# US 11,999,153 B2 · Composite laminate resin and fiberglass structure

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- Number: US 11,999,153 B2
- Document ID: US11999153B2
- Status: Granted
- Kind: B2
- Application number: 16/706,021
- Filed: 2019-12-06
- Published: 2020-06-11
- Granted: 2024-06-04
- Earliest claimed: 2018-12-07
- Assignees: TekModo OZ Holdings, LLC
- Applicants: TekModo OZ Holdings, LLC
- Inventors: Marc Douglas LaCounte
- Web page: https://patentgrep.com/patent/US11999153B2

## CPC

- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/12: characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other}
- B32B 37/18: involving the assembly of discrete sheets or panels only
- B32B 38/0036: {Heat treatment (for heating or cooling of layers during lamination B32B37/06, B32B37/08)}
- B32B 38/04: Punching, slitting or perforating
- B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12}
- B32B 2038/042: {Punching}
- B32B 2250/03: 3 layers
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2260/023: Two or more layers
- B32B 2260/046: Synthetic resin
- B32B 2262/101: Glass fibres
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/732: Dimensional properties
- B32B 2605/00: Vehicles
- Y10T 428/24273: including aperture
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A structure comprising a composite laminate resin and fiberglass panel and method of manufacture thereof is provided.

## Claims

### Claim 1

A composite laminate structure comprising:
a core of non-woven thermoplastic/fiberglass mix matte having a homogenous appearance, with virtually no strands observable to the eye;
a top layer located on one side of said core, said top layer including uni-directional structural tape of woven glass/thermoplastic composites wherein a majority of fibers of said uni-directional structural tape on said top layer run in a first direction; and
a bottom layer, on a side of said core opposite said top layer, said bottom layer including uni-directional structural tape of woven glass/thermoplastic composites wherein a majority of fibers of said uni-directional structural tape on said bottom layer run in a second direction, said second direction being at an angle greater than 45 degrees to said first direction, said top and bottom layers are sealed to said core in a laminating process to form a laminate.

### Claim 2 (depends on 1)

The composite laminate structure of claim 1 wherein said first direction of said top and said second direction of said_bottom layers run 0°-90° to one another.

### Claim 3 (depends on 2)

The composite laminate structure of claim 2 wherein the core includes a needle punched matte.

### Claim 4 (depends on 2)

The composite laminate structure of claim 2 wherein the core includes a thermally treated matte.

### Claim 5 (depends on 2)

The composite laminate structure of claim 2 wherein the core has an area weight of 100 to 2500 g/m2 and a thickness from 0.5 to 6 mm.

### Claim 6 (depends on 2)

The composite laminate structure of claim 2 wherein the top and bottom layers are heat-fused to the non-woven thermoplastic/fiberglass mix matte.

### Claim 7 (depends on 2)

The composite laminate structure of claim 2 wherein the core includes thermoplastic and reinforcing fibers supplied in the form of multi-fiber strands.

### Claim 8 (depends on 7)

The composite laminate structure of claim 7 wherein multi-fiber strands are carded so that, there are few unopened and partially opened strands and the matte has a homogenous appearance.

### Claim 9 (depends on 8)

The composite laminate structure of claim 8 wherein the carded matte has a lofty appearance prior to sealing with said top and bottom layers.

### Claim 10 (depends on 1)

The composite laminate structure of claim 1 wherein said top and bottom layers uni-directional continuous composites are oriented perpendicular to one another.

### Claim 11

A method of manufacturing a composite laminate structure including the steps of:
providing a core of non-woven thermoplastic/fiberglass mix matte having a homogenous appearance, with virtually no strands observable to the eye;
providing a top layer said top layer including a uni-directional fiberglass reinforced thermoplastic wherein a majority of fibers of said uni-directional structural tape on said top layer run in a first direction;
locating said top layer on one side of said core;
providing a bottom layer, said bottom layer including a uni-directional fiberglass reinforced thermoplastic wherein a majority of fibers of said uni-directional structural tape on said bottom layer run in a second direction, the second direction running 45°-90° to the first direction;
locating said bottom layer on a side of said core opposite said top layer;
sealing said top and bottom layers to said core using a heat fusing process to create an “I” Beam type composite structure, and thereby laminating said top layer, to said core and said core to said bottom layer to form a laminate.

### Claim 12 (depends on 11)

The method of manufacturing a composite laminate structure as set forth in claim 11 wherein said top layer includes uni-directional structural tape of woven glass/thermoplastic composites.

### Claim 13 (depends on 12)

The method of manufacturing a composite laminate structure as set forth in claim 12 wherein said bottom layer includes uni-directional structural tape of woven glass/thermoplastic composites.

### Claim 14 (depends on 13)

The method of manufacturing a composite laminate structure as set forth in claim 13 including the step of needle punching said core prior to sealing to said top and bottom layers.

### Claim 15 (depends on 13)

The method of manufacturing a composite laminate structure as set forth in claim 13 including the step of thermally treating said matte prior to sealing to said top and bottom layers.

### Claim 16 (depends on 13)

The method of manufacturing a composite laminate structure as set forth in claim 13 wherein the core has an area weight of 100 to 2500 g/m2 and a thickness from 0.5 to 6 mm.

### Claim 17 (depends on 13)

The method of manufacturing a composite laminate structure as set forth in claim 13 including the step of heat fusing said top and bottom layers to said non-woven thermoplastic/fiberglass mix matte.

### Claim 18 (depends on 13)

The method of manufacturing a composite laminate structure as set forth in claim 13 including the steps of supplying thermoplastic and reinforcing fibers in the form of multi-fiber strands, blending the multi-fiber strands in an air stream, and depositing the multi-fiber strands on a moving belt.

### Claim 19 (depends on 13)

The method of manufacturing a composite laminate structure as set forth in claim 13 including the steps of carding multi-fiber strands to reduce unopened and partially opened strands and providing the matte in a homogenous appearance.

### Claim 20 (depends on 13)

The method of manufacturing a composite laminate structure as set forth in claim 13 including the step of orienting said uni-directional fiberglass reinforced thermoplastic in said top and bottom layers perpendicular to one another.