Plastic and nonmetallic article shaping or treating: processes – Pore forming in situ – Composite article making
Patent
1993-04-20
1995-04-25
Woo, Jay H.
Plastic and nonmetallic article shaping or treating: processes
Pore forming in situ
Composite article making
156242, 1563082, 156326, 156338, 264 455, 264134, 264135, 264255, 264257, 264300, B29C 4514
Patent
active
054096480
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND OF THE INVENTION
The invention relates to a process for producing multi-layer molded bodies by injection molding onto the back of an essentially flexible laminate composed of an upper sheet material such as leather or textiles, and a foamed layer bonded to the back side of the upper sheet material, wherein the process includes: laminate from its foamed layer side;
Such objects are often employed, for example, in automobile construction as dashboards, glove compartment door flaps, center consoles, side door linings and the like, but also for the production of luggage, small leather goods, furniture and similar items. In order to obtain a surface that is soft to the touch for such products, the upper material forming the visible surface during later use is laminated on its back with a foamed material. The procedure for manufacturing the mentioned molded bodies is generally such that a flexible, essentially planar, laminate composed of an upper material, such as, for example, leather, and a layer of a foamed substance is inserted into an injection mold and is covered with a thermoplastic synthetic material on the side of the foamed material.
In view of its later re-use particularly in the field of motor vehicles, the prior art molded bodies have the drawback that their layers, which are generally composed of different materials, are bonded so firmly together that it is practically impossible to separate them again and introduce them individually to recycling processes. However, this is often a requirement that the automobile industry in particular is confronted with.
SUMMARY OF THE INVENTION
Based on these facts, it is the object of the invention, to provide molded bodies, particularly for outfitting automobiles, whose individual layers can be separated from one another in the course of the disposal of used cars for recycling purposes. The above and other objects are accomplished according to the invention wherein, in the context of the process first mentioned above, a release layer comprising a release agent including a mixture of an aqueous rubber dispersion and an aqueous silicone emulsion is formed on the back side of the laminate prior to the laminate being shaped into the injection mold so that when the thermoplastic synthetic material is injection molded onto the back side of the laminate, the release layer is between the foamed layer and the thermoplastic synthetic material.
Accordingly, a release agent is applied to the surface of foamed material that is to be connected with the thermoplastic synthetic material so as to fill the open pores on the surface of the foamed material and form a release layer that has an essentially smooth surface between the foamed layer and the thermoplastic synthetic material. The hot thermoplastic synthetic material deposited on the layer of foamed substance during the injection molding process is in this way prevented from entering into the open pores of the foamed substance and forming an inseparable bond with the foamed layer. Another effect that is favorable for the later separability of the two layers is that the selected composition of the release agent produces adhesion on the thermoplastic synthetic material which, during use of the molded body, ensures a sufficiently strong bond and nevertheless permits the layers to be separated later with relative ease.
Another advantage of the invention is that the release layer performs a protective function for the foamed substance against the thermoplastic synthetic material which is applied to the foamed substance at relatively high pressure during the injection molding process. During the prior art processes it frequently happens that the foamed layer is partially compacted by the sprayed-on synthetic material or is removed in some locations. As a consequence, distinct unevennesses occur on the upper material which considerably reduce the quality of the product in question or even cause it to be rejected. Another advantage of the invention is that, due to the use of water as the dispersion and emulsifying
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Metraplast H. Jung GmbH
Smith Duane S.
Woo Jay H.
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