Method for producing laminate composite materials

Patent metadata

Field	Value
Publication number	US-11084251-B2
Application number	US-201716345029-A
Country	US
Kind code	B2
Filing date	Nov 3, 2017
Priority date	Nov 8, 2016
Publication date	Aug 10, 2021
Grant date	Aug 10, 2021

Abstract

A method for producing laminate composite materials, as well as the laminate composite materials produced by this method and their use are described. The laminate composite materials are sandwich-like in construction and based on halogenated polymers and comprise a first laminar structure formed from halogenated polymer and a second laminar structure formed from halogenated polymer as well as at least one textile mat structure based on inorganic fibres, which is disposed between the first and the second laminar structure. The textile mat structure based on inorganic fibres comprises regions with high air permeability and regions with low air permeability, through which the two laminar structures formed from halogenated polymer are monolithically bonded together.

First claim

What is claimed is:

1. A method for the production of laminate composite materials based on halogenated polymers comprising:
providing a laminar structure formed from halogenated polymer;
applying a textile mat structure based on inorganic fibres onto at least one side of the laminar structure;
applying a second laminar structure formed from halogenated polymer to the textile mat structure based on glass fibres to form a composite; and
laminating the composite by applying one or both of pressure and temperature, wherein:
the textile mat structure based on inorganic fibres is a fibre nonwoven;
the fibre nonwoven comprises regions with high air permeability having a first thickness and regions with low air permeability with a second thickness;
peripheral edges of the regions with high air permeability are banked up and have a third thickness;
the third thickness is greater than the second thickness; and
the second thickness is greater than the first thickness.

2. A sandwich-like laminate composite material based on halogenated polymers comprising:
a first laminar structure formed from halogenated polymer;
a second laminar structure formed from halogenated polymer;
a textile mat structure based on inorganic fibres is disposed between the first laminar structure and the second laminar structure, wherein:
the first laminar structure, the textile mat structure based on inorganic fibres, and the second laminar structure are bonded together by lamination;

the textile mat structure based on inorganic fibres is a nonwoven; and
the fibre nonwoven, comprises regions with high air permeability having a first thickness and regions with low air permeability with a second thickness;
peripheral edges of the regions with high air permeability are banked up and have a third thickness;
the third thickness is greater than the second thickness; and
the second thickness is greater than the first thickness.

3. A carpet product comprising:
a carpet material; and
a fibre nonwoven coupled with the carpet material, the fibre nonwoven,
comprising regions with high air permeability having a first thickness and regions with low air permeability with a second thickness, wherein:
peripheral edges of the regions with high air permeability are banked up and have a third thickness;
the third thickness is greater than the second thickness; and
the second thickness is greater than the first thickness.

4. A composite material comprising:
a support material,
a textile mat structure based on inorganic fibres disposed on the support material, wherein:
the support material and the textile mat structure are bonded together by lamination;
the textile mat structure based on inorganic fibres is a nonwoven; and
the fibre nonwoven comprises regions with high air permeability having a first thickness and regions with low air permeability with a second thickness;
peripheral edges of the regions with high air permeability are banked up and have a third thickness;
the third thickness is greater than the second thickness; and
the second thickness is greater than the first thickness.

5. A textile mat structure based on inorganic fibers comprising;
a fibre nonwoven
comprising regions with high air permeability having a first thickness and regions with low air permeability with a second thickness;
peripheral edges of the regions with high air permeability are banked up and have a third thickness;
the third thickness is greater than the second thickness; and
the second thickness is greater than the first thickness.

6. The textile mat structure as claimed in claim 5 , wherein:
a difference in air permeability between the regions with high air permeability and the regions with low air permeability is a minimum of 50%.

7. The textile mat structure as claimed in claim 5 , wherein:
a basis weight in the regions with high air permeability is a maximum of 70% by weight of the mean basis weight.

8. The textile mat structure as claimed in claim 5 , wherein:
the regions with high air permeability have a local thickness which is a maximum of 80% of the mean nonwoven thickness “d”.

9. The textile mat structure as claimed in claim 5 , wherein:
the regions with high air permeability have a geometry with a larger length L1 and a smaller length L2; and
L1>5 mm and the ratio L1/L2 is in the range 1-10.

10. The textile mat structure as claimed in claim 5 , wherein:
an edge of the regions with high air permeability is banked up and the banking Δ is the difference “D” minus “d” and is a maximum of 20% of the thickness “d”.

11. The textile mat structure as claimed in claim 5 , wherein:
the regions with high air permeability are separated from each other by the regions with low air permeability; and
the distances between the respective regions with high air permeability is between 5 and 20 mm.

12. The textile mat structure as claimed in claim 5 , wherein:
a surface area of the regions with high air permeability is between 5 and 90% of a total surface area of the textile mat structure.

13. The textile mat structure as claimed in claim 2 , wherein:
the halogenated polymer comprises polyvinyl chloride (PVC).

14. The textile mat structure as claimed in claim 5 , further comprising:
a laminar structure formed from halogenated polymer coupled with the textile mat structure.

15. The textile mat structure as claimed in claim 14 , wherein:
the halogenated polymer comprises polyvinyl chloride (PVC).

Assignees

• Johns Manville

Inventors

• Eckert Bernhard

Classifications

• B32B27/322

  comprising halogenated polyolefins, e.g. PTFE · CPC title

• B32B3/266 Primary

  characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12 · CPC title

• B32B2262/10

  Inorganic fibres · CPC title

• B32B27/304

  comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF · CPC title

• B32B27/12

  next to a fibrous or filamentary layer · CPC title