Composite panel including an aesthetic edge

Abstract

A specific configuration of a composite panel including at least one aesthetic edge is described. In some embodiments, the composite panel having an aesthetic edge includes a sandwich panel coupled to a shell layer. The sandwich panel may include an outer layer and a core layer.

Description

Technology Field

[0001] Priority application

[0002] This application relates to and claims priority and interest in U.S. Provisional Application No. 62 / 830,260 filed April 5, 2019, the entire disclosure of which is incorporated herein by reference for all purposes.

[0003] Technology field

[0004] The specific configuration described herein relates to a composite panel having an aesthetic edge. More specifically, a specific embodiment of a composite panel comprising a sandwich panel coupled to a shell layer to provide a composite article having an aesthetic edge is described. Background Technology

[0005] Composite articles are often used in various applications. The edges of composite articles can often be unsightly as a result of the processes and / or materials used to prepare the composite articles. means of solving the problem

[0006] Specific embodiments, configurations, and examples of composite articles including aesthetic edges are described. Composite panels may include two or more aesthetic edges if desired. Composite articles may be used in other end articles and other vehicle and non-vehicle applications, including but not limited to vehicle loading floors, structural panels, leisure vehicle tables, leisure vehicle storage doors or panels.

[0007] In one embodiment, the composite article comprises a first skin comprising a thermoplastic material and reinforcing fibers, a second skin comprising a thermoplastic material and reinforcing fibers, a sandwich panel comprising a core layer positioned between the first skin and the second skin, and a shell layer coupled to the sandwich panel through the second skin, wherein the shell layer and the sandwich panel together provide an aesthetic edge to the composite article.

[0008] In certain embodiments, the basis weight of the shell layer and the second outer shell together is the same basis weight or a different basis weight as the basis weight of the first outer shell. In some embodiments, the composite article comprises four sides, the first side facing the third side and the second side facing the fourth side, the second outer shell is positioned in the machine direction from the first side to the third side, and the shell layer is positioned in the machine direction from the second side to the fourth side. In other examples, the composite article comprises an air gap at the aesthetic edge, and the air gap exists between the shell layer and the second outer shell.

[0009] In some embodiments, the composite article comprises at least two aesthetic edges, each having an air gap, and each of the air gaps exists between the shell layer and the second outer shell.

[0010] In some configurations, the reinforcing fibers of the first and second skins, respectively, comprise one or more of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers such as para- and meta-aramid fibers, for example, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool fibers, wollastonite, alumina silica, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In other examples, the thermoplastic material of the first and second skins, respectively, comprises a polyolefin material.

[0011] In some embodiments, the composite article comprises a decorative layer coupled to a first outer shell of a sandwich panel. In other examples, the core layer comprises a cellulose material or a non-cellulose material. In additional embodiments, the thickness of the composite article is about 5 mm to about 100 mm.

[0012] In another embodiment, a vehicle loading floor sized and positioned to cover a rear interior section of a vehicle comprises a decorative layer facing the interior of the vehicle and a loading floor substrate coupled to the decorative layer, wherein the loading floor substrate is a sandwich panel coupled to the decorative layer, the sandwich panel comprises a first outer shell comprising a thermoplastic material and reinforcing fibers, a second outer shell comprising a thermoplastic material and reinforcing fibers, and a core layer located between the first outer shell and the second outer shell, and a shell layer coupled to the sandwich panel through the second outer shell, and the vehicle loading floor comprises an aesthetic edge.

[0013] In a specific example, the basis weight of the shell layer and the second outer shell together is the same basis weight or a different basis weight as the basis weight of the first outer shell. In another example, the vehicle loading floor includes four sides, the first side facing the third side and the second side facing the fourth side, the second outer shell is arranged in the machine direction from the first side to the third side, and the shell layer is arranged in the machine direction from the second side to the fourth side.

[0014] In some embodiments, the vehicle loading floor includes at least one aesthetic edge having an air gap, and the air gap exists between the shell layer and the second outer shell. In some examples, the vehicle loading floor includes at least two aesthetic edges, each having an air gap, and each of the air gaps exists between the shell layer and the second outer shell.

[0015] In certain examples, the reinforcing fibers of the first and second sheaths, respectively, comprise one or more of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high-elasticity organic fibers such as para- and meta-aramid fibers, for example, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool fibers, wollastonite, alumina silica, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, the thermoplastic material of the first and second sheaths, respectively, comprises a polyolefin material.

[0016] In certain configurations, the loading floor includes a second decorative layer coupled to the lower side of the vehicle loading floor. In some examples, the core layer includes a cellulose material or a non-cellulose material. In other examples, the thickness of the vehicle loading floor is about 5 mm to about 30 mm.

[0017] In a further embodiment, the structural panel comprises at least one interconnection, and the structural panel comprises a sandwich panel comprising a first outer shell comprising a thermoplastic material and reinforcing fibers, a second outer shell comprising a thermoplastic material and reinforcing fibers, and a core layer positioned between the first outer shell and the second outer shell, and a shell layer coupled to the sandwich panel through the second outer shell, wherein the structural panel comprises a shell layer comprising an aesthetic edge on one side of the structural panel. If desired, the structural panel also comprises an air gap at the aesthetic edge, the air gap existing between the shell layer and the second outer shell and configured to accommodate the interconnection.

[0018] In some examples, the interconnection includes a wire. In other examples, the structural panel is configured as a table removable from the vehicle. In some embodiments, the interconnection includes a USB charging port. In other examples, the interconnection is electrically coupled to a battery of the structural panel. In additional examples, the interconnection is electrically coupled to a photovoltaic cell of the structural panel.

[0019] In some examples, the reinforcing fibers of the first and second sheaths, respectively, comprise one or more of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high-elasticity organic fibers such as para- and meta-aramid fibers, for example, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool fibers, wollastonite, alumina silica, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In certain embodiments, the thermoplastic material of the first and second sheaths, respectively, comprises a polyolefin material.

[0020] In another example, the structural panel includes a decorative layer coupled to a first outer shell of the sandwich panel. In some embodiments, each edge of the structural panel includes an aesthetic edge.

[0021] In another embodiment, a method for producing a composite panel having an aesthetic edge is provided. In some examples, the method comprises the step of coupling a pre-molded shell layer to a sandwich panel to provide an aesthetic edge, wherein the sandwich panel comprises a first outer shell comprising a thermoplastic material and reinforcing fibers, a second outer shell comprising a thermoplastic material and reinforcing fibers, and a core layer positioned between the first outer shell and the second outer shell.

[0022] In certain embodiments, a pre-molded shell layer is coupled to a second skin of the sandwich panel. In other embodiments, the coupling of the pre-molded shell layer to the second skin provides an air gap at the aesthetic edge between the second skin and the pre-molded shell layer. In some examples, the pre-molded shell layer comprises a thermoplastic material and reinforcing fibers. In certain embodiments, the second skin comprises a fiber orientation different from the fiber orientation of the reinforcing fibers in the shell layer. In some embodiments, each skin of the sandwich panel is produced using a wet process. In other embodiments, each of the first skin and the second skin comprises polyolefin and glass reinforcing fibers, and the core comprises a paper honeycomb. In additional examples, each of the first skin and the second skin comprises polyolefin and glass reinforcing fibers, and the core comprises a non-cellulose core.

[0023] Additional aspects, configurations, examples, and embodiments are described below. Brief explanation of the drawing

[0024] FIG. 1a is an example of an aesthetic edge on the side of a composite panel according to some embodiments. Figure 1b is an example of some aspects of the aesthetic edge according to some configurations. FIG. 2 is an example of a sandwich panel according to some embodiments. FIG. 3 is an example of a sandwich panel according to some embodiments. FIG. 4 is an example of a shell layer according to some embodiments. Figure 5 is an example of a composite panel according to a specific example. FIGS. 6, FIGS. 7, FIGS. 8 and FIGS. 9 are examples of an outer layer and a shell layer comprising fibers of different orientations according to some embodiments. Figure 10 is an example of a loading floor according to a specific example. FIG. 11 is an example of a composite article including an aesthetic edge on each side according to some examples. Given the advantages of the present disclosure, it will be recognized by those skilled in the art that the dimensions of the various layers in the drawings are not depicted to scale. Unless explicitly stated in specific descriptions relating to a particular layer or other component, specific layer thicknesses or dimensions are not intended or implied. The exact dimensions will vary depending on the final composition of the article and / or its intended use. Specific details for implementing the invention

[0025] A specific configuration of a composite panel having an aesthetic edge is described. The phrase “aesthetic edge” generally refers to an edge that includes a change in direction when viewed in cross-section. For example, referring to FIG. 1a, a panel (100) having an aesthetic edge is shown, comprising a first surface (110) coupled to a second surface (120) through a rounded edge or a narrow-radius curve (105). If desired, the surfaces (110, 120) may be positioned at different angles, but if not necessary, the first surface (110) may generally be perpendicular to the second surface (120). When viewed from the side of the first surface (110) or panel (100), the second surface (120) is generally not visible but is shown as a dashed line in FIG. 1b for reference. In contrast to conventional composite panels having curved or sharp edges that tend to be rough, uneven, or bridging, aesthetic edges generally provide more rounded edges that couple the faces of the panel without bridging. Aesthetic edges may feature a change in the direction of the edge, which generally consists of a sharp edge or a rounded curve rather than a curved edge from the top surface of the panel to the bottom surface of the panel.

[0026] In some examples, an aesthetic edge may be created by coupling the sandwich panel to a shell layer, and the shell layer may be pre-molded and produced separately from the composite panel or produced together with the composite panel. Referring to FIG. 2, a cross-section of the sandwich panel (200) is shown. The sandwich panel (200) generally comprises a first outer shell (220), a second outer shell (230), and a core layer (210) between the first outer shell (220) and the second outer shell (230). In some examples, the fibers of the outer shell layers (220, 230) may be arranged similarly or similarly, for example, one of the outer shells (220, 230) may include fibers parallel to the mechanical direction of the outer shell and the other outer shell may include fibers parallel to the transverse direction of the outer shell. In certain examples, the outer layer (220, 230) may generally contain the same material, but the amount of the material may differ, for example, the amount of reinforcing fibers and / or the amount of thermoplastic material may differ. In other examples, the outer layer (220, 230) may contain the same thermoplastic material but different reinforcing fibers. In additional configurations, the outer layer (220, 230) may contain the same reinforcing fibers but different thermoplastic materials. In other examples, the outer layer (220, 230) may contain the same reinforcing material and thermoplastic material but may have different basis weights, different porosities, or different physical properties. In some examples, the outer layer (220, 230) may contain the same reinforcing fibers and the same thermoplastic material but may have different thicknesses or different amounts of lofting agent to provide variable lofting capacity.

[0027] In certain examples, each of the outer layer (220, 230) may be independently configured similarly to the outer layer (120), and, for example, each of the outer layer (220, 230) may be a glass mat thermoplastic (GMT) outer layer or a lightweight reinforced thermoplastic (LWRT) outer layer. For example, each of the outer layer (220, 230) may be configured as an LWRT outer layer comprising one or more thermoplastic materials. In some examples, the thermoplastic material present in each of the layers (220, 230) may independently at least partially comprise one or more of plasticized and unplasticized polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachloride, and polyvinyl chloride, and mixtures of these materials with each other or other polymer materials. Other suitable thermoplastic materials include, but are not limited to, polyarylene ethers, polycarbonates, polyester carbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, co-polyamides, acrylonitrile-butyl acrylate-styrene polymers, amorphous nylons, polyarylene ether ketones, polyphenylene sulfides, polyaryl sulfones, polyether sulfones, liquid crystal polymers, poly(1,4-phenylene) compounds commercially known as PARMAX®, high-temperature polycarbonates such as Bayer's APEC®PC, high-temperature nylons, and silicones, as well as copolymers, alloys, and blends between these materials or with other polymer materials. The thermoplastic material used to form the layers (220, 230) can be used in powder form, resin form, rosin form, particle form, fiber form or other suitable form, and the form used for different layers (220, 230) does not need to be the same.Various forms of exemplary thermoplastic materials are described herein, for example, as described in U.S. Publication No. 20130244528 and U.S. 20120065283. The exact amount of thermoplastic material present in the outer layer (220, 230) may vary, and exemplary amounts are in the range of about 20 wt% to about 80 wt%, for example, 30-70 wt% or 35-65 wt%. As mentioned herein, the amount of thermoplastic material present in the outer layer (220, 230) does not need to be the same.

[0028] In certain examples, the reinforcing fibers of the outer layer (220, 230) may independently comprise glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high-elasticity organic fibers such as para- and meta-aramid fibers, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool (e.g., rock or slag wool), wollastonite, alumina silica, etc., or mixtures thereof, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the aforementioned fibers may be chemically treated before use to provide desired functional groups or to impart other physical properties to the fibers, for example, to be chemically treated to react with thermoplastic materials, lofting agents, or both. In some examples, one fiber of the outer layer (220, 230) is chemically treated and the other fiber of the outer layer (220, 230) is not chemically treated. The fiber content of each layer (220, 230) may independently be about 20 weight% to about 90 weight% of the layer, more specifically about 30 weight% to about 70 weight% of the layer. Typically, the fiber content of a sandwich panel comprising the outer layer (220, 230) varies from about 20 weight% to about 90 weight% of the assembly, more specifically from about 30 weight% to about 80 weight%, for example, from about 40 weight% to about 70 weight%. The specific size and / or orientation of the fibers used may depend at least partially on the desired properties of the thermoplastic polymer material and / or outer layer (220, 230) used. Suitable additional types of fibers, fiber sizes, and amounts will be readily selected by a person skilled in the art, taking into account the advantages of the present disclosure.In one non-limiting example, the lofting agent for providing fibers dispersed within a thermoplastic material and optionally a skin layer (220, 230) may generally have a diameter greater than about 5 microns, more specifically about 5 microns to about 22 microns, and may have a length of about 5 mm to about 200 mm, and more specifically, the fiber diameter may be about 5 microns to about 22 microns and the fiber length may be about 5 mm to about 75 mm.

[0029] In certain embodiments, the outer layer (220, 230) may comprise different fiber materials or different fiber loadings. Where different fiber materials are present, the fibers may be entirely different fibers, for example, one layer of glass fiber and another layer of carbon fiber, or may comprise the same modified base material, for example, one layer of glass fiber and another layer of chemically treated glass fiber. In some examples, the fibers may be the same fiber material, but one or more physical properties of the fibers may differ. For example, the fibers of layer (220) may have a first diameter different from the diameter of the fibers present in layer (230), even if the fiber material of layer (220, 230) may be the same or different. In other examples, the fiber material present in layer (220, 230) may be the same or different, but the length of the fibers of layer (220) may differ from the length of the fibers present in layer (230). In additional examples, the fiber material present in the layers (220, 230) may be the same or different, but the length and diameter of the fibers in layer (220) may differ from the length and diameter of the fibers in layer (230). In another example, two or more different fibers may be used in one of the layers (220, 230) and a single type of fiber may be present in another layer. By selecting the amount and / or type and / or direction of the fibers, it is possible to change the physical properties of the outer layers (220, 230) to provide, for example, different lofting capacities for different outer layers of the assembly.

[0030] In some embodiments, reinforcing fibers form a web held in place by a thermoplastic material of the sheath (220, 230). The web is generally porous. In some examples, the pores of each sheath (220, 230) may contain additives including flame retardants, particles, or other materials. Exemplary basis weights for each sheath (220, 230) include, but are not limited to, about 100 g (gsm) to about 2000 gsm per square meter, more specifically about 300 gsm to about 1500 gsm or about 500 gsm to about 1200 gsm. The sheaths (220, 230) do not need to have the same basis weight in the composite article. In some examples, each sheath layer (220, 230) may first be formed as a prepreg, which is generally a precursor to the sheath and does not necessarily need to be fully formed. The outer shell is typically porous to allow gas to flow through it. For example, the outer shell (220, 230) is 0-30%, 10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10-90%, 10-95%, 20-60%, 20-70%, 20-80%, 20-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95%, 40-80%, It may include a porosity or pore content of 40-90%, 40-95%, 50-90%, 50-95%, 60-95%, 70-80%, 70-90%, 70-95%, 80-90%, 80-95%, or any exemplary value within these exemplary ranges. In some examples, the outer shell (220, 230) includes a porosity or pore content greater than 0% and does not fully harden, for example, up to about 95%.

[0031] In some examples, the core layer (210) may comprise a cellulose-based material or a non-cellulose-based material. For example, the core layer (210) may comprise a paper honeycomb or other core material comprising cellulose fibers. The cellulose fibers may be present with or without other materials, for example, in combination with a thermoplastic material. In other examples, the core layer (210) may comprise a foam, such as a polyurethane foam, which may be a closed-cell foam or an open-cell foam. If the core layer (210) is a closed-cell foam, the closed-cell foam of the core layer (210) may have a porosity of about 5%, 4%, 3%, 2%, or less than 1%.

[0032] In some embodiments, the core layer is not a sprayable or sprayable core layer, but instead a flat layer of solid that can be coupled to the outer layer (220, 230) after the formation of the core layer (210). In some examples, the core layer (210) may comprise one or more of a foam, cardboard, or paper honeycomb or a combination thereof. In other examples, the core layer (210) may comprise or be a polystyrene foam, an expanded or extruded polyolefin foam (e.g., extruded polyethylene or expanded polypropylene), or other foam. In some examples, the core layer (210) may lack any polyurethane material and / or lack any cellulose material. An exemplary basis weight for the core layer (210) includes, but is not limited to, about 300 gsm to about 2000 gsm, more specifically about 500 gsm to about 1900 gsm or about 500 gsm to about 1500 gsm.

[0033] In some embodiments, the core layer (210) may comprise a foam having greater compressive strength in the transverse direction than in the machine direction. For example, the core layer (210) may comprise a foam having directional compressive strength, for example, a foam having different compressive strength in the vertical direction, to impart greater stiffness to the entire article comprising the core layer (210) and the outer layer (220, 230). Foams capable of providing directional compressive strength are commercially available from Dow Corning and other suppliers. The core layer (210) is typically formed first from a foam (or other material) and then coupled to the outer layer (220, 230). In some configurations, the material of the core layer (210) may be configured and arranged to allow compression of the core layer (210) without substantial damage to the core layer (210). The material of the core layer (210) can also be selected so that the article (200) can be thermoformed, e.g., compressed, molded, etc. without substantial damage to the core layer (210). Compared to a fiber thermoplastic core material, the presence of a core layer (210) comprising a closed-cell foam (or non-fiber reinforced thermoplastic material) at a comparable basis weight can provide better performance and higher strength.

[0034] In certain examples, the core layer (210) itself may be composed of a GMT material or an LWRT material. For example, the core layer (210) may include reinforcing fibers and thermoplastic materials as described in relation to the outer shell (220, 230). The thickness of the core layer (210) is typically greater than the thickness of the outer shell (220, 230), but this configuration is not essential. In some examples where the core layer (210) is composed of an LWRT material, the thermoplastic material present in the core layer (210) may include at least partially one or more of plasticized and unplasticized polyethylene, polypropylene, polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachloride, polyvinyl chloride, and mixtures of these materials with each other or with other polymer materials. Other suitable thermoplastic materials include, but are not limited to, polyarylene ethers, polycarbonates, polyester carbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, co-polyamides, acrylonitrile-butyl acrylate-styrene polymers, amorphous nylons, polyarylene ether ketones, polyphenylene sulfides, polyaryl sulfones, polyether sulfones, liquid crystal polymers, poly(1,4-phenylene) compounds commercially known as PARMAX®, high-temperature polycarbonates such as Bayer's APEC®PC, high-temperature nylons, and silicones, as well as copolymers, alloys, and mixtures of these materials or with other polymer materials. The thermoplastic material used to form the core layer (210) may 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. Publication No. 20130244528 and U.S.20120065283.The exact amount of thermoplastic material present in the outer layer (220, 230) may vary, and an exemplary amount is in the range of about 20 weight% to about 80 weight%, for example, 30-70 weight% or 35-65 weight%.

[0035] In certain examples, the reinforcing fibers of the core layer (210) may independently comprise glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high-elasticity organic fibers such as para- and meta-aramid fibers, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool (e.g., rock or slag wool), wollastonite, alumina silica, etc., or mixtures thereof, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the aforementioned fibers may be chemically treated before use to provide desired functional groups or to impart other physical properties to the fibers, for example, to be chemically treated so as to react with thermoplastic materials, lofting agents, or both. In some examples, the fibers of the core layer (210) may be chemically treated. The fiber content of the core layer (210) may be about 20 weight% to about 90 weight% of the layer, more specifically about 30 weight% to about 70 weight% of the layer. Typically, the fiber content of the core layer (210) varies from about 20 weight% to about 90 weight% of the core layer (210), more specifically from about 30 weight% to about 80 weight%, for example, from about 40 weight% to about 70 weight%. The specific size and / or orientation of the fibers used may depend at least partially on the desired properties of the thermoplastic polymer material and / or the core layer (210). Suitable additional types of fibers, fiber sizes, and amounts will be readily selected by a person skilled in the art, taking into account the advantages of the present disclosure.In one non-limiting example, the lofting agent for providing fibers dispersed within a thermoplastic material and optionally a core layer (210) may generally have a diameter greater than about 5 microns, more specifically about 5 microns to about 22 microns, and may have a length of about 5 mm to about 200 mm, and more specifically, the fiber diameter may be about 5 microns to about 22 microns and the fiber length may be about 5 mm to about 75 mm.

[0036] In a specific example, the core layer (210) may first be formed as a prepreg that is a precursor to the core layer (210) and does not necessarily need to be fully formed. The core layer (210) is typically porous so that gas can flow through the core layer. For example, the core layer (210) is 0-30%, 10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10-90%, 10-95%, 20-60%, 20-70%, 20-80%, 20-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95%, 40-80%, 40-90%, It may include a porosity or pore content of 40-95%, 50-90%, 50-95%, 60-95%, 70-80%, 70-90%, 70-95%, 80-90%, 80-95%, or any exemplary value within these exemplary ranges. In some examples, the core layer (210) includes a porosity or pore content greater than 0% and does not fully solidify, for example, up to about 95%.

[0037] In some configurations, the outer layer (220, 230) (and optionally the core layer (210)) may be substantially halogen-free or halogen-free to meet the restrictions on hazardous substance requirements for specific applications. In other examples, one or more of the layers (210, 220, 230) may comprise a halogenated flame retardant, such as a compound containing, for example, F, Cl, Br, I, and At, or one or more of these halogens, such as tetrabromo bisphenol-A polycarbonate or monohalo-, dihalo-, trihalo-, or tetrahalo- polycarbonate. In some examples, the thermoplastic material used in one or more of the outer layer (220, 230) may comprise one or more halogens to impart some flame retardancy without the addition of other flame retardants. If a halogenated flame retardant is present, it is preferable that the flame retardant be present in an amount that varies depending on other components present. For example, the halogenated flame retardant may be present in an amount of about 0.1 wt% to about 15 wt% (based on the weight of the layer), more specifically about 1 wt% to about 13 wt%, for example, about 5 wt% to about 13 wt%. If desired, two other halogenated flame retardants may be added to the layer. In other examples, a non-halogenated flame retardant may be added, such as a flame retardant comprising one or more of N, P, As, Sb, Bi, S, Se, and Te. In some embodiments, the non-halogenated flame retardant may comprise a phosphate material so that the layer may be more environmentally friendly. If a non-halogenated or substantially halogen-free flame retardant is present, it is preferable that the flame retardant be present in an amount that varies depending on other components present. For example, a flame retardant that is practically halogen-free is about 0 (based on the weight of the layer).It may be present in an amount of 1 weight% to about 15 weight%, more specifically about 1 weight% to about 13 weight%, for example, about 5 weight% to about 13 weight% based on the weight of the layer. If desired, two different substantially halogen-free flame retardants may be added to one or more of the layers (210, 220, 230). In a specific example, one or more of the layers (210, 220 and 230) may comprise one or more halogenated flame retardants in combination with one or more substantially halogen-free flame retardants. Where two different flame retardants are present, the combination of the two flame retardants may be present in an amount of flame retardant that may vary depending on the other components present. For example, the total weight of the flame retardant present may be about 0.1 wt% to about 20 wt% (based on the weight of the layer), more specifically about 1 wt% to about 15 wt%, for example, about 2 wt% to about 14 wt% based on the weight of the layer. The flame retardant used in the layer described herein may be added to a mixture comprising a thermoplastic material and fibers (before processing the mixture on the wire screen or other processing components), or may be added after the layer is formed. In some examples, the flame retardant material may comprise one or more of an expandable graphite material, magnesium hydroxide (MDH), and aluminum hydroxide (ATH).

[0038] In the configuration illustrated in FIG. 2, the lofting capacity of the outer layers (220, 230) may be the same or different. The exact type of lofting agent used in the layers (220, 230) may depend on many factors, such as, for example, the desired lofting temperature, the desired degree of loft, etc. In some examples, a microsphere lofting agent, for example, an expandable microsphere capable of increasing in size when exposed to convective heating, may be used. An exemplary commercially available lofting agent is available from Kureha Corp. (Japan). In other examples, a first lofting agent having a first average particle size and a second lofting agent having a second average particle size different from the first average particle size may be used. In other examples, the lofting agent may be an expandable graphite material. The outer layers (220, 230) may be configured to provide the same lofting capacity or different lofting capacity. For example, when exposed to heat or other lofting stimuli, the post-loft thickness of the layer (220) may be greater than the thickness of the layer (230). For example, the thickness of the layer (220) before lofting may be about 1-2 mm and the thickness after lofting may be about 10-15 mm. The thickness of the layer (220, 230) before lofting may also be about 1-2 mm and the thickness after lofting may be about 6-8 mm. Such thickness changes may occur even without added lofting agents. For example, without wanting to be bound by a specific theory, during lofting the thermoplastic material may melt, releasing its fixation to the reinforcing material so that the reinforcing material takes up more volume. Subsequent cooling of the thermoplastic material may result in the reshaping of the web into an open-cell structure having a larger volume than the pre-lofted web. The extent to which the volume of the layer (220) can be increased can be selected by adjusting the level of the thermoplastic material and / or reinforcing material of the layer (220).In contrast, the amount of thermoplastic material and / or reinforcing material present in the layer (230) may be selected such that the melting of the thermoplastic material during lofting does not result in a substantial increase in the total volume. As the web of the layer (230) is reformed after lofting, the resulting post-lofted web volume is substantially no different from the pre-lofted web volume. If desired, one or more layers (220, 230) may include additional lofting agents to further increase the total volume. For example, the layer (220) may include additional lofting agents to further select the total post-lofted volume. In some examples, sufficient lofting agents are present so that the post-lofted layer (220) (and / or post-lofted layer (230)) has a thickness of about 20-25 mm. In some examples, layer (220) may comprise a polyolefin, reinforcing fibers, and a lofting agent, and layer (230) may comprise a polyolefin (which may be the same or different from the polyolefin of layer (220)) and a reinforcing material. In certain configurations, the polyolefin present in each of layers (220, 230) may be polypropylene or a polyolefin copolymer including polypropylene. In some embodiments, the reinforcing material of each of layers (220, 230) may optionally comprise glass fibers in combination with other fibers. The exact weight percentages of the thermoplastic material and the reinforcing material in each layer (220, 230) may vary, and an exemplary weight percentage in layers (220, 230) is about 40-60 weight percent of the thermoplastic material, with the remainder being the reinforcing material. If desired, the outer layer (230) can be configured to have a higher lofting capacity than the layer (220).

[0039] In some embodiments, an adhesive layer may or may not be present between the various layers shown in FIG. 2. For example, the layers may be coupled to each other without using an adhesive, or the adhesive layer may be present between the core layer (210) and the outer layer (220) and / or between the core layer (210) and the outer layer (230). Where an adhesive layer is present, the adhesive layer may include, but is not limited to, a thermoplastic adhesive such as a pressure-sensitive adhesive and a hot melt adhesive, such as a polyamide, a modified polyolefin, a urethane, and a polyolefin. In some examples, the thermoplastic component of the adhesive layer may independently include a thermoplastic polymer such as a polyolefin, for example, polyethylene or polypropylene. In another example, the thermoplastic polymer of the adhesive layer may include independently plasticized or unplasticized polystyrene, acrylonitrile styrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate and polyvinyl chloride, and mixtures of these materials with each other or with other polymer materials. Other suitable thermoplastic polymers for use in adhesive layers include, but are not limited to, polyarylene ethers, polycarbonates, polyester carbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, co-polyamides, acrylonitrile-butyl acrylate-styrene polymers, amorphous nylons, polyarylene ether ketones, polyphenylene sulfides, polyaryl sulfones, polyether sulfones, liquid crystal polymers, poly(1,4-phenylene) compounds commercially known as PARMAX®, high-temperature polycarbonates such as Bayer's APEC®PC, high-temperature nylons, and silicones, as well as alloys and mixtures between these materials or with other polymer materials.If desired, the adhesive layer may also independently include some thermosetting materials including, but not limited to, epoxides, epoxy resins, polyesters, polyester resins, urethanes, polyurethanes, diallyl-phthalates, polyimides, cyanate esters, polycyanurates, and combinations thereof.

[0040] In some examples and with reference to FIG. 3, one or more surface layers may be present on the surface of the sandwich panel. As described in more detail below, one outer layer of the sandwich panel is typically coupled to the shell layer, and the remaining outer layer may include a surface layer (340) as illustrated in FIG. 3. The layer (340) may take many forms and is typically different from the outer layer (230), and may not be, for example, a fiber-reinforced thermoplastic layer. In some embodiments, the layer (340) may take the form of an outer layer. The outer layer (340) may include, for example, a film (e.g., a thermoplastic film or an elastomer film), a frim, a scrim (e.g., a fiber-based scrim), a foil, a fabric, a nonwoven fabric, or may exist as an inorganic coating, an organic coating, or a thermosetting coating. In another example, the outer layer (340) may contain a limiting oxygen index greater than about 22 as measured according to ISO 4589 of 1996. Where a thermoplastic film is present as (or as part of) the outer layer (340), the thermoplastic film may comprise at least one of poly(ether imide), 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. Where a fiber-based scrim is present as (or as part of) the outer layer (340), 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. Where a thermosetting coating is present as an outer layer (340) (or as part thereof), the coating may include at least one of unsaturated polyurethane, vinyl ester, phenol, and epoxy.If an inorganic coating is present as (or as part thereof) the outer layer (340), the inorganic coating may comprise a mineral containing a cation selected from Ca, Mg, Ba, Si, Zn, Ti, and Al, or may comprise at least one of gypsum, calcium carbonate, and mortar. If a nonwoven fabric is present as (or as part thereof) the outer layer (340), the nonwoven fabric may comprise a thermoplastic material, a thermosetting binder, an inorganic fiber, a metal fiber, a metallized inorganic fiber, and a metallized synthetic fiber. If desired, the outer layer (340) may also comprise a lofting agent. If desired, an adhesive layer (not shown) may be used to couple the layer (340) to the outer layer (230).

[0041] In a specific example, the layer (340) may be configured as a decorative layer. The decorative layer (340) may be formed from a thermoplastic film, for example, polyvinyl chloride, polyolefin, thermoplastic polyester, thermoplastic elastomer, etc. The decorative layer (340) may include carpet, rubber, or other aesthetic covering. The decorative layer (340) may also be a multilayered structure comprising a foam core formed from, for example, polypropylene, polyethylene, polyvinyl chloride, polyurethane, etc. Fabrics such as natural and synthetic fibers, organic fiber nonwoven fabrics after needle punching, raised fabrics, knitted products, flocked fabrics, or other woven fabrics made of these materials may be bonded to the foam core. The fabric may also be bonded to the foam core with thermoplastic adhesives, including pressure-sensitive adhesives and hot melt adhesives, such as polyamide, modified polyolefin, urethane, and polyolefin. The decorative layer (340) may also be produced using spunbond, heat bonding, spun lace, melt-blown, wet and / or dry processes. Although not illustrated, an outer shell, e.g., scrim, film, decorative layer, etc., may also be coupled to the layer (220) if desired.

[0042] In certain embodiments, the composite panel also includes a shell layer that can typically be coupled to the outer layer of the sandwich panel. In certain examples, the shell layer (400) is typically a single layer of material, but if desired, the shell layer may include two or more individual layers. An example of a shell layer is illustrated in FIG. 4. The shell layer (400) is typically a pre-molded or pre-produced layer coupled to the sandwich panel to provide a composite panel having an aesthetic edge. For example, the shell layer (410) may be match-molded to the outer surface of the sandwich panel to hide the rough surface or bump surface of the sandwich panel from view. Although the panel (400) is illustrated as having an aesthetic edge (405, 410), only one aesthetic edge may exist, or, depending on the composition and intended use of the composite panel, each edge of the composite panel may have an aesthetic edge.

[0043] In certain configurations, the shell layer (400) itself may comprise a GMT material or an LWRT material. For example, the shell layer (400) may be configured as an LWRT article comprising one or more thermoplastic materials and reinforcing fibers. In some examples, the thermoplastic material present in the shell layer (400) may comprise at least partially one or more of plasticized or unplasticized polyethylene, polypropylene, polystyrene, acrylonitrilestyrene, butadiene, polyethylene terephthalate, polybutylene terephthalate, polybutylene tetrachlorate, and polyvinyl chloride, and mixtures of these materials with each other or with other polymer materials. Other suitable thermoplastic polymers include, but are not limited to, polyarylene ethers, polycarbonates, polyester carbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, co-polyamides, acrylonitrile-butyl acrylate-styrene polymers, amorphous nylons, polyarylene ether ketones, polyphenylene sulfides, polyaryl sulfones, polyether sulfones, liquid crystal polymers, poly(1,4-phenylene) compounds commercially known as PARMAX®, high-temperature polycarbonates such as Bayer's APEC®PC, high-temperature nylons, and silicones, as well as alloys and mixtures with other polymer materials between these materials. The thermoplastic material used to form the layer (400) may 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, for example, as described in U.S. Publication No. 20130244528 and U.S.20120065283. The exact amount of thermoplastic material present in the layer (400) may vary, and exemplary amounts are in the range of about 20 weight% to about 80 weight%, for example, 30-70 weight% or 35-65 weight%.

[0044] In certain examples, the reinforcing fibers of the layer (400) may independently comprise glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high-elasticity organic fibers such as para- and meta-aramid fibers, nylon fibers, polyester fibers, mineral fibers such as basalt, mineral wool (e.g., rock or slag wool), wollastonite, alumina silica, etc., or mixtures thereof, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In some embodiments, any of the aforementioned fibers may be chemically treated before use to provide desired functional groups or to impart other physical properties to the fibers, for example, to be chemically treated so as to react with thermoplastic materials, lofting agents, or both. In some examples, the fibers of the layer (400) are chemically treated. The fiber content of the layer (400) may be about 20 weight% to about 90 weight% of the layer, more specifically about 30 weight% to about 70 weight% of the layer. The specific size and / or orientation of the fibers used may depend at least partially on the desired properties of the thermoplastic polymer material and / or layer (400) used. Suitable additional types of fibers, fiber sizes and amounts will be readily selected by a person skilled in the art, taking into account the advantages of the present disclosure. In one non-limiting example, the fibers dispersed within the thermoplastic material and the lofting agent for optionally providing the outer layer (400) may generally have a diameter greater than about 5 microns, more specifically about 5 microns to about 22 microns, and may have a length of about 5 mm to about 200 mm; more specifically, the fiber diameter may be about 5 microns to about 22 microns and the fiber length may be about 5 mm to about 75 mm. In some embodiments, the reinforcing fibers form a web held in place by the thermoplastic material of the layer (400).The web is generally porous, for example, containing a porosity of 5% or more and permeable to gas. In some examples, the pores of the layer (400) may contain additives including flame retardants, particles, or other materials. Exemplary basis weights for the layer (400) include, but are not limited to, about 100 gsm to about 2000 gsm, more specifically about 300 gsm to about 1500 gsm or about 500 gsm to about 1200 gsm. If desired, the layer (400) may be halogen-free or may contain halogenated materials such as lofting agents, flame retardants, or other materials.

[0045] In a specific embodiment, a cross-section of a composite panel (500) including a shell layer is illustrated in FIG. 5. The composite panel (500) includes a core layer (510), an outer layer (520, 530), and a shell layer (550). An aesthetic edge (505) is present on one side of the composite panel (500). If desired, an air gap (515) may exist between the outer layer (530) and the shell layer (550), or such air gap (515) may be filled with foam or other material. As described in more detail below, the presence of the air gap (515) provides a channel in which an interconnect, cable, or other article may be positioned in the air gap (505) of the composite panel (500). Although not illustrated, other edges of the composite panel (500) may also include an aesthetic edge similar to the edge (505).

[0046] In some embodiments, the basis weight of the outer shell (520) may be approximately equal to the combined basis weight of the outer shell (530) and the shell layer (550). For example, since the basis weight of the outer shell (530) may be selected to be smaller than the basis weight of the outer shell (520), when the shell layer (550) is coupled to the outer shell (530), the combined basis weight of the outer shell (530) and the shell layer (550) is approximately equal to the basis weight of the outer shell (520).

[0047] In other embodiments, the fiber loading and / or fiber orientation in the outer layer (520, 530) and the shell layer (550) may be selected so that the fibers of the different layers exist in different orientations. Referring to FIG. 6, an example is illustrated in which the shell layer (650) contains fibers oriented in a first direction and the outer layer (630) contains fibers oriented in a second direction. One of the layers (630, 650) may have randomly oriented fibers if desired. For convenience of explanation, the shell layer (650) and the outer layer (630) are shown separately. The fiber orientations illustrated in FIG. 6 may be interchanged if desired. In any case, the coupling of the outer layer (630) to the shell layer (650) has provided a composite material having fibers proceeding in different directions.

[0048] In another embodiment, the shell layer may include bidirectional fibers and the outer layer may include a unidirectional or random arrangement of fibers. Referring to FIG. 7, the shell layer (750) includes bidirectional fibers and the outer layer (730) includes a unidirectional fiber arrangement, but the fibers of the outer layer (730) may be randomly oriented. The bidirectional fibers of the shell layer (750) do not need to be arranged in the 0 / 90 direction as shown in FIG. 7. Instead, the fibers may be arranged in a 0 / (>0-90) arrangement, and some fibers are not parallel to other fibers.

[0049] In another embodiment, the shell layer may comprise unidirectional fibers (or randomly distributed fibers) and the outer layer may comprise a bidirectional arrangement of fibers. Referring to FIG. 8, the shell layer (850) comprises unidirectional fibers, and the outer layer (830) comprises a bidirectional arrangement of fibers. The bidirectional fibers of the outer layer (830) do not need to be arranged in a 0 / 90 direction as shown in FIG. 8. Instead, the fibers may be arranged in a 0 / (> 0-90) direction, and some fibers are not parallel to other fibers.

[0050] In some examples, the shell layer may include a bidirectional arrangement of fibers and the outer layer may include a bidirectional arrangement of fibers. Referring to FIG. 9, the shell layer (950) includes bidirectional fibers and the outer layer (930) includes a bidirectional arrangement of fibers. The bidirectional fibers of the outer layer (930) and the layer (950) respectively do not need to be arranged in the 0 / 90 direction as shown in FIG. 9. Instead, the fibers may be arranged in a 0 / (>0-90) arrangement, and some fibers are not parallel to other fibers.

[0051] In some examples, the composite article described herein may be present in a vehicle cargo floor. One example is illustrated in FIG. 10. A side view of a drawn article (1000) that may be used as a vehicle cargo floor is shown. The article (1000) is typically located in the rear portion of a vehicle, for example, the rear storage portion of a sports utility vehicle or minivan, and is designed to accommodate components, gears, luggage, spare tires, etc., for storage. A lid or cover (not shown) may also be present to surround components within the vehicle cargo floor (1000) and block them from view. The cargo floor (1000) may include, for example, a composite article having an aesthetic edge as described herein, or other similar articles having an aesthetic edge selected by a person skilled in the art, taking into account the advantages of the present disclosure. In some examples, the cargo floor (1000) provides sufficient weight-bearing capacity so that a lower support member from the vehicle does not need to be present to support it.

[0052] In some embodiments, and as described herein, the presence of a shell layer and a sandwich panel of the loading floor may provide an air gap through which one or more wires, interconnects, cables, or other devices can be routed. For example, the air gap of the loading floor may include wiring that allows USB charging using a port or other device present on the loading floor or its cover. In other examples, the loading floor may include a charging or power port electrically coupled to one or more wires routed through the air gap. The charging or power port may be used to charge or power a telephone, pump, inflator, backup battery source, or other device that may be present on or near the loading floor or its cover.

[0053] In other examples, the composite panel may exist or be configured as a table that can be removed from a vehicle, such as a recreational vehicle (RV) van, truck, etc. For example, the composite panel may be configured as a dining table of a recreational vehicle or as part thereof. The table may be detached from the vehicle and placed outside the vehicle for use. In some examples, the table may include interconnects, an on-board battery, or other power sources, or other electronic means in which part thereof may be present in the air gap of the composite panel. If desired, one or more surfaces of the table may also include photovoltaics that allow the table to be moved outside the RV and the table to be used as a solar cell to charge the RV's battery or to supply power to the RV.

[0054] In other embodiments, the composite panel described herein may be used as a structural panel. For example, the aesthetic edge of the panel enables it to be used as a wall panel, partition panel, ceiling panel, ceiling tile, or other applications of panels and tiles in the construction industry. Other applications of the structural panel including the aesthetic edge will be selected by a person skilled in the art in light of the advantages of the present disclosure.

[0055] In certain embodiments, the outer and shell layers described herein may generally be prepared using reinforcing fibers and thermoplastic materials in combination with optional flame-retardant materials or other materials. To produce the layers, the thermoplastic material, reinforcing fibers, and optionally other materials may be added to or metered into a dispersed foam contained in an open-top mixing tank equipped with an impeller. Without being bound by any specific theory, the presence of trapped air pockets in the foam may aid in dispersing the reinforcing fibers, thermoplastic materials, and other materials. In some examples, the dispersed mixture of fibers and thermoplastic materials may be pumped through a distribution manifold to a head box located above the wire section of a paper machine. The dispersed mixture of fibers or non-thermoplastic foam may be removed as it is fed to a moving support, such as a wire screen, using pressure to continuously produce a uniform fibrous wet web. The wet web may pass through a dryer at an appropriate temperature to reduce moisture content and melt or soften the thermoplastic material. As the high-temperature web exits the dryer, the web of reinforcing fibers, thermoplastic materials, and films can be passed through the nips of a heated roller set to laminate other layers, such as optional films or other materials, onto the web. If desired, additional layers, such as other film layers or scrim layers, may also be attached to one or both sides of the web along with the film to facilitate the handling of the produced layers or composites. The composites can then pass through tension rolls and be continuously cut to the desired size to be formed into a final composite article later.Additional information regarding the preparation of such composites, including suitable materials and processing conditions used to form such composites, is described, for example, in U.S. Patents 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 Publications U.S. 2005 / 0082881, U.S. 2005 / 0228108, U.S. 2005 / 0217932, U.S. 2005 / 0215698, U.S. 2005 / 0164023 and U.S. 2005 / 0161865.

[0056] In some embodiments, the shell layer is first prepared as described above and match-molded to a shape and dimensions suitable for coupling to a sandwich panel. The sandwich panel may be prepared separately and then coupled to the shell layer via an adhesive, film, or other material. If desired, the entire coupled layer may be heated. In other examples, the shell layer is first prepared and match-molded, and optionally, a shell is added to the shell layer using an adhesive or film between the shell layer and the shell. Then, a core layer may be placed on the added shell using an optional adhesive or film between the core layer and the shell. Subsequently, a second shell may be placed on top of the core layer using an optional adhesive or film between the core layer and the second shell. The resulting composite article may be heated to bond the various layers together. An optional decorative layer or other surface layer may then be added to one or more surfaces of the composite article if desired.

[0057] In certain embodiments, the panel described herein may include an aesthetic edge on each side of the panel. Referring to FIG. 11, a panel (1100) including an aesthetic edge (1105, 1106) is illustrated. If desired, an air gap may exist between the second outer shell (1130) and the shell layer (1150) on each side of the panel (1100). The panel (1100) may also include a core layer (1110) and an outer shell (1120). An optional decorative layer (not shown) may also be present.

[0058] When introducing elements of the embodiments disclosed herein, the articles “a,” “an,” “the,” and “said” are intended to imply that there is one or more elements. Terms such as “comprising,” “including,” “with,” and “having” are open-ended and imply that there may be additional elements other than those listed. In light of the benefits of this disclosure, it will be recognized by those skilled in the art that various components of the examples may be replaced or substituted with various components of other examples.

[0059] Although specific aspects, examples, and embodiments have been described above, it will be recognized by those skilled in the art that additions, substitutions, modifications, and changes to the exemplary aspects, examples, and embodiments disclosed are possible in light of the advantages of this disclosure.

Claims

Claim 1 A composite article comprising: a sandwich panel comprising a first porous skin comprising a web of randomly arranged reinforcing fibers held in place by a thermoplastic polyolefin material; a second porous skin comprising a web of randomly arranged reinforcing fibers held in place by a thermoplastic polyolefin material; and a core layer positioned between the first porous skin and the second porous skin; and a shell layer coupled to the sandwich panel through the second porous skin; wherein the shell layer and the sandwich panel together provide an aesthetic edge to the composite article, the aesthetic edge includes a change in direction when viewed in cross-section, and the aesthetic edge is configured as a rounded curve or a curved edge from the upper surface of the sandwich panel to the bottom surface of the sandwich panel. Claim 2 A composite article according to claim 1, wherein the basis weight of the shell layer and the second porous outer layer together is the same as the basis weight of the first porous outer layer. Claim 3 A composite article according to claim 1, wherein the composite article comprises four sides, the first side facing the third side and the second side facing the fourth side, and the shell layer is arranged in a mechanical direction from the second side to the fourth side. Claim 4 A composite article according to claim 1, further comprising an air gap at the aesthetic edge, wherein the air gap exists between the shell layer and the second porous outer shell. Claim 5 The composite article of claim 4, wherein the composite article comprises at least two aesthetic edges each having an air gap, and each of the air gaps exists between the shell layer and the second porous outer shell. Claim 6 A composite article according to claim 1, wherein the reinforcing fibers of each of the first porous outer layer and the second porous outer layer comprise one or more of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, nylon fibers, polyester fibers, mineral fibers, mineral wool fibers, wollastonite, alumina silica, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. Claim 7 A composite article according to claim 6, wherein the thermoplastic polyolefin material of each of the first porous outer shell and the second porous outer shell is polypropylene. Claim 8 A composite article according to claim 1, further comprising a decorative layer coupled to the first porous outer shell of the sandwich panel. Claim 9 A composite article according to claim 1, wherein the core layer comprises a cellulose material or a non-cellulose material. Claim 10 A composite article according to claim 1, wherein the thickness of the composite article is 5 mm to 100 mm. Claim 11 A vehicle loading floor sized and positioned to cover a rear interior section of a vehicle, comprising: a decorative layer facing the interior of the vehicle; and a loading floor substrate coupled to the decorative layer, wherein the loading floor substrate comprises: a sandwich panel coupled to the decorative layer, wherein the sandwich panel comprises a first porous outer shell comprising a web of randomly arranged reinforcing fibers held in place by a thermoplastic polyolefin material, a second porous outer shell comprising a web of randomly arranged reinforcing fibers held in place by a thermoplastic polyolefin material, and a core layer positioned between the first porous outer shell and the second porous outer shell; A vehicle loading floor comprising a shell layer coupled to the sandwich panel through the second porous outer shell, wherein the vehicle loading floor comprises an aesthetic edge, wherein the aesthetic edge comprises a change in direction when viewed in cross-section, and wherein the aesthetic edge is configured as a rounded curve or a curved edge from the upper surface of the sandwich panel to the bottom surface of the sandwich panel. Claim 12 A vehicle loading floor according to claim 11, wherein the basis weight of the shell layer and the second porous outer shell together is the same as the basis weight of the first porous outer shell. Claim 13 A vehicle loading floor according to claim 11, wherein the loading floor substrate comprises four sides, the first side facing the third side and the second side facing the fourth side, and the shell layer is arranged in a machine direction from the second side to the fourth side. Claim 14 The vehicle loading floor of claim 11, wherein the vehicle loading floor includes an air gap at the aesthetic edge, and the air gap exists between the shell layer and the second porous outer skin. Claim 15 The vehicle loading floor of claim 14, wherein the vehicle loading floor comprises at least two aesthetic edges each having an air gap, and each of the air gaps exists between the shell layer and the second porous outer skin. Claim 16 A vehicle loading floor according to claim 11, wherein the reinforcing fibers of each of the first porous outer shell and the second porous outer shell comprise one or more of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, nylon fibers, polyester fibers, mineral fibers, mineral wool fibers, wollastonite, alumina silica, metal fibers, metallized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. Claim 17 A vehicle loading floor according to claim 16, wherein the thermoplastic polyolefin material of each of the first porous outer shell and the second porous outer shell is polypropylene. Claim 18 A vehicle loading floor according to claim 11, further comprising a second decorative layer coupled to the lower side of the vehicle loading floor. Claim 19 A vehicle loading floor according to claim 11, wherein the core layer comprises a cellulose material or a non-cellulose material. Claim 20 A vehicle loading floor according to claim 11, wherein the thickness of the vehicle loading floor is 5 mm to 30 mm. Claim 21 delete Claim 22 delete Claim 23 delete Claim 24 delete Claim 25 delete Claim 26 delete Claim 27 delete Claim 28 delete Claim 29 delete Claim 30 delete Claim 31 delete Claim 32 delete Claim 33 delete Claim 34 delete Claim 35 delete Claim 36 delete Claim 37 delete Claim 38 delete

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