GB805236A - Improvements in method of making fabric-surfaced articles - Google Patents

Abstract

805,236. Laminates. UNITED STATES RUBBER CO. Nov. 28, 1955 [Feb. 25, 1955], No. 33989/55. Class 140. Moulded, fabric-surfaced articles such as car mats are made by forming a laminate including an impervious thermoplastic resin sheet and a stretchable fabric sheet, heating the laminate to a temperature above the forming temperature of the resin sheet, applying the laminate to the surface of a forming mould before the resin has cooled to a temperature below its forming temperature, pressing the laminate into conformity with the surface of the mould by means of fluid pressure and simultaneously stretching the fabric to conform it to the said surface. A preformed sheet of vinyl resin united by adhesive to the fabric layer or a layer of vinyl resin plastisol (e.g. polyvinyl chloride, octadecyl phthalate, polyester resin plasticizer, York whiting and cadmium naphthenate) or organosol coated on to a fabric layer and subsequently heat treated may be used. The laminate may be formed by passing the two sheet materials through a pair of heated pressure rollers or by the transfer process described in Specification 801,938. Backing material such as jute, foam rubber or sponge rubber may be cemented to the laminate after moulding. As shown in Fig. 1, fabric F passes over back-up roller 10 of a knife coater 11 and receives a coating C, preferably of a vinyl resin plastisol. The coated material passes by driven rolls 29 through fusing oven 13 and, while still mouldable, into severing means 14 consisting of die head 15 vertically reciprocable against anvil 16. The severed blanks are carried on endless belt 17 running on rollers 18 to a vacuum forming mould of the kind described in Specification 805,235. Alternatively, blanks cut from a calendered vinyl resin film may be bonded with the aid of a vacuum forming apparatus to fabric blanks coated with a heat activatable adhesive. The vacuum forming apparatus may comprise a trolley 36, Fig. 4, with a vacuum pan 40 connected to a vacuum line 41 and above it card clothing 42. A templet 43 is positioned above the card clothing and is provided with an opening 44 of the shape of the fabric blank. The fabric is placed with the nap against the card clothing and the backing 35 (which overlaps the templet to avoid leakage) is placed over it. Vacuum is applied and the table moved under heaters 39. The laminate thus formed is transferred to a mould as used with Fig. 1 while still hot and moulded to shape.