GB2359274A - Manufacturing shaped panels - Google Patents

Manufacturing shaped panels Download PDF

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Publication number
GB2359274A
GB2359274A GB0025387A GB0025387A GB2359274A GB 2359274 A GB2359274 A GB 2359274A GB 0025387 A GB0025387 A GB 0025387A GB 0025387 A GB0025387 A GB 0025387A GB 2359274 A GB2359274 A GB 2359274A
Authority
GB
United Kingdom
Prior art keywords
adhesive
given temperature
sheet
heated
oven
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Withdrawn
Application number
GB0025387A
Other versions
GB0025387D0 (en
Inventor
Alan John Franks
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hodgson & Hodgson Group Ltd
NOISCO PRODUCTS Ltd
Original Assignee
Hodgson & Hodgson Group Ltd
NOISCO PRODUCTS Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Hodgson & Hodgson Group Ltd, NOISCO PRODUCTS Ltd filed Critical Hodgson & Hodgson Group Ltd
Priority to GB0025387A priority Critical patent/GB2359274A/en
Publication of GB0025387D0 publication Critical patent/GB0025387D0/en
Publication of GB2359274A publication Critical patent/GB2359274A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/02—Bending or folding
    • B29C53/04—Bending or folding of plates or sheets
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • 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
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
    • B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
    • 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
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/06—PVC, i.e. polyvinylchloride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • B29K2105/128—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles in the form of a mat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2267/00—Use of polyesters or derivatives thereof as reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B29L2009/001—Layered products the layers being loose
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/10—Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working

Abstract

A body of substrate material such as a polyester fibre mat or sheet which will become pliable when heated to a given temperature for moulding into a final shape is covered with a sheet of facing material such as a PVC sheet having a lower melting point from the given temperature before final shaping. One method involves heating the body to the given temperature, removing it from the source of heat, applying adhesive, applying the sheet material, reheating the coated substrate for just sufficient time to cure the adhesive but not melt the applied sheet material, placing the coated substrate in a press mould, shaping the body of material to the final desired shape and removing the shaped component from the mould. In a second method an adhesive is selected which will cure with the residual heat in the substrate so that it is not necessary to reheat the substrate in the oven. In a third method the heated substrate is placed in the press mould before the adhesive is applied, and the adhesive and facing sheet material are applied in turn to the substrate after it has been located in the press mould but before the mould is closed.

Description

<U>Method of Manufacturing Shaped Panels</U> This invention relates to a method of manufacturing shaped panels.
Shaped panels are used in industry for a variety of purposes including, for example, as interior trims for motor vehicles.
It is known to produce shaped panels by press moulding polyester fibre material in the form of a mix of high melt and low melt fibres. The material has the property of becoming pliable when heated to a given temperature, although maintaining its integrity. Typically the shaped panels are required for use with a facing of sheet material, such as a fabric, over part of the surface of the panel, i.e. the exterior surface when the panel is fitted in place. Conventionally, for this purpose, the fibre material first has an adhesive coating applied to part of its surface and then the facing material is laid in place over the adhesive before the fibre material is heated to the given temperature and press moulded while hot.
A problem arises with this method however, if it is desired to face the panel with a sheet of material of lower melting point than the said given temperature, because the sheet material will melt when the fibre material is heated prior to press moulding.
The aim of the present invention is to provide a solution to this problem.
According to the invention, there is provided a method of manufacturing a shaped panel comprising a body of a material which maintains its integrity but becomes pliable when heated to a given temperature, said body having bonded to at least one face a sheet of material having a lower melting point than said given temperature, said method comprising the steps of applying an adhesive to the surface region of the body to be faced, heating the body in an oven to said given temperature, removing the body from the oven and immediately laying the facing material over the adhesive covered region thereof, replacing the body in the oven for a relatively brief period short enough not to melt the facing material, again removing the body from the oven and immediately placing it in a press mould in order to form the required shaped panel.
The invention is especially applicable to a polyester fibre mat, sheet or other partially formed shape, containing a mix of high melt and low melt fibres. As a result of heating, the low melt fibres are softened, so that the material becomes pliable without any loss of integrity.
It may be desired to face a portion of the surface of the mat with any of a range of sheet materials, including fabric materials and plastics sheeting such as PVC sheeting. The present invention is also especially applicable to the case where a plastics sheet facing is required, where the plastics sheeting has a melting point below the given temperature to which the polyester fibre mat must be heated in order to enable press moulding. One example of such a plastics sheeting is thin PVC Sheet.
The invention is further described in the following example of a method for forming a shaped panel for constituting an interior trim for a vehicle.
A polyester fibre mat, which contains a mix of high melt and low melt fibres, has an adhesive layer applied to that part of its surface which is to be faced with thin PVC sheet. The mat is then heated on a removable shelf in an oven to a temperature between 170 and 200 degrees C, typically 180 degrees C, for between 15 and 25, typically 20 minutes. The shelf is then pulled from the oven, thin PVC sheet is laid over the adhesive, and the shelf immediately returned to the oven for a period of between 15 seconds and 1 minute, typically 30 seconds. Although the melting point of thin PVC sheet is lower than 180 degrees C, only its surface in contact with the adhesive is softened during this brief period of residence in the oven to cure the adhesive, whereby to ensure a good bond between the fibre mat and the surface facing.
After the brief re-heating period, the mat is again removed from the oven and immediately, i.e. while still hot, placed in a press mould, thereby to complete production of the shaped panel.
Where the adhesive material will cure using the latent heat in the substrate and does not require oven temperatures to cure - the method can be simplified by coating the substrate (after heating it in the oven) with an adhesive and applying the sheet coating material to the adhesive before the now coated substrate is inserted into the press tooling.
According therefore to another aspect of the invention there is provided an alternative method of manufacturing a shaped panel comprising a body of a material which maintains its integrity but becomes pliable when heated to a given temperature, said body having bonded to at least one face thereof a sheet of material having a lower melting point than said given temperature, said method comprising the steps of: 1) heating the body to said given temperature; 2) applying an adhesive to the surface region of the body which is to be faced; 3) laying the facing material over the adhesive coated region of the body surface; 4) placing the body with facing material adhering thereto into a press mould, in order to form the shaped panel under pressure; and 5) removing the shaped panel from the press mould wherein the residual heat in the body after being heated is sufficient to cure the adhesive, and the adhesive is selected accordingly, so that no further heating is required after the facing material has been applied to the surface of the body.
Conveniently the heated substrate is inserted into the tooling before the adhesive is applied, so that the latter is applied after the substrate is in the tooling. According therefore to a further aspect of the invention there is provided a further alternative method of manufacturing a shaped panel comprising a body of a material which maintains its integrity but becomes pliable when heated to a given temperature, said body having bonded to at least one face thereof a sheet of material having a lower melting point than said given temperature, said method comprising the steps of: 1) heating the body to said given temperature; 2) placing the heated body into a press mould for forming under pressure the required shape, and before closing the mould 3) applying an adhesive to the surface region of the body which is to be faced; 4) laying the facing material over the adhesive coated region of the body surface; 5) closing the mould and applying pressure to form the desired shape, and 6) removing the shaped panel from the press mould, wherein the residual heat in the body after being heated is sufficient to cure the adhesive, and the adhesive is selected accordingly, so that no further heating is required after the facing material has been applied to the surface of the body.
The invention makes it possible to face shaped panels with low melting point facing materials which hitherto have not been used.

Claims (7)

  1. <U>Claims</U> 1. A method of manufacturing a shaped panel comprising a body of a material which maintains its integrity but becomes pliable when heated to a given temperature, said body having bonded to at least one face a sheet of material having a lower melting point than said given temperature, said method comprising the steps of: (1) applying an adhesive to the surface region of the body to be faced, (2) heating the body in an oven to said given temperature, (3) removing the body from the oven, (4) laying the facing material over the adhesive covered region thereof, (5) replacing the body in the oven for a relatively brief period short enough not to melt the facing material, (6) removing the body from the oven, and (7) placing it in a press mould in order to form the shaped panel.
  2. 2. A method as claimed in claim 1, wherein the body material is a polyester fibre mat, containing a mix of high melt and low melt fibres, wherein as a result of heating, the low melt fibres are softened, so that the material becomes pliable without any loss of integrity, and the sheet material applied to a face thereof is selected from a range of sheet materials, including fabric materials and plastics sheeting such as PVC sheeting, which has a melting point below the given temperature to which the polyester fibre mat must be heated in order to enable press moulding.
  3. 3. A method as claimed in claim 1 or 2 wherein the sheet material is thin PVC sheet.
  4. 4. A method as claimed in claim 1, 2 or 3, wherein the body of material is shaped to comprise an interior trim for a vehicle.
  5. 5. A method as claimed in claim 3, insofar as it depends from claim 2, wherein after coating with adhesive, the mat is heated on a removable shelf in an oven to a temperature between<B>170</B> and 200 degrees C, typically 180 degrees C for between 15 and 25 minutes, typically 20minutes; the shelf is then pulled from the oven, thin PVC sheet is laid over the adhesive; the shelf is returned to the oven for a period of between 15 seconds and 1 minute, typically 30 seconds, to cure the adhesive, whereafter the shelf containing the mat is again removed from the oven and while still hot, the mat is removed from the shelf and placed in a press mould, thereby to complete the production of the shaped panel.
  6. 6. A method of manufacturing a shaped panel comprising a body of a material which maintains its integrity but becomes pliable when heated to a given temperature, said body having bonded to at least one face thereof a sheet of a material having a lower melting point than said given temperature, said method comprising the steps of: 1) heating the body to said given temperature; 2) applying an adhesive to the surface region of the body which is to be faced; 3) laying the facing material over the adhesive coated region of the body surface; 4) placing the body with facing material adhering thereto into a press mould, in order to form the shaped panel under pressure, and 5) removing the shaped panel from the press mould, wherein the residual heat in the body after being heated is sufficient to cure the adhesive, and the adhesive is selected accordingly, so that no further heating is required after the facing material has been applied to the surface of the body.
  7. 7. A method of manufacturing a shaped panel comprising a body of a material which maintains its integrity but becomes pliable when heated to a given temperature, said body having bonded to at least one face thereof a sheet of material having a lower melting point than said given temperature, said method comprising the steps of: 1) heating the body to said given temperature; 2) placing the heated body into a press mould in for forming under pressure the required shape, and before closing the mould 3) applying an adhesive to the surface region of the body which is to be faced, 4) laying the facing material over the adhesive coated region of the body surface; 5) closing the mould and applying pressure to form the desired shape, and 6) removing the shaped panel from the press mould, wherein the residual heat in the body after being heated is sufficient to cure the adhesive, and the adhesive is selected accordingly, so that no further heating is required after the facing material has been applied to the surface of the body.
GB0025387A 2000-10-17 2000-10-17 Manufacturing shaped panels Withdrawn GB2359274A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB0025387A GB2359274A (en) 2000-10-17 2000-10-17 Manufacturing shaped panels

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0025387A GB2359274A (en) 2000-10-17 2000-10-17 Manufacturing shaped panels

Publications (2)

Publication Number Publication Date
GB0025387D0 GB0025387D0 (en) 2000-11-29
GB2359274A true GB2359274A (en) 2001-08-22

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
GB0025387A Withdrawn GB2359274A (en) 2000-10-17 2000-10-17 Manufacturing shaped panels

Country Status (1)

Country Link
GB (1) GB2359274A (en)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2716858A1 (en) * 1976-10-21 1978-04-27 Raschig Gmbh Soft laminate decorative material for cars - has decorative layer uniformly bonded to substrate and moulded hot using air pressure
DE4241401A1 (en) * 1992-12-09 1994-06-16 Philippine Tech Kunststoff Laminated plastic panel, esp. for vehicle interiors - has carrier layer heated briefly before application of two-part adhesive and lamination to facing layer
US5832685A (en) * 1995-08-03 1998-11-10 Hermanson; Lars S. Self-supporting interior surface panel

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2716858A1 (en) * 1976-10-21 1978-04-27 Raschig Gmbh Soft laminate decorative material for cars - has decorative layer uniformly bonded to substrate and moulded hot using air pressure
DE4241401A1 (en) * 1992-12-09 1994-06-16 Philippine Tech Kunststoff Laminated plastic panel, esp. for vehicle interiors - has carrier layer heated briefly before application of two-part adhesive and lamination to facing layer
US5832685A (en) * 1995-08-03 1998-11-10 Hermanson; Lars S. Self-supporting interior surface panel

Also Published As

Publication number Publication date
GB0025387D0 (en) 2000-11-29

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