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GB2121354A - Decorative laminate panel - Google Patents

Decorative laminate panel Download PDF

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Publication number
GB2121354A
GB2121354A GB08311511A GB8311511A GB2121354A GB 2121354 A GB2121354 A GB 2121354A GB 08311511 A GB08311511 A GB 08311511A GB 8311511 A GB8311511 A GB 8311511A GB 2121354 A GB2121354 A GB 2121354A
Authority
GB
United Kingdom
Prior art keywords
fabric sheet
fabric
foam
sheets
panel
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.)
Granted
Application number
GB08311511A
Other versions
GB2121354B (en
GB8311511D0 (en
Inventor
Ronald W Adams
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.)
Albany International Corp
Original Assignee
Albany International Corp
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 Albany International Corp filed Critical Albany International Corp
Publication of GB8311511D0 publication Critical patent/GB8311511D0/en
Publication of GB2121354A publication Critical patent/GB2121354A/en
Application granted granted Critical
Publication of GB2121354B publication Critical patent/GB2121354B/en
Expired legal-status Critical Current

Links

Classifications

    • 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
    • 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
    • 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
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • 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
    • B32B5/02—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 structural features of a fibrous or filamentary layer
    • B32B5/026—Knitted fabric
    • 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
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • 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
    • 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
    • B29K2105/25—Solid
    • B29K2105/253—Preform
    • B29K2105/256—Sheets, plates, blanks or films
    • 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
    • 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
    • B32B2451/00—Decorative or ornamental articles
    • 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
    • B32B2607/00—Walls, panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R13/0237—Side or rear panels
    • B60R13/0243—Doors

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

A cushioned decorative laminate panel comprises a non-woven fabric sheet 10 having a surface layer composed of thermoplastic fibres, e.g. polypropylene, a decorative surface fabric sheet 12, and a piece of cushioning foam 14 located between the sheets 10 and 12. The panel is moulded to shape, and the two sheets 10 and 12 are bonded together at edge portions 32 and 34 thereof outwardly of the foam 14 by means of a portion of the thermoplastic surface layer of the fabric sheet 10 at least partially penetrating into the fabric sheet 12 as a result of the thermoplastic material being melted and the sheets 10 and 12 being pressed together in the region of the edge portions 32 and 34. This compression and bonding of the sheets 10 and 12 at the edge portions 32 and 34 pinches the edges of the foam 14 inwardly thereof to lock the foam in position between the sheets. <IMAGE>

Description

1 GB 2 121 354 A 1
SPECIFICATION Decorative laminate panel
This invention relates to decorative laminate panels, and according to the invention such a panel comprises a first fabric sheet having at least one thermoplastics surface layer, a second fabric sheet having an edge portion bonded to an edge portion of the first fabric sheet by means of a portion of the thermoplastics surface layer of the first fabric at least partially penetrating into the second fabric sheet and creating a mechanical bond therewith, and a piece of foam positioned between and contacting the first and second fabric sheets, the second fabric sheet having a decorative outer surface.
Preferably the panel has a substantially Ushaped cross-section comprising a body portion and two symmetrical projecting portions at opposite ends of the body portion, the foam piece being positioned between the two fabric sheets for the length of the body portion, the fabric sheets being bonded to each other near the outer ends of the projecting portions, the thickness of the first fabric sheet in the projecting portions progressively decreasing towards their outer ends, 90 and the foam piece having opposite edge portions which extend partially into the projecting portions and which are compressed therein.
The foam forms a cushion which is locked between the two fabric sheets of the panel and which is not visible from either side of the panel.
Such panels may be used in many situations, but are particularly suitable for use as trim panels on the inside of vehicle doors.
A particularly advantageous method of making 100 a panel in accordance with the invention is described and claimed in our application no.
8224737, from which the present application is divided, and comprises using a mould having male and female halves which fit together to define a 105 mould cavity between a recess in the female half and a portion of the male half which projects partly into the recess, inserting the first and second fabric sheets between the two halves of the mould, locating the piece of foam between the 110 first and second fabric sheets within the mould so that the foam is at least partly positioned in the mould cavity, heating the first fabric sheet to a temperature above the melting point of the thermoplastic material of its surface layer, 115 pressing the two halves of the mould together so that the first and second fabric sheets are pressed together adjacent the foam and molten thermoplastic material of the first fabric sheet penetrates into the second fabric sheet, and cooling the first fabric sheet so that the thermoplastic sheet solidifies and forms a mechanical bond between the first and second fabric sheets and the piece of foam is locked between the two sheets.
With this method, the two fabric sheets are bonded together adjacent the edges of the mould cavity to lock the foam cushioning material between them, and are simultaneously moulded to the desired shape. The method is advantageous in that no powders, films, or adhesives need to be used, no secondary operation is required to attach a fabric to a moulded substrate, and the bonding between the two fabric sheets will withstand relatively high temperatures for long periods of time.
An example of a laminate panel in accordance with the invention, and of a method of making the panel, will now be described with reference to the accompanying drawings, in which:- Figure 1 is a section through a mould used in the method of making the panel, showing the first and second fabric sheets and the foam positioned therein; Figure 2 is a section through the panel; and, Figure 3 is a perspective view of the panel.
In this example the first fabric sheet of the panel is a non-woven sheet 10 which is similar in construction to the composite web described in U.S. Patent No. 4,199,635, comprising a core layer of unconsolidated synthetic fibres and outer layers composed of polypropylene or other thermoplastic fibres. The second fabric sheet of the panel is a decorative knit, woven or non woven surface fabric 12 having a textile backing.
In making the panel the surface fabric sheet 12 is positioned over the female portion 16 of a mould 18 having a mould recess 20, and a die cut piece of foam 14 is laid over the surface fabric sheet 12 in contact with its textile backing. The non-woven fabric sheet 10 is then placed over the foam 14, sandwiching the foam between the two fabric sheets 10 and 12. As shown in Figure 1, the foam 14 is laid over the surface fabric sheet 12 in such a manner that the outer perimeter of the recess 20 of the female portion 16 of the mould is not covered by the foam. Decorative blades may be incorporated in the surface of the mould recess 20.
The mould 18 is designed so that the edges of the male 22 and female 16 mould halves around the recess 20 compress the overlapping portions of the non-woven fabric sheet 10 and the surface fabric sheet 12 to a thickness of approximately 0.040 inches (about 1 mm) when the mould is closed. Prior to the compression, the non-woven fabric sheet 10 is heated to a temperature above the melting point of its outer layers. If the outer layers are composed of polypropylene fibres, heat should be applied until the temperature of the fibres exceeds 3901 F (about 200IC).
The heated non-woven fabric sheet 10 and the surface fabric sheet 12 are compressed within the mould as shown in Figure 1. A symmetrical cavity is defined between the surface of the recess 20 and the projecting portion 24 of the male mould half 22 to accommodate the foam 14 so that high pressure is not applied to the foam during the moulding operation. Where the two fabric sheets 10 and 12 are pressed against each other however, the pressure exerted by the mould halves forces the molten surface of the sheet 10 into the interstices of the surface fabric sheet 12. On cooling, a mechanical bond is formed between 2 GB 2 121 354 A 2 the two fabrics, particularly in the tapered areas 26 near the perimeter of the recess 20, which may be referred to as the "pinching gaps-, where the mould pressure is relatively high. The moulded laminate is then die cut or cut by other mechanical means from the full sheet (not shown) and is ready for use. A panel as shown in Figures 2 and 3 is obtained. Other configurations would of course be possible using different shaped moulds.
As shown, the panel has substantially flat 40 opposite surfaces 28 and 30, and a pair of projecting portions 32 and 34 extending from the bottom surface. Due to the shape of the mould, the thickness of the non-woven fabric sheet 10 is 15, significantly compressed in the area of the 45 projecting portions 32 and 34, providing excellent bonding between it and the decorative surface fabric sheet 12. The foam 14 does not extend between the fabrics in the bonding areas, and only a portion of the foam is compressed in the pinching gap 26. This compression substantially locks the foam in place between the two fabric sheets 10 and 12. The decorative surface fabric sheet 12 defines three contiguous surfaces of the panel, the fourth surface 30 being defined by the first fabric sheet 10.

Claims (4)

1. A decorative laminate panel comprising a 60 first fabric sheet having at least one thermoplastic surface layer, a second fabric sheet having an edge portion bonded to an edge portion of the first fabric sheet by means of a portion of the thermoplastic surface layer of -the first fabric at least partially penetrating into the second fabric sheet and creating a mechanical bond therewith, and a piece of foam positioned between and contacting the first and second fabric sheets, the second fabric sheet having a decorative outer surface.
2. A panel according to claim 1, in which the decorative surface covers the first, second, and third sides of the panel, and a surface of the first fabric defines a fourth side of the panel opposite the first side, the second and third sides adjoining the first and fourth sides.
3. A panel according to claim 1 or claim 2, having a substantially Ushaped cross-section comprising a body portion and two symmetrical projecting portions at opposite ends of the body portion, the foam piece being positioned between the two fabric sheets for the length of the body portion, the fabric sheets being bonded to each other near the outer ends of the projecting portions, the thickness of the first fabric sheet in the projecting portions progressively decreasing towards their outer ends, and the foam piece having opposite edge portions which extend partially into the projecting portions and which are compressed therein.
4. A panel according to claim 1, substantially as described with reference to the accompanying drawings.
Printed for Her Majesty's Stationery Office by the Courier Press, Leamington Spa, 1983. Published by the Patent Office 25 Southampton Buildings, London, WC2A lAY, from which copies may be obtained.
F 3 Z.
GB08311511A 1981-08-27 1983-04-27 Decorative laminate panel Expired GB2121354B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US29688681A 1981-08-27 1981-08-27

Publications (3)

Publication Number Publication Date
GB8311511D0 GB8311511D0 (en) 1983-06-02
GB2121354A true GB2121354A (en) 1983-12-21
GB2121354B GB2121354B (en) 1985-06-26

Family

ID=23143983

Family Applications (2)

Application Number Title Priority Date Filing Date
GB08224737A Expired GB2112319B (en) 1981-08-27 1982-08-27 Laminated panel and method of making such a panel
GB08311511A Expired GB2121354B (en) 1981-08-27 1983-04-27 Decorative laminate panel

Family Applications Before (1)

Application Number Title Priority Date Filing Date
GB08224737A Expired GB2112319B (en) 1981-08-27 1982-08-27 Laminated panel and method of making such a panel

Country Status (2)

Country Link
CA (1) CA1196846A (en)
GB (2) GB2112319B (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2636266A1 (en) * 1988-09-12 1990-03-16 Reydel Sa J Method of colouring linings, especially for rigid or semi-rigid elements covering the inside of a motor vehicle, and product obtained according to this method
EP0483221A4 (en) * 1989-07-19 1993-03-31 Kenneth R. Sanborn Carpet and method of attachment
WO1997006320A1 (en) * 1995-08-03 1997-02-20 Hermanson Lars S Self-supporting interior surface panel
FR3030430A1 (en) * 2014-12-22 2016-06-24 Cera Aps AUTOMOTIVE VEHICLE INTERIOR CLOSURE PANEL
EP3037256A1 (en) * 2014-12-22 2016-06-29 Cera APS Method for producing an interior trim panel of a motor vehicle

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5626382A (en) * 1995-04-03 1997-05-06 Lear Corporation Molded plastic panel having integrated, localized soft-touch aesthetic feature
FR2746953B1 (en) * 1996-03-29 1998-05-29 Plasto Sa COMPOSITE MATERIAL FOR SHEATHING OF ELECTRICAL BEAMS
EP1220764A1 (en) * 1999-10-01 2002-07-10 Lear Corporation Sandwich structural door inner panel
DE10196876T5 (en) * 2001-10-31 2004-04-22 Lear Corp., Southfield Vehicle part and method of manufacturing the same
CN111168913B (en) * 2019-09-02 2022-06-17 天津三和泰奥汽车部件有限公司 3D (three-dimensional) setting device and production method for non-woven fabric for foaming of automobile seat

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2636266A1 (en) * 1988-09-12 1990-03-16 Reydel Sa J Method of colouring linings, especially for rigid or semi-rigid elements covering the inside of a motor vehicle, and product obtained according to this method
EP0483221A4 (en) * 1989-07-19 1993-03-31 Kenneth R. Sanborn Carpet and method of attachment
WO1997006320A1 (en) * 1995-08-03 1997-02-20 Hermanson Lars S Self-supporting interior surface panel
US5832685A (en) * 1995-08-03 1998-11-10 Hermanson; Lars S. Self-supporting interior surface panel
FR3030430A1 (en) * 2014-12-22 2016-06-24 Cera Aps AUTOMOTIVE VEHICLE INTERIOR CLOSURE PANEL
FR3030429A1 (en) * 2014-12-22 2016-06-24 Centre D'etude Et De Rech Pour L'automobile (Cera) AUTOMOTIVE VEHICLE INTERIOR CLOSURE PANEL
EP3037256A1 (en) * 2014-12-22 2016-06-29 Cera APS Method for producing an interior trim panel of a motor vehicle

Also Published As

Publication number Publication date
GB2121354B (en) 1985-06-26
CA1196846A (en) 1985-11-19
GB2112319A (en) 1983-07-20
GB2112319B (en) 1985-06-26
GB8311511D0 (en) 1983-06-02

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Legal Events

Date Code Title Description
732 Registration of transactions, instruments or events in the register (sect. 32/1977)
PCNP Patent ceased through non-payment of renewal fee