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US 10,240,017 B2Granted
Composite panel
AssigneeSACO AEI Polymers, Inc.
InventorsAndrea Savonuzzi, Paolo Steinbach
Life of this patent
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Abstract
Composite panel, particularly for forming roof panels of cars and/or industrial vehicles, and method of manufacturing the composite panel, which composite panel includes a core of foamed material, at least one skin layer of nonwoven material, and at least one connecting layer between the core of foamed material and the skin layer of nonwoven material.
Claims34
Composite panel comprising:
- a core layer, which comprises cross-linked foamed polyolefin;
- wherein the cross-linked foamed polyolefin comprises high-density polyethylene (HDPE);
- and
- a reinforcing layer on at least one of two faces of the core layer, wherein the reinforcing layer comprises a first non-woven layer comprising unidirectionally-oriented continuous thermoplastic polyester fibers and a non-woven web of randomly-oriented fibers;
- and
- the first non-woven layer and the non-woven web are joined together by at least one layer comprising a second thermoplastic polymer, which has a lower softening temperature than a first softening temperature of the unidirectionally-oriented continuous thermoplastic polymer fibers, such that the reinforcing layer is in the form of a sheet having said layers of fibers joined together by the second thermoplastic polymer with a three-dimensional fiber structure comprising a first side with randomly-oriented fibers and a second opposite side with unidirectionally-oriented fibers;
- and
- the composite panel has a total weight of less than 950 g/m2, a total thickness of less than 6.5 mm and a deflection value of less than 5 mm.
5 more elements
Composite panel comprising:
- a cross-linked foamed polyolefin core layer;
- and a reinforcing layer on at least one of two faces of the core layer, the reinforcing layer comprising a first non-woven layer, which comprises unidirectionally-oriented continuous thermoplastic polyester fibers reinforced with unidirectionally-oriented glass fibers, and a non-woven web of randomly-oriented fibers;
- wherein the first non-woven layer and the non-woven web are embedded into a matrix of a second thermoplastic polymer having a lower softening temperature than the softening temperature of the unidirectionally-oriented continuous thermoplastic polyester fibers;
- and
- the composite panel has a total weight of less than 950 g/m2, a total thickness of less than 6.5 mm and a deflection value of less than 5 mm.
2 more elements
Composite panel comprising:
- a cross-linked foamed polyolefin core layer, which comprises 20 to 40 wt. % HDPE and has a basis weight of less than 100 g/m2;
- and
- a reinforcing layer on at least one of two faces of the core layer,
- the reinforcing layer comprising a non-woven layer, which has a basis weight of less than 150 g/m2 and comprises unidirectionally-oriented continuous thermoplastic polyester fibers reinforced with unidirectionally-oriented glass fibers, and a non-woven web of randomly-oriented fibers having a basis weight of less than 140 g/m2;
- wherein the first non-woven layer and the non-woven web are embedded into a thermoplastic polyolefin matrix adhered to the core layer;
- and
- the composite panel has a total weight of less than 950 g/m2, a total thickness of less than 6.5 mm and a deflection value of less than 5 mm.
4 more elements
Dependencies are inferred from the claim text.