JPWO2020051140A5

JPWO2020051140A5 -

Info

Publication number: JPWO2020051140A5
Application number: JP2021512564A
Authority: JP
Publication date: 2022-09-12

Claims

A method of manufacturing a recreational vehicle panel comprising:
disposing a dispersion comprising a substantially homogeneous mixture of thermoplastic material and reinforcing fibers over a shaped support element;
applying pressure to less than the entire surface of the shaped support element containing the disposed foam to provide the porous web comprising a variable basis weight in different regions of the web;
compressing the porous web comprising the variable basis weight in different regions of the web to a substantially uniform thickness across the width of the web;
drying the compressed web to provide a recreational vehicle panel comprising a porous core layer, the recreational vehicle panel comprising a variable basis weight across the width of the porous core layer and substantially and drying to a uniform thickness.

2. The method of claim 1, further comprising applying a negative pressure to the underside of said shaped support element containing said disposed dispersion.

applying said negative pressure to a central region of said shaped support element containing said disposed dispersion to provide said central region with a higher basis weight than at edges of said porous core layer. Item 1. The method according to item 1.

further comprising applying the negative pressure to an edge region of the shaped support element containing the disposed dispersion to provide the edge region with a higher basis weight than a central region of the porous core layer. A method according to claim 1.

2. The method of claim 1, further comprising placing a first skin on the first surface of the porous web prior to compressing the porous web.

6. The method of claim 5, further comprising placing a second skin on a second surface of said porous web prior to compressing said porous web.

7. The method of Claim 6, wherein at least one of the first skin and the second skin comprises a variable basis weight.

7. The method of claim 6, wherein at least one of the first skin and the second skin comprises a water repellent scrim.

7. The method of claim 6, wherein each of said first skin and said second skin comprises a water repellent scrim.

7. The method of claim 6, wherein each of said first skin layer and said second skin layer is bonded to said porous web without the use of an adhesive layer.

A recreational vehicle panel,
A porous core layer comprising an open-cell structured web formed of reinforcing fibers held together by a thermoplastic material, the porous core layer comprising a variable basis weight across the width of said porous core layer; said porous core layer also comprising a substantially uniform thickness across said width;
a first skin layer bonded to a first surface of the porous core layer;
a second skin layer bonded to a second surface of the porous core layer.

12. The recreational vehicle panel of claim 11, wherein the porous core layer comprises a lower basis weight at the lateral edges than in the central region.

13. The recreational vehicle panel of claim 12, further comprising a transition zone between each of said lateral edges and said central region, said transition zone having a variable basis weight.

14. The recreational vehicle panel of claim 13, wherein the transition zone comprises a basis weight/distance gradient of greater than 0 gsm/cm and up to 100 gsm/m.

15. The recreational vehicle panel of claim 14, wherein said basis weight/distance gradient is linear from said lateral edge to said central region.

12. The recreational vehicle panel of claim 11, wherein said reinforcing fibers comprise glass fibers.

17. The recreational vehicle panel of Claim 16, wherein said thermoplastic material comprises a polyolefin material.

18. The recreational vehicle panel of claim 17, wherein at least one of said first skin layer and said second skin layer comprises a water repellent scrim.

18. The method of claim 17, wherein each of the first skin layer and the second skin layer comprises a water repellent scrim.

20. The recreational vehicle panel of Claim 19, wherein each of said first skin layer and said second skin layer are bonded to said porous web without the use of an adhesive layer.