Method of lining plastic objects with a thin layer of heat sensi

Details Method of lining plastic objects with a thin layer of heat sensi Method of lining plastic objects with a thin layer of heat sensi

1991-09-27

1993-04-27

Silbaugh, Jan H.

Adhesive bonding and miscellaneous chemical manufacture

Methods

Surface bonding and/or assembly therefor

156245, 156285, 1563082, 156324, 264135, 264136, 264171, 264257, 264265, 264510, B29C 3516, B29C 4514, B29C 4702, B29C 5112

Patent

active

052058921

DESCRIPTION:

BRIEF SUMMARY
The invention relates to a process for the manufacture of a product made of plastic materials.
It is known that the use of heat is impossible when uniting thin layers of synthetic material, such as woven and non-woven fabrics, moquettes and the like, with articles made of plastic material using the usual molding processes--especially injection molding--vacuum forming, thermoforming, extrusion, calendaring and others, since said thin layers tend to melt at high temperatures, and in any case they are damaged by the heat.
The limitations inherent in other methods of uniting are also well known.
Gluing is only possible when the product is responsive to solvents and glues, therefore excluding for example products made of polyolefins such as polypropylene, polyethylene and others.
The purpose of the above invention is to overcome these drawbacks as will be described below.
According to the invention the thin layers of synthetic material, such as woven and non-woven fabrics, moquettes and the like, are provided with heat-conducting properties and are made to adhere to a metal or in any case to a highly heat-conducting surface.
Consequently, during the operation of uniting the thin layer with a product made of plastic material, the heat transferred from said material to the thin layer rapidly passes through the latter and into the heat-conducting wall behind, thus preventing the thin layer from becoming so hot as to be damaged
The aforesaid thin layer can be made heat-conductive by impregnation with a water-oil emulsion or some similar emulsion, or by application of pastes containing a high percentage of metal or, in any case, heat-conductive particles. During the uniting process the volatile parts evaporate, removing heat and leaving the product dry.
In the technique of molding plastic materials by means of dies, the aforesaid thin layer can be made to adhere to the moveable die by bushings and the like, which apply contact pressure against said thin layer and are kept in place by pins, sliding in holes made in the fixed die and pressed by springs.
The bushings are made of plastic material of substantially the same sort as the product to be molded, their length not exceeding the thickness of said product, so as to allow them to become spontaneously embedded in the mass of material during the molding process.
The above thin layer can be protected from the flow of injected plastic material by means of a screen placed in front of the injection port and supported by pins and the like sliding in holes made for them in the fixed die.
The dimensions of said screen must be substantially smaller than those of the product to be molded, and the material from which it is made must be the same as that of said product so that said screen can become spontaneously embedded in the mass of plastic material during molding
In the vacuum forming technique the above thin layer is placed over the preformed sheet with which it is to be united, said sheet having been pre-heated, and is then pressed by counter dies against the lower die.
In the vacuum thermoforming technique using vertical molding machines said thin layer already united with a sheet is placed so as to face upwards, while the electric heating elements heating the forming die lie below the sheet to be thermoformed.
In extrusion, said thin layer is united with sheets of thermoplastics and similar material, when extrusion takes place.
Rollers are used to treat said thin layer with the heat-conducting emulsion or with another heat-conducting product.
By suitably adjusting the temperature of the extruded material and the pressure of the extruding rollers, the thickness of said thin layer to be left free can be determined at will.
In the thermoforming process said thin layer, already united with a sheet, is positioned so as to lie outside the product, facing downward and towards the female die, the male die being placed above.
In calendaring to unite said thin layer with a sheet of thermoplastic material, said layer is made to pass--together with the sheet of thermoplastic mater

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