Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Patent
1992-02-14
1994-07-19
Ryan, Patrick J.
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
1563075, 427195, 428402, 428418, 428431, B32B 3100, C09J 502
Patent
active
053306023
DESCRIPTION:
BRIEF SUMMARY
This invention relates to methods of manufacturing an article, of the kind in which thermosetting organic powder-coating material is melted to fuse it into a layer, and a bond is made between the layer and a component that is to form part of the manufactured article by establishing contact between the layer and said component while the layer is in a melted condition and until the material is cured.
Methods of manufacture of this above-specified kind are described in UK Patent Specification No 2,207,089. In particular, there is described a method for establishing a bond between a surface of a glass sheet to which a thermosetting organic powder has been applied, and a metal foil that is to back the glass sheet in a manufactured architectural panel. Contact is established between the foil and the powder while the powder is in a melted condition on the glass prior to curing, and is maintained during curing of the powder so that a bond is formed between the foil and the glass sheet via the cured powder material.
The present invention represents a development from the invention described in UK Patent Specification No 2,207,089. In this regard, it is an object of the present invention to provide a method of manufacturing an article, of said above-specified kind, that facilitates making the bond.
According to the present invention there is provided a method of manufacturing an article, of said above-specified kind, wherein following the step of melting the powder material to fuse it into the layer and before the step of establishing contact between the layer and said component, the temperature of the layer is reduced so as to retard curing of the layer between those two steps.
The reduction of temperature of the layer may be sufficient to harden the fused material. Heat to melt the hardened layer for making the bond with said component may be applied before or after contact is established with said component.
According to a feature of the present invention, a method of manufacturing an article comprises the steps of forming a substantially solidified layer of fused, but uncured, thermosetting organic powder-coating material on a backing, and establishing contact between the backed layer and a component that is to form part of the manufactured article, heat being applied to the layer to melt it and fulfil curing of the powder material while the melted layer is in contact with said component so that a bond is formed between the powder material and said component.
At least part of the heat required to melt the layer and cure it, may be derived from heat of said component itself.
The step according to the present invention of forming the layer of fused, but uncured, powder-coating material, may be carried out remotely from the step of establishing contact with said component and making the bond between the cured powder material and said component. This is of especial advantage in circumstances in which deposition of powder cannot be readily or desirably carried out where the ultimate bond is to be made, because, for example, the facilities are inadequate or cleanliness is required. The method according to the present invention, like that of the invention described in UK Patent Specification No 2,207,089, has application for bonding together items of varying materials, typically: of a metal or plastics item to a metal item; of a metal foil or other item to a glass sheet; and of glass items to one another, as for example in forming a glass laminate. Furthermore, the invention is of advantage more especially in the provision of glass cladding and other glazing for both exterior and interior architectural purposes. In this latter respect, the fused layer of powder material can be brought to the glass for the bond to be established, without the necessity for the powder to be deposited on the glass; this enables the coating to be bonded to glazing at the place of installation or even when already installed. More especially, it enables the bonding to take place where the glass is manufactured and the presence of loose powder
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Krynski William A.
Ryan Patrick J.
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