Process for the manufacture of multi-layer composites with sensitive outer surfaces

• US 5,403,424 A
• Filed: 05/24/1993
• Issued: 04/04/1995
• Est. Priority Date: 06/05/1992
• Status: Expired due to Term

• Current Assignee: 3A Technology & Management Ltd.
• Original Assignee: Alusuisse-Lonza Services Ltd.
• Inventors: Ehrat, Rainer, Schlatter, Reinhard
• Primary Examiner(s): CRISPINO, RICHARD D
• Application Number:
  US08/065,874
• Time in Patent Office: 680 Days
• Field of Search: 156/39, 156/45, 156/242, 156/245, 156/246, 156/247, 156/323, 156/288, 156/243, 156/344
• US Class Current: 156/247
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 15/082 comprising vinyl resins; comprising acrylic resins
• CPC Class Codes: B32B 15/085 comprising polyolefins
• CPC Class Codes: B32B 2307/536 Hardness
• CPC Class Codes: B32B 2309/105 Thickness
• CPC Class Codes: B32B 37/26 with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers
• CPC Class Codes: Y10T 156/1142 Changing dimension during delaminating [e.g., crushing, expanding, warping, etc.]

Abstract

The invention relates to a process for protecting sensitive surfaces from mechanical and physical effects, in particular the effects of pressure and/or heat, whereby the surfaces are covered by a protective layer during the application of pressure and/or heat. The protective layer is a thermoplastic or elastic plastic that is molten, plastic or elastic under the conditions of applied pressure and/or heat, and has a lower resistance to deformation than the surface to be protected.

Claims

1. A process for the manufacture of multi-layer composites having a sensitive outer surface and for protecting the sensitive outer surface from mechanical and physical defects, comprising the steps of:

providing a protective layer on an adhesive layer comprising a carrier on an adhesive layer, wherein the carrier is a plastic material having shear modulus values falling below a curve defined by the shear modulus values 0.7 Pa×

10⁸ at 10°

C., 0.5 Pa×

10⁸ at 30°

C., 0.3 Pa×

10⁸ at 50°

C., 0.1 Pa×

10⁸ at 100°

C., and falling asymptotically towards zero above 150°

C. under at least one of the conditions of pressure and heat, wherein the protective layer exhibits a lower resistance to deformation than the sensitive outer surface being protected;

covering the sensitive outer surface with said protective layer on said adhesive layer during the application of pressure and heat, wherein the adhesive layer is in contact with the surface to be protected; and

shielding the sensitive outer surface from said heat and pressure and the consequential mechanical and physical effect thereof via said protective layer on said adhesive layer during the step of covering and creating a sliding layer on said sensitive outer surface.

2. The process according to claim 1, wherein said protective layer, in a cold condition and without the application of pressure, is in the form of a plastic film.

3. The process according to claim 1, wherein the protective layer is at least one of molten, plastic and elastic at pressures of 1 to 50 bar and temperatures of 100 to 250°

C.

4. The process according to claim 1, wherein the thickness of the protective layer is 10 μ

m to 250 μ

m.

5. The process according to claim 1, wherein the protective layer contains at least one thermoplastic from the group consisting of polyolefins, polyacrylates, polyesters, and polymers of vinyl compounds.

6. The process according to claim 5, wherein the thermoplastic contains a plasticizer additive.

7. The process according to claim 1, wherein the protective layer contains at least one elastic plastic.

8. The process according to claim 1, wherein the protective layer comprises a film containing at least one of polyolefins and polyesters, and an adhesive layer.

9. The process according to claim 1, wherein the multi-layer composite includes a plurality of sensitive surfaces which represent the outer layers of a multi-layer composite and the effects of pressure and heat are applied to permanently join together and form said composite of at least three layers, wherein at least one protective layer is deposited on each of the plurality of sensitive surfaces prior to the application of pressure and heat, further including the step of removing each of the protective layers in the form of a film after the application of pressure and heat.

10. The process according to claim 1, wherein the protective layer is at least one protective film employed in a double-belt press.