US 11,938,691 B2
Thermoplastic prepreg based foam product
Malay Nandi, Littleton, CO (US); Mingfu Zhang, Littleton, CO (US); Lance Wang, Parker, CO (US); and Jawed Asrar, Englewood, CO (US)
Assigned to Johns Manville, Denver, CO (US)
Filed by JOHNS MANVILLE, Denver, CO (US)
Filed on Nov. 2, 2022, as Appl. No. 17/979,104.
Application 17/979,104 is a division of application No. 16/833,794, filed on Mar. 30, 2020, granted, now 11,518,119.
Prior Publication US 2023/0066342 A1, Mar. 2, 2023
Int. Cl. B32B 5/18 (2006.01); B29B 11/16 (2006.01); B29B 15/12 (2006.01); B29C 70/50 (2006.01); B32B 5/24 (2006.01); B32B 7/02 (2019.01); B29K 101/12 (2006.01); B29K 105/08 (2006.01)
CPC B29C 70/50 (2013.01) [B29B 11/16 (2013.01); B29B 15/122 (2013.01); B32B 5/18 (2013.01); B32B 5/245 (2013.01); B29K 2101/12 (2013.01); B29K 2105/0872 (2013.01)] 78 Claims
OG exemplary drawing
 
1. A thermoplastic prepreg product comprising:
a thermoplastic prepreg that forms a bottom layer of the thermoplastic prepreg product, the thermoplastic prepreg having a length and a width and the thermoplastic prepreg including:
a fabric, mat, or web of fibers, in which the fibers have an average length of 0.5 inches or greater; and
a thermoplastic material that is impregnated within the fabric, mat, or web of fibers; and
a foam core positioned atop the thermoplastic prepreg and bonded to the thermoplastic prepreg so that the foam core extends across the length and width of the thermoplastic prepreg;
wherein the thermoplastic prepreg has a surface having a mean roughness of at least 5 micrometers at an interface between the thermoplastic prepreg and the foam core.