US20170043814A1 - Impact resistant underbody shield materials and articles and methods of using them - Google Patents

Impact resistant underbody shield materials and articles and methods of using them Download PDF

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Publication number
US20170043814A1
US20170043814A1 US15/179,411 US201615179411A US2017043814A1 US 20170043814 A1 US20170043814 A1 US 20170043814A1 US 201615179411 A US201615179411 A US 201615179411A US 2017043814 A1 US2017043814 A1 US 2017043814A1
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United States
Prior art keywords
core layer
film
fibers
core
resin
Prior art date
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Abandoned
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US15/179,411
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English (en)
Inventor
Yankai Yang
Anthony J. Messina
Mark O. Mason
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Individual
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Individual
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Priority to US15/179,411 priority Critical patent/US20170043814A1/en
Publication of US20170043814A1 publication Critical patent/US20170043814A1/en
Priority to US17/069,650 priority patent/US20210139080A1/en
Abandoned legal-status Critical Current

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    • B62D35/02—Streamlining the undersurfaces

Definitions

  • This application is related to underbody shield materials that provide impact resistance. More particularly, certain embodiments described herein are directed to underbody shield materials that can be used in an impact resistant underbody shield that comprises a core layer and a film together effective to provide the impact resistance.
  • a gravelometer test which is similar to ASTM D3170-14 dated Jul. 1, 2014.
  • the materials can be used to produce a composite article that can withstand 50 or more individual impacts, e.g., 100 or more individual impacts, as provided under the gravelometer test conditions, without any substantial damage or effects to the article.
  • an underbody shield composition comprising a thermoplastic core layer comprising a web of open celled structures defined by random crossing over of reinforcing fibers held together by a thermoplastic polymer, the thermoplastic core layer further comprising a lofting agent effective to increase a thickness of the core layer upon exposure to heat to provide a post lofted core layer, and a film disposed on a first surface of the core layer, in which the post lofted core layer and film together provide an underbody shield article that can withstand at least 50 individual impacts according to a SAE J400 protocol without damage to the film is provided.
  • the film is a homopolymer or copolymer film, e.g., an impact modified homopolymer or copolymer film.
  • the homopolymer is a polyolefin.
  • the thermoplastic polymer is present at 50 weight percent or more in the core layer.
  • the film is at least 10 mils thick.
  • the lofting agent is present at 4 percent by weight or more in the core layer.
  • the reinforcing fibers are selected from the group consisting of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, inorganic fibers, natural fibers, mineral fibers, metal fibers, metalized inorganic fibers, metalized synthetic fibers, ceramic fibers, and combinations thereof.
  • the thermoplastic polymer is a polymer resin that is selected from the group consisting of a polyolefin resin, a thermoplastic polyolefin blend resin, a polyvinyl polymer resin, a butadiene polymer resin, an acrylic polymer resin, a polyamide resin, a polyester resin, a polycarbonate resin, a polyestercarbonate resin, a polystyrene resin, an acrylonitrylstyrene polymer resin, an acrylonitrile-butylacrylate-styrene polymer resin, a polyether imide resin, a polyphenylene ether resin, a polyphenylene oxide resin, a polyphenylenesulphide resin, a polyether resin, a polyetherketone resin, a polyacetal resin, a polyurethane resin, a polybenzimidazole resin, and copolymers and mixtures thereof.
  • a polyolefin resin a thermoplastic polyolefin blend resin
  • the thermoplastic core layer comprises polypropylene, glass fibers and microsphere lofting agents, and in which the film is a polypropylene homopolymer film.
  • the film is directly disposed on the first surface of the core layer without any intervening layer or material.
  • the composition may comprise a scrim disposed on a second surface of the core layer opposite the first surface of the core layer.
  • the scrim comprises glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metalized synthetic fibers, and metalized inorganic fibers.
  • the composition comprises an additional skin layer disposed on the scrim.
  • the thermoplastic core layer comprises polypropylene, glass fibers and microsphere lofting agents, in which the film is a polypropylene homopolymer film and the scrim is polyester nonwoven scrim.
  • the film is directly disposed on the first surface of the core layer without any intervening layer or material and the scrim is directly disposed on the second surface of the core layer without any intervening layer or material.
  • the scrim is disposed as one or more strips on the second surface of the core layer.
  • the composition further comprises an additional core layer coupled to the core layer, the additional core layer comprising a web of open celled structures defined by random crossing over of reinforcing fibers held together by a thermoplastic polymer.
  • the additional core layer further comprises a lofting agent effective to increase a thickness of the additional core layer.
  • the additional core layer comprises a lower weight percentage of thermoplastic material than an amount of thermoplastic material present in the core layer.
  • the film is configured to withstand more impacts as a thickness of the core layer is decreased.
  • an underbody shield composition comprising a thermoplastic core layer comprising a web of open celled structures defined by random crossing over of reinforcing fibers held together by a thermoplastic polymer, the thermoplastic core layer further comprising a lofting agent effective to increase a thickness of the core layer upon exposure to heat to provide a post lofted core layer, a homopolymer polyolefin film or a copolymer polyolefin film disposed on a first surface of the core layer, a scrim disposed on a second surface of the core layer, in which the post lofted core layer, film and scrim together provide an underbody shield article that can withstand at least 50 individual impacts according to a SAE J400 protocol without damage to the film is provided.
  • the composition comprises a decorative layer disposed on the scrim.
  • the thermoplastic core layer comprises a void content of greater than 5% and up to about 95%.
  • the thermoplastic polymer is present at 50 weight percent or more in the core layer.
  • the film is at least 10 mils thick.
  • the lofting agent is present at 4 percent by weight or more in the core layer.
  • the reinforcing fibers are selected from the group consisting of glass fibers, carbon fibers, graphite fibers, synthetic organic fibers, inorganic fibers, natural fibers, mineral fibers, metal fibers, metalized inorganic fibers, metalized synthetic fibers, ceramic fibers, and combinations thereof.
  • the thermoplastic polymer is a polymer resin that is selected from the group consisting of a polyolefin resin, a thermoplastic polyolefin blend resin, a polyvinyl polymer resin, a butadiene polymer resin, an acrylic polymer resin, a polyamide resin, a polyester resin, a polycarbonate resin, a polyestercarbonate resin, a polystyrene resin, an acrylonitrylstyrene polymer resin, an acrylonitrile-butylacrylate-styrene polymer resin, a polyether imide resin, a polyphenylene ether resin, a polyphenylene oxide resin, a polyphenylenesulphide resin, a polyether resin, a polyetherketone resin, a polyacetal resin, a polyurethane resin, a polybenzimidazole resin, and copolymers and mixtures thereof.
  • a polyolefin resin a thermoplastic polyolefin blend resin
  • a prepreg comprises a first layer comprising a thermoplastic polymer, reinforcing fibers and a lofting agent, the first layer effective to form a layer comprising a web of open cell structures upon curing of the first layer, wherein the web open celled structures is defined by random crossing over of the reinforcing fibers held together by the thermoplastic polymer with the lofting agent trapped in the open cell structures of the web, wherein the lofting agent is effective to increase a thickness of the first layer after exposure to heat to provide a post-lofted first layer, and a film disposed on a first surface of the first layer, in which the post lofted first layer and film together can withstand at least 50 individual impacts according to a SAE J400 protocol without damage to the film.
  • the thermoplastic polymer is a polymer resin that is selected from the group consisting of a polyolefin resin, a thermoplastic polyolefin blend resin, a polyvinyl polymer resin, a butadiene polymer resin, an acrylic polymer resin, a polyamide resin, a polyester resin, a polycarbonate resin, a polyestercarbonate resin, a polystyrene resin, an acrylonitrylstyrene polymer resin, an acrylonitrile-butylacrylate-styrene polymer resin, a polyether imide resin, a polyphenylene ether resin, a polyphenylene oxide resin, a polyphenylenesulphide resin, a polyether resin, a polyetherketone resin, a polyacetal resin, a polyurethane resin, a polybenzimidazole resin, and copolymers and mixtures thereof.
  • a polyolefin resin a thermoplastic polyolefin blend resin
  • the first layer comprises polypropylene, glass fibers and microsphere lofting agents, in which the film is a polypropylene homopolymer film and the scrim is polyester non-woven scrim.
  • the film is directly disposed on the first surface of the first layer without any intervening layer or material and the scrim is directly disposed on the second surface of the first layer without any intervening layer or material.
  • the scrim is disposed as one or more strips on the second surface of the first layer.
  • the prepreg comprises an additional layer coupled to the first layer, the additional layer comprising a web of open celled structures defined by random crossing over of reinforcing fibers held together by a thermoplastic polymer.
  • the additional layer further comprises a lofting agent effective to increase a thickness of the additional layer.
  • the additional layer comprises a lower weight percentage of thermoplastic material than an amount of thermoplastic material present in the first layer.
  • the film is configured to withstand more impacts as a thickness of the first layer is decreased.
  • the method comprises compressing the composite prepreg to a predetermined thickness to form a composite article. In other examples, the method comprises lofting the composite article to increase the thickness of the composite article. In further examples, the method comprises disposing a scrim on a second surface of the web. In some examples, the method comprises compressing the composite prepreg to a predetermined thickness to form a composite article. In other examples, the method comprises configuring the thermoplastic polymer as a polypropylene resin, configuring the reinforcing fibers as glass fibers and configuring the lofting agent as microspheres. In certain examples, the method comprises configuring the film as a homopolymer film or a copolymer film.
  • the method comprises selecting the homopolymer film to be a polyolefin film. In certain instances, the method comprises configuring the film to have a thickness of at least 10 mils. In other embodiments, the method comprises configuring the thermoplastic resin to be present at 50% by weight or more in the aqueous solution.
  • the method comprises lofting the composite article to increase the thickness of the composite article.
  • the method comprises selecting the scrim as a scrim that comprises glass fibers, aramid fibers, graphite fibers, carbon fibers, inorganic mineral fibers, metal fibers, metalized synthetic fibers, and metalized inorganic fibers.
  • the film and the scrim are simultaneously disposed on the core layer.
  • the method comprises configuring each of the thermoplastic polymer and the lofting agent as particles with about the same average particle diameter.
  • the method comprises configuring the thermoplastic polymer as a polypropylene resin, configuring the reinforcing fibers as glass fibers and configuring the lofting agent as microspheres.
  • a method of reducing drag on a vehicle comprises coupling an underbody shield to the vehicle, the underbody shield comprising a thermoplastic core layer comprising a web of open celled structures defined by random crossing over of reinforcing fibers held together by a thermoplastic polymer, the thermoplastic core layer further comprising a lofting agent effective to increase a thickness of the core layer upon exposure to heat to provide a post lofted core layer, a film disposed on a first surface of the core layer and a scrim disposed on a second surface of the core layer, in which the underbody shield can withstand at least 50 individual impacts according to a SAE J400 protocol without damage to the film of the underbody shield.
  • a method of reducing drag on a vehicle comprises providing an underbody shield comprising a thermoplastic core layer comprising a web of open celled structures defined by random crossing over of reinforcing fibers held together by a thermoplastic polymer, the thermoplastic core layer further comprising a lofting agent effective to increase a thickness of the core layer upon exposure to heat to provide a post lofted core layer, and a film disposed on a first surface of the core layer, in which the underbody shield can withstand at least 50 individual impacts according to a SAE J400 protocol without damage to the film of the underbody shield.
  • a method of reducing drag on a vehicle comprises providing an underbody shield comprising a thermoplastic core layer comprising a web of open celled structures defined by random crossing over of reinforcing fibers held together by a thermoplastic polymer, the thermoplastic core layer further comprising a lofting agent effective to increase a thickness of the core layer upon exposure to heat to provide a post lofted core layer, a film disposed on a first surface of the core layer and a scrim disposed on a second surface of the core layer, in which the underbody shield can withstand at least 50 individual impacts according to a SAE J400 protocol without damage to the film of the underbody shield.
  • a molded composite comprises a fiber reinforced thermoplastic polymer core, a film disposed on a first surface of the fiber reinforced thermoplastic polymer core, and a scrim disposed on a second surface of the fiber reinforced thermoplastic polymer core, in which the molded composite can withstand at least 50 individual impacts according to a SAE J400 protocol without damage to the film of the underbody shield.
  • the fiber reinforced thermoplastic polymer core comprises a web of open celled structures defined by random crossing over of reinforcing fibers held together by a thermoplastic polymer.
  • the reinforcing fibers comprise glass fibers.
  • the film comprises a thickness of at least 10 mils.
  • the thermoplastic polymer is present at 50% by weight or more and the polymer core further comprises a lofting agent.
  • FIG. 1 is an illustration of a core layer coupled to a skin layer, in accordance with certain examples
  • FIG. 2 is an illustration of two core layers and a skin layer, in accordance with certain configurations
  • FIG. 4 is an illustration of a composite article including a core layer, two skin layers and a decorative layer, in accordance with certain embodiments
  • FIG. 5 is an example of a core layer and two skins layers, in accordance with certain configurations
  • FIG. 6 is an illustration of a core layer, a skin layer, and skin layer strips in accordance with certain examples
  • FIGS. 7A and 7B show illustrations of skin layers smaller than a surface of a core layer, in accordance with certain embodiments
  • FIGS. 8A-8D show various configurations of a prepreg, in accordance with certain configurations
  • FIG. 9 is an illustration of an article comprising a prepreg or core and a film, in accordance with certain embodiments.
  • FIG. 10 is an illustration of an article comprising a prepreg or core, a film and a scrim, in accordance with certain embodiments
  • FIG. 11 is an illustration of an article comprising a prepreg or core, a film, a scrim and a decorative layer, in accordance with certain embodiments.
  • FIGS. 12A-12C are photographs of various boards subjected to a gravelometer test.
  • the materials described herein are typically used together to provide an underbody shield which can be coupled to the underside of a vehicle. While some illustrations below refer to coupling of an underbody shield to a passenger automobile, the underbody shields can also be used in commercial vehicles, recreational vehicles, all-terrain vehicles and in other vehicles comprising a gas engine, hybrid engine, electric engine, fuel cell as an engine and the like. Further, the underbody shields can be used in other areas of the engine compartment, e.g., as an engine cover or positioned along the side of an engine block, as wheel well liners, as trunk liners or in other vehicular applications where a light weight, impact resistant composite panel is desired.
  • the composite article can be tested according to the SAE J400 test and may be considered to pass the test if the number of impact cycles exceeds a desired value, e.g., greater than or equal to 50 impacts by individual stones, gravels or equivalent flying objects, greater than or equal to 100 impacts by individual stones, gravels or equivalent flying objects, greater than or equal to 200 impacts by individual stones, gravels or equivalent flying objects, or greater than or equal to 300 impacts by individual stones, gravels or equivalent flying objects.
  • a desired value e.g., greater than or equal to 50 impacts by individual stones, gravels or equivalent flying objects, greater than or equal to 100 impacts by individual stones, gravels or equivalent flying objects, greater than or equal to 200 impacts by individual stones, gravels or equivalent flying objects, or greater than or equal to 300 impacts by individual stones, gravels or equivalent flying objects.
  • the film may be present (or include) a homopolymer with optionally with one or more additives or a co-polymer optionally with one or more additives.
  • the film may comprise a homopolymer or copolymer comprising one or more polyolefins optionally with one or more additives such as, for example, colorants, impact modifiers, elastomers, etc.
  • Illustrative polymers which may be present in the film or from which the film may be produced include, but are not limited to, one or more of polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate.
  • impact modified films and other films can be used to provide an article that can meet at least 50 impacts, 100 impacts or more according to the SAE Standard J400.
  • the underbody shield compositions described herein may comprise a core layer and a skin layer, e.g., a film or other material which can provide impact resistance to the underbody shield, disposed on the core layer to provide a composite article with an impact resistance of at least 100 individual impacts (according to SAE J400) without any destruction of the skin layer.
  • a simplified illustration of an underbody shield board which can be formed into an underbody shield, e.g., using molding, thermoforming, drawing or other forming processes, is shown.
  • the board 100 comprises a core layer 110 and a skin layer 120 disposed on the core layer 110 .
  • the skin layer 120 is typically a film with a suitable thickness and properties to provide impact resistance though other materials may instead be used in some configurations.
  • the core layer 110 can also impart some impact resistance to the composite article even though the impact is not directly incident on the core layer 110 .
  • the particular dimensions shown in FIG. 1 have been enlarged for illustration and no particular thickness of one component, relative to the thickness of another component, is intended to be applied.
  • the core layer 110 generally comprises a web open celled structures defined by random crossing over of reinforcing materials, e.g., reinforcing fibers, held together by a thermoplastic polymer.
  • the thermoplastic core layer 110 may also comprise a lofting agent effective to increase a thickness of the core layer upon exposure to heat to provide a post lofted core layer.
  • the molding process and the lofting process may be performed together, e.g., by placing the board 100 into a heated mold and applying a sufficient amount of heat to mold the board and loft the core of the board.
  • the particular amounts and types of materials present in the core layer 110 and the skin layer 120 are discussed in more detail below.
  • the resin content of the core layer 110 may be increased (compared to a non-impact resistance board), the thickness of the core layer 110 may be decreased and/or the film thickness can be increased to enhance impact resistance of the board 100 .
  • the core layer may comprise a higher polymer to reinforcing material ratio (e.g., greater than or equal to 50% by weight thermoplastic polymer in the core layer 110 ).
  • a higher polymer resin amount present in a core layer adjacent to a film can increase the impact resistance of the composite article.
  • the overall thickness of a core layer adjacent to a skin layer 120 may be decreased to provide for enhanced impact strength.
  • impact resistance of the composite article can be increased.
  • selection of skin layer properties and/or thickness in combination with a decreased thickness core layer may further enhance impact resistance of the article.
  • a core layer 110 may comprise at least 50 weight percent or at least 55 weight percent thermoplastic polymer.
  • the balance of the core layer 110 may comprise reinforcing materials and/or a lofting agent.
  • glass fibers may be present in the core layer 110 up to about 30-45 weight percent, and a lofting agent may be present from about 0 weight percent to about 15 weight percent.
  • the skin layer 120 may be a film (or may comprise a film) with a thickness of 10 mils or more, and the composite article formed using the layers 110 , 120 may withstand at least 50 impacts by individual stones, gravels or equivalent flying objects as tested using a gravelometer test.
  • the film 120 may comprise a homopolymer or copolymer such as a polyolefin homopolymer or a polyolefin copolymer (optionally with one or more additives) that provides impact resistance.
  • a homopolymer or copolymer such as a polyolefin homopolymer or a polyolefin copolymer (optionally with one or more additives) that provides impact resistance.
  • Illustrative homopolymers for the film 120 include but are not limited to, polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate homopolymers.
  • the copolymers may be produced, for example, using one or more of polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate.
  • the exact thickness of the film can vary and in some instances the film is desirably thick enough to provide at least 50 impacts (to the article comprising the film) under the SAE J400 protocol.
  • the film thickness can vary, for example, based on the thickness and properties of the core layer.
  • the film 120 is at least about 10 mils thick, more particularly, 12 mils, thick, 14 mils thick, 16 mils thick, 18 mils thick or 20 mils thick or more.
  • the core layer can be split into two or more separate core layers if desired. While in some instances, a first and second core layer may comprise the same polymer and/or reinforcing materials, the reinforcing materials and/or polymer of the different core layers can be different if desired.
  • FIG. 2 an article 200 is shown comprising a first core layer 210 and a second core layer 220 .
  • a skin layer 230 e.g., impact resistance film, is disposed on the core layer 210 . Where two or more core layers are present, the core layer adjacent to the skin layer 230 may comprise a higher polymer to reinforcing material ratio than other core layers.
  • a higher polymer resin amount present in a core layer adjacent to a skin layer can increase the impact resistance of the article.
  • the overall thickness of a core layer adjacent to a skin layer 230 may be decreased to provide for enhanced impact strength.
  • impact resistance can be increased.
  • selection of film properties and/or thickness in combination with a decreased thickness core layer may further enhance impact resistance of the article.
  • the combination of the first core layer 210 and the second core layer 220 may provide an overall desired thickness with the second core layer 220 being thicker than the first core layer 210 .
  • the core layer 210 may comprise at least 50 weight percent may comprise at least 50 weight percent or at least 55 weight percent thermoplastic polymer.
  • the balance of the core layer 210 may comprise reinforcing materials and/or a lofting agent.
  • glass fibers may be present in the core layer 210 up to about 30-45 weight percent, and a lofting agent may be present from about 0 weight percent to about 15 weight percent.
  • the core layer 220 may be configured similar to the core layer 210 or may comprise a lower weight percent thermoplastic polymer, e.g., less than 50 weight percent thermoplastic polymer.
  • the reinforcing material present in the core layers 210 , 220 may be the same or may be different, e.g., may both be glass fibers.
  • one of the core layers 210 , 220 may comprise more lofting agent such that increased thickness can be achieved by lofting one of the core layers 210 , 220 .
  • the core layer 220 may comprise more lofting agent than the core layer 210
  • the core layer 210 may comprise more lofting agent than the core layer 220 . While not wishing to be bound by any particular theory, by including more lofting agent in the core layer 210 , during the lofting process expansion of the core layer 210 can result in higher compression ratio for the molding process which enhances bonding between the two layers 210 , 230 .
  • the skin layer 230 may be a film (or may comprise a film) with a thickness of 10 mils or more, and the composite article formed using the layers 210 - 230 may withstand at least 50 impacts by individual stones, gravels or equivalent flying objects as tested using a gravelometer test.
  • the film 230 may comprise a homopolymer or copolymer such as a polyolefin (optionally with one or more additives) that provides impact resistance.
  • Illustrative homopolymers for the film 230 include but are not limited to, polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate homopolymers.
  • the copolymers may be produced, for example, using one or more of polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate.
  • the exact thickness of the film can vary and in some instances the film is desirably thick enough to provide at least 50 impacts (to the article comprising the film) under the SAE J400 protocol.
  • the film thickness can vary, for example, based on the thickness and properties of the core layer.
  • the film 230 is at least about 10 mils thick, more particularly, 12 mils, thick, 14 mils thick, 16 mils thick, 18 mils thick or 20 mils thick or more.
  • materials for use as an underbody shield material may include a core layer, a first skin layer and a second skin layer.
  • an underbody shield board 300 is shown comprising a core layer 310 , a first skin layer 320 disposed on one surface and a second skin layer 330 disposed on another surface. While the first and second skin layers 320 , 330 may be the same, in a typical configuration, the skin layer 320 is selected to provide impact resistance and the skin layer 330 is selected for properties other than impact resistance, e.g., to provide acoustics properties, flame retardancy, liquid absorption, aesthetic features, etc.
  • the skin layer 320 is typically exposed to the outside environment and may receive impacts from gravel or other debris in its use environment.
  • the particular dimensions shown in FIG. 3 have been enlarged for illustration and no particular thickness of one component, relative to the thickness of another component, is intended to be applied.
  • the skin layers 320 , 330 may have the same or a different thickness.
  • the core layer 310 generally comprises a web open celled structures defined by random crossing over of reinforcing materials, e.g., reinforcing fibers, held together by a thermoplastic polymer.
  • the thermoplastic core layer 310 may also comprise a lofting agent effective to increase a thickness of the core layer 310 upon exposure to heat to provide a post lofted core layer.
  • the molding process and the lofting process may be performed together, e.g., by placing the board 300 into a heated mold and applying a sufficient amount of heat to mold the board and loft the core of the board.
  • the resin content of the core layer 310 may be increased (compared to a non-impact resistance board), the thickness of the core layer 310 may be decreased and/or the film thickness of the layer 320 can be increased to enhance impact resistance of the board 300 .
  • the core layer 310 may comprise a higher polymer to reinforcing material ratio (e.g., greater than or equal to 50% by weight thermoplastic polymer in the core layer 310 ).
  • a higher polymer resin amount present in a core layer 310 adjacent to a skin layer 320 comprising a film can increase the impact resistance of the composite article.
  • the overall thickness of a core layer 310 adjacent to the skin layer 320 may be decreased to provide for enhanced impact strength.
  • by decreasing the overall thickness of the core layer 310 impact resistance of the composite article can be increased.
  • selection of skin layer properties and/or thickness in combination with a decreased thickness core layer 310 may further enhance impact resistance of the article.
  • a core layer 310 may comprise at least 50 weight percent or at least 55 weight percent thermoplastic polymer.
  • the balance of the core layer 310 may comprise reinforcing materials and/or a lofting agent.
  • glass fibers may be present in the core layer 310 up to about 30-45 weight percent, and a lofting agent may be present from about 0 weight percent to about 15 weight percent.
  • the skin layer 320 may be a film (or may comprise a film) with a thickness of 10 mils or more.
  • the layer 330 may comprise a scrim.
  • a composite article formed using the layers 310 , 320 and 330 may withstand at least 50 impacts by individual stones, gravels or equivalent flying objects as tested using a gravelometer test.
  • the film 320 may comprise a homopolymer such as a polyolefin (optionally with one or more additives) that provides impact resistance.
  • a homopolymer such as a polyolefin (optionally with one or more additives) that provides impact resistance.
  • Illustrative homopolymers for the film 320 include but are not limited to, polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate homopolymers.
  • the copolymers may be produced, for example, using one or more of polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate.
  • the exact thickness of the film can vary and in some instances the film is desirably thick enough to provide at least 50 impacts (to the article comprising the film) under the SAE J400 protocol.
  • the film thickness can vary, for example, based on the thickness and properties of the core layer.
  • the film 320 is at least about 10 mils thick, more particularly, 12 mils, thick, 14 mils thick, 16 mils thick, 18 mils thick or 20 mils thick or more.
  • the components of the boards shown in FIGS. 1-3 may be coupled to each other without the use of any intervening adhesive layer.
  • an adhesive layer is present to enhance bonding between the various components.
  • the components are directly coupled to each other without any intervening adhesive layer or other layers.
  • a skin layer can be disposed directly on a surface of the core layer. The construct may be heated and/or compressed to bond the skin layer directly to the core layer without the use of an adhesive layer.
  • the core layers can be directly coupled to each other without the use of an adhesive layer between them.
  • the core layer 410 generally comprises a web open celled structures defined by random crossing over of reinforcing materials, e.g., reinforcing fibers, held together by a thermoplastic polymer.
  • the thermoplastic core layer 410 may also comprise a lofting agent effective to increase a thickness of the core layer 410 upon exposure to heat to provide a post lofted core layer.
  • the molding process and the lofting process may be performed together, e.g., by placing the board 400 into a heated mold and applying a sufficient amount of heat to mold the board and loft the core of the board.
  • the resin content of the core layer 410 may be increased (compared to a non-impact resistance board), the thickness of the core layer 410 may be decreased and/or the thickness of the layer 420 can be increased to enhance impact resistance of the board 400 .
  • the core layer 410 may comprise a higher polymer to reinforcing material ratio (e.g., greater than or equal to 50% by weight thermoplastic polymer in the core layer 410 ).
  • a higher polymer resin amount present in a core layer 410 adjacent to a skin layer 420 comprising a film can increase the impact resistance of the composite article.
  • the overall thickness of a core layer 410 adjacent to the skin layer 420 may be decreased to provide for enhanced impact strength.
  • by decreasing the overall thickness of the core layer 410 impact resistance of the composite article can be increased.
  • selection of skin layer properties and/or thickness in combination with a decreased thickness core layer 410 may further enhance impact resistance of the article.
  • a core layer 410 may comprise at least 50 weight percent or at least 55 weight percent thermoplastic polymer.
  • the balance of the core layer 410 may comprise reinforcing materials and/or a lofting agent.
  • glass fibers may be present in the core layer 410 up to about 30-45 weight percent, and a lofting agent may be present from about 0 weight percent to about 15 weight percent.
  • the skin layer 420 may be a film (or may comprise a film) with a thickness of 10 mils or more.
  • the layer 430 may comprise a scrim.
  • the adhesive layer 440 may comprise a thermoplastic polymer adhesive and/or a thermoset adhesive. In certain embodiments, the adhesive layer 440 may comprise a polyolefin thermoplastic adhesive.
  • the particular dimensions shown in FIG. 5 have been enlarged for illustration and no particular thickness of one component, relative to the thickness of another component, is intended to be applied.
  • the skin layers 520 , 530 may have the same or a different thickness.
  • the core layer 510 generally comprises a web open celled structures defined by random crossing over of reinforcing materials, e.g., reinforcing fibers, held together by a thermoplastic polymer.
  • the thermoplastic core layer 510 may also comprise a lofting agent effective to increase a thickness of the core layer 510 upon exposure to heat to provide a post lofted core layer.
  • the exact thickness of the film can vary and in some instances the film is desirably thick enough to provide at least 50 impacts (to the article comprising the film) under the SAE J400 protocol.
  • the film thickness can vary, for example, based on the thickness and properties of the core layer.
  • the film 520 is at least about 10 mils thick, more particularly, 12 mils, thick, 14 mils thick, 16 mils thick, 18 mils thick or 20 mils thick or more.
  • the skin strips 630 a , 630 b may have the same or a different thickness and may comprise a similar or a different composition. In use, the strips 630 a , 630 b may not be positioned in areas that will experience impacts. Instead, the skin layer 620 can be selected to be impact resistant with the skins 630 a , 630 b being present in non-impact areas of the board 600 .
  • the core layer 610 generally comprises a web open celled structures defined by random crossing over of reinforcing materials, e.g., reinforcing fibers, held together by a thermoplastic polymer.
  • the thermoplastic core layer 610 may also comprise a lofting agent effective to increase a thickness of the core layer 610 upon exposure to heat to provide a post lofted core layer.
  • the molding process and the lofting process may be performed together, e.g., by placing the board 600 into a heated mold and applying a sufficient amount of heat to mold the board and loft the core of the board.
  • the resin content of the core layer 610 may be increased (compared to a non-impact resistance board), the thickness of the core layer 610 may be decreased and/or the thickness of the layer 620 can be increased to enhance impact resistance of the board 600 .
  • the core layer 610 may comprise a higher polymer to reinforcing material ratio (e.g., greater than or equal to 50% by weight thermoplastic polymer in the core layer 610 ).
  • a higher polymer resin amount present in a core layer 610 in combination with a skin layer 620 comprising a film can increase the impact resistance of the composite article.
  • the overall thickness of a core layer 610 may be decreased to provide for enhanced impact strength. In some configurations, by decreasing the overall thickness of the core layer 610 , impact resistance of the composite article can be increased. In addition, selection of skin layer properties and/or thickness in combination with a decreased thickness core layer 610 may further enhance impact resistance of the article.
  • a composite article formed using the layers 610 , 620 , and 630 a , 630 b may withstand at least 50 impacts by individual stones, gravels or equivalent flying objects as tested using a gravelometer test.
  • the core layer 610 may comprise a scrim disposed on an opposite surface similar to the scrim 330 present in FIG. 3 .
  • the film 620 may comprise a homopolymer such as a polyolefin (optionally with one or more additives) that provides impact resistance.
  • Illustrative homopolymers for the film 620 include but are not limited to, polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate homopolymers.
  • the skin layer need not traverse the entire surface of the core layer.
  • a board 700 comprising a core layer 710 and a skin layer 720 disposed on the core layer 710 is shown.
  • the outer edges of the core layer 710 do not comprise any skin layer 720 .
  • a board 750 is shown that comprises strips 730 a , 730 b adjacent to the skin layer 720 .
  • the molding process and the lofting process may be performed together, e.g., by placing the board 700 or 750 into a heated mold and applying a sufficient amount of heat to mold the board and loft the core of the board.
  • the resin content of the core layer 710 may be increased (compared to a non-impact resistance board), the thickness of the core layer 710 may be decreased and/or the thickness of the layer 720 can be increased to enhance impact resistance of the board 700 or 750 .
  • the core layer 710 may comprise a higher polymer to reinforcing material ratio (e.g., greater than or equal to 50% by weight thermoplastic polymer in the core layer 710 ).
  • a higher polymer resin amount present in a core layer 710 in combination with a skin layer 720 comprising a film can increase the impact resistance of the composite article.
  • the overall thickness of a core layer 710 may be decreased to provide for enhanced impact strength. In some configurations, by decreasing the overall thickness of the core layer 710 , impact resistance of the composite article can be increased. In addition, selection of skin layer properties and/or thickness in combination with a decreased thickness core layer 710 may further enhance impact resistance of the article.
  • a core layer 710 may comprise at least 50 weight percent or at least 55 weight percent thermoplastic polymer.
  • the balance of the core layer 610 may comprise reinforcing materials and/or a lofting agent.
  • glass fibers may be present in the core layer 610 up to about 30-45 weight percent, and a lofting agent may be present from about 0 weight percent to about 15 weight percent.
  • the skin layer 720 may be a film (or may comprise a film) with a thickness of 10 mils or more.
  • the skin strips 730 a , 730 b may also comprise a film, a scrim or other suitable skin layers.
  • a composite article formed using the layers 710 , 720 , and optionally 730 a , 730 b may withstand at least 50 impacts by individual stones, gravels or equivalent flying objects as tested using a gravelometer test.
  • the core layer 710 may comprise a scrim disposed on an opposite surface similar to the scrim 330 present in FIG. 3 , e.g., either of the boards 700 or 750 may comprise a scrim or other layer disposed on a surface of the core layer 710 .
  • the film 720 may comprise a homopolymer such as a polyolefin (optionally with one or more additives) that provides impact resistance.
  • a homopolymer such as a polyolefin (optionally with one or more additives) that provides impact resistance.
  • Illustrative homopolymers for the film 720 include but are not limited to, polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate homopolymers.
  • the copolymers may be produced, for example, using one or more of polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate.
  • the exact thickness of the film can vary and in some instances the film is desirably thick enough to provide at least 50 impacts (to the article comprising the film) under the SAE J400 protocol.
  • the film thickness can vary, for example, based on the thickness and properties of the core layer.
  • the film 720 is at least about 10 mils thick, more particularly, 12 mils, thick, 14 mils thick, 16 mils thick, 18 mils thick or 20 mils thick or more.
  • the underbody shields described herein are often molded or processed into various shapes to provide a final formed part or article. During processing, it may be desirable to increase the overall thickness of one or more components or layers of the article to be processed.
  • the presence of a lofting agent in a thermoplastic prepreg or a thermoplastic core permits alteration of the overall thickness of the article (or a portion thereof) during heating, molding or other temperature or processing operations.
  • the lofting agent can be dispersed, e.g., in a substantially uniform distribution from surface to surface if desired, in void space of a thermoplastic prepreg or core comprising a thermoplastic material and a plurality of fibers.
  • the lofting agent may be present in the prepreg or core but not covalently bonded to the other materials in the prepreg or core.
  • the lofting agent may be covalently bonded to one or more groups present in the thermoplastic material or covalently bonded to one or more groups of the plurality of fibers or both.
  • the exact lofting temperature used can vary depending on the other materials present in the prepregs, cores and articles, and in some instances, the lofting temperature may be greater than or equal to the melting point temperature of the thermoplastic material(s) present in the prepregs, cores and articles.
  • the articles described herein can comprise a prepreg or core layer.
  • a prepreg is generally not a fully cured or processed version of a core.
  • a prepreg comprising a thermoplastic material, a plurality of reinforcing fibers and a lofting agent
  • a fully cured layer (which may or may not yet be lofted) comprising thermoplastic material, a plurality of reinforcing materials such as fibers and a lofting agent is generally referred to as a core or core layer.
  • the core may be considered cured, the core can still be further processed to increase its thickness, to alter its shape or to otherwise provide a formed article or product suitable for an intended use.
  • the description below makes reference to both a prepreg and a core and the materials (and their amounts and properties) used in connection with a prepreg can also be used in a core if desired.
  • a suitable amount of a lofting agent is included in the prepregs core and articles to provide for selective lofting of the prepregs, cores and articles.
  • Lofting generally refers to an overall increase in thickness of the prepreg, core or article during or after a processing condition, e.g., application of heat and/or pressure.
  • a lofting agent can be selected such that the prepreg, core or article is substantially insensitive to loft at a first temperature and/or first heating conditions and then is sensitive to loft at a second temperature and/or second heating conditions.
  • the lofting agent can be selected to not substantially loft at 180-190 or 190-200 deg. Celsius and to loft at 210 or 220 deg. Celsius.
  • the first and second temperatures can vary depending on the thermoplastic material present in the prepreg, core or article.
  • the lofting agent is selected such that substantially no loft occurs until the loft temperature is about 20 deg. Celsius or more higher than the melting point of the thermoplastic material in the prepreg or core layer. In other instances, the lofting agent is selected such that substantially no loft occurs until the loft temperature is about 40 deg. Celsius or more higher than the melting point of the thermoplastic material in the core layer. In further instances, the lofting agent (and/or the lofting conditions) is selected such that substantially no loft occurs until the loft temperature is about 60 deg. Celsius or more higher than the melting point of the thermoplastic material of the core layer. In some instances, the lofting agent is selected such that substantially no loft occurs until the loft temperature is about 80 deg. Celsius or more higher than the melting point of the thermoplastic material in the core layer.
  • the lofting agent of the prepregs and cores described herein may comprise one or more liquid hydrocarbon-polymer shell materials.
  • the exact type of lofting agent used in the core can depend on numerous factors including, for example, the desired lofting temperature, the desired basis weight, desired processing conditions and other factors.
  • Illustrative commercially available lofting agents that can be present in a prepreg or core are commercially available from Kureha Corp. (Japan) and include, for example, H1100 liquid hydrocarbon core-polymer microspheres.
  • the lofting agent can be present in many forms including fiber form, particle form, microsphere form or other forms.
  • the lofting agent can be present in microsphere form and may comprise an average particle size of at least 40 microns, for example, or may comprise an average particle size that is substantially similar to the average particle size of thermoplastic material in the core. In some examples, the lofting agent may be present from about 2 weight percent to about 20 weight percent, though depending on the desired degree of loft, more or less lofting agent can be used in the prepreg or core. While not wishing to be bound by any particular theory, liquid hydrocarbon-polymer shell materials can provide some softness or flexural properties to the core to permit the core to flex and/or absorb some of the impact energy received by the skin layer. This energy absorption can further enhance the impact resistance of the underbody shield materials.
  • a porous prepreg comprising one or more thermoplastic materials and a plurality of reinforcing materials, e.g., reinforcing fibers, that together have an open cell structure, e.g., void space
  • a lofting agent can be loaded into the void space in a manner where the lofting agent generally does not covalently bond with the thermoplastic materials and/or the fibers.
  • the thermoplastic materials and/or the fibers can be selected so that they are generally inert or non-reactive with the lofting agent. Even though the lofting agent may not covalently bond to the thermoplastic material and/or the fibers, there can be covalent bonding present in or within the lofting agent itself.
  • the lofting agent may be desirable to covalently bond the lofting agent to the thermoplastic materials, the fibers or both to provide some covalently bonded lofting agent in the prepreg. Even where bonded lofting agent is present, the lofting agent desirably can still increase their occupied volume under suitable conditions such as, for example, convection heating to permit lofting of the prepreg. In some instances, both covalently bonded lofting agent and non-covalently bonded lofting agent materials may also be present in the prepreg.
  • the prepregs may comprise lofting agent where about 100% of the lofting agent materials are non-covalently bonded, weak interactions such as van der Waals' interactions or electrostatic interactions can take place between the lofting agent and the other components of the prepreg.
  • a prepreg 800 that comprises a thermoplastic material and a plurality of reinforcing fibers.
  • the prepreg 800 also comprises a lofting agent (shown for illustration purposes as dots 805 ) dispersed through the prepreg 800 .
  • the lofting agent dispersion can be substantially homogeneous or substantially uniform from a first surface 802 to a second surface 804 of the prepreg 800 .
  • the components of the prepreg 800 can be mixed together to form a substantially uniform dispersion.
  • the prepreg 800 may then be formed as described herein, e.g., by disposing the dispersion on a wire screen using a suitable laying process. In other configurations, it may be desirable to provide a gradient distribution of lofting agent from the surface 802 to the surface 804 such that more lofting agent materials are present toward one of the surfaces 802 , 804 than the other surface. In some embodiments, a substantially uniform distribution of lofting agent is present in a prepreg 800 and then additional lofting agent is added to one side of the prepreg 800 to provide a gradient distribution.
  • the prepregs 810 , 820 may comprise a lofting agent and the other prepreg may not comprise a lofting agent or may comprise a different lofting agent.
  • the thermoplastic materials of the prepregs 810 , 820 can be melted to provide a single prepreg 850 ( FIG. 8C ).
  • the result of melting of the prepregs 810 , 820 together is a gradient distribution of lofting agent in the prepreg 850 with increased amounts of lofting agent adjacent to a surface 852 as compared to the amount present adjacent to a surface 854 .
  • the exact overall thickness of the prepreg 850 may vary depending on the conditions used and no particular thickness is intended to be implied in FIG. 8B .
  • a distribution of lofting agent in a prepreg can be provided by coupling a skin or other material comprising lofting agent to the prepreg.
  • a skin 870 comprising lofting agent is shown as being disposed on a prepreg 860 comprising a thermoplastic material, reinforcing fibers and lofting agent. While not required, the skin 870 is typically present at a much lower thickness than a pre-lofted thickness of the prepreg 860 .
  • a discernible interface is typically present between the skin 870 and the prepreg 860 , whereas coupling of two prepregs to each other, as described in connection with FIG.
  • the skin 870 can be melted into the prepreg 860 to couple the skin 870 and the prepreg 860 to leave a coupled skin/prepreg composite material without any substantial interface.
  • an additional skin which may or may not comprise lofting agent, can also be coupled to the prepreg on an opposite side from the skin 870 .
  • the thermoplastic material of the prepreg may be present in fiber form, particle form, resin form or other suitable forms.
  • the thermoplastic material used in the prepreg can be present in particle form and have an average particle size that is substantially the same as the average particle size of the lofting agent. While not wishing to be bound by any particular scientific theory, by matching the particles sizes of the thermoplastic material and the lofting agent, enhanced processing of the prepregs including, for example, increased retention of the lofting agent in the prepreg can be achieved. In some instances, the average particle size of the lofting agent and the average particle size of the thermoplastic material can vary by about 5% to about 10% and enhanced processing can still be achieved.
  • the average particle size of each of the thermoplastic material and the lofting agent in the prepreg can differ by about 50 microns to about 120 microns. In some configurations, the average particle size of the lofting agent is at least 50% of the average particle size of the thermoplastic material particles to provide for enhanced processing. In other instances, lofting agent with an average particle size about the same as the average particle size of the thermoplastic material can be present along with lofting agent of an average particle size that is different than the average particle size of the thermoplastic material. Even though the average particle size of the lofting agent may differ, the chemical composition of the lofting agent can be the same or can be different. In yet other configurations, two or more thermoplastic materials with different average particle sizes can be present.
  • two lofting agents with average particle sizes that are substantially the same as the average particle sizes of the thermoplastic materials can be present.
  • the two lofting agents may be chemically the same or may be chemically distinct.
  • the thermoplastic materials can be chemically the same (but have a different average particle size) or can be chemically distinct.
  • the prepreg or core 700 generally comprises a substantial amount of open cell structure such that void space is present in the prepreg.
  • the prepreg or 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%, 80-95% or any illustrative value within these exemplary ranges.
  • the prepreg comprises a porosity or void content of greater than 0%, e.g., is not fully consolidated, up to about 95%.
  • the reference to the prepreg comprising a certain void content or porosity is based on the total volume of the prepreg and not necessarily the total volume of the prepreg plus any other materials or layers coupled to the prepreg.
  • the high porosity present in the prepreg or core permits trapping of lofting agent within the pores of the prepreg.
  • lofting agent can reside in the void space in a non-covalently bonded manner.
  • Application of heat or other perturbations can act to increase the volume of the non-covalently bonded lofting agent which in turn increases the overall thickness of the prepreg or core, e.g., the prepreg or core thickness increases as the size of the lofting agent increases and/or additional air becomes trapped in the prepreg.
  • the lofting agent can be operative as a heat-sensitive agent such that application of a suitable stimulus, e.g., radiant heat, functions to increase the overall thickness of the prepreg.
  • thermoplastic material of the prepregs or cores described herein may comprise, at least in part, one or more of polyethylene, polypropylene, 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.
  • thermoplastics include, but are not limited to, polyarylene ethers, polycarbonates, polyestercarbonates, thermoplastic polyesters, polyimides, polyetherimides, 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 alloys and blends of these materials with each other or other polymeric materials.
  • PARMAX® high heat polycarbonate
  • APEC® PC high temperature nylon
  • silicones as well as alloys and blends of these materials with each other or other polymeric materials.
  • thermoplastic material used to form the prepreg can be used in powder form, resin form, rosin 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 prepreg can vary and illustrative amounts range from about 20% by weight to about 90% by weight.
  • the reinforcing materials of the prepregs may take the form of fibers which are dispersed throughout the prepreg.
  • fibers which are dispersed throughout the prepreg.
  • glass fibers such as hemp, sisal, jute,
  • 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 fibers used in the prepreg can first be reacted with the lofting agent to provide a derivatized fiber that is then mixed with the thermoplastic material.
  • the lofting agent can be reacted with the thermoplastic material of the prepreg to provide a derivatized thermoplastic material that is then mixed with the fibers.
  • the fiber content in the prepreg may be from about 20% to about 90% by weight of the prepreg, more particularly from about 30% to about 70%, by weight of the prepreg.
  • the fiber content of a composite article comprising the prepreg varies between about 20% to about 90% by weight, more particularly about 30% by weight to about 80% by weight, e.g., about 40% to about 70% by weight of the composite.
  • the amount of reinforcing materials or fibers present in the prepreg or core layer may be below 50 weight percent, more particularly below 45 weight percent, e.g., below 40 weight percent or below 30 weight percent.
  • the particular size and/or orientation of the fibers used may depend, at least in part, on the polymer material used and/or the desired properties of the resulting prepreg.
  • fibers dispersed within a thermoplastic material and lofting agent to provide a prepreg generally have a diameter of greater than about 5 microns, more particularly from about 5 microns to about 22 microns, and a length of from about 5 mm to about 200 mm; more particularly, the fiber diameter may be from about 5 microns to about 22 microns and the fiber length may be from about 5 mm to about 75 mm.
  • lofting agent used in the prepreg can depend on numerous factors including, for example, the desired lofting temperature, the desired degree of loft, etc.
  • microsphere lofting agents which can increase their size upon exposure to convection heating may be used.
  • Illustrative commercially available lofting agents are available from Kureha Corp.
  • the lofting agent is present in microsphere form and may comprise an average particle size of at least 40 microns, for example.
  • a first lofting agent with a first average particle size and a second lofting agent with a second average particle size, different from the first average particle size may be used.
  • the prepreg of the underbody shield may be a substantially halogen free or halogen free prepreg to meet the restrictions on hazardous substances requirements for certain applications.
  • the prepreg 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.
  • the thermoplastic material used in the prepregs and cores may comprise one or more halogens to impart some flame retardancy without the addition of another flame retardant agent.
  • the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present.
  • the halogenated flame retardant may be present in about 0.1 weight percent to about 15 weight percent (based on the weight of the prepreg), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent.
  • two different halogenated flame retardants may be added to the prepregs.
  • 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.
  • the non-halogenated flame retardant may comprise a phosphorated material so the prepregs may be more environmentally friendly.
  • the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present.
  • 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 prepreg), 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 prepreg.
  • two different substantially halogen free flame retardants may be added to the prepregs.
  • the prepregs 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.
  • 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 prepreg), 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 prepreg.
  • the flame retardant agents used in the prepregs described herein can be added to the mixture comprising the lofting agent, thermoplastic material and fibers (prior to disposal of the mixture on a wire screen or other processing component) or can be added after the prepreg is formed.
  • the articles described herein may comprise a porous core.
  • the porous core comprises one or more thermoplastic materials and a plurality of reinforcing materials, e.g., reinforcing fibers, that can be held in place by the cured thermoplastic material in a web or network structure to provide a plurality of open cells, void space or a web in the core.
  • lofting agent can be present in the void space of the porous core in a manner where the lofting agent generally does not covalently bond with the thermoplastic materials and/or the fibers.
  • the thermoplastic materials and/or the fibers can be selected so that they are generally inert or non-reactive with the lofting agent.
  • the lofting agent may not covalently bond to the thermoplastic material and/or the fibers, there typically is covalent bonding present in or within the lofting agent itself. In other instances, it may be desirable to covalently bond the lofting agent to the thermoplastic materials, the fibers or both to provide some covalently bonded lofting agent in the core. Even where bonded lofting agent are present in the core, the lofting agent desirably can still increase their occupied volume under suitable conditions such as, for example, convection heating to permit lofting of the core. In some instances, both covalently bonded lofting agent and non-covalently bonded lofting agent may also be present in the core.
  • the core may comprise lofting agent where about 100% of the lofting agent are non-covalently bonded
  • weak interactions such as van der Waals' interactions or electrostatic interactions can take place between the lofting agent and the other components of the core, e.g., charge-charge interactions or hydrophobic interactions can take place between the various components present in the core.
  • a core can comprise lofting agent dispersed throughout the core.
  • the lofting agent dispersion can be substantially homogeneous or substantially uniform from a first surface to a second surface of the core.
  • the components of the core can be mixed together to form a dispersion. Mixing can be performed until the dispersion comprises a substantially homogeneous or substantially uniform mixture of the lofting agent, the thermoplastic materials and the fibers in the dispersion.
  • the core may then be formed as described herein, e.g., by disposing the dispersion on a wire screen using a suitable laying process followed by melting, compressing and/or consolidation of the thermoplastic material of the core.
  • a substantially uniform distribution of lofting agent is present in a core and then additional lofting agent is added to one side of the core to provide a gradient distribution.
  • additional lofting agent can be added directly to the core, e.g., by spraying or coating a solution comprising the lofting agent, or can be added by coupling a skin, additional prepreg or core or other component comprising lofting agent to the core.
  • a first core and a second core disposed on the first core can provide a composite article.
  • Each of the cores may comprise a substantially uniform distribution of lofting agent, but the amount and/or type of lofting agent in the two cores can be different, e.g., the loading rates can be different or the materials themselves may be different. If desired, however, only one of the cores may comprise lofting agent and the other core may not comprise a lofting agent or may comprise a different lofting agent.
  • the thermoplastic materials of the cores can be melted to provide a single combined core including materials from the two cores. The result of melting of the cores is a composite core with a gradient distribution of lofting agent.
  • a distribution of lofting agent in a core can be provided by coupling a skin or other material comprising lofting agent to the core.
  • the skin can be melted into the core to couple the skin and the core to leave a coupled skin/core composite material without any substantial interface.
  • an additional skin which may or may not comprise lofting agent can also be coupled to the core on an opposite side from the first skin.
  • the thermoplastic material of the core may be used to provide a core in fiber form, particle form, resin form or other suitable forms.
  • the thermoplastic material used in the core can be present in particle form and have an average particle size that is substantially the same as the average particle size of the lofting agent (when present).
  • the average particle size of the lofting agent and the average particle size of the thermoplastic material can vary by about 5% to about 10% and enhanced processing can still be achieved.
  • the average particle size of each of the thermoplastic material and the lofting agent in the core can range from about 50 microns to about 900 microns.
  • lofting agent with an average particle size about the same as the average particle size of the thermoplastic material can be present along with lofting agent of an average particle size that is different than the average particle size of the thermoplastic material.
  • the chemical composition of the lofting agent can be the same or can be different.
  • two or more thermoplastic materials with different average particle sizes can be present. If desired, two lofting agent with average particle sizes that are substantially the same as the average particle sizes of the two thermoplastic materials can be present in the core.
  • the two lofting agent may be chemically the same or may be chemically distinct.
  • the thermoplastic materials can be chemically the same (but have a different average particle size) or can be chemically distinct.
  • the core generally comprises a substantial amount of open cell structure such that void space is present in the core.
  • the 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%, 5-30%, 5-40%, 5-50%, 5-60%, 5-70%, 5-80%, 5-90%, 5-95%, 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%, 80-95% or any illustrative value within these exemplary ranges.
  • the core comprises a porosity or void content of greater than 0%, e.g., is not fully consolidated, up to about 95%.
  • the reference to the core comprising a certain void content or porosity is based on the total volume of the core and not necessarily the total volume of the core plus any other materials or layers coupled to the core.
  • the porosity of the core can be the same or can be different.
  • a prepreg is formed into a core by passing a prepreg through a set of rollers or by pressing one or both surfaces of the prepreg.
  • the porosity of the core may be different than the porosity of the prepreg, e.g., can be lower.
  • the porosity of the core is intentionally selected to be less than a comparable prepreg to provide for increased lofting capacity of the core into a final formed article or product.
  • the high porosity present in the core permits trapping of lofting agent within the pores of the core.
  • lofting agent can reside in the void space in a non-covalently bonded manner.
  • Application of heat or other perturbations can act to increase the volume of the non-covalently bonded lofting agent which in turn increases the overall thickness of the core.
  • the lofting agent can be operative as a lofting agent such that application of a suitable stimulus, e.g., convection heat, functions to increase the overall thickness of the core.
  • thermoplastic material of the cores described herein may comprise, at least in part, one or more polymers including, but not limited to, polyethylene, polypropylene, 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.
  • polymers including, but not limited to, polyethylene, polypropylene, 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.
  • thermoplastics include, but are not limited to, polyarylene ethers, polycarbonates, polyestercarbonates, thermoplastic polyesters, polyimides, polyetherimides, 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 alloys and blends of these materials with each other or other polymeric materials.
  • PARMAX® high heat polycarbonate
  • APEC® PC high temperature nylon
  • silicones as well as alloys and blends of these materials with each other or other polymeric materials.
  • thermoplastic material used to form the core can be used in powder form, resin form, rosin 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 can vary and illustrative amounts range from about 20% by weight to about 90% by weight.
  • the thermoplastic polymer component of the core is the “major” component of the core in that it is the material present in the highest weight percentage of the core.
  • the reinforcing materials of the cores may take the form of fibers that can 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, or any of the high melt flow index resins described herein that are suitable for use as fibers, natural fibers such as hemp, sisal, jute, flax, coir, kenaf and cellulosic fibers, 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.
  • fibers that can 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 fiber
  • 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 fibers used in the core can first be reacted with the lofting agent to provide a derivatized fiber that is then mixed with the thermoplastic material.
  • the lofting agent may be reacted with the thermoplastic material of the core to provide a derivatized thermoplastic material that is then mixed with the fibers.
  • the fiber content in the core may be from about 20% to about 90% by weight of the core, more particularly from about 30% to about 70%, by weight of the core.
  • fibers dispersed within a thermoplastic material and lofting agent to provide a core generally have a diameter of greater than about 5 microns, more particularly from about 5 microns to about 22 microns, and a length of from about 5 mm to about 200 mm; more particularly, the fiber diameter may be from about microns to about 22 microns and the fiber length may be from about 5 mm to about 75 mm.
  • the core may be a substantially halogen free or halogen free core to meet the restrictions on hazardous substances requirements for certain applications.
  • the core 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.
  • the thermoplastic material used in the cores may comprise one or more halogens to impart some flame retardancy without the addition of another flame retardant agent.
  • the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present.
  • 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), more particularly about 1 weight percent to about 13 weight percent, e.g., about 5 weight percent to about 13 weight percent.
  • two different halogenated flame retardants may be added to the core.
  • 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.
  • the non-halogenated flame retardant may comprise a phosphorated material so the cores may be more environmentally friendly.
  • the flame retardant is desirably present in a flame retardant amount, which can vary depending on the other components which are present.
  • 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 core), 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 cores.
  • two different substantially halogen free flame retardants may be added to the cores.
  • the prepregs and cores described herein may comprise one or more halogenated flame retardants in combination with one or more substantially halogen free flame retardants.
  • 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.
  • 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 core), 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.
  • the flame retardant agents used in the cores described herein can be added to the mixture comprising the lofting agent materials, thermoplastic material and fibers (prior to disposal of the mixture on a wire screen or other processing component) or can be added after the prepreg is formed or the core is cured, e.g., by soaking the prepreg or core in the flame retardant agent or spraying flame retardant agent on the prepreg or core.
  • an article 900 comprises a prepreg or core 910 that comprises a thermoplastic polymer material, a plurality of reinforcing fibers and lofting agent disposed in the void space of the prepreg or core.
  • the article 900 comprises a first film 920 disposed on the prepreg or core 910 .
  • the film comprises suitable properties to increase impact resistance.
  • the film 920 may be comprised of a homopolymer such as a polyolefin (optionally with one or more additives) that provides impact resistance.
  • Illustrative homopolymers for the film 920 include but are not limited to, polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate homopolymers. Where a copolymer is present in the film 920 , the copolymers may be produced, for example, using one or more of polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate.
  • the exact thickness of the film can vary and in some instances the film is desirably thick enough to provide at least 50 impacts under the SAE J400 protocol. The film thickness can vary, for example, based on the thickness and properties of the core layer.
  • the film 920 is at least about 10 mils thick, more particularly, 12 mils, thick, 14 mils thick, 16 mils thick, 18 mils thick or 20 mils thick.
  • the exact weight percentages of thermoplastic polymer in the core 910 can also vary, the thermoplastic polymer is typically present at a larger weight percentage than the reinforcing fibers and the lofting agent, e.g., the thermoplastic polymer may be present at 50-55 weight percent or more in the core 910 .
  • thermoplastic polymer of the core 910 may comprise polypropylene
  • the reinforcing fibers of the core 910 may be glass fibers
  • the lofting agent of the core may comprise microspheres
  • the skin layer 920 may be (or may comprise) a polypropylene homopolymer film.
  • the prepregs and cores described herein can be used to provide an article comprising a skin on each side of the prepreg or core.
  • an article 1000 is shown comprising a prepreg or core 1010 , an impact resistant film 1020 disposed on a first surface of the prepreg or core 1010 and a scrim 1030 disposed on a second surface of the prepreg or core 1010 .
  • the prepreg or core 1010 may comprise any of the materials described herein in connection with prepregs and cores, e.g., a thermoplastic material, reinforcing fibers and a lofting agent dispersed in the prepreg or core 1010 .
  • a thermoplastic polymer comprises a major component of the prepreg or core 1010 , e.g., is present at 50 weight percent or more in the prepreg or core.
  • the film 1020 may be comprised of a homopolymer such as a polyolefin (optionally with one or more additives) that provides impact resistance.
  • a homopolymer such as a polyolefin (optionally with one or more additives) that provides impact resistance.
  • Illustrative homopolymers for the film 1020 include but are not limited to, polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate homopolymers.
  • the copolymers may be produced, for example, using one or more of polyethylene, polypropylene, polyamide, polyethylene terephthalate, polycarbonate and polymethyl methacrylate.
  • the scrim 1030 may be a fiber based scrim and 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.
  • the core 1010 comprises polypropylene, glass fibers and a microsphere lofting agent
  • the film 1020 is a polypropylene homopolymer film
  • the scrim is a polyester non-woven.
  • an underbody shield can comprise a prepreg or core, at least one film disposed on the prepreg or core, a scrim disposed on the prepreg or core and a decorative or cover layer disposed on the scrim.
  • an article such as an underbody shield 1100 is shown comprising a prepreg or core 1110 , a film 1120 disposed on a first surface of the prepreg or core 1110 , a scrim 1030 disposed on a second surface of the prepreg or corer 1110 and a decorative layer 1140 disposed on the scrim 1130 .
  • the core 1110 comprises polypropylene, glass fibers and a microsphere lofting agent
  • the film 1120 is a polypropylene homopolymer film
  • the scrim 1130 is a polyester non-woven
  • the decorative layer 1140 may be formed, e.g., from a thermoplastic film of polyvinyl chloride, polyolefins, thermoplastic polyesters, thermoplastic elastomers, or the like.
  • the decorative layer 1140 may also be a multi-layered structure that includes a foam core formed from, e.g., polypropylene, polyethylene, polyvinyl chloride, polyurethane, and the like.
  • a fabric may be bonded to the foam core, such as woven fabrics made from natural and synthetic fibers, organic fiber non-woven fabric after needle punching or the like, raised fabric, knitted goods, flocked fabric, or other such materials.
  • the fabric may also be bonded to the foam core with a thermoplastic adhesive, including pressure sensitive adhesives and hot melt adhesives, such as polyamides, modified polyolefins, urethanes and polyolefins.
  • the decorative layer 1140 may also be produced using spunbond, thermal bonded, spun lace, melt-blown, wet-laid, and/or dry-laid processes.
  • the cores, films, scrims, etc. may instead be present as a multi-layer assembly if desired.
  • the film may desirably be present as a single layer to avoid delamination or peeling between film layers. Further, after processing of the various layers in the article, a discernible interface may not be present to distinguish one layer from another.
  • the prepregs and cores may include additional materials or additives to impart desired physical or chemical properties.
  • additional materials or additives to impart desired physical or chemical properties.
  • one or more dyes, texturizing agents, colorants, viscosity modifiers, smoke suppressants, synergistic materials, lofting agents, particles, powders, biocidal agents, foams or other materials can be mixed with or added to the prepregs or the cores.
  • the prepregs or cores may comprise one or more smoke suppressant compositions in the amount of about 0.2 weight percent to about 10 weight percent.
  • Illustrative smoke suppressant compositions include, but are not limited to, stannates, zinc borates, zinc molybdate, magnesium silicates, calcium zinc molybdate, calcium silicates, calcium hydroxides, and mixtures thereof.
  • a synergist material can be present to enhance the physical properties of the prepregs or cores. If desired, a synergist material that enhances lofting ability may be present.
  • Illustrative synergist materials include, but are not limited to, sodium trichlorobenzene sulfonate potassium, diphenyl sulfone-3-sulfonate, and mixtures thereof.
  • the prepregs or cores described herein may comprise a thermosetting material in a desired amount, e.g., in a minor amount less than about 50 weight percent based on the total weight of the prepreg or core, to impart desired properties to the core.
  • the thermosetting material may be mixed with the thermoplastic material or may be added as a coating on one or more surfaces of the prepregs or cores.
  • the prepregs or cores described herein can be configured as (or used in) a glass mat thermoplastic composite (GMT) or a light weight reinforced thermoplastic (LWRT).
  • a glass mat thermoplastic composite (GMT) or a light weight reinforced thermoplastic (LWRT).
  • LWRT is prepared by HANWHA AZDEL, Inc. and sold under the trademark SUPERLITE® mat.
  • SUPERLITE® mat loaded with lofting agent can provide desirable attributed including, for example, flame retardancy and enhanced processing capabilities.
  • the areal density of such a GMT or LWRT can range from about 400 grams per square meter (gsm) of the GMT or LWRT to about 4000 gsm, although the areal density may be less than 400 gsm or greater than 4000 gsm depending on the specific application needs.
  • the upper density can be less than about 4000 gsm.
  • the GMT or the LWRT may comprise lofting agent material disposed in void space of the GMT or the LWRT.
  • non-covalently bonded lofting agent can be present in void space of the GMT or the LWRT.
  • covalently-bonded lofting agent can be present in void space of the GMT or the LWRT.
  • both non-covalently bonded lofting agent and covalently bonded lofting agent can be present in the GMT or the LWRT.
  • the basis weight of the GMT or LWRT can be reduced to less than 800 gsm, 600 gsm or 400 gsm, for example, while still providing suitable performance properties, e.g., suitable peel strength between the LWRT and any skin disposed thereon.
  • suitable performance properties e.g., suitable peel strength between the LWRT and any skin disposed thereon.
  • an additional lofting agent e.g., microspheres can be present in the GMT or LWRT.
  • the basis weight of the LWRT used as a core of the underbody shield may be less than about 1500 gsm, e.g., 1400 gsm, 1350 gsm, 1300 gsm, 1275 gsm, 1250 gsm, 1225 gsm or 1200 gsm, and may comprise polypropylene, glass fibers and microspheres as a lofting agent.
  • the polypropylene component may be present in a major amount, e.g., 50 weight percent or more.
  • a wet-laid process For example, a liquid or fluid medium comprising dispersed material, e.g., thermoplastic materials, fibers and lofting agent material optionally with any one or more additives described herein (e.g., other lofting agents or flame retardant agents), may be stirred or agitated in the presence of a gas, e.g., air or other gas.
  • a gas e.g., air or other gas.
  • the dispersion may then be laid onto a support, e.g., a wire screen or other support material.
  • the stirred dispersion may comprise one or more active agents, e.g., anionic, cationic, or non-ionic such as, for example, those sold under the name ACE liquid by Industrial Soaps Ltd., that sold as TEXOFOR® FN 15 material, by Glover Chemicals Ltd., and those sold as AMINE Fb 19 material by Float-Ore Ltd. These agents can assist in dispersal of air in the liquid dispersion.
  • the components can be added to a mixing tank, flotation cell or other suitable devices in the presence of air to provide the dispersion.
  • one or more non-aqueous fluids may also be present to assist in dispersion, alter the viscosity of the fluid or otherwise impart a desired physical or chemical property to the dispersion or the prepreg, core or article.
  • the amount of thermoplastic polymer present in the mixture may exceed the amount of reinforcing fibers and/or lofting agent present in the mixture.
  • the fluid with the suspended materials can be disposed onto a screen, moving wire or other suitable support structure to provide a web of laid down material. Suction or reduced pressure may be provided to the web to remove any liquid from laid down material to leave behind the thermoplastic material, lofting agent and any other materials that are present, e.g., fibers, additives, etc.
  • the resulting web can be dried, consolidated, pressed, lofted, laminated, sized or otherwise processed further to provide a desired prepreg, core or article.
  • an additive or additional lofting agent material can be added to the web prior to drying, consolidation, pressing, lofting, laminating, sizing or other further processing to provide a desired prepreg, core or article.
  • the lofting agent may be added to the web subsequent to drying, consolidation, pressing, lofting, laminating, sizing or other further processing to provide a desired prepreg, core or article. While wet laid processes may be used, depending on the nature of the thermoplastic material, the lofting agent material and other materials present, it may be desirable to instead use an air laid process, a dry blend process, a carding and needle process, or other known process that are employed for making non-woven products.
  • additional lofting agent material can be sprayed onto the surface of the prepreg or core after the prepreg or core has hardened to some degree by passing the board underneath a plurality of coating jets that are configured to spray the lofting agent material at about a ninety degree angle to the prepreg or core surface.
  • the prepregs and cores described herein can be produced by combining a thermoplastic material, fibers, and microsphere lofting agent in the presence of a surfactant in an aqueous solution or foam.
  • the combined components can be mixed or agitated for a sufficient time to disperse the various materials and provide a substantially homogeneous aqueous mixture of the materials.
  • the dispersed mixture is then laid down on any suitable support structure, for example, a wire mesh or other mesh or support having a desired porosity. Water can then be evacuated through the wire mesh forming a web. The web is dried and heated above the softening temperature of the thermoplastic powder.
  • the aqueous foam also includes a binder material.
  • an adhesive layer comprising a thermoplastic polymer and a thermosetting material can then be disposed on the web.
  • a prepreg or core in the form of a GMT can be produced.
  • the GMT can be generally prepared using chopped glass fibers, a thermoplastic material, lofting agent and an optional thermoplastic polymer film or films and/or woven or non-woven fabrics made with glass fibers or thermoplastic resin fibers such as, for example, polypropylene (PP), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polycarbonate (PC), a blend of PC/PBT, or a blend of PC/PET.
  • PP, a PBT, a PET, a PC/PET blend or a PC/PBT blend can be used as a resin.
  • a thermoplastic material, reinforcing materials, lofting agent and/or other additives can be added or metered into a dispersing foam contained in an open top mixing tank fitted with an impeller.
  • the presence of trapped pockets of air of the foam can assist in dispersing the glass fibers, the thermoplastic material and the lofting agent.
  • the dispersed mixture of glass and resin can be pumped to a head-box located above a wire section of a paper machine via a distribution manifold.
  • the foam, not the glass fiber, lofting agent or thermoplastic can then be removed as the dispersed mixture is provided to a moving wire screen using a vacuum, continuously producing a uniform, fibrous wet web.
  • the wet web can be passed through a dryer at a suitable temperature to reduce moisture content and to melt or soften the thermoplastic material.
  • a surface layer such as, for example, a film and/or scrim may be laid onto the web.
  • an impact resistant film may be coupled to the web by pressing the film against the web using rollers or other devices.
  • a film may be added to an underside of the web and the combined construct can be passed between a set of rollers to couple the film to the web.
  • a scrim may be added to the top of the web to couple the scrim to the web. The scrim may be added before, after or simultaneously with the film.
  • a film can be disposed on the web from below and a scrim can be disposed on the web from above.
  • the 3-layered assembly may be passed through a set of nip rollers with selected spacing to press the film and scrim onto the surfaces of the web.
  • the 3-layer assembly may be passed through the nip of a set of heated rollers.
  • additional layers such as, for example, a non-woven and/or woven fabric layer or skin layer may also be attached to one side or to both sides of the web to facilitate ease of handling the glass fiber-reinforced mat.
  • the composite can then be passed through tension rolls and continuously cut (guillotined) into the desired size for later forming into an end product article.
  • heating conditions that are effective to loft the sheet can be applied to increase the overall board thickness.
  • the multi-layer assembly can be placed in a mold and heating conditions can be applied to loft the sheet to press the surfaces of the sheet against the other layers of the assembly while still providing a desired peel strength.
  • one or more areas of the multi-layer assembly can be drawn to a desired depth to form structures with a selected geometry and/or dimensions.
  • a method of producing a composite article comprises combining a thermoplastic material, reinforcing fibers and a lofting agent in a mixture to form an agitated aqueous foam.
  • the foam is disposed onto a wire support, and the water is evacuated to form a web or open cell structure comprising the thermoplastic material, fibers and lofting agent materials.
  • the web is then heated to a first temperature above the melting temperature of the thermoplastic material, in which the first temperature is below a loft onset temperature of the lofting agent so substantially no loft occurs.
  • the web can be heating using heating conditions that melt the thermoplastic material, e.g., convection heating, but do not substantially loft the lofting agent.
  • pressure can then be applied to the web, e.g., using nip rollers or other devices, to provide a thermoplastic composite sheet comprising the lofting agent dispersed in the web.
  • an impact resistant film may be coupled to an LWRT web by pressing the film against the web using rollers or other devices.
  • a film may be added to an underside of the web and the combined construct can be passed between a set of rollers to couple the film to the web.
  • a scrim may be added to the top of the web to couple the scrim to the web.
  • the scrim may be added before, after or simultaneously with the film.
  • a film can be disposed on the web from below and a scrim can be disposed on the web from above.
  • the 3-layered assembly may be passed through a set of nip rollers with selected spacing to press the film and scrim onto the surfaces of the web.
  • the basis weight of the tested plaques was about 1250 grams per square meter (gsm).
  • the tested plaques included a scrim (0.1-0.2 mm thick), a film (50-500 microns thick) and a polypropylene resin/glass fiber core between them to provide an overall thickness of about 2 mm.
  • the tested LWRT consisted of two primary components: chopped glass fiber and polypropylene (PP) resin.
  • the glass fiber acts as the high modulus reinforcement and the PP resin is the matrix, which holds the reinforcement in place and deforms to distribute the stress to the reinforcement under applied load.
  • PP resin polypropylene
  • the higher resin content can improve the bonding strength between the skin film and the composite core.
  • the lower adhesion strength will lead to the earlier delamination of the skin film from the core which causes the cover film to fail faster. Therefore, the high resin content sample could undergo much more gravel impact cycles than the low resin content sample.
  • MFI melt flow index
  • the effect of the melt flow index (MFI) of the resin of the core was measured to determine if changes to the MFI of the core resin altered the impact performance.
  • MFI may be measured, for example, using ASTM D1238, condition L dated 2013 and may be expressed, for example, in g/10 min. although the units are typically omitted.
  • the resin MFI can affect how fast the resin will be able to flow during the drying process in the oven and how well it can wet-out the glass fiber. The better wet-out usually gives the composite better mechanical strength.
  • Two different MFI PP resins were tested: the high MFI resin had a MFI value, e.g., about 300, of about three times of the low MFI resin, e.g., about 100.
  • the comparison of their gravelometer test results are shown in Table 3.
  • a lofting agent can be added to the LWRT formulation to increase its loft capability, reducing the weight and improving the acoustical performance.
  • the effect of the addition of lofting agent is shown in Table 4. HS1100 microsphere lofting agent was used.
  • An underbody shield can be produced by disposing a polypropylene homopolymer film on a LWRT core board comprising about 55 weight percent or more thermoplastic polymer, glass fibers and a lofting agent.
  • a non-woven scrim may be coupled to an opposite side of the board.
  • the resulting composite can be further processed by thermoforming to a desired shape and/or size for use as an underbody shield.
  • An underbody shield can be produced by disposing a polypropylene-polyethylene copolymer film (with more than 50% of the copolymer being polypropylene) on a LWRT core board comprising about 55 weight percent or more thermoplastic polymer, glass fibers and a lofting agent.
  • a non-woven scrim may be coupled to an opposite side of the board.
  • the resulting composite can be further processed by thermoforming to a desired shape and/or size for use as an underbody shield.
  • An underbody shield can be produced by disposing a polypropylene homopolymer film on a LWRT core board comprising about 55-60 weight percent or more thermoplastic polymer, about 40-45 weight percent glass fibers and about 0.1-5% by weight lofting agent.
  • a non-woven scrim may be coupled to an opposite side of the board.
  • the resulting composite can be further processed by thermoforming to a desired shape and/or size for use as an underbody shield.
  • An underbody shield can be produced by disposing a polypropylene-polyethylene copolymer film (with more than 50% of the copolymer being polypropylene) on a LWRT core board comprising about 55-60 weight percent or more thermoplastic polymer, about 40-45 weight percent glass fibers and about 0.1-5% by weight lofting agent.
  • a non-woven scrim may be coupled to an opposite side of the board.
  • the resulting composite can be further processed by thermoforming to a desired shape and/or size for use as an underbody shield.
  • An underbody shield can be produced by disposing a polypropylene homopolymer film on a LWRT core board comprising about 55-60 weight percent or more thermoplastic polymer, about 40-45 weight percent glass fibers and about 0.1-5% by weight microsphere lofting agent.
  • a non-woven scrim may be coupled to an opposite side of the board.
  • the resulting composite can be further processed by thermoforming to a desired shape and/or size for use as an underbody shield.
  • An underbody shield can be produced by disposing a polypropylene-polyethylene copolymer film (with more than 50% of the copolymer being polypropylene) on a LWRT core board comprising about 55-60 weight percent or more thermoplastic polymer, about 40-45 weight percent glass fibers and about 0.1-5% by weight microsphere lofting agent.
  • a non-woven scrim may be coupled to an opposite side of the board.
  • the resulting composite can be further processed by thermoforming to a desired shape and/or size for use as an underbody shield.
  • the Standard LWRT included a 1200 gsm core 45:55 resin:glass content (100 MFI polypropylene and glass fibers).
  • the high gravel resistant LWRT included a 1200 gsm XL2 core (included about 2.8% by weight lofting agent with the balance being resin:glass content at a ratio of about 55:45 resin:glass (325 MFI polypropylene and glass fibers).
  • Both LWRT boards included a 225 gsm polypropylene film on one surface of the core the core and 35 gsm PET scrim on an opposite surface of the core.
  • Low resin MFI refers to an MFI of about 100
  • High resin MFI refers to an MFI of about 300 or more.
  • MFI may be measured, for example, using ASTM D1238, condition L dated 2013.
  • ST-10500 included a 900 gsm XL2 core with a 225 gsm EXV2601-0500 polypropylene film on one surface of the XL2 core and a 35 gsm PET scrim on an opposite surface of the XL2 core.
  • ST-10198 included a 900 gsm XL2 core with a 225 gsm polypropylene film on one surface of the XL2 core and a 35 gsm PET scrim on an opposite surface of the XL2 core.
  • FIGS. 12A-12C Photographs of the sample boards after testing are shown in FIGS. 12A-12C .
  • FIG. 12A is a photograph of the two ST-10198 boards
  • FIG. 12B is a photograph of the two ST-10499 boards
  • FIG. 12C is a photograph of the two ST-10500 boards.

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  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Acoustics & Sound (AREA)
  • Physics & Mathematics (AREA)
  • Laminated Bodies (AREA)
  • Body Structure For Vehicles (AREA)
  • Moulding By Coating Moulds (AREA)
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CA2989126A1 (en) 2016-12-15
KR20180018698A (ko) 2018-02-21
AU2021277740A1 (en) 2021-12-23
CN107921673A (zh) 2018-04-17
EP3307507A4 (en) 2019-02-20
EP3307507A1 (en) 2018-04-18
WO2016201279A1 (en) 2016-12-15
AU2016274968A1 (en) 2018-02-01
JP2018520022A (ja) 2018-07-26
CN107921673B (zh) 2021-04-30
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AU2023282221A1 (en) 2024-01-04
JP7017936B2 (ja) 2022-02-09

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