Embossing and laminating process

• US 4,199,390 A
• Filed: 09/19/1975
• Issued: 04/22/1980
• Est. Priority Date: 02/22/1974
• Status: Expired due to Term

• Current Assignee: Stephen L. Pollard
• Original Assignee: Stephen L. Pollard
• Inventors: Pollard, Stephen L.
• Primary Examiner(s): Simmons, David A.
• Application Number:
  US05/615,125
• Time in Patent Office: 1,677 Days
• Field of Search: 156/219, 156/220, 156/209, 156/314, 156/315, 156/77, 156/310, 428/320, 428/158-160
• US Class Current: 156/209
• CPC Class Codes: B29C 59/026 of layered or coated substantially flat surfaces
• CPC Class Codes: B29C 65/18 using heated tools
• 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 66/436 Joining sheets for making articles comprising cushioning or padding materials, the weld being performed through the cushioning material, e.g. car seats joining through openings B29C66/304
• 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 66/727 being porous, e.g. foam
• CPC Class Codes: B29C 66/7394 characterised by the material of at least one of the parts being a thermoset
• CPC Class Codes: B29C 66/8223 Worm or spindle mechanisms
• CPC Class Codes: B29C 66/8242 Pneumatic or hydraulic drives using fluid pressure directly acting on the parts to be joined B29C66/8266
• CPC Class Codes: B29C 66/8322 Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29C 66/83411 Roller, cylinder or drum types B29C66/83431 takes precedence; rollers, cylinders or drums moving relative to and tangentially to the parts to be joined B29C66/8362
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2305/022 Foam
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 38/06 Embossing
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 156/1023 Surface deformation only [e.g., embossing]
• CPC Class Codes: Y10T 156/1039 Surface deformation only of sandwich or lamina [e.g., embossed panels]
• CPC Class Codes: Y10T 428/24504 : Component comprises a polymer [e.g., rubber, etc.]

Abstract

A method of making a composite product having a preformed, self-sustaining pliable skin sheet and a preformed non-rigid void containing, low density plastic layer which comprises:

(1) establishing a layer of said low density plastic,

(2) applying to at least one side a liquid sprayable curative,

(3) next applying to the same said side thereof a liquid sprayable polymer which together with said curative is reactive at elevated temperature to form a tenacious, essentially non-porous adhesive which bonds to both said sheet and said layer,

(4) next contacting said skin sheet with said side of the low density plastic layer,

(5) curing said polymer at elevated temperature whereby said skin sheet is adhered to said layer.

Claims

1. A method of making a composite product having a preformed, self-sustaining pliable non-void containing skin sheet and a preformed non-rigid void containing, low density plastic layer which comprises:

(1) establishing a layer of said low density plastic,

(2) spraying on at least one side of liquid sprayable curative to yield a wetted surface on said low density plastic,

(3) next spraying on said wet surface of the low density plastic a liquid sprayable polymer to wet the surface of the low density plastic with said polymer, said polymer being one which together with said curative is reactive at elevated temperature to form a tenacious, essentially non-porous adhesive which bonds to both said sheet and said layer,

(4) next contacting said skin sheet with said wetted surface of said low density plastic layer, and

(5) curing said polymer at elevated temperature whereby said skin sheet is adhered to said layer.

2. The product of the method of claim 1.

3. The method of claim 1 wherein the low-density plastic is polyurethane foam.

4. The method of claim 1 wherein said polymer and said curative are essentially non-reactive at about room temperature.

5. The method of claim 1 wherein said curing is carried out such that embossing occurs in selective areas under the influence of externally applied mechanical pressure and laminating occurs in the remaining areas under a lesser pressure which is the self-generated pressure of the trapped gases and vapors generated by heating said polymer and said curative to their interreactive temperature.

6. The method of claim 1 wherein said polymer is a polyurethane having functional groups of complementary reactivity with functional groups on said curative.

7. The method of claim 1 wherein the spraying steps are carried out in a closure which contains any fumes or vapors and said fumes or vapors are removed from said closure in a controlled and channeled manner.

8. The method of claim 1 wherein said curative is an aqueous solution and said laminating occurs under the vapor pressure of water at the curing temperature.