Reinforced laminate

• US 4,579,774 A
• Filed: 10/30/1984
• Issued: 04/01/1986
• Est. Priority Date: 10/30/1984
• Status: Expired due to Fees

• Current Assignee: Sekisui Kagaku Kogyo Kabushiki Kaisha (Sekisui), Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Sekisui Kagaku Kogyo Kabushiki Kaisha (Sekisui), Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Ikemoto, Rikuo, Kuwazuru, Issei, Yada, Kozo
• Primary Examiner(s): Van Balen, William J.
• Application Number:
  US06/666,377
• Time in Patent Office: 518 Days
• Field of Search: 428/285, 428/287, 428/288, 428/298, 428/301, 428/302, 428/303, 428/313.5, 428/314.4, 428/314.8, 428/319.1, 428/290, 428/319.7, 428/304.4
• US Class Current: 428/300.4
• CPC Class Codes: B29C 70/086 and with one or more layers of pure plastics material, e.g. foam layers applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86
• CPC Class Codes: B29K 2025/00 Use of polymers of vinyl-aromatic compounds or derivatives thereof as moulding material
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: Y10T 428/249949 Two or more chemically different fibers
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249992 Linear or thermoplastic

Abstract

A reinforced laminate comprising

(a) a foamed styrene resin sheet layer, and

(b) thermoplastic resin layers reinforced with a mixture of glass fibers and organic fibers and laminated on both surfaces of the sheet layer (a). This laminate is suitable for use as a core material of a ceiling liner of an automobile.

Claims

1. A reinforced laminate comprising

(a) a foamed styrene resin sheet layer, and

(b) thermoplastic resin layers reinforced with a mixture of glass fibers and crimped organic fibers and laminated on both surfaces of the sheet layer (a).

2. The laminate of claim 1 wherein the foamed styrene resin sheet is a foamed polystyrene sheet.

3. The laminate of claim 1 wherein the glass fibers are long fibers.

4. The laminate of claim 1 wherein the mixing ratio of the glass fibers to the organic fibers is from 8:

2 to 2;

8 by weight.

5. The laminate of claim 1 wherein the fiber mixture is in the form of a mixed fibrous web of the glass fibers and the organic fibers.

6. The laminate of claim 5 wherein the mixed fibrous web is partially bonded by a resin binder having a softening point of less than about 140°

C.

7. The laminate of claim 5 wherein the thermoplastic resin layers are each formed by impregnating the mixed fibrous web with an emulsion of a thermoplastic resin.

8. The laminate of claim 1 wherein the weight ratio of the thermoplastic resin to the fiber mixture in the layers (b) is from 1:

1 to 5;

1.

9. The laminate of claim 1 wherein the weight ratio of the foamed sheet layer (a) to the thermoplastic resin layers (b) is from 1:

2 to 2;

1.

10. A molded article prepared from the laminate of claim 1.

11. A core material of a ceiling liner of an automobile, said core material being composed of the laminate of claim 1.

12. A reinforced laminate comprising

(a) a foamed styrene resin sheet layer, and

(b) thermoplastic resin layers reinforced with a mixture of glass fibers and organic fibers and laminated on both surfaces of the sheet layer (a), said thermoplastic resin layers being each formed by impregnating a nonwoven web of the organic fibers with an emulsion or a thermoplastic resin having the glass fibers dispersed therein.

13. The laminate of claim 12 wherein the foamed styrene resin sheet is a foamed polystyrene sheet.

14. The laminate of claim 12 wherein the glass fibers are long fibers.

15. The laminate of claim 12 wherein the organic fibers are crimped fibers.

16. The laminate of claim 12 wherein the mixing ratio of the glass fibers to the organic fibers is from 8:

2 to 2;

8 by weight.

17. The laminate of claim 12 wherein the fiber mixture is in the form of a mixed fibrous web of the glass fibers and the organic fibers.

18. The laminate of claim 17 wherein the mixed fibrous web is partially bonded by a resin binder having a softening point of less than about 140°

C.

19. The laminate of claim 17 wherein the thermoplastic resin layers are each formed by impregnating the mixed fibrous web with an emulsion of a thermoplastic resin.

20. The laminate of claim 17 wherein the weight ratio of the thermoplastic resin to the fiber mixture in the layers (b) is from 1:

1 to 5;

1.

21. The laminate of claim 17 wherein the weight ratio of the formed sheet layer (a) to the thermoplastic resin layers (b) is from 1:

2 to 2;

1.

22. A molded article prepared from the laminate of claim 12.

23. A core material of a ceiling liner of an automobile, said core material being composed of the laminate of claim 12.