GB1561883A

GB1561883A - Workable panel of thermoplastic plastics material and a filler

Info

Publication number: GB1561883A
Application number: GB51577/76A
Authority: GB
Original assignee: Individual
Current assignee: Individual
Priority date: 1976-11-05
Filing date: 1976-12-10
Publication date: 1980-03-05
Also published as: IT1067331B; FR2369933A1; DE2650628A1; SE7613561L; NL7613611A

Description

(54) WORKABLE PANEL OF THERMOPLASTIC PLASTICS MATERIAL AND A FILLER (71) 1, HUGo LINDENBERG, a citizen of the Federal German Republic, of Haus Hebborn, 5060 Bergisch Gladbach, Federal German Republic, do hereby declare the invention, for which I pray that a patent may be granted to me, and the method by which it is to be performed, to be particularly described in and by the following statement: The invention relates to a moulded laminated panel construction of thermoplastic plastics material and a filler especially a cellulose-containing material, particularly finely divided wood, which is clad with a plastics foil, preferably thermoplastic plastics foil.

Moulded laminated panels of a mixture of thermoplastic plastics material with a filler are used for the most varied purposes, especially as covering panels. Such panels are in many cases manufactured as moulded components with irregular shape, for example, with more or less pronounced bulges on one or the other side and the like. At the same time the moulded panels should have a cladding, for example be covered with a plastics foil, the plastics foil for its part possibly being multi-layered and possibly having a filled or inlay of soft foam material between the layers. The moulded panels must in this case be able to cope in part with considerable mechanical stresses.

They should have a tensile strength of predetermined magnitude. It is particularly necessary that the moulded panels are able to withstand deformation, that is maintain a desired cross-sectional area during production. There must be no occurrence of cracking or wrinkling. Moreover the moulded panels must remain true to size and inherently stable.

The most varied attempts have already been made to produce moulded panels which satisfy the various requirements aforesaid. It has not been possible to achieve satisfactory results hitherto. There are moulded panels of the most varied materials in which contraction phenomena can appear during production. There are furthermore known panels consisting of wood fibres and the like and also panels and panel formations of fibre reinforced textile material. These products are relatively expensive or not sufficiently deformable and therefore are frequently not economical in practice. The method of production is also expensive and complicated. There are further known panels which as far as the plastics material portions are concerned are based on a polymer of ethylene, the filling material concerned being particularly finely divided wood. for example wood dust or wood fibres.The portions of plastics material and filler may amount to about 50-50, and if occasion should arise the plastics material portion can be changed both upwardly and also downwardly proportionately.

Moulded panels of such moulding batches have in general a sufficient sterngth. These mechanical properties are however not suffi dent for many spheres of use. In order to obtain better results, moulded panels were developed in which the plastics material portion is based on a polymere of propylene.

With that in the case of moulded panels of this material the result has been that they may have mechanical properties which are even better in relation to the panels on an ethylene basis. The inherent stability is increased. Moulded panels with a binder based on propylene (homopolymers and copolymers of same) show on the other hand a good stability in shape. It has been proved however thta the moulded panel with a plastics material based on propylene has a property which in many cases does not make possible cladding with a plastics foil or the like. The surface of such a moulded panel does not offer sufficient adhesion for an adhesive or other adhesive agent which serves the purpose of binding fast, for example a plastics foil with a smooth surface facing the moulded panel. The bonded plastics foil or the like can be easily re moved with a small expenditure of force.

Moreover there is the danger that the applied plastics foil loosens under atmospheric influences, for example great heat or damp ness and heat, at least at points, automatically from the surface of the moulded panel. The permanence of the adhesive bond is not guaranteed.

The problem with which the invention is concerned is to produce moulded panels of thermoplastic plastics material and a filler, especially a plastics material based on propylene and a filler of finely divided wood, in which the cladding with a plastics foil is unobjectionable, reliable and permanent.

In accordance with the present invention, I provide a moulded laminated panel construction comprising a base panel of predetermined stable configuration and comprising a thermoplastic propylene-containing polymer and a filler, a non-woven expansible fabric mechanically anchored to and extending as a continuous unbroken layer over a surface of said base panel, said fabric being of synthetic and/or natural fibres and having a weight per unit area of 20 to 40 gm/cm2 and a thermoplastic foil having a surface thereof secured to said non-woven fabric by an adhesive material such that said foil surface and non-woven fabric are maintained coextensive.

In the case of such a moulded panel there is achieved a combination of remarkable advantages and properties. There is obtained a moulded panel in which on the one hand there is the certainty that it turns out perfectly in the production procedure, that is in the moulding. The panel material can be deformed on one or other side without there being any formation of cracks or wrinkles. The material as such has first rate mechanical properties especially involving the strength and stability in shape.

Above all the panel provided with these good properties is suitable for subsequent cladding with security with a plastics foil or the like.

Even in the case of a smooth foil the adhesive agent between the smooth foil and the surface of the panel holds in an outstanding manner. The adhesive bond is reliable, extremely firm and permanent, this being attributable to the interposed nonwoven fabric which for its part is bonded without adhesive agent with the surface of the plastics substance of the moulded panel.

This mechanical tying of the non-woven fabric on the moulded panel and the plastics foil cladding mounted thereon and secured bv an adhesive lead to a finished product which satisfies all of the requirements to be made thereon. This is especially true, for example in the use of the moulded panel according to the invention as a cladding part in motor vehicle construction. There is obtained a high quality moulded panel of high stability against all weather influences and of long durability.

The subject of the invention is impervious to heat and has also good properties when exposed to extreme cold. The material is able to cope with first class demands.

Also, in accordance with the present invention, I provide a method of producing a moulded laminated panel construction comprising compressing a non-woven expansible fabric of synthetic and/or natural fibres and having a weight per unit area of 20 to 40 gm/cm2, on to a surface of a base panel which comprises a thermoplastic propylene-containing polymer and a filler, under high pressure while said base panel and fabric are maintained at a temperature of about 1500 to 2100C to mechanically anchor said non-woven fabric to said surface of said base panel, moulding said base panel with said non-woven fabric secured to the surface thereof into a predetermined stable configuration with said non-woven fabric extending as a continuous unbroken layer over said base panel surface, and then securing a surface of a thermoplastic foil to said non-woven fabric by means of an adhesive material such that said foil surface and non-woven fabric are maintained coextensive. The non-woven fabric as sup port for the adhesive agent to the plastics foil or the like is advantageously an expansible fleece of synthetic or natural fibrous material, for example synthetic wool and/or natural wool. The workable panel may be provided on one or both sides with the nonwoven fabric as intermediate layer. There is to be understood by mechanical anchoring of the non-woven fabric on the moulded panel a bond in the hot pressed condition.

No adhesive is required in any way at this point. The plastics foil serving as the cladding is preferably an inelastic plastics foil or an expanded plastics foil suitable for deep drawing, and may consist of PVC.

Finely divided wood in the form of dust chip fibres and the like is preferably used as a filler for the plastics substance for the moulded panel. Other fillers, for example such as fillers of a mineral kind or the like are also suitable. The panels may have different thicknesses, for example from about 1 mm to 15 mm and thereabove. The panels may further be provided partly or wholly with reinforcements of known kind.

It has been shown that the moulded panel according to the invention with the hot pressed non-woven fabric applied thereto is also suitable for the secure fixing thereon by means of an adhesive substance or the like of individual attachment elements such for example as hooks or the like provided with a base plate. The moulded panel according to the invention may for example be clad on one side with the plastics foil while on the other side of the moulded panel individual elements can be affixed. The adhesive strength may in this instance be chosen to be of such magnitude that the individual elements mounted thereon, such as hooks or the like, can be used for receiving components of any kind to be hung thereon and withstand the desired loading.

The moulded panels according to the invention can be used with advantage in motor vehicle construction, for internal lining of rooms, in furniture maufacture, in packaging electrical engineering and in machine construction.

The invention will be more fully explained with reference to two embodiments which are diagrammatically represented in the drawing.

Fig. 1 shows a perspective view of a moulded panel.

Fig. 2 is a cross-section of the panel along the line II-II in Fig. 1.

Fig. 3 shows another embodiment of a moulded panel and Fig. 4 represents a cross-section along the line IV-IV in Fig. 3.

The moulded panel 1 includes a plate 2 which consists of a mixture of a filler with a plastics material based on propylene.

Between the plate 2 and a plastics foil serv ing as a decorative covering or the like there is a non-woven fabric 3 which is an chored in the hot pressed condition with the surface of the plate 2. The plastics foil 4 may be put on by means of an adhesive substance or other adhesive agent. This is effected preferably by deep drawing.

The moulded panel 5 of Figs. 3 and 4 corresponds in construction to that of the moulded panel 1. In the example of Figs.

3 and 4 bulges 6, 7 or other embossments are provided as deformations. The defor mation may however also consist of a bevel 8 which may extend partly or wholly over the length of one edge of the panel.

The deformation may, for example, be pro vided in a distortion in the form of a five sided closed pocket or the like.

WHAT I CLAIM IS: 1. A moulded laminated panel construc tion comprising a base panel of predeter mined stable configuration and comprising a thermoplastic propylene-containing poly mer and a filler, a non-woven expansible fabric mechanically anchored to and exten tending as a continuous unbroken layer over a surface of said base panel, said fabric being of synthetic and/or natural fibres and having a weight per unit area of 20 to 40 gm/cm2, and a thermoplastic foil having a surface thereof secured to said non-woven fabric by an adhesive material such that said foil surface and non-woven fabric are maintained coextensive.

2. A laminated panel construction as claimed in Claim 1 wherein said propylene containing polymer is polypropylene.

3. A laminated panel construction as claimed in Claim 1 or 2, wherein said nonwoven fabric is an expansible fleece of synthetic wool and/or natural wool.

4. A laminated panel construction as claimed in any one of the preceding Claims wherein said thermoplastic foil is an inelaestic plastics foil or an expanded plastics foil suitable for deep drawing.

5. A laminated panel construction as claimed in any one of the preceding Claims wherein said filler is a cellulose-containing filler such as finely divided wood.

6. A laminated panel construction as claimed in Claim 4 wherein said thermoplastic foil comprises polyvinyl chloride.

7. A method of producing a moulded laminated panel construction comprising compressing a non-woven expansible fabric of synthetic and/or natural fibres and having a weight per unit area of 20 to 40 gm/cm2 onto a surface of a base panel which comprises a thermoplastic propylene-containing polymer and a filler, under high pressure while said base panel and fabric are maintained at a temperature of about 1500 to 210"C to mechanically anchor said nonwoven fabric to said surface of said base panel moulding said base panel with said non-woven fabric secured to the surface thereof into a predetermined stable configuration with said non-woven fabric extending as a continuous unbroken layer over said base panel surface, and then securing a surface of a thermoplastic foil to said non-woven fabric by means of an adhesive material such that said foil surface and non-woven fabric are maintained coextensive.

8. A method as claimed in Claim 7 wherein said propylene containing polymer is polypropylene.

9. A method as claimed in Claim 7 or 8, wherein said non-woven fabric is an expansible fleece of synthetic wool and/or natural wool.

10. A method as claimed in any one of Claims 7 to 9, wherein said thermoplastic foil is an inelastic plastics foil or an expanded plastics foil suitable for deep drawing.

11. A method as claimed in any one of Claims 7 to 10, wherein said filler is a cellulose-containing filler such as finely divided wood.

12. A method as claimed in Claim 10, wherein said thermoplastics foil comprises polyvinyl chloride.

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **.

while on the other side of the moulded panel individual elements can be affixed. The adhesive strength may in this instance be chosen to be of such magnitude that the individual elements mounted thereon, such as hooks or the like, can be used for receiving components of any kind to be hung thereon and withstand the desired loading.

The moulded panels according to the invention can be used with advantage in motor vehicle construction, for internal lining of rooms, in furniture maufacture, in packaging electrical engineering and in machine construction.

The invention will be more fully explained with reference to two embodiments which are diagrammatically represented in the drawing.

Fig. 1 shows a perspective view of a moulded panel.

Fig. 2 is a cross-section of the panel along the line II-II in Fig. 1.

Fig. 3 shows another embodiment of a moulded panel and Fig. 4 represents a cross-section along the line IV-IV in Fig. 3.

The moulded panel 1 includes a plate 2 which consists of a mixture of a filler with a plastics material based on propylene.

Between the plate 2 and a plastics foil serv ing as a decorative covering or the like there is a non-woven fabric 3 which is an chored in the hot pressed condition with the surface of the plate 2. The plastics foil

4 may be put on by means of an adhesive substance or other adhesive agent. This is effected preferably by deep drawing.

The moulded panel 5 of Figs. 3 and 4 corresponds in construction to that of the moulded panel 1. In the example of Figs.

3 and 4 bulges 6, 7 or other embossments are provided as deformations. The defor mation may however also consist of a bevel 8 which may extend partly or wholly over the length of one edge of the panel.

The deformation may, for example, be pro vided in a distortion in the form of a five sided closed pocket or the like.

WHAT I CLAIM IS: 1. A moulded laminated panel construc tion comprising a base panel of predeter mined stable configuration and comprising a thermoplastic propylene-containing poly mer and a filler, a non-woven expansible fabric mechanically anchored to and exten tending as a continuous unbroken layer over a surface of said base panel, said fabric being of synthetic and/or natural fibres and having a weight per unit area of 20 to 40 gm/cm2, and a thermoplastic foil having a surface thereof secured to said non-woven fabric by an adhesive material such that said foil surface and non-woven fabric are maintained coextensive.
2. A laminated panel construction as claimed in Claim 1 wherein said propylene containing polymer is polypropylene.
3. A laminated panel construction as claimed in Claim 1 or 2, wherein said nonwoven fabric is an expansible fleece of synthetic wool and/or natural wool.
4. A laminated panel construction as claimed in any one of the preceding Claims wherein said thermoplastic foil is an inelaestic plastics foil or an expanded plastics foil suitable for deep drawing.
5. A laminated panel construction as claimed in any one of the preceding Claims wherein said filler is a cellulose-containing filler such as finely divided wood.
6. A laminated panel construction as claimed in Claim 4 wherein said thermoplastic foil comprises polyvinyl chloride.
7. A method of producing a moulded laminated panel construction comprising compressing a non-woven expansible fabric of synthetic and/or natural fibres and having a weight per unit area of 20 to 40 gm/cm2 onto a surface of a base panel which comprises a thermoplastic propylene-containing polymer and a filler, under high pressure while said base panel and fabric are maintained at a temperature of about 1500 to 210"C to mechanically anchor said nonwoven fabric to said surface of said base panel moulding said base panel with said non-woven fabric secured to the surface thereof into a predetermined stable configuration with said non-woven fabric extending as a continuous unbroken layer over said base panel surface, and then securing a surface of a thermoplastic foil to said non-woven fabric by means of an adhesive material such that said foil surface and non-woven fabric are maintained coextensive.
8. A method as claimed in Claim 7 wherein said propylene containing polymer is polypropylene.
9. A method as claimed in Claim 7 or 8, wherein said non-woven fabric is an expansible fleece of synthetic wool and/or natural wool.
10. A method as claimed in any one of Claims 7 to 9, wherein said thermoplastic foil is an inelastic plastics foil or an expanded plastics foil suitable for deep drawing.
11. A method as claimed in any one of Claims 7 to 10, wherein said filler is a cellulose-containing filler such as finely divided wood.
12. A method as claimed in Claim 10, wherein said thermoplastics foil comprises polyvinyl chloride.
13. A laminated panel construction sub

stantially as hereinbefore described with reference to Figs. 1 and 2 of the accompanying drawings.
14. A laminated panel construction substantially as hereinbefore described with reference to Figs. 3 and 4 of the accompanying drawings.