GB2123744A - Improvements in and relating to the moulding of materials - Google Patents

Improvements in and relating to the moulding of materials Download PDF

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Publication number
GB2123744A
GB2123744A GB08220323A GB8220323A GB2123744A GB 2123744 A GB2123744 A GB 2123744A GB 08220323 A GB08220323 A GB 08220323A GB 8220323 A GB8220323 A GB 8220323A GB 2123744 A GB2123744 A GB 2123744A
Authority
GB
United Kingdom
Prior art keywords
outer layers
fluted
mouldable
mouldable material
corrugated layer
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
GB08220323A
Other versions
GB2123744B (en
Inventor
Robert Arnold Sebelin
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.)
FABCO IND Ltd
Original Assignee
FABCO IND Ltd
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 FABCO IND Ltd filed Critical FABCO IND Ltd
Priority to GB08220323A priority Critical patent/GB2123744B/en
Publication of GB2123744A publication Critical patent/GB2123744A/en
Application granted granted Critical
Publication of GB2123744B publication Critical patent/GB2123744B/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
    • 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
    • B32B3/26—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 a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—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 a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D24/00—Producing articles with hollow walls
    • B29D24/002—Producing articles with hollow walls formed with structures, e.g. cores placed between two plates or sheets, e.g. partially filled
    • 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
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard 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
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/08—Corrugated paper or cardboard
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30—Multi-ply
    • D21H27/40—Multi-ply at least one of the sheets being non-planar, e.g. crêped
    • 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
    • B29K2711/00—Use of natural products or their composites, not provided for in groups B29K2601/00 - B29K2709/00, for preformed parts, e.g. for inserts
    • B29K2711/12—Paper, e.g. cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/028—Paper 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
    • B32B2317/00—Animal or vegetable based
    • B32B2317/12—Paper, e.g. cardboard
    • B32B2317/127—Corrugated cardboard

Landscapes

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

Abstract

A mouldable material 1 includes at least two spaced apart outer layers 2, 4 of material which are impregnated with a thermosetting compound. At least one intermediate fluted or corrugated layer 3 of material is located between the outer layers 2, 4. Securing or bonding material 5 is provided between the fluted or corrugated layer 3 and each outer spaced layer 2, 4. Temperature is applied to said layers 2, 4 and 3 to secure or bond together said layers to form a mouldable material. The invention also provides for a method of forming a moulded article from the mouldable material, wherein the mouldable material 1 is subjected to pressure and heat sufficient to mould the article and activate the thermosetting compound. <IMAGE>

Description

SPECIFICATION Improvements in and relating to the moulding of materials This invention relates to a method of moulding materials and to materials for use in such mouldings, and to articles moulded from said materials and method.
The invention has particular, although not exclusive, application in the preparation and moulding of material for use in linings, and in particular lining motor vehicles.
Up until this time, the lining of motor vehicles and in particular the preparation of what is known as "head linings" has been time consuming in so far as material and labour is concerned. In addition, methods employed in the preparation of materials for use in such head linings have been expensive from both a labour and material point of view. Such methods have also been said to contribute to pollution, due to emission resulting from periods required for curing materials such as phenols.
The mounting and attachment of lining materials (in particular in motor vehicles), resulting from methods used up until this time, has in a number of cases also been time consuming and difficult.
It is an object of this invention to go some way towards overcoming these problems and to at least provide the public with a useful choice.
While the invention is described with reference to the preparation and moulding of linings for particular use in motor vehicles, it should be appreciated that the method and materials described and claimed are not limited in their use but have other uses.
According to one aspect of this invention there is provided a mouldable material including at least two spaced apart outer layers of material impregnated with thermosetting compound; at least one intermediate flute or corrugated layer of material being provided between said outer layers; securing or bonding material being provided between inner surfaces of said outer layers and adjacent surfaces of said fluted or corrugated layer(s).
According to a further aspect of this invention, there is provided a method of forming a mouldable material including: (a) locating at least one fluted or corrugated layer of material between at least two outer layers of material impregnated with thermosetting compounds, and (b) locating or positioning, securing or bonding material between inner surfaces of said outer layers and adjacent surfaces of said fluted or corrugated layer(s); (c) applying heat thereto at a predetermined temperature to cause said securing or bonding material to secure, bond or fuse together said layers, such as to form said mouldable material.
This invention will now be described by way of example only and with reference to the accompanying drawings, wherein: Figure 1: is an exploded view of a section of mouldable material according to one form of the invention.
Figure 2: is a sectional view of a section of mouldable material according to one form of the invention.
The present invention sets out to provide a light, yet strong, effective and rigid construction capable of being used for example for lining motor vehicles, such as in what is known and termed "head lining".
The mouldable material 1 is formed from at least two spaced apart sheets 2, 4 of suitable material such as for example or cardboard, which are impregnated with a bonding or adhesive material, such as known and herein term "thermosetting compounds".
Located between two such outer layers 2 of material is located and provided at least one layer 3 of a corrugated or fluted material having a generally fluted or corrugated contour or valleys and peaks of a generally rounded formation.
The fluted or corrugated material is preferably constructed of a suitable paper or cardboard.
Other suitable materials can however be used.
Between and intermediate inner surfaces or faces 4a of the outer layers and adjacent faces or surfaces 3a of the fluted or corrugated layer of material, is provided a suitable securing or bonding material 5 which serves to bond and secure together, the layers of material, so as to form the mouldable material of the present invention.
In the preferred form of the invention at least one layer of thin plastic sheet or film is provided which runs over the corrugations of the fluted or corrugated layer 3 of material and is sandwiched between these and the inner surfaces 2a of an outer layer 2 of material, on each side. This is shown in the accompanying drawings.
If desired, more than one intermediate fluted or corrugated layer 3 of material may be provided.
Additionally, and if desired, more than one layer of film 5 or plastic material can be provided.
Alternatively, a suitable securing, bonding, or adhesive agent can be applied to the inner surfaces 4a of the outer layers of material 2, 4 and/or the adjacent surfaces 3a of the fluted or corrugated layer 3, so that the layers can be secured together. Preferably, any such securing, bonding or adhesive agent used, would be heat responsive. That is to say, it would be activated upon the application of heat.
In order to bond or secure the layers of material 2 and 3 together, to form the mouldable material 1 of the present invention, heat is applied to the combined layers, such as in a suitable known press or mould, the heat being applied for a predetermined period of time and at a sufficient temperature to melt or fuse the plastic film 5 to such an extent as to cause it to secure together and to thus bond and secure together the outer layers of material 2 and the at least one inner fluted or corrugated layer of material 3.
The heat applied is sufficient to cause the securing or bonding of the layers together, but not sufficient to activate any thermosetting compound impregnated in the outer layers 2 of material.
The outer layers of material 2 are formed or provided with a plurality of spaced apart holes 6 passing therethrough (herein referred to as "needling") which provides a plurality of holes 6 passing through the outer layers 2 and therefore forms venting or ventilation from within the mouldable material 1. As will be appreciated from the description hereinafter, application of heat or mould a mouldable article into a desired or predetermined shape or configuration, can generate fumes and emissions from the heat applied to the component parts and thermosetting compounds, which are thereby vented from the mouldable material 1 and the article formed from the mouldable material, by the holes 6.
The use of plastic film or sheet 5 also has advantages, being film or sheet 5 covering both sides of the fluted or corrugated layer 3, which serves as a moisture barrier.
Following the formation of the moulded material 1 , as generally described above, the mouldable material 1 is able to be used for the formation of an article of a predetermined shape or configuration.
In forming the head lining of a motor vehicle, the shape and configuration will depend very much on the motor vehicle to which the lining is to be attached. Likewise the size will depend very much upon the vehicle involved. If the mouldable material 1 is to be used for other uses, then as will be apparent, the size, shape and configuration will depend upon the use to which the mouldable material is to be put.
For the formation of a head lining or moulded article of a desired shape and configuration, a suitable mould or die is provided, the mould or die being of the desired shape and configuration. The mouldable material 1 is placed in the die and predetermined pressure and temperature are applied to the mouldable material for a predetermined period of time.
The pressure and heat cause the mouldable material to form into a predetermined shape or configuration, corresponding substantially to the mould or die.
It has been found that the use of the fluted or corrugated intermediate layer(s) 3, in the mouldable material 1, serves to permit the material to be bent or moulded into a desired shape or configuration in a more straight forward and efficient manner, especially having regard to the flexible or bendable properties of the fluted or corrugated intemediate layer 3.
The application of heat as well as pressure, during the formation of the moulded article, is such as to activate the thermosetting compound, impregnated into the thermosetting compound, and as the heat and pressure causes the mouldable material to be formed into the desired shape and configuration, the thermosetting compound is activated by the heat.
Once the predetermined period of time for application of heat and pressure has expired, the application of pressure and heat ceases and the thermosetting compound sets in the moulded shape and configuration, thereby reinforcing the moulded article in its moulded shape and configuration and assisting in maintaining it in such a desired and moulded shape and configuration.
The amount of pressure and degree of heat varies from article to article, depending upon the thickness of material and depending also upon prevailing temperatures, in that it will be appreciated that higher temperatures are required in colder climates or in factories or work areas of low humidity. In comparison however, in areas of high humidity or heat, lesser temperatures are required for the formation of the moulded articles.
The pressure however must be sufficient to result in the mouldable material being moulded and formed into the desired shape and configuration, aided by the flexible nature of the fluted or corrugated intermediate layer(s) 3. The temperature must be such as to assist in the moulding, and to activate the thermosetting compound such that it assists in the moulding of the material, so that when setting or curing it is able to set such as to secure or bond the mouldable material into an article of the predetermined shape and configuration.
The temperature applied during the moulding process will however usually be between about 1 350C and 1 380C. This may however vary, as will pressure times, for the reasons set out above. In addition, it should be appreciated that the moulding may take place at the same time as some other part of a process. For example, a covering such as a vinyl covering may be added to one side of the article at the time of moulding.
Alternatively, some additional material or padding may be added to or moulded into the article (for example the head lining) at the time of moulding.
These such addition or adjuncts to the process may well affect the overall time, pressures and temperatures.
The leading side of the moulded article, for example that side that is to be seen in use, can be formally finished, by surface coatings, or can have attached thereto a suitable vinyl coating, which can be attached either before, during (as referred to above) or after the moulding process. It can be attached such as by bonding, adhesive, heat sealing, pressing stapling or the like.
It should be appreciated that modifications and improvements may be made to this invention without departing from the scope or spirit thereof.

Claims (14)

1. A mouldable material including at least two spaced apart outer layers of material impregnated with thermosetting compound; at least one intermediate fluted or corrugated layer of material being provided betwen said outer layers; securing or bonding material being provided between inner surfaces of said outer layes and adjacent surfaces of said fluted or corrugated layer(s).
2. A mouldable material as claimed in claim 1, wherein the outer layers are formed of impregnated paper or cardboard.
3. A mouldable material as claimed in claim 1 or claim 2, wherein plastic film or sheet is provided between said inner surfaces of outer layers and adjacent surfaces of said fluted or corrugated layer(s).
4. A mouldable material as claimed in any one of the preceding claims, wherein a predetermined temperature has been applied for a predetermined period of time, to cause said securing or bonding material to fuse and secure and bond together, said inner fluted or corrugated layer(s) of material and said outer layers of said impregnated material.
5. A mouldable material as claimed in any one of the preceding claims, wherein the outer layers of material are formed or provided with needling in the form of a plurality of spaced apart holes, passing through said outer layers.
6. A mouldable material as claimed in any one of the preceding claims wherein at least one outer layer of material is provided on an outer or leading side thereof, with a surface coating.
7. A method of forming a mouldable material, including: (a) locating at least one fluted or corrugated layer of material between at least two outer layers of material each impregnated with thermosetting compound, and (b) locating or positioning securing or bonding material between inner surfaces of said outer layers and adjacent surfaces of said fluted or corrugated layer(s); (c) applying temperature to said layers, such as to secure or bond together said layers to form said mouldable material.
8. A method as claimed in claim 7 wherein the temperature is sufficient to activate said securing or bonding material but insufficient to activate said thermosetting compound.
9. A method as claimed in claim 7 or claim 8 wherein the outer layers are needled, to provide or form a plurality of spaced apart holes therein.
10. A method as claimed in any one of claims 7, 8 or 9, including locating or positioning plastic sheet or film between the inner surface of each outer layer of material and the adjacent surfaces of said fluted or corrugated layer(s).
11. A method of forming a moulded article from a mouldable material as claimed in any one of the preceding claim 1 through 6, including subjecting said mouldable material to pressure and heat.
12. A method as claimed in claim 11, wherein heat is applied at a temperature sufficient to activate said thermosetting compound.
13. A method as claimed in claim 11 or claim 12 wherein after application of heat and pressure, the moulded article is removed from the mould or die in a predetermined or desired shape or configuration and thereafter allowed to cure such that cured or set thermosetting compound assists in maintaining said moulded article in a predetermined shape or configuration.
14. A mouldable material as claimed in any one of claims 1 to 6, substantially as hereinbefore described.
1 5. A method as claimed in any one of claims 7 to 10, substantially as hereinbefore described.
1 6. A method as claimed in any one of claims 11 to 13, substantially as hereinbefore described.
GB08220323A 1982-07-13 1982-07-13 Improvements in and relating to the moulding of materials Expired GB2123744B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB08220323A GB2123744B (en) 1982-07-13 1982-07-13 Improvements in and relating to the moulding of materials

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB08220323A GB2123744B (en) 1982-07-13 1982-07-13 Improvements in and relating to the moulding of materials

Publications (2)

Publication Number Publication Date
GB2123744A true GB2123744A (en) 1984-02-08
GB2123744B GB2123744B (en) 1986-05-14

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GB08220323A Expired GB2123744B (en) 1982-07-13 1982-07-13 Improvements in and relating to the moulding of materials

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4891084A (en) * 1986-03-11 1990-01-02 Raychem Limited Method of making a curved composite article
EP0358158A2 (en) * 1988-09-09 1990-03-14 Nippon Zeon Co., Ltd. Hollow polycycloolefin molded product
EP0688378A1 (en) * 1993-02-17 1995-12-27 Carter Holt Harvey Limited Case forming materials and components and structures thereof

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1287829A (en) * 1969-09-26 1972-09-06
GB1315729A (en) * 1969-12-19 1973-05-02 Cons Paper Bahamas Ltd Polymer impregnated board
GB1388895A (en) * 1971-03-30 1975-03-26 Munters Ab Carl Method for the manufacture of an exchanger body
GB1589715A (en) * 1977-10-07 1981-05-20 Rigby F A Structural panels

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1287829A (en) * 1969-09-26 1972-09-06
GB1315729A (en) * 1969-12-19 1973-05-02 Cons Paper Bahamas Ltd Polymer impregnated board
GB1388895A (en) * 1971-03-30 1975-03-26 Munters Ab Carl Method for the manufacture of an exchanger body
GB1589715A (en) * 1977-10-07 1981-05-20 Rigby F A Structural panels

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4891084A (en) * 1986-03-11 1990-01-02 Raychem Limited Method of making a curved composite article
EP0358158A2 (en) * 1988-09-09 1990-03-14 Nippon Zeon Co., Ltd. Hollow polycycloolefin molded product
EP0358158A3 (en) * 1988-09-09 1991-10-16 Nippon Zeon Co., Ltd. Hollow polycycloolefin molded product
EP0688378A1 (en) * 1993-02-17 1995-12-27 Carter Holt Harvey Limited Case forming materials and components and structures thereof
EP0688378A4 (en) * 1993-02-17 1997-05-28 Carter Holt Harvey Ltd Case forming materials and components and structures thereof

Also Published As

Publication number Publication date
GB2123744B (en) 1986-05-14

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