Thermofused reinforced decorative composite material with thermoplastic stiffener core
A reinforced composite material includes a decorative layer, a stiffener core, and, optionally, a backing layer, which are thermofused to each other. Also provided is a method for the production of such a material.
1 . A reinforced composite material comprising:
a decorative layer;
a stiffener core comprising a thermoplastic material and a reinforcement embedded therein; and, optionally,
a backing layer facing a surface of the stiffener substrate opposite to that facing the decorative layer,
wherein the decorative layer and, if included, the backing layer are thermofused to the stiffener core.
2 . The reinforced composite material according to claim 1 , wherein the decorative layer comprises wood, metal, film and/or resin-saturated paper.
3 . The reinforced composite material according to claim 2 , wherein the paper is saturated with a resin selected from the group consisting of a polyester resin and a melamine resin.
4 . The reinforced composite material according to claim 1 , wherein the thermoplastic material is selected from the group consisting of polypropylene, polyethylene, PET, PVC and ABS.
5 . The reinforced composite material according to claim 1 , wherein the reinforcement comprises fibers.
6 . The reinforced composite material according to claim 5 , wherein the reinforcement comprises continuous and/or discontinuous fiberglass.
7 . The reinforced composite material according to claim 6 , wherein the continuous fiberglass is random or oriented.
8 . The reinforced composite material according to claim 5 , wherein the fibers comprise glass, aramid, polyamide and/or carbon fibers.
9 . The reinforced composite material according to claim 1 , wherein the reinforcement comprises a woven material.
10 . The reinforced composite material according to claim 1 , wherein the stiffener core further comprises an additional thermoplastic material, stiffening material, and/or insulation material.
11 . The reinforced composite material according to claim 10 , wherein the stiffening material comprises foam, wood, metal and/or film.
12 . The reinforced composite material according to claim 11 , wherein the foam is thermoplastic or thermoset closed- or open-celled.
13 . The reinforced composite material according to claim 1 , wherein the backing layer comprises a fiber material.
14 . The reinforced composite material according to claim 13 , wherein the fiber material of the backing layer is paper or non-woven scrim.
15 . The reinforced composite material according to claim 1 , wherein a portion of the reinforcement protrudes from the surface of the stiffener substrate opposite to that facing the decorative layer.
16 . The reinforced composite material according to claim 15 , wherein the portion is at least partially not coated with the thermoplastic material.
17 . A method for making a reinforced composite material, comprising the steps of:
providing a decorative layer and a stiffener core, which comprises a thermoplastic material and a reinforcement embedded therein, and, optionally, a backing layer; and
thermofusing the stiffener substrate with the decorative layer and, if provided, the backing material.
18 . The method according to claim 17 , wherein the backing layer comprises a fiber material.
19 . The method according to claim 18 , wherein the fiber material comprises paper or non-woven scrim.
20 . The method according to claim 17 , wherein a stiffening material or an insulation material or both is provided in addition to the decorative layer the stiffener substrate, and, optionally, the backing layer.
21 . The method according to claim 20 , wherein the stiffening material comprises foam, metal, film and/or wood.
22 . The method according to claim 21 , wherein the foam is thermoplastic or thermoset open- or closed-cell.