Fiber reinforced thermoplastic composite articles with tunable water barriers

Abstract

Certain configurations of a porous core layer in combination with a water barrier layer are described that can be used in wall assemblies and other articles. The water barrier layers can be used in composite articles designed to permit water vapor to be transmitted through the composite articles while preventing transmittal or absorption of liquid water by the composite articles. Wall assemblies, vehicles, building applications and other applications that include the water barrier layers having selected or tuned water vapor transmission rates are also described.

Description

HANAZD-707510 FIBER REINFORCED THERMOPLASTIC COMPOSITE ARTICLES WITH TUNABLE WATER BARRIERS

[0001] PRIORITY APPLICATIONS

[0002] This application is related to, and claims priority to and the benefit of, each of U.S. Provisional Application No.63 / 691,093 filed on September 5, 2024, U.S. Provisional Application No. 63 / 745,117 filed on January 14, 2025, U.S. Provisional Application No. 63 / 803,413 filed on May 9, 2025 and U.S. Provisional Application No. 63 / 855,239 filed on July 31, 2025, the entire disclosure of each of which is hereby incorporated herein by reference.

[0003] TECHNOLOGICAL FIELD

[0004] Composite articles including water barrier layers that can be used to tune or select water vapor transmission rates through the composite articles are described.

[0005] BACKGROUND

[0006] Articles are often used in environments where exposure to either liquid water or water vapor may occur. Where the articles include certain types of substrates, exposure to the liquid water or water vapor can lead to warping, rotting, mold or bacterial growth, delamination or other undesirable results.

[0007] SUMMARY

[0008] Various aspects and features are described below related to fiber reinforced thermoplastic composite articles including tunable water barriers. The tunable water barriers can provide for desired water vapor transmission levels, liquid water resistance levels or other properties related to exposure to water vapor or liquid water in the use environment of the fiber reinforced thermoplastic composite articles.

[0009] In an aspect, a fiber reinforced thermoplastic composite article comprises a porous core layer and a water barrier layer. In certain embodiments, the porous core layer comprises a web formed from reinforcing materials held in place by a thermoplastic material. In other embodiments, the water barrier layer is coupled to a first surface of the porous core layer and provides for a selected water vapor transmission rate through the water barrier layer or is resistant to movement of liquid water through the water barrier layer or both.

[0010] In certain configurations, the water vapor transmission rate of the fiber reinforced thermoplastic composite article is at least 120 g / m2 / day as tested by ASTM E96-23. In some embodiments, liquid water resistance of the fiber reinforced thermoplastic composite article is at least 800 minutes as tested by ASTM D779-16 (R2022). In other embodiments, the water vaporHANAZD-707510 transmission rate of the fiber reinforced thermoplastic composite article is greater than 0 g / m2 / day and no more than 5 g / m2 / day as tested by ASTM E96-23. In certain embodiments, the water barrier layer comprises a polyolefin material doped with a water barrier additive to resist movement of liquid water through the water barrier layer and permit transmission of water vapor from a first surface of the water barrier layer to a second surface of the water barrier layer. In additional embodiments, the water barrier layer comprises spunbond polyolefin fibers.

[0011] In certain configurations, the porous core layer comprises glass fibers as the reinforcing materials and polypropylene as the polyolefin thermoplastic material, and wherein the web is formed from random crossing over of the glass fibers held in place by the polyolefin thermoplastic material.

[0012] In some embodiments, the water barrier layer comprises a polyamine, a polyamide or a polyester. In other embodiments, the porous core layer comprises glass fibers as the reinforcing materials and polypropylene as the polyolefin thermoplastic material.

[0013] In certain embodiments, the water barrier layer comprises a metal layer laminated to a support layer or a metal coating on the support layer. In instances where a metal layer or coating is present, the porous core layer can include glass fibers as the reinforcing materials and polypropylene as the polyolefin thermoplastic material.

[0014] In other embodiments, the water barrier layer comprises spunbond polyolefin fibers and at least one of a polyamine or a polyamide.

[0015] In certain embodiments, the water barrier layer comprises at least one of polyvinylidene chloride and polychlorotrifluoroethylene.

[0016] In other embodiments, the water barrier layer comprises a first layer and a second layer, wherein the first layer comprises a different material than a material of the second layer, and wherein the water transmission vapor rate of the fiber reinforced thermoplastic composite article is at least 15 g / m2 / day as tested by ASTM E96-23.

[0017] In some embodiments, the fiber reinforced thermoplastic composite article comprises a skin layer coupled to a second surface of the porous core layer. In some embodiments, the skin layer is permeable to water vapor. In other embodiments, the skin layer is an open cell insulation layer. In certain embodiments, the skin layer comprises a tape layer comprising oriented fibers.

[0018] In some embodiments, an adhesive layer (or other material) can be present between the porous core layer and the water barrier layer. Where an adhesive layer is present, the adhesive layer does not substantially alter a water vapor transmission rate of the fiber reinforced thermoplastic composite article.

[0019] In certain embodiments, the fiber reinforced thermoplastic composite article is cellulose free.HANAZD-707510

[0020] In other embodiments, the water barrier layer comprises a metal layer or metal coating. In certain embodiments, where a metal layer or metal coating is present, a water vapor transmission rate of the fiber reinforced thermoplastic composite article is greater than 0 g / m2 / day and no more than 1.5 g / m2 / day as tested by ASTM E96-23. In some embodiments where a metal layer or metal coating is present, a liquid water resistance value of the fiber reinforced thermoplastic composite article provides is at least 800 minutes as tested by ASTM D779-16 (R2022).

[0021] In certain embodiments, the metal layer is a metal scrim or a metal film. In other embodiments, the metal layer is coupled to a non-metal support layer.

[0022] In some configurations, the water barrier layer comprises a basis weight of 5 g / m2to 175 g / m2. In other configurations, the water barrier layer comprises a thickness of 4 microns to 150 microns

[0023] In certain embodiments, a barrier layer can be present between the porous core layer and the water barrier layer.

[0024] In other embodiments, the water vapor barrier comprises metal particles or comprises a film comprising metal particles.

[0025] In some embodiments, the fiber reinforced thermoplastic composite article can include a closed cell skin on a second surface of the porous core layer.

[0026] In another aspect, a wall assembly comprises a plurality of individual framing members coupled to each other to form a wall frame, wherein each of the plurality of individual framing members comprises an interior facing surface and an exterior facing surface. The wall assembly can also include a composite article coupled to the wall frame at the interior facing surface of the individual framing members or at the exterior facing surface of the individual framing members or both. The composite article comprises a porous core layer comprising a web formed from reinforcing materials held in place by a thermoplastic material, and a water barrier layer coupled to a first surface of the porous core layer, wherein the water barrier layer provides for a selected water vapor transmission rate through the water barrier layer or is resistant to movement of liquid water through the water barrier layer or both.

[0027] In certain embodiments, the water barrier layer is coupled to the interior facing surface of the individual framing members.

[0028] In some embodiments, the water barrier layer provides a water vapor transmission rate of at least 15 g / m2 / day as tested by ASTM E96-23.

[0029] In other embodiments, the water barrier layer provides a liquid water resistance value of at least 800 minutes as tested by ASTM D779-16 (R2022).

[0030] In certain embodiments, the water barrier layer provides a water vapor transmission rate of greater than 0 g / m2 / day and no more than 5 g / m2 / day as tested by ASTM E96-23.HANAZD-707510

[0031] In some embodiments, at least one of the individual framing members comprises a wood stud.

[0032] In other embodiments, a barrier layer can be present between the water barrier layer and the porous core layer.

[0033] In certain embodiments, the water barrier layer comprises a basis weight of 5 g / m2to 175 g / m2. In other embodiments, the water barrier layer comprises a thickness of 4 microns to 150 microns.

[0034] In some embodiments, the water barrier layer comprises one or more of a polyolefin, a polyester, a polyamine, a polyamide, a metallized film, metal particles, a metal coating or a film comprising metal particles.

[0035] In another aspect, a recreational vehicle comprises a vehicle frame and a vehicle housing couple to the vehicle frame. If desired, the recreational vehicle can also include wheels to move the recreational vehicle, e.g., tow it behind another vehicle or drive it. In some embodiments, the vehicle housing comprises a wall assembly comprises a plurality of individual framing members coupled to each other to form a wall frame, wherein each of the plurality of individual framing members comprises an interior facing surface and an exterior facing surface. The wall assembly can include a composite article coupled to the wall frame at one or both of the interior facing surface of the individual framing members or the exterior facing surface of the individual framing members. The composite article comprises a porous core layer comprising a web formed from reinforcing materials held in place by a thermoplastic material, and a water barrier layer coupled to a first surface of the porous core layer, wherein the water barrier layer provides for a selected water vapor transmission rate through the water barrier layer or is resistant to movement of liquid water through the water barrier layer or both.

[0036] In certain embodiments, the water barrier layer is coupled to the interior facing surface of the individual framing members.

[0037] In other embodiments, the water barrier layer provides a water vapor transmission rate of at least 15 g / m2 / day as tested by ASTM E96-23.

[0038] In some embodiments, the water barrier layer provides a liquid water resistance value of at least 800 minutes as tested by ASTM D779-16 (R2022).

[0039] In other embodiments, the water barrier layer provides a water vapor transmission rate of greater than 0 g / m2 / day and no more than 5 g / m2 / day as tested by ASTM E96-23.

[0040] In certain embodiments, a barrier layer can be present between the water barrier layer and the porous core layer.

[0041] In some embodiments, a skin layer can be present on a second surface of the porous core layer.HANAZD-707510

[0042] In certain embodiments, the water barrier layer comprises a basis weight of 5 g / m2to 175 g / m2.

[0043] In other embodiments, the water barrier layer comprises a thickness of 4 microns to 150 microns.

[0044] In some embodiments, the water barrier layer comprises one or more of a polyolefin, a polyester, a polyamine, a polyamide, a metallized film, metal particles, a metal coating or a film comprising metal particles.

[0045] In another aspect, a modular home comprises a plurality of walls, a floor coupled to the plurality of walls and a roof coupled to the plurality of walls to form the modular home. At least one wall of the modular home can include a wall assembly comprising a plurality of individual framing members coupled to each other to form a wall frame, wherein each of the plurality of individual framing members comprises an interior facing surface and an exterior facing surface, and a composite article coupled to the wall frame at one of the interior facing surface of the individual framing members or the exterior facing surface of the individual framing members or both, wherein the composite article comprises a porous core layer comprising a web formed from reinforcing materials held in place by a thermoplastic material, and a water barrier layer coupled to a first surface of the porous core layer, wherein the water barrier layer provides for a selected water vapor transmission rate through the water barrier layer or is resistant to movement of liquid water through the water barrier layer or both.

[0046] In certain embodiments, the water barrier layer is coupled to the interior facing surface of the individual framing members.

[0047] In other embodiments, the water barrier layer provides a water vapor transmission rate of at least 15 g / day / m2as tested by ASTM E96-23.

[0048] In some embodiments, the water barrier layer provides a liquid water resistance value of at least 800 minutes as tested by ASTM D779-16 (R2022).

[0049] In certain embodiments, the water barrier layer provides a water vapor transmission rate of greater than 0 g / m2 / day and no more than 5 g / m2 / day as tested by ASTM E96-23.

[0050] In other embodiments, a barrier layer can be present between the water barrier layer and the porous core layer.

[0051] In some embodiments, a skin layer on a second surface of the porous core layer can be present

[0052] In certain embodiments, the water barrier layer comprises a basis weight of 5 g / m2to 175 g / m2.

[0053] In other embodiments, the water barrier layer comprises a thickness of 4 microns to 150 microns.HANAZD-707510

[0054] In certain embodiments, the water barrier layer comprises one or more of a polyolefin, a polyester, a polyamine, a polyamide, a metallized film, metal particles, a metal coating or a film comprising metal particles. Additional aspects, examples, embodiments and features are described in more detail below.

[0055] BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0056] Certain aspects, features, elements, configurations and components are described with reference to the accompanying drawings in which:

[0057] FIG. 1 is an illustration showing an article comprising a porous core layer and a water vapor barrier layer on the porous core layer;

[0058] FIG. 2 is an illustration showing a water barrier layer on a porous core layer;

[0059] FIG. 3 is another illustration showing a water barrier on a porous core layer;

[0060] FIG. 4 is another illustration showing a water barrier layer on a porous core layer;

[0061] FIG. 5 is an illustration showing a metal layer and a skin on a porous core layer;

[0062] FIG. 6 is an illustration showing a water barrier layer on one surface of a core layer and a skin on another surface of the core layer;

[0063] FIG. 7 is an illustration showing two water barrier layers on a core layer;

[0064] FIG. 8 is an illustration showing a water barrier layer on one surface of a core layer;

[0065] FIG. 9 is an illustration showing a water barrier layer on one core layer where multiple core layers are present;

[0066] FIG. 10 is an illustration showing a water barrier layer between two core layers;

[0067] FIG. 11 is an illustration showing a decorative layer on one surface of a core layer;

[0068] FIG. 12 is an illustration showing that the water barrier layer may include some depth across a surface of the water barrier layer;

[0069] FIG. 13 is an illustration showing a lightweight fiber reinforced thermoplastic (LWRT) composite article attached to a framing member with the water barrier layer facing toward the framing member;

[0070] FIG.14 is an illustration showing a LWRT composite article attached to a framing member with the water barrier layer facing toward an interior space;

[0071] FIG.15 is an illustration showing a LWRT composite article attached to a framing member with a first water barrier layer facing toward an interior space and a second water barrier layer facing toward the framing member;

[0072] FIG.16 is an illustration showing a LWRT composite article attached to a framing member with a first discontinuous water barrier layer facing toward an interior space and a second continuous water barrier layer facing toward the framing member;HANAZD-707510

[0073] FIG. 17 is a block diagram showing certain steps in producing a LWRT composite article with a water barrier layer, in accordance with certain configurations;

[0074] FIG.18 is an illustration showing mixing of materials in a mixing tank, in accordance with certain configurations;

[0075] FIG. 19 is an illustration showing deposition of materials onto a moving support, in accordance with certain configurations;

[0076] FIG. 20 is an illustration showing a moving support, in accordance with certain configurations;

[0077] FIG. 21 is an illustration showing a web moving down a moving support, in accordance with certain configurations;

[0078] FIG. 22 is an illustration showing formation of a porous core layer, in accordance with certain configurations;

[0079] FIG. 23 is an illustration showing removal of water from the moving support to provide a web, in accordance with certain configurations;

[0080] FIG. 24 is an illustration of a sprayer that can spray a material onto a surface of a porous core layer, in accordance with certain configurations;

[0081] FIG.25 is an illustration showing application of a skin layer to a surface of a web or porous core layer, in accordance with certain configurations;

[0082] FIG. 26 is an illustration showing pressing of a LWRT composite article, in accordance with certain configurations;

[0083] FIG.27 is an illustration showing spraying of a solid material onto a surface of a skin layer, in accordance with certain configurations;

[0084] FIG.28 is an illustration showing application of skins on each side of a web, in accordance with certain configurations;

[0085] FIG. 29 is an illustration showing a recreational vehicle, in accordance with certain configurations; and

[0086] FIG. 30 is an illustration showing a modular home, in accordance with certain embodiments;

[0087] FIG. 31 is a photograph showing a test wall assembly used to measure water vapor transmission rates for a test article; and

[0088] FIG.32 is an illustration showing a wall assembly with a first composite article, a framing member and a second composite article.

[0089] It will be recognized by the person of ordinary skill in the art, given the benefit of this disclosure, that the figures, and certain layers or components thereof, are not drawn to scale and that certain dimensions may have been enlarged, reduced or otherwise distorted to facilitate a moreHANAZD-707510 user-friendly description. Unless specified in connection with a particular embodiment or feature, a particular size or orientation is not intended.

[0090] DETAILED DESCRIPTION

[0091] Certain embodiments are described below to illustrate better some of the novel and inventive features that can be present in the fiber reinforced thermoplastic composite articles described herein. Not necessarily all features are present in all embodiments, and various features can be interchanged or substituted with other features to provide a desired composite article for an intended use.

[0092] In certain embodiments, the composite articles and assemblies described herein can include a porous core layer in combination with a water barrier layer. The term “water barrier layer” includes layers that provide for certain levels of water vapor transmission rates and layers that can resistant transmission of liquid water from one surface of the water barrier layer to another surface of the water barrier layer. The water barrier layer need not provide both liquid water resistance and any specific water vapor transmission rate. For example, one water barrier layer may provide for a specific water vapor transmission rate while not providing substantial resistance to liquid water. In other instances, the water barrier layer may be resistant to liquid water transmission but not have any measurable water vapor transmission rate. In other configurations, the water barrier layer can provide for a specific water vapor transmission rate and be resistant to liquid water transmission to at least some degree, e.g., can be water vapor permeable and liquid water impermeable. Various combinations of properties for a water barrier layers are discussed in more detail below. For example, the water vapor barrier layer may also have printed indicia on a surface or have a printable surface so an ink or other materials can be deposited using a printer or other devices or means.

[0093] In certain configurations, water vapor transmission rates of the fiber reinforced thermoplastic composite articles described herein can be evaluated using, for example, ASTM E96-23 (Procedure A: Desiccant Method) entitled “Standard Test Methods for Gravimetric Determination of Water Vapor Transmission Rate of Materials.” Alternatively, water vapor transmission rates could instead be measured according to ISO 15106-3:2003 entitled “Plastics — Film and sheeting — Determination of water vapour transmission rate.” In the ISO 15106-3:2003 test (Part 3: Electrolytic detection sensor method) the sample is tested as supplied by placing it in the measuring chamber with the coated side to the dry gas in the controlled temperature environment, with dry nitrogen passing on one side of the sample with a saturated salt solution below the sample on the other to generate the required percent relative humidity (RH). Water vapor passing through the sample was swept to the electrolytic water vapor sensor downstreamHANAZD-707510 and the permeation rate calculated. The test can be continued until a stable reading is achieved. Results are converted to 100% RH and expressed as g / m²-day. Different testing methodologies are often preferred in different countries. In some embodiments, water vapor transmission, to at least some degree through the fiber reinforced thermoplastic composite article, can be desirable to prevent humidity levels within a building structure, recreational vehicle, wall assembly, roof assembly, ceiling assembly, flooring or other areas from becoming too high or too low. Further, water vapor can become trapped within wall assemblies, roofs, floors, attics, etc. and can increase the humidity within those areas to high levels that can support decay and / or mold growth. It can be desirable to select a different water vapor transmission rate (WVTR) through external surfaces of the building structure, recreational vehicle, wall assembly, roof assembly, ceiling assembly, flooring, etc. compared to the WVTR which is desired for water vapor present in interior areas the building structure, recreational vehicle, wall assembly, roof assembly, ceiling assembly, flooring, etc. By selecting the specific materials for use in a water barrier layer and / or their arrangement, the WVTR of a composite article can be tuned for a specific application, e.g., for an exterior application or for an interior application. For exterior applications, the water barrier layer can be selected so the composite article has a high WVTR, e.g., 5 g / m2 / day or more as tested by ASTM E96-23, but is resistant to transmission of liquid water. Exterior applications often use a high WVTR, e.g., 120 g / m2 / day or more, but can be resistant to movement of liquid water, e.g., can be liquid water impermeable. For interior applications, liquid water resistance is typically not an issue as most interior surfaces are not continuously exposed to liquid water. The WVTR for composite articles used in interior applications is typically significantly lower than the WVTR for composite articles used in exterior applications, e.g., the water barrier layers used in interior applications can provide composite articles with a WVTR of less than 5 g / m2 / day as tested by ASTM E96-23 compared to the WVTR of a composite article used in exterior applications which is often 120 g / m2 / day or more. The porous core layer on its own may not provide a significant barrier to water vapor transmission, but the combination of the porous core layer and the water barrier layer in a composite article typically has a lower WVTR than either material on its own. For example, a composite article including a porous core layer and a water barrier layer can have a WVTR that is two times, three times, four times or even five times less than the WVTR of the water barrier layer by itself.

[0094] In some instances, the water vapor transmission rate of the fiber reinforced thermoplastic composite articles described herein is greater than zero g / m2 / day and no more than 35 g / m2 / day or greater than zero g / m2 / day and no more than 25 g / m2 / day or greater than zero g / m2 / day and no more than 15 g / m2 / day or greater than zero g / m2 / day and no more than 10 g / m2 / day or greater than zero g / m2 / day and no more than 5 g / m2 / day or greater than zero g / m2 / day and no more than 3HANAZD-707510 g / m2 / day or greater than zero g / m2 / day and no more than 2.5 g / m2 / day or greater than zero g / m2 / day and no more than 2 g / m2 / day or greater than zero g / m2 / day and no more than 1.5 g / m2 / day or greater than zero g / m2 / day and no more than 1 g / m2 / day as measured by ASTM E96- 23. In other embodiments, the water vapor transmission rate of the fiber reinforced thermoplastic composite articles described herein is at least 15 g / m2 / day or at least 20 g / m2 / day or at least 25 g / m2 / day or at least 35 g / m2 / day or at least 40 g / m2 / day or at least 45 g / m2 / day or at least 50 g / m2 / day or at least 55 g / m2 / day or at least 60 g / m2 / day or at least 65 g / m2 / day or at least 70 g / m2 / day or at least 75 g / m2 / day or at least 80 g / m2 / day or at least 85 g / m2 / day or at least 90 g / m2 / day or at least 95 g / m2 / day or at least 100 g / m2 / day as measured by ASTM E96-23 or ISO 15106-3:2003. These illustrative water vapor transmission rates may occur in water barrier layers which are permeable or impermeable to liquid water movement as noted in more detail below.

[0095] Liquid water resistance of the fiber reinforced thermoplastic composite articles described herein can be evaluating using, for example, ASTM D779-16 (R2022) (by the Dry Indicator Method (Procedure A)) entitled “Standard Test Method for Determining the Water Vapor Resistance of Sheet Materials in Contact with Liquid Water by the Dry Indicator Method.” In some embodiments, the water barrier layer is impermeable to movement of liquid water through the barrier layer. In other embodiments, the water barrier layer is impermeable to liquid water for at least 60 minutes of continuous exposure to liquid water, e.g., immersion, or for at least 120 minutes of continuous exposure to liquid water or for at least 180 minutes of continuous exposure to liquid water or for at least 240 minutes of continuous exposure to liquid water or for at least 360 minutes of continuous exposure to liquid water or for at least 480 minutes of continuous exposure to liquid water or for at least 600 minutes of continuous exposure to liquid water or for at least 720 minutes of continuous exposure to liquid water or for at least 8000 minutes of continuous exposure to liquid water or for at least 840 minutes of continuous exposure to liquid water. Where the water barrier layer is impermeable to movement of liquid water, the water barrier can still be permeable to water vapor movement as noted above. For example, a liquid water impermeable barrier layer with a water vapor transmission rated noted herein can be present in the composite article to facilitate movement of water vapor into or out of areas while prohibiting liquid water from getting into those areas.

[0096] In certain embodiments, a water barrier layer can include polyolefin materials and / or polyolefin fibers optionally with water barrier additives including metals, acetates, amines, vinyl acetates, polyamines, amides, polyamides, fluoro- compounds or other materials. For example, the water barrier layer can include polyethylene, polypropylene, high density polyethylene, low density polyethylene and combinations and copolymers of these materials optionally in combination with a polyamide, a polyamide or both. The polyolefin materials can be present inHANAZD-707510 film form or may be present in fiber form or a combination of fiber and non-fiber forms. If desired, commercially available barrier layers including Tyvek® material from Dupont, Typar from Fiberweb, James Hardie layers, Weathermate from Dow, Pinkwrap from Owens Corning, Protector Wrap, Poly-Wall Henry Blueskin, Benjamin Obdyke, CertaWrap, GreenGuard and Delta-Dry or other wraps or layers can be used as water barrier layers or a component thereof.

[0097] In other embodiments, a water barrier layer can include polyester materials and / or polyester fibers optionally with water barrier additives including metals, amines, polyamines, amides, polyamides, fluoro- compounds or other materials. For example, the water barrier layer can include polyethylene terephthalate optionally in combination with a polyamide, a polyamide or both. The polyester materials can be present in film form or may be present in fiber form or a combination of fiber and non-fiber forms. In some configurations, the water barrier layer can include other polymeric materials including, but not limited to, polycarbonates, polyimides, polyetheretherketone, nylon, cellulose acetate, vinyl acetate and fluoropolymers including, for example, polyvinylidene fluoride, polyvinylidene chloride, polychlorotrifluoroethylene, fluorinated ethylene polypropylene and ethylene tetrafluoroethylene.

[0098] In some embodiments, the water barrier layer can include metals, metal particles or an individual metal layer that is deposited onto an underlying support layer, e.g., an underlying polymeric layer, which can include polyolefin materials, polyolefin fibers, polyester materials, polyester fibers, fluoropolymers, fluorofibers, etc. The metals, metal particles, etc. can be embedded in the support layer of the water barrier layer or be present in a separate layer having an interface with the underlying support layer. In some instances, the amount and / or type of metal loading, polyolefin material, polyolefin fibers, polyester, polyester material, polyester fiber, fluoropolymer, fluorofiber, etc. can be selected to control or tune the level of water vapor transmission through the water barrier layer. Combinations of polyamines, polyamides, metals, polyolefin materials, polyolefin fibers, polyester materials, polyester fibers, fluoropolymers, fluorofibers, etc. can also be used as water barrier layers.

[0099] In certain embodiments, the water barrier layer can include two or more individual layers which are laminated to each other. For example, a polymeric support layer can be laminated to a metallized layer and together the two layer material can function as a water barrier layer with the specified WVTR and liquid resistance described herein. Alternatively, a metal coating can be applied to a polymeric support layer and the combined layers can function as water barrier layer with the specified WVTR and liquid resistance described herein. Examples of metals which can be used in the metallized layer are described in more detail below. The exact arrangement of the water barrier layers can vary, and in some instances a metal coating can be placed closer to aHANAZD-707510 surface of a core layer whereas in other instances a polymeric support layer can be placed closed to a surface of the core layer.

[0100] In certain configurations, a fiber reinforced thermoplastic composite article can include a porous core layer in combination with a water barrier layer. A simplified illustration is shown in FIG.1 where a composite article 100 comprises a porous core layer 110 coupled to a water barrier layer 115. As noted herein, the water barrier layer 115 can permit passage of some water vapor at a desired water vapor transmission rate. The water barrier layer 115 can be liquid water permeable or liquid water impermeable or otherwise can pass liquid water to some degree if desired. The porous core layer 110 generally provides little resistance to the passage of water vapor or liquid water on its own as the porous core layer 110 often has a high porosity, e.g., 50% or more. When the water barrier layer 115 and porous core layer 110 are used together, the WVTR of the combined layers is typically lower than the WVTR of either of the layers 110, 115 on its own.

[0101] In certain embodiments, the exact configuration of the water barrier layer 115 can vary and may include polyolefin materials, polyolefin fibers, polyolefin fibers, polyester materials, polyester fibers, fluoropolymers, fluorofibers, and optionally water barrier additives including acetates, vinyl acetates, polyamines, polyamides or other amino based materials that can alter the overall transmission rate of water vapor through the water barrier layer 115. In other embodiments, the water barrier layer 115 can include polyester materials and / or polyester fibers optionally with water barrier additives including metals, amines, polyamines, amides, polyamides, fluoro- compounds or other materials. For example, the water barrier layer can include polyethylene terephthalate optionally in combination with a polyamide, a polyamide or both. The polyester materials can be present in film form or may be present in fiber form or a combination of fiber and non-fiber forms. In some configurations, the water barrier layer 115 can include other polymeric materials including, but not limited to, polycarbonates, polyimides, polyetheretherketone, nylon, cellulose acetate, vinyl acetate and fluoropolymers including, for example, polyvinylidene fluoride, polyvinylidene chloride, polychlorotrifluoroethylene, fluorinated ethylene polypropylene and ethylene tetrafluoroethylene.

[0102] In other embodiments, the water barrier layer 115 can include metals, metal particles, a film with metal particles or include a metallized film layer or a metal coating. For example, the water barrier layer can include a combination of polymeric materials and metal particles in a single layer or can be configured as a bi-layer material (or multi-layer material) including a polymeric support layer, e.g., a polymeric film layer, laminated to a metal layer or a polymeric layer including a metal coating. Where a metal layer / coating is present, the metal layer / coating can be continuous across a top surface of the water barrier layer 115. For example, one or more of lithium, beryllium, sodium, magnesium, aluminum, potassium, calcium, scandium, titanium, vanadium, chromium,HANAZD-707510 manganese, iron, cobalt, nickel, copper, zinc, gallium, rubidium, strontium, yttrium, zirconium, niobium, molybdenum, technetium, ruthenium, rhodium, palladium, silver, cadmium, indium, tin, cesium, barium, lanthanum, cerium, praseodymium, neodymium, promethium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium, hafnium, tantalum, tungsten, rhenium, osmium, iridium, platinum, gold, mercury, thallium, lead, bismuth, polonium, francium, radium, actinium, thorium, protactinium, uranium, neptunium, plutonium, americium, curium, berkelium, californium, einsteinium, fermium, mendelevium, nobelium, lawrencium, rutherfordium, dubnium, seaborgium, bohrium, hassium, meitnerium, darmstadtium, roentgenium, copernicium, nihonium, flerovium, moscovium or livermorium can be present in the metal of the water vapor barrier layer. The metal can be present in elemental form, as an alloy with one or more other metals, in a metal compound, as a particle, a microparticle, a nanoparticle, or other forms. In certain embodiments, non-radioactive metals and non-toxic metals are desirable for use in the water barrier layers described herein. In other embodiments, non-radioactive transition metals or non-toxic transition metals can be used in the water barrier layers described herein. For example, the water barrier layer may be free of lead, free of mercury, and / or free of hexavalent chromium.

[0103] In certain embodiments, the metal or metals present in the water barrier layer 115 may be limited to those non-radioactive transition metals including, but not limited to, scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium, niobium, molybdenum, technetium, ruthenium, rhodium, palladium, silver, cadmium, lanthanum, hafnium, tantalum, tungsten, rhenium, osmium, iridium, platinum, gold or mercury. A single transition metal or multiple transition metals may be present as desired. In some instances, the water barrier layer 115 can include one or more Period IV transition metals, e.g., scandium, titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc and combinations thereof. In other embodiments, the water barrier layer 115 can include one or more Period V transition metals, e.g., yttrium, zirconium, niobium, molybdenum, technetium, ruthenium, rhodium, palladium, silver, cadmium, and combinations thereof. In some embodiments, the water barrier layer 115 can include one or more Period VI transition metals, e.g., lanthanum, hafnium, tantalum, tungsten, rhenium, osmium, iridium, platinum, gold, mercury and combinations thereof. In other instances, the water barrier layer 115 can include a Period IV transition metal in combination with a Period V transition metal. In some embodiments, the water barrier layer 115 can include a Period V transition metal in combination with a Period VI transition metal. In other embodiments, the water barrier layer 115 can include a Period IV transition metal in combination with a Period VI transition metal. In certain configurations, the water barrier layer 115 can include a Period IVHANAZD-707510 transition metal in combination with one or more Period V transition metals and in combination with one or more Period VI transition metals.

[0104] The exact amount of the metal or metals present in the water barrier layer 115 can vary and the skilled person, given the benefit of this disclosure, will recognize that the total weight percentage of the materials in any one layer sum to 100 weight percent when multiple different materials are present. For example, the water barrier layer 115 can include at least one Period IV transition metal present at least 50% by weight based on the total weight in a metal layer or metal coating. The remaining materials in the metal layer or metal coating may be present from another Period IV transition metal, a Period V transition metal, a Period VI transition metal, a non- transition metal and non-metal materials including polymers, binders, water barrier additives, etc. In another embodiment, the water barrier layer 115 can include at least one Period V transition metal present at least 50% by weight based on the total weight in a metal layer or metal coating. The remaining materials in the metal layer or metal coating may be present from another Period V transition metal, a Period IV transition metal, a Period VI transition metal, a non-transition metal and non-metal materials including polymers, binders, water barrier additives, etc. In some configurations, the water barrier layer 115 can include at least one Period IV transition metal present at least 50% by weight based on the total weight in a metal layer or metal coating. The remaining materials may be present from another Period VI transition metal, a Period IV transition metal, a Period V transition metal, a non-transition metal and non-metal materials including polymers, binders, water barrier additives, etc. In some embodiments, the amount of metal present in the metal layer or metal coating may be 80% by weight or more, 85% by weight or more, 90% by weight or more, or 95% by weight or more based on the total weight in a metal layer or metal coating.

[0105] In some embodiments, a water barrier layer 115 including an individual metal layer / coating can include at least one Period IV transition metal present at least 50% by weight based on the total weight in a metal layer or metal coating. The remaining materials in the metal layer may be present from another Period IV transition metal, a Period V transition metal, a Period VI transition metal, a non-transition metal and non-metal materials including polymers, binders, water barrier additives, etc. In another embodiment, the water barrier layer 115 including an individual metal layer / coating can include at least one Period V transition metal present at least 50% by weight based on the total weight in a metal layer or metal coating. The remaining materials may be present from another Period V transition metal, a Period IV transition metal, a Period VI transition metal, a non-transition metal and non-metal materials including polymers, binders, water barrier additives, etc. In some configurations, the water barrier layer 115 including an individual metal layer / coating can include at least one Period IV transition metal present atHANAZD-707510 least 50% by weight based on the total weight in a metal layer or metal coating. The remaining materials may be present from another Period VI transition metal, a Period IV transition metal, a Period V transition metal, a non-transition metal and non-metal materials including polymers, binders, water barrier additives, etc. In some embodiments, the amount of metal present in the metal layer / coating of a water vapor layer 115 may be 80% by weight or more, 85% by weight or more, 90% by weight or more, or 95% by weight or more based on the total weight in a metal layer or metal coating.

[0106] In certain embodiments, the metal materials which are present in the water barrier layer 115 can be present in elemental form, as an alloy, as a particle, as a nanoparticle, as a nanostructure, as a microparticle, as a microstructure, or as a metal compound or other forms. In some embodiments, the water vapor layer 115 may be fiber free, lead free, chromium free, mercury free, free of perfluorooctanoic acid (PFOA) or free of polyfluoroalkyl substances (PFOS). If desired, the metal material can be embedded in a support layer or deposited as a coating or one, two or more layers which can include the same or different metals in the different layers. In other embodiments, the water barrier layer can include spunbond fibers, e.g., polyolefin spunbond fibers including spunbond polyethylene fibers, spunbond polypropylene fibers or combinations thereof, optionally in combination with metals, a polyamide, a polyamine or other materials. If desired, a metal layer can be laminated to a support layer comprising spunbond fibers and optionally water barrier additives in the support layer.

[0107] In certain embodiments, a thickness of the water barrier layer 115, or some layer thereof, may vary from a few Angstroms to a few mm depending on which particular materials are present, how many layers are present and the exact arrangement of the materials in the water barrier layer 115. In some embodiments, two, three, four or more atomic layers of the metal can be stacked or deposited onto each other to form a very thin metal layer or metal coating. The metal may be the same or may different in the different atomic layers. The metal atoms are desirably closely packed together to minimize any space between metals to reduce the amount of open space in the metal layers and this arrangement can be used to tune the transmission rate of water vapor through the water barrier layer. The exact metal packing may vary, and illustrative metal packing arrangements include, but are not limited to, simple cubic, body-centered cubic, hexagonal closest-packed, cubic-closest packed, face centered and other metal packing arrangements which can vary based on the metal or metals which are present. Different packing arrangements in different metal layers can intentionally be selected if desired. In some embodiments, the metal packing efficiency can exceed 0.60, 0.65 or even 0.70. Metals with high packing efficiency, e.g., aluminum, silver, gold, etc. may provide particularly desirable water vapor transmission properties when present in a composite article. These thin metal layers can be deposited directly on a porousHANAZD-707510 core layer, can be deposited directly on a support layer or can be deposited as an individual layer which is then laminated to another layer to form a water barrier layer.

[0108] In certain embodiments, the water barrier layer comprises a basis weight of 5 g / m2to 175 g / m2. In other configurations, the water barrier layer comprises a thickness of 4 microns to 150 microns. The exact thickness and basis weight can vary depending on the configuration, the number of layers present in the water barrier layer, the materials present in the water barrier layer, etc. While not required, it can be desirable to select a water barrier layer with a desired WVTR which is as light as possible to reduce the overall weight of a composite article including the water barrier layer.

[0109] In certain embodiments, the water barrier layer 115 can include metal deposited directly onto a surface of the porous core layer 110 or may include a skin or other material that includes the metal material, e.g., either within the skin or as a metal layer deposited onto a surface of the skin. The representation shown in FIG. 1 is intended to encompass the arrangement where the metal material is deposited directly on the core layer 110 as the layer 115. For example, a top surface 111 of the core layer 110 can be rendered non-porous, fully consolidated or have low porosity, e.g., by thermal heating, laser heating, etc. followed by cooling, so the deposited metal material remains on the surface of the porous core layer 110 and does not end up entirely inside the voids of the porous core layer 110. Alternatively, an adhesive or coating or primer layer may be deposited onto the top surface 111 of the porous core layer to “plug” or “occupy” the voids adjacent to a top surface 111 of the porous core layer 110 so a significant amount of deposited metal material remains on the top surface 111. Suitable materials to plug the voids in the top surface 111 of the porous core layer include, but are not limited to, polyolefins, polyesters, polyamides, copolyamides, polyurethanes and the like. The materials can be sprayed onto the porous core layer 110 during production and allowed to cure or cross-link to provide a top surface 111 that is substantially non-porous. The metal layer can be continuous across the top surface 111 to function as a water barrier layer.

[0110] Another embodiment of a water barrier on a porous core layer is shown in FIG. 2. An article 200 comprises a porous core layer 110 and a water barrier layer 210 deposited on the core layer 110. The water barrier layer 210 comprises a support layer 211 and a metal layer 212. These layers are shown as enlarged for illustration purposes even though the metal layer 212 is typically orders of magnitude thinner than the support layer 211. The support layer 211 can be selected to permit the metal material of the metal layer 212 to remain on the surface of the support layer 211.

[0111] In certain embodiments, the metal layer 212 can include any or those materials described in reference to the water vapor barrier layer 115 above. In particular, transition metals in periods IV, V or VI or other metals can be present in the metal layer 212. The metal layer 212 is oftenHANAZD-707510 very thin, e.g., 1 nm to tens of nanometers, whereas the support layer 211 is typically much thicker, e.g., a few microns up to a few mm. There may exist a defined interface between the metal layer 212 and the support layer 211 even though some metal can penetrate into the support layer 211. The metal layer 212 can be disposed directly on the support layer 211 or intermediate layers including adhesive, primers, etc. may be present between the layers 211, 212 to enhance retention of the metal layer 212 on the support layer 211. The metal layer 212 can be continuous across the surface of the support layer 211 so the layers 211, 212 together can function as a water vapor barrier layer. The metal layer 212 can include polymeric materials or polymeric fibers including polyolefin materials or polyolefin fibers.

[0112] The exact configuration of the support layer 211 may vary and illustrative materials include, but are not limited to, a film (closed cell, open cell, perforated, etc.), a scrim, a frim (film + scrim), a foil, a woven fabric, a non-woven fabric or combinations of these materials. The support layer 211 may be a single layer, a bilayer, a tri-layer or include more than three layers. The support layer 211 can be porous, non-porous or perforated as desired. The metal layer 212 is typically deposited on one surface of the support layer 211 but may also be present on both surfaces of the support layer 211 if desired. When present on more than one surface, a thickness of the different metals layers can be the same or can be different. Further, the metal material in different layers can be the same or can be different. Alternatively, different layers can include similar metals but at different amounts. The support layer 211 and metal layer 212 can together function as a water barrier layer 210 which can provide for a selected water vapor transmission rate through the water barrier layer 210. If desired, an adhesive, primer or other materials can be present between the metal layer 212 and the core layer 110.

[0113] In some configurations, the metal material can be integral to the water barrier layer deposited on a porous core layer. For example and referring to FIG. 3, a composite article 300 comprises a porous core layer 110 and a water barrier layer 310 comprising integral metal material. The metal material is mixed throughout the water barrier layer 310 and may be homogeneously distributed from one surface to another surface of the skin. Alternatively, the metal can be present in a gradient distribution with more metal material toward one surface of the water barrier layer 310 than the other surface of the water barrier layer 310. The water barrier layer 310 can be, for example, a closed cell skin to minimize the amount of open porosity within the layer 310. The metal of the layer 310 can be any of those metals described in reference to the water vapor barrier layer 115.

[0114] In certain embodiments, a composite article can include a metal layer deposited onto a skin layer which together can function as a water barrier layer. For example and referring to FIG. 4, a composite article 400 includes a porous core layer 110, a water barrier layer 410 can include aHANAZD-707510 skin 411 and a metal layer 415 disposed on the skin 411. In some embodiments, the skin 411 can be selected such that it retains the metal layer 415 above an interface between the skin 411 and the metal layer 415. In certain configurations, the metal layer 415 can be subsequently added on top of the skin 411 during production to permit the amount, thickness and / or content of the metal layer 415 to vary as desired. The metal of the layer 415 can be any of those metals described in reference to the water vapor barrier layer 115. The metal of the layer 415 can be continuous across the top surface of the skin 411 to function as a water vapor barrier layer. If desired, the arrangement of the metal layer 415 and the skin 411 can be reversed so the metal layer 415 is positioned closer to the core layer 110 than the skin 411.

[0115] In some embodiments, the skin 411 can be a film, a scrim, a frim, a coating or combinations thereof. It may be desirable to include the skin 411 where the porous core layer 110 is highly porous to avoid the metal from becoming internalized into the voids or pores of the core layer 110 during production. The skin 411 can be, for example, a film (closed cell, open cell, perforated, etc.), a scrim, a frim (film + scrim), a foil, a woven fabric, a non-woven fabric or be present as an inorganic coating, an organic coating, or a thermoset coating. In other instances, the skin 411 may comprise a limiting oxygen index greater than about 22, as measured per ISO 4589 dated 1996. Where a fiber based scrim is present as (or as part of) the skin 411, the fiber based scrim may comprise at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metalized synthetic fibers, and metalized inorganic fibers. If desired, the scrim may comprise materials or fibers produced from one or more of the thermoplastic materials described herein in connection with the porous core layers. Where a thermoset coating is present as (or as part of) the skin 411, the coating may comprise at least one of unsaturated polyurethanes, vinyl esters, phenolics and epoxies. Where an inorganic coating is present as (or as part of) the skin 411, the inorganic coating may comprise minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti and Al or may comprise at least one of gypsum, calcium carbonate and mortar. Where a non-woven fabric is present as (or as part of) the skin 411, the non-woven fabric may comprise a thermoplastic material, a thermal setting binder, inorganic fibers, metal fibers, metallized inorganic fibers and metallized synthetic fibers. If desired, the skin 411 may also comprise a lofting agent, an expandable graphite material, a flame retardant material, bicomponent fibers, biaxially oriented fibers, reproduced fibers, polymeric fibers, natural fibers, natural particles, bioparticles, biofillers, etc. The skin 411 may have open cell structure to permit sound waves to travel into the core layer 110 to enhance sound absorption by a composite article including the core layer 110 and the skin 411. In other embodiments, the skin 411 can be a tape or layered tape comprising an arrangement of fibers. For example, the skin 411 can include a bi- directional arrangement of fibers or the skin 411 can include two or more individual tape layersHANAZD-707510 where fiber orientations in adjacent tape layers can be the same or can be different. In certain arrangements, fibers in the skin 411 can be randomly oriented, though if desired, the fibers in the skin 411 could be oriented in suitable directions, e.g., at 0 degrees, 15 degrees, 30 degrees, 45 degrees, 60 degrees, 75 degrees or 90 degrees, relative to a machine direction used to produce the thermoplastic composite articles. Different fibers may also be present with different orientations in the skin 411. If desired, the skin 411 can include liquid crystals which can be oriented in a desired manner to provide a desired optical effect.

[0116] In some embodiments, the skin 411 can be a film which includes a polymeric material. For example, polyolefin materials and / or polyolefin fibers optionally with water barrier additives including metals, amines, polyamines, amides, polyamides, fluoro compounds or other materials can be present in the skin 411. The skin 411 can include, for example, polyethylene, polypropylene, high density polyethylene, low density polyethylene and combinations and copolymers of these materials optionally in combination with a polyamide, a polyamide or both. The polyolefin materials can be present in skin 411 in fiber form, non-fiber form or a combination of fiber and non-fiber forms. If desired, commercially available barrier layers including Tyvek® material from Dupont, Typar from Fiberweb, James Hardie layers, Weathermate from Dow, Pinkwrap from Owens Corning, Protector Wrap, Poly-Wall Henry Blueskin, Benjamin Obdyke, CertaWrap, GreenGuard and Delta-Dry or other wraps or layers can be used as the skin 411. In other embodiments, the skin can include polyester materials and / or polyester fibers optionally with water barrier additives including metals, amines, polyamines, amides, polyamides, fluoro compounds or other materials. For example, the skin 411 can include polyethylene terephthalate optionally in combination with a polyamide, a polyamide or both. The polyester materials can be present in the skin 411 in fiber form, non-fiber form or a combination of fiber and non-fiber forms. In some configurations, the skin 411 can include other polymeric materials including, but not limited to, polycarbonates, polyimides, polyetheretherketone, nylon, cellulose acetate, vinyl acetate and fluoropolymers including, for example, polyvinylidene fluoride, polyvinylidene chloride, polychlorotrifluoroethylene, fluorinated ethylene polypropylene and ethylene tetrafluoroethylene.

[0117] In some embodiments, a coating, adhesive layer or other materials can be present between the skin 411 and the metal layer 415. Suitable materials include, but are not limited to, polyurethanes, acetates, hot melt coatings including acetates such as for example, vinyl acetates including ethylene-vinyl acetate, and coatings including mixtures of vinyl acetates and a polyolefin including polypropylene, polyethylene and co-polymers thereof.

[0118] In some configurations, a composite article can include a water barrier layer on one surface and a skin on another surface. Referring to FIG.5, a composite article 500 includes a porous coreHANAZD-707510 layer 110, a water barrier layer 510 on one surface of the porous core layer 110 and a skin 515 on an opposite or second surface of the porous core layer 110. The skin 515 typically does not include any metal, e.g., is metal free. The skin 515 can be, for example, a film (closed cell, open cell, perforated, etc.), a scrim, a frim (film + scrim), a foil, a woven fabric, a non-woven fabric or be present as an inorganic coating, an organic coating, or a thermoset coating. In other instances, the skin 515 may comprise a limiting oxygen index greater than about 22, as measured per ISO 4589 dated 1996. Where a fiber based scrim is present as (or as part of) the skin 515, the fiber based scrim may comprise at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metalized synthetic fibers, and metalized inorganic fibers. If desired, the scrim may comprise materials or fibers produced from one or more of the thermoplastic materials described above in connection with the core layers. Where a thermoset coating is present as (or as part of) the skin 515, the coating may comprise at least one of unsaturated polyurethanes, vinyl esters, phenolics and epoxies. Where an inorganic coating is present as (or as part of) the skin 515, the inorganic coating may comprise minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti and Al or may comprise at least one of gypsum, calcium carbonate and mortar. Where a non-woven fabric is present as (or as part of) the skin 515, the non-woven fabric may comprise a thermoplastic material, a thermal setting binder, inorganic fibers, metal fibers, metallized inorganic fibers and metallized synthetic fibers. If desired, the skin 515 may also comprise a lofting agent, an expandable graphite material, a flame retardant material, bicomponent fibers, biaxially oriented fibers, reproduced fibers, polymeric fibers, natural fibers, natural particles, bioparticles, biofillers, etc. The skin 515 may have open cell structure to permit sound waves to travel into the core 110 to enhance sound absorption by a Composite article including the core layer and the skin. Alternatively, the skin 515 may have a closed cell structure. The water barrier layer 510 can be any of those metals described in reference to the water barrier layer 115. The water barrier layer 510 is generally continuous across the first surface of the core 110 to function as a water barrier layer. In other embodiments, the skin 510 can be a tape or layered tape comprising an arrangement of fibers. For example, the skin 515 can include a bi-directional arrangement of fibers or the skin 515 can include two or more individual tape layers where fiber orientations in adjacent tape layers can be the same or can be different. In certain arrangements, fibers in the skin 515 can be randomly oriented, though if desired, the fibers in the skin 515 could be oriented in suitable directions, e.g., at 0 degrees, 15 degrees, 30 degrees, 45 degrees, 60 degrees, 75 degrees or 90 degrees, relative to a machine direction used to produce the thermoplastic composite articles. Different fibers may also be present with different orientations in the skin 515. If desired, the skin 515 can include liquid crystals which can be oriented in a desired manner to provide a desired optical effect.HANAZD-707510

[0119] In certain embodiments, a composite article can include more than one skin either or both of which can function as a water barrier layer. Referring to FIG. 6, a composite article 600 is shown that comprises a porous core layer 110, a skin 615 with an optional metal layer that functions as a water barrier layer and a second skin 616 on an opposite surface of the core. In this illustration, the skin 616 is not intended to function as a water barrier layer but, if desired, the skin 616 could be a metallized skin or be a skin combined with a separate metal layer. The skins 615, 616 can have the same or different thicknesses and / or basis weights. In some embodiments, the skin 616 can be selected to enhance adherence of the composite article 600 to an underlying support structure. For example, the skin 616 can be an adhesive skin or may be a skin designed to facilitate receipt of an adhesive material to bond the composite article 600 to an underlying support structure as noted in more detail below. In an alternative arrangement, the skin 616 is facing outward away from the support structure and the skin 615 is adhered to the underlying support structure. Each of the skins 615, 616 can independently include, for example, a film (closed cell, open cell, perforated, etc.), a scrim, a frim (film + scrim), a foil, a woven fabric, a non-woven fabric or be present as an inorganic coating, an organic coating, or a thermoset coating. In other instances, one or both of the skins 615, 616 may comprise a limiting oxygen index greater than about 22, as measured per ISO 4589 dated 1996. Where a fiber based scrim is present as (or as part of) one or both of the skins 615, 616, the fiber based scrim may comprise at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metalized synthetic fibers, and metalized inorganic fibers. If desired, the scrim may comprise materials or fibers produced from one or more of the thermoplastic materials described above in connection with the core layers. Where a thermoset coating is present as (or as part of) one or both of the skins 615, 616, the coating may comprise at least one of unsaturated polyurethanes, vinyl esters, phenolics and epoxies. Where an inorganic coating is present as (or as part of) one or both of the skins 615, 616, the inorganic coating may comprise minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti and Al or may comprise at least one of gypsum, calcium carbonate and mortar. Where a non-woven fabric is present as (or as part of) one or both of the skins 615, 616, the non-woven fabric may comprise a thermoplastic material, a thermal setting binder, inorganic fibers, metal fibers, metallized inorganic fibers and metallized synthetic fibers. If desired, one or both of the skins 615, 616 may also comprise a lofting agent, an expandable graphite material, a flame retardant material, bicomponent fibers, biaxially oriented fibers, reproduced fibers, polymeric fibers, natural fibers, natural particles, bioparticles, biofillers, etc. One or both of the skins 615, 616 may have open cell structure to permit sound waves to travel into the core 105 to enhance sound absorption by a composite article including the core layer 110 and the skins 615, 616. Alternatively, one or both of the skins 615, 616 may have a closed cellHANAZD-707510 structure. The metal on the skin 615 is typically present at a significantly lower thickness than the underlying skin material. The metal (when present) of the skin 615 can be any of those metals described in reference to the water vapor barrier layer 115. The metal layer on the skin 615 can be continuous across the top surface of the core 105 to function as a water vapor barrier layer. In other embodiments, each of the skins 615, 616 can independently be a tape or layered tape comprising an arrangement of fibers. For example, one or both of the skins 615, 616 can include a bi-directional arrangement of fibers or the skins 615, 616 can include two or more individual tape layers where fiber orientations in adjacent tape layers can be the same or can be different. In certain embodiments, fibers in the skins 615, 616 can be randomly oriented, though if desired, the fibers in the skins 615, 616 could be oriented in suitable directions, e.g., at 0 degrees, 15 degrees, 30 degrees, 45 degrees, 60 degrees, 75 degrees or 90 degrees, relative to a machine direction used to produce the thermoplastic composite articles. Different fibers may also be present with different orientations in the skins 615, 616. If desired, the skins 615, 616 can include liquid crystals which can be oriented in a desired manner to provide a desired optical effect. If desired, any metal layer / coating of the skin 615 could be arranged adjacent to the core layer 110.

[0120] In certain configurations, a composite article can include a porous core layer in combination with two or more water barrier layers. Referring to FIG. 7, a composite article 700 comprises a porous core layer 110, a first water barrier layer 710 and a second water barrier layer 711. The first water barrier layer 710 and the second water barrier layer 711 can be the same or can be different. In some instances, the water barrier layers 710, 711 can include the same materials but have different thicknesses. Each of the water barrier layers 710, 711 can be deposited directly on the porous core layer 110 or can be present on a support layer as noted in reference to FIGS. 2-4. Alternatively, an area of the core 110 adjacent to where the metal layers 710, 711 are present may have a reduced porosity or be fully consolidated to assist in retaining the deposited material on the surface of the core 110. The water barrier materials of the layers 710, 711 can be any of those materials described in reference to the water barrier layer 115. At least one of the water barrier layers 710, 711 can be continuous across the surface of the core 110. One of the water barrier layers 710, 711 may be discontinuous if desired. In other configurations, one of the water barrier layers 710, 711 is continuous across the surface of the core 110 to function as a water vapor barrier layer and the other water barrier layer is discontinuous to permit water vapor to pass into and out of the composite article 700. In some embodiments, each of the layers 710, 711 can independently be a tape or layered tape comprising an arrangement of fibers. For example, one or both of the layers 710, 711 can include a bi-directional arrangement of fibers or the layers 710, 711 can include two or more individual tape layers where fiber orientations in adjacent tape layers can be the same or can be different. In certain embodiments, fibers in the layers 710, 711 can beHANAZD-707510 randomly oriented, though if desired, the fibers in the layers 710, 711 could be oriented in suitable directions, e.g., at 0 degrees, 15 degrees, 30 degrees, 45 degrees, 60 degrees, 75 degrees or 90 degrees, relative to a machine direction used to produce the thermoplastic composite articles. Different fibers may also be present with different orientations in the layers 710, 711. If desired, the layers 710, 711 can include liquid crystals which can be oriented in a desired manner to provide a desired optical effect. In some embodiments, one or both of the layers 710, 711 can include a metal layer / coating if desired.

[0121] In other configurations, a composite article can include a core layer, a skin layer and two or more water barrier layers. Referring to FIG.8, a composite article 800 comprises a porous core layer 110, a skin 810, a first water barrier layer 815 on the skin layer 810 and a second water barrier layer 816 on another surface of the core 110. The skin 810 can be, for example, a film (closed cell, open cell, perforated, etc.), a scrim, a frim (film + scrim), a foil, a woven fabric, a non-woven fabric or be present as an inorganic coating, an organic coating, or a thermoset coating. In other instances, the skin 810 may comprise a limiting oxygen index greater than about 22, as measured per ISO 4589 dated 1996. Where a fiber based scrim is present as (or as part of) the skin 810, the fiber based scrim may comprise at least one of glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metalized synthetic fibers, and metalized inorganic fibers. If desired, the scrim may comprise materials or fibers produced from one or more of the thermoplastic materials described above in connection with the core layers. Where a thermoset coating is present as (or as part of) the skin 810, the coating may comprise at least one of unsaturated polyurethanes, vinyl esters, phenolics and epoxies. Where an inorganic coating is present as (or as part of) the skin 810, the inorganic coating may comprise minerals containing cations selected from Ca, Mg, Ba, Si, Zn, Ti and Al or may comprise at least one of gypsum, calcium carbonate and mortar. Where a non-woven fabric is present as (or as part of) the skin 810, the non-woven fabric may comprise a thermoplastic material, a thermal setting binder, inorganic fibers, metal fibers, metallized inorganic fibers and metallized synthetic fibers. If desired, the skin 810 may also comprise a lofting agent, an expandable graphite material, a flame retardant material, bicomponent fibers, biaxially oriented fibers, reproduced fibers, polymeric fibers, natural fibers, natural particles, bioparticles, biofillers, etc. The skin 810 may have open cell structure to permit sound waves to travel into the core 110 to enhance sound absorption by a composite article including the core layer and the skins. Alternatively, the skin 810 may have a closed cell structure. The water barrier layer 815 on the skin 810 can be any of those water barrier layers described in reference to water barrier layer 115 or the water barrier layer 210 or 410 or the other water barrier layers described herein. The water barrier layer 816 can be any of those water barrier layers described in reference to water barrier layer 115 or the water barrier layer 210 orHANAZD-707510 410 or the other water barrier layers described herein. In some embodiments, the water barrier layers 815, 816 are the same, whereas in other embodiments the water barrier layers 815, 816 are different. The water barrier layer 815 is typically present at a significantly lower thickness than the underlying skin 810. In some embodiments, the skin 810 and / or each of the layers 815, 816 can independently be a tape or layered tape comprising an arrangement of fibers. For example, the skin 810 and / or one or both of the layers 815, 816 can include a bi-directional arrangement of fibers or can include two or more individual tape layers where fiber orientations in adjacent tape layers can be the same or can be different. In certain embodiments, fibers in the skin 810 and / or layers 815, 816 can be randomly oriented, though if desired, the fibers in the skin 810 and / or layers 815, 816 could be oriented in suitable directions, e.g., at 0 degrees, 15 degrees, 30 degrees, 45 degrees, 60 degrees, 75 degrees or 90 degrees, relative to a machine direction used to produce the thermoplastic composite articles. Different fibers may also be present with different orientations in the skin 810 and / or layers 815, 816. If desired, the skin 810 and / or the layers 815, 816 can include liquid crystals which can be oriented in a desired manner to provide a desired optical effect.

[0122] In some embodiments, a composite article can include two or more core layers in combination with a water barrier layer. Referring to FIG. 9, a composite article 900 comprises a first core layer 110, a second core layer 906 and a water barrier layer 910 disposed on the second core layer 906. The first core layer 110 and the second core layer 906 can be the same or can be different. Further, one or more skins or support layers may be present between the water barrier layer 910 and the core layer 906. The water barrier layer 910 can include any of those materials described in reference to the water barrier layer 115. If desired, one or more skins can be present between the core layers 110, 906. The core layer 110 can receive a skin on a surface opposite of where the barrier layer 910 is placed, e.g., a film, scrim, decorative layer or other materials that may face into an interior space of a house, modular housing, building or a vehicle can be present on the core layer 110. The water barrier layer 910 is typically continuous across the surface of the core 110 to function as a water barrier layer.

[0123] In certain embodiments, a composite article can include a water barrier layer between two core layers. Referring to FIG. 10, a composite article 1000 comprises a first core layer 110, a second core layer 906 and a water barrier layer 1010 between the first core layer 110 and the second core layer 906. The first core layer 110 and the second core layer 906 can be the same or can be different. Further, one or more skins may be present between the water barrier layer 1010 and the core layer 110 or between the water barrier layer 1010 and the core layer 906. The water barrier layer 1010 can include any of those materials described in reference to the water barrier layer 115. One of the core layer 110, 906 can adhere to an underlying support structure and mayHANAZD-707510 optionally include a film, scrim, frim, adhesive or other materials on the surface that attaches to the underlying support structure. The other core layer can receive a film, scrim, decorative layer or other materials that may face into an interior space of a house, modular housing, building or a vehicle. The water barrier layer 1010 is continuous across the surface of the cores 110, 906 to function as a water barrier layer.

[0124] In certain embodiments, a composite article can include a decorative layer on a surface of the composite article. Referring to FIG.11, a composite article 1100 comprises a core 110, a water barrier layer 1110 on a first surface of the core 110 and a decorative layer 1130 on a second surface of the core 1110. The water barrier layer 1110 can include any of those materials described in reference to water barrier layer 115 or the water barrier layer 210 or 410 or the other water barrier layers described herein. The decorative layer 1130 can be a fabric, film, scrim, a paper, a textured film, an embossed film or other additional materials that generally face toward the interior of the building or vehicle. If desired, the decorative layer can include some open cell structure to permit sound waves to pass from the interior compartment into the composite article. The decorative layer 1130 can also include a printable surface so ink or other materials can be deposited onto it using a 3D printer or other printing devices.

[0125] In certain embodiments, the water barrier layers described herein can be textured or embossed to provide some “depth” that can enhance bonding of the water barrier layer to an underlying support structure. An illustration is shown in FIG.12, where a water barrier layer 1210 is shown as including some peaks and valleys. The water barrier layer 1210 can include any of those materials described in reference to the water barrier layer 115.

[0126] In certain embodiments, the porous core layers described herein generally comprise a web of open cell structures formed by reinforcing materials held together with a thermoplastic material. The web can be formed from a random crossing over of reinforcing materials, e.g., reinforcing fibers, which are held in place by the thermoplastic material. The porous core layers described herein are generally produced as planar sheets or articles that comprise the web of open cell structures formed by reinforcing materials held together with a thermoplastic material.

[0127] In certain embodiments, the reinforcing materials of the porous core layers may be reinforcing fibers, whiskers or other materials that can impart some reinforcement to the composite articles. The porous core layers typically comprise a substantial amount of open cell structure such that void space is present in the core layer. In some instances, the porous core layer may comprise a void content or porosity of 0-30%, 10-40%, 20-50%, 30-60%, 40-70%, 50-80%, 60-90%, 0-40%, 0-50%, 0-60%, 0-70%, 0-80%, 0-90%, 10-50%, 10-60%, 10-70%, 10-80%, 10- 90%, 10-95%, 20-60%, 20-70%, 20-80%, 20-90%, 20-95%, 30-70%, 30-80%, 30-90%, 30-95%, 40-80%, 40-90%, 40-95%, 50-90%, 50-95%, 60-95% 70-80%, 70-90%, 70-95%, 80-90%, 80-HANAZD-707510 95% or any illustrative value within these exemplary ranges. The overall thickness of the core layer is typically below 20 mm, 15 mm or even 10 mm to minimize the thickness and / or weight of the porous core layer when used in a multi-component assembly, though thicker core layers can also be used if desired.

[0128] In certain embodiments, the thermoplastic material used to form the porous core layers described herein may include one or more of a polyolefin (e.g., one or more of polyethylene, polypropylene, etc.), polystyrene, acrylonitrylstyrene, butadiene, polyethyleneterephthalate, polybutyleneterephthalate, polybutylenetetrachlorate, and polyvinyl chloride, both plasticized and unplasticized, and blends of these materials with each other or other polymeric materials. Other suitable thermoplastics include, but are not limited to, polyarylene ethers, polycarbonates, polyestercarbonates, thermoplastic polyesters, polyimides, polyetherimides, polyamides, co- polyamides, acrylonitrile-butylacrylate-styrene polymers, amorphous nylon, polyarylene ether ketone, polyphenylene sulfide, polyaryl sulfone, polyether sulfone, liquid crystalline polymers, poly(1,4 phenylene) compounds commercially known as PARMAX®, high heat polycarbonate such as Bayer's APEC® PC, high temperature nylon, and silicones, as well as copolymers, alloys and blends of these materials with each other or other polymeric materials. The thermoplastic material used to form the porous core layer can be used in powder form, resin form, rosin form, particle form, fiber form or other suitable forms. Illustrative thermoplastic materials in various forms are described herein and are also described, for example in U.S. Publication Nos. 20130244528 and US20120065283. The exact amount of thermoplastic material present in the core layer can vary and illustrative amounts range from 20% by weight or more, e.g., 20 % to 80% by weight or 25% to 80% by weight or 35% to 75% by weight or 40% to 70% by weight or 45% to 65% by weight of 45% to 60% by weight based on the weight of the porous core layer. It will be recognized by the skilled person that the weight percentages of all materials used in the porous core layer will add to 100 weight percent. The thermoplastic material can include virgin materials, recycled or reproduced materials or both. For example, the thermoplastic material can include recycled thermoplastic material to increase the sustainability of the LWRT composite articles including the porous core layer. In some instances, a combination of virgin and recycled thermoplastic material together can be present in the porous core layer. For example, virgin polyolefin (e.g., polypropylene, polyethylene, etc.) can be used in combination with recycled polyolefin (e.g., polypropylene, polyethylene, etc.) to provide the total content of thermoplastic material in the porous core layer. Where multiple different thermoplastic materials are present in the core layer, the total amount of thermoplastic material is desirably 20% by weight or more, e.g., 20 % to 80% by weight or 25% to 80% by weight or 35% to 75% by weight or 40% to 70% by weight or 45% to 65% by weight of 45% to 60% by weight based on the weight of the porous coreHANAZD-707510 layer.. For example, where polypropylene and polyethylene are present in the porous core layer, the polypropylene can be present from 15% by weight to 70% by weight and the polyethylene can be present at least at 5% by weight or at least 10% by weight or at least 15% by weight or 20% by weight or at least at 30% by weight, so the amount of polypropylene and polyethylene together account for the total amount of thermoplastic material in the core layer.

[0129] In certain embodiments, the reinforcing materials of the core layers described herein may comprise glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, particularly high modulus organic fibers such as, for example, para- and meta-aramid fibers, nylon fibers, polyester fibers, a high melt flow index resin fiber (e.g., 100 g / 10 min. MFI or above), mineral fibers such as basalt, mineral wool (e.g., rock or slag wool), wollastonite, alumina silica, and the like, or mixtures thereof, metal fibers, metalized natural and / or synthetic fibers, ceramic fibers, yarn fibers, or mixtures thereof. In other embodiments, the core layers can include reproduced polymeric fibers, bi-component fibers, e.g., sheath-core fibers, or fibers produced from recycled materials. In some embodiments, any of the aforementioned fibers can be chemically treated prior to use to provide desired functional groups or to impart other physical properties to the fibers, e.g., may be chemically treated so that they can react with the thermoplastic material, the lofting agent or both. The fiber content in the core layers may independently be from about 20% to about 70% by weight of the core layer, more particularly from about 30% to about 70%, by weight of the core layer or 30% by weight to 65% by weight of the core layer or 30% by weight to 60% by weight of the core layer. The particular size and / or orientation of the fibers used may depend, at least in part, on the thermoplastic material used and / or the desired properties of the core layer. In one non-limiting illustration, fibers dispersed within a thermoplastic material and optionally other additives to provide the core layers can generally have a diameter of greater than about 5 microns, more particularly from about 5 microns to about 22 microns, and a length from about 5 mm to about 200 mm, more particularly, the fiber diameter may be from about 2 microns to about 22 microns and the fiber length may be from about 5 mm to about 75 mm.

[0130] In certain arrangements, reinforcing fibers in the core layer are typically randomly oriented, though if desired, the fibers in the core layer could be oriented in suitable directions, e.g., at 0 degrees, 15 degrees, 30 degrees, 45 degrees, 60 degrees, 75 degrees or 90 degrees, relative to a machine direction used to produce the thermoplastic composite articles. Different fibers may also be present with different orientations in the porous core layer.

[0131] In other embodiments, other additives may also be present in the core layer comprising the thermoplastic resin and the reinforcing materials. For example, a lofting agent, flame retardants, colorants, smoke suppressants, surfactants, foams or other materials may be present in the core layer. If desired, recycled materials, biomaterials, bioparticles, ground natural material or otherHANAZD-707510 sustainable materials can be included in the core layers. In some examples, the core layer may be a substantially halogen free or halogen free core layer to meet the restrictions on hazardous substances requirements for certain applications. In other instances, the core layer may comprise a halogenated flame retardant agent such as, for example, a halogenated flame retardant that comprises one of more of F, Cl, Br, I, and At or compounds that including such halogens, e.g., tetrabromo bisphenol-A polycarbonate or monohalo-, dihalo-, trihalo- or tetrahalo- polycarbonates. In some instances, the thermoplastic material used in the core layer may comprise one or more halogens to impart some flame retardancy without the addition of another flame retardant agent. Where halogenated flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the halogenated flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the core layer), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent based on the weight of the core layer. If desired, two different halogenated flame retardants may be added to the layers. In other instances, a non-halogenated flame retardant agent such as, for example, a flame retardant agent comprising one or more of N, P, As, Sb, Bi, S, Se, and Te can be added. In some embodiments, the non-halogenated flame retardant may comprise a phosphorated material so the layers may be more environmentally friendly. Where non- halogenated or substantially halogen free flame retardants are present, the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present. For example, the substantially halogen free flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent based on the weight of the core layer. If desired, two different substantially halogen free flame retardants may be added to one or more of the core layers described herein. In certain instances, one or more of the core layers described herein 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 a flame retardant amount, which can vary depending on the other components which are present. For example, the total weight of flame retardants present may be about 0.1 weight percent to about 20 weight percent (based on the weight of the layer), more particularly about 1 weight percent to about 15 weight percent, e.g., about 2 weight percent to about 14 weight percent based on the weight of the core layer. The flame retardant agents used in the layers described herein can be added to the mixture comprising the thermoplastic material and reinforcing materials (prior to disposal of the mixture on a wire screenHANAZD-707510 or other processing component) or can be added after the web / core layer is formed. In some examples, the flame retardant material may comprise one or more of expandable graphite materials, magnesium hydroxide (MDH) and aluminum hydroxide (ATH).

[0132] In certain embodiments, the exact basis weight of the porous core layer may vary depending on the materials present and thickness. For example, the core layer may have a basis weight of 300 grams / m2(gsm) up to 3000 gsm. Depending on the particular water barrier layers and / or skin layers which are used, the composite article may have a basis weight of 310 gsm up to 3500 gsm. The thickness of the core layer can vary from about 1 mm to about 20 mm, more particularly about 2 mm to about 15 mm or 3 mm to about 15 mm or 4 mm to about 15 mm or 5 mm to about 15 mm. The composite article is generally thicker than the core layer even though very thin water barrier layers and / or skins may add negligible thickness to the overall composite article thickness.

[0133] In certain embodiments, the composite articles described herein can be present in a panel assembly or wall assembly of a building, a vehicle or other structures. For example, the wall assembly can be present in a house, a commercial building, a recreational vehicle, a shed or be present in a panel assembly which can attach to a frame of the building, vehicle or other structure. Referring to FIG. 13, a composite panel 1300 is shown as being coupled to a framing member 1350. The composite panel 1300 includes a porous core layer 110 and a water barrier layer 1310. In this arrangement, the water barrier layer 1310 is facing and adjacent to the framing member 1350. The framing member 1350 can be wood, e.g., wood studs, a wood panel, etc., aluminum, steel, polymeric or other materials. The water barrier layer 1310 is generally continuous and functions as a water barrier layer to permit transmission of at least some water vapor. While not shown, one or more skins can be present between the core layer 110 of the panel 1300 and the water barrier layer 1310. Alternatively, an adhesive layer (not shown) can be present between the water barrier layer 1310 and the framing member 1350. If desired, a decorative layer may be present on an opposite surface of the core layer 110 and positioned to face an interior space of building or vehicle formed, at least in part, by the framing member 1350. While the exact attachment method of the panel 1300 to the framing member 1350 may vary, suitable methods and materials include nails, screws, adhesives and combinations thereof. Where the water barrier layer 1310 includes a metal layer / coating, the metal layer / coating can be placed adjacent to the core layer 110 or adjacent to the framing member 1350 as desired. Further, water barrier additives can be present between the composite panel 1300 and the framing member 1350.

[0134] In certain embodiments, the water barrier layer may face away from the framing member. Referring to FIG. 14, a composite panel 1400 is shown as being coupled to a framing member 1450. The composite panel 1400 includes a porous core layer 110 and a water barrier layer 1410.HANAZD-707510 In this arrangement, the water barrier layer 1410 is facing toward an interior space. The framing member 1450 can be wood, e.g., wood studs, a wood panel, etc., aluminum, steel, polymeric or other materials. The water barrier layer 1410 is generally continuous and functions as a water barrier layer to permit transmission of at least some water vapor. While not shown, one or more skins can be present between the core layer 110 of the panel 1400 and the framing member 1450. If desired, a decorative layer may be present on the water barrier layer 1410 and positioned to face an interior space of building or vehicle formed, at least in part, by the framing member 1450. While the exact attachment method of the panel 1400 to the framing member 1450 may vary, suitable methods and materials include nails, screws, adhesives and combinations thereof. Where the water barrier layer 1410 includes a metal layer / coating, the metal layer / coating can be placed adjacent to the core layer 110 surface or a support layer or other material may be present between the metal layer / coating and the core layer surface. Further, water barrier additives can be present between the composite panel 1400 and the framing member 1450.

[0135] In certain embodiments, a first water barrier layer may face away from the framing member and a second water barrier layer can face toward and be adjacent to the framing member. Referring to FIG. 15, a composite panel 1500 is shown as being coupled to a framing member 1550. The composite panel includes a porous core layer 110, a first water barrier layer 1510 and a second water barrier layer 1511. In this arrangement, the water barrier layer 1510 is facing toward an interior space. The water barrier layer 1511 is facing and adjacent to the framing member 1550. The framing member 1550 can be wood, e.g., wood studs, a wood panel, etc., aluminum, steel, polymeric or other materials. Each of the water barrier layers 1510, 1511 can generally be continuous and function to permit transmission of at least some water vapor. While not shown, one or more skins can be present between the core layer 110 of the panel 1500 and the framing member 1550 or on a surface facing toward the interior space. Alternatively, one of the water barrier layers 1510, 1511 could be replaced with a skin. Further, a decorative layer may be present on the water barrier layer 1510 and positioned to face an interior space of building or vehicle formed, at least in part, by the framing member 1550. While the exact attachment method of the panel 1500 to the framing member 1550 may vary, suitable methods and materials include nails, screws, adhesives and combinations thereof.

[0136] In certain embodiments, a discontinuous water barrier layer may face away from the framing member and a second water barrier layer can face toward and be adjacent to the framing member. Referring to FIG. 16, a composite panel 1600, which includes a porous core layer 110, a water barrier layer 1611 and another water barrier layer 1610, is shown as being coupled to a framing member 1650. In this arrangement, a discontinuous water barrier layer 1610 is facing toward an interior space. A continuous water barrier layer 1611 is facing and adjacent to theHANAZD-707510 framing member 1650. The arrangement of the layers 1610, 1611 can be switched of desired. The framing member 1650 can be wood, e.g., wood studs, a wood panel, etc., aluminum, steel, polymeric or other materials. The layer 1611 can function as a water vapor barrier layer, and the layer 1610 can inhibit water transmission to some degree while still permitting entry of sound waves into the core layer 110. While not shown, one or more skins can be present between the core layer 110 of the panel 1600 and the framing member 1650 or on a surface facing toward the interior space. If desired, a decorative layer may be present on the layer 1610 and positioned to face an interior space of building or vehicle formed, at least in part, by the framing member 1650. While the exact attachment method of the panel 1600 to the framing member 1650 may vary, suitable methods and materials include nails, screws, adhesives and combinations thereof.

[0137] In certain embodiments, the composite articles with a barrier layer can be produced using an in-line process Certain steps of the process, and the various materials used / produced by each step, are shown by way of the block diagram in FIG. 17. A core layer is prepared by combining a thermoplastic material (TP), e.g., a thermoplastic resin and reinforcing materials (RM) to form a dispersion or mixture 1702. This mixture can then be deposited onto a suitable moving support to provide a web 1704 formed by the reinforcing materials and the thermoplastic resin. The resulting web can include open cell structures of reinforcing materials, e.g., fibers, held in place by the thermoplastic material. The resulting web can be heated and dried to soften or melt the thermoplastic resin and form a porous core layer 1706. In certain embodiments, a material, e.g., water barrier material, can then be deposited onto a surface of the porous core layer 1706 or, as noted below, can be applied in the form of a water barrier skin. In instances where water barrier material is sprayed or deposited onto the core layer, the skin mentioned below can be omitted. Alternatively, one or more pre-configured skin layers which include suitable materials for the skin to function as a water barrier can be applied to a surface of the formed and heated porous core layer. For example, a film, scrim or frim that can function as a water barrier layer can be applied to form a lightweight fiber reinforced thermoplastic (LWRT) composite article 1708. The resulting article, which is typically in sheet form, can be cooled and consolidated, if desired, and can be used as part of a panel or other structure to provide a final article. For example, the articles 1710 on the moving support can be cut to provide individual LWRT composite articles 1712 which can be stacked or palletized for shipping. In some embodiments, the LWRT composite article is used “as-produced” to avoid any change in thickness of the LWRT composite article. Various illustrations of process conditions, steps and materials are described in more detail below.

[0138] As shown in FIG. 18, a thermoplastic material can be present in a reservoir 1802 and reinforcing fibers (or other reinforcing materials) can be present in a second reservoir 1804. Each of the thermoplastic material and the reinforcing fibers can be metered, sprayed, or otherwiseHANAZD-707510 introduced into an aqueous solution in a mixing tank 1806 comprising water, a liquid or an aqueous solution. If desired, a foam or other additives (as discussed below) may be present in the mixing tank 1806. The thermoplastic material and reinforcing fibers can be mixed for a suitable time and at a suitable temperature to provide a substantially homogenous aqueous dispersion of the fibers and the thermoplastic material. For example, the materials may be mixed at room temperature, e.g., about 25 deg. Celsius, or above room temperature or below room temperature by heating or cooling the mixing tank. In some embodiments, the materials can be added continuously into the mixing tank 1806 to permit continuous deposition of the dispersion onto a moving support as noted below. While the exact mixing time may vary depending on the materials used, illustrative mixing times include 10 seconds to about 10 minutes, more particularly about 30 seconds to about 5 minutes. As noted above, however, in instances where the materials are continuously added to the mixing tank 1806, mixing is performed constantly. The mixing tank 1806 can include a paddle mixer, an impeller or other devices to facilitate mixing. Where the produced core layer is intended to be colored, an ink or other colorant can be added to the mixing tank 1806.

[0139] In certain embodiments and referring to FIG. 19, the dispersion in the mixing tank 1806 can be sprayed, dripped or otherwise deposited onto a moving support 1910. While the moving support 1910 is shown as a single segment in certain figures depicted herein, the moving support 1910 could be broken up into two or more individual segments as desired. The moving support generally moves in a “machine direction” with a “cross-direction” being perpendicular to the machine direction. The mixing tank 1806 can be fluidically coupled to a plurality of spray heads 1902 that can spray the dispersion onto a surface of the moving support 1910. As shown in the top view of FIG. 20, the moving support 1910 can be porous or include a mesh that can receive the dispersion. If desired, the moving support may contain levels or be three-dimensional to impart a desired non-flat shape to the porous core layer. The exact deposition rate used may vary depending on the amount of material to be deposited per square meter. The moving support 1910 may move at a continuous and constant speed to permit continuous spraying of the dispersion along a top surface of the moving support 1910. The area of the moving support 1910 under the spray heads may be heated, cooled or present at room temperature during deposition of the dispersion. As noted below, different areas of the moving support 1910 may have different temperatures. The exact dimensions of the moving support 1910 can vary and typically the moving support is about 4 feet wide and can include a mesh or pore size of about 40 openings / square inch to about 80 openings / square inch of moving support 1910. The moving support 1910 permits receipt of the dispersion and movement of the received dispersion to additional sites or stations of the in-line system. For example, after formation of the core layer onHANAZD-707510 the moving support, a skin with a metal layer can be added in an automated manner on a surface of the formed core layer. At the end of the moving support 1910, the formed LWRT composite articles can be cut and stacked. The moving support 1910 permits continuous formation of LWRT composite articles. In certain embodiments, the moving support 1910 can be split into two or more separate sections or segments. For example, a wet mat can be formed on a former belt and then transferred, e.g., manually or automatically, onto a separate dryer belt where it can pass through an oven or other drying device. Alternatively, the formed porous core layer 1910 can be transferred to a second belt. In another configuration, the formed porous core layer 1910 can be transferred into a mold that is configured to impart three-dimensional shapes to the porous core layer. One or more skin layers or decorative layers can be added to the porous core layer before or after molding as desired.

[0140] In certain embodiments and referring to FIG. 21, the moving support 1910 with the dispersion of the thermoplastic material and reinforcing fibers can migrate to a drying device 2110. The drying device 2110 can provide heat and / or a negative pressure (vacuum) to remove the water from the web 2102 on the moving support and leave behind the reinforcing fibers and the thermoplastic material on the moving support 2110. This process can form a core layer 2212 (see FIG. 22) with a high porosity that includes open cell structures formed from the reinforcing materials that are held in place by the thermoplastic material. If desired, other materials may also be present in the core layer or sprayed onto the core layer 2212. For example, an adhesive from a reservoir can be sprayed on a surface of the formed core layer 2212. The exact temperature used to heat the web 2102 and / or core layer 2212 may vary and desirably the temperature is above a melting point of the thermoplastic material and below a melting point of the reinforcing materials. In some examples, the moving support itself 1910 can be heated, whereas in other examples the drying device 2110 can include a heating element or be configured as an oven or other heating devices. If desired, the drying device 2110 and the moving support 1910 can both provide heat to the web 2102 on the moving support 1910. In some instances, the moving support 1910 can include a thermally conductive material that can retain the heat from the drying device 2110 to assist in maintaining the core layer 2212 in a softened form during application of skin layers or other materials. In some examples, a pressure device 2320 separate from the drying device 2110 may be present (see FIG.23). For example, a vacuum may be applied to the web 2102 to remove water from the web and leave behind the reinforcing materials and the thermoplastic material. The pressure device 2320 is typically upstream of the drying device 2110 and is designed to remove at least 40% by volume of the water from the web 2102, more particularly about 60% by volume of the water from the web 2102. If desired, another pressure device (not shown) can be downstream of the pressure device 2320.HANAZD-707510

[0141] In certain embodiments, as the core layer 2312 exits the drying device 2110, one or more materials can be sprayed onto a surface of the core layer 2312. Referring to FIG. 24, a sprayer 2420 that is fluidically coupled to a material tank (not shown) can be used to apply a metal layer, water barrier additives, adhesive, coating or other material onto a surface of the core layer 2312. If desired, solid or semi-solid materials can be sprayed onto the surface of the core layer 2312. As the LWRT composite articles are produced, they can be cut and stacked for shipping.

[0142] In another embodiment, a skin can be applied to a surface of a core layer in an automated process. The skin can be a water barrier layer which permits water vapor transmission through the skin to at least some degree. Alternatively, the skin can include a pre-coated metal layer or a layer pre-coated with water barrier additives. Referring to FIG. 25, one or more skin layers 2610 can be applied to the core layer 2312. A skin layer 2610 is applied to a core layer 2312 as the core layer 2312 exits the moving support 1910 or remains moving along the moving support. For example, the skin layer 2610 may be present as a roll 2605 of skin layer material that is unrolled and applied in a continuous manner onto one surface of the core layer 2312. The material on the roll 2605 can be pre-conditioned or conditioned, e.g., adjusted to a specific humidity level, heated, etc., prior to application of the material from the roll 2605 to the core layer 2312. The skin layer and core layer may then be used in combination with a press 2710 (FIG. 26) to consolidate the composite article 2712 with a water barrier layer. A sprayer 2820 (FIG. 27) can be used to apply additional material on the skin layer 2610 if desired. For example, a water barrier additive can be sprayed onto a non-water barrier skin to provide a LWRT composite article with a skin that fan function to transmit a selected level of water vapor. If desired, s second skin 2915 (see FIG. 28) can be applied to another surface of the core layer 1910 as shown by skin 2920 being present on an opposite surface of the core layer 2312. The second skin 2920 can include a water barrier layer or not as desired.

[0143] In certain embodiments, the resulting LWRT composite article can be consolidated by applying pressure to the surfaces of the LWRT composite article. Consolidation typically occurs prior to formation of the final article. Consolidation can be performed using rollers, plates or other devices. If desired, consolidation can be performed prior to disposing the skin with metal layer on the core layer.

[0144] The exact methodology used to apply the water barrier additives onto the core layer and / or skin layer may vary. Illustrative methods include, but are not limited to, vapor deposition including physical vapor deposition and chemical vapor deposition, extrusion, inkjet printing, brushing, spray coating, electrodeposition or other techniques commonly used to apply thin layers to surfaces. As noted herein, the water barrier additives can be applied in an inline process or can be pre-applied to a skin which is then applied to a core layer using an inline or other processes.HANAZD-707510

[0145] In certain embodiments, the composite articles described herein can be present in caravans or recreational vehicles. Referring to FIG. 29, a recreational vehicle 2900 is shown that includes wheels (wheel 2950 is shown) and a vehicle housing 2960 on a frame 2970. The vehicle housing 2960 generally include wall assemblies, a floor and a roof which are coupled to each other to form an interior space. For example, a wall assembly comprises a plurality of individual framing members coupled to each other to form a wall frame, wherein each of the plurality of individual wall members comprises an interior facing surface and an exterior facing surface. A composite article as described herein can be coupled to the wall frame at the interior facing surface of the individual framing members. For example, the composite article comprises a porous core layer comprising a web of reinforcing materials held in place by a thermoplastic material and a water barrier layer coupled to a first surface of the porous core layer, wherein the water barrier layer is coupled to the interior facing surface of the individual framing members. If desired, a composite article could also be coupled to an exterior facing surface of the framing members. Any of those articles, and variations thereof, described in reference to FIGS. 1-12 can be used in a recreational vehicles. Further, in high humidity areas including kitchens and bathrooms, it may be desirable to include water vapor barriers on the walls in these areas with higher water vapor transmissions to facilitate movement of the water vapor out the interior space of the RV and to the outside. In such instances, materials used on external surfaces of the wall assembly can be selected to be water vapor permeable (at least to some degree) so water vapor does not become trapped within internal spaces within the wall assembly.

[0146] In certain embodiments, the composite articles described herein can be used in housing applications including modular housing, a static caravan or a mobile home. Referring to FIG.30, a modular home 3000 comprises a plurality of walls 3002, 3004, a floor (not shown), and a roof 3010 which together form an interior space within the modular home 3000. The modular home 3000 typically comprises a plurality of wall assemblies including individual framing members, e.g., wood studs or aluminum studs. Each of the plurality of individual framing members comprises an interior facing surface and an exterior facing surface. One or more of the composite articles described herein can be coupled to the wall frame at the interior facing surface of the individual framing members or at the exterior facing surface of the individual framing members (or both) if desired. As noted herein, the composite article generally includes a porous core layer comprising a web of reinforcing materials held in place by a thermoplastic material and a water barrier layer coupled to a first surface of the porous core layer, wherein the water barrier layer is coupled to the interior facing surface of the individual framing members. Any of those articles, and variations thereof, described in reference to FIGS. 1-12 can be used in a modular home or static caravans or a mobile home.HANAZD-707510

[0147] Certain specific examples are described to illustrate further some of the novel features of the technology.

[0148] Example 1

[0149] Two materials were produced with a first material (ST-15117) including a 105 gsm water barrier layer including a polyolefin skin layer with a metallized layer on the polyolefin skin layer. The water barrier layer was laminated to a first surface of a core layer. A second material (ST-2) including a frim (film+scrim) laminated to the first surface of the core layer was also tested. The core layer of each tested material had a basis weight of 960 gsm and included a 23 gsm black non- woven scrim on a second surface of each core layer. The core layer of ST-15117 included 48% by weight glass fibers, 32% by weight virgin polypropylene and 20% by weight regrind material including both glass fibers and polypropylene. The ST-2 material included 55% by weight glass fibers and 45% by weight polypropylene with no regrind material.

[0150] Each panel was glued to wood studs as shown in FIG. 31 using an adhesive. The water barrier layer or frim of the tested articles faced toward the wood studs. Water vapor transmission rates were measured for ST-15117 and for ST-2. The results are shown in Table 1 for different testing methodologies. Table 1The physical and mechanical properties of the ST-15117 sample were also measured as shown in Table 2.HANAZD-707510 Table 2

[0151] MD refers to the machine direction and CD refers to the cross direction. Top up refers to the water barrier layer being oriented as the top surface for testing, and bottom up refers to the 23 gsm black non-woven scrim being oriented as the top surface for testing. Cohesive failure within the water barrier layer was observed, but this failure is not believed to occur in the normal use environment of the water barrier layer. The tested results were consistent with the water barrier layer permitting a higher water vapor transmission rate (WVTR) than a conventional frim with the WVTR of ST-11517 being about 5X higher compared to the frim WVTR of ST-2.HANAZD-707510

[0152] Example 2

[0153] The samples of Example 1 were placed soaking / floating in water and tested for their ability to keep liquid from entering into the composite article. The test results are shown in Table 3. ASTM D779-16 (R2022) was used to measure liquid water resistance. Table 3Testing was discontinued at 24 hours for ST-2. Both samples exhibited liquid water resistance. The results demonstrate the ST-15117 provided good water vapor transmission rates but remains resistant to transport of liquid water. The combined properties demonstrate the water barrier layer

[0154] Example 3

[0155] A water barrier layer including a 26 gsm metallized polyester film was used to produce a composite article. The water barrier layer included ethylene vinyl-acetate (EVA) on top of a metal layer present on a polyethylene terephthalate film layer to provide the 26 gsm metallized polyester film. The water barrier layer was coupled to a first surface of a porous core layer (55% glass fibers / 45% polypropylene by weight) through the EVA coating on the metal layer, so the EVA material is present between the metal layer and the core layer. A 23 gsm repellent black scrim was present on a second surface of the porous core layer. The physical properties of the resulting composite article are shown in Table 4. The testing results demonstrate the water barrier layer construct is suitable for controlling water permeability through the composite article.HANAZD-707510 Table 4

[0156] Example 4

[0157] A water barrier layer including a 40 gsm metallized polyester film was used to produce a composite article. The water barrier layer included ethylene vinyl-acetate (EVA) on top of a metal layer present on a polyethylene terephthalate film layer to provide the 40 gsm metallized polyester film. The water barrier layer was coupled to a first surface of a porous core layer (55% glass fibers / 45% polypropylene by weight) through the EVA coating on the metal layer, so the EVA material is present between the metal layer and the core layer. A 23 gsm repellent black scrim was present on a second surface of the porous core layer. The physical properties of the resulting composite article are shown in Table 5. Top up refers to the water barrier layer being oriented as the top surface for testing, and bottom up refers to the 23 gsm scrim being oriented as the top surface for testing. The testing results demonstrate the water barrier layer construct is suitable for controlling water permeability through the composite article.HANAZD-707510 Table 5

[0158] Example 5

[0159] A wall assembly can be produced which includes framing members and a composite article on each side of the framing member. An illustration is shown in FIG. 32. The wall assembly includes a first composite article 3210, a framing member 3220 and a second composite article 3230. The first composite article 3210 is coupled to the framing member 3220 at an interior facing surface of the framing member 3220. The first composite article 3210 can include a porous core layer and a water barrier layer so the WVTR of the first composite article 3210 is less than 5 g / m2 / day as tested by ASTM E96-23. The second composite article 3230 is coupled to an exterior facing surface of the framing member 3220. The second composite article 3230 can include a porous core layer and a water barrier layer so the WVTR of the second composite article 3230 is 5 g / m2 / day or more as tested by ASTM E96-23. In a typical arrangement, the WVTR of the first composite article 3210 can be 1.5 g / m2 / day or less as tested by ASTM E96-23, and the WVTR of the second composite article 3230 can be 95 g / m2 / day or more as tested by ASTM E96-23. WhileHANAZD-707510 two composite articles are shown in FIG. 32, either composite article could be omitted if desired so the wall assembly only included a single composite article.

[0160] When introducing elements of the examples disclosed herein, the articles "a,” “an,” “the” and “said” are intended to mean that there are one or more of the 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. It will be recognized by the person of ordinary skill in the art, given the benefit of this disclosure, that various components of the examples can be interchanged or substituted with various components in other examples.

[0161] Although certain aspects, configurations, examples and embodiments have been described above, it will be recognized by the person of ordinary skill in the art, given the benefit of this disclosure, that additions, substitutions, modifications, and alterations of the disclosed illustrative aspects, configurations, examples and embodiments are possible.

Claims

HANAZD-707510 CLAIMS 1. A fiber reinforced thermoplastic composite article comprising: a porous core layer comprising a web formed from reinforcing materials held in place by a thermoplastic material; and a water barrier layer coupled to a first surface of the porous core layer, wherein the water barrier layer provides for a selected water vapor transmission rate through the water barrier layer or is resistant to movement of liquid water through the water barrier layer or both.

2. The fiber reinforced thermoplastic composite article of claim 1, wherein the water vapor transmission rate of the fiber reinforced thermoplastic composite article is at least 120g / m2 / day as tested by ASTM E96-23.

3. The fiber reinforced thermoplastic composite article of claim 1, wherein liquid water resistance of the fiber reinforced thermoplastic composite article is at least 800 minutes as tested by ASTM D779-16 (R2022).

4. The fiber reinforced thermoplastic composite article of claim 1, wherein the water vapor transmission rate of the fiber reinforced thermoplastic composite article is greater than 0 g / m2 / day and no more than 5 g / m2 / day as tested by ASTM E96-23.

5. The fiber reinforced thermoplastic composite article of claim 1, wherein the water barrier layer comprises a polyolefin material doped with a water barrier additive to resist movement of liquid water through the water barrier layer and permit transmission of water vapor from a first surface of the water barrier layer to a second surface of the water barrier layer.

6. The fiber reinforced thermoplastic composite article of claim 1, wherein the water barrier layer comprises spunbond polyolefin fibers.

7. The fiber reinforced thermoplastic composite article of claim 6, wherein the porous core layer comprises glass fibers as the reinforcing materials and polypropylene as the polyolefin thermoplastic material, and wherein the web is formed from random crossing over of the glass fibers held in place by the polyolefin thermoplastic material.HANAZD-707510 8. The fiber reinforced thermoplastic composite article of claim 1, wherein the water barrier layer comprises a polyamine, a polyamide or a polyester.

9. The fiber reinforced thermoplastic composite article of claim 1, wherein the porous core layer comprises glass fibers as the reinforcing materials and polypropylene as the polyolefin thermoplastic material.

10. The fiber reinforced thermoplastic composite article of claim 1, wherein the water barrier layer comprises a metal layer laminated to a support layer or a metal coating on the support layer.

11. The fiber reinforced thermoplastic composite article of claim 10, wherein the porous core layer comprises glass fibers as the reinforcing materials and polypropylene as the polyolefin thermoplastic material.

12. The fiber reinforced thermoplastic composite article of claim 1, wherein the water barrier layer comprises spunbond polyolefin fibers and at least one of a polyamine or a polyamide.

13. The fiber reinforced thermoplastic composite article of claim 1, wherein the water barrier layer comprises at least one of polyvinylidene chloride and polychlorotrifluoroethylene.

14. The fiber reinforced thermoplastic composite article of claim 1, wherein the water barrier layer comprises a first layer and a second layer, wherein the first layer comprises a different material than a material of the second layer, and wherein the water transmission vapor rate of the fiber reinforced thermoplastic composite article is at least 15 g / m2 / day as tested by ASTM E96- 23.

15. The fiber reinforced thermoplastic composite article of claim 1, further comprising a skin layer coupled to a second surface of the porous core layer.

16. The fiber reinforced thermoplastic composite article of claim 15, wherein the skin layer is permeable to water vapor.

17. The fiber reinforced thermoplastic composite article of claim 15, wherein the skin layer is an open cell insulation layer.HANAZD-707510 18. The fiber reinforced thermoplastic composite article of claim 17, wherein the skin layer comprises a tape layer comprising oriented fibers.

19. The fiber reinforced thermoplastic composite article of claim 1, further comprising an adhesive layer between the porous core layer and the water barrier layer, wherein the adhesive layer does not substantially alter a water vapor transmission rate of the fiber reinforced thermoplastic composite article.

20. The fiber reinforced thermoplastic composite article of claim 1, wherein the fiber reinforced thermoplastic composite article is cellulose free.

21. The fiber reinforced thermoplastic composite article of claim 1, wherein the water barrier layer comprises a metal layer or metal coating.

22. The fiber reinforced thermoplastic composite article of claim 21, wherein a water vapor transmission rate of the fiber reinforced thermoplastic composite article is greater than 0 g / m2 / day and no more than 1.5 g / m2 / day as tested by ASTM E96-23.

23. The fiber reinforced thermoplastic composite article of claim 22, wherein a liquid water resistance value of the fiber reinforced thermoplastic composite article provides is at least 800 minutes as tested by ASTM D779-16 (R2022).

24. The fiber reinforced thermoplastic composite article of claim 23, wherein the metal layer is a metal scrim or a metal film.

25. The fiber reinforced thermoplastic composite article of claim 23, wherein the metal layer is coupled to a non-metal support layer.

26. The fiber reinforced thermoplastic composite article of claim 1, wherein the water barrier layer comprises a basis weight of 5 g / m2to 175 g / m2.

27. The fiber reinforced thermoplastic composite article of claim 1, wherein the water barrier layer comprises a thickness of 4 microns to 150 microns.HANAZD-707510 28. The fiber reinforced thermoplastic composite article of claim 1, further comprising a barrier layer between the porous core layer and the water barrier layer.

29. The fiber reinforced thermoplastic composite article of claim 1, wherein the water vapor barrier comprises metal particles or comprises a film comprising metal particles.

30. The fiber reinforced thermoplastic composite article of claim 1, further comprising a closed cell skin on a second surface of the porous core layer.

31. A wall assembly comprising: a plurality of individual framing members coupled to each other to form a wall frame, wherein each of the plurality of individual framing members comprises an interior facing surface and an exterior facing surface; and a composite article coupled to the wall frame at one of the interior facing surface of the individual framing members or the exterior facing surface of the individual framing members, wherein the composite article comprises a porous core layer comprising a web formed from reinforcing materials held in place by a thermoplastic material, and a water barrier layer coupled to a first surface of the porous core layer, wherein the water barrier layer provides for a selected water vapor transmission rate through the water barrier layer or is resistant to movement of liquid water through the water barrier layer or both.

32. The wall assembly of claim 31, wherein the water barrier layer is coupled to the interior facing surface of the individual framing members.

33. The wall assembly of claim 31, wherein the water barrier layer provides a water vapor transmission rate of at least 15 g / m2 / day as tested by ASTM E96-23.

34. The wall assembly of claim 31, wherein the water barrier layer provides a liquid water resistance value of at least 800 minutes as tested by ASTM D779-16 (R2022).

35. The wall assembly of claim 31, wherein the water barrier layer provides a water vapor transmission rate of greater than 0 g / m2 / day and no more than 5 g / m2 / day as tested by ASTM E96- .HANAZD-707510 36. The wall assembly of claim 31, wherein at least one of the individual framing members comprises a wood stud.

37. The wall assembly of claim 31, further comprising a barrier layer between the water barrier layer and the porous core layer.

38. The wall assembly of claim 31, wherein the water barrier layer comprises a basis weight of 5 g / m2to 175 g / m2.

39. The wall assembly of claim 31, wherein the water barrier layer comprises a thickness of 4 microns to 150 microns.

40. The wall assembly of claim 31, wherein the water barrier layer comprises one or more of a polyolefin, a polyester, a polyamine, a polyamide, a metallized film, metal particles, a metal coating or a film comprising metal particles.

41. A recreational vehicle comprising a vehicle frame and a vehicle housing couple to the vehicle frame, wherein the vehicle housing comprises a wall assembly comprises a plurality of individual framing members coupled to each other to form a wall frame, wherein each of the plurality of individual framing members comprises an interior facing surface and an exterior facing surface, and a composite article coupled to the wall frame at one of the interior facing surface of the individual framing members or the exterior facing surface of the individual framing members, wherein the composite article comprises a porous core layer comprising a web formed from reinforcing materials held in place by a thermoplastic material, and a water barrier layer coupled to a first surface of the porous core layer, wherein the water barrier layer provides for a selected water vapor transmission rate through the water barrier layer or is resistant to movement of liquid water through the water barrier layer or both.

42. The recreational vehicle of claim 41, wherein the water barrier layer is coupled to the interior facing surface of the individual framing members.

43. The recreational vehicle of claim 41, wherein the water barrier layer provides a water vapor transmission rate of at least 15 g / m2 / day as tested by ASTM E96-23.

44. The recreational vehicle of claim 41, wherein the water barrier layer provides a liquid water resistance value of at least 800 minutes as tested by ASTM D779-16 (R2022).HANAZD-707510 45. The recreational vehicle of claim 41, wherein the water barrier layer provides a water vapor transmission rate of greater than 0 g / m2 / day and no more than 5 g / m2 / day as tested by ASTM E96- 23.

46. The recreational vehicle of claim 41, further comprising a barrier layer between the water barrier layer and the porous core layer.

47. The recreational vehicle of claim 41, further comprising a skin layer on a second surface of the porous core layer.

48. The recreational vehicle of claim 41, wherein the water barrier layer comprises a basis weight of 5 g / m2to 175 g / m2.

49. The recreational vehicle of claim 41, wherein the water barrier layer comprises a thickness of 4 microns to 150 microns.

50. The recreational vehicle of claim 41, wherein the water barrier layer comprises one or more of a polyolefin, a polyester, a polyamine, a polyamide, a metallized film, metal particles, a metal coating or a film comprising metal particles.

51. A modular home comprising a plurality of walls, a floor coupled to the plurality of walls and a roof coupled to the plurality of walls to form the modular home, wherein at least one wall of the modular home comprises a wall assembly comprising a plurality of individual framing members coupled to each other to form a wall frame, wherein each of the plurality of individual framing members comprises an interior facing surface and an exterior facing surface, and a composite article coupled to the wall frame at the interior facing surface of the individual framing members, wherein the composite article comprises a porous core layer comprising a web formed from reinforcing materials held in place by a thermoplastic material, and a water barrier layer coupled to a first surface of the porous core layer, wherein the water barrier layer provides for a selected water vapor transmission rate through the water barrier layer or is resistant to movement of liquid water through the water barrier layer or both.

52. The modular home of claim 51, wherein the water barrier layer is coupled to the interior facing surface of the individual framing members.HANAZD-707510 53. The modular home of claim 51, wherein the water barrier layer provides a water vapor transmission rate of at least 15 g / day / m2as tested by ASTM E96-23.

54. The modular home of claim 51, wherein the water barrier layer provides a liquid water resistance value of at least 800 minutes as tested by ASTM D779-16 (R2022).

55. The modular home of claim 51, wherein the water barrier layer provides a water vapor transmission rate of greater than 0 g / m2 / day and no more than 5 g / m2 / day as tested by ASTM E96- 23.

56. The modular home of claim 51, further comprising a barrier layer between the water barrier layer and the porous core layer.

57. The modular home of claim 51, further comprising a skin layer on a second surface of the porous core layer.

58. The modular home of claim 51, wherein the water barrier layer comprises a basis weight of 5 g / m2to 175 g / m2.

59. The modular home of claim 51, wherein the water barrier layer comprises a thickness of 4 microns to 150 microns.

60. The modular home of claim 51, wherein the water barrier layer comprises one or more of a polyolefin, a polyester, a polyamine, a polyamide, a metallized film, metal particles, a metal coating or a film comprising metal particles.

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