Method of preparing an article

• US 20040247828A1
• Filed: 06/06/2003
• Published: 12/09/2004
• Est. Priority Date: 06/06/2003
• Status: Active Grant

• Current Assignee: Bayer Materialscience LLC (Covestro AG)
• Original Assignee: Bayer Materialscience LLC (Covestro AG)
• Inventors: Zoellner, Olaf, Brozenick, Norman J.
• Granted Patent: US 7,045,090 B2
• Time in Patent Office: Days
• US Class Current: 428/139
• CPC Class Codes: B29C 37/0085 by means of openings in the layers joining through openings B29C66/304
• CPC Class Codes: B29C 65/00 Joining or sealing of preformed parts , e.g. welding of plastics materials; Apparatus therefor general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326
• CPC Class Codes: B29C 65/1412 Infrared [IR] radiation
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/4865 containing additives C09J11/00 and subgroups take precedence
• CPC Class Codes: B29C 65/54 between pre-assembled parts
• CPC Class Codes: B29C 65/606 the rivets being integral with one of the parts to be joined, i.e. staking
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/21 said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
• CPC Class Codes: B29C 66/30325 making use of cavities belonging to at least one of the parts to be joined
• CPC Class Codes: B29C 66/304 Joining through openings in an intermediate part of the article B29C66/3034 takes precedence
• CPC Class Codes: B29C 66/41 Joining substantially flat articles B29C66/47 and subgroups take precedence; Making flat seams in tubular or hollow articles B29C66/51 and subgroups take precedence
• CPC Class Codes: B29C 66/43 Joining a relatively small portion of the surface of said articles B29C66/45 takes precedence
• CPC Class Codes: B29C 66/431 Joining the articles to themselves B29C66/4322 and B29C66/4332 take precedence
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/723 being multi-layered B29C66/7292, B29C66/72941 take precedence
• CPC Class Codes: B29C 66/73755 the to-be-joined area of at least one of the parts to be joined being fully cured, i.e. fully cross-linked, fully vulcanized
• CPC Class Codes: B29C 66/73773 the to-be-joined area of at least one of the parts to be joined being semi-crystalline
• CPC Class Codes: B29C 66/7392 characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/73921 : characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/7394 : characterised by the material of at least one of the parts being a thermoset
• CPC Class Codes: B29C 66/7422 : Aluminium or alloys of aluminium
• CPC Class Codes: B29C 66/81423 : being concave
• CPC Class Codes: B29C 66/81431 : comprising a single cavity, e.g. a groove
• CPC Class Codes: B29C 66/8322 : Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29K 2023/00 : Use of polyalkenes or derivatives thereof as moulding material
• CPC Class Codes: B29K 2023/06 : PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/12 : PP, i.e. polypropylene
• CPC Class Codes: B29K 2027/06 : PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2033/12 : Polymers of methacrylic acid esters, e.g. PMMA, i.e. polymethylmethacrylate
• CPC Class Codes: B29K 2055/02 : ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
• CPC Class Codes: B29K 2067/00 : Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2069/00 : Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 : Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/02 : Polyureas
• CPC Class Codes: B29K 2077/00 : Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2079/08 : PI, i.e. polyimides or derivatives thereof
• CPC Class Codes: B29K 2081/06 : PSU, i.e. polysulfones; PES, i.e. polyethersulfones or derivatives thereof
• CPC Class Codes: B32B 15/082 : comprising vinyl resins; comprising acrylic resins
• CPC Class Codes: B32B 15/085 : comprising polyolefins
• CPC Class Codes: B32B 15/088 : comprising polyamides
• CPC Class Codes: B32B 15/09 : comprising polyesters
• CPC Class Codes: B32B 15/095 : comprising polyurethanes
• CPC Class Codes: B32B 2038/047 : Perforating
• CPC Class Codes: B32B 2367/00 : Polyesters, e.g. PET, i.e. polyethylene terephthalate
• CPC Class Codes: B32B 2375/00 : Polyureas; Polyurethanes
• CPC Class Codes: B32B 2377/00 : Polyamides
• CPC Class Codes: B32B 27/30 : comprising vinyl (co)polymers; comprising acrylic (co)polymers
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 : comprising polyamides
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/365 : comprising polycarbonates
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 38/04 : Punching, slitting or perforating
• CPC Class Codes: B32B 7/08 : by mechanical means
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B60R 13/02 : Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners B60R13/01 takes precedence ; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18
• CPC Class Codes: B60R 13/04 : External Ornamental or guard strips; Ornamental inscriptive devices thereon fastening strips or bars to sheets or plates by means of clips F16B5/12
• CPC Class Codes: B60R 2013/0281 : made of a plurality of visible parts
• CPC Class Codes: B60R 2013/0293 : Connection or positioning of adjacent panels
• CPC Class Codes: Y10T 156/1028 : by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith
• CPC Class Codes: Y10T 156/103 : Encasing or enveloping the configured lamina
• CPC Class Codes: Y10T 156/1056 : Perforating lamina
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24339 : Keyed
• CPC Class Codes: Y10T 428/24347 : From both sides

Abstract

The present invention is directed to a method of preparing an article of manufacture. The method includes bringing at least a portion of a heated thermoplastic sheet into contact with at least a portion of the first surface of a support having a plurality of perforations. A vacuum is formed on the second surface of the support, and portions the heated thermoplastic sheet are drawn through the perforations of the support and to the second surface side of the support. Thermoplastic attachment heads are formed on the second surface side of the support, from the thermoplastic material of the sheet that is drawn through the perforations. The thermoplastic sheet and the support are fixedly attached one to the other by means of the edges of the perforations being embedded in the thermoplastic material of the sheet drawn therethrough, and the thermoplastic attachment heads. Also disclosed are articles of manufacture, such as interior and exterior automotive body panels and components.

Claims

1. A method of preparing an article comprising:

(a) providing a thermoplastic sheet having a first surface and a second surface;

(b) providing a support having a plurality of perforations having edges, a first surface and a second surface;

(c) heating said thermoplastic sheet to a temperature that is at least equal to the softening point and less than the melting point of said thermoplastic sheet;

(d) bringing at least a portion of the second surface of the heated thermoplastic sheet into contact with at least a portion of the first surface of said support;

(e) forming reduced gaseous pressure on the second surface of said support, thereby drawing portions of said heated thermoplastic sheet through at least some of said perforations, the edges of said perforations being embedded in the thermoplastic material drawn therethrough;

(f) forming at least one thermoplastic attachment head on the second surface side of said support, said thermoplastic attachment head being formed from and being continuous with the portions of said thermoplastic sheet that are drawn through said perforations; and

(g) cooling the heated thermoplastic sheet below its softening point,

wherein said thermoplastic sheet is fixedly attached to said support by means of said attachment heads and the edges of said perforations being embedded in the thermoplastic material drawn therethrough.

2. The method of claim 1 wherein said support is fabricated from a material selected from the group consisting of metal, thermoset plastic material, thermoplastic material and combinations thereof.

3. The method of claim 1 wherein said thermoplastic sheet is selected from single layer thermoplastic sheets and multilayer thermoplastic sheets.

4. The method of claim 1 wherein said thermoplastic sheet comprises at least one material selected from thermoplastic polycarbonate, thermoplastic polyester, thermoplastic polyamide, thermoplastic graft copolymer, thermoplastic vinyl polymer, thermoplastic polyolefin, thermoplastic poly(meth)acrylate and thermoplastic polyurethane.

5. The method of claim 1 wherein said thermoplastic sheet comprises at least one thermoplastic semicrystalline polymer.

6. The method of claim 5 wherein said thermoplastic semicrystalline polymer is selected from thermoplastic semicrystalline polyester, thermoplastic semicrystalline polyamide and combinations thereof.

7. The method of claim 1 wherein said attachment heads in step (f) are formed by means of contacting reversibly an opposing mold member with the thermoplastic material drawn through said perforations on the second surface side of said support.

8. The method of claim 1 further comprising:

providing a second thermoplastic sheet having a first surface and a second surface; and

adhering at least a portion of the second surface of said second thermoplastic sheet to at least a portion of the first surface of said thermoplastic sheet.

9. The method of claim 8 wherein said second thermoplastic sheet is adhered to said thermoplastic sheet by means of,

heating said second thermoplastic sheet to a temperature that is at least equal to the softening point and less than the melting point of said second thermoplastic sheet;

and

bringing at least a portion of the second surface of said thermoplastic sheet into contact with at least a portion of the first surface of said heated thermoplastic sheet, thereby causing said second thermoplastic sheet and said thermoplastic sheet to fuse one to the other.

10. The process of claim 1 wherein said thermoplastic sheet is further fixedly attached to said support by attachment means selected from fasteners, adhesives and combinations thereof.

11. The process of claim 1 wherein said perforations have deformed edge portions, and said deformed edge portions are embedded in the thermoplastic material drawn therethrough.

12. The process of claim 1 wherein said support has terminal edges, and said process further comprises wrapping a portion of said thermoplastic sheet around at least a portion of said terminal edges of said support, the terminal edges of said support being embedded in the thermoplastic material of said sheet wrapped there-around, thereby further fixedly attaching said sheet and said support one to the other.

13. An article of manufacture comprising:

(a) a support having a plurality of perforations having edges, a first surface and a second surface; and

(b) a thermoplastic sheet having a first surface and a second surface, at least a portion of the second surface of said thermoplastic sheet being in contact with at least a portion of the first surface of said support,

wherein said thermoplastic sheet is fixedly attached to said support by means of a portion of said thermoplastic sheet extending through at least some of said perforations and being continuous with attachment heads on the second surface side of said support, and the edges of said perforations being embedded in the thermoplastic material extending there through.

14. The article of claim 13 wherein said support is fabricated from a material selected from the group consisting of metal, thermoset plastic material, thermoplastic material and combinations thereof.

15. The article of claim 13 wherein said thermoplastic sheet comprises at least one material selected from thermoplastic polycarbonate, thermoplastic polyester, thermoplastic polyamide, thermoplastic graft copolymer, thermoplastic vinyl polymer, thermoplastic polyolefin, thermoplastic poly(meth)acrylate and thermoplastic polyurethane.

16. The article of claim 13 wherein said thermoplastic sheet comprises at least one thermoplastic semicrystalline polymer.

17. The article of claim 16 wherein said thermoplastic semicrystalline polymer is selected from thermoplastic semicrystalline polyester, thermoplastic semicrystalline polyamide and combinations thereof.

18. The article of manufacture of claim 13 wherein said article further comprises a second thermoplastic sheet having a first surface and a second surface, at least a portion of the second surface of said second thermoplastic sheet being adhered to at least a portion of the first surface of said thermoplastic sheet (b).

19. The article of manufacture of claim 13 wherein said perforations have deformed edge portions, and said deformed edge portions are embedded in the thermoplastic material extending therethrough.

20. The article of manufacture of claim 13 wherein said thermoplastic sheet is further fixedly attached to said support by attachment means selected from fasteners, adhesives and combinations thereof.

21. The article of manufacture of claim 13 wherein said perforations have deformed edge portions, and said deformed edge portions are embedded in the thermoplastic material extending therethrough.

22. The article of manufacture of claim 13 wherein said support has terminal edges, and a portion of said thermoplastic sheet is wrapped around at least a portion of said terminal edges of said support, the terminal edges of said support being embedded in the thermoplastic material of said sheet wrapped there-around, thereby further fixedly attaching said sheet and said support one to the other.