GB2244238A - Producing veneer-faced moulded items - Google Patents

Producing veneer-faced moulded items Download PDF

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Publication number
GB2244238A
GB2244238A GB9011432A GB9011432A GB2244238A GB 2244238 A GB2244238 A GB 2244238A GB 9011432 A GB9011432 A GB 9011432A GB 9011432 A GB9011432 A GB 9011432A GB 2244238 A GB2244238 A GB 2244238A
Authority
GB
United Kingdom
Prior art keywords
dies
moulding compound
wood veneer
faced
moulded
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
GB9011432A
Other versions
GB2244238B (en
GB9011432D0 (en
Inventor
Alan Fraser Sawyer
Raymond Paul Mccluskey
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.)
AUTOMOTIVE FASCIA SYSTEMS LIMI
Original Assignee
AUTOMOTIVE FASCIA SYSTEMS LIMI
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 AUTOMOTIVE FASCIA SYSTEMS LIMI filed Critical AUTOMOTIVE FASCIA SYSTEMS LIMI
Priority to GB9011432A priority Critical patent/GB2244238B/en
Publication of GB9011432D0 publication Critical patent/GB9011432D0/en
Publication of GB2244238A publication Critical patent/GB2244238A/en
Priority to CA002083736A priority patent/CA2083736A1/en
Application granted granted Critical
Publication of GB2244238B publication Critical patent/GB2244238B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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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
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27D—WORKING VENEER OR PLYWOOD
    • B27D1/00—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27D—WORKING VENEER OR PLYWOOD
    • B27D1/00—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring
    • B27D1/04—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring to produce plywood or articles made therefrom; Plywood sheets
    • B27D1/08—Manufacture of shaped articles; Presses specially designed therefor
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B29C43/183—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould
    • B29C43/184—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould shaped by the compression of the material during moulding
    • 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
    • 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
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
    • 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
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • 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
    • B29K2711/14—Wood, e.g. woodboard or fibreboard
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/02—2 layers
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/03—3 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/746—Slipping, anti-blocking, low friction
    • 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
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • 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
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/04—Time
    • 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
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12—Pressure
    • 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
    • B32B2317/16—Wood, e.g. woodboard, fibreboard, woodchips
    • 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
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings

Landscapes

  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Forests & Forestry (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Laminated Bodies (AREA)

Abstract

Wood veneer-faced moulded items are produced by placing between a pair of heated profile forming dies (13, 15) a pro-cut blank (17) of a decorative wood veneer, and a quantity of a hot curing catalysed polyester resin-based moulding compound (18) containing a mixture of fillers and reinforcing fibres, with a slip sheet (16) between the wood veneer and the adjacent die surface, and thus closing the dies together under a predetermined pressure and temperature and for a predetermined time. After subsequently opening the dies and trimming off any excess materials there is provided a wood veneer-faced moulded article produced without the use of adhesives and having sufficient inherent integrity for use without additional reinforcement. <IMAGE>

Description

A WETHOD OF PRODUCING VENKER-FACKI) MOULDED ITEMS THIS INVENTION concerns a method of producing wood veneer-faced moulded items. Such items are used particularly, though by no means exclusively, in the automotive industry for the interior trim of vehicles, and are traditionally produced by a lamination process in which a decorative wood veneer is bonded to a preformed rigid backing material, usually by membrane forming.
The traditional process involves the application of a liquid adhesive between a number of laminae which are built up to form the completed article, and is usually carried out in at least two stages i.e. the initial production of the preformed backing or substrate which is then finished by the application of one or more other materials including the wood veneer. Thus the process can be lengthy and expensive, and the surface finish of the article is dependent largely upon the combining force which can be applied by the membrane moulding process, and the characteristics of the materials used.
An object of the present invention is to provide a method of producing veneer-faced moulded items, which is performed using less materials in a shorter time and without specially skilled personnel, and does not involve the use of adhesives.
According to the present invention there is provided a method of producing wood veneer-faced moulded items, comprising the steps of providing a quantity of an uncured thermosetting polyester resin based moulding compound and a sheet of a decorative wood veneer; placing said two components in superimposed relationship between a pair of heated forming dies; closing the dies together with a predetermined pressure and temperature, and for a predetermined time; and after subsequently opening the dies removing the so-formed laminated product therefrom.
Preferably, a slip sheet of a material having a low coefficient of friction is placed between the decorative veneer and the adjacent die surface prior to closing the dies.
An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Fig. 1 is a schematic cross-sectional view of a pair of dies closed together to form a moulded item, in accordance with the method of the invention; and Fig. 2 is an isometric view of a moulded item produced by said method.
A moulded item of the kind illustrated in Fig. 2 comprises a two-part lamination consisting of an inner layer 10 of a thermosetting polyester resin based moulding compound, and a sheet of wood veneer 11 moulded thereto. The item may be, for example, a decorative wooden strip forming part of a fascia rail for the interior of a motor car. Therefore the view illustrated in Fig. 2 is of the rear or underside of such an item and there are included a number of attachment pegs 12 which are integrally formed with the compound layer 10, as will be described, during the process.
Referring now to Fig. 1 which shows a pair of dies closed together in the forming process, a lower die 13 contains a central recessed profile 14 which will determine the shape of the finished article.
Initially, with an upper die 15 raised in an open condition with respect to the lower die, there is placed over the recess 14 a cut blank 16 of polyester film. There is then superimposed on film 16 a cut blank or sheet 17 of wood veneer. This is then covered with a quantity, preferably in sheet form, of a thermosetting polyester resin based moulding compound 18.
Upper die 15 has a mating profile 19 which is related in shape to the profile 14 of die 13 except for a number of bores 20 which are spaced apart along the upper die 15 to receive some of the moulding compound in the formation of the location pegs 12.
The dies are heated to a temperature which is adjustable, for example between 800C and 1600C and the pressure under which the dies are closed may be adjusted between, for example, 50 bar and 500 bar. The temperature and pressure to which the dies are set and the period during which they are maintained in the closed condition, which may be between 30 seconds and 10 minutes, are all variable and selected according to the thicknesses and quantities of the materials being formed, the complexity of configuration of the article to be produced, and the surface finishes to be afforded.
It will be seen from Fig. 1 that after the forming process is complete excess compound together with the edge regions of the polyester film 16 and wood veneer 17, extend as indicated at 21 along the interface between the die faces.
Upon completion of the forming process the dies are separated and the formed item is removed from between the dies whereupon the excess material may be trimmed, for example along lines 22 to produce the finished article as illustrated in Fig. 2. Also, any additional machining may take place at this stage.
Pegs 12 are integrally formed with the moulding compound, and the polyester film 16 is removed and discarded.
The components of the moulded article, after trimming of surplus material will retain their moulded form, no post-moulding curing being required to achieve this stability.
The veneer is, in effect, bonded to the moulding compound by virtue of the heat and pressure applied in the forming process and the interfacial characteristics of the two materials. No additional adhesive substance is needed to bond the laminae together.
The material used for the moulding compound is a reinforced thermosetting plastics material in the form of an uncured, hot curring, catalysed polyester resin impregnated with glass fibres and filters. One such material may be so-called "dough moulding compound" which has a dough-like texture, is somewhat tacky to the touch and is normally supplied in quantities which are commensurate with the expected period of use or shelf life. The required quantity of dough moulding compound is cut from the bulk supply and placed over the wood veneer prior to moulding. An alternative material is so-called "bulk moulding compound" which is very similar in appearance and texture to dough moulding compound but is formulated to produce mouldings of improved quality and finish.
As a further alternative, there is so-called "sheet moulding compound" which is supplied in sheet form usually some 3mm thick and sandwiched between two polyethylene film layers to prevent contamination and adhesion during delivery and storage. This form of the compound is much easier to use since blanks equivalent in size to the wood veneer blanks may be cut from the sheet using a sharp knife.
Preferably, the process is enhanced by impregnating the wood veneer with a polyester resin prior to use. The use of a polyester lining as illustrated at 16 in Fig. 1 reduces the incidence of the veneer cracking by allowing it to form more readily by sliding into the desired component profile.
The die which is to come into contact with the moulding compound is preferably pre-coated with a release agent such as a zinc stearate wax, particularly in cases where the compound is to fill the blind bores 20 to form the pegs 12.
A method of producing veneer faced moulded items as described herein provides considerable advantage over the conventional vacuum/diaphragm forming system in requiring less material whilst ensuring lower manufacturing times and higher quality surface definition on the finished product.
Further, the wood veneer will conform to more complex profiles with the increased temperature and pressure provided by the present process when compared with vacuum forming, whilst only two laminae are required to produce complex shapes normally requiring a greater number of laminated materials. This aspect also ensures reduced preparation times and thus production costs.
Yet again the increased pressure created during the moulding process in accordance with the invention ensures a more effective impregnation or passage of polyester resin through the veneer thus preparing the veneer surface for a final application of lacquer. This results in the actual numbers of coats of lacquer being reduced when compared with conventional processes. Integral location or fixing means such as the pegs 12 of adequate strength may be formed with a process according to the invention in view of the increased pressure and temperature achieved therein.

Claims (14)

1. A method of producing wood veneer-faced moulded items, comprising the steps of providing a quantity of uncured thermosetting polyester resin-based moulding compound and a sheet of a decorative wood veneer; placing said two components in superimposed relationship between a pair of heated forming dies; closing the dies together with a predetermined pressure and temperature, and for a predetermined time; and after subsequently opening the dies removing the soformed laminated product therefrom.
2. A method according to Claim 1, wherein a slip sheet of a material having a low coefficient of friction is placed between the wood veneer and the adjacent die surface prior to closing the dies.
3. A method according to Claim 1 or Claim 2, wherein the die surface which is to come into contact with the moulding compound is pre-coated with a release agent such as a zinc stearate wax.
4. A method according to any preceding claim, wherein the predetermined closing pressure of said dies is between 50 bar and 500 bar.
5. A method according to any preceding claim, wherein the dies are heated to a temperature of between 800C and 1600C.
6. A method according to any preceding claim, wherein the predetermined time for which said dies are closed together is between 30 seconds and 10 minutes.
7. A method according to any preceding claim, wherein excess materials are trimmed from the moulded item after removal from the dies.
8. A method according to any preceding claim, wherein the moulding compound is so-called "dough moulding compound".
9. A method according to any one of Claims 1 to 7, wherein the moulding compound is so-called "bulk moulding compound".
10. A method according to any one of Claims 1 to 7, wherein said moulding compound is so-called "sheet moulding compound".
11. A method according to any preceding claim wherein the moulding compound is a hot curing catalysed polyester resin containing a mixture of fillers and reinforcing fibres.
12. A method according to any preceding claim, wherein said wood veneer is impregnated with a polyester resin prior to use.
13. A method of producing wood veneer-faced moulded items, substantially as hereinbefore described.
14. A wood veneer-faced moulded item produced by the method of any one of the preceding claims.
GB9011432A 1990-05-22 1990-05-22 A method of producing veneer-faced moulded items Expired - Fee Related GB2244238B (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB9011432A GB2244238B (en) 1990-05-22 1990-05-22 A method of producing veneer-faced moulded items
CA002083736A CA2083736A1 (en) 1990-05-22 1992-11-25 Method of producing veneer-faced moulded items

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9011432A GB2244238B (en) 1990-05-22 1990-05-22 A method of producing veneer-faced moulded items
CA002083736A CA2083736A1 (en) 1990-05-22 1992-11-25 Method of producing veneer-faced moulded items

Publications (3)

Publication Number Publication Date
GB9011432D0 GB9011432D0 (en) 1990-07-11
GB2244238A true GB2244238A (en) 1991-11-27
GB2244238B GB2244238B (en) 1994-03-16

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GB9011432A Expired - Fee Related GB2244238B (en) 1990-05-22 1990-05-22 A method of producing veneer-faced moulded items

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1994005480A1 (en) * 1992-08-26 1994-03-17 Automotive Fascia Systems Limited A method of producing veneer-faced items
FR2725149A1 (en) * 1994-10-04 1996-04-05 Profichet Richard Nicolas Jean Mfr. of curved plywood panels which retain their shape after binding
FR2760208A1 (en) * 1997-02-28 1998-09-04 Cuty Fort Entreprises Manufacturing procedure for shaped component with wood veneer surface
EP3115162A1 (en) * 2015-07-10 2017-01-11 Bond Laminates GmbH Wood veneer coated plastic mould

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117382069B (en) * 2023-12-12 2024-04-12 北京玻钢院复合材料有限公司 Integral compression molding method for low-density heat-resistant layer of embedded metal part

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB848290A (en) * 1957-07-20 1960-09-14 Daimler Benz Ag Improvements relating to veneered shaped objects and the production thereof
GB1205893A (en) * 1967-02-13 1970-09-23 Bayer Ag Process for the production of composite articles provided with covering layers

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB848290A (en) * 1957-07-20 1960-09-14 Daimler Benz Ag Improvements relating to veneered shaped objects and the production thereof
GB1205893A (en) * 1967-02-13 1970-09-23 Bayer Ag Process for the production of composite articles provided with covering layers

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1994005480A1 (en) * 1992-08-26 1994-03-17 Automotive Fascia Systems Limited A method of producing veneer-faced items
FR2725149A1 (en) * 1994-10-04 1996-04-05 Profichet Richard Nicolas Jean Mfr. of curved plywood panels which retain their shape after binding
FR2760208A1 (en) * 1997-02-28 1998-09-04 Cuty Fort Entreprises Manufacturing procedure for shaped component with wood veneer surface
EP3115162A1 (en) * 2015-07-10 2017-01-11 Bond Laminates GmbH Wood veneer coated plastic mould
WO2017009152A1 (en) * 2015-07-10 2017-01-19 Bond-Laminates Gmbh Plastic moulding covered with a wood veneer

Also Published As

Publication number Publication date
GB2244238B (en) 1994-03-16
GB9011432D0 (en) 1990-07-11
CA2083736A1 (en) 1994-05-26

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732E Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977)
PCNP Patent ceased through non-payment of renewal fee

Effective date: 19970522