Adhesive bonding and miscellaneous chemical manufacture – Surface bonding means and/or assembly means therefor – With gas – vapor – or flame contact means for work
Reexamination Certificate
1998-10-21
2001-02-20
Ball, Michael W. (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Surface bonding means and/or assembly means therefor
With gas, vapor, or flame contact means for work
C156S580000, C156S581000, C425S405100, C425S406000, C425S420000
Reexamination Certificate
active
06189589
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a molding method and a molding apparatus for a laminated molded body such as insulator dashboards of cars.
2. Description of the Prior Art
Ordinarily, an insulator dashboard having sound insulation function is installed on a dashboard panel facing a car interior, with the dashboard panel placed in front of the driver seat and the passenger seat of a car. The dashboard panel is made of a laminated molded body of a sound insulation material such as a thermoplastic resin sheet and a sound absorption material such as felt and polyurethane foam.
Conventional molding method for the insulator dashboard will be explained on the basis of the drawings of FIG.
19
and FIG.
20
.
First, sound absorbing material is heated to 165 to 175° C. measured at its surface through a hot blast heating furnace, the hot material is shaped to its desired shape by cold pressing step and the sound absorption material shaped is cooled, and the material is molded to its precise shape of the dashboard.
Next, as shown in
FIG. 19
, the sound absorption material
1
of desired shape is set on a lower mold
3
for cold-pressing-molding, and a sound insulating material
2
heated to 130 through 135° C. measured at its surface is placed on the sound absorbing material
1
. A cold-pressing-molding upper mold
4
having substantially the same shape or profile as that of the cold-pressing-molding lower mold
3
is placed above the lower mold
3
.
Next, as shown in
FIG. 20
, the cold pressing molding upper mold
4
is lowered, a pressing pressure of 15 to 30 kg/cm
2
is applied between the lower mold
3
and the upper mold
4
for in order to mold the sound absorbing material
1
and the sound insulation material
2
, a predetermined cooling period is elapsed, a second pressing (pressure: 100 to 150 kg/cm
2
) is done in order to trim or cut the circumference or the outer periphery of the product by means of trimming blade
8
provided around the circumference of the cold-pressing-molding upper mold
4
.
Then, a water-jet cutting device or special purpose mold is used to carry out a trimming or piecing the process completing the molding of products.
According to the conventional molding method for insulator dashboards, after the sound absorbing material
1
is shaped in a desired shape by means of a press mold, a different press mold is used to press the sound insulation material
2
and the sound absorbing material
1
, so that it is necessary to employ two steps of pressing and to prepare plural mold installations.
In addition, it has been difficult to control the pressure level in pressing of the sound insulation material
2
and the sound absorbing material
1
. When the pressure level is too high, the sound absorbing material
1
may be crushed the resulting in failure of obtaining appropriate thickness of the product. On the contrary, if pressure level is too weak, one of the sound insulation material
2
and the sound absorbing material
1
may be peeled from other one.
Still, according to the prior art, the elasticity of the sound absorption material
1
prevents the pressing pressure from being appropriately transferred to the sound insulation material
2
, making it difficult to precisely or sharply shape the of corners of the product.
Additionally, the sound absorbing material
1
is typically made of a thermal-molded felt having thermal insulation quality. Thus, it takes a long time to cool the molded sound absorbing material
1
, requiring a longer molding cycle.
SUMMARY OF THE INVENTION
The present invention relates to a forming and molding method of a laminated product of a laminated bodies formed of a sound insulating material made of thermoplastic resin sheet and a sound absorbing material made of a thermal-molding felt. The method comprises the steps of mounting the thermal-molding felt and the thermoplastic resin sheet in a heated and soft state on a lower mold for cold pressing and molding, lowering an upper mold for cold pressing and molding onto the lower mold, pressing and molding the thermoplastic resin sheet and the thermal-molding felt integrally with a predetermined clearance left between the upper mold and the lower mold for cold pressing and molding, and supplying cooling air into the thermal-molding felt through pressed air holes in order to accelerate the molding process of the thermoplastic resin sheet and the cooling process of the thermal-molding felt.
Also, the present invention relates to the forming and molding method of laminated products or laminated molded bodies according to claim
1
, wherein the sound insulating material is made contact with a mold face of the thermoplastic resin sheet side through a vacuum suction hole formed in a mold at the thermoplastic resin sheet side.
Still also, the present invention relates to the molding method of laminated products wherein air is blown through a blowing pipe provided with a front end protruded from the mold face of thermal-molding felt side and intruded in the thermal-molding felt in order to help mold the sound insulation material and simultaneously forcibly cool the thermal-molding felt.
Still also, the present invention relates to the molding method of laminated product according to claim
1
, wherein air supplied in the thermal-molding felt through the blowing pipe is exhausted from a circumferential portion, and simultaneously exhausted to the outside through vacuum suction holes provided at suitable locations of the mold face at the thermal-molding felt side.
Still also, the present invention relates to the molding method of a laminated product of a laminated body formed of a sound insulation material made of a thermoplastic resin sheet and a sound absorbing material made of a thermal-molding felt. The method comprises the steps of preheating the cold-pressing-molding molds and the materials, setting and mounting the thermoplastic resin sheet and the thermal-molding felt in the heated and soft condition on the lower mold for cold pressing and molding, lowering the upper mold for cold pressing and molding, pressing integrally the thermoplastic resin sheet and thermal-molding felt with a predetermined clearance left between the upper mold and the lower mold for cold pressing and molding, sealing the circumference with a seal member, supplying cooling air in the thermal-molding felt from a plurality of air supply ports provided in the upper mold for cold-pressing-molding, applying predetermined face pressure to the thermoplastic resin sheet in order to press and mold the sound insulation layer and the sound absorbing layer, raising the upper mold for cold-pressing-molding in order to cancel sealed condition of the circumference of the upper mold and the lower mold for cold-pressing-molding, and supplying cooling air in the sound absorbing layer through air supply ports or holes in order to forcibly cool the sound absorbing layer.
Still also, a molding apparatus for a laminated molded body of the present invention consists of a cold-pressing-molding lower mold provided with a predetermined mold face and a cold-pressing-molding upper mold placed above the lower mold in order to press and mold the thermal-molding felt in a predetermined shape, wherein one of these molds for cold-pressing-molding has pressure air holes accelerate cooling of the thermal-molding felt.
Still also, the molding apparatus for a laminated molded body according to claim
6
has vacuum suction holes provided in the other mold for cold-pressing-molding in order to vacuum-mold the thermoplastic resin sheet.
Still also, the molding apparatus for laminated molded bodies according to claim
1
has a blowing pipe provided in other mold for cold-pressing-molding, and a front end of the blowing pipes protrude upwardly from the mold face and adapted to insert in the thermal-molding felt when the laminated molded body is pressed.
Still also, the molding apparatus for laminated molded bodies according to claim
1
has vacuum suction holes provided with the other mold for cold pres
Itoh Shoichi
Tokunaga Kazuhiro
Tsubosaki Takashi
Yamada Hisashi
Ball Michael W.
Foley & Lardner
Haran John T.
Kasai Kogyo Co. Ltd.
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