Method of molding a recyclable multi-layer component from plasti

Details Method of molding a recyclable multi-layer component from plasti Method of molding a recyclable multi-layer component from plasti

1997-10-15

1999-11-02

Silbaugh, Jan H.

Adhesive bonding and miscellaneous chemical manufacture

Methods

Surface bonding and/or assembly therefor

156 622, 1563099, 156322, 156209, 156 83, 156266, 1563073, 156242, 1563077, 156245, 156221, 264258, 264DIG26, 264DIG29, 264DIG75, 296191, 296214, 296 391, 428141, 428174, 428175, B27N 312, B32B 3120

Patent

active

059762950

ABSTRACT:
A method of molding a component such as a headliner or sun visor for the interior of automotive vehicles is molded from different thermoplastic materials from the same family that can be subsequently recycled as a whole without the need of separation into its constituents. The interior component is a multi layer composite of polyester (PET) finishing fabric, a resilient layer of bicomponent polyester fiber padding composed of blend of a low melting point fibers and high melting point fibers, and a relatively stiff core layer of polyester/glass fiber composite of polyester and glass fibers. The different fibers of the core layer are blended into a thin and porous sheet which is cut to size. The cut sheets are consolidated and molded under heat and pressure into a light weight, dense and structurally strong composite. A mold charge comprises the polyester/glass fiber composite layered with the bicomponent. The charge is heated in an oven and transferred to an open mold having the polyester finishing fabric facing therein. The mold is dosed and pressure is applied to complete formation of the headliner or sun visor component.

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