Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1999-01-13
2001-08-14
Silbaugh, Jan H. (Department: 1732)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C264S173170, C264S173190, C264S173140, C264S248000, C156S244250, C156S245000
Reexamination Certificate
active
06273983
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a molding for all kinds of automobiles and its manufacturing method. More particularly, this invention relates to the moldings of all kinds and method for manufacturing the molding of all kinds, such as a window molding, an outer molding, an inner molding, a roof molding of weather strip, etc. for mounting to automobiles, wherein the components of the molding body are made from high rigid and small linear expansion coefficient materials and wherein the surface sides exposed outside of the molding body are integrally laminated with a protective film layer excellent in resistance to scuffing, chemicals and climate.
2. Description of Prior Art
Polyvinyl chloride based resin was heretofore used widely in manufacturing the window molding, outer molding and inner molding of weather-strip of this kind. However, in view of the points, such as the weight-saving, recycling, atmospheric contaminating due to dioxin etc. the polyvinyl chloride based resin was substituted for olefin based thermoplastic elastomer resin, or styrene based thermoplastic elastomer resin which have come to be used, but depending on a location where it is to be fitted to automobile, the molding body of high rigid and of small linear expansion coefficient products has become to be necessary. Accordingly a reinforcing piece of metal such as stainless steel was embedded by using an adhesive into the thermoplastic elastomer resins as mentioned above, in which case there was the problems making the recycling impossible, and increasing the weight of molding body as well as the manufacturing cost.
To solve the above described problems, an inexpensive and highly rigid polypropylene resin among the hard olefin based resins was used for the molding body, but there was such problem that scuffing was easily formed on the exposed surface.
Trying to improve such problems as above described, olefin based resin composition, excellent in resistance to scuffing, chemicals and in appearance quality, was coated by extruding it on the exposed surface of polypropylene resin surface, but due to an inability of forming a film by extruding unless the molding temperature exceeds 250° C. as in the case with highly crystalline polypropylene resin, the extrusion molding capacity and appearance quality was problematic. Further the protective film comprising ethylene-methacrylic acid copolymer resin composition or a composition of metal salt thereof had also such problem that the protective film was easily removed during use of a long period of time from the molding body comprising the polypropylene resin. For this reason, adhesives with solvent were used, but the adhesives caused gases to generate from the solvents at the time of application which was problematic in respect to the working environment and atmospheric pollution.
Then, as described in the Japanese Patent Application No. 354722/1995, polyvinyl chloride based resin was laminated on the exposed surface of the molding body, but the dynamic crosslinking thermoplastic elastomer (Styrene based thermoplastic elastomer) of the adhesive layer between the protective film of polyvinyl chloride based resin and the molding body of polypropylene resin was very weak in thermofusion bond property and has easily been released therefrom with use for a long period of time, and also from the environment view of the polyvinyl chloride resin itself it was not practically used.
SUMMARY OF THE INVENTION
An object of the present invention is to resolve the short comings of all kinds of the prior arts and to provide a molding for vehicle and its manufacturing method, wherein a molding body excellent in rigidity is formed by the components of hard olefin based resin and powders such as mica, talc, glass fibre, etc. mixed into said hard olefin based resin, and is coated with a protective film layer comprising olefin based resin, excellent in resistance to scuffing and chemicals, on the exposed surface.
Another object of the present invention is to provide the molding for vehicle and its manufacturing method wherein an intermediate adhesive layer having thermofusion bond property and comprising an olefin based thermoplastic elastomer resin composition, or styrene based thermoplastic elastomer resin composition is sandwiched between the hard olefin based resin of the molding body and olefin based resin, or styrene based resin of the protective film layer located on the exposed surface of the molding body and wherein the molding body, the intermediate adhesive layer, and the protective film layer are integrally molded by several extruders and laminated toughly as whole.
In order to achieve the objects described above, the molding in accordance with the present invention comprises a molding body formed from a hard olefin based resin or a mixed synthetic resin having powders of mica, talc, glass fibre, etc. mixed into said hard olefin based resin. The molding body comprises a vertical supporting portion which functions as fitting member and a decorative portion exposed outwardly. The decorative portion is laminated with a protective film layer of olefin based resin, excellent in resistance to scuffing, chemicals, also in appearance quality, on the exposed surface. Further, the molding body comprising the hard olefin based resin has powders of mica, talc, glass fibre, etc. mixed as additive into the hard olefin based resin for the purpose of making the linear expansion coefficient smaller and the high rigidity.
The decorative portion is laminated with an intermediate adhesive layer comprising olefin based thermoplastic elastomer resin composition, or styrene based thermoplastic elastomer resin composition having the thermofusion bond property favourable to the molding body, and the intermediate adhesive layer on the decorative portion is laminated with the protective layer comprising olefin based resin composition or styrene based resin composition having the thermofusion bond property favourable to the intermediate adhesive layer and effective for resistance to scuffing, chemicals, etc. In addition, the component of the intermediate adhesive layer comprises olefin based thermoplastic elastomer resin composition, or styrene based thermoplastic elastomer resin composition of material more flexible and elastomeric than the hard olefin based resin forming the molding body and the olefin based resin composition or styrene based resin composition forming the protective layer to enhance the resistance to scuffing and the cushioning property.
In the method for manufacturing the molding body, there are two cases of two kinds of resins and three kinds of resins being used. In the former case, the hard olefin based resin forming the molding body or the mixed synthetic resin having powders of mica, talc, glass fibre, etc. mixed into the hard olefin based resin is poured into a first extruder, and the olefin based resin composition or styrene based resin composition forming the protective film layer is poured into a second extruder.
The molding body and the protective film layer are integrally and toughly laminated polymerically inside a single molding die in operating the first and the second extruders simultaneously.
In the case of three kinds of resins used, the hard olefin based resin or the mixed synthetic resin having powders of mica, talc, glass fibre, etc. mixed into the hard olefin based resin is poured into a first extruder for forming the molding body. The olefin based thermoplastic elastomer resin composition or styrene based thermoplastic elastomer resin composition is poured into a second extruder for forming the intermediate adhesive layer. The olefin based resin composition or styrene based resin composition is poured into a third extruder for forming the protective film layer on the exposed surface of the molding body. The molding body, the intermediate adhesive layer and the protective film layer are integrally formed and toughly laminated together inside a single molding die by operating three extruders simultaneously.
Kato Katsuhisa
Miyakawa Naohisa
Eashoo Mark
Silbaugh Jan H.
Tokiwa Chemical Industries & Co., Ltd.
Wenderoth , Lind & Ponack, L.L.P.
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