WO1980001892A1 - Structure laminee a fine pellicule externe renforcee par des mousses polymeres - Google Patents

Structure laminee a fine pellicule externe renforcee par des mousses polymeres Download PDF

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Publication number
WO1980001892A1
WO1980001892A1 PCT/US1980/000225 US8000225W WO8001892A1 WO 1980001892 A1 WO1980001892 A1 WO 1980001892A1 US 8000225 W US8000225 W US 8000225W WO 8001892 A1 WO8001892 A1 WO 8001892A1
Authority
WO
WIPO (PCT)
Prior art keywords
foam
flexible
sheet
thin skin
thin
Prior art date
Application number
PCT/US1980/000225
Other languages
English (en)
Inventor
L Windecker
Original Assignee
Int Harvester Co
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 Int Harvester Co filed Critical Int Harvester Co
Priority to BR8007234A priority Critical patent/BR8007234A/pt
Publication of WO1980001892A1 publication Critical patent/WO1980001892A1/fr

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
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
    • B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
    • B29C44/145—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining the lining being a laminate
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • 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
    • 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
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • 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
    • B32B2266/00—Composition of foam
    • B32B2266/06—Open cell foam
    • 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
    • B32B2305/08—Reinforcements
    • 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
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness

Definitions

  • the expansion casting system consists of filling the mold cavity with a polymeric foam material and a blowing agent which, when activated, foams the polymeric material to the shape of the mold cavity.
  • a blowing agent which, when activated, foams the polymeric material to the shape of the mold cavity.
  • This invention produces a smooth skin laminated structure using the foam casting technique by interposing a flexible open-celled foam wetted with a thermoset resin between the outer thin skin and an expandable thermoset polymeric foam.
  • the polymeric foam as it expands in the interior of the mold, comprises the inner surface of the flexible foam.
  • the resin in the flexible foam cures after the expanded foam cures.
  • the flexible foam compresses differentially in proportion to the uneven expansion of the expandable foam and thereby prevents any distortion of the outer thin skin.
  • FIGURE 1 is a cross-sectional view of a closed mold in which a thin skinned laminated structure is cast by means of an expandable polymerxc foam in accordance with the principles of this invention.
  • FIGURE 2 is another embodiment in which the principles of this invention are used to reinforce a thin skin body portion.
  • FIG. 1 there is shown a mold 10 having an upper part 12 and lower part 14 and a cavity 16 of a desired pattern shape.
  • the first step is to lay up along the surface of the cavity 16 a thin sheet of material 18.
  • the thin sheet 18 could be made of any plyable material such as metal, wood or fibrous reinforced material.
  • the thickness of this sheet, of material depends on the particular material employed, for example: .020 inches for aluminum, .1 inch for wood veneer, and .040 inch for fiber glass laminates. In any event, this thin sheet of material would be of a thickness that causes the skin to buckle upon an expandable polymeric foam being introduced into the cavity 16, which when activated expands outwardly and compresses against sheet 18.
  • the next step is to lay up onto the thin sheet 18, a sheet of flexible open-celled foam 20.
  • the open-celled foam sheet 20 Prior to insertion into the cavity 16, the open-celled foam sheet 20 is impregnated with a resinous material.
  • the flexible foam may be any of the commercially available material such as flexible polyurethane, sponge rubber, cellulose foams, etc. Its impregnation is prefer ably performed in a manner that the open cells of the foam are left coated with the thin film of a settable resin. A suitable technique for accomplishing this objective is described in my U.S. patent No. 3,269,887.
  • an expandable polymeric foam mixed with a chemical blowing agent 22 is inserted into the cavity 16. The quantity of this mixture must be sufficient to permit the polymeric foam to expand when activated to fill the volume defined by the inner walls of the flexible foam layer 20.
  • the chemical blowing agent When activated, it expands the polymeric foam outwardly until it contacts and compresses the flexible foam.
  • the flexible foam's inner surface 24 compresses differentially, in proportion to the uneven pressure applied by the gases of the expanding foam 22.
  • the flexible foam layer 20 acts as a buffer zone between the expandable polymeric foam 22 and the thin skin layer 18 by absorbing the uneven expansion of the gaseous blowing agent. Due to this uneven expansion of the blowing agent, the impression in the inner surface of the open cell flexible foam 20 will vary around the perimeter of the mold cavity 16, but the pressure applied to the outer skin layer 18 will be negligible around the mold cavity perimeter.
  • the resin used to wet the flexible foam sheet 20 must be compatible with the polymeric foam mixture 22.
  • an epoxy resin and an amine curing agent would be suitable for wetting the flexible foam 20 when using a polyurethane rigid foam mixture as the expandable polymeric foam material. It is important that the settable resin cures after the expandable foam cures.
  • the settable resin bonds the thin skin 18 to the rigidized flexible foam 20.
  • the bottom wall 52 of the door sill is constructed of a thin skin which may be metallic, plastic composite, or the like, and which extends the length of the door to define a generally U-shaped interior channel 54.
  • a flexible open-celled foam 56 wetted with a settable resin is layed up along the interior walls 58 of the U-shaped channel 54. This flexible foam 56 would be wetted in a manner described with reference to
  • Figure 1 to provide the flexible foam's open cells with the thin coating of settable resin.
  • An expandable polymeric foam 60 in sufficient quantities to fill the U-shaped chan nel 54 when expanded is then added to the interior of the channel mixed with a chemical blowing agent.
  • the bottom portion of the U-shaped channel 54 is left open to permit any excess of the expandable foam to pass through it.
  • the chemical blowing agent is activated to cause the polymeric foam 60 to expand outwardly toward the flexible foam 56.
  • the inner surface 62 of the flexible foam compresses and applies a resultant negligible pressure outwardly against the thin skin wall members 52.
  • the excess 64 of the expandable foam pushes through the open bottom of U-shaped channel 54.
  • the settable resin in the flexible foam is selected to cure after the polymeric foam has cured.
  • the resulting structure is a high impact resistant laminated structure which is reinforced by the expanded polymeric foam.

Landscapes

  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

Une structure composite laminee a fine pellicule externe est construite en utilisant une mousse flexible a cellules ouvertes (20) comme materiau tampon entre la pellicule externe (18) et la mousse polymere expansible thermo-durcissable (22) pour produire une piece ayant une surface a pellicule fine avec un meilleur fini superficiel et une plus grande rigidite.
PCT/US1980/000225 1979-03-05 1980-03-03 Structure laminee a fine pellicule externe renforcee par des mousses polymeres WO1980001892A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
BR8007234A BR8007234A (pt) 1979-03-05 1980-03-03 Estrutura laminada de revestimento fino e repectivo processo de fabrico

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US1764779A 1979-03-05 1979-03-05
US17647 1987-02-24

Publications (1)

Publication Number Publication Date
WO1980001892A1 true WO1980001892A1 (fr) 1980-09-18

Family

ID=21783768

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1980/000225 WO1980001892A1 (fr) 1979-03-05 1980-03-03 Structure laminee a fine pellicule externe renforcee par des mousses polymeres

Country Status (7)

Country Link
EP (1) EP0025065A1 (fr)
JP (1) JPS56500040A (fr)
AR (1) AR219442A1 (fr)
AU (1) AU5620780A (fr)
BR (1) BR8007234A (fr)
ES (1) ES489207A0 (fr)
WO (1) WO1980001892A1 (fr)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0149303A2 (fr) * 1984-01-19 1985-07-24 Sears Manufacturing Company Procédé pour former des articles rembourrés
EP0348033A2 (fr) * 1988-05-10 1989-12-27 Company 'a' Foam Limited Mousse composite et son procédé de préparation
US4977018A (en) * 1987-11-23 1990-12-11 Irbit Research & Consulting Ag Sealing element
WO1993003910A1 (fr) * 1991-08-13 1993-03-04 Woodbridge Foam Corporation Procede de production d'un panneau renforce en mousse de polyurethane
WO1994017995A1 (fr) * 1993-02-12 1994-08-18 Woodbridge Foam Corporation Panneau absorbant l'energie
EP0623491A1 (fr) * 1993-05-03 1994-11-09 Reydel Produit stratifié destiné notamment à réaliser des éléments d'habillage intérieur de carroserie
US5580651A (en) * 1991-08-13 1996-12-03 Woodbridge Foam Corporation Energy absorbing panel
EP0834422A3 (fr) * 1996-10-05 1999-04-28 Johnson Controls Interiors GmbH Elément de garniture intérieure
EP1391283A1 (fr) * 2002-08-19 2004-02-25 ArvinMeritor GmbH Procédé de fabrication d'un revêtement intérieur pour véhicules et revêtement intérieur pour véhicules

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4581262A (en) * 1985-01-14 1986-04-08 Owens-Illinois, Inc. Coextruded multilayer sheet and sleeve label made therefrom
US4626455A (en) * 1985-01-14 1986-12-02 Owens-Illinois, Inc. Coextruded multilayer sheet and sleeve label for bottles

Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3118153A (en) * 1960-10-21 1964-01-21 Davidson Rubber Company Inc Upholstery corner construction
US3193598A (en) * 1961-08-16 1965-07-06 Freeman Chemical Corp Process of molding laminating preforms of foamed polyurethane having open, connected cells
US3269887A (en) * 1963-08-07 1966-08-30 Dow Chemical Co Settable, flexible, foamed resins
US3437551A (en) * 1964-09-15 1969-04-08 Mobay Chemical Corp Method of bonding thermoplastic film to polyurethane foam and product
US3649325A (en) * 1968-09-25 1972-03-14 Metallgesellschaft Ag Coating porous substrates with solid rubber foam
US3664976A (en) * 1969-08-21 1972-05-23 Uniroyal Ltd Polyurethane foam with integral skin
US3698927A (en) * 1970-10-28 1972-10-17 Goodyear Tire & Rubber Foam structure with protective overcoat
US3795722A (en) * 1970-10-02 1974-03-05 Goodyear Tire & Rubber Method of making a skin covered foam article and said article
US3873407A (en) * 1971-12-18 1975-03-25 Sanyo Chemical Ind Ltd Skin polyurethane foam
US3946095A (en) * 1973-12-03 1976-03-23 Carnation Company Method of restoring the shape of a flexible-shell model
US3989781A (en) * 1971-08-17 1976-11-02 Shell Oil Company Process for producing a fibrous reinforced thermosetting resin impregnated foamed polymeric resin article
US4017656A (en) * 1975-09-18 1977-04-12 Pandel-Bradford, Inc. Imitation leather material and method of preparing such material
US4073998A (en) * 1977-01-24 1978-02-14 Bay Mills Limited Scrim/foil laminate

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3118153A (en) * 1960-10-21 1964-01-21 Davidson Rubber Company Inc Upholstery corner construction
US3193598A (en) * 1961-08-16 1965-07-06 Freeman Chemical Corp Process of molding laminating preforms of foamed polyurethane having open, connected cells
US3269887A (en) * 1963-08-07 1966-08-30 Dow Chemical Co Settable, flexible, foamed resins
US3437551A (en) * 1964-09-15 1969-04-08 Mobay Chemical Corp Method of bonding thermoplastic film to polyurethane foam and product
US3649325A (en) * 1968-09-25 1972-03-14 Metallgesellschaft Ag Coating porous substrates with solid rubber foam
US3664976A (en) * 1969-08-21 1972-05-23 Uniroyal Ltd Polyurethane foam with integral skin
US3795722A (en) * 1970-10-02 1974-03-05 Goodyear Tire & Rubber Method of making a skin covered foam article and said article
US3698927A (en) * 1970-10-28 1972-10-17 Goodyear Tire & Rubber Foam structure with protective overcoat
US3989781A (en) * 1971-08-17 1976-11-02 Shell Oil Company Process for producing a fibrous reinforced thermosetting resin impregnated foamed polymeric resin article
US3873407A (en) * 1971-12-18 1975-03-25 Sanyo Chemical Ind Ltd Skin polyurethane foam
US3946095A (en) * 1973-12-03 1976-03-23 Carnation Company Method of restoring the shape of a flexible-shell model
US4017656A (en) * 1975-09-18 1977-04-12 Pandel-Bradford, Inc. Imitation leather material and method of preparing such material
US4073998A (en) * 1977-01-24 1978-02-14 Bay Mills Limited Scrim/foil laminate

Cited By (15)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0149303A2 (fr) * 1984-01-19 1985-07-24 Sears Manufacturing Company Procédé pour former des articles rembourrés
EP0149303A3 (en) * 1984-01-19 1987-10-21 Sears Manufacturing Company Process for forming cushion articles
US4977018A (en) * 1987-11-23 1990-12-11 Irbit Research & Consulting Ag Sealing element
EP0348033A2 (fr) * 1988-05-10 1989-12-27 Company 'a' Foam Limited Mousse composite et son procédé de préparation
EP0348033A3 (fr) * 1988-05-10 1990-09-12 Company 'a' Foam Limited Mousse composite et son procédé de préparation
US5060291A (en) * 1988-05-10 1991-10-22 Company `A` Foam Limited Foam composite and method of forming same
WO1993003910A1 (fr) * 1991-08-13 1993-03-04 Woodbridge Foam Corporation Procede de production d'un panneau renforce en mousse de polyurethane
US5389316A (en) * 1991-08-13 1995-02-14 Woodbridge Foam Corporation Process for producing an energy absorbing panel
US5580651A (en) * 1991-08-13 1996-12-03 Woodbridge Foam Corporation Energy absorbing panel
WO1994017995A1 (fr) * 1993-02-12 1994-08-18 Woodbridge Foam Corporation Panneau absorbant l'energie
EP0623491A1 (fr) * 1993-05-03 1994-11-09 Reydel Produit stratifié destiné notamment à réaliser des éléments d'habillage intérieur de carroserie
FR2704804A1 (fr) * 1993-05-03 1994-11-10 Reydel Dev Produit stratifié destiné notamment à réaliser des éléments d'habillage intérieur de carrosserie.
EP0834422A3 (fr) * 1996-10-05 1999-04-28 Johnson Controls Interiors GmbH Elément de garniture intérieure
EP1391283A1 (fr) * 2002-08-19 2004-02-25 ArvinMeritor GmbH Procédé de fabrication d'un revêtement intérieur pour véhicules et revêtement intérieur pour véhicules
US6977019B2 (en) 2002-08-19 2005-12-20 Arvinmeritor, Gmbh Method of producing a vehicle interior lining and vehicle interior lining

Also Published As

Publication number Publication date
EP0025065A1 (fr) 1981-03-18
AU5620780A (en) 1980-09-11
AR219442A1 (es) 1980-08-15
ES8104053A1 (es) 1981-04-01
JPS56500040A (fr) 1981-01-16
ES489207A0 (es) 1981-04-01
BR8007234A (pt) 1981-02-03

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