US20050242474A1 - Method of forming a delamination-resistant three dimensional double curvature surface colored composite article - Google Patents
Method of forming a delamination-resistant three dimensional double curvature surface colored composite article Download PDFInfo
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- US20050242474A1 US20050242474A1 US11/178,628 US17862805A US2005242474A1 US 20050242474 A1 US20050242474 A1 US 20050242474A1 US 17862805 A US17862805 A US 17862805A US 2005242474 A1 US2005242474 A1 US 2005242474A1
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- delamination
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- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
- B29C43/30—Making multilayered or multicoloured articles
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- 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
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
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- 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
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14811—Multilayered articles
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- 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
- B29C51/02—Combined thermoforming and manufacture of the preform
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- 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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
- B29C70/502—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC] by first forming a mat composed of short fibres
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- 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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
- B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state
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- 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
- B29C2791/00—Shaping characteristics in general
- B29C2791/001—Shaping in several steps
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- 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
- B29C51/002—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 characterised by the choice of material
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- 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
- B29C51/002—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 characterised by the choice of material
- B29C51/004—Textile or other fibrous material made from plastics fibres
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- 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
- 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
- B29C51/145—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 having at least one layer of textile or fibrous material combined with at least one plastics layer
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- 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
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0809—Fabrics
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- 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
- B29L2009/005—Layered products coated
- B29L2009/006—Layered products coated painted
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- 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
- B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
- B32B2260/02—Composition of the impregnated, bonded or embedded layer
- B32B2260/021—Fibrous or filamentary layer
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- 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
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/22—Fibres of short length
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- 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
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/402—Coloured
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- 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
- B32B2398/00—Unspecified macromolecular compounds
- B32B2398/10—Thermosetting resins
Definitions
- the present invention is in the field of colored laminated thermoplastic and thermoset sheet materials. In particular it addresses a method for enhancing the resistance to delamination of such sheet materials
- FIG. 1 is a side view of an apparatus for making a two-thermoset-layers delamination resistant colored membrane.
- FIG. 2 is a side view of an apparatus for making a two-thermoplastic layers delamination resistant colored membrane.
- FIG. 3 is a side view of an apparatus for making a thermoset bottom layer and a thermoplastic top layer delamination resistant colored membrane.
- FIG. 4 is a side view of an apparatus for making a thermoplastic bottom layer and a thermoset top layer delamination resistant colored membrane.
- FIG. 5 is a cross-sectional view of uncured/unsolidified membrane after laying fibrous web on its surface.
- FIG. 6 is a cross-sectional view of a two-layer delamination-resistant colored membrane.
- FIG. 7 is a cross-sectional view of a three-layer delamination-resistant colored membrane.
- FIG. ( 1 ) shows an apparatus 52 for making a two-thermoset-layer delamination-resistant colored membrane composite.
- an uncured thermoset membrane 14 is extruded, in a sheet form, from membrane-forming die 15 .
- the membrane is formed by mixing of its first reactive component 1 , contained in tank 45 , with its second reactive component 2 , contained in tank 46 .
- liquid additives 4 contained in tank 47 , and/or solid additives 3 may be added to the thermoset membrane-forming mixture, in tank 48 .
- mixture 6 is homogenized, for example by mixing stirrer 5 or other means.
- thermoset membrane 14 After mixing all the components of membrane 14 , the mixture is allowed to flow into membrane-forming die 15 by opening valve 7 . In some applications a pump may also be used in order to generate the required pressure and desired volume flow rate.
- uncured thermoset membrane 14 As uncured thermoset membrane 14 is extruded from die 15 , it is laid on a non-stick release liner 8 which is unwound from a roll of non-stick release liner 33 , on conveyor belt 30 , and rewound into a roll 35 which is driven by friction drive roll 34 .
- Guide rolls 39 , 42 and 36 are used to direct the release liner 8 and colored laminated composite as the process is performed from one end of apparatus 52 to its other end.
- release liner 8 may be eliminated if conveyor belt 30 is made of a non-sticking material or is coated with a non-sticking release coating.
- Conveyor rolls 31 and 32 provide an adjustable or constant rate of travel to belt 30 , which, in combination with the rate of flow of mixture 6 , determine the thickness of membrane 14 .
- the thickness of membrane 14 is an important parameter in this process since subsequent operations, for example thermoforming or injection molding a layer of molten plastic on it and subsequent or simultaneous stretching of the composite may result in significant surface deformation which may alter the exterior color or the surface characteristics of the delamination-resistant colored membrane.
- An example of such subsequent operations that may be performed on the colored laminated composite of the present invention is disclosed in U.S. Pat. No. 5,401,457 which is incorporated herein by reference.
- thermoset membrane 14 As uncured thermoset membrane 14 is extruded on release liner 8 , its top surface 9 is of a tacky nature. Depending on its rate of curing or solidification, its surface tack and viscosity, a first partial curing zone 16 is provided in order to allow for adequate development of surface of membrane 14 before entering the fibrous media application zone 18 . In doing so, one can have at least a portion of fibers, in fibrous web 37 or sprinkled fibers 38 , partially encapsulated within membrane 14 , as shown in FIG. 5 . Such partially encapsulated fibers, when also subsequently partially encapsulated within coloring coating 20 , serve as an interfacial reinforcement that provides a bond between the two layers of colored composite 44 . Such an interfacial reinforcement profoundly enhances the resistance to delamination between the layers of the colored composite.
- Fibrous web 37 is fed into zone 18 from fibrous web roll 10 .
- a guide roll 41 is used to direct fibrous web 37 to the desired location, height and point of contact with uncured or unsolidified surface 9 of membrane 14 .
- Fibrous web 37 may be made of woven, knitted , stitch-bonded or non-woven fibers and/or yarns.
- fibrous web 37 is made of a needle punched non-woven in order to provide the most possible tensile and in-plane shear deformability, without breakage, during subsequent thermoforming or injection molding processes where the colored composite may be formed into three dimensional double curvature surfaces.
- the fibers of fibrous web 37 may be of a natural origin (for example cotton or other natural staple fibers) or of a man-made type, such as synthetic fibers, regenerated fibers or metallic fibers.
- loose fibers 12 may be sprinkled on the top surface 9 of uncured/unsolidified membrane 14 by using fiber sprinkler 13 .
- sprinkled fibers 38 are deposited on membrane 14 in fibrous media application zone 18 .
- sprinkled fibers 38 may be of a natural origin or of a man-made type, such as synthetic fibers, regenerated fibers or metallic fibers.
- thermoset coloring coating 20 is formed and extruded through coloring coating application die 50 onto the surface of membrane 14 covered by fibrous web 37 and/or sprinkled fibers 38 .
- Coloring coating 50 is also prepared in a manner similar to that of preparing membrane 14 .
- a first reactive component 22 and a second reactive component 23 , of coloring coating 20 are directed from tanks 28 and 29 into mixing tank 51 .
- Liquid additives 24 which may also include coloring agents or pigments, are also directed from tank 49 into mixing tank 51 .
- solid additives 25 may be added to the coloring coating mixture 26 in tank 51 .
- the mixture is then homogenized by rotating stirrer 27 or some other means and is allowed to flow into coloring coating application die 50 by opening valve 17 and controlling flow rate to yield the desired thickness of coloring coating 20 .
- the thickness of coloring coating 20 is an important parameter and a variety of means, known in the art, including metering pumps may be used for its control.
- uncured coloring coating 20 is extruded onto the surface of membrane 14 , which is covered by fibrous web 37 and/or sprinkled fibers 38 , its bottom surface 21 is of a tacky or liquid nature and thus encapsulates the remaining portions of those fibers which had been partially encapsulated within membrane 14 .
- the two-layer thermoset composite then proceeds through curing or cooling zone 19 where the components are fully cured/solidified and directed to a take up unit along the direction of arrow 43 as a delamination-resistant colored composite 44 .
- FIG. ( 2 ) an apparatus 63 for making a thermoplastic delamination-resistant colored composite 68 is shown in FIG. ( 2 ).
- a first molten thermoplastic membrane 53 is extruded, through molten membrane extrusion die 57 , in a similar manner and is treated in the same way as uncured thermoset membrane 14 .
- Hopper 61 feeds the thermoplastic material into plasticating extruder 59 which, in turn, melts it and feeds it into die 57 .
- the top surface 55 of molten thermoplastic membrane 53 is treated and coated with fibrous web 37 and/or sprinkled fibers 38 in a manner similar to that of treating top surface 9 of membrane 14 .
- a similar thermoplastic coloring coating 54 is produced by using feeding hopper 62 , plasticating extruder 60 and molten coloring coating extrusion die 58 .
- the thermoplastic material contained in feeding hopper 62 may be of a pre-compounded colored nature or a blend of colored and uncolored thermoplastic materials selected to produce the desired exterior color of composite.
- the bottom surface 56 of molten thermoplastic coloring coating 54 is treated and coated with fibrous web 37 and/or sprinkled fibers 38 in a manner similar to that of treating top surface 9 of membrane 14 .
- FIG. ( 3 ) shows a side view of an apparatus 64 for making a thermoset bottom layer and a thermoplastic top layer delamination resistant colored composite 66
- FIG. ( 4 ) shows a side view of an apparatus 65 for making a thermoplastic bottom layer and a thermoset top layer delamination resistant colored composite 67 .
- FIG. 5 shows an uncured or molten membrane 69 in fibrous application zone 18 with fibers 73 completely encapsulated within it, fibers 71 partially encapsulated in it and other loose fibers 72 lying completely outside of it.
- first layer 70 has a bottom surface 95 and a top uncured or molten surface 85 .
- FIG. 6 shows a cross-sectional view of a two-layer delamination-resistant colored composite 74 comprising bottom layer 70 , top layer 84 , joined at their interface 86 , and having fibers 71 partially encapsulated in bottom layer 70 and partially encapsulated in top layer 84 , thus providing enhanced resistance to delamination.
- FIG. 7 shows a cross-sectional view of a three-layer delamination resistant colored composite 75 comprising bottom layer 76 , middle layer 77 , top layer 78 , joined at their respective interfaces 87 and 88 and, as described earlier, having an enhanced resistance to delamination which is attributable to interlaminar reinforcement fibers 80 and 82 .
- a colored composite may be produced by combining a plurality of successive membrane-making steps, fibrous web/sprinkled fibers application zones and coloring coating membrane application zones of thermoplastic and thermoset materials as described in this invention.
- a process for forming a color coated or decorated article is provided by applying a color coated material to an injection mold having mold halves, a mold parting face, mold cavity edge and a mold cavity therein for the formation of an injection molded article, and injecting molten plastic into said mold cavity to form a laminated article with the color coated material bonded to the injected plastic.
- thermoset or thermoplastic membrane may be utilized, for coloring the surface of a thermoset or thermoplastic membrane, without departing from the spirit and scope of the disclosed invention.
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Abstract
In this method, a delamination resistant three dimensional double curvature surface colored composite article is made by providing a membrane with a delamination-resistant coloring coating and applying the membrane to an injection mold having mold halves, a mold parting face, mold cavity edge and a mold cavity therein for the formation of an injection molded article, and injecting molten plastic into the mold cavity in order to form a three dimensional double curvature surface composite article with the membrane bonded to the injected plastic. Alternatively, the membrane is thermoformed.
Description
- This application is a continuation of application Ser. No. 10/329,170 which is scheduled to issue as U.S. Pat. No. 6,916,439 on Jul. 12, 2005, which, in turn, is a continuation of application Ser. No. 09/677,713 which issued as U.S. Pat. No. 6,497,833 on Dec. 24, 2002, which claims priority of Provisional Patent Application No. 60/156,723 filed on Sep. 30, 1999 which is incorporated herein by reference. Further, application Ser. No. 09/677,713 incorporates by reference U.S. Pat. No. 5,401,457. Accordingly, the specification section of this continuation application has been amended, without adding any new matter, by inserting
lines 17 to 22 inpage 7 of this application. This amendment of the specification has basis inColumn 2,lines 1 to 8 in U.S. Pat. No. 5,401,457. - The present invention is in the field of colored laminated thermoplastic and thermoset sheet materials. In particular it addresses a method for enhancing the resistance to delamination of such sheet materials
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FIG. 1 is a side view of an apparatus for making a two-thermoset-layers delamination resistant colored membrane. -
FIG. 2 is a side view of an apparatus for making a two-thermoplastic layers delamination resistant colored membrane. -
FIG. 3 is a side view of an apparatus for making a thermoset bottom layer and a thermoplastic top layer delamination resistant colored membrane. -
FIG. 4 is a side view of an apparatus for making a thermoplastic bottom layer and a thermoset top layer delamination resistant colored membrane. -
FIG. 5 is a cross-sectional view of uncured/unsolidified membrane after laying fibrous web on its surface. -
FIG. 6 is a cross-sectional view of a two-layer delamination-resistant colored membrane. -
FIG. 7 is a cross-sectional view of a three-layer delamination-resistant colored membrane. - FIG. (1) shows an
apparatus 52 for making a two-thermoset-layer delamination-resistant colored membrane composite. As shown therein, an uncuredthermoset membrane 14 is extruded, in a sheet form, from membrane-forming die 15. The membrane is formed by mixing of its firstreactive component 1, contained intank 45, with its secondreactive component 2, contained intank 46. For coloring, reinforcement, cellular structure (foam) development or for other purposes,liquid additives 4, contained intank 47, and/or solid additives 3 may be added to the thermoset membrane-forming mixture, intank 48. Typically,mixture 6 is homogenized, for example by mixing stirrer 5 or other means. After mixing all the components ofmembrane 14, the mixture is allowed to flow into membrane-forming die 15 byopening valve 7. In some applications a pump may also be used in order to generate the required pressure and desired volume flow rate. As uncuredthermoset membrane 14 is extruded from die 15, it is laid on anon-stick release liner 8 which is unwound from a roll ofnon-stick release liner 33, onconveyor belt 30, and rewound into aroll 35 which is driven byfriction drive roll 34.Guide rolls release liner 8 and colored laminated composite as the process is performed from one end ofapparatus 52 to its other end. Alternatively,release liner 8 may be eliminated ifconveyor belt 30 is made of a non-sticking material or is coated with a non-sticking release coating.Conveyor rolls mixture 6, determine the thickness ofmembrane 14. The thickness ofmembrane 14 is an important parameter in this process since subsequent operations, for example thermoforming or injection molding a layer of molten plastic on it and subsequent or simultaneous stretching of the composite may result in significant surface deformation which may alter the exterior color or the surface characteristics of the delamination-resistant colored membrane. An example of such subsequent operations that may be performed on the colored laminated composite of the present invention is disclosed in U.S. Pat. No. 5,401,457 which is incorporated herein by reference. - As uncured
thermoset membrane 14 is extruded onrelease liner 8, itstop surface 9 is of a tacky nature. Depending on its rate of curing or solidification, its surface tack and viscosity, a firstpartial curing zone 16 is provided in order to allow for adequate development of surface ofmembrane 14 before entering the fibrousmedia application zone 18. In doing so, one can have at least a portion of fibers, infibrous web 37 or sprinkledfibers 38, partially encapsulated withinmembrane 14, as shown inFIG. 5 . Such partially encapsulated fibers, when also subsequently partially encapsulated withincoloring coating 20, serve as an interfacial reinforcement that provides a bond between the two layers ofcolored composite 44. Such an interfacial reinforcement profoundly enhances the resistance to delamination between the layers of the colored composite. - Fibrous
web 37 is fed intozone 18 fromfibrous web roll 10. In some applications, aguide roll 41 is used to directfibrous web 37 to the desired location, height and point of contact with uncured orunsolidified surface 9 ofmembrane 14. -
Fibrous web 37 may be made of woven, knitted , stitch-bonded or non-woven fibers and/or yarns. In its most preferred embodiment,fibrous web 37 is made of a needle punched non-woven in order to provide the most possible tensile and in-plane shear deformability, without breakage, during subsequent thermoforming or injection molding processes where the colored composite may be formed into three dimensional double curvature surfaces. The fibers offibrous web 37 may be of a natural origin (for example cotton or other natural staple fibers) or of a man-made type, such as synthetic fibers, regenerated fibers or metallic fibers. - Alternatively or in addition to
fibrous web 37,loose fibers 12, contained in hopper 11, may be sprinkled on thetop surface 9 of uncured/unsolidified membrane 14 by usingfiber sprinkler 13. As shown in FIG. (1), sprinkledfibers 38 are deposited onmembrane 14 in fibrousmedia application zone 18. Similar tofibrous web 37, sprinkledfibers 38 may be of a natural origin or of a man-made type, such as synthetic fibers, regenerated fibers or metallic fibers. - In a similar manner, an uncured
thermoset coloring coating 20 is formed and extruded through coloring coating application die 50 onto the surface ofmembrane 14 covered byfibrous web 37 and/or sprinkledfibers 38. - Coloring
coating 50 is also prepared in a manner similar to that of preparingmembrane 14. A firstreactive component 22 and a secondreactive component 23, ofcoloring coating 20, are directed fromtanks mixing tank 51.Liquid additives 24, which may also include coloring agents or pigments, are also directed fromtank 49 intomixing tank 51. Similarly,solid additives 25 may be added to thecoloring coating mixture 26 intank 51. The mixture is then homogenized by rotatingstirrer 27 or some other means and is allowed to flow into coloring coating application die 50 by openingvalve 17 and controlling flow rate to yield the desired thickness ofcoloring coating 20. As discussed above and for the same reasons stated in connection withmembrane 14, the thickness ofcoloring coating 20 is an important parameter and a variety of means, known in the art, including metering pumps may be used for its control. - As
uncured coloring coating 20 is extruded onto the surface ofmembrane 14, which is covered byfibrous web 37 and/or sprinkledfibers 38, itsbottom surface 21 is of a tacky or liquid nature and thus encapsulates the remaining portions of those fibers which had been partially encapsulated withinmembrane 14. The two-layer thermoset composite then proceeds through curing orcooling zone 19 where the components are fully cured/solidified and directed to a take up unit along the direction ofarrow 43 as a delamination-resistant coloredcomposite 44. - Using same or similar components and zones (as 8, 10, 11, 12, 13, 16, 18, 19, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 41, 42, and 43) shown in FIG. (1) and described above and following similar steps and thickness controls, an
apparatus 63 for making a thermoplastic delamination-resistant colored composite 68 is shown in FIG. (2). As shown therein, a first molten thermoplastic membrane 53 is extruded, through molten membrane extrusion die 57, in a similar manner and is treated in the same way as uncuredthermoset membrane 14. Hopper 61 feeds the thermoplastic material into plasticatingextruder 59 which, in turn, melts it and feeds it into die 57. Also, similarly, the top surface 55 of molten thermoplastic membrane 53 is treated and coated withfibrous web 37 and/or sprinkledfibers 38 in a manner similar to that of treatingtop surface 9 ofmembrane 14. Also, as shown in FIG. (2), a similarthermoplastic coloring coating 54 is produced by usingfeeding hopper 62,plasticating extruder 60 and molten coloring coating extrusion die 58. The thermoplastic material contained infeeding hopper 62 may be of a pre-compounded colored nature or a blend of colored and uncolored thermoplastic materials selected to produce the desired exterior color of composite. - Also, similarly, the
bottom surface 56 of moltenthermoplastic coloring coating 54 is treated and coated withfibrous web 37 and/or sprinkledfibers 38 in a manner similar to that of treatingtop surface 9 ofmembrane 14. - Again, using combinations of same or similar components and zones, as shown in FIGS. (1) and (2) and as described above, FIG. (3) shows a side view of an
apparatus 64 for making a thermoset bottom layer and a thermoplastic top layer delamination resistant colored composite 66 and FIG. (4) shows a side view of anapparatus 65 for making a thermoplastic bottom layer and a thermoset top layer delamination resistantcolored composite 67. -
FIG. 5 shows an uncured ormolten membrane 69 infibrous application zone 18 withfibers 73 completely encapsulated within it,fibers 71 partially encapsulated in it and otherloose fibers 72 lying completely outside of it. As shown therein,first layer 70 has abottom surface 95 and a top uncured or molten surface 85. -
FIG. 6 shows a cross-sectional view of a two-layer delamination-resistant colored composite 74 comprisingbottom layer 70,top layer 84, joined at theirinterface 86, and havingfibers 71 partially encapsulated inbottom layer 70 and partially encapsulated intop layer 84, thus providing enhanced resistance to delamination. -
FIG. 7 shows a cross-sectional view of a three-layer delamination resistant colored composite 75 comprisingbottom layer 76,middle layer 77,top layer 78, joined at theirrespective interfaces 87 and 88 and, as described earlier, having an enhanced resistance to delamination which is attributable tointerlaminar reinforcement fibers - In the present invention, a process for forming a color coated or decorated article is provided by applying a color coated material to an injection mold having mold halves, a mold parting face, mold cavity edge and a mold cavity therein for the formation of an injection molded article, and injecting molten plastic into said mold cavity to form a laminated article with the color coated material bonded to the injected plastic.
- It should be noted that other variants of the above described methods or combinations of their steps may be utilized, for coloring the surface of a thermoset or thermoplastic membrane, without departing from the spirit and scope of the disclosed invention.
Claims (4)
1. A method of forming a delamination resistant three dimensional double curvature surface colored composite article, comprising the steps of:
1) providing a membrane with a delamination-resistant coloring coating, prepared by;
a) forming a membrane, said membrane having a tacky surface,
b) laying a fibrous material onto said tacky surface of said membrane such that portions of fibers, comprising said fibrous material, are encapsulated, below said surface of said membrane and within said membrane, and
c) applying an uncured thermoset coloring coating, said coloring coating having a bottom surface, said bottom surface being of a tacky nature, onto said fibrous material such that remaining portions of said fibers are encapsulated within said coating, whereby fibers encapsulated by and originating within said membrane are also partially encapsulated and terminating within said coloring coating, thus providing a delamination-resistant mechanical bond between said membrane and said coloring coating, and
2) applying said membrane with a delamination-resistant coloring coating to an injection mold having mold halves, a mold parting face, mold cavity edge and a mold cavity therein for the formation of an injection molded article, and
3) injecting molten plastic into said mold cavity to form a three dimensional double curvature surface composite article with said membrane bonded to the injected plastic.
2. A method of forming a delamination resistant three dimensional double 2 curvature surface colored composite article, comprising the steps of:
1) providing a membrane with a delamination-resistant coloring coating, prepared by;
a) forming a membrane, said membrane having a tacky surface,
b) laying a fibrous material onto said tacky surface of said membrane such that portions of fibers, comprising said fibrous material, are encapsulated, below said surface of said membrane and within said membrane, and
c) applying an uncured thermoset coloring coating, said coloring coating having a bottom surface, said bottom surface being of a tacky nature, onto said fibrous material such that remaining portions of said fibers are encapsulated within said coating, whereby fibers encapsulated by and originating within said membrane are also partially encapsulated and terminating within said coloring coating, thus providing a delamination-resistant mechanical bond between said membrane and said coloring coating, and
2) subsequently, thermoforming said membrane with a delamination-resistant coloring coating into a three dimensional double curvature surface composite article.
3. A method of forming a delamination resistant three dimensional double curvature surface colored composite article, comprising the steps of:
1) providing a membrane with a delamination-resistant coloring coating, prepared by;
a) forming a membrane, said membrane having a tacky surface,
b) laying a fibrous material onto said tacky surface of said membrane such that portions of fibers, comprising said fibrous material, are encapsulated, below said surface of said membrane and within said membrane, and
c) applying a thermoplastic coloring coating, said coloring coating having a bottom surface, said bottom surface being of a tacky nature, onto said fibrous material such that remaining portions of said fibers are encapsulated within said coating, whereby fibers encapsulated by and originating within said membrane are also partially encapsulated and terminating within said coloring coating, thus providing a delamination-resistant mechanical bond between said membrane and said coloring coating, and
2) applying said membrane with a delamination-resistant coloring coating to an injection mold having mold halves, a mold parting face, mold cavity edge and a mold cavity therein for the formation of an injection molded article, and
3) injecting molten plastic into said mold cavity to form a three dimensional double curvature surface composite article with said membrane bonded to the injected plastic.
4. A method of forming a delamination resistant three dimensional double curvature surface colored composite article, comprising the steps of:
1) providing a membrane with a delamination-resistant coloring coating, prepared by;
a) forming a membrane, said membrane having a tacky surface,
b) laying a fibrous material onto said tacky surface of said membrane such that portions of fibers, comprising said fibrous material, are encapsulated, below said surface of said membrane and within said membrane, and
c) applying a thermoplastic coloring coating, said coloring coating having a bottom surface, said bottom surface being of a tacky nature, onto said fibrous material such that remaining portions of said fibers are encapsulated within said coating, whereby fibers encapsulated by and originating within said membrane are also partially encapsulated and terminating within said coloring coating, thus providing a delamination-resistant mechanical bond between said membrane and said coloring coating, and
2) subsequently, thermoforming said membrane with a delamination-resistant coloring coating into a three dimensional double curvature surface composite article.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/178,628 US20050242474A1 (en) | 1999-09-30 | 2005-07-11 | Method of forming a delamination-resistant three dimensional double curvature surface colored composite article |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15672399P | 1999-09-30 | 1999-09-30 | |
US09/677,713 US6497833B1 (en) | 1999-09-30 | 2000-09-30 | Colored laminate and a method for coloring the surface of a membrane |
US10/329,170 US6916439B2 (en) | 1999-09-30 | 2002-12-23 | Colored laminate and a method for coloring the surface of a membrane |
US11/178,628 US20050242474A1 (en) | 1999-09-30 | 2005-07-11 | Method of forming a delamination-resistant three dimensional double curvature surface colored composite article |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US10/329,170 Continuation US6916439B2 (en) | 1999-09-30 | 2002-12-23 | Colored laminate and a method for coloring the surface of a membrane |
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Publication Number | Publication Date |
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US20050242474A1 true US20050242474A1 (en) | 2005-11-03 |
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US09/677,713 Expired - Lifetime US6497833B1 (en) | 1999-09-30 | 2000-09-30 | Colored laminate and a method for coloring the surface of a membrane |
US10/329,170 Expired - Fee Related US6916439B2 (en) | 1999-09-30 | 2002-12-23 | Colored laminate and a method for coloring the surface of a membrane |
US11/178,628 Abandoned US20050242474A1 (en) | 1999-09-30 | 2005-07-11 | Method of forming a delamination-resistant three dimensional double curvature surface colored composite article |
Family Applications Before (2)
Application Number | Title | Priority Date | Filing Date |
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US09/677,713 Expired - Lifetime US6497833B1 (en) | 1999-09-30 | 2000-09-30 | Colored laminate and a method for coloring the surface of a membrane |
US10/329,170 Expired - Fee Related US6916439B2 (en) | 1999-09-30 | 2002-12-23 | Colored laminate and a method for coloring the surface of a membrane |
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US (3) | US6497833B1 (en) |
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US6497833B1 (en) * | 1999-09-30 | 2002-12-24 | Amad Tayebi | Colored laminate and a method for coloring the surface of a membrane |
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JP2009511215A (en) | 2005-10-15 | 2009-03-19 | アトリウム メディカル コーポレーション | Hydrophobic crosslinked gel for bioabsorbable drug carrier coating |
US20070085235A1 (en) * | 2005-10-18 | 2007-04-19 | Boyle Timothy J | Method and apparatus for continuously preparing crosslinked, solution-cast polymer film |
US20070085234A1 (en) * | 2005-10-19 | 2007-04-19 | Boyle Timothy J | Method and apparatus for solution casting film with secondary component |
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US9492596B2 (en) | 2006-11-06 | 2016-11-15 | Atrium Medical Corporation | Barrier layer with underlying medical device and one or more reinforcing support structures |
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US20110038910A1 (en) | 2009-08-11 | 2011-02-17 | Atrium Medical Corporation | Anti-infective antimicrobial-containing biomaterials |
DE102010002844A1 (en) * | 2010-03-13 | 2011-09-15 | Dieffenbacher Gmbh + Co. Kg | Process, installation and resin mat for producing fiber-reinforced molded parts in a molding press |
WO2012009707A2 (en) | 2010-07-16 | 2012-01-19 | Atrium Medical Corporation | Composition and methods for altering the rate of hydrolysis of cured oil-based materials |
US9867880B2 (en) | 2012-06-13 | 2018-01-16 | Atrium Medical Corporation | Cured oil-hydrogel biomaterial compositions for controlled drug delivery |
WO2018149761A1 (en) * | 2017-02-17 | 2018-08-23 | Mubea Carbo Tech Gmbh | Composite product |
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Also Published As
Publication number | Publication date |
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US6916439B2 (en) | 2005-07-12 |
US20030094728A1 (en) | 2003-05-22 |
US6497833B1 (en) | 2002-12-24 |
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