Composite sheet material and method for forming the same

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 and a thermoplastic layer,
• the substrate has a first face surface, a second face surface, and a plurality of edges;
• the support layer includes a support component material that has a first melting point;
• and
• the thermoplastic component includes a thermoplastic component material that has a second melting point less than the first melting point,
• the thermoplastic component is adjacent to the support component,
• the thermoplastic component is migrated into the support component,
• the thermoplastic component and the support component together provide a laminate,
• a percentage amount of the thermoplastic component material at a first side of the laminate is greater than a percentage amount of the thermoplastic component material at a second, opposing side of the laminate,
• the thermoplastic component 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 component 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 material, comprising:

• a substrate having a first face surface, a second face surface, and a plurality of edges;
• a backing layer attached to the second face surface of the substrate;
• a support component having a support component material that has a first melting point;
• and
• a thermoplastic component having a thermoplastic component material that has a second melting point less than the first melting point, wherein
• the substrate includes a thermoplastic material and a fiberglass material, and
• the backing layer includes one or more materials selected from the group consisting of polyethylene terephthalate, nylon, fiberglass, polyurethane, butadiene, acrylic, polyacrylic, polymethacrylic ester, acrylic polymer, polyester, polypropylene, polyethylene, polylactic acid, and combinations thereof,
• the thermoplastic component is adjacent to the support component,
• the thermoplastic component is migrated into the support component,
• the thermoplastic component and the support component together provide a laminate,
• the laminate is attached to the first face surface of the substrate,
• a percentage amount of the thermoplastic component material at a first side of the laminate is greater than a percentage amount of the thermoplastic component material at a second, opposing side of the laminate,
• the thermoplastic component 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 component 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.