SK401992A3 - Process for manufacturing laminated products - Google Patents

Abstract

The invention relates to a method for manufacturing a laminated product which has an at least partially curved shape, particularly a panel for covering a surface in an automotive vehicle or the like. In accordance with the invention, one surface of a carrier layer (14) in the form of a thermoplastically moldable material is placed in contact with one surface of a covering layer (15) in the form of an elastically resilient material having an outer layer on the surface thereof remote from the carrier layer (14). The carrier layer (14) and the covering layer (15) are then introduced into a compression molding machine, between a bottom tool part (2) and a top tool part (3), of which at least one is heated. The bottom tool part (2) and the top tool part (3) are then moved towards one another to a terminal position. The tool parts (2, 3) are held in the terminal position for a predetermined length of time and at a predetermined pressure, so that the carrier layer (14) and the covering layer (15) will be joined one to the other, whereafter pressure on the tool parts (2, 3) is relieved, the tool parts are separated and the product is removed.

Description

Process for the production of laminated fibers

Qblast Techniques! 'U <

rn ŕ c

- <rn IM - <

ro o

what

The present invention relates to a production method having at least partially a curved shape, covering surfaces in automobiles and the like.

laminated products, especially flat parts,

BACKGROUND OF THE INVENTION Flat parts shelves

Flat parts which are suitable for mass production using the method of the invention are, for example, ceilings, under rear windows and other automotive parts and the like.

of this kind, they have so far been produced by a two-step method, in which the substrate or carrier is first pressed into a desired shape corresponding to the shape of the surface to which the flat part is to be attached and the appearance to be achieved, for example, a layer of textile material, woven fabric, and the like. with the aid of a suitable binder. If improper temperature or pressure is used during compression, surface defects occur and, moreover, the relief of the carrier layer is transferred to the surface layer. Furthermore, the time required to make the product is relatively long due to the use of a binder.

of the invention

The object of the present invention is to provide drawbacks and provide improved and enable rapid production of

ZV L áä t é p ´ lochých dilô from the top change other That is achieved according to this stated methods which is in charakt erization cluster, .iso point i pat

Preferred embodiments of the invention are the second and so forth.

to prevent from the above a simple method, the aforementioned products which merely characterize the features of the said claims. referred to in / subclaims c) of the claims.

The invention will now be described in detail using the accompanying drawings, in which:

1 is a schematic plan view of a production line for manufacturing laminated products according to the method of the present invention; and Figure 2 is a schematic cross-sectional view of a portion of a press used to carry out the process of the present invention, showing the starting material loaded into the machine.

Figure 1 is a schematic plan view of a line for carrying out production according to the present invention. In the central part of the line is a conventional press 1 having two press forms, a lower press mold 2 and an upper press mold 3 (see Fig. 2). The molds 2 and 3 can be brought closer together and have a shape corresponding to the shape of the molding. Before press, t. j. in the left part of FIG. The table is located near the filling table and 7 where the various materials used are stored. The material which lies on the filling stool 4 is transported from there to the press by means of the first feeder S. If it is shown, the feeder S can be a discontinuous feeder or other suitable load for the insertion of the material. Optionally, the material can be found in the filling cartridges 5, be loaded into the machine i by a manual 2a press 1, which serves to the right side of FIG. 1, the second feeder P, which is machine-operated, removes the aforesaid and for transporting these articles to the device 10, in which trimming or cutting is performed. This device may include a mechanical shearing device, a water saving device (notably for recirculation), a laser cut-out device not!

hocne device.

Pressed objects of the final cutter 10 their final inspection.

plant 10 is intended for the purpose of the zoo and is then t r ap.sportc '. The station 11, where there is a possibility of being produced by a pressing device. the exchange consists of an exchanging bottom and bottom. hernizh and 3 for other molds suitable for the production of articles in the press 1. These molds have a different shape.

in the manufacture of the starch according to this 4, the separating layer may be placed first, it may be a sheet of paper or a fabric,

T <71 * ·; 39C.3. y Π1 'ζ / »Ό * .ϊ chž The purpose is to prevent the material to be molded from being attached to. lower mold 2 ' Separation layer. 13 there may optionally be 1 layer of wax,

Which is applied directly to the surface of the mold 2 by spraying.

The carrier or backing layer 14 is then placed on the filling table 4. This carrier layer is a moldable material such as a fabric impregnated with a thermosetting resin. The carrier layer determines the final shape of the article and preferably consists of 2 fabrics impregnated with the prepolymerized stage

B with expanded thermoplastic microspheres uniformly dispersed throughout the material. The resin used for this purpose is a phenol-formaldehyde resin containing carbamide, phenol, resorcinol or melamine or mixtures thereof. Material of this kind can be purchased under the name Compoiet ^R.

a layer 15 is placed on the filling table 4, which is preferably plastic foam

On a carrier surface layer, a material which is on its surface facing away from the carrier layer of the layer 15 is such a material capable of adhering to the carrier layer material 14 a material suitable for use as a resilient outer layer material. An elastic material which is one of the surface layers 15 is a melamine resin having a density of 5 to 30 kg / m ³ , which is short-term stable ρΠ temperatures up to 300 ° C. An outer layer, such as a fabric, a suitable plastic film, a needled felt, or other suitable material, is laminated to the surface layer.

The material assembly on the feed table 4 is then transported to the press 1 via the feeder 3. The lower press mold is heated, not. a temperature of 120 to 300 ° C, wherein the upper die is either not heated or is heated to a temperature below the temperature corresponding to the heat resistance of the outer layer of the surface layer 15 and particularly below the temperature corresponding to the short term heat resistance of the layer. Depending on the material used, this temperature may be up to 300 ° C. The molds 2 and 3 are then clamped. Their final position is set by other shoulder or stops of the press, and the press molds are in a changed final position, their distance being such that they do not obtain the desired shape and that the carrier layer L4 and the surface layer 15 are connected to each other. .

The molds 2 and 3 are held in said final position for a time that corresponds to the thermo used and the properties of the material used. This time is usually 30 to 120 seconds. Then he is released

-4 the pressure exerted on the molds 2 and 3, the molds are removed and the molded object is transported by means of the feeder 9 to the machine 1 into the cut-out recess 10. The outer contours of the compact are trimmed to their final shape and , cutouts and. ätérbiny.

After being cut out, the object is transported from the cutting device 10 to the inspection station 11 where it is subjected to final inspection and packaging.

Claims (9)

Method for producing laminated products having at least partially a curved shape, in particular flat parts covering car surfaces and the like, comprising contacting a surface of a carrier layer (14) capable of being compression molded with a surface of the surface layer (15), its material being a resilient material and having an outer layer facing away from said carrier layer (14); a carrier layer (14) and a surface layer (15) are inserted into a press (1) between the lower die (2) and the upper die (3), wherein at least one of said die is heated; the lower die (2) and the upper die (3) are brought to their final position by moving together; leave the molds (2, 3)! in the mentioned final! positioning for a predetermined period of time at a predetermined pressure, thereby joining the carrier layer (14) and the surface layer (15); the pressure exerted on each other by the compression molds (2, 3); the molds are removed and the product is removed. 2. The method according to claim 1, wherein the carrier layer (14) is formed with at least one layer of fabric or the like impregnated with a thermosetting resin. 3. Method according to claim 2, characterized in that the support layer (14) _{19 is} formed from a material pre-impregnated with the prepolymerized resin in stage B. 4. A method according to any of the carrier layer material of points 1 and 3, characterized in that it is 14? it contains expanded microspheres uniformly dispersed therein. 5. A method according to any one of Claims 1 and 4, characterized in that the surface layer t. 15) is made of thermoset foam on which the outer layer is clarified. 6. The method of claim 5, wherein the melamine resin has a density of 5 to 30 with a heat resistance of up to 300 ° C. With thermosetting foam kg / m ³ with short-term -ΟΙ. A method according to any one of points 1 to 6, characterized in that the surface layer material has properties that equalize the surface. any folds or depressions in the carrier layer material. S. A method according to any one of claims 1 to 7, characterized in that a separating layer (13) is inserted between the carrier layer (14) and the press mold (2) which is in contact with said carrier layer (14) in order to adhesion between the support layer (14) and the altered mold (2) is prevented. Method according to any one of Claims 1 to 8, characterized in that the residence time of the product in the press (1) is 10 to 200 seconds, preferably 30 to 120 seconds. Method according to any one of the preceding claims, characterized in that the mold (2), which is in contact with the carrier layer (14), is heated to a temperature of 120 to 300 ° C. 11. Method according to point. 10, characterized in that the mold (3) which comes into contact with the surface layer (15) is maintained at a temperature which is lower than the temperature of the short-term heat resistance of the outer layer material.