Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1999-04-28
2001-05-22
Yao, Sam Chuan (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S212000, C156S222000, C156S224000, C156S255000, C156S256000
Reexamination Certificate
active
06235138
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates to polyurethane foam/PVC (polyvinyl chloride) laminates for automotive instrument panels, and to a process for the production of these automotive instrument panels.
Automotive instrument panels are typically assessed for commercial applications in terms of their ability to satisfy certain requirements including, for example, colorfastness of the skin material after ageing, adhesion properties, fogging characteristics, physical properties, processability, etc. The use of semi-rigid polyurethane foam systems in automotive instrument panels is discussed in the paper entitled “New Developments in Polyurethane Foam Systems for Automotive Instrument Panels” by K. L. Parks, P. Gansen, J. R. Gricar and U. Liman, Society of the Plastics Industry, Proceedings of the Polyurethanes International Technical Conference and Exposition (1996). This paper describes the typical processes and materials that are used in instrument panel manufacturing. Included are descriptions of new instrument panel polyurethane foam systems with improved ageing performance.
Laminated artificial leather and a method of preparing it are disclosed in U.S. Pat. No. 4,504,536. This polyvinyl chloride (PVC) laminated artificial leather has an unfoamed polymeric resin outer layer, a foamed polyvinyl chloride bottom layer having an abraded outer surface and at least one intermediate layer comprising a fabric free polyvinyl chloride between the facing surfaces of the outer and bottom layers, with the outer layer being embossed on the outer surface to provide a leather appearance.
U.S. Pat. No. 4,769,278 describes resilient multi-layered members comprising a surface skin layer, formed of PVC resin powder in gel form, the outer side; a foam material layer, formed from foamed PVC resin powder, the outer side of which is adhered to the inner side of the surface skin layer; a cushion material layer, the outer side of which is adhered to the under side of the foam material layer; and a stiff core material layer on its inside side, the outer side of which is adhered to the inner side of the cushion material layer.
Thermoplastic foam core, fiber reinforced resin structural composite materials are described by U.S. Pat. No. 4,910,067. These structural composite materials comprise a thermoplastic layer, a layer of fibrous material spaced from the thermoplastic layer and a foam core disposed in the space between the thermoplastic layer and the fibrous material. The layer of fibrous material includes a resin impregnating this material and holding the layer of fibrous material together to form a fiber reinforced resin structure. Boats can be made from these structural composites.
U.S. Pat. Nos. 5,395,580, 5,407,225, 5,445,208 and 5,616,396 describe methods of producing automotive interior components, including door trim, door panels and airbag doors. The automotive interior components of U.S. Pat. No. 5,395,580 are laminated structures comprising a surface skin layer having an attractive appearance and feel, and a rigid core member comprising a synthetic resin. Door trim is one example of the types of automotive interior components which may be prepared from this method.
U.S. Pat. No. 5,407,225 describes an invisible airbag door having a reinforced polyvinyl chloride shell. The invisible door arrangement of the airbag is covered by the decorative instrument panel and comprises a curved substrate or insert that is molded of relatively rigid plastic material and secured in the passenger compartment behind the instrument panel and in front of the canister containing a deflated airbag. The substrate has an integral, rectangular frame which projects inward toward the canister and defines a rectangular opening for deployment of the airbag when inflated. This invisible door arrangement further comprises two similar sheet metal doors that close the opening outlined by the face and cooperate to create an opening through the instrument panel upon deployment of the airbag. The doors are made of one-piece construction and preferably of aluminum. The PVC shell is reinforced with a urethane adhesive coating that is flexible.
U.S. Pat. No. 5,445,208 discloses vinyl door panel sections and a method of making door panel sections, specifically garage door panels. These door panel sections comprise a rectangular door panel section having a front skin, a rear skin, opposing top and bottom portions and first and second sides. The door panel section includes a first sheet member and a second sheet member. The first sheet member is a polyvinylchloride material and has outer and inner surfaces, and top and bottom sections. The second sheet member is a non-metallic material and has outer and inner surfaces, and top and bottom sections. The front skin of the panel is comprised essentially of the first sheet member, and the rear skin of the panel section is comprised essentially of the second sheet member. The rigid foamed core is bonded to the inner surface of the first sheet member and is enclosed between the front and rear skins for unitizing the panel section.
Laminated building panels and a method for their production are disclosed by U.S. Pat. No. 5,633,063. These comprise plastic facing sheets on one or both faces of a rigid foam core with fibrous glass fiber mat material mechanically connecting the facing sheet to the core. The facing sheets are formed of suitable thermoplastic polymers including polyvinyl chloride, polyolefins, polycarbonates, acrylics, etc. These building panels are formed by extruding a molten polymer through an extrusion die to form a polymer layer, positioning the glass fiber mat adjacent to the polymer layer, and compressing the polymer layer and mat together before the polymer layer has solidified so that portions of the glass mat are embedded in the polymer and portions of the mat project from the polymer layer. Embossing rollers can be used to compress and emboss the polymer layer. The assembled facing sheet is solidified by cooling. Inner facing sheets are made in a similar manner, except the glass mats are preferably applied to both sides or faces of the polymer layer so that glass fibers project from both faces of the sheet.
Automotive door trim components comprise a main body integrally combining a resin core member and a surface skin member by a mold press forming process and an attachment member attached to a part of the main body. The attachment member is attached to the main body by way of connecting parts of the resin core member still at least in a semi-molten state due to the mold press forming process. The connecting part eventually solidifies so as to achieve a secure engagement between the resin core member and the attachment member.
U.S. Pat. No. 5,759,324 provides a process for binding a cover to a shaped padding, which specifically comprises polyurethane foam. Seat cushions can be produced by this process. This process comprises arranging a cover in a cold-shaping device and fixing it there by means of a holding frame. Then, an adhesive is placed on the internal walls of the cover and subsequently heated to a high temperature with the surface of the padding intended to cooperate with the internal walls of the cover. The heating is interrupted once a predetermined temperature is reached and the heated foam padding is immediately applied to the internal walls of the cover coated with the adhesive, leading to rapid setting of the adhesive. The cold-shaping device is then opened and the padding with its cover is removed.
Pressure sensitive adhesive laminates and methods of producing these are disclosed by U.S. Pat. No. 5,503,927. These laminates comprise a polymeric layer having an active surface, a coating of a curable urethane primary on the surface and a pressure sensitive adhesive applied to the coated surface. The method of forming these laminates comprises applying to the active surface of the polymeric layer a coating of a curable urethane primer, then applying to the coated surface a layer of pressure sensitive adhesive. Laminates are also formed comprisi
Milliren Charles M.
Parks Kristen L.
Brown N. Denise
Gil Joseph C.
Yao Sam Chuan
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