Flat pressed composite product for vehicle interior lining panels comprises a lightweight core with internal chambers between outer layers of natural fiber and thermoplastic

摘要

The product comprises at least one core layer(5) with hollow internal chambers arranged between two or more layers of a composite material based on natural fibers and a thermoplastic material. Core layers are either: a) honeycomb structures, in particular bee honeycomb, rhomboid-shaped or prismatic hollow chambered structures; b) an expandable foam or c) a corrugated layer(2) with facing layers(3,4) on both sides. The weight ratio of natural fibers to thermoplastic fibers is 40:60, preferably 50:50. A fleece or film may be arranged on the outer faces of at least one of the fiber composite layers(6,7). A decorative material layer may also be arranged on the outside of the fleece layer. An Independent claim is included for a process for manufacturing a flat pressed composite product in which: a) a fiber composite mat of natural fibers and thermoplastic fibers is hot pressed above the plasticization temperature of the thermoplastic fibers, preferably 190-220degreesC; b) a core layer forming hollow chambers is arranged between at least two of the hot pressed layers while the latter are still hot; c) the assembly is compressed to join all layers.