ended and mean that there may be additional elements other than the listed elements. Those skilled in the art will recognize, given the benefit of this disclosure, that various elements of the embodiments can be interchanged or substituted for various elements of other embodiments.

[0076] While certain aspects, examples, and embodiments have been described above, it will be appreciated by those skilled in the art, given the benefit of this disclosure, that additions, substitutions, modifications, and variations of the disclosed exemplary aspects, examples, and embodiments are possible.

Claims

1. 1. A multi-layer assembly comprising: a mesh layer comprising an arrangement of reinforcing fibers held in place by a thermoplastic material, and a woven tape layer comprising an arrangement of crossing or overlapping fibers in combination with a polyolefin material, the woven tape layer being non-porous; a first porous fiber-reinforced thermoplastic layer disposed on the first surface of the mesh layer, the first porous fiber-reinforced thermoplastic layer including an open-cell web formed by a plurality of reinforcing glass fibers bonded with polypropylene, the first porous fiber-reinforced thermoplastic layer including 30% to 70% by weight of the reinforcing glass fibers; a second porous fiber-reinforced thermoplastic layer disposed on the second surface of the mesh layer, the second porous fiber-reinforced thermoplastic layer including an open-cell web formed by a plurality of reinforcing glass fibers bonded with polypropylene, the second porous fiber-reinforced thermoplastic layer including 30% to 70% by weight of the reinforcing glass fibers; A multi-layer assembly, wherein the mesh layer functions to directly bond the first porous fiber reinforced thermoplastic layer to the second porous fiber reinforced thermoplastic layer without any intervening layers or materials.

2. The multi-layer assembly of claim 1 , wherein the mesh layer comprises a thickness and basis weight that is less than the first porous fiber-reinforced thermoplastic layer and the second porous fiber-reinforced thermoplastic layer.

3. 10. The multi-layer assembly of claim 1, wherein the woven tape layer comprises 1 to 6 tapes per 10 cm of length and 1 to 6 tapes per 10 cm of width.

4. The multi-layer assembly of claim 3 further comprising a first skin layer disposed on the first porous fiber reinforced thermoplastic layer.

5. The multi-layer assembly of claim 4 , further comprising a second skin layer disposed on the second porous fiber reinforced thermoplastic layer.

6. A multi-layer assembly comprising: a mesh layer comprising an arrangement of reinforcing fibers held in place by a thermoplastic material, the mesh layer comprising a woven tape layer comprising an arrangement of fibers that cross or overlap one another in combination with a polyolefin material; a first porous fiber-reinforced thermoplastic layer disposed on the first surface of the mesh layer, the first porous fiber-reinforced thermoplastic layer including an open-cell web formed by a plurality of reinforcing glass fibers bonded with polypropylene, the first porous fiber-reinforced thermoplastic layer including 30% to 70% by weight of the reinforcing glass fibers; a second porous fiber-reinforced thermoplastic layer disposed on the second surface of the mesh layer, the second porous fiber-reinforced thermoplastic layer including an open-cell web formed by a plurality of reinforcing glass fibers bonded with polypropylene, the second porous fiber-reinforced thermoplastic layer including 30% to 70% by weight of the reinforcing glass fibers; a multi-layer assembly, wherein the mesh layer functions to directly bond the first porous fiber reinforced thermoplastic layer to the second porous fiber reinforced thermoplastic layer without any intervening layers or materials; a thermoplastic polyolefin material of the woven tape layer that is polypropylene; a thermoplastic polyolefin material of the first porous fiber reinforced thermoplastic layer that is polypropylene; a thermoplastic polyolefin material of the second porous fiber reinforced thermoplastic layer that is polypropylene; a plurality of reinforcing fibers of the first porous fiber reinforced thermoplastic layer that is glass fiber; a plurality of reinforcing fibers of the second porous fiber reinforced thermoplastic layer that is glass fiber; and each of the first porous fiber reinforced thermoplastic layer and the second porous fiber reinforced thermoplastic layer that is glass fiber.

7. The multi-layer assembly of claim 1 , further comprising a decorative layer bonded to one of the first porous fiber reinforced thermoplastic layer and the second porous fiber reinforced thermoplastic layer.

8. The multi-layer assembly of claim 7 , wherein the decorative layer comprises foam adhered to a fabric.

9. 5. The multi-layer assembly of claim 4, 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 nonwoven fabric, a fibrous scrim, an inorganic coating, an organic coating, a thermoplastic coating, and a thermoset coating.

10. The multi-layer assembly of claim 4 , wherein the first porous fiber reinforced thermoplastic layer further comprises a lofting agent.

11. The multi-layer assembly of claim 1 , further comprising a decorative layer bonded to the first porous fiber reinforced thermoplastic layer.

12. 1. A multi-layer assembly comprising: a mesh layer including a first woven tape layer and a second woven tape layer, each of the first woven tape layer and the second woven tape layer including an array of reinforcing fibers held in place by a thermoplastic polyolefin material, and each of the first tape layer and the second tape layer including an array of reinforcing glass fibers crossing or overlapping each other in combination with the polyolefin material; a first porous fiber-reinforced thermoplastic layer disposed on the first surface of the mesh layer, the first porous fiber-reinforced thermoplastic layer including an open-cell web formed by a plurality of reinforcing glass fibers bonded with polypropylene; and a second porous fiber-reinforced thermoplastic layer disposed on the second surface of the mesh layer, the second porous fiber-reinforced thermoplastic layer including an open-cell web formed by a plurality of reinforcing glass fibers bonded with polypropylene; and A multi-layer assembly, wherein each of the first porous fiber reinforced thermoplastic layer and the second porous fiber reinforced thermoplastic layer functions to bond directly to the mesh layer without any intervening layers or materials.

13. The multi-layer assembly of claim 12 , further comprising a second mesh layer disposed on a surface of the second porous fiber reinforced thermoplastic layer.

Images