Process for producing multilayer molded article

• US 5,308,570 A
• Filed: 12/20/1991
• Issued: 05/03/1994
• Est. Priority Date: 12/21/1990
• Status: Expired due to Term

• Current Assignee: Sumitomo Chemical Company Limited
• Original Assignee: Sumitomo Chemical Company Limited
• Inventors: Usui, Nobuhiro, Matsubara, Shigeyoshi, Matsumoto, Masahito, Hara, Takahisa
• Primary Examiner(s): Woo, Jay H.
• Assistant Examiner(s): Davis, Robert B.
• Application Number:
  US07/811,302
• Time in Patent Office: 865 Days
• Field of Search: 264/250, 264/255, 264/257, 264/258, 264/261, 264/154, 264/155, 264/156, 264/241, 264/275, 264/277, 264/278, 264/279, 264/246, 264/247, 264/254, 264/259, 264/273, 425/90, 425/96, 425/97, 425/98, 425/290, 425/310, 425/553, 425/566, 425/571, 425/DIG. 37
• US Class Current: 264/255
• CPC Class Codes: B29C 2035/0283 Thermal pretreatment of the plastics material thermal after-treatment B29C71/02
• CPC Class Codes: B29C 2045/14877 preheating or precooling the insert for non-deforming purposes
• CPC Class Codes: B29C 2045/14967 Injecting through an opening of the insert
• 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 45/14786 Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
• CPC Class Codes: B29C 45/14795 Porous or permeable material, e.g. foam
• CPC Class Codes: B29C 45/14811 Multilayered articles B29C45/14827 takes precedence
• CPC Class Codes: B29C 45/1671 with an insert
• CPC Class Codes: B29C 70/78 Moulding material on one side only of the preformed part
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: B29K 2105/0863 SMC, i.e. sheet moulding compound
• CPC Class Codes: B29K 2105/256 Sheets, plates, blanks or films
• CPC Class Codes: B32B 2305/08 Reinforcements
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 27/04 as impregnant, bonding, or embedding substance not used
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material

Abstract

A multilayer molded article having good appearance is produced by providing a preheated fiber-reinforced resin sheet between a pair of upper and lower molds, and supplying a thermoplastic resin melt and optionally a foam sheet between the upper mold and the fiber-reinforced resin sheet. The thermoplastic resin melt is supplied through a resin supplying opening provided in the lower mold, and through a hole made in the fiber-reinforced resin sheet and the foam sheet. During the supply of the resin melt or as soon as the resin supply is finished, the molds are closed to further flow, and the resin melt is formed to produce a mu molded article made of the fiber-reinforced resin sheet, a skin layer of the thermoplastic resin and optionally the foam sheet therebetween.

Claims

1. A process for producing a multilayer molded article comprising the steps of:

providing a preheated fiber-reinforced resin sheet between a pair of upper and lower molds,

supplying a resin melt of a thermoplastic resin between said upper mold and said fiber-reinforced resin sheet from a resin supplying opening provided in said lower mold through a hole made in said fiber-reinforced resin sheet, and

closing of the molds by moving the upper mold toward the lower mold during resin supply or as soon as the resin supply is finished to produce a multilayer molded article comprising said fiber-reinforced resin sheet and a skin layer of said thermoplastic resin which is integrally laminated on said resin sheet.

2. The process according to claim 1, wherein said thermoplastic resin is an olefinic thermoplastic elastomer.

5. The process according to claim 1, wherein said fiber-reinforced resin sheet comprises reinforcing fibers embedded in a thermoplastic resin.

6. The process according to claim 5, wherein said thermoplastic resin of said fiber-reinforced resin sheet is selected from the group consisting of polypropylene and polyamide.

7. The process according to claim 1, wherein the reinforcing fibers of said fiber-reinforced resin sheet are selected from the group consisting of glass fiber, carbon fiber, stainless steel fiber, polyamide fiber, polyester fiber, aramid fiber, and mixtures thereof.

8. The process according to claim 7, wherein said fiber is a glass fiber.

3. A process for producing a multilayer molded article comprising the steps of:

providing a preheated fiber-reinforced resin sheet between a pair of upper and lower molds and then a foam sheet on said resin sheet

supplying a resin melt of a thermoplastic resin between said upper mold and said foam sheet from a resin supplying opening provided in said lower mold through holes made in said fiber-reinforced resin sheet and said foam sheet, and

closing of the molds by moving the upper mold toward the lower mold during resin supply or as soon as the resin supply is finished to produce a multilayer molded article comprising said fiber-reinforced resin sheet, said foam sheet and a skin layer of said thermoplastic resin which is integrally laminated on said foam sheet.

4. The process according to claim 3, wherein said thermoplastic resin is an olefinic thermoplastic elastomer.

9. The process according to claim 3, wherein said fiber-reinforced resin sheet comprises reinforcing fibers embedded in a thermoplastic resin.

10. The process according to claim 9, wherein said thermoplastic resin of said fiber-reinforced resin sheet is selected from the group consisting of polypropylene and polyamide.

11. The process according to claim 3, wherein the reinforcing fibers of said fiber-reinforced resin sheet are selected from the group consisting of glass fiber, carbon fiber, stainless steel fiber, polyamide fiber, polyester fiber, aramid fiber, and mixtures thereof.

12. The process according to claim 11, wherein said fiber is a glass fiber.