Stock material or miscellaneous articles – Structurally defined web or sheet – Including aperture
Reexamination Certificate
1998-07-31
2001-08-14
Jones, Deborah (Department: 1771)
Stock material or miscellaneous articles
Structurally defined web or sheet
Including aperture
C428S091000, C428S096000, C442S337000, C442S366000, C442S394000, C442S398000
Reexamination Certificate
active
06274219
ABSTRACT:
FIELD OF THE INVENTION
The invention relates to a multilayer formed part as well as a method of manufacturing the same.
BACKGROUND OF THE INVENTION
Such formed parts are employed for inner coverings in motor vehicles particularly in the region of the trunk. Duroplastics, especially phenolic resins, are used as binders. An illustrative example of this prior art is Eisel, D. “Recyclate aus Rei&bgr;baumwolle und Phenoplast—ein bewährtes System,”
Melliand Textilberichte
, November 1992, pages 873 to 878.
Due to the low compression of the carrier fibrous web forming the core of the sandwich structure, such formed parts exhibit good acoustic properties However, these formed parts are not sufficiently rigid despite the sandwich structure, since the low compression carrier fibrous web is “weak to shearing,” only restrictedly transmitting shearing forces as well, and thus not being ideal for the core of a sandwich construction. Hence, it has been common practice for quite some time to improve the rigidity of such formed parts, especially the package trays for which such increased carrying capacity is required. Such rigidity has been improved, by at least one of the following measures:
Incorporating reinforcing fibers such as glass fiber, flax fibers or high-strength synthetic fibers as well into the carrier fibrous web;
Incorporating metal inserts into the carrier fibrous web; and
“Hard” pressing of a greater marginal region, in order to gain more rigidity there by means of a greater marginal region and by a greater compression of material.
However, incorporating of reinforcing fibers means a greater manufacturing requirement. As far as natural fibers such as flax is concerned, it has to be reckoned with an odor emission; mineral fibers affect in case a considered recycling. The same applies for metal inserts too, which cause both a considerable expenditure in manufacturing and still a significant weight gain of the formed parts as well. The branch-used utilization of phenolic resins is uncertain with regard to the climate inside the seating compartment. Hence, the car industry more frequently demands for a substitute of duroplastics by thermoplastic binders, not least with regard to a better recycling capability of thermoplastic binders, as well.
A “hard” pressing of the marginal regions is only operative when these regions are adequately large. Usually, they comprise more than one third of the formed part surface. For improvement of the seating compartment acoustic, the “hard” pressed regions of formed part are no longer usable.
SUMMARY OF THE INVENTION
Therefore, it is the object of the invention to improve the (flexural strength) rigidity of precharacterized multilayer formed parts with renunciation of reinforcing inserts as well as to enhance the recycling capability of such formed parts. It is the further object of the invention to minimize the surface portion that is not usable for acoustic improvements. Finally, it is also the object of the invention to mention manufacturing methods for such formed parts.
Thereby the carrier fibrous web distributed across the surface is interlaced with prismatic regions, which give an increased strength to the carrier fibrous web and which are connected to the cover layer and/or decorative layer in a shearing resistant manner, the properties of the sandwich become independent of the pressing degree of the carrier fibrous web of the medium layer. The sandwich properties of the multilayer structure are determined within the region of less pressed carrier fibrous webs being important to the acoustic properties only by sort, material, size and distribution of the prismatic regions, which surface requirement thereof is distinctly less than the surface requirement of the hard pressed margins of the formed part in the prior art.
Hence, the strength characteristics of the formed parts can largely be optimized independent of the acoustic parameters thereof.
REFERENCES:
patent: 4298643 (1981-11-01), Miyagawa
patent: 4420526 (1983-12-01), Schilling et al.
patent: 4859524 (1989-08-01), Kim et al.
patent: 5326523 (1994-07-01), Gustavel et al.
patent: 5514458 (1996-05-01), Schulze-kadelbach
patent: 5527581 (1996-06-01), Sugawara et al.
patent: 6048628 (2000-04-01), Hillmann et al.
Eisele, Dieter, “Recyclate aus Reissbaumwolle und Phenoplast—ein bewährtes System”, Melliand Textilberichte, Nov. 1992, pp. 873 to 878.
Meyer Roland
Schuster Dieter
Bahta Abraham
Jones Deborah
Sommer Allibert-Lignotock GmbH
Young & Basile P.C.
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