Composite sheet material and method for forming the same

A method of forming a composite sheet material, comprising:

• providing a substrate having a first face surface, a second face surface, and a plurality of edges;
• forming a laminate from a support layer and a thermoplastic layer, wherein the support layer has a support layer material having a first melting point, and the thermoplastic layer has thermoplastic layer material having a second melting point less than the first melting point;
• positioning the substrate and the laminate such that the laminate is contiguous with the first face surface of the substrate;
• and
• laminating the substrate and laminate together in a thermo-pressure process to form the composite sheet material, wherein
• after the laminating, the thermoplastic layer is migrated into the support layer, and a percentage amount of the thermoplastic layer material at a first side of the laminate is greater than a percentage amount of the thermoplastic layer material at a second, opposing side of the laminate,
• the thermoplastic layer includes one or more polymeric materials selected from the group consisting of polypropylene, polyethylene, polyethylene terephthalate, low-density polyethylene, polyurethane, polyamide, polyamide-imide, ionomer, acrylic, combinations thereof, and co-polymers thereof, and
• the support layer includes one or more materials selected from the group consisting of polyester, polyamide, polyphenylsulfide, aromatic polyamide, fiberglass, polytetrafluoroethylene, wool, alumina, silica, polyimide, cellulose, rayon, viscose, and combinations thereof.

A method of forming a composite sheet material, comprising:

• providing a substrate having a first face surface, a second face surface, and a plurality of edges;
• forming a laminate by extruding a multilayer thermoplastic onto a support layer, wherein the support layer has a support layer material having a first melting point and the multilayer thermoplastic has a thermoplastic layer material having a second melting point less than the first melting point;
• positioning the substrate and the laminate such that the laminate is contiguous with the first face surface of the substrate;
• and
• laminating the substrate and laminate together in a thermo-pressure process to form the composite sheet material, wherein
• after the laminating, the multilayer thermoplastic is migrated into the support layer, and a percentage amount of the thermoplastic layer material at a first side of the laminate is greater than a percentage amount of the thermoplastic layer material at a second, opposing side of the laminate,
• the multilayer thermoplastic includes one or more polymeric materials selected from the group consisting of polypropylene, polyethylene, polyethylene terephthalate, low-density polyethylene, polyurethane, polyamide, polyamide-imide, ionomer, acrylic, combinations thereof, and co-polymers thereof, and
• the support layer includes one or more materials selected from the group consisting of polyester, polyamide, polyphenylsulfide, aromatic polyamide, fiberglass, polytetrafluoroethylene, wool, alumina, silica, polyimide, cellulose, rayon, viscose, and combinations thereof.

A composite sheet material matrix, comprising:

• a support layer having a support layer material that has a first melting point;
• and
• a multilayer thermoplastic having a thermoplastic layer material that has a second melting point less than the first melting point, wherein
• the multilayer thermoplastic is adjacent to the support layer,
• the multilayer thermoplastic is migrated into the support layer,
• the multilayer thermoplastic and the support layer together provide a laminate,
• a percentage amount of the thermoplastic layer material at a first side of the laminate is greater than a percentage amount of the thermoplastic layer material at a second, opposing side of the laminate,
• the multilayer thermoplastic includes one or more polymeric materials selected from the group consisting of polypropylene, polyethylene, polyethylene terephthalate, low-density polyethylene, polyurethane, polyamide, polyamide-imide, ionomer, acrylic, combinations thereof, and co-polymers thereof, and
• the support layer includes one or more materials selected from the group consisting of polyester, polyamide, polyphenylsulfide, aromatic polyamide, fiberglass, polytetrafluoroethylene, wool, alumina, silica, polyimide, cellulose, rayon, viscose, and combinations thereof.

A composite sheet material, comprising:

• a substrate having a first face surface, a second face surface, and a plurality of edges;
• a support layer having a support layer material that has a first melting point;
• a thermoplastic layer having a thermoplastic layer material that has a second melting point less than the first melting point;
• and
• a secondary thermoplastic layer having a second thermoplastic layer material that has a third melting point that is equal to or greater than the first melting point, wherein
• the thermoplastic layer or the secondary thermoplastic layer is adjacent to the support layer,
• the thermoplastic layer or the secondary thermoplastic layer is migrated into the support layer,
• the thermoplastic layer, the secondary thermoplastic layer and the support layer together provide a laminate,
• a percentage amount of the thermoplastic layer material or the second thermoplastic layer material at a first side of the laminate is greater than a percentage amount of the thermoplastic layer material or the second thermoplastic layer material at a second, opposing side of the laminate,
• the thermoplastic layer or the secondary thermoplastic layer includes one or more polymeric materials selected from the group consisting of polypropylene, polyethylene, polyethylene terephthalate, low-density polyethylene, polyurethane, polyamide, polyamide-imide, ionomer, acrylic, combinations thereof, and co-polymers thereof, and
• the support layer includes one or more materials selected from the group consisting of polyester, polyamide, polyphenylsulfide, aromatic polyamide, fiberglass, polytetrafluoroethylene, wool, alumina, silica, polyimide, cellulose, rayon, viscose, and combinations thereof.

A side skirt assembly adapted to be mounted to a tractor trailer, comprising:

• a support frame configured to attach to the tractor trailer;
• and
• a side skirt panel attached to the support frame, wherein
• the side skirt panel is a composite sheet material that has a length and a width,
• the composite sheet material includes a substrate, a support layer, a thermoplastic layer, and a cover sheet,
• the support layer has a support component material having a first melting point,
• the thermoplastic layer has a thermoplastic layer material having a second melting point less than the first melting point,
• the thermoplastic layer is adjacent to the support layer,
• the thermoplastic layer is migrated into the support layer,
• the thermoplastic layer and the support layer together provide a laminate,
• the laminate is attached to the substrate,
• a percentage amount of the thermoplastic layer material at a first side of the laminate is greater than a percentage amount of the thermoplastic layer material at a second, opposing side of the laminate,
• the cover sheet is configured to impart one or more surface characteristics to the composite sheet material during a thermo-pressure formation of the composite sheet material,
• the thermoplastic layer includes one or more polymeric materials selected from the group consisting of polypropylene, polyethylene, polyethylene terephthalate, low-density polyethylene, polyurethane, polyamide, polyamide-imide, ionomer, acrylic, combinations thereof, and co-polymers thereof, and
• the support layer includes one or more materials selected from the group consisting of polyester, polyamide, polyphenylsulfide, aromatic polyamide, fiberglass, polytetrafluoroethylene, wool, alumina, silica, polyimide, cellulose, rayon, viscose, and combinations thereof.

A panel for a tractor trailer box container having a frame, comprising:

• a composite sheet material panel that has a length and a width and is configured for attachment to the frame of the tractor trailer box container frame, the composite sheet material panel including:
• a substrate, a support layer, a thermoplastic layer, and a cover sheet,
• the support layer includes a support layer material having a first melting point,
• the thermoplastic layer includes a thermoplastic layer material having a second melting point less than the first melting point,
• the thermoplastic layer is adjacent to the support layer,
• the thermoplastic layer is migrated into the support layer,
• the thermoplastic layer and the support layer together provide a laminate,
• the laminate is attached to the substrate,
• a percentage amount of the thermoplastic layer material at a first side of the laminate is greater than a percentage amount of the thermoplastic layer material at a second, opposing side of the laminate,
• the cover sheet is configured to impart one or more surface characteristics to the composite sheet material during a thermo-pressure formation of the composite sheet material,
• the thermoplastic layer includes one or more polymeric materials selected from the group consisting of polypropylene, polyethylene, polyethylene terephthalate, low-density polyethylene, polyurethane, polyamide, polyamide-imide, ionomer, acrylic, combinations thereof, and co-polymers thereof, and
• the support layer includes one or more materials selected from the group consisting of polyester, polyamide, polyphenylsulfide, aromatic polyamide, fiberglass, polytetrafluoroethylene, wool, alumina, silica, polyimide, cellulose, rayon, viscose, and combinations thereof.