GB1169548A - Process and apparatus for making Laminated Structures - Google Patents

Abstract

1,169,548. Foamed plastics laminate. WOODALL INDUSTRIES Inc. 16 Dec., 1966 [17 Dec., 1965], No. 56551/66. Heading B5N. A laminated structure comprises a rigid thermosetting synthetic resin foam layer 12 having a surface exhibiting a non-planar contour, a flexible cover sheet 15 being secured to said surface so that the cover sheet is held to the non-planar contour. In the method described for making a laminated structure, e.g. a motor vehicle trim panel, batches of a synthetic resin foam-forming mixture are applied in spaced relation from a mixer 17, Fig. 1, between cover sheets 15, 16. The assembly so formed is passed together with a caul 25, having a non-planar surface, between a pair of metering rolls 21, 22 and is cut into sections between batches of the form mixture before expansion of the latter. Each section is then transferred on a carrier plate to a shaped two-part press in which the foam mixture expands fully and is cured by heat. The upper and lower press parts are of porous material and include pipes through which suction is applied to the cover sheets 15, 16 to hold them in position during shaping. The cover sheets 15, 16 may be of paper, aluminium foil, or polyethylene lined paper, and the foam forming mixture may contain polymethylene polyisocyanate, polyoxypropylene sorbitol, and trichlorofluoromethane, to give a rigid foam. The assembly is then placed, together with a laminate consisting of an uncured polyurethane foam layer 13 and a vinyl plastics cover layer 14, into a shaped two part press 116, 126, Fig. 9, and heat and pressure are applied to cure the layer 13 and adhere the layers 13 and 16 together. The product is then removed from the press and trimmed. The laminate of layers 13 and 14 may be formed in a similar manner to that shown in Fig. 1 but in which the upper cover layer is removed before the foam layer 13 expands, or alternatively as shown in Fig. 6. In Fig. 6 batches of foam are applied between a cover sheet 72, and the layer 14 which is supported on a belt 64. The belt is advanced intermittently through an oven 80 in which the foam is expanded. During heating in the oven the sheet 72 is held down by bars 86, and the layer 14 is stretched by spring-loaded devices which grip its edges by suction. The layers 72, 13 and 14 are cut between batches and the layer 72 stripped off.