초록 ▼

This invention relates to construction panels comprising metal-thermoplastic-metal laminates and a process for preparing same, said laminates possessing in combination critical service properties of high heat distortion temperature, low coefficient of linear thermal expansion, low inelastic ratio, a

This invention relates to construction panels comprising metal-thermoplastic-metal laminates and a process for preparing same, said laminates possessing in combination critical service properties of high heat distortion temperature, low coefficient of linear thermal expansion, low inelastic ratio, and lightness in weight.

대표청구항 ▼

A metal-thermoplastic-metal laminate having in combination: an inelastic ratio less than about 93%; a coefficient of linear thermal expansion less than about 63×10-6°C.-1; a heat distortion temperature of at least about 130°C.; and a maximum weight of no more than about 9.76 kg/m2; said laminate com

A metal-thermoplastic-metal laminate having in combination: an inelastic ratio less than about 93%; a coefficient of linear thermal expansion less than about 63×10-6°C.-1; a heat distortion temperature of at least about 130°C.; and a maximum weight of no more than about 9.76 kg/m2; said laminate comprising: a thermoplastic core layer selected from the group consisting of partly crystalline polyamides and polyesters having a crystalline melting point greater than about 130°C., said thermoplastic core having a minimum thickness of about 0.0483 cm; and a metal layer laminated on each side of the thermoplastic core layer, each metal layer having: a melting point greater than the crystalline melting point of the thermoplastic core layer; and a minimum thickness of about 0.00127 cm; wherein the thickness ratio of the sum of the metal layer-thicknesses to the thermoplastic core layer thickness is described by the region of numerical overlap of the parameter TR(YSm/TSc) as determined from the areas defined by the relationships of TR(YSm/TSc) to IRl, CLTEl, and (HDTl-HDTc)/(Tmc-HDTc), the lower boundary of said areas being defined by the equation of a straight line y=mx+b in which y is the y-axis parameters of IRl, CLTEl, and (HDTl-HDTc)/(Tmc-HDTc), x is the x-axis parameter of TR(YSm/TSc), m is the slope of the straight line, and b is the intercept on the y-axis, with the proviso that: when y is IRl, m is 108 and b is zero (0) for values of x from zero (0) to 0.65, and m is zero (0) and b is 70 for values of x greater than 0.65; when y is CLTEl, m is -3.6×10-4 and b is 45×10-6 for values of x from zero (0) to 0.1, and m is zero (0) and b is 9×10-6 for values of x greater than 0.1; and when y is (HDTl-HDTc)/(Tmc-HDTc), m is 1 and b is zero (0) for values of x from zero (0) to 0.05, m is 10 and b is -0.45 for values of x from 0.05 to 0.12, and m is zero (0) and b is 0.75 for values of x greater than 0.12; and the upper boundary of said areas being defined by the equation of a straight line as defined hereinabove, with the proviso that: when y is IRl, m is 280 and b is 30 for values of x from zero (0) to 0.25, and m is zero (0) and b is 100 for values of x greater than 0.25; when y is CLTEl, m is -2.88×10-3 and b is 216×10-6 for values of x from zero (0) to 0.05, m is -1.29×10-4 and b is 78.5×10-6 for values of x from 0.05 to 0.26, and m is zero (0) and b is 45×10-6 for values of x greater than 0.26; and when y is (HDTl-HDTc)/(Tmc-HDTc), m is 112.5 b is zero (0) for values of x from zero (0) to 0.004, m is 15.3 and b is 0.389 for values of x from 0.004 to 0.04, and m is zero (0) and b is 1 for values of x greater than 0.04; wherein: IRl is the inelastic ratio of the laminate as measured in flexure at 5% strain in the outer metal layers at the point of maximum deflection; CLTEl is the coefficient of linear thermal expansion of the laminate; (HDTl-HDTc)/(Tmc-HDTc) is a normalized heat distortion temperature variable wherein HDTl is the heat distortion temperature of the laminate; HDTc is the heat distortion temperature of the thermoplastic core layer; Tmc is the crystalline melting point of the thermoplastic core layer; TR is the thickness ratio of the sum of the metal layer-thicknesses to the thermoplastic core layer thickness; YSm is the thickness-weight-average tensile yield strength of the two metal layers at an offset of 5% elongation; and TSc is the tensile strength of the thermoplastic core layer. A process for the preparation of a metal-thermoplastic-metal laminate having in combination: an inelastic ratio less than about 93%; a coefficient of linear thermal expansion less than about 63×10-6°C.-1; a heat distortion temperature of at least about 130°C.; and a maximum weight of no more than about 9.76 kg/m2; which process comprises: disposing a metal layer on each side of a thermoplastic core layer selected from the group consisting of partly crystalline polyamides and polyesters having a crystalline melting point greater than about 130°C., said polyamide consisting essentially of: nylon 6; nylon 6,6; nylon 6-co-6,6; nylon 6, terephthalic acid-co-6, isophthalic acid; blends thereof; and copolymers thereof, each metal layer having a melting point greater than the crystalline melting point of the thermoplastic core layer and a minimum thickness of about 0.00127 cm; wherein the thickness ratio of the sum of the metal layer-thicknesses to the thermoplastic core layer thickness is described by the region of numerical overlap of the parameter TR(YSm/TSc) as determined from the areas defined by the relationships of TR(YSm/TSc) to IRl, CLTEl, and (HDTl-HDTc)/(Tmc-HDTc), the lower boundary of said areas being defined by the equation of a straight line y=mx+b in which y is the y-axis parameters of IRl, CLTEl, and (HDTl-HDTc)/(Tmc-HDTc), x is the x-axis parameter of TR(YSm/TSc), m is the slope of the straight line, and b is the intercept on the y-axis, with the proviso that: when y is IRl, m is 108 and b is zero (0) for values of x from zero (0) to 0.65, and m is zero (0) and b is 70 for values of x greater than 0.65; when y is CLTEl, m is -3.6×10-4 and b is 45×10-6 for values of x from zero (0) to 0.1, and m is zero (0) and b is 9×10-6 for values of x greater than 0.1; and when y is (HDTl-HDTc)/(Tmc-HDTc), m is 1 and b is zero (0) for values of x from zero (0) to 0.05, m is 10 and b is -0.45 for values of x from 0.05 to 0.12, and m is zero (0) and b is 0.75 for values of x greater than 0.12; and the upper boundary of said areas being defined by the equation of a straight line as defined hereinabove, with the proviso that: when y is IRl, m is 280 and b is 30 for values of x from zero (0) to 0.25, and m is zero (0) and b is 100 for values of x greater than 0.25; when y is CLTEl, m is -2.88×10-3 and b is 216×10-6 for values of x from zero (0) to 0.05, m is -1.29×10-4 and b is 78.5×10-6 for values of x from 0.005 to 0.26, and m is zero (0) and b is 45×10-6 for values of x greater than 0.26; and when y is (HDTl-HDTc) /(Tmc-HDTc), m is 112.5 and b is zero (0) for values of x from zero (0) to 0.004, m is 15.3 and b is 0.389 for values of x from 0.004 to 0.04, and m is zero (0) and b is 1 for values of x greater than 0.04; wherein: IRl is the inelastic ratio of the laminate as measured in flexure at 5% strain in the outer metal layers at the point of maximum deflection; CLTEl is the coefficient of linear thermal expansion of the laminate; (HDTl-HDTc)/(Tmc-HDTc) is a normalized heat distortion temperature variable wherein HDTl is the heat distortion temperature of the laminate; HDTc is the heat distortion temperature of the thermoplastic; Tmc is the crystalline melting point of the thermoplastic core layer; TR is the thickness ratio of the sum of the metal layer-thicknesses to the thermoplastic core layer thickness; YSm is the thickness-weight-average tensile yield strength of the two metal layers at an offset of 5% elongation; and TSc is the tensile strength of the thermoplastic core layer; laminating the thermoplastic core layer and the metal layers by subjecting the combination to elevated temperatures and a pressure sufficient to maintain fare-adhering contact; and cooling to ambient temperatures. A metal-thermoplastic-metal laminate having in combination: an inelastic ratio less than about 93%; a coefficient of linear thermal expansion less than about 63×10-6°C.-1; a heat distortion temperature of at least 130°C.; and a maximum weight of no more than about 9.76 kg/m2; said laminate comprising: a thermoplastic core layer selected from the group consisting of partly crystalline polyamides and polyesters having a crystalline melting point greater than about 130°C., said polyamides consisting essentially of: nylon 6; nylon 6,6; nylon 6-co-6,6; nylon 6, terephthalic acid-co-6, isophthalic acid; blends thereof; and copolymers thereof; and a metal layer laminated on each side of the thermoplastic core layer, each metal layer having: a melting point greater than the crystalline melting point of the thermoplastic core layer; and a minimum thickness of about 0.00127 cm; wherein the thickness ratio of the sum of the metal layer-thicknesses to the thermoplastic core layer thickness is described by the region of numerical overlap of the parameter TR(YSm/TSc) as determined from the areas defined by the relationships of TR(YSm/TSc) to IRl, CLTEl, and (HDTl-HDTc)/(Tmc-HDTc), the lower boundary of said areas being defined by the equation of a straight line y=mx+b in which y is the y-axis parameters of IRl, CLTEl, and (HDTl-HDTc)/(Tmc-HDTc), x is the x-axis parameter of TR(YSm/TSc), m is the slope of the straight line, and b is the intercept on the y-axis, with the proviso that: when y is IRl, m is 108 and b is zero (0) for values of x from zero (0) to 0.65, and m is zero (0) and b is 70 for values of x greater than 0.65; when y is CLTEl, m is -3.6×10-4 and b is 45×10-6 for values of x from zero (0) to 0.1, and m is zero (0) and b is 9×10-6 for values of x greater than 0.1; and when y is (HDTl-HDTc)/(Tmc-HDTc), m is 1 and b is zero (0) for values of x from zero (0) to 0.05, m is 10 and b is -0.45 for values of x from 0.05 to 0.12, and m is zero (0) and b is 0.75 for values of x greater than 0.12; and the upper boundary of said areas being defined by the equation of a straight line as defined hereinabove, with the proviso that: when y is IRl, m is 280 and b is 30 for values of x from zero (0) to 0.25, and m is zero (0) and b is 100 for values of x greater than 0.25; when y is CLTEl, m is -2.88×10-3 and b is 216×10-6 for values of x from zero (0) to 0.05, m is -1.29×10-4 and b is 78.5×10-6 for values of x from 0.05 to 0.26, and m is zero (0) and b is 45×10-6 for values of x greater than 0.26; and when y is (HDTl-HDTc)/(Tmc-HDTc), m is 112.5 be is zero (0) for values of x from zero (0) to 0.004, m is 15.3 and b is 0.389 for values of x from 0.004 to 0.04, and m is zero (0) and b is 1 for values of x greater than 0.04; wherein: IRl is the inelastic ratio of the laminate as measured in flexure at 5% strain in the outer metal layers at the point of maximum deflection; CLTEl is the coefficient of linear thermal expansion of the laminate; (HDTl-HDTc)/(Tmc-HDTc) is a normalized heat distortion temperature variable wherein HDTl is the heat distortion temperature of the laminate; HDTc is the heat distortion temperature of the thermoplastic core layer; Tmc is the crystalline melting point of the thermoplastic core layer; TR is the thickness ratio of the sum of the metal layer-thicknesses to the thermoplastic core layer thickness; YSm is the thickness-weight-average tensile yield strength of the two metal layers at an offset of 5% elongation; and TSc is the tensile strength of the thermoplastic core layer. A metal-thermoplastic-metal laminate having in combination: an inelastic ratio less than about 93%; a coefficient of linear thermal expansion less than about 63×10-6°C.-1; a heat distortion temperature of at least about 130°C.; and a maximum weight of no more than about 9.76 kg/m2; said laminate comprising: a thermoplastic core layer selected from the group consisting of partly crystalline polyamides and polyesters having a crystalline melting point greater than about 130°C., said polyamides consisting essentially of: poly(S0.00127 cm; wherein the thickness ratio of the sum of the metal layer-thicknesses to the thermoplastic core layer thickness is described by the region of numerical overlap of the parameter TR(YSm/TSc) as determined from the areas defined by the relationships of TR(YSm/TSc) to IRl, CLTEl, and (HDTl-HDTc)/(Tmc-HDTc), the lower boundary of said areas being defined by the equation of a straight line y=mx+b in which y is the y-axis parameters of IRl, CLTEl, and (HDTl-HDTc)/(Tmc-HDTc), x is the x-axis parameter of TR(YSm/TSc), m is the slope of the straight line, and b is the intercept on the y-axis, with the proviso that: when y is IRl, m is 108 and b is zero (0) for values of x from zero (0) to 0.65, and m is zero (0) and b is 70 for values of x greater than 0.65; when y is CLTEl, m is -3.6×10-4 and b is 45×10-6 for values of x from zero (0) to 0.1, and m is zero (0) and b is 9×10-6 for values of x greater than 0.1; and when y is (HDTl-HDTc)/(Tmc-HDTc), m is 1 and b is zero (0) for values of x from zero (0) to 0.05, m is 10 and b is -0.45 for values of x from 0.05 to 0.12, and m is zero (0) and b is 0.75 for values of x greater than 0.12; and the upper boundary of said areas being defined by the equation of a straight line as defined hereinabove, with the proviso that: when y is IRl, m is 280 and b is 30 for values of x from zero (0) to 0.25, and m is zero (0) and b is 100 for values of x greater than 0.25; when y is CLTEl, m is -2.88×10-3 and b is 216×10-6 for values of x from zero (0) to 0.05, m is -1.29×10-4 and b is 78.5×10-6 for values of x from 0.05 to 0.26, and m is zero (0) and b is 45×10-6 for values of x greater than 0.26; and when y is (HDTl-HDTc), m is 112.5 b is zero (0) for values of x from zero (0) to 0.004, m is 15.3 and b is 0.389 for values of x from 0.004 to 0.04, and m is zero (0) and b is 1 for values of x greater than 0.04; wherein: IRl is the inelastic ratio of the laminate as measured in flexure at 5% strain in the outer metal layers at the point of maximum deflection; CLTEl is the coefficient of linear thermal expansion of the laminate; (HDTl-HDTc)/(Tmc-HDTc) is a normalized heat distortion temperature variable wherein HDTl is the heat distortion temperature of the laminate; HDTc is the heat distortion temperature of the thermoplastic core layer; Tmc is the crystalline melting point of the thermoplastic core layer; TR is the thicknss ratio of the sum of the metal layer-thicknesses to the thermoplastic core layer thickness; YSm is the thickness-weight-average tensile yield strength of the two metal layers at an offset of 5% elongation; and TSc is the tensile strength of the thermoplastic core layer.