US2024017531A1PendingUtilityA1

Laminate Facing for Fiber Reinforced Materials and Composite Materials Formed Therefrom

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Assignee: MILLER THOMAS SPriority: Mar 28, 2012Filed: Mar 16, 2023Published: Jan 18, 2024
Est. expiryMar 28, 2032(~5.7 yrs left)· nominal 20-yr term from priority
Inventors:Thomas MillerTimothy Johnson
B32B 27/12B32B 7/05B32B 5/024B32B 7/14B32B 27/36Y10T428/266B32B 2305/08B32B 2327/06B32B 2419/00B32B 2260/046B32B 2607/00B32B 27/40B32B 2255/10B32B 2255/205B32B 2262/0253B32B 2262/101Y10T428/31786Y10T428/269Y10T428/31681Y10T428/23914Y10T428/27Y10T428/31565Y10T428/31797Y10T428/249923Y10T442/675Y10T442/2861Y10T442/3862B32B 15/08B32B 2323/04B32B 2305/07B32B 2260/021B32B 27/322B32B 27/42B32B 7/04B32B 2323/10B32B 7/12B32B 2262/0276B32B 2375/00B32B 15/09B32B 2367/00B32B 5/02B32B 27/32B32B 2305/073B32B 5/06
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Claims

Abstract

The present invention provides a laminate material having a polyester film and a web of polyester fibers cohesively bonded directly thereto, such that portions of the fibers are bonded to the polyester film and portions of the fibers are free from the polyester film. The invention may also include a glass reinforced polymer layer formed on the laminated facer where the polymer of the glass reinforced polymer layer is commingled with the nonwoven of the laminated facer. The laminate may further include a second polymer layer having a thickness joined to the fiber layer and/or a layer of hot melt adhesive applied to the polyester fibers. Also presented is a composite material having a polyester film, a layer of polyester fibers bonded to the second polymer layer; a second polymer layer joined to the polyester film; and a glass reinforced polymer layer formed on the laminated facer, where the polymer of the class reinforced polymer layer is commingled with the nonwoven of the laminated facer.

Claims

exact text as granted — not AI-modified
What is claimed is: 
     
         1 . A laminate material comprising:
 a base layer of a polymer film   a heat sealable polymer film having a thickness of 0.5-5 mil, and   a bonded fiber web having a density of 17-100 GSM and including polymer fibers cohesively bonded directly thereto, such that portions of the fibers are bonded to the polymer film and portions of the fibers are free from the polymer film.   
     
     
         2 . The laminate material of  claim 1 , wherein the polymer tint is a polyester film. 
     
     
         3 . The laminate material of  claim 1 , wherein the polymer film is a polyethylene terephthalate film. 
     
     
         4 . The laminate material of  claim 1 , wherein the polymer fibers comprise polyester. 
     
     
         5 . The laminate material of  claim 1 , wherein the polymer polyethylene terephthalate. 
     
     
         6 . The laminate material of  claim 1 , wherein the polymer is selected from the group consisting of polyethylene, polyvinylidene fluoride, poly(methyl methacrylate), polycarbonate, acrylonitrile butadiene styrene, polyvinyl fluoride, polyester, polyurethane, polypropylene, polyethylene terephthalate, polyurea, polyvinyl chloride, EMA, or EVA. 
     
     
         7 . The laminate material of  claim 1 , wherein the polymer fibers are selected from the group consisting of polyethylene, polyvinylidene fluoride, poly(methyl methacrylate), polycarbonate, acrylonitrile butadiene styrene, polyvinyl fluoride, polyester, polyurethane, polypropylene, polyethylene terephthalate, polyurea, polyvinyl chloride, EMA, or EVA. 
     
     
         8 . The laminate material of  claim 1 , wherein the base layer has a softening point T1 and the and the heat sealable layer has a softening point T2, such that T2<T1. 
     
     
         9 . The laminate material of  claim 1 , wherein the monocomponent fibers have a softening point T3 such that T3>T2. 
     
     
         10 . The laminate material of  claim 1  wherein a polymer in the multicomponent fibers has a softening point T4 such that T4<T1. 
     
     
         11 . The laminate of  claim 1 , wherein the bonded fiber web includes a mixture of monocomponent fibers and multicomponent fibers. 
     
     
         12 . The laminate of  claim 1 , wherein the bonded fiber has a density of 20-50 GSM and the web includes staple fibers. 
     
     
         13 . The laminate of  claim 1 , wherein the bonded fiber has a density of 20-50 GSM and the web includes continuous fibers. 
     
     
         14 . The laminate of  claim 1 , wherein the cohesive bond is selected from the group consisting of melt bonding, point bonding and roll bonding. 
     
     
         15 . The laminate of  claim 1 , further comprising:
 a layer selected from the group consisting of a metal layer, an ink layer, a polymer layer deposited on at least one surface of the laminate.   
     
     
         16 . The laminate of  claim 1 , further comprising:
 a layer applied to the base layer opposite heat sealable layer, the layer se   -polymers (polyethylene, low melt PET, acrylic, polyurethane, ink, polyester, polypropylene, polyethylene terephthalate, polyurea or polyvinyl chloride) or a vapor deposited metals.   
     
     
         17 . The laminate of  claim 1 , wherein the polyester film has a thickness of 0.5-3.0 MIL. 
     
     
         18 . The laminate of  claim 1 , wherein the polyester film has a thickness of 0.5-3.0 MIL and the nonwoven has a density of 30-65 GSM 31 . 
     
     
         19 . The laminate of  claim 1 , wherein the polyester film has a thickness of 0.5-1.5 MIL and the nonwoven has a density of 17-35 GSM. 
     
     
         20 . The laminate of  claim 1 , further comprising:
 an extrusion coated polymer layer having a thickness of 30-260 GSM joined to the nonwoven.   
     
     
         21 . The laminate of  claim 20 , wherein the extrusion coated polymer layer is selected from the group consisting of polyethylene, polyester, polyurethane, polypropylene, polyethylene terephthalate, polyurea, polyvinyl chloride, EMA, or EVA. 
     
     
         22 . A composite material, comprising:
 a laminated facer having a polymer film haying a thickness of 0.5-5 mil and a bonded fiber web having a density of 17-100 GSM fibers being cohesively bonded directly to the polymer film, such that portions of the fibers are bonded to the polymer film and portions of the fibers are free from the polymer film; and   a fiber reinforced polymer layer formed on die laminated facer;
 whereby, the polymer of the reinforced polymer layer is commingled with the nonwoven of the laminated facer. 
   
     
     
         23 . The composite material of  claim 22 , wherein the polymer film is a polyester film. 
     
     
         24 . The composite material of  claim 22 , wherein the polymer film is a polyethylene terephthalate film. 
     
     
         25 . The composite material of  claim 22 , wherein the polymer fibers comprise polyester. 
     
     
         26 . The composite material of  claim 22 , wherein the polymer polyethylene terephthalate. 
     
     
         27 . The composite material of  claim 22 , wherein the polymer film is selected from the group consisting of polyethylene, polyvinylidene fluoride, poly(methyl methacrylate), polycarbonate, acrylonitrile butadiene styrene, polyvinyl fluoride, polyester, polyurethane, polypropylene, polyethylene terephthalate, polyurea, polyvinyl chloride, EMA or EVA. 
     
     
         28 . The composite material of  claim 22 , wherein the polymer fibers are selected from the group consisting of polyethylene, polyvinylidene fluoride, poly(methyl methacrylate), polycarbonate, acrylonitrile butadiene styrene, polyvinyl fluoride, polyester, polyurethane, polypropylene, polyethylene terephthalate, polyurea, polyvinyl chloride, EMA, or EVA. 
     
     
         29 . The material of  claim 22 , further comprising:
 a layer selected from the group consisting of a metal layer, an ink layer, a polymer layer deposited on at least one surface of the laminate.   
     
     
         30 . The laminate of  claim 21 , wherein the polyester film has a thickness of 0.5-3.0 MIL and the nonwoven has a density of 17-50 GSM. 
     
     
         31 . A laminate material comprising:
 a polyester film having a thickness of 0.5-2 mil,   a bonded fiber web having a density of 17-100 GSM and including 20% PET fibers and 80% PET bicomponent fibers cohesively bonded directly to the polyester film, such that portions of the fibers are bonded to the polyester film and portions of the fibers are free from the polyester film; and

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