Structural composite panels for motor homes, recreational vehicles, and trailers

Abstract

The present disclosure relates to laminate composite panels comprising a first layer of fiberglass reinforced polyester (“FRP”) and a second layer of a polyurethane material. The polyurethane layer can comprise a reaction product between an aromatic polyester polyether polyol and a diisocyanate. The polyurethane is cured-in-place on a surface of the FRP, thus creating a laminate composite material wherein the layers are adhered together without application of a separate adhesive layer. The panels exhibit improved water resistance and strength properties. The laminate composite can be adhered to a second material such as wood, polystyrene, polyurethane, or non-wovens. Such panels are particularly suitable for use in recreational vehicles, motor homes, trailers, and as building materials. Methods of making such laminate composite materials are also provided.

What is claimed is: 
     
         1 . A composite laminate material comprising:
 (a). a first layer comprising a fiber reinforced polyester (“FRP”) material having a front-facing side and a back side; and   (b). a second layer comprising a polyurethane reaction product of an aromatic polyester polyether polyol and a diisocyanate, wherein the polyester polyether polyol and the diisocyanate are cured-in-place on the back side of the FRP material to form the second layer, thereby providing the composite laminate material.   
     
     
         2 . The composite laminate material of  claim 1 , wherein the second layer is adhered to the back side of the first layer without application of a separate adhesive layer. 
     
     
         3 . The composite material of  claim 1 , wherein the polyester polyether polyol is derived from a transesterification reaction between PET and either ethoxylated trimethylol propane or ethoxylated glycerol. 
     
     
         4 . The composite material of  claim 3 , wherein the ethoxylated trimethylol propane or ethoxylated glycerol comprise from about 2 to about 9 moles of ethoxylation. 
     
     
         5 . The composite material of  claim 3 , wherein at least some of the polyester polyether polyol PET is derived from a recycled source. 
     
     
         6 . The composite material of  claim 1 , wherein the composite laminate material layer has a thickness of from about 1 mm to about 5 mm. 
     
     
         7 . The composite material of  claim 1 , wherein the second layer is foamed. 
     
     
         8 . A laminate composite material comprising:
 (a). a first layer comprising:
 (i). a composite layer comprising:
 (a). a fiber reinforced polyester (“FRP”) material having a front-facing side and a back side; and 
 (b). a polyurethane reaction product of an aromatic polyester polyether polyol and a diisocyanate, wherein the polyol and the diisocyanate are cured-in-place on the back side of the FRP material to provide a FRP-polyurethane laminate composite material; 
 
 (ii). a second layer, 
 wherein the composite layer is adhered to the second layer via an adhesive. 
   
     
     
         9 . The laminate composite of  claim 8 , wherein the adhesive comprises a layer of the polyurethane reaction product of the aromatic polyester polyether polyol and a diisocyanate, wherein the polyol and the diisocyanate are cured-in-place between the composite layer and the second layer. 
     
     
         10 . The laminate composite of  claim 8 , wherein the polyol is derived from a transesterification reaction between PET and either ethoxylated trimethylol propane or ethoxylated glycerol. 
     
     
         11 . The laminate composite of  claim 8 , wherein the ethoxylated trimethylol propane or ethoxylated glycerol comprise from about 2 to about 9 moles of ethoxylation. 
     
     
         12 . The laminate composite of  claim 8 , wherein at least some of the PET is derived from a recycled source. 
     
     
         13 . The laminate composite of  claim 8 , wherein the second layer comprises wood, non-woven material, expanded polystyrene, extruded polyurethane, or foamed polyurethane. 
     
     
         14 . The laminate composite of  claim 13 , wherein the second layer comprises wood, and the wood comprises plywood or oriented strand board. 
     
     
         15 . The laminate composite of  claim 13 , wherein the second layer comprises foamed polyurethane and the foamed polyurethane is derived from the reaction product of:
 (a). the aromatic polyester polyether polyol and the diisocyanate, wherein a blowing agent is incorporated therein.   
     
     
         16 . The laminate composite of  claim 13 , wherein the second layer is expanded polystyrene or extruded polyurethane. 
     
     
         17 . The laminate composite of  claim 13 , wherein the second layer is a non-woven.