Thermofused reinforced decorative composite material with thermoplastic stiffener core

Abstract

A reinforced composite material includes a decorative layer, a stiffener core, and, optionally, a backing layer, which are thermofused to each other. Also provided is a method for the production of such a material.

1 . A reinforced composite material comprising: 
 a decorative layer;    a stiffener core comprising a thermoplastic material and a reinforcement embedded therein; and, optionally,    a backing layer facing a surface of the stiffener substrate opposite to that facing the decorative layer,    wherein the decorative layer and, if included, the backing layer are thermofused to the stiffener core.    
   
   
       2 . The reinforced composite material according to  claim 1 , wherein the decorative layer comprises wood, metal, film and/or resin-saturated paper.  
   
   
       3 . The reinforced composite material according to  claim 2 , wherein the paper is saturated with a resin selected from the group consisting of a polyester resin and a melamine resin.  
   
   
       4 . The reinforced composite material according to  claim 1 , wherein the thermoplastic material is selected from the group consisting of polypropylene, polyethylene, PET, PVC and ABS.  
   
   
       5 . The reinforced composite material according to  claim 1 , wherein the reinforcement comprises fibers.  
   
   
       6 . The reinforced composite material according to  claim 5 , wherein the reinforcement comprises continuous and/or discontinuous fiberglass.  
   
   
       7 . The reinforced composite material according to  claim 6 , wherein the continuous fiberglass is random or oriented.  
   
   
       8 . The reinforced composite material according to  claim 5 , wherein the fibers comprise glass, aramid, polyamide and/or carbon fibers.  
   
   
       9 . The reinforced composite material according to  claim 1 , wherein the reinforcement comprises a woven material.  
   
   
       10 . The reinforced composite material according to  claim 1 , wherein the stiffener core further comprises an additional thermoplastic material, stiffening material, and/or insulation material.  
   
   
       11 . The reinforced composite material according to  claim 10 , wherein the stiffening material comprises foam, wood, metal and/or film.  
   
   
       12 . The reinforced composite material according to  claim 11 , wherein the foam is thermoplastic or thermoset closed- or open-celled.  
   
   
       13 . The reinforced composite material according to  claim 1 , wherein the backing layer comprises a fiber material.  
   
   
       14 . The reinforced composite material according to  claim 13 , wherein the fiber material of the backing layer is paper or non-woven scrim.  
   
   
       15 . The reinforced composite material according to  claim 1 , wherein a portion of the reinforcement protrudes from the surface of the stiffener substrate opposite to that facing the decorative layer.  
   
   
       16 . The reinforced composite material according to  claim 15 , wherein the portion is at least partially not coated with the thermoplastic material.  
   
   
       17 . A method for making a reinforced composite material, comprising the steps of: 
 providing a decorative layer and a stiffener core, which comprises a thermoplastic material and a reinforcement embedded therein, and, optionally, a backing layer; and    thermofusing the stiffener substrate with the decorative layer and, if provided, the backing material.    
   
   
       18 . The method according to  claim 17 , wherein the backing layer comprises a fiber material.  
   
   
       19 . The method according to  claim 18 , wherein the fiber material comprises paper or non-woven scrim.  
   
   
       20 . The method according to  claim 17 , wherein a stiffening material or an insulation material or both is provided in addition to the decorative layer the stiffener substrate, and, optionally, the backing layer.  
   
   
       21 . The method according to  claim 20 , wherein the stiffening material comprises foam, metal, film and/or wood.  
   
   
       22 . The method according to  claim 21 , wherein the foam is thermoplastic or thermoset open- or closed-cell.