Method for molding a laminate

• US 5,110,532 A
• Filed: 03/04/1991
• Issued: 05/05/1992
• Est. Priority Date: 03/04/1991
• Status: Expired due to Fees

• Current Assignee: Siebolt Hettinga
• Original Assignee: Siebolt Hettinga
• Inventors: Hettinga, Siebolt
• Primary Examiner(s): Woo, Jay H.
• Assistant Examiner(s): DURKIN, JEREMIAH
• Application Number:
  US07/665,571
• Time in Patent Office: 428 Days
• Field of Search: 264/339, 264/257, 264/258, 264/275, 264/276, 264/277, 264/278, 264/279, 264/261
• US Class Current: 264/257
• CPC Class Codes: B29C 2045/1495 Coating undercut inserts
• CPC Class Codes: B29C 45/14 incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles B29C45/1671 takes precedence
• CPC Class Codes: B29C 45/14196 the inserts being positioned around an edge of the injected part
• CPC Class Codes: B29C 70/683 Pretreatment of the preformed part, e.g. insert

Abstract

An improved method for manufacturing a laminate wherein the edges of a deformable surface layer, such as cloth or carpet, are folded under and releasably secured to the undersurface of the deformable surface layer. The deformable surface layer is then placed into a mold unit and the securement between the folded edge and the undersurface of the deformable surface layer is released either prior to or during the injection of a plastic material for forming a plastic support layer. The method produces a laminate including a deformable surface layer having edges which are folded under and totally bonded to the plastic support layer. The bonded edges improve the securement between the deformable surface layer and the plastic support layer and give the laminate a "finished" appearance without tacks or staples.

Claims

1. A process of injection molding for forming a laminate having a deformable surface layer and a thermoplastic substrate, as the bonding agent, said process comprising the steps of:

(a) providing a male mold member and a female mold member;

(b) folding under an edge portion along at least a partial perimeter of said deformable surface layer;

(c) releasably securing said folded edge portion of said deformable surface layer to the undersurface of said deformable surface layer;

(d) placing said deformable surface layer between said male mold member and said female mold member, said undersurface of said deformable surface layer directed toward said male mold member;

(e) clamping said male mold member and said female mold member together to form a mold cavity;

(f) allowing time for said securement between said folded edge portion and said undersurface of said deformable surface to release;

(g) injecting a plastic material into the mold cavity and between said folded perimeter edge portion of said deformable surface layer and said undersurface of said deformable surface layer;

(h) allowing said plastic material to at least partially cool and harden; and

then

(i) removing the resultant laminate from the mold cavity.

2. The process, according to claim 1, further comprising the steps of:

(a) placing an adhesive at intermittent points between said perimeter edge portion of said deformable surface layer and said undersurface of said deformable surface layer; and

then to secure releasably

(b) applying pressure the points of adhesive contact between said folded edge portion of said deformable surface layer and said undersurface of said deformable surface layer.

3. A process of injection molding for forming a laminate having a fabric surface layer upon a plastic support layer, said process comprising the steps of:

(a) providing a male mold member and a female mold member;

(b) folding under an edge portion along at least a partial perimeter of a main portion of said fabric surface layer;

(c) releasably attaching said edge portion to an undersurface of said main portion of said fabric surface layer;

(d) placing said fabric surface layer between said male mold member and said female mold member, said undersurface of said main portion of said fabric surface layer directed toward said male mold member;

(e) clamping said male mold member and said female mold member together to form a mold cavity;

(f) injecting a plastic material into the mold cavity thus breaking the attachment between said edge portion and said main portion of said fabric surface layer while concurrently filling said edge portion with said plastic;

(g) allowing said plastic material to at least partially cool and harden; and

then

(h) removing the resultant laminate from the mold cavity.

4. The process, according to claim 3, further comprising the steps of:

(a) placing an adhesive at spaced intervals between said edge portion and said undersurface of said main portion of said fabric surface layer;

(b) applying pressure to secure releasably the points of adhesive contact between said edge portion and said undersurface of said main portion thus forming a tunnel between said edge portion and said undersurface of said main portion of said fabric surface layer; and

then

(c) breaking said points of adhesive contact by injecting said plastic into said tunnel between said edge portion and said undersurface of said main portion of said fabric surface layer.