EP0025065A1 - Thin skin laminated structure reinforced by polymeric foams - Google Patents
Thin skin laminated structure reinforced by polymeric foamsInfo
- Publication number
- EP0025065A1 EP0025065A1 EP80900691A EP80900691A EP0025065A1 EP 0025065 A1 EP0025065 A1 EP 0025065A1 EP 80900691 A EP80900691 A EP 80900691A EP 80900691 A EP80900691 A EP 80900691A EP 0025065 A1 EP0025065 A1 EP 0025065A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- foam
- flexible
- sheet
- thin skin
- thin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 239000006260 foam Substances 0.000 title claims abstract description 81
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 5
- 229920005989 resin Polymers 0.000 claims description 16
- 239000011347 resin Substances 0.000 claims description 16
- 238000000034 method Methods 0.000 claims description 15
- 239000000463 material Substances 0.000 claims description 12
- 238000005266 casting Methods 0.000 claims description 6
- 239000002666 chemical blowing agent Substances 0.000 claims description 6
- 239000004604 Blowing Agent Substances 0.000 claims description 5
- 239000004814 polyurethane Substances 0.000 claims description 5
- 229920002635 polyurethane Polymers 0.000 claims description 5
- 239000003822 epoxy resin Substances 0.000 claims description 4
- 229920000647 polyepoxide Polymers 0.000 claims description 4
- 239000003795 chemical substances by application Substances 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 2
- 229920005830 Polyurethane Foam Polymers 0.000 claims 3
- 239000011496 polyurethane foam Substances 0.000 claims 3
- 230000003213 activating effect Effects 0.000 claims 2
- 239000012779 reinforcing material Substances 0.000 claims 2
- 239000000835 fiber Substances 0.000 claims 1
- 230000001788 irregular Effects 0.000 claims 1
- 239000002131 composite material Substances 0.000 abstract description 3
- 239000010409 thin film Substances 0.000 abstract description 2
- 239000010408 film Substances 0.000 abstract 2
- 229920000642 polymer Polymers 0.000 abstract 1
- 108091006146 Channels Proteins 0.000 description 6
- 239000000203 mixture Substances 0.000 description 3
- 239000006261 foam material Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 150000001412 amines Chemical class 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 239000012260 resinous material Substances 0.000 description 1
- 239000004634 thermosetting polymer Substances 0.000 description 1
- 238000009736 wetting Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
- B29C44/145—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining the lining being a laminate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
- B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/021—Fibrous or filamentary layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/04—Impregnation, embedding, or binder material
- B32B2260/046—Synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/02—Organic
- B32B2266/0214—Materials belonging to B32B27/00
- B32B2266/0278—Polyurethane
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2266/00—Composition of foam
- B32B2266/06—Open cell foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/08—Reinforcements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/50—Properties of the layers or laminate having particular mechanical properties
- B32B2307/558—Impact strength, toughness
Definitions
- the expansion casting system consists of filling the mold cavity with a polymeric foam material and a blowing agent which, when activated, foams the polymeric material to the shape of the mold cavity.
- a blowing agent which, when activated, foams the polymeric material to the shape of the mold cavity.
- This invention produces a smooth skin laminated structure using the foam casting technique by interposing a flexible open-celled foam wetted with a thermoset resin between the outer thin skin and an expandable thermoset polymeric foam.
- the polymeric foam as it expands in the interior of the mold, comprises the inner surface of the flexible foam.
- the resin in the flexible foam cures after the expanded foam cures.
- the flexible foam compresses differentially in proportion to the uneven expansion of the expandable foam and thereby prevents any distortion of the outer thin skin.
- FIGURE 1 is a cross-sectional view of a closed mold in which a thin skinned laminated structure is cast by means of an expandable polymerxc foam in accordance with the principles of this invention.
- FIGURE 2 is another embodiment in which the principles of this invention are used to reinforce a thin skin body portion.
- FIG. 1 there is shown a mold 10 having an upper part 12 and lower part 14 and a cavity 16 of a desired pattern shape.
- the first step is to lay up along the surface of the cavity 16 a thin sheet of material 18.
- the thin sheet 18 could be made of any plyable material such as metal, wood or fibrous reinforced material.
- the thickness of this sheet, of material depends on the particular material employed, for example: .020 inches for aluminum, .1 inch for wood veneer, and .040 inch for fiber glass laminates. In any event, this thin sheet of material would be of a thickness that causes the skin to buckle upon an expandable polymeric foam being introduced into the cavity 16, which when activated expands outwardly and compresses against sheet 18.
- the next step is to lay up onto the thin sheet 18, a sheet of flexible open-celled foam 20.
- the open-celled foam sheet 20 Prior to insertion into the cavity 16, the open-celled foam sheet 20 is impregnated with a resinous material.
- the flexible foam may be any of the commercially available material such as flexible polyurethane, sponge rubber, cellulose foams, etc. Its impregnation is prefer ably performed in a manner that the open cells of the foam are left coated with the thin film of a settable resin. A suitable technique for accomplishing this objective is described in my U.S. patent No. 3,269,887.
- an expandable polymeric foam mixed with a chemical blowing agent 22 is inserted into the cavity 16. The quantity of this mixture must be sufficient to permit the polymeric foam to expand when activated to fill the volume defined by the inner walls of the flexible foam layer 20.
- the chemical blowing agent When activated, it expands the polymeric foam outwardly until it contacts and compresses the flexible foam.
- the flexible foam's inner surface 24 compresses differentially, in proportion to the uneven pressure applied by the gases of the expanding foam 22.
- the flexible foam layer 20 acts as a buffer zone between the expandable polymeric foam 22 and the thin skin layer 18 by absorbing the uneven expansion of the gaseous blowing agent. Due to this uneven expansion of the blowing agent, the impression in the inner surface of the open cell flexible foam 20 will vary around the perimeter of the mold cavity 16, but the pressure applied to the outer skin layer 18 will be negligible around the mold cavity perimeter.
- the resin used to wet the flexible foam sheet 20 must be compatible with the polymeric foam mixture 22.
- an epoxy resin and an amine curing agent would be suitable for wetting the flexible foam 20 when using a polyurethane rigid foam mixture as the expandable polymeric foam material. It is important that the settable resin cures after the expandable foam cures.
- the settable resin bonds the thin skin 18 to the rigidized flexible foam 20.
- the bottom wall 52 of the door sill is constructed of a thin skin which may be metallic, plastic composite, or the like, and which extends the length of the door to define a generally U-shaped interior channel 54.
- a flexible open-celled foam 56 wetted with a settable resin is layed up along the interior walls 58 of the U-shaped channel 54. This flexible foam 56 would be wetted in a manner described with reference to
- Figure 1 to provide the flexible foam's open cells with the thin coating of settable resin.
- An expandable polymeric foam 60 in sufficient quantities to fill the U-shaped chan nel 54 when expanded is then added to the interior of the channel mixed with a chemical blowing agent.
- the bottom portion of the U-shaped channel 54 is left open to permit any excess of the expandable foam to pass through it.
- the chemical blowing agent is activated to cause the polymeric foam 60 to expand outwardly toward the flexible foam 56.
- the inner surface 62 of the flexible foam compresses and applies a resultant negligible pressure outwardly against the thin skin wall members 52.
- the excess 64 of the expandable foam pushes through the open bottom of U-shaped channel 54.
- the settable resin in the flexible foam is selected to cure after the polymeric foam has cured.
- the resulting structure is a high impact resistant laminated structure which is reinforced by the expanded polymeric foam.
Landscapes
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US1764779A | 1979-03-05 | 1979-03-05 | |
| US17647 | 1979-03-05 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| EP0025065A1 true EP0025065A1 (en) | 1981-03-18 |
Family
ID=21783768
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| EP80900691A Withdrawn EP0025065A1 (en) | 1979-03-05 | 1980-09-24 | Thin skin laminated structure reinforced by polymeric foams |
Country Status (7)
| Country | Link |
|---|---|
| EP (1) | EP0025065A1 (enrdf_load_html_response) |
| JP (1) | JPS56500040A (enrdf_load_html_response) |
| AR (1) | AR219442A1 (enrdf_load_html_response) |
| AU (1) | AU5620780A (enrdf_load_html_response) |
| BR (1) | BR8007234A (enrdf_load_html_response) |
| ES (1) | ES8104053A1 (enrdf_load_html_response) |
| WO (1) | WO1980001892A1 (enrdf_load_html_response) |
Families Citing this family (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4559094A (en) * | 1984-01-19 | 1985-12-17 | Sears Manufacturing Company | Process for forming cushion articles |
| US4581262A (en) * | 1985-01-14 | 1986-04-08 | Owens-Illinois, Inc. | Coextruded multilayer sheet and sleeve label made therefrom |
| US4626455A (en) * | 1985-01-14 | 1986-12-02 | Owens-Illinois, Inc. | Coextruded multilayer sheet and sleeve label for bottles |
| EP0317833A1 (de) * | 1987-11-23 | 1989-05-31 | Irbit Research + Consulting AG | Dichtungselement |
| GB8811033D0 (en) * | 1988-05-10 | 1988-06-15 | A Foam Co Ltd | Foam composite & method of forming same |
| US5580651A (en) * | 1991-08-13 | 1996-12-03 | Woodbridge Foam Corporation | Energy absorbing panel |
| US5389316A (en) * | 1991-08-13 | 1995-02-14 | Woodbridge Foam Corporation | Process for producing an energy absorbing panel |
| BR9406444A (pt) * | 1993-02-12 | 1996-02-27 | Woodbridge Foam Corp | Painel absorvedor de energia |
| FR2704804B1 (fr) * | 1993-05-03 | 1995-08-18 | Reydel Dev | Produit stratifié destiné notamment à réaliser des éléments d'habillage intérieur de carrosserie. |
| DE19641134A1 (de) * | 1996-10-05 | 1998-04-16 | Happich Gmbh Gebr | Innenausstattungsteil |
| DE10237836A1 (de) * | 2002-08-19 | 2004-03-04 | Arvinmeritor Gmbh | Verfahren zum Herstellen einer Fahrzeuginnenraumverkleidung sowie Fahrzeuginnenraumverkleidung |
Family Cites Families (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3118153A (en) * | 1960-10-21 | 1964-01-21 | Davidson Rubber Company Inc | Upholstery corner construction |
| US3193598A (en) * | 1961-08-16 | 1965-07-06 | Freeman Chemical Corp | Process of molding laminating preforms of foamed polyurethane having open, connected cells |
| US3269887A (en) * | 1963-08-07 | 1966-08-30 | Dow Chemical Co | Settable, flexible, foamed resins |
| US3437551A (en) * | 1964-09-15 | 1969-04-08 | Mobay Chemical Corp | Method of bonding thermoplastic film to polyurethane foam and product |
| DE1785441A1 (de) * | 1968-09-25 | 1971-07-15 | Metallgesellschaft Ag | Verfahren zur Rueckenbeschichtung von Teppichware,insbesondere Nadelflorteppichen |
| US3664976A (en) * | 1969-08-21 | 1972-05-23 | Uniroyal Ltd | Polyurethane foam with integral skin |
| US3795722A (en) * | 1970-10-02 | 1974-03-05 | Goodyear Tire & Rubber | Method of making a skin covered foam article and said article |
| US3698927A (en) * | 1970-10-28 | 1972-10-17 | Goodyear Tire & Rubber | Foam structure with protective overcoat |
| US3989781A (en) * | 1971-08-17 | 1976-11-02 | Shell Oil Company | Process for producing a fibrous reinforced thermosetting resin impregnated foamed polymeric resin article |
| JPS518422B2 (enrdf_load_html_response) * | 1971-12-18 | 1976-03-16 | ||
| US3946095A (en) * | 1973-12-03 | 1976-03-23 | Carnation Company | Method of restoring the shape of a flexible-shell model |
| US4017656A (en) * | 1975-09-18 | 1977-04-12 | Pandel-Bradford, Inc. | Imitation leather material and method of preparing such material |
| US4073998A (en) * | 1977-01-24 | 1978-02-14 | Bay Mills Limited | Scrim/foil laminate |
-
1980
- 1980-03-03 JP JP50079580A patent/JPS56500040A/ja active Pending
- 1980-03-03 WO PCT/US1980/000225 patent/WO1980001892A1/en not_active Application Discontinuation
- 1980-03-03 BR BR8007234A patent/BR8007234A/pt unknown
- 1980-03-05 ES ES489207A patent/ES8104053A1/es not_active Expired
- 1980-03-05 AR AR280180A patent/AR219442A1/es active
- 1980-03-06 AU AU56207/80A patent/AU5620780A/en not_active Abandoned
- 1980-09-24 EP EP80900691A patent/EP0025065A1/en not_active Withdrawn
Non-Patent Citations (1)
| Title |
|---|
| See references of WO8001892A1 * |
Also Published As
| Publication number | Publication date |
|---|---|
| ES489207A0 (es) | 1981-04-01 |
| WO1980001892A1 (en) | 1980-09-18 |
| BR8007234A (pt) | 1981-02-03 |
| AU5620780A (en) | 1980-09-11 |
| ES8104053A1 (es) | 1981-04-01 |
| JPS56500040A (enrdf_load_html_response) | 1981-01-16 |
| AR219442A1 (es) | 1980-08-15 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PUAI | Public reference made under article 153(3) epc to a published international application that has entered the european phase |
Free format text: ORIGINAL CODE: 0009012 |
|
| 17P | Request for examination filed |
Effective date: 19801030 |
|
| AK | Designated contracting states |
Designated state(s): AT DE FR GB NL SE |
|
| STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: THE APPLICATION HAS BEEN WITHDRAWN |
|
| 18W | Application withdrawn |
Withdrawal date: 19810415 |
|
| RIN1 | Information on inventor provided before grant (corrected) |
Inventor name: WINDECKER, LEO J. |