MX2007005772A - Laminate panel and process for production thereof - Google Patents

Abstract

There is disclosed a laminate panel and a process for production thereof. The laminate panel comprises a core layer disposed between and bonded to each of a first metal layer and a second metal layer. The core layer comprises a porous layer substantially encapsulated by a thermoplastic resin. An advantage of the present laminate material is that it can withstand paint/bake cycles while maintaining a desirable balance of physical properties (e.g., peel strength, stiffness, impact resistance and the like). Another distinct advantage of the present laminate panel is its formability. This allows for the use medium or deep draw forming techniques to facilitate production of parts having a variety of shapes and radii (e.g., 90°bends, draws, stretches, multi-shape configurations and the like) for vehicular applications.

Description

LAMINATED PANEL AND PROCESS FOR PRODUCTION OF THE SAME Field of the Invention In one of its aspects, the present invention relates to a laminated panel, more particularly to a laminated panel covered with metal. In yet another embodiment of these aspects, the present invention relates to a method for producing a laminated panel. BACKGROUND OF THE INVENTION Sheet steel is used extensively to form panels. The required structural characteristics, such as stiffness, vary depending on the specific application. When higher higher stiffness values are required, the thickness of the steel is normally increased. However, the thickness of the steel sheet increases, produces a panel that is not only heavier, but also more expensive. A number of methods have been made in the past to provide improved acoustic characteristics of the panels. For example, steel sheet composites having said polymer center have been used in applications where sound removal and vibration damping are required. The weight and cost of the laminated products incorporating said polymer center materials are, however, less than desirable.

In recent years, attention has been directed to the use of other center materials in structural panels covered with metal. U.S. Patent No. 5,985,457 [David D'Arcy Clifford (Clifford # 1)], teaches a structural panel comprising a metal and paper composite in which the outer metal covers have a minimum thickness of 0.0127 cm (0.0127 cm). 0.005 inches)), which exceed the sheets and a maximum thickness of 0.03048 cm (0.012 inches), while the center of paper ranges from 0.0254 cm (0.0254 cm (0.01 in)) to 0.127 cm (0.05 in). The panel is a lightweight, rigid substitute for thicker metals and can replace light metal sheets such as aluminum with a compound in which the metal covers comprise sheets from heavy metals such as steel. The paper center is a coil which attaches adhesively to the metal skins and has openings to create trajectories for the adhesive bridges between the metal covers to minimize the failure caused by the anchoring. U.S. Patent No. 6,171,705 [David D'Arcy Clifford (Clifford # 2)], teaches a structural laminate that has a first and second sheet metal covers. Each of the sheet metal covers has a thickness of at least about 0.0127 cm (0.0127 cm (0.005 inches)). A fibrous center layer is provided between the sheet metal covers and attached to the covers. In one aspect, the fibrous center layer is impregnated with an adhesive resin which bonds the center layer directly to the covers. In another aspect, the adhesive layers are placed between the center material and the metal covers that connect the center to the covers. Although reference is made to the use of a thermoplastic resin as the adhesive, Clifford Patent # 2 emphasizes the use of a thermosetting resin. The resulting laminate structure has an extremely light weight compared to a simple steel sheet of comparable thickness and strength.

Although the teachings of Clifford # 1 and Clifford # 2 represent significant advances in the technique, improvements are still needed. Specifically, an application of particular interest in laminated materials such as those described in Clifford # 1 and Clifford # 2 is in vehicular applications, such as door panels, car roofs, hoods, floor panels, decks Tonneau, loading panels, exterior panels, interior panels and similar. In order for such laminate material to be useful in vehicular applications, it is highly recommended that the so-called "paint / bake" cycles to which the exterior vehicle parts and panels are subjected during the manufacture / assembly of the vehicle are supported. SpecificallyIt is conventional to subject the particular panel to a number of successive painting and baking cycles to build a high quality panel finish. The temperatures of the baking cycle may exceed a temperature of 150 ° C (normally, the temperature is approximately 180 ° C). When the panel is made of steel alone, this is not a problem. However, if a composite material, such as the one described in the Clifford Patent # 1 and Clifford # 2 is used, there is a risk that the resin used in the laminate may have a softening point near or a point of melting below the baking temperature referred to above. On the other hand, whatever materials are used in the laminate, it is important that the successive painting / baking cycles to which the panel is subjected, do not have a detrimental effect on the physical properties (for example, roof strength, rigidity). , impact resistance and the like) of the resulting laminated panel. Therefore, it may be advisable to have a laminate material having the physical property advantages set forth in Clifford # 1 and Clifford # 2, while avoiding the problems associated with the painting / baking cycle referred to above. It may be particularly convenient if said laminate possesses a desirable combination of physical properties that make it suitable for use in vehicular applications.

Brief Description of the Invention It is an object of the present invention to eliminate or mitigate at least one of the aforementioned disadvantages of the prior art. It is another object of the present invention to provide a laminated panel with the ability to withstand the paint / bake cycle conditions to which the vehicle panels are conventionally subjected. It is another object of the present invention to provide a laminated panel having desirable properties (e.g., impact load or impact resistance) for use in a vehicular application. It is another object of the present invention to provide a novel process for producing a laminated panel. According to the present invention, in one of its aspects there is provided a laminated panel comprising: a center layer placed and joined to each of the first metal layer and the second metal layer, the middle layer comprising a layer porous substantially encapsulated through a thermoplastic resin. In another of its aspects, the present invention provides a process for producing a laminated panel comprising the steps of: placing a center layer between a first metal layer and a second metal layer to define an interim laminate, the layer comprising center a first layer of adhesive on a surface of a porous layer, the first layer of adhesive comprising a thermoplastic material; and subjecting the interim laminate to a compression step at a temperature of at least about 150 ° C, and at a pressure sufficient to cause the first adhesive layer to substantially encase the porous layer, to produce the laminated panel. Therefore, the inventors of the present invention have discovered a laminated material consisting of a novel combination of a porous layer and a thermoplastic resin which can withstand the painting / baking cycles referred to above, while maintaining a desirable balance of physical properties (for example, roof strength, rigidity, impact resistance and the like). Another distinct advantage of the laminated panel of the present invention is its formability. This allows for medium or deep engraving forming techniques to be used to facilitate the production of parts having a variety of shapes and radii (eg, 90 ° bends, shots, stretches, multiple configurations and the like) for vehicular applications. BRIEF DESCRIPTION OF THE FIGURES The embodiments of the present invention will be described with reference to the drawings that the. accompany, wherein similar reference numerals denote similar parts, and in which: Figure 1 illustrates a sectional view of one embodiment of the laminated panel of the present invention; Figure 2 illustrates a perspective view, and a partial section of the laminated panel illustrated in Figure 1; Figure 3 illustrates a sectioned view of a second embodiment of the present invention; Figure 4 illustrates a top plan view of a preferred embodiment of a porous layer useful in the center layer of the laminate of the present invention; and Figure 5 is a graphic illustration of the results of the samples elaborated in the examples reported below. Detailed Description of the Invention The center layer of the laminated panel of the present invention comprises at least one porous layer that is substantially encapsulated by a thermoplastic resin. As used throughout the present specification, the term "porosity" and "porous", for example, when used in conjunction with the center layer of the laminated panel of the present invention, is intended to comprise a material having a number enough of pores or openings through which a liquid can pass with little or no resistance when the liquid is poured over the material. In a preferred embodiment, the porous layer can be fiber. A particularly preferred example of said porous layer can be selected through the group comprising, hemp, jute and the like. Alternatively, the porous layer can be made from a material without fiber. For example, the porous layer can be made of a wire or an all-metal material such as plastic and the like. The porous layer can be woven or non-woven. It is preferred that the porous layer has sufficient porosity so that it can be substantially completely completely encapsulated by resin or thermoplastic material. Preferably, the porous layer is made of a network or grid-like arrangement of metal or non-metal material that defines a series of openings. In such adjustment, the porosity of the porous layer can be defined as the percentage of the aggregate pore surface area of a flat surface of the porous layer, as a function of the total surface area of the porous layer (in other words, the porosity "can be seen as the degree of opening in a network network, grid type or similar in the porous layer). For example, a porous layer comprises a porosity of 10%, a flat sample of 1 square foot of a porous layer containing 0.1 square foot with the remainder (eg, 0.9 square foot) consisting of fiber material. It should be appreciated that the reference to a flat sample for the porosity specification is simply to evaluate said property of the porous layer and not to otherwise restrict the shape of a laminate comprising said porous layer. Therefore, it is preferred that the porous layer comprises a porosity of at least about 10%, more preferably in the range of from about 10% to about 90%, more preferably in the range of from about 20% to about 80%, more preferably in the range from about 30% to about 70%, most preferably in the range from about 35% to about 65%. From a processing point of view, the porous layer must have sufficient porosity to allow encapsulation of the same by thermoplastic resin at temperatures and pressures that are normally used in the production of laminates such as those described in the US Pat. Clifford # 1 and Clifford # 2. Practically, this excludes Kraft paper (the preferred material in Clifford Patent # 1 and Clifford # 2), as being suitable for use as the only porous layer in the laminated panel of the present invention. It is also preferred that the porous layer can be sheet-like material. In some cases one or more of said sheets can be used in the center layer, although it is preferable to use only one of said simple sheets. Alternatively, it is possible that the porous layer may be thicker than a typical sheet-like material - for example, a layer of reticular foam and the like. With reference to Figure 1, an interim laminate panel 10 is illustrated. The interim laminate panel 10 includes a first metal cover layer 12 and a second metal cover layer 20. Interposed between the first metal cover layer 12 and the second metal cover layer 20 is a porous layer 16. A first layer of adhesive 14 is placed between the first metal cover layer 12 and the porous layer 16. A second layer of adhesive 18 is placed (optional ) between the porous layer and the second metal cover layer 20. The first adhesive layer 14 and the second adhesive 18 (if present) each comprise a thermoplastic resin. The laminated panel 10 is referred to as interim, since, during the process of the present invention, the thermoplastic resin that is in the adhesive layer (s), substantially encapsulates the porous layer 16. In addition, the first layer of adhesive 14 serves to join the first metal cover layer 12 to the porous layer 16. If the second layer of adhesive is used 18, serves to join the porous layer 16 to the second metal cover layer 20. If the second adhesive layer 18 is not used, the first adhesive layer 14 substantially encapsulates the porous layer 16 and also serves to join the porous layer 16. to a second metal layer 20. Referring to Figure 3, an interim laminate panel 30 is illustrated. The interim laminate panel 30 comprises a first metal cover layer 32 and a second metal cover layer 44. Positioned between the first metal cover layer 32 and the second metal cover layer 44 is a center 31. The center layer 31 comprises a pair of porous layers 36 and 40 interposed with a layer of adhesive 38. The laminate panel 30 is referred to as interim, since, during the process of the present invention, the thermoplastic resins in each of the adhesive layers 34, 38, 42, are intermixed to substantially encase the porous layer 16 and for a go center 31 to a first metal cover layer 32 and a second metal cover layer 44. Those skilled in the art will appreciate that the center 31 can be modified to have more porous layers and adhesive layers, so that the center layer 31 itself is a laminate. Therefore, although not shown for purposes of clarity in Figures 1 through 3, the adhesive layer substantially completely encompasses the adjacent porous layer. If a plurality of porous layers are used, it is preferred that the thermoplastic resin (e.g., one or both of the first adhesive layer and the second adhesive layer) substantially completely encompass the adjacent porous layer. The first adhesive layer and the second adhesive layer (if present) comprise a thermoplastic resin. The thermoplastic resin may be the same or different in the first adhesive layer and the second adhesive layer. In a preferred embodiment of the laminated panel of the present invention, the thermoplastic adhesive layer comprises polyethylene or thermoplastic elastomer, such as a copolyester elastomer (e.g., ether polyester elastomer or ester polyester elastomer). A particularly preferred embodiment of the copolyester elastomer used in the first adhesive layer and / or the second adhesive layer of the laminated panel of the present invention is commercially available under the trademark of Arnitel ™. The particular lesson of the metal cover layers used in the laminated panel of the present invention is not particularly restricted, and again, more details can be seen in this regard in the Clifford Patent # 1 and Clifford # 2 described above. Therefore, the first metal layer and the second metal layer can be the same or different. Examples without limitation of metal layers suitable for use in the laminate of the present invention include aluminum, cold rolled steel, galvanized steel, hardened steel, galvalum steel, tin coated steel, zinc coated steel, high steel. resistance with low carbon micro-alloy and stainless steel. Preferably, the first metal cover and the second metal cover have the same or a different thickness, and the thickness is within the range of from about 0.0127 cm (0.005 inches) to about 0.762 cm (0.762 cm (0.030 inches). inches)). In a preferred embodiment of the laminated panel of the present invention, one or both of the first metal layer and the second metal layer comprise steel, which has been previously treated, with a conversion coating to promote the integrity of the bond and the resistance to corrosion. In a further preferred embodiment of the laminated panel of the present invention, the center layer comprises a material for retarding the flame. With reference to Figure 4, an expanded view of a preferred embodiment of the porous layer 16 (Figures 1 and 2) and 36 is illustrated., 40 (figure 3). As will be appreciated, the porous layer of Figure 4 comprises a grid-like arrangement of natural fibers, plastic, metal and the like. The porosity of the porous layer refers to the porosity of the entire layer and not to any particular fiber from which the layer is made. Therefore, with reference to Figure 4, the porosity (as defined above) of the porous layer can be determined by calculating the aggregate surface area of the openings in the porous layer, and converting this to a percentage of the area of the porous layer. total surface of the sample. Preferably, the compression step in the process of the present invention is carried out at a temperature sufficient to soften or melt the thermoplastic resin. Practically, the compression step is carried out at a temperature of at least about 150 ° C, more preferably in the range of from about 175 ° C to about 250 ° C, more preferably from about 200 ° C to about 250 ° C. . Preferably, the compression step in the process of the present invention is carried out at a pressure of at least about 50 psi, more preferably within the range of from about 75 psi to about 600 psi, more preferably within the range of about 100 to about 400 psi. Preferably, the compression step in the process of the present invention is carried out for a period of less than 5 minutes, more preferably less than 2 minutes, most preferably within the range of from about 5 seconds to about 60 seconds. Preferably, the above compression step can be carried out in a die press or other suitable equipment. Those skilled in the art will recognize that the process of the present invention can be conducted in a batch press or use continuous rolling equipment (in the latter embodiment if it is preferred, in some cases, to pre-apply the thermoplastic resin in the porous layer before the production of the laminated panel). The embodiments of the present invention will be described with reference to the following examples, which are for illustrative purposes only and will not be used to construct or otherwise limit the scope of the present invention. EXAMPLES In the examples, a number of samples are made using steel covers and a center. Each steel cover has a thickness of 0.0254 cm (0.010 inches) and a zinc cover (-60 g / m2) on each side. The center was either a single resin or a combination of resin and a reinforcement layer. The resin was an elastomer based on thermoplastic co-polyester, wherein the co-polyester is a polyether-ester formulation. The resin was used in the form of a leaf. The thickness used in each sample was reported in Table 1. The reinforcement layers used in the samples were: woven steel mesh, jute woven of different types of waves, paper, cotton and linen. Various combinations of pressure, temperature and cycle times were investigated. The samples were made on a Carver press (75t) at a temperature of 232.2 ° C (450 ° F), for 1 minute at a pressure of 10 tons (approximately 138 psi), except for samples of only resin); followed by cooling in the press, under a pressure of 176.6 ° C (350 ° F), cooled to about 1.5 s. ° F "1. The samples produced are summarized in Table 1. Table 1 Samples 1, 2 and 9 are provided solely for comparison purposes, and therefore, these Samples are outside the scope of the present invention. Adhesion is evaluated through a T-shell test (ASTM D1876-01). The size of the samples used for this test was 2.54 cm (1 inch) or 5.08 m (2 inches) wide and 30.48 cm (12 inches) long. Stiffness was determined through a 3-point bending test (ASTM D790-02). Samples with a width of 5.08 cm (2 inches) and length of 25.4 cm (10 inches) were tested. An important parameter to consider is the ratio of interval to thickness, since this will affect the reliability of any module predictions (recommended> 40: 1). The impact performance was compared through a fall ball type impact tester. Impact results are useful for relative or comparative purposes. The test is similar to the one performed for the impact of plastics-Gardner ASTM D5420-98a. The impact test included the use of a weight of 4 Ib at different heights; the maximum weight was equivalent to 18 J of transferred energy (indentation diameter of 1.5875 cm (0.625 inches)). The reported energy is the maximum energy at which the cracking was observed. A strip of 5.08 cm (2 inches) by 25.4 cm (10 inches) was used for a series of indentations. The results of the adhesion (cover-T) are reported Ib feet / inches, the results for stiffness / t3 are in N / mm4. Two impact tests were carried out, the first one with an indenter of 1,814 kg (4 Ib), and the results are shown in J. The results are shown in graph form in figure 5.

As shown in Figure 5, Samples 1 and 2 (center with resin only) had a reference adhesion (T-shell), stiffness and impact resistance. The use of paper in the center - for example, Sample 9 (resin / paper center) - resulted in a significant drop in adhesion (T-cover) compared to that observed for Samples 1 and 2. In contrast, the use of jute at the center - ie, Samples 3 through 5 reinforced with jute - resulted in a desirable combination of adhesion, stiffness and impact resistance. In particular, and to our surprise, the use of jute in the center resulted in a significant increase in adhesion (T-cover) compared to Samples 1 and 2 (resin center only) and with Sample 9 (center of resin / paper). In addition, the use of a porous layer (for example, jute, cotton, linen, etc. - particularly jute) in the center, resulted in a highly desirable combination of ease of manufacture, product control (dimension, integrity of the sample). , etc.) and cost in comparison with Samples 1 and 2 (resin center only) and with Sample 9 (resin / paper center). Although the present invention has been described with reference to illustrative embodiments and examples, the description is not intended to be constructed in a sense of limitation. Therefore, various modifications of the illustrative embodiments, as well as other embodiments of the present invention, may be appreciated by those skilled in the art at the time of reference to this description. For example, it is possible to use, as the thermoplastic resin, a laminate of an adhesive layer and a resin layer, for example, a laminated product co-extruded from said layers. As an alternative, it is possible to use a thermoplastic resin to which an adhesion promoter material is added thereto. Accordingly, it is contemplated that the appended claims will cover any such modifications or modalities. All the publications, patents and patent applications referred to herein are incorporated in their entirety to the present invention as a reference, to the same extent as if each publication, patent or patent application was specifically or individually indicated to be incorporated in its entirety. to the present invention as reference.

Claims (67)

R E I V I N D I C A C I O N S

1. A laminated panel comprising: a center layer positioned between, and measuring each of the first metal layer and a second metal layer, the center layer comprising a porous layer substantially encapsulated by a thermoplastic resin.

2. The laminated panel as described in claim 1, characterized in that the porous layer comprises a porosity of at least about 10%.

3. The laminated panel as described in claim 1, characterized in that the porous layer comprises a porosity within the range of from about 10% to about 90%.

4. The laminated panel as described in claim 1, characterized in that the porous layer comprises a porosity within the range of from about 20% to about 80%.

The laminated panel as described in claim 1, characterized in that the porous layer comprises a porosity within the range of from about 30% to about 70%.

6. The laminated panel as described in claim 1, characterized in that the porous layer comprises a porosity within the range of from about 35% to about 65%.

7. The laminated panel as described in any of claims 1 to 6, characterized in that the porous layer is fiber.

8. The laminated panel as described in any of claims 1 to 6, characterized in that the porous layer is fiber free.

9. The laminated panel as described in any of claims 1 to 8, characterized in that the porous layer is metal-free.

10. The laminated panel as described in any of claims 1 to 8, characterized in that the porous layer comprises a metal.

The laminated panel as described in any of claims 1 to 10, characterized in that the thermoplastic resin comprises polyethylene.

12. The laminated panel as described in any of claims 1 to 10, characterized in that the thermoplastic resin comprises polypropylene.

13. The laminated panel as described in any of claims 1 to 10, characterized in that the thermoplastic resin comprises a polyolefin.

14. The laminated panel as described in any of claims 1 to 10, characterized in that the thermoplastic resin comprises a co-polyester elastomer.

15. The laminated panel as described in any of claims 1 to 14, characterized in that the center layer comprises a simple porous layer.

16. The laminated panel as described in any of claims 1 to 14, characterized in that the center layer comprises a plurality of porous layers adhered to each other.

The laminated panel as described in claim 16, characterized in that the center layer comprises a laminate of alternating layers and adhesive layers of the center, the first adhesive layer and the second adhesive layer being placed on substantially opposite surfaces. of the center layer.

18. The laminated panel as described in claim 17, characterized in that the first and second adhesive layers comprise a thermoplastic resin.

19. The laminated panel as described in any of claims 1 to 18, characterized in that the porous layer comprises natural fibers.

20. The laminated panel as described in any of claims 1 to 18, characterized in that the porous layer comprises jute.

21. The laminated panel as described in any of claims 1 to 18, characterized in that the porous layer comprises hemp.

22. The laminated panel as described in any of claims 1 to 18, characterized in that the porous layer comprises woven fibers.

23. The laminated panel as described in any of claims 1 to 18, characterized in that the porous layer comprises woven jute.

24. The laminated panel as described in any of claims 1 to 18, characterized in that the first metal layer and the second metal layer are the same.

25. The laminated panel as described in any of claims 1 to 24, characterized in that the first metal layer and the second metal layer are different.

26. The laminated panel as described in any of claims 1 to 24, characterized in that the first metal layer and the second metal layer are the same or different and each is selected from the group consisting of aluminum , titanium, magnesium, cold rolled steel, galvanized steel, hardened steel, galvalume steel, tin-coated steel, zinc-coated steel, high-strength low-carbon micro-alloy steel and stainless steel.

27. The laminated panel as described in any of claims 1 to 26, characterized in that the first metal cover and the second metal cover have the same thickness or a different thickness within the range of from about 0.0127 cm (0.005) inches) to approximately 0.762 cm (0.030 inches).

28. The laminated panel as described in any of claims 1 to 27, characterized in that the porous layer has a thickness of at least about 0.0254 cm (0.01 inch).

29. The laminated panel as described in any of claims 1 to 27, characterized in that the porous layer has a thickness within the range of from about 0.0254 cm (0.01 inches) to 0.635 cm (0.25 inches).

30. The laminated panel as described in any of claims 1 to 29, characterized in that the laminate is non-planar.

31. The laminated panel as described in any of claims 1 to 29, characterized in that the laminate is planar and the center layer is flat or non-planar.

32. The laminated panel as described in any of claims 1 to 31, characterized in that one or both of the first metal cover and the second metal cover comprise steel, which has been previously treated with a coating Conversion to promote the integrity of the joint and the corrosion resistance.

33. The laminated panel as described in any of claims 1 to 32, characterized in that the center layer comprises a material for retarding the flame.

34. A vehicular panel comprising a laminated panel as described in any of claims 1 to 33.

35. A process for producing a laminated panel, wherein the process comprises the steps of: placing a center layer between a first metal layer and a second metal layer to define an interim laminate, the center layer comprising a first adhesive layer on a surface of a porous layer, the first adhesive layer comprising a thermoplastic material; and subjecting the interim laminate to a compression step at a temperature of at least about 150 ° C and at a pressure sufficient to cause the first adhesive layer to substantially encase the porous layer, to produce the laminated panel.

36. The process as described in claim 35, characterized in that the center layer comprises the first adhesive layer and a second adhesive layer on substantially opposite surfaces of the porous layer, the second adhesive layer comprising a thermoplastic material.

37. The process as described in any of claims 35 and 36, characterized in that the compression step is carried out at a temperature within the range of from about 175 ° C to about 275 ° C.

38. The process as described in any of claims 35 and 36, characterized in that the compression step is carried out at a temperature within the range of from about 200 ° C to about 250 ° C.

39. The process as described in any of claims 36 to 38, characterized in that the center layer comprises a laminate of alternating porous layers and layers of adhesive from the center, the first adhesive layer being placed and the second adhesive layer on substantially opposite surfaces of the center layer.

40. The process as described in the claim 39, characterized in that the adhesive layers of the center comprise a thermoplastic resin.

41. The process as described in any of claims 36 to 40, characterized in that the first adhesive layer and the second adhesive layer each comprise the same thermoplastic resin.

42. The process as described in any of claims 36 to 40, characterized in that the first adhesive layer and the second adhesive layer comprise a different thermoplastic resin.

43. The process as described in any of claims 35 to 42, characterized in that the thermoplastic material comprises a polyethylene resin.

44. The process as described in any of claims 35 to 42, characterized in that the thermoplastic material comprises a polyolefin resin (e.g., polypropylene resin).

45. The process as described in any of claims 35 to 42, characterized in that the thermoplastic material comprises a copolyester elastomer.

46. The process as described in any of claims 35 to 45, characterized in that the first metal layer and the second metal layer are the same.

47. The process as described in any of claims 35 to 45, characterized in that the first metal layer and the second metal layer are different.

48. The process as described in any of claims 35 to 45, characterized in that the first metal layer and the second metal layer are the same or different, and each is selected from the group consisting of aluminum , titanium, magnesium, cold rolled steel, galvanized steel, hardened steel, galvalume steel, tin-coated steel, zinc-coated steel, high-strength low-carbon micro-alloy steel and stainless steel.

49. The process as described in any of claims 35 to 48, characterized in that the first metal cover and the second metal cover have the same thickness or a different one within the range of from about 0.0127 cm (0.005). inches) to approximately 0.762 cm (0.030 inches).

50. The process as described in any of claims 35 to 49, characterized in that the porous layer has a thickness of at least about 0.0254 cm (0.01 inch).

51. The process as described in any of claims 35 to 49, characterized in that the porous layer has a thickness within the range of from about 0.0254 cm (0.01 inches) to 0.635 cm (0.25 inches).

52. The process as described in any of claims 35 to 51, characterized in that the laminate is non-planar.

53. The process as described in any of claims 35 to 51, characterized in that the laminate is flat.

54. The process as described in any of claims 35 to 51, characterized in that one or both of the first metal cover and the second metal cover comprise steel, which has been previously treated with a coating of Conversion to promote bonding integrity and corrosion resistance.

55. The process as described in any of claims 35 to 54, characterized in that the porous layer comprises a flame retardant material.

56. The process as described in any of claims 35 to 55, characterized in that the porous layer is fiber.

57. The process as described in any of claims 35 to 55, characterized in that the porous layer is fiber free.

58. The process as described in any of claims 35 to 57, characterized in that the porous layer is non-metal.

59. The process as described in any of claims 35 to 57, characterized in that the porous layer comprises a metal.

60. The process as described in any of claims 35 to 55, characterized in that the porous layer comprises natural fibers.

61. The process as described in any of claims 35 to 55, characterized in that the porous layer comprises jute.

62. The process as described in any of claims 35 to 55, characterized in that the porous layer comprises hemp.

63. The process as described in any of claims 35 to 55, characterized in that the porous layer comprises woven fibers.

64. The process as described in any of claims 35 to 55, characterized in that the porous layer comprises woven jute.

65. The process as described in any of claims 35 to 64, characterized in that the center layer is flat.

66. The process as described in any of claims 35 to 64, characterized in that the center layer is non-planar.

67. The process as described in any of claims 35 to 64, characterized in that it comprises the additional step of forming the laminate in a non-planar configuration. R E S U M E N A laminated panel and a process for its production are described. The laminated panel comprises a center layer positioned between, and joined to, each first metal layer and a second metal layer. The center layer comprises a porous layer substantially encapsulated by a thermoplastic resin. An advantage of the laminate material of the present invention is that it can withstand painting / baking cycles, while maintaining a desirable balance of physical properties (e.g., cover strength, stiffness, impact resistance and the like) at the same time. Another distinct advantage of the laminated panel of the present invention is its formability. This allows for the use of medium or deep extension forming techniques to facilitate the production of parts having a variety of shapes and radii (eg, 90 ° flexions, extensions, flexibility, multi-form configurations and the like) for applications vehicular