Composite thermoplastic laminate
AssigneeXamax Industries, Inc.
InventorsRobert G. Markowski, Martin J. Weinberg, James Yuan
Life of this patent
Estimating the term…
Abstract
A composite sheet material includes a cover sheet, a substrate and an adhesion promoting layer. The cover sheet has a cover sheet material. The substrate has a substrate material. The adhesion promoting layer is disposed between the cover sheet and the substrate. A first side of the adhesion promoting layer disposed towards the cover sheet has an affinity to bond with the cover sheet material. A second side of the adhesion promoting layer disposed towards the substrate has an affinity to bond with the substrate material.
Claims30
A method of making a composite sheet material, comprising:
- providing a cover sheet having a cover sheet material;
- providing a substrate having a substrate material;
- providing an adhesion promoting layer disposed between the cover sheet and the substrate;
- applying a first temperature above room temperature and first pressure above atmospheric pressure for a first time period to the cover sheet and the substrate as part of a first formation process that combines the cover sheet, the substrate and the adhesion promoting layer into a laminate;
- allowing the laminate to cool down to a lower temperature after the applying the first temperature and first pressure;
- and
- applying, after the allowing the laminate to cool down to the lower temperature, a second temperature above room temperature and second pressure above atmospheric pressure for a second time period to the laminate, wherein
- applying the second temperature and second pressure for a second time period provides a larger amount of energy to the laminate than the applying the first temperature and first pressure for the first time period provides to the laminate,
- a first side of the adhesion promoting layer disposed towards the cover sheet has an affinity to bond with the cover sheet material,
- a second side of the adhesion promoting layer disposed towards the substrate has an affinity to bond with the substrate material, and
- at least one of the first temperature and second temperature is above a melting point of a thermoplastic material of the composite sheet material.
A method of forming a composite sheet material, comprising:
- applying a first temperature above room temperature and first pressure above atmospheric pressure to a plurality of layers for a first time period as part of a first formation process that increases the temperature of the plurality of layers and combines the plurality of layers into a laminate;
- allowing the laminate to cool down to a lower temperature after the applying the first temperature and first pressure;
- and
- applying, after the allowing the laminate to cool down to the lower temperature, a second temperature and second pressure above atmospheric pressure to the laminate and a substrate for a second time period as part of a second formation process that combines the laminate and the substrate, wherein
- the applying the second temperature and second pressure for a second time period provides a larger amount of energy to the laminate and the substrate than the applying the first temperature and first pressure for the first time period provides to the laminate, and
- at least one of the first temperature and second temperature is above a melting point of a thermoplastic material of the composite sheet material.
Dependencies are inferred from the claim text.