CA2257385A1 - Method for forming products such as simulated leather or like products - Google Patents
Method for forming products such as simulated leather or like products Download PDFInfo
- Publication number
- CA2257385A1 CA2257385A1 CA002257385A CA2257385A CA2257385A1 CA 2257385 A1 CA2257385 A1 CA 2257385A1 CA 002257385 A CA002257385 A CA 002257385A CA 2257385 A CA2257385 A CA 2257385A CA 2257385 A1 CA2257385 A1 CA 2257385A1
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- CA
- Canada
- Prior art keywords
- layer
- expanded
- support
- moulding
- rigid
- 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.)
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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
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C41/18—Slush casting, i.e. pouring moulding material into a hollow mould with excess material being poured off
-
- 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
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C41/22—Making multilayered or multicoloured articles
-
- 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
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/78—Moulding material on one side only of the preformed part
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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
- B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
- B29K2105/043—Skinned foam
-
- 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
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
Abstract
A method for forming products such as simulated leather or like products with at least one expanded layer (2) from thermoplastic, thermosetting or elastomer materials, comprising the following stages: forming in a slush-moulding mould a first layer (1) of compact material representing the exposed layer of the finished product, on said first layer forming a second layer (2) of expandable material by further slush-moulding, completing with heat the consolidation of said layers by gelling and the expansion of said second layer, to the layered material formed in this manner there being coupled a support of rigid material (7), possibly filled with reinforcement fibres, characterised by comprising a stage involving the filling of every possible interspace (6, 3) between said rigid material support (7) and said expanded second layer (2).
Description
CA 022~738~ 1998-12-04 METHOD FOR FORMING PRODUCTS SUCH AS SIMULATED LEATHER OR LIKE PRODUCTS
The copending patent application PCT/EP g6jOl583 (nct yet published) of the present applicant describes a method for forming products such as simulated leather or like products with at leas~
one expanded layer from thermoplastic, thermosetting or elastomer materials, comprising the following stages: forming in a slush-moulding mould a first layer of compact material representing theexposed layer of the finished product, on this firs~ layer forming the second layer of expandable material by further slush-moulding, completing with heat the consolidation of the formed layers by gelling and the expansion of said second layer by suitable means to obtain predetermined thicknesses and shapes in said expanded layer, to the layered material formed in this manner there being coupled a support of rigid material possibly filled with reinforcement fibres, said suitable means for obtaining predetermined thicknesses and shapes of said expanded layer consisting either of a counter-mould or of the actual said support of rigid material.
As explained in the said patent application, the finished products CA 022~738~ l998-l2-04 W O 97/48537 PCTtEP97tO2327 obtained by the method in question are generally appropriate for interior trimmings in particular of motor vehicles, for example for parts such as dash panels, consoles, compartment lids and other similar objects for which an appearance as similar as possible to natural leather is required.
As described in the said patent application, the method in question represents considerable progress in particular compared with the preceding method for obtaining such objects produced by thermoforming calendered sheets possibly laminated with an expanded layer.
In this respect, in this preceding method the presence of stretched parts containing congealed forces gives rise to serious shrinking problems with consequent cracking and breakage under hot conditions, especially in that region which in automobiles is exposed to direct sunlight, such as the upper surface of the dash panel.
The inclination of windscreens at increasing1y acute angles in accordance with the latest preferred styles has aggravated this problem by causing the temperature to which these interior parts of the vehicle are exposed to often exceed 100~ under solar radiation.
The simulated leather obtained by the method of the aforesaid patent application, which essentially uses a slush-moulding method, avoids this defect.
Notwithstanding the substantial progress represented by this patent application, in the practical implementation of the method it has been found that a defect can sometimes arise in the leather CA 022~738~ 1998-12-04 produced by it, due substantially to the circumstance that in said stage involving the control of the thickness and shape of the expanded layer, also known as the surface shaping stage for the expanded layer, a uniform and regular surface cannot always be obtained, so that in the next stage involving adhesion to the support, generally by gluing, discontinuity points or regions can arise between the inner surface of the expanded layer and the support itself, which the layer of glue is unable to compensate.
This can occur at either cavities or protuberances in the surface of the expanded layer, so that voids or humps are consequently created at the expanded layer/support interface, which are inevitably transmitted to the exposed outer surface of the simulated leather.
This means that the aesthetic effect sought is completely ruined, because those cavities and protuberances transmitted from the interior of the layered structure to the exposed outer surface of the simulated leather are immediately visible.
An analogous defect can occur if, instead of being present on the expanded layer surface, the imperfections are present on the rigid support itself, or on both surfaces.
The object of the present invention is mainly to solve this problem.
The present invention therefore essentiaily proposes to improve the method described in patent application PCT/EP 96/01583 of the present applicant.
This object, and other advantages which will be apparent from the ensuing description, are attained according to the invention by a CA 022~738~ 1998-12-04 WO g7/48537 PCT/EP97/02327 method for forming products such as simulated leather or like products with at least one expanded layer from thermoplastic, thermosetting or elastomer materials, comprising the following stages: forming in a slush-moulding mould a first layer of compact material representing the exposed layer of the finished product, on said first layer forming a second layer of expandable material by further slush-moulding, completing with heat the consolidation of said layers by gelling and the expansion of said second layer, to the layered materiai formed in this manner there being coupled a support of rigid material possibly filled with reinforcement fibres, characterised by comprising a stage involving the filling of every possible interspace between said rigid material support and said expanded second layer.
According to one embodiment of the present invention, said stage involving the filling of every possible interspace between the rigid material support and the expanded second layer consists of coupling the rigid material support to said thus formed layered material by applying a layer of expandable adhesive to their interface.
A suitable expandable adhesive is a bicomponent polyurethane. It is possible in any event to apply a layer of expandable adhesive compatible with the materials to be coupled. The expandable material adhesive can be used either as such or together with suitable adhesion promoters.
In a different embodiment of the method of the present invention, said stage involving the filling of every possible interspace between the rigid material support and said expanded second layer CA 022~738~ 1998-12-04 W O 97148537 P~ 57/02327 of the layered material consists of coupling to said thus formed layered material the rigid material support possibly filled with reinforcement fibres predispersed in the material or forming a layer to be inserted into the rigid material, this latter being formed by direct moulding onto the free face of said expanded second layer within a suitable mould, for example by casting or by pressure injection moulding so as not to lose the mechanical properties to the expanded layer.
In this embodiment, once formed, the simulated ieather is placed in an injection or casting mould, the mould profile reproducing that of the finished product, the rigid support hence being moulded onto the leather in the mould prepared in this manner, to give the finished product.
The thermoplastic, thermosetting or elastomer materials suitable for slush-moulding simulated leather or the like can be chosen from a wide range of resins in powder or liquid form.
The second layer of expandable material compri~es expansion agents as azodicarbonamide, sodium bicarbonate, citric acid and others.
Said first layer can be formed of a single colour, or of two or more colours for example by using the methods of patents of the present applicant, namely EP 476,742 or W0 94/12331.
For moulding the rigid support, particularly indicated are expanded or non-expanded rigid or semi-rigid thermosetting materials, such as polyurethanes, polyesters, epoxy resins and the like, possibly reinforced with fillers of glass fibres, carbon fibres, polyaramid fibres or fibres with similar characteristics, possibly forming a layer to be inserted into the material.
In that embodiment of the present invention comprising moulding CA 022~738~ l998-l2-04 W O 97/48537 PCT~EP97/02327 the support directly onto the leather in a mould, particularly indicated are resins liquid at ambient temperature, and hence injectable or castable cold.
The characteristics and advantages of the invention will be more apparent from the practical examples given hereinafter with reference to the accompanying figures. These examples are not to be considered as limitative.
Figure l is a cross-section through coupled materials of a first embodiment of the invention;
Figure 2 is a cross-section through a second embodiment of the invention; and Figure 3 is a cross-section through the finished product obtained by the method of Figure 2.
Figure l shows a cross-section through a product comprising simulated leather consisting of a first layer 1 of thermoplastic material, for example PVC, and a second layer 2 of expanded material, obtained by slush-moulding expandable PVC.
The simulated leather consisting of the layered structure 1 and 2 is produced for example by the method of the aforesaid patent application PCT/EP96/01583 of the present applicant.
As shown in Figure 1, the free face of the expanded second layer 2 comprises irregularities, such as concavities 3, due for example to an executional defect in the shaping stage for this face of the expanded layer during its moulding, for example due to irregularities in the profile of the counter-mould used for this shaplng.
Finally, in Figure 1 the reference numeral 7 indicates a rigid CA 022~738~ 1998-12-04 support, for example of reinforced thermoplastic or thermosetting material, suitable for coupling to the layered structure 1 and 2 by gluing. The figure also indicates by the reference numeral 6 the interspace between the outer face of the expanded layer 2 and the support 7, in which interspace the glue for fixing the support to the layered structure is deposited.
As can be seen, this interspace is not of regular dimensions, but varies considerably due to the aforesaid circumstance of the irregularities in the outer face of the layer 2.
In the embodiment of Figure 1, the interspace 6 is filled with an expandable adhesive, for example a bicomponent polyurethane, which when deposited on the interface between the layer 2 and the support 7 begins to expand to fill every possible interspace between said rigid material support and said expanded second layer 2.
The layer of expandable glue is deposited in the interspace 6 by placing the support and the layered structure in a pressing system, for example between a mould and a counter-moula, able to exert the pressure required for gluing and for containing the expansion of the adhesive, so that this effectively fills every minimum interspace between the layer 2 and the support 7 to achieve the required technical effect.
Figures 2 and 3 show a different embodiment of the method of the invention, in which the simulated leather consisting of the first layer 1 and the expanded layer 2 has been obtained by a slush-moulding method such as that described in the aforesaid patent application PCT/EP/96/01583, but without any shaping operation on CA 022~738~ 1998-12-04 W O 97/48537 PCT~EP97/02327 the free face of the expanded second layer 2, ie without providing any means for controlling the thickness and shape thereof.
In this respect, it can be seen from Figures 2 and 3 that the free face of the expanded layer 2 is of absolutely irregular shape.
The simulated leather obtained in this manner, consisting of the layered structure 1 and 2, is placed within a mould in the form of two half-moulds 8 and 14.
The half-mould 8 is suitably provided with retractable pressure means, consisting for example of pistons 9 slidable within cylinders 10 particularly suitable for compressing undercuts 11 which are typically present in the layered product. The profile of the half-mould 8 hence corresponds exactly to the profile of the finished product. Devices can be provided in this half-mould to maintain the simulated leather in the correct shape, such as holes for the vacuum etc. In the undercut regions 11 the compression systems consisting of the pistons 9 act, these operationally maintaining the product in shape during moulding in these undercut regions.
In contrast, the half-mould 14 is typically a half-mould provided with channels 12 for injecting the plastic material for forming said rigid support, or for use as a casting mould.
Having closed the mould formed from the two half-moulds 8 and 14, there remains defined between the lower face of the half-mould 14 and the free face of the expanded layer 2 an interspace 4 reproducing the shape of the support to be moulded.
Figure 2 shows the forming mould for the rigid support in its closed operating position.
CA 022~738~ 1998-12-04 W O 97/48537 PCT~EP97/02327 Essentially, the procedure comprises initially opening the mould, positioning the layered structure l and 2 on the half-mould 8 with the pistons 9 in their rest position, hence retracted within the cylinders 10, and then operating these latter to assume their compression position shown in Figure 2.
At this point a layer for example of unwoven glass fibre fabric can be located in the interspace 4 remaining between the half-moulds 8 and 14 to reinforce the support to be moulded.
The mould is closed by locating the half-mould 14 in the position shown in Figure 2. The resin, for example a bicomponent thermosetting resin, is injected or cast, and its cross-linking is awaited.
The pistons 9 are again retracted into the rest position within the cylinders 10, the half-mould 14 is raised and the finished 1~ piece is extracted, this being shown in Figure 3, illustrating the finished product composed of a rigid support 13, an expanded intermediate layer 2 and the exposed outer layer 1.
As can be seen in Figure 3, again in this case total filling of every possible interspace between the free face of the layer 2 and the rigid support 13 is achieved, this latter in fact being formed by moulding, necessarily following the pattern of the interface with the expanded layer 2.
As stated heretofore, instead of using as reinforcement a layer of suitable material such as unwoven fabric, a resin for injection or cast moulding can be used, containing a strengthening filler.
As is apparent from the aforegoing examples and the description, it is no longer necessary to operate the method described in the CA 022~738~ 1998-l2-04 W O 97/48537 PCT~EP97/02327 aforesaid PCT patent application such as to obtain a regular and uniform free face of the expanded layer, because the method of the present invention in any event results in total filling of every single interspace which can occur between the rigid support and said face of the expanded layer.
If the expanded product does not require its thickness to be predetermined> then compared with the method of said prior PCT
patent application, that shaping stage involving adjusting and controlling the shape of the free face of the expanded layer may be omitted.
This does not mean that said stage must not in fact be carried out, but merely that special care need not be taken to achieve perfect uniformity of the free face of the expanded layer.
It could in particular be carried out if the method of the present invention is to use an expandable adhesive.
However it would appear superfluous to effect such a shaping stage if the present invention is implemented by the embodiment comprisin~ moulding the rigid support directly onto the expanded l~yer, if predetermined thicknesses of the expanded product are not required.
The copending patent application PCT/EP g6jOl583 (nct yet published) of the present applicant describes a method for forming products such as simulated leather or like products with at leas~
one expanded layer from thermoplastic, thermosetting or elastomer materials, comprising the following stages: forming in a slush-moulding mould a first layer of compact material representing theexposed layer of the finished product, on this firs~ layer forming the second layer of expandable material by further slush-moulding, completing with heat the consolidation of the formed layers by gelling and the expansion of said second layer by suitable means to obtain predetermined thicknesses and shapes in said expanded layer, to the layered material formed in this manner there being coupled a support of rigid material possibly filled with reinforcement fibres, said suitable means for obtaining predetermined thicknesses and shapes of said expanded layer consisting either of a counter-mould or of the actual said support of rigid material.
As explained in the said patent application, the finished products CA 022~738~ l998-l2-04 W O 97/48537 PCTtEP97tO2327 obtained by the method in question are generally appropriate for interior trimmings in particular of motor vehicles, for example for parts such as dash panels, consoles, compartment lids and other similar objects for which an appearance as similar as possible to natural leather is required.
As described in the said patent application, the method in question represents considerable progress in particular compared with the preceding method for obtaining such objects produced by thermoforming calendered sheets possibly laminated with an expanded layer.
In this respect, in this preceding method the presence of stretched parts containing congealed forces gives rise to serious shrinking problems with consequent cracking and breakage under hot conditions, especially in that region which in automobiles is exposed to direct sunlight, such as the upper surface of the dash panel.
The inclination of windscreens at increasing1y acute angles in accordance with the latest preferred styles has aggravated this problem by causing the temperature to which these interior parts of the vehicle are exposed to often exceed 100~ under solar radiation.
The simulated leather obtained by the method of the aforesaid patent application, which essentially uses a slush-moulding method, avoids this defect.
Notwithstanding the substantial progress represented by this patent application, in the practical implementation of the method it has been found that a defect can sometimes arise in the leather CA 022~738~ 1998-12-04 produced by it, due substantially to the circumstance that in said stage involving the control of the thickness and shape of the expanded layer, also known as the surface shaping stage for the expanded layer, a uniform and regular surface cannot always be obtained, so that in the next stage involving adhesion to the support, generally by gluing, discontinuity points or regions can arise between the inner surface of the expanded layer and the support itself, which the layer of glue is unable to compensate.
This can occur at either cavities or protuberances in the surface of the expanded layer, so that voids or humps are consequently created at the expanded layer/support interface, which are inevitably transmitted to the exposed outer surface of the simulated leather.
This means that the aesthetic effect sought is completely ruined, because those cavities and protuberances transmitted from the interior of the layered structure to the exposed outer surface of the simulated leather are immediately visible.
An analogous defect can occur if, instead of being present on the expanded layer surface, the imperfections are present on the rigid support itself, or on both surfaces.
The object of the present invention is mainly to solve this problem.
The present invention therefore essentiaily proposes to improve the method described in patent application PCT/EP 96/01583 of the present applicant.
This object, and other advantages which will be apparent from the ensuing description, are attained according to the invention by a CA 022~738~ 1998-12-04 WO g7/48537 PCT/EP97/02327 method for forming products such as simulated leather or like products with at least one expanded layer from thermoplastic, thermosetting or elastomer materials, comprising the following stages: forming in a slush-moulding mould a first layer of compact material representing the exposed layer of the finished product, on said first layer forming a second layer of expandable material by further slush-moulding, completing with heat the consolidation of said layers by gelling and the expansion of said second layer, to the layered materiai formed in this manner there being coupled a support of rigid material possibly filled with reinforcement fibres, characterised by comprising a stage involving the filling of every possible interspace between said rigid material support and said expanded second layer.
According to one embodiment of the present invention, said stage involving the filling of every possible interspace between the rigid material support and the expanded second layer consists of coupling the rigid material support to said thus formed layered material by applying a layer of expandable adhesive to their interface.
A suitable expandable adhesive is a bicomponent polyurethane. It is possible in any event to apply a layer of expandable adhesive compatible with the materials to be coupled. The expandable material adhesive can be used either as such or together with suitable adhesion promoters.
In a different embodiment of the method of the present invention, said stage involving the filling of every possible interspace between the rigid material support and said expanded second layer CA 022~738~ 1998-12-04 W O 97148537 P~ 57/02327 of the layered material consists of coupling to said thus formed layered material the rigid material support possibly filled with reinforcement fibres predispersed in the material or forming a layer to be inserted into the rigid material, this latter being formed by direct moulding onto the free face of said expanded second layer within a suitable mould, for example by casting or by pressure injection moulding so as not to lose the mechanical properties to the expanded layer.
In this embodiment, once formed, the simulated ieather is placed in an injection or casting mould, the mould profile reproducing that of the finished product, the rigid support hence being moulded onto the leather in the mould prepared in this manner, to give the finished product.
The thermoplastic, thermosetting or elastomer materials suitable for slush-moulding simulated leather or the like can be chosen from a wide range of resins in powder or liquid form.
The second layer of expandable material compri~es expansion agents as azodicarbonamide, sodium bicarbonate, citric acid and others.
Said first layer can be formed of a single colour, or of two or more colours for example by using the methods of patents of the present applicant, namely EP 476,742 or W0 94/12331.
For moulding the rigid support, particularly indicated are expanded or non-expanded rigid or semi-rigid thermosetting materials, such as polyurethanes, polyesters, epoxy resins and the like, possibly reinforced with fillers of glass fibres, carbon fibres, polyaramid fibres or fibres with similar characteristics, possibly forming a layer to be inserted into the material.
In that embodiment of the present invention comprising moulding CA 022~738~ l998-l2-04 W O 97/48537 PCT~EP97/02327 the support directly onto the leather in a mould, particularly indicated are resins liquid at ambient temperature, and hence injectable or castable cold.
The characteristics and advantages of the invention will be more apparent from the practical examples given hereinafter with reference to the accompanying figures. These examples are not to be considered as limitative.
Figure l is a cross-section through coupled materials of a first embodiment of the invention;
Figure 2 is a cross-section through a second embodiment of the invention; and Figure 3 is a cross-section through the finished product obtained by the method of Figure 2.
Figure l shows a cross-section through a product comprising simulated leather consisting of a first layer 1 of thermoplastic material, for example PVC, and a second layer 2 of expanded material, obtained by slush-moulding expandable PVC.
The simulated leather consisting of the layered structure 1 and 2 is produced for example by the method of the aforesaid patent application PCT/EP96/01583 of the present applicant.
As shown in Figure 1, the free face of the expanded second layer 2 comprises irregularities, such as concavities 3, due for example to an executional defect in the shaping stage for this face of the expanded layer during its moulding, for example due to irregularities in the profile of the counter-mould used for this shaplng.
Finally, in Figure 1 the reference numeral 7 indicates a rigid CA 022~738~ 1998-12-04 support, for example of reinforced thermoplastic or thermosetting material, suitable for coupling to the layered structure 1 and 2 by gluing. The figure also indicates by the reference numeral 6 the interspace between the outer face of the expanded layer 2 and the support 7, in which interspace the glue for fixing the support to the layered structure is deposited.
As can be seen, this interspace is not of regular dimensions, but varies considerably due to the aforesaid circumstance of the irregularities in the outer face of the layer 2.
In the embodiment of Figure 1, the interspace 6 is filled with an expandable adhesive, for example a bicomponent polyurethane, which when deposited on the interface between the layer 2 and the support 7 begins to expand to fill every possible interspace between said rigid material support and said expanded second layer 2.
The layer of expandable glue is deposited in the interspace 6 by placing the support and the layered structure in a pressing system, for example between a mould and a counter-moula, able to exert the pressure required for gluing and for containing the expansion of the adhesive, so that this effectively fills every minimum interspace between the layer 2 and the support 7 to achieve the required technical effect.
Figures 2 and 3 show a different embodiment of the method of the invention, in which the simulated leather consisting of the first layer 1 and the expanded layer 2 has been obtained by a slush-moulding method such as that described in the aforesaid patent application PCT/EP/96/01583, but without any shaping operation on CA 022~738~ 1998-12-04 W O 97/48537 PCT~EP97/02327 the free face of the expanded second layer 2, ie without providing any means for controlling the thickness and shape thereof.
In this respect, it can be seen from Figures 2 and 3 that the free face of the expanded layer 2 is of absolutely irregular shape.
The simulated leather obtained in this manner, consisting of the layered structure 1 and 2, is placed within a mould in the form of two half-moulds 8 and 14.
The half-mould 8 is suitably provided with retractable pressure means, consisting for example of pistons 9 slidable within cylinders 10 particularly suitable for compressing undercuts 11 which are typically present in the layered product. The profile of the half-mould 8 hence corresponds exactly to the profile of the finished product. Devices can be provided in this half-mould to maintain the simulated leather in the correct shape, such as holes for the vacuum etc. In the undercut regions 11 the compression systems consisting of the pistons 9 act, these operationally maintaining the product in shape during moulding in these undercut regions.
In contrast, the half-mould 14 is typically a half-mould provided with channels 12 for injecting the plastic material for forming said rigid support, or for use as a casting mould.
Having closed the mould formed from the two half-moulds 8 and 14, there remains defined between the lower face of the half-mould 14 and the free face of the expanded layer 2 an interspace 4 reproducing the shape of the support to be moulded.
Figure 2 shows the forming mould for the rigid support in its closed operating position.
CA 022~738~ 1998-12-04 W O 97/48537 PCT~EP97/02327 Essentially, the procedure comprises initially opening the mould, positioning the layered structure l and 2 on the half-mould 8 with the pistons 9 in their rest position, hence retracted within the cylinders 10, and then operating these latter to assume their compression position shown in Figure 2.
At this point a layer for example of unwoven glass fibre fabric can be located in the interspace 4 remaining between the half-moulds 8 and 14 to reinforce the support to be moulded.
The mould is closed by locating the half-mould 14 in the position shown in Figure 2. The resin, for example a bicomponent thermosetting resin, is injected or cast, and its cross-linking is awaited.
The pistons 9 are again retracted into the rest position within the cylinders 10, the half-mould 14 is raised and the finished 1~ piece is extracted, this being shown in Figure 3, illustrating the finished product composed of a rigid support 13, an expanded intermediate layer 2 and the exposed outer layer 1.
As can be seen in Figure 3, again in this case total filling of every possible interspace between the free face of the layer 2 and the rigid support 13 is achieved, this latter in fact being formed by moulding, necessarily following the pattern of the interface with the expanded layer 2.
As stated heretofore, instead of using as reinforcement a layer of suitable material such as unwoven fabric, a resin for injection or cast moulding can be used, containing a strengthening filler.
As is apparent from the aforegoing examples and the description, it is no longer necessary to operate the method described in the CA 022~738~ 1998-l2-04 W O 97/48537 PCT~EP97/02327 aforesaid PCT patent application such as to obtain a regular and uniform free face of the expanded layer, because the method of the present invention in any event results in total filling of every single interspace which can occur between the rigid support and said face of the expanded layer.
If the expanded product does not require its thickness to be predetermined> then compared with the method of said prior PCT
patent application, that shaping stage involving adjusting and controlling the shape of the free face of the expanded layer may be omitted.
This does not mean that said stage must not in fact be carried out, but merely that special care need not be taken to achieve perfect uniformity of the free face of the expanded layer.
It could in particular be carried out if the method of the present invention is to use an expandable adhesive.
However it would appear superfluous to effect such a shaping stage if the present invention is implemented by the embodiment comprisin~ moulding the rigid support directly onto the expanded l~yer, if predetermined thicknesses of the expanded product are not required.
Claims (9)
1. A method for forming products such as simulated leather or like products with at least one expanded layer from thermoplastic, thermosetting or elastomer materials, comprising the following stages: forming in slush-moulding mould a first layer of compacted material representing the exposed layer of the finished product, on said first layer forming a second layer of expandable material by further slush-moulding, completing with heat the consolidation of said layers by gelling and the expansion of said second layer, to the layered material formed in this manner there being coupled a support of rigid material, characterised by comprising a stage involving the filling of every possible interspace between said rigid material support and said expanded second layer.
2. A method as claimed in claim 1, characterised in that said stage involving the filling of every possible interspace between said rigid material support and said expanded second layer consists of coupling said rigid material support to said thus formed layered material by applying an expandable adhesive to their interface.
3. A method as claimed in claim 2, characterised in that said expandable adhesive is a bicomponent polyurethane.
4. A method as claimed in claim 1, characterised in that said stage involving the filling of every possible interspace between said rigid material support and said expanded second layer consists of coupling said rigid material support to said thus formed layered material by moulding said support directly onto the free face of said expanded second layer within a suitable mould.
5. A method as claimed in claim 4, characterised in that said rigid material support is formed by casting or injection moulding onto said free face of said expanded second layer within said mould.
6. A method as claimed in claim 4, characterised in that said rigid support moulding is effected with a thermoplastic, thermosetting or elastomer resin reinforced with a filler.
7. A method as claimed in claim 4, characterised in that said rigid support moulding is effected by positioning a layer of suitable reinforcement material on the free face of said expanded second layer and then effecting said moulding with a suitable resin.
8. A method as claimed in claim 4, characterised in that for said rigid support moulding a pair of half-moulds are used, of which that in which the layered leather is to be positioned is provided with movable means enabling the leather to be maintained in its correct form, particularly in undercut areas.
9. A method as claimed in claim 1, characterised in that said stage involving completing with heat the consolidation of the formed layers by gelling and the expansion of said second layer is carried out with suitable means for obtaining predetermined thicknesses and shapes of said expanded layer.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| IT96MI001247A IT1284038B1 (en) | 1996-06-20 | 1996-06-20 | PERFECTED PROCESS FOR THE FORMING OF PRODUCTS SUCH AS FAKE LEATHER OR SIMILAR FROM THERMOPLASTIC, THERMOSET OR |
| ITMI96A001247 | 1996-06-20 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2257385A1 true CA2257385A1 (en) | 1997-12-24 |
Family
ID=11374450
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002257385A Abandoned CA2257385A1 (en) | 1996-06-20 | 1997-05-02 | Method for forming products such as simulated leather or like products |
Country Status (19)
| Country | Link |
|---|---|
| US (1) | US6190587B1 (en) |
| EP (1) | EP0907477B1 (en) |
| AT (1) | ATE226879T1 (en) |
| AU (1) | AU2893397A (en) |
| BG (1) | BG64084B1 (en) |
| BR (1) | BR9709909A (en) |
| CA (1) | CA2257385A1 (en) |
| CZ (1) | CZ293370B6 (en) |
| DE (1) | DE69716734T2 (en) |
| DK (1) | DK0907477T3 (en) |
| ES (1) | ES2185014T3 (en) |
| HU (1) | HU223428B1 (en) |
| IT (1) | IT1284038B1 (en) |
| NO (1) | NO314659B1 (en) |
| PL (1) | PL182640B1 (en) |
| PT (1) | PT907477E (en) |
| SK (1) | SK284050B6 (en) |
| TR (1) | TR199802653T2 (en) |
| WO (1) | WO1997048537A1 (en) |
Families Citing this family (12)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE10022644A1 (en) * | 2000-04-28 | 2001-10-31 | Volkswagen Ag | Twin slush skin molding process for producing vehicle instrument panels, permits variation of process parameters during all molding stages |
| EP1149677A3 (en) * | 2000-04-28 | 2001-12-12 | Volkswagen AG | Method and apparatus for making a two-layer slush skin |
| DE10027201A1 (en) * | 2000-05-23 | 2001-11-29 | Volkswagen Ag | Laboratory apparatus for investigating hot-coating behavior of plastic powders, comprises detachable powder box held to swinging hot plate |
| DE10105770A1 (en) * | 2001-02-08 | 2002-08-14 | Volkswagen Ag | Twin slush skin molding process, involves extraction of trapped air and gas from an expandable layer through a porous male punch wall |
| DE10107970B4 (en) | 2001-02-20 | 2018-06-21 | Volkswagen Ag | Process for producing a composite fabric and composite material |
| DE10234375A1 (en) * | 2002-07-27 | 2004-02-05 | Volkswagen Ag | Plastic slush skin manufacture involves molding a given powder amount in a heated cavity formed by a tool and an opposing shell to create a visible skin and compressed rear foam layer |
| KR20060095936A (en) * | 2003-07-11 | 2006-09-05 | 콜린스 앤 아이크만 프로덕츠 콤파니. | Cloth texture cover material |
| DE102007006691B4 (en) | 2007-02-10 | 2019-06-27 | Volkswagen Ag | Method for producing contours on a Galvanoform determining the outer contour of Slush skins |
| US7976749B2 (en) | 2007-05-24 | 2011-07-12 | Basf Aktiengesellschaft | Injection process for making a moulding completely recyclable, multilayered article |
| DE102008013332A1 (en) * | 2007-09-14 | 2009-04-02 | Johnson Controls Interiors Gmbh & Co. Kg | Interior fitting for a motor vehicle and method for producing an interior trim part for a motor vehicle |
| EP2543488A1 (en) | 2011-07-06 | 2013-01-09 | SMP Deutschland GmbH | Method for producing a plastic skin in slush moulding method using a temperable galvanisation mould |
| KR101721319B1 (en) | 2015-07-03 | 2017-03-29 | 피 그룹 에스.알.엘. | An Injection Process for Making a Moulding Completely Recyclable, Multi-layered Article |
Family Cites Families (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| NL242484A (en) * | 1958-08-20 | |||
| US4664864A (en) * | 1983-06-03 | 1987-05-12 | Ex-Cell-O Corporation | Mold loading method and apparatus |
| JPS61162328A (en) * | 1985-01-11 | 1986-07-23 | Toyota Motor Corp | Molding method of skin in integral foaming |
| JPH049143Y2 (en) * | 1986-04-11 | 1992-03-06 | ||
| JPH0686177B2 (en) * | 1986-09-29 | 1994-11-02 | 河西工業株式会社 | Interior parts for automobiles |
| FR2605263B1 (en) * | 1986-10-16 | 1989-04-14 | Peugeot | METHOD FOR MANUFACTURING A TRIM PANEL AND PANEL OBTAINED THEREBY |
| US4878827A (en) * | 1988-08-22 | 1989-11-07 | Davidson Textron Inc. | Plastic shell for foam moldings |
| CA1322565C (en) * | 1988-09-27 | 1993-09-28 | Milo L. Rohrlach | Vehicle inner panel |
| JPH0784157B2 (en) * | 1989-01-26 | 1995-09-13 | 三菱自動車工業株式会社 | Interior parts for automobiles and molding method thereof |
| JPH0617076B2 (en) * | 1989-03-08 | 1994-03-09 | 小島プレス工業株式会社 | Method of joining slush molded members |
| US5395578A (en) * | 1990-09-17 | 1995-03-07 | Industrie Ilpea S.P.A. | Method for slush molding articles, of two or more colors from thermoplastic, thermosetting or elastomeric resins in powder form |
| IT1245843B (en) * | 1990-09-17 | 1994-10-25 | Ilpea Ind Spa | PROCESS FOR MOLD FORMING BY WASTE REFUSED CASTING, SUCH AS FAKE SKIN OR SIMILAR, WITH TWO OR MORE COLORS, FROM THERMOPLASTIC RESINS, THERMO-HARDENERS OR ELASTOMERS IN POWDER, MANUFACTURED SO OBTAINED AND PROCESSING EQUIPMENT. |
| US5328651A (en) * | 1993-03-05 | 1994-07-12 | Davidson Textron Inc. | Method for manufacturing an automobile trim component by blow molding and injection molding |
| US5580501A (en) * | 1994-11-07 | 1996-12-03 | Gallagher; Michael J. | Method of manufacturing an interior trim panel using polyurethane powder |
| IT1273580B (en) * | 1995-04-19 | 1997-07-08 | Ilpea Ind Spa | PROCESS FOR THE FORMATION BY REFUSAL CASTING OF ARTICLES SUCH AS FAKE LEATHER OR SIMILAR THERMO-HARD THERMOPLASTIC MATERIALS AND ELASTOMERS HAVING AT LEAST ONE EXPANDED LAYER WITH CONTROLLED AND PRE-DETERMINED THICKNESSES |
-
1996
- 1996-06-20 IT IT96MI001247A patent/IT1284038B1/en active IP Right Grant
-
1997
- 1997-05-02 ES ES97922996T patent/ES2185014T3/en not_active Expired - Lifetime
- 1997-05-02 WO PCT/EP1997/002327 patent/WO1997048537A1/en active IP Right Grant
- 1997-05-02 DK DK97922996T patent/DK0907477T3/en active
- 1997-05-02 TR TR1998/02653T patent/TR199802653T2/en unknown
- 1997-05-02 AT AT97922996T patent/ATE226879T1/en not_active IP Right Cessation
- 1997-05-02 PT PT97922996T patent/PT907477E/en unknown
- 1997-05-02 HU HU9903038A patent/HU223428B1/en not_active IP Right Cessation
- 1997-05-02 BR BR9709909A patent/BR9709909A/en not_active IP Right Cessation
- 1997-05-02 AU AU28933/97A patent/AU2893397A/en not_active Abandoned
- 1997-05-02 DE DE69716734T patent/DE69716734T2/en not_active Expired - Lifetime
- 1997-05-02 EP EP97922996A patent/EP0907477B1/en not_active Expired - Lifetime
- 1997-05-02 CA CA002257385A patent/CA2257385A1/en not_active Abandoned
- 1997-05-02 PL PL97330477A patent/PL182640B1/en unknown
- 1997-05-02 US US09/147,408 patent/US6190587B1/en not_active Expired - Fee Related
- 1997-05-02 SK SK1747-98A patent/SK284050B6/en unknown
- 1997-05-02 CZ CZ19984160A patent/CZ293370B6/en not_active IP Right Cessation
-
1998
- 1998-12-04 BG BG102989A patent/BG64084B1/en unknown
- 1998-12-15 NO NO19985873A patent/NO314659B1/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| EP0907477A1 (en) | 1999-04-14 |
| US6190587B1 (en) | 2001-02-20 |
| HUP9903038A2 (en) | 2000-01-28 |
| SK174798A3 (en) | 1999-05-07 |
| PL182640B1 (en) | 2002-02-28 |
| ITMI961247A0 (en) | 1996-06-20 |
| DE69716734D1 (en) | 2002-12-05 |
| HUP9903038A3 (en) | 2000-07-28 |
| ITMI961247A1 (en) | 1997-12-20 |
| BG102989A (en) | 1999-08-31 |
| DE69716734T2 (en) | 2004-03-11 |
| BR9709909A (en) | 1999-08-10 |
| TR199802653T2 (en) | 1999-03-22 |
| NO314659B1 (en) | 2003-04-28 |
| PL330477A1 (en) | 1999-05-24 |
| WO1997048537A1 (en) | 1997-12-24 |
| HU223428B1 (en) | 2004-07-28 |
| BG64084B1 (en) | 2003-12-31 |
| CZ416098A3 (en) | 1999-04-14 |
| AU2893397A (en) | 1998-01-07 |
| IT1284038B1 (en) | 1998-05-08 |
| SK284050B6 (en) | 2004-08-03 |
| NO985873D0 (en) | 1998-12-15 |
| DK0907477T3 (en) | 2003-03-03 |
| NO985873L (en) | 1998-12-15 |
| CZ293370B6 (en) | 2004-04-14 |
| PT907477E (en) | 2003-03-31 |
| EP0907477B1 (en) | 2002-10-30 |
| ATE226879T1 (en) | 2002-11-15 |
| ES2185014T3 (en) | 2003-04-16 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued |