Method of laminating a fabric covered article

• US 5,234,523 A
• Filed: 04/24/1992
• Issued: 08/10/1993
• Est. Priority Date: 04/24/1992
• Status: Expired due to Fees

• Current Assignee: UT Automotive Dearborn, Inc.
• Original Assignee: United Technologies Automotive, Inc. (Lear Corporation)
• Inventors: Battreall, Marc A.
• Primary Examiner(s): Gallagher, John J.
• Application Number:
  US07/874,276
• Time in Patent Office: 473 Days
• Field of Search: 156/308.8, 156/281, 156/278, 156/305, 156/283, 156/285, 428/246, 264/85
• US Class Current: 156/283
• CPC Class Codes: B32B 2038/0056 Moistening
• CPC Class Codes: B32B 2305/026 Porous
• CPC Class Codes: B32B 2310/049 using steam or damp
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles
• CPC Class Codes: B32B 37/06 characterised by the heating method
• CPC Class Codes: B32B 37/1207 Heat-activated adhesive B32B37/04 takes precedence
• CPC Class Codes: Y10T 442/3667 Composite consisting of at least two woven fabrics bonded by an interposed adhesive layer [but not two woven fabrics bonded together by an impregnation which penetrates through the thickness of at least one of the woven fabric layers]
• CPC Class Codes: Y10T 442/3813 Coating or impregnation contains synthetic polymeric material

Abstract

The present invention discloses a method for laminating a gas permeable layer onto a preformed substrate by forming a laminate precursor comprising a substrate and a gas permeable layer in which a layer of adhesive is positioned between the gas permeable layer and the substrate surface. A layer of water is formed on the surface of the gas permeable layer and the wetted surface is contacted by a preheated platen and super heated steam is ejected onto the gas permeable layer causing the adhesive to cure and bond the gas permeable layer to the substrate.

Claims

1. A method for adhesively laminating a gas permeable layer to a preformed substrate comprising;

forming a laminate precursor comprising a substrate, a gas permeable layer having a first surface and a second surface, said gas permeable layer being positioned over a portion of the substrate surface and a layer of adhesive placed between the first surface of the gas permeable layer and the substrate surface;

wetting the second surface of the gas permeable layer;

contacting a heated platen with the wetted surface of the gas permeable layer and applying pressure to the gas permeable layer while ejecting super heated steam onto the gas permeable layer causing the adhesive to bond the gas permeable layer to the substrate surface.

2. The process of claim 1 wherein the gas permeable layer is a decorative fabric.

3. The process of claim 1 wherein the gas permeable layer is selected from the group comprising nylon, rayon, polyurethane, polyethylene or polypropylene.

4. The process of claim 1 wherein the substrate comprises shoddy.

5. The process of claim 1 wherein the temperature of the super heated steam ejected from the die is about 400°

F. to about 700°

F.

6. The process of claim 1 wherein the adhesive is powdered hot melt adhesive.

7. A method for adhesively laminating a gas permeable layer to a preformed substrate comprising;

forming a laminate precursor comprising a substrate, at least one gas permeable layer having a first surface and a second surface wherein said first surface is positioned over at least a portion of the surface of the substrate and a layer of adhesive is positioned between the substrate and the gas permeable layer;

positioning a preheated platen sufficiently close to the second surface of the gas permeable layer such that when super heated steam is ejected from the surface of the platen a layer of water condensate is caused to form on the second surface of the gas permeable layer;

contacting the preheated platen with the wetted surface of the gas permeable layer and applying pressure and super heated steam to the gas permeable layer causing the adhesive to bond the gas permeable layer to the substrate.

8. The method of claim 7 wherein the preheated platen is positioned above the gas permeable layer at a distance of between about 2 inches and 8 inches.