Articles including frims and methods of using them

Abstract

Certain embodiments described herein are directed to articles that provide less sag. In some examples, the articles can include a fiber reinforced thermoplastic polymer core layer comprising reinforcing fibers and a thermoplastic polymer, and a frim disposed on the fiber reinforced polymer core layer. In certain examples, the frim comprises a film coupled to a scrim comprising an effective basis weight to prevent substantial sag of the article, e.g., during a forming operation.

1 . A thermoplastic composite article comprising:
 a fiber reinforced thermoplastic polymer core layer comprising reinforcing fibers and a thermoplastic polymer; and   a frim disposed on the fiber reinforced polymer core layer, the frim comprising a film coupled to a scrim comprising an effective basis weight to prevent substantial sag of the article during a forming operation.   
     
     
         2 . The thermoplastic article of  claim 1 , in which the scrim comprises a basis weight of at least 30 gsm. 
     
     
         3 . The thermoplastic article of  claim 1 , in which the scrim comprises a basis weight of at least 45 gsm. 
     
     
         4 . (canceled) 
     
     
         5 . The thermoplastic article of  claim 1 , in which the film comprises a basis weight of at least 15 gsm. 
     
     
         6 . (canceled) 
     
     
         7 . The thermoplastic article of  claim 1 , in which the film comprises a basis weight of at least 40 gsm. 
     
     
         8 . The thermoplastic article of  claim 1 , in which the scrim comprises a basis weight of at least 30 gsm and the film comprises a basis weight of at least 30 gsm. 
     
     
         9 - 15 . (canceled) 
     
     
         16 . The thermoplastic article of  claim 1 , in which the scrim comprises a basis weight of at least 50 gsm and the film comprises a basis weight of at least 40 gsm. 
     
     
         17 . The thermoplastic composite article of  claim 1 , in which the film is coupled to the scrim with an adhesive. 
     
     
         18 . The thermoplastic article of  claim 1 , in which the film is melt bonded to the scrim. 
     
     
         19 . The thermoplastic article of  claim 1 , in which the scrim comprises polyethylene terephthalate. 
     
     
         20 . The thermoplastic article of  claim 1 , in which the film comprises a polyamide. 
     
     
         21 - 30 . (canceled) 
     
     
         31 . A thermoplastic composite article comprising:
 a fiber reinforced thermoplastic polymer core layer comprising reinforcing fibers and a thermoplastic polymer;   a film disposed on the polymer core layer; and   a scrim disposed on the film, in which the scrim comprises an effective basis weight to prevent substantial sag of the article during a forming operation.   
     
     
         32 . The thermoplastic composite article of  claim 31 , in which the film is coupled to the scrim with an adhesive. 
     
     
         33 . The thermoplastic article of  claim 31 , in which the scrim comprises polyethylene terephthalate. 
     
     
         34 . The thermoplastic article of  claim 31 , in which the film comprises a polyamide. 
     
     
         35 - 40 . (canceled) 
     
     
         41 . The thermoplastic article of  claim 31 , further comprising a film layer disposed on a surface opposite a surface where the scrim is disposed. 
     
     
         42 . (canceled) 
     
     
         43 . The thermoplastic article of  claim 41 , further comprising fabric layer coupled to the film layer disposed on the surface opposite the surface where scrim is disposed. 
     
     
         44 . (canceled) 
     
     
         45 . (canceled) 
     
     
         46 . The thermoplastic article of  claim 41 , in which the core layer is permeable and comprises a density of about 0.1 gm/cm 3  to about 1.8 gm/cm 3 . 
     
     
         47 . The thermoplastic article of  claim 41 , in which the core layer a porosity between about 20% to about 80% by volume of the core layer. 
     
     
         48 - 49 . (canceled) 
     
     
         50 . The thermoplastic article of  claim 31 , further comprising a polypropylene film disposed on an opposite surface from a surface where the scrim is disposed. 
     
     
         51 - 85 . (canceled)