Composite Materials With Multilayer Laminate Facing

Abstract

A composite board with a multilayer laminated facer is presented having a nonwoven, a first polymer layer, and a second polymer layer. The laminate may be printed on the nonwoven, on the upper surface of the first polymer layer or inverted printed on the backside of an applied film. A number of configurations for the polymer layers are disclosed. The laminate may include exposed fibers on the lower surface or the nonwoven may be saturated. A removable peel-ply may be included. By controlling the placement and thickness of the polymer layers it is possible to tailor additive in the polymers such as colorants, opacifiers, UV stabilizers, and fire retardants to improve quality and reduce costs. In an alternate embodiment of the present invention, a first polymer layer is applied to the topside of the nonwoven and the second polymer is laminated to the first polymer layer as a preformed film. The laminated facer is thermally or adhesively bonded to the composite board.

1 . A composite material with a multilayer laminated facer, comprising:
 a fiber reinforced polymer board, including:   a polymer matrix; and   a plurality of reinforcing fibers dispersed within the matrix; and   a laminated facer on the fiber reinforced board, including:   a nonwoven having an upper surface and a lower surface;   a first polymer layer having an upper surface and a lower surface; and   a second polymer layer having an upper surface and a lower surface,   wherein the interface between the first polymer layer and the second polymer layer is within the nonwoven; and   wherein the first polymer layer is applied to the upper surface of the nonwoven and the second polymer layer is applied to the upper surface of the first polymer layer.   
     
     
         2 - 7 . (canceled) 
     
     
         8 . The composite material of  claim 1 , wherein second polymer layer is applied as a preformed polymer layer formed on a peel ply. 
     
     
         9 . The composite material of  claim 8 , further comprising:
 a reverse printed layer on the lower side of the second polymer layer.   
     
     
         10 . The composite material of  claim 1 , further comprising:
 A printed layer on the upper surface of the non-woven.   
     
     
         11 . The composite material of  claim 1 , wherein the a printed layer is at the interface between the first and second polymer layer. 
     
     
         12 - 14 . (canceled) 
     
     
         15 . The composite material of  claim 1 , wherein the interface between the first polymer layer and the second polymer layer is at the upper surface of the nonwoven. 
     
     
         16 . The composite material of  claim 1 , wherein the interface between the first polymer layer and the second polymer layer is above the upper surface of the nonwoven. 
     
     
         17 . The composite material of  claim 1 , wherein the interface between the first polymer layer and the second polymer layer is at the lower surface of the nonwoven. 
     
     
         18 - 19 . (canceled) 
     
     
         20 . A composite material with a multilayer laminated face, comprising:
 a fiber reinforced polymer board; including   a polymer matrix;   a plurality of reinforcing fibers dispersed within the matrix; and a laminated facer on the fiber reinforced board, including:   a nonwoven having an upper surface and a lower surface;   a printed layer on the upper surface of the non-woven   a first polymer layer having an upper surface and a lower surface;   a second polymer layer having an upper surface and a lower surface; and   a peel-ply protective film.   
     
     
         21 . The composite material of  claim 20 , wherein the first polymer layer is applied to the lower surface of the nonwoven and the second polymer layer is applied to the upper surface of the nonwoven. 
     
     
         22 . The composite material of  claim 20 , wherein the a printed layer is at the interface between the first and second polymer layer. 
     
     
         23 . The composite material of  claim 20 , wherein the upper surface of the non-woven and the upper surface of the first polymer layer are substantially coplanar. 
     
     
         24 . A composite material with a multilayer laminated facer, comprising:
 a fiber reinforced polymer board; including   a polymer matrix;   a plurality of reinforcing fibers dispersed within the matrix; and a laminated facer on the fiber reinforced board, including:   a nonwoven having an upper surface and a lower surface;   a preformed protective film, having an upper surface and a lower surface;   a first polymer layer applied between the lower surface of the protective film and the upper surface of the nonwoven and generally saturating the non-woven.   
     
     
         25 . The composite material of  claim 24 , further comprising:
 a printed layer on the upper surface of the non-woven.   
     
     
         26 . The composite material of  claim 24 , further comprising:
 a printed layer on the lower surface of the preformed protective film.   
     
     
         27 . The composite material of  claim 24 , further comprising:
 a peel-ply layer on the upper surface of the protective film.