Method for forming a structural panel with decorative facing and product thereof

• US 5,238,725 A
• Filed: 12/21/1990
• Issued: 08/24/1993
• Est. Priority Date: 12/21/1990
• Status: Expired due to Term

• Current Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Original Assignee: E. I. du Pont de Nemours and Company (Corteva, Inc.)
• Inventors: Effing, Michael J., Walrave, Albertus P., Nollen, Dennis A., Okine, Richard K.
• Primary Examiner(s): Epstein, Henry F.
• Application Number:
  US07/631,436
• Time in Patent Office: 977 Days
• Field of Search: 156/245, 156/292, 156/322, 264/255, 264/257, 264/320, 264/321, 264/324, 428/116, 428/285, 428/308.4, 428/241, 428/310.5, 428/192, 428/73, 428/117, 428/118
• US Class Current: 428/116
• CPC Class Codes: B29B 13/023 Half-products, e.g. films, plates
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29C 51/12 of articles having inserts or reinforcements
• CPC Class Codes: B29C 53/04 of plates or sheets B29C63/04 takes precedence; bending or folding paper B31F1/0003; folding films B65H45/00
• CPC Class Codes: B29C 70/46 using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
• CPC Class Codes: B29K 2027/12 containing fluorine
• CPC Class Codes: B29K 2027/14 PVF, i.e. polyvinyl fluoride
• CPC Class Codes: B29K 2071/00 Use of polyethers , e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: B29L 2031/3041 Trim panels
• CPC Class Codes: B29L 2031/608 Honeycomb structures
• CPC Class Codes: B32B 2262/0269 Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2305/08 Reinforcements
• CPC Class Codes: B32B 2309/02 Temperature
• CPC Class Codes: B32B 2309/025 Temperature vs time profiles
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/10 of paper or cardboard
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 3/12 : characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 37/146 : whereby one or more of the layers is a honeycomb structure
• CPC Class Codes: B32B 38/0036 : Heat treatment for heating or cooling of layers during lamination B32B37/06, B32B37/08
• CPC Class Codes: Y10T 428/24149 : Honeycomb-like

Abstract

A panel having a honeycomb core and thermoplastic resin facings with adhered decorative polyvinyl fluoride overlayer is shaped in a press after being preheated to the softening temperature of the resin and the placing of the heated thermoplastic resin facing in registry with the overlayer which is preheated, thus pressing the two together in the press.

Claims

1. A composite structure comprising a honeycomb core member of aramid paper having bonded to one of its faces a facesheet comprising fiber reinforced thermoplastic resin and an adhered decorative polyvinyl fluoride overlayer, said decorative overlayer having a peel adhesion of from about 1.5 to 2.5 pounds per inch of width.

2. A method for bonding a polyvinyl fluoride film to a thermoplastic facing bonded to a honeycomb core member of aramid paper of a panel and molding the panel to form a laminated shaped structure, said method comprising:

heating the thermoplastic facing of the panel to a temperature in the range of from about 150°

C. to about 400°

C. within 30 to 240 seconds;

placing the panel in a mold configured to said shaped structure;

heating a sheet of polyvinyl fluoride film in a separate heating step to a temperature of from about 75°

C. to about 150°

C.;

placing said sheet in registry with the thermoplastic facing;

pressing the panel and the film together to form a laminated shaped structure; and

cooling said structure.

3. The method of claim 2 wherein the thermoplastic facing and sheet of polyvinyl fluoride film are pressed together at a pressure of from about 50 to about 90 psi.