GB1570303A - Plastics-based laminated material - Google Patents

Plastics-based laminated material Download PDF

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Publication number
GB1570303A
GB1570303A GB27790/76A GB2779076A GB1570303A GB 1570303 A GB1570303 A GB 1570303A GB 27790/76 A GB27790/76 A GB 27790/76A GB 2779076 A GB2779076 A GB 2779076A GB 1570303 A GB1570303 A GB 1570303A
Authority
GB
United Kingdom
Prior art keywords
web
plastics
cloth
filler
textile
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.)
Expired
Application number
GB27790/76A
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.)
Ford Motor Co Ltd
Ford Motor Co
Original Assignee
Ford Motor Co Ltd
Ford Motor 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 Ford Motor Co Ltd, Ford Motor Co filed Critical Ford Motor Co Ltd
Priority to GB27790/76A priority Critical patent/GB1570303A/en
Priority to DE2727285A priority patent/DE2727285B2/en
Publication of GB1570303A publication Critical patent/GB1570303A/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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • 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
    • B32B2323/00—Polyalkenes
    • B32B2323/04—Polyethylene
    • 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
    • B32B2323/00—Polyalkenes
    • B32B2323/10—Polypropylene
    • 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
    • B32B2325/00—Polymers of vinyl-aromatic compounds, e.g. polystyrene
    • 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
    • B32B2327/00—Polyvinylhalogenides
    • B32B2327/06—PVC, i.e. polyvinylchloride
    • 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
    • B32B2355/00—Specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of index codes B32B2323/00 - B32B2333/00
    • B32B2355/02—ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
    • 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
    • B32B2377/00—Polyamides

Description

(54) PLASTICS-BASED LAMINATED MATERIAL (71) We FORD MOTOR COMPANY LIM ITED, of Eagle Way, Brentwood, Essex CM13 3BW, a British Company, do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- This invention relates to a laminated material of particular utility in the manufacture of vehicle trim panels.
Automotive trim panels in common use comprise a support, for example of plastics, hardboard or metal, and a decorative surface of paint or of plastics film or cloth secured to the support as by an adhesive or dielectric bonding.
An object of this invention is to provide a material which may be used in the manufacture of trim panels and other products with a reduction in the number of manu facturing steps as compared with the methods quoted above.
The invention provides a method of manufacturing a laminated sheet material, comprising extruding a web from a mixture of a plastics material and an inert particulate filler, the filler forming between 35% and 75O/o by weight of the total and the filler particles having a particle size in the range of 0 5 to 25 microns, applying a textile web to one face of the plastics web while the latter is still in a softened state, pressing the webs together, and cooling the webs to form a self-supporting laminate capable of being moulded by the application of heat and pressure.
The invention will be described in greater detail by way of example, with reference to the accompanying drawing, which is a schematic side view of apparatus for use in carrying out the invention.
Thermoplastic material is extruded from an extruder 10 through an extrusion die 12 to form a web 14. A web 16 of cloth is fed from a reel 18 onto the surface of the web 14 at a position where the latter is still in a softened state. The webs 14, 16 are then passed together through sizing rolls 22, that is hardfaced rolls (e.g. of steel) operating with a predetermined separation in the nip between the rolls, which force the two together while cooling the plastics web 14, to form a laminate in which the cloth is bonded to the plastics web and forms a decorative finish on one side thereof. An infra-red heater 20 may be used to raise the temperature of the plastics web 14 before the cloth is applied, to improve adhesion.In an alternative (not shown), the two webs may be fed first to a heated roll which contacts the plastics web 14 only, and then between sizing rolls; the initial heated roll also improves adhesion.
The cloth suitably has a melting point equal to or greater than the temperature of the extruded web at the point of contact. It is preferably a knitted or woven fabric capable of stretching in one or both directions.
Suitable fabrics are of polyamide 6, polyamide 6 : 6, and cotton.
The extruded plastics material may be a crystalline polymer such as polyethylene, polypropylene (homopolymer or copolymer), or a polyamide, or an amorphous polymer such as an acrylonitrile-butadiene-styrene terpolymer, polyvinyl chloride ar polystyrene.
In accordance with the invention, the extruded material contains an inert filler of particles having a particle size of 0.5 to 25 microns, such as limestone, chalk, glass fibre, mica, or talc, the proportion of filler being between 35% and 75% by weight. The filler acts to hold the plastics material in a controllable sheet form while its temperature is elevated in the region of the extruder and sizing rolls. A mixture of filler and polymer powder may be extruded from a twin screw or planetary screw compounder extruder.
Alternatively, the mixture may be extruded to form granules and subsequently reextruded to form the web 14.
A typical example of the material is polypropylene copolymer filled with 50% to 65% by weight, and preferably 60%, of limestone and bonded to a knitted brushed nylon fabric. The limestone is in the form of particles with a particle size between 1 and 7 microns.
It is also possible to use as the cloth web a sandwich having a laminated foam interlayer, e.g. two layers of polyamide 6 bonded to either side of polyether foam, or a composite cloth/plastics sheet arranged with the cloth adjacent the extruded plastics web, e.g. PVC sheet backed by cloth such as knitted polyamide.
Pieces of the material thus produced may be formed into a shaped product such as a vehicle trim panel in a further operation, by vacuum forming after heating above the crystalline point (or melting point, if amorphous) of the plastics web, or by press forming after heating to a temperature sufficient for forming without splitting of the plastics web.
WHAT WE CLAIM IS: 1. A method of manufacturing a laminated sheet material, comprising extruding a web from a mixture of plastics material and an inert particulate filler, the filler forming between 35% and 75% by weight of the total and the filler particles having a particle size in the range of 0.5 to 25 microns, applying a textile web to one face of the plastics web while the latter is still in a softened state, pressing the webs together, and cooling the webs to form a self-supporting laminate capable of being moulded by the application of heat and pressure.
2. A method according to claim 2, in which the plastics web is heated before the textile web is applied, to improve adhesion.
3. A method according to claim 2, in which said one face of the plastics web is heated by radiant heat.
4. A method according to claim 2, in which the plastics web is heated by contact with a heated roll.
5. A method according to any preceding claim, in which the cloth has a melting point equal to or greater than the temperature of the plastics web at the point of contact.
6. A method according to any preceding claim, in which the filler forms 50% to 65% by weight of the extrusion mixture.
7. A method according to any preceding claim, in which the filler has a particle size between 1 and 7 microns.
8. A method according to any preceding claim, in which the filler is limestone, chalk, glass fibre, talc, or mica.
9. A method according to any preceding claim, in which the webs are pressed together and cooled by being passed through sizing rolls.
10. A method according to any preceding claim, in which the extruded plastics material is polyethylene, polypropylene, polyamide an acrylonitrile-butadiene-styrene terpolymer, polyvinyl chloride or ABS, polystyrene.
11. A method according to any preceding claim, in which the textile web is a knitted or woven fabric capable of stretching in one or both directions.
12. A method according to any preceding claim, in which the textile web is of polyamide or cotton.
13. A method according to any preceding claim, in which the textile web comprises two layers of textile material bonded to either sid of a foam sheet.
14. A method according to any of claims 1 to 12, in which the textile web is formed by a cloth-backed plastics sheet.
15. A method of manufacturing a laminated sheet material substantially as herein described with reference to the drawing.
16. A laminated sheet material produced by the method of any preceding claim.
17. A method of forming a shaped article with a decorative surface, comprising shaping the laminated sheet material of claim 13 by vacuum forming or press forming.
18. A shaped article produced by the method of claim 17.
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (18)

**WARNING** start of CLMS field may overlap end of DESC **. by weight, and preferably 60%, of limestone and bonded to a knitted brushed nylon fabric. The limestone is in the form of particles with a particle size between 1 and 7 microns. It is also possible to use as the cloth web a sandwich having a laminated foam interlayer, e.g. two layers of polyamide 6 bonded to either side of polyether foam, or a composite cloth/plastics sheet arranged with the cloth adjacent the extruded plastics web, e.g. PVC sheet backed by cloth such as knitted polyamide. Pieces of the material thus produced may be formed into a shaped product such as a vehicle trim panel in a further operation, by vacuum forming after heating above the crystalline point (or melting point, if amorphous) of the plastics web, or by press forming after heating to a temperature sufficient for forming without splitting of the plastics web. WHAT WE CLAIM IS:
1. A method of manufacturing a laminated sheet material, comprising extruding a web from a mixture of plastics material and an inert particulate filler, the filler forming between 35% and 75% by weight of the total and the filler particles having a particle size in the range of 0.5 to 25 microns, applying a textile web to one face of the plastics web while the latter is still in a softened state, pressing the webs together, and cooling the webs to form a self-supporting laminate capable of being moulded by the application of heat and pressure.
2. A method according to claim 2, in which the plastics web is heated before the textile web is applied, to improve adhesion.
3. A method according to claim 2, in which said one face of the plastics web is heated by radiant heat.
4. A method according to claim 2, in which the plastics web is heated by contact with a heated roll.
5. A method according to any preceding claim, in which the cloth has a melting point equal to or greater than the temperature of the plastics web at the point of contact.
6. A method according to any preceding claim, in which the filler forms 50% to 65% by weight of the extrusion mixture.
7. A method according to any preceding claim, in which the filler has a particle size between 1 and 7 microns.
8. A method according to any preceding claim, in which the filler is limestone, chalk, glass fibre, talc, or mica.
9. A method according to any preceding claim, in which the webs are pressed together and cooled by being passed through sizing rolls.
10. A method according to any preceding claim, in which the extruded plastics material is polyethylene, polypropylene, polyamide an acrylonitrile-butadiene-styrene terpolymer, polyvinyl chloride or ABS, polystyrene.
11. A method according to any preceding claim, in which the textile web is a knitted or woven fabric capable of stretching in one or both directions.
12. A method according to any preceding claim, in which the textile web is of polyamide or cotton.
13. A method according to any preceding claim, in which the textile web comprises two layers of textile material bonded to either sid of a foam sheet.
14. A method according to any of claims 1 to 12, in which the textile web is formed by a cloth-backed plastics sheet.
15. A method of manufacturing a laminated sheet material substantially as herein described with reference to the drawing.
16. A laminated sheet material produced by the method of any preceding claim.
17. A method of forming a shaped article with a decorative surface, comprising shaping the laminated sheet material of claim 13 by vacuum forming or press forming.
18. A shaped article produced by the method of claim 17.
GB27790/76A 1976-07-03 1976-07-03 Plastics-based laminated material Expired GB1570303A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB27790/76A GB1570303A (en) 1976-07-03 1976-07-03 Plastics-based laminated material
DE2727285A DE2727285B2 (en) 1976-07-03 1977-06-16 Process for the production of a three-dimensional, multilayer molded body

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB27790/76A GB1570303A (en) 1976-07-03 1976-07-03 Plastics-based laminated material

Publications (1)

Publication Number Publication Date
GB1570303A true GB1570303A (en) 1980-06-25

Family

ID=10265355

Family Applications (1)

Application Number Title Priority Date Filing Date
GB27790/76A Expired GB1570303A (en) 1976-07-03 1976-07-03 Plastics-based laminated material

Country Status (2)

Country Link
DE (1) DE2727285B2 (en)
GB (1) GB1570303A (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9051683B2 (en) 1997-02-28 2015-06-09 Columbia Insurance Company Carpet, carpet backings and methods
US9376769B2 (en) 1997-02-28 2016-06-28 Columbia Insurance Company Homogeneously branched ethylene polymer carpet backsizing compositions

Families Citing this family (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2965694D1 (en) * 1978-12-29 1983-07-21 Ici Plc Laminates of cloth or other sheet material and filled crystalline polypropylenes and a method for making them
DE3231393C2 (en) * 1982-08-24 1985-04-18 I.G. Bauerhin GmbH elektro-technische Fabrik, 6466 Gründau Method for lamination or for firmly adhering free surfaces, molded parts made of thermoplastic material with textile material or the like.
DE3402666A1 (en) * 1984-01-26 1985-08-08 Vsesojuznyj naučno-issledovatel'skij i proektnyj institut "Teploproekt", Moskva Process for producing a multi-layer material and apparatus for carrying out the same
US5076870A (en) * 1989-07-19 1991-12-31 Sanborn Kenneth R Carpet and method of attachment
US5282915A (en) * 1991-11-06 1994-02-01 Westlake Jr Edward F Method and apparatus for producing continuous plastic-fabric bicomponent lamina
BE1007353A3 (en) * 1993-07-20 1995-05-23 Bercopa Sa Method for manufacturing carpet
AU6955094A (en) * 1993-01-08 1994-08-15 Bercopa S.A. Method for manufacturing carpets
DE4313911A1 (en) * 1993-04-28 1994-11-03 Naeher Georg Gmbh Shaped laminated body, in particular interior lining part for motor vehicles, and method and device for its production
DE4313910A1 (en) * 1993-04-28 1994-11-03 Naeher Georg Gmbh Shaped laminated body, in particular interior lining part for motor vehicles and method for its production
EP0747213B1 (en) * 1995-06-07 2002-10-16 G.O.R. Applicazioni Speciali S.p.A. Composite panel of plastic material, and process and device for its fabrication

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9051683B2 (en) 1997-02-28 2015-06-09 Columbia Insurance Company Carpet, carpet backings and methods
US9376769B2 (en) 1997-02-28 2016-06-28 Columbia Insurance Company Homogeneously branched ethylene polymer carpet backsizing compositions

Also Published As

Publication number Publication date
DE2727285A1 (en) 1978-01-12
DE2727285B2 (en) 1979-09-27

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Legal Events

Date Code Title Description
PS Patent sealed
746 Register noted 'licences of right' (sect. 46/1977)
PCNP Patent ceased through non-payment of renewal fee