WO2001019900A2 - Polymer laminates for vehicle liner - Google Patents
Polymer laminates for vehicle liner Download PDFInfo
- Publication number
- WO2001019900A2 WO2001019900A2 PCT/US2000/015909 US0015909W WO0119900A2 WO 2001019900 A2 WO2001019900 A2 WO 2001019900A2 US 0015909 W US0015909 W US 0015909W WO 0119900 A2 WO0119900 A2 WO 0119900A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- film
- fabric
- layer
- laminate
- thermoplastic olefin
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
- B60J7/00—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs
- B60J7/08—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs of non-sliding type, i.e. movable or removable roofs or panels, e.g. let-down tops or roofs capable of being easily detached or of assuming a collapsed or inoperative position
- B60J7/12—Non-fixed roofs; Roofs with movable panels, e.g. rotary sunroofs of non-sliding type, i.e. movable or removable roofs or panels, e.g. let-down tops or roofs capable of being easily detached or of assuming a collapsed or inoperative position foldable; Tensioning mechanisms therefor, e.g. struts
- B60J7/1226—Soft tops for convertible vehicles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0253—Polyolefin fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2323/00—Polyalkenes
- B32B2323/04—Polyethylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2323/00—Polyalkenes
- B32B2323/10—Polypropylene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/08—Cars
Definitions
- the present invention relates to an environmentally friendly polymer laminate which comprises a thermoplastic olefin film fused to a thermoplastic olefin woven layer.
- polymer laminates such as those utilized for vehi- cle toppings have often been made of polyvinyl chloride (PVC) or a PVC laminate.
- PVC polyvinyl chloride
- Such laminates are generally not environmentally friendly inasmuch as they contain plasticizers, chlorine, and thus are not readily recycled in a landfill or incinerated.
- the top PVC layer is not easily separated from the bottom polyester or cotton layer.
- the top layer of film can be a copolymer of polyethylene and polypropylene whereas the bottom layer can be a weave of polypropylene.
- Such a laminate can be utilized for convertible tops, and the like.
- FIG. 1 is a cross-sectional view of a polymer laminate according to the present invention.
- a polymer laminate according to the present invention has a solid top layer which is a thermoplastic olefin film derived from olefin monomers containing from 2 to 8 carbon atoms with 2 or 3 carbon at ⁇ oms, i.e., polypropylene or polyethylene, being preferred. Copoiymers can also be utilized with poly(ethylene-propylene) being highly preferred. Various density polyethylenes such as low density, high density, ultra high density, etc., can also be utilized
- the top film layer is preferably formed by calendering but it can also be extruded
- the top polyolefin film is desirably flexible and has a soft hand.
- the thickness of the top layer can vary depending upon end use, but generally is from about 4 to about 30, desirably from about 6 to about 25, and preferably from about 8 to about 20 mils
- the Shore D hardness of top film 20 is generally from about 30 to about 60, and desirably from about 40 to about 50, whereas the density is from about 0.87 to about 1 .25 and desirably from about 1 .0 to about 1 .20.
- the flexural modulus thereof is from about 7,000 to about
- film 20 is solid and hence is not po- rous, micro porous, or a foam. That is, it generally has a moisture vapor transmission rate of less than 450, and desirably less than 400 or 300 g/m 2 /24 hours or less according to ASTM E-96 Procedure E. Moreover, the film is not stretch orientated.
- top layers 20 can be utilized, preferably only one such top layer exists and the same is bonded to bottom fabric layer
- Bottom layer 30 is a woven fabric, which upon fusing or heat laminating is compatible with film 20.
- the woven fabric can be made out or fibers or filaments of a thermoplastic olefin, for example, a poly- mer or copolymer of a polyolefin derived from monomers having from 2 to 8 carbon atoms, with 3 carbon atoms, i.e., polypropylene being preferred.
- the polypropylene fabric is either isotactic or syndio- tactic
- the weight of the fabric is generally from about 1 to about 1 5, desirably from about 2 to about 1 0, and preferably from about 2 5 to about 7 ounces per sq. yd.
- the woven fabric is made from fibers or filaments which are extruded and is not made from fibers which are melt blown or spun blown.
- the weave can be any suitable or desired weave such as a square weave, such as, for example, sheeting or sa teen
- the top layer can be made from thermoplastic olefin pellets
- the pellets can be mixed with conventional additives in conventional amounts such as fillers, for example, si cone or clay, various antioxi- dants, various UV stabilizers, flame retardants, and the like, and mixed and heated as in a Banbury at a temperature above the melting point of the thermoplastic olefin
- the melt can then dropped onto a two roll mill and subsequently calendered at a temperature slightly above the soften ing point and sheeted to a desirable thickness and cooled
- the top and bottom layers that is, thermoplastic olefin film 20 and woven fabric 30 are bonded together through the utilization of heat and pressure
- the two layers are heat fused together as by heating the fabric layer and the film layer above their softening point and applying the layers together under pressure
- Heat fusing the two layers together can be conveniently accomplished by laminating the heated layers at a pressure of from about 35 to about 300 pounds per linear inch (PLI)
- PLI pounds per linear inch
- Heat fusing results in the top portions of the fabric extending into the bottom portion of thermoplastic olefin film 20 to form a thin intermingled or fused zone 40 It is noted that the film layer is not extruded onto to fabric layer.
- thermoplastic olefin film Another method of bonding a thermoplastic olefin film to the thermoplastic olefin woven fabric layer is to utilize an adhesive How ever, adhesives are not preferred inasmuch as they require additional process steps, add cost to the product, and adversely affect the flexibility of the polymer laminate
- Laminate 10 can have the top exposed film surface thereof subsequently altered as by corona treatment, etc to clean it as well as to render it more susceptible to finishing applications such as printing and/or coating
- Thermoplastic olefin laminate 1 0 has many desirable advantages such as that it is chlorine free, plasticizer (for example, phthalate) free, has good low temperature crack resistance at -40 ° F, is UV resistant, can be coated if desired, is flexible, can be embossed, and importantly, can be completely recycled.
- a woven polypropylene fabric layer having a square weave from Johnston Industries, Phenix City, Alabama was heated to a temperature of approximately 250°C. Both layers were then fed to a laminator having a temperature of approximately 250°F and laminated at a pressure of approximately 60 PLI The lamination produced a fused laminate as shown in Fig 1 wherein part of the woven fibers were fused into the bottom of the copolymer film layer The laminate was then cooled and rolled into a roll for subsequent use
- the laminate of the present invention can generally be util- ized as a substitute for prior PVC laminates and the like Some uses include vehicle seat covers, tire covers, convertible tops for vehicles including sport utility toppings, truck tarps, and the like Moreover, the laminate can be pigmented to achieve any desirable color
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
Abstract
An environmentally friendly polymer laminate is generally plasticizer free, chlorine free, and recyclable. The laminate has a thermoplastic olefin top layer of film which is heat fused to a woven thermoplastic olefin such as polypropylene. The laminate can be utilized as a convertible top for a vehicle.
Description
POLYMER LAMINATES FOR A VEHICLE TOPPING
FIELD OF INVENTION
The present invention relates to an environmentally friendly polymer laminate which comprises a thermoplastic olefin film fused to a thermoplastic olefin woven layer.
BACKGROUND OF THE INVENTION
Heretofore, polymer laminates such as those utilized for vehi- cle toppings have often been made of polyvinyl chloride (PVC) or a PVC laminate. Such laminates are generally not environmentally friendly inasmuch as they contain plasticizers, chlorine, and thus are not readily recycled in a landfill or incinerated. Moreover, the top PVC layer is not easily separated from the bottom polyester or cotton layer.
SUMMARY OF INVENTION
It is an object of the present invention to provide a non- PVC polymer laminate having a thermoplastic olefin top layer fused to a woven thermoplastic olefin bottom layer. The top layer of film can be a copolymer of polyethylene and polypropylene whereas the bottom layer can be a weave of polypropylene. Such a laminate can be utilized for convertible tops, and the like.
DESCRIPTION OF THE DRAWINGS Fig. 1 is a cross-sectional view of a polymer laminate according to the present invention.
DETAILED DESCRIPTION
A polymer laminate according to the present invention has a solid top layer which is a thermoplastic olefin film derived from olefin monomers containing from 2 to 8 carbon atoms with 2 or 3 carbon at¬ oms, i.e., polypropylene or polyethylene, being preferred. Copoiymers can also be utilized with poly(ethylene-propylene) being highly preferred. Various density polyethylenes such as low density, high density, ultra
high density, etc., can also be utilized The top film layer is preferably formed by calendering but it can also be extruded The top polyolefin film is desirably flexible and has a soft hand. The thickness of the top layer can vary depending upon end use, but generally is from about 4 to about 30, desirably from about 6 to about 25, and preferably from about 8 to about 20 mils The Shore D hardness of top film 20 is generally from about 30 to about 60, and desirably from about 40 to about 50, whereas the density is from about 0.87 to about 1 .25 and desirably from about 1 .0 to about 1 .20. Inasmuch as top layer or film 20 is flexible, the flexural modulus thereof is from about 7,000 to about
70,000 and desirably from about 1 0,000 to about 1 5,000 kgm/Newtons
In order to provide suitable end properties, it is an important aspect of the present invention that film 20 is solid and hence is not po- rous, micro porous, or a foam. That is, it generally has a moisture vapor transmission rate of less than 450, and desirably less than 400 or 300 g/m2 /24 hours or less according to ASTM E-96 Procedure E. Moreover, the film is not stretch orientated.
While multiple top layers 20 can be utilized, preferably only one such top layer exists and the same is bonded to bottom fabric layer
30 as shown in Fig. 1 .
Bottom layer 30 is a woven fabric, which upon fusing or heat laminating is compatible with film 20. The woven fabric can be made out or fibers or filaments of a thermoplastic olefin, for example, a poly- mer or copolymer of a polyolefin derived from monomers having from 2 to 8 carbon atoms, with 3 carbon atoms, i.e., polypropylene being preferred. Desirably, the polypropylene fabric is either isotactic or syndio- tactic The weight of the fabric is generally from about 1 to about 1 5, desirably from about 2 to about 1 0, and preferably from about 2 5 to about 7 ounces per sq. yd. The woven fabric is made from fibers or filaments which are extruded and is not made from fibers which are melt blown or spun blown. The weave can be any suitable or desired
weave such as a square weave, such as, for example, sheeting or sa teen
The top layer can be made from thermoplastic olefin pellets The pellets can be mixed with conventional additives in conventional amounts such as fillers, for example, si cone or clay, various antioxi- dants, various UV stabilizers, flame retardants, and the like, and mixed and heated as in a Banbury at a temperature above the melting point of the thermoplastic olefin The melt can then dropped onto a two roll mill and subsequently calendered at a temperature slightly above the soften ing point and sheeted to a desirable thickness and cooled
The top and bottom layers, that is, thermoplastic olefin film 20 and woven fabric 30 are bonded together through the utilization of heat and pressure Preferably, the two layers are heat fused together as by heating the fabric layer and the film layer above their softening point and applying the layers together under pressure Heat fusing the two layers together can be conveniently accomplished by laminating the heated layers at a pressure of from about 35 to about 300 pounds per linear inch (PLI) Heat fusing results in the top portions of the fabric extending into the bottom portion of thermoplastic olefin film 20 to form a thin intermingled or fused zone 40 It is noted that the film layer is not extruded onto to fabric layer.
Another method of bonding a thermoplastic olefin film to the thermoplastic olefin woven fabric layer is to utilize an adhesive How ever, adhesives are not preferred inasmuch as they require additional process steps, add cost to the product, and adversely affect the flexibility of the polymer laminate
Laminate 10 can have the top exposed film surface thereof subsequently altered as by corona treatment, etc to clean it as well as to render it more susceptible to finishing applications such as printing and/or coating
Thermoplastic olefin laminate 1 0 has many desirable advantages such as that it is chlorine free, plasticizer (for example, phthalate)
free, has good low temperature crack resistance at -40 ° F, is UV resistant, can be coated if desired, is flexible, can be embossed, and importantly, can be completely recycled.
The invention will be better understood by reference to the following example, which serves to illustrate, but not to limit, the present invention.
Pellets of Montell KS 353 P, a copolymer of polyethylene polypropylene made by Montell of Wilmington, Delaware, was mixed with conventional additives such as a filler, UV stabilizer, flame retar dant, and antioxidants, etc , and heated to a temperature of approximately 360°F in a Banbury until melted and then dropped onto a two- roll mill The polymer was then calendered at a temperature of about 365 ° F and sheeted to a thickness of approximately 1 2 mils The sheet was then cooled and stored Subsequently, the ethylene- propylene copolymer film was heated to a temperature of approximately
300°F. Similarly, a woven polypropylene fabric layer having a square weave from Johnston Industries, Phenix City, Alabama, was heated to a temperature of approximately 250°C. Both layers were then fed to a laminator having a temperature of approximately 250°F and laminated at a pressure of approximately 60 PLI The lamination produced a fused laminate as shown in Fig 1 wherein part of the woven fibers were fused into the bottom of the copolymer film layer The laminate was then cooled and rolled into a roll for subsequent use
The laminate of the present invention can generally be util- ized as a substitute for prior PVC laminates and the like Some uses include vehicle seat covers, tire covers, convertible tops for vehicles including sport utility toppings, truck tarps, and the like Moreover, the laminate can be pigmented to achieve any desirable color
While in accordance with the patent statutes the best mode and preferred embodiment have been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims.
Claims
1 . A laminate; comprising: a single thermoplastic olefin film layer heat fused to a woven thermoplastic olefin fabric layer.
2. A laminate according to Claim 1 , wherein said film is a polymer or copolymer derived from olefin monomers having from 2 to 8 carbon atoms, and wherein said fabric is made from olefin polymers or copoiymers derived from olefin monomers having from 2 to 8 carbon atoms.
3. A laminate according to Claim 2, wherein said film is poly- ethylene, polypropylene, or combinations thereof, or a polyethylene- propylene copolymer, wherein said film is a solid layer and has a thickness of from about 4 to about 30 mils.
4. A laminate according to Claim 3, wherein said fabric layer weighs from about 2.0 to about 10 ounces per sq. yd .
5. A laminate according to Claim 4, wherein said film is a polyethylene-propylene copolymer, wherein the thickness of said film is from about 6 to about 25 mils, and wherein said fabric is a polypropyl- ene fabric.
6. A laminate according to Claim 5, wherein said film is non- stretchable, wherein said film has a flex modulus of from about 7,000 to about 20,000 kgms/Newtons, and wherein said fabric contains ex- truded fibers.
7. A convertible top, comprising: a laminate having a solid thermoplastic olefin film top layer fused to a woven thermoplastic olefin fabric layer.
8. A convertible top according to Claim 7, wherein the thickness of said thermoplastic olefin film is from about 4 to about 30 mils, and wherein said fabric layer is heat fused to said thermoplastic olefin film.
9. A convertible top according to Claim 8, wherein said film is a polymer or copolymer derived from olefin monomers having from 2 to 8 carbon atoms, wherein said top film layer is a single layer, wherein said fabric is made from extruded fibers, and wherein said fibers are a polymer or copolymer derived from olefin monomers having from 2 to 8 carbon atoms.
10. A convertible top according to Claim 9, wherein said film has a thickness of from about 6 to about 25 mils, and wherein the weight of said fabric layer is from about 2.0 to about 1 0 ounces per sq. yd.
1 1 . A convertible top according to Claim 1 0, wherein said film is a polyethylene-propylene copolymer, and wherein said fabric con- tains polypropylene fibers.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US36527799A | 1999-07-30 | 1999-07-30 | |
| US09/365,277 | 1999-07-30 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| WO2001019900A2 true WO2001019900A2 (en) | 2001-03-22 |
| WO2001019900A3 WO2001019900A3 (en) | 2001-11-29 |
Family
ID=23438201
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US2000/015909 WO2001019900A2 (en) | 1999-07-30 | 2000-06-09 | Polymer laminates for vehicle liner |
Country Status (1)
| Country | Link |
|---|---|
| WO (1) | WO2001019900A2 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP2197673B1 (en) * | 2007-09-28 | 2018-02-28 | Invista Technologies S.à.r.l. | Laminated fabric construction with polyolefin compositions |
| US20200187657A1 (en) * | 2018-12-17 | 2020-06-18 | OW Lee Co. | Outdoor Chair Assembly and Method of Making Same |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE4211708A1 (en) * | 1992-04-08 | 1993-10-14 | Schaeffler Teppichboden Gmbh | Fully recyclable shaped lining e.g. for car interior or boot - consists of top covering of polypropylene@ fabric heat-bonded on to at least one suitable substrate of non-textile polypropylene@ |
-
2000
- 2000-06-09 WO PCT/US2000/015909 patent/WO2001019900A2/en active Application Filing
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE4211708A1 (en) * | 1992-04-08 | 1993-10-14 | Schaeffler Teppichboden Gmbh | Fully recyclable shaped lining e.g. for car interior or boot - consists of top covering of polypropylene@ fabric heat-bonded on to at least one suitable substrate of non-textile polypropylene@ |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP2197673B1 (en) * | 2007-09-28 | 2018-02-28 | Invista Technologies S.à.r.l. | Laminated fabric construction with polyolefin compositions |
| US20200187657A1 (en) * | 2018-12-17 | 2020-06-18 | OW Lee Co. | Outdoor Chair Assembly and Method of Making Same |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2001019900A3 (en) | 2001-11-29 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US6291048B1 (en) | Polymeric based carpet | |
| CA2030422C (en) | Pressure and vacuum formable foam foil for lining the interior spaces of motor vehicles | |
| US4297408A (en) | Laminates of cloth and filled crystalline polypropylene and a method for making them | |
| US4939009A (en) | Multilayered sheets having excellent adhesion | |
| US5985071A (en) | Reinforced laminate with elastomeric tie layer | |
| US4511619A (en) | Sealing sheet of elastomeric synthetic resins with textile reinforcement on outer layer | |
| US8057910B2 (en) | Toughened thermoplastic polyamide compositions | |
| US20120108134A1 (en) | Polyolefin-Based Artificial Leather | |
| US6534150B1 (en) | Stretched film of thermoplastic resin | |
| TW201532806A (en) | Laminated fabric shipping sacks, methods of manufacturing, and related systems | |
| EP2427334B1 (en) | Heat sealable and oriented multi-layer polypropylene-based films for shrink applications | |
| US5318649A (en) | Laminates and process for producing the same | |
| WO1999054400A1 (en) | Compositions of polyolefin and polyvinyl alcohol, and films, sheets and articles processed therefrom and multilayer products using the same | |
| JP6979741B2 (en) | Flat yarn laminated sheet for molding and molded products | |
| WO2000035596A1 (en) | Rubber compositions and laminates thereof | |
| JP3345896B2 (en) | Laminated film | |
| WO2001019900A2 (en) | Polymer laminates for vehicle liner | |
| WO2019039555A1 (en) | Multilayered film, laminate, production method for laminate, and air bag | |
| US20040116600A1 (en) | Foil or molded body based on a transparent polymeric mixture | |
| JP3271301B2 (en) | Laminated film | |
| KR101458828B1 (en) | Manufacturing method of laminated sheet using a automobile interiors | |
| WO1999064533A1 (en) | Multilayer adhesive film | |
| JP7369308B2 (en) | laminate | |
| WO2022186370A1 (en) | Laminate and method for molding laminate molded article | |
| US20030225193A1 (en) | Reinforced thermoplastic film composition |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| AK | Designated states |
Kind code of ref document: A2 Designated state(s): JP |
|
| AL | Designated countries for regional patents |
Kind code of ref document: A2 Designated state(s): AT BE CH CY DE DK ES FI FR GB GR IE IT LU MC NL PT SE |
|
| 121 | Ep: the epo has been informed by wipo that ep was designated in this application | ||
| DFPE | Request for preliminary examination filed prior to expiration of 19th month from priority date (pct application filed before 20040101) | ||
| AK | Designated states |
Kind code of ref document: A3 Designated state(s): JP |
|
| AL | Designated countries for regional patents |
Kind code of ref document: A3 Designated state(s): AT BE CH CY DE DK ES FI FR GB GR IE IT LU MC NL PT SE |
|
| 122 | Ep: pct application non-entry in european phase | ||
| NENP | Non-entry into the national phase in: |
Ref country code: JP |