Composite sheet material and method for forming the same
AssigneeXamax Industries, Inc.
InventorsMartin Weinberg, James Yuan, Robert Markowski
Life of this patent
Estimating the term…
Abstract
A composite sheet material and method for forming the same is provided that includes a substrate, a matrix, and a cover sheet. The substrate has a first face surface, a second face surface, and a plurality of edges, and includes a thermoplastic material. The matrix is attached to the substrate. The matrix includes a support component having a first melting point, and a thermoplastic component having a second melting point. The second melting point is less than the first melting point. The cover sheet imparts one or more surface characteristics to the composite sheet material during thermo-pressure formation of the composite sheet material.
Claims28
A composite sheet material, comprising:
- a support layer having a support layer material selected from the group consisting of non-woven polyamide, non-woven fiberglass, and combinations thereof, and
- a thermoplastic layer having a thermoplastic layer material selected from the group consisting of polypropylene, polyethylene, polyamide, combinations thereof, and copolymers thereof, wherein
- a melting point of the thermoplastic layer is less than a melting point of the support layer,
- 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, 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.
A method of forming a composite sheet material, comprising:
- providing a support layer having a support layer material selected from the group consisting of non-woven fiberglass, non-woven polyamide, and combinations thereof;
- providing a thermoplastic layer having a thermoplastic layer material selected from the group consisting of polypropylene, polyethylene, polyamide, combinations thereof, and copolymers thereof, a melting point of the thermoplastic layer being less than a melting point of the support layer;
- positioning the thermoplastic layer adjacent to the support layer;
- and
- laminating the thermoplastic layer and the support layer together such that the thermoplastic layer migrates into the support layer, wherein
- the thermoplastic layer and the support layer together provide a laminate, 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.
Dependencies are inferred from the claim text.