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Lightweight Polymeric Composites with Finished A-Surface for Wall and Ceiling Paneling Inside Recreational Vehicles


Title: Lightweight Polymeric Composites with Finished A-Surface for Wall and Ceiling Paneling Inside Recreational Vehicles

Authors: Liqing Wei, Ruomiao Wang, Mark O. Mason, Hanwha Azdel

DOI: 10.33599/nasampe/c.22.0078

Abstract: This paper describes the application of decorative textured films onto the lightweight reinforced thermoplastic (LWRT) composite core mat during the core manufacturing process, which is followed by a consolidation process. This method is defined as an in-line lamination process with a finished A-surface panel in comparison with a conventional off-line decorative materials lamination process in which the decorative film is applied in a separate process from core manufacture. Decorative films with multiple types of textures have been reported. In-line laminated panels were tested for physical (areal density, thickness, density, and ash content), surface roughness and scratch hardness, mechanical property (flexural, flatwise tensile, and film peel test), sound absorption, and flame retardant performance. A stylus surface roughness method was used to determine quantitatively how much of the embossed texture was retained in the in-line lamination process on the finished panel. The surface scratch hardness of panels varied with different types of films. The adhesion performance between the decorative film layer and LWRT composite substrate has been evaluated by 180° peel adhesion test following ASTM standard D903. The bonding strength between film and composite core was > 20 N. Finished panels showed various performances of the flexural performances caused by the differences of films. The FMVSS302 method was used to compare the fire retardancy (FR) of panels. These panels had acceptable FR and burning rate ranged from 2.0 to 7.0 cm/min, depending on the film type. The laminated panels showed excellent sound absorption performance. These decorative panels with custom design are used as wall and ceiling paneling inside the recreational vehicle (RV) because of their durability, water proof, lightweight, and good fire resistant performances.

References: 1. Wei L., Wang R., and Mason M.O. In-line laminate decorative thermoplastic composite panel. In proceedings of SPE Annual Technical Conference (2021). 2. Lozier T.B., and Romanowski S.J., Jayco Inc, (2020). Recreational vehicle component with data and method of manufacturing. U.S. Patent Application 16/356,721. 3. Mummery L. (1990). Surface texture analysis: the handbook. Hommelwerke, p.106. 4. Thomas D. Acoustics - Determination of Sound Absorption Coefficient and Impedance in Impedance Tubes - Part 2: Transfer Function Method, Springer (2001). 5. Singh J., Kumar M., Kumar S., Mohapatra S.K. (2017). Properties of Glass-Fiber Hybrid Composites: A Review. Polymer-Plastics Technology and Engineering, 56(5), 455-469. 6. Tiuc A.E., Nemeş O., Vermeşan H., and Toma A.C. (2019). New sound absorbent composite materials based on sawdust and polyurethane foam. Composites Part B: Engineering, 165, 120-130. 7. Wang R. and Yang Y. Flame retardant and acoustic light weight reinforced thermoplastic panel. In proceedings of CAMX - The Composites and Advanced Materials Expo, Orlando, FL, September 11-14 (2017). 8. Wang R. Acoustic and flame retardant light weight reinforced thermoplastic composite. In proceedings of SPE-ANTEC, Orlando, FL, May 7-9 (2018). 9. Wei L., Wang R., and Mason M.O. Reinforced Thermoplastic Containing Recycled Cardboard Fibers for Recreational Vehicle Applications. In proceedings of SPE Annual Technical Conference Virtual (2020).

Conference: CAMX 2022

Publication Date: 2022/10/17

SKU: TP22-0000000078

Pages: 11

Price: $22.00

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