Resilient multi layered member incorporating skin layer, foam layer cushion layer and core, and method of manufacture thereof

• US 4,769,278 A
• Filed: 06/18/1987
• Issued: 09/06/1988
• Est. Priority Date: 09/29/1986
• Status: Expired due to Term

• Current Assignee: Kasai Kogyo Company Limited
• Original Assignee: Kasai Kogyo Company Limited
• Inventors: Suzuki, Noriyoshi, Imaizumi, Takashi, Kamimura, Tomohisa
• Primary Examiner(s): Van Balen, William J.
• Application Number:
  US06/063,403
• Time in Patent Office: 446 Days
• Field of Search: 428/159, 428/174, 428/280, 428/282, 428/316.6, 428/317.1, 428/319.3, 428/319.7, 156/228, 156/245
• US Class Current: 442/326
• CPC Class Codes: B29C 44/06 Making multilayered articles B29C44/0407 - B29C44/0492 take precedence
• CPC Class Codes: B29C 44/10 Applying counter-pressure during expanding
• CPC Class Codes: B29K 2027/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B32B 2038/0084 Foaming
• CPC Class Codes: B32B 2266/0235 Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2305/022 Foam
• CPC Class Codes: B32B 2307/51 Elastic
• CPC Class Codes: B32B 2327/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 3/26 characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205; characterised by an apertured layer
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: B32B 5/32 at least two layers being foamed and next to each other
• 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: Y10T 428/24504 Component comprises a polymer [e.g., rubber, etc.]
• CPC Class Codes: Y10T 428/24628 : Nonplanar uniform thickness material
• CPC Class Codes: Y10T 428/249981 : Plural void-containing components
• CPC Class Codes: Y10T 428/249982 : With component specified as adhesive or bonding agent
• CPC Class Codes: Y10T 428/249992 : Linear or thermoplastic
• CPC Class Codes: Y10T 442/59 : At least three layers
• CPC Class Codes: Y10T 442/647 : Including a foamed layer or component

Abstract

In this resilient multi layered member, there are provided as laminated together: a surface skin layer, formed of PVC resin powder made into a gel, on the outside side of the resilient multi layered member; 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 inner side of the foam material layer; and a substantially stiff core material layer, the outer side of which is adhered to the inner side of the cushion material layer, on the inside side of the resilient multi layered member. There may be further included an adhesive layer by means of which the outer side of the cushion material layer is adhered to the inner side of the foam material layer. The cushion material layer may be formed from urethane foam, or from non woven fabric, which may be a felt material, and may have a density greater than about 200 grams per square meter. This density may more particularly be between about 260 grams per square meter and about 300 grams per square meter. Alternatively, the cushion material layer may be formed from compressed urethane material, which may be compressed by a factor of from about 50% to about 80%, and may have a density of between about 0.05 grams per cubic centimeter and about 0.10 grams per cubic centimeter.

Claims

1. A resilient multi layered member, comprising:

a surface skin layer, formed of PVC resin powder made into a gel, on its outside side;

a foam material layer, formed from foamed PVC resin powder, the outer side of which is adhered to the inner side of said surface skin layer;

a cushion material layer, the outer side of which is adhered to the inner side of said foam material layer;

and a substantially stiff core material layer on its inside side, the outer side of which is adhered to the inner side of said cushion material layer.

2. A resilient multi layered member according to claim 1, further comprising an adhesive layer by means of which the outer side of said cushion material layer is adhered to the inner side of said foam material layer.

3. A resilient multi layered member according to claim 1 or claim 2, wherein said cushion material layer is formed from urethane foam.

4. A resilient multi layered member according to claim 1 or claim 2, wherein said cushion material layer is formed from non woven fabric.

5. A resilient multi layered member according to claim 4, wherein said cushion material layer is formed from a felt material.

6. A resilient multi layered member according to claim 4, wherein said cushion material layer has a density greater than about 200 grams per square meter.

7. A resilient multi layered member according to claim 4, wherein said cushion material layer has a density between about 260 grams per square meter and about 300 grams per square meter.

8. A resilient multi layered member according to claim 1 or claim 2, wherein said cushion material layer is formed from compressed urethane material.

9. A resilient multi layered member according to claim 8, wherein said urethane material is compressed by a factor of from about 50% to about 80%.

10. A resilient multi layered member according to claim 8, wherein said cushion material layer has a density of between about 0.05 grams per cubic centimeter and about 0.10 grams per cubic centimeter.

11. A method for manufacturing a resilient multi layered member, comprising the steps of:

laying a surface skin layer, formed of PVC resin powder made into a gel, into an outer mold portion;

adhering a foam material layer, formed from foamed PVC resin powder, to the inner side of said surface skin layer, as they lie in said outer mold portion;

laying a substantially stiff core material layer on an inner mold portion;

adhering a cushion material layer to the inner side of said core material layer, as they lie in said inner mold portion;

and approaching together said outer mold portion bearing said surface skin layer and said foam material layer and said inner mold portion bearing said cushion material layer and said core material layer, and adhering together said cushion material layer and said foam material layer.

12. A method for manufacturing a resilient multi layered member according to claim 11, wherein said cushion material layer is adhered to said foam material layer by an adhesive layer.

13. A method for manufacturing a resilient multi layered member according to claim 11 or claim 12, wherein said cushion material layer is formed from urethane foam.

14. A method for manufacturing a resilient multi layered member according to claim 11 or claim 12, wherein said cushion material layer is formed from non woven fabric.

15. A method for manufacturing a resilient multi layered member according to claim 14, wherein said cushion material layer is formed from a felt material.

16. A method for manufacturing a resilient multi layered member according to claim 14, wherein said cushion material layer has a density greater than about 200 grams per square meter.

17. A method for manufacturing a resilient multi layered member according to claim 14, wherein said cushion material layer has a density between about 260 grams per square meter and about 300 grams per square meter.

18. A method for manufacturing a resilient multi layered member according to claim 11 or claim 12, wherein said cushion material layer is formed from compressed urethane material.

19. A method for manufacturing a resilient multi layered member according to claim 18, wherein said urethane material is compressed by a factor of from about 50% to about 80%.

20. A method for manufacturing a resilient multi layered member according to claim 18, wherein said cushion material layer has a density of between about 0.05 grams per cubic centimeter and about 0.10 grams per cubic centimeter.