Process for producing a multilayer molded article

• US 5,509,990 A
• Filed: 12/29/1993
• Issued: 04/23/1996
• Est. Priority Date: 12/27/1988
• Status: Expired due to Term

• Current Assignee: Sumitomo Chemical Company Limited
• Original Assignee: Sumitomo Chemical Company Limited
• Inventors: Usui, Nobuhiro, Hosokawa, Toshihiro, Matsumoto, Masahito, Masui, Shohei, Ishitsubo, Ryuichi
• Primary Examiner(s): Silbaugh, Jan H.
• Assistant Examiner(s): ORTIZ, ANGELA Y
• Application Number:
  US08/174,757
• Time in Patent Office: 846 Days
• Field of Search: 264/46.4, 264/46.6, 264/247, 264/257, 264/259, 264/266, 264/263, 264/275, 425/129.1, 425/111, 425/112, 425/123, 156/242, 156/245, 156/213, 156/214
• US Class Current: 156/242
• CPC Class Codes: B29C 33/12 with incorporated means for positioning inserts, e.g. labels positioning reinforcements B29C70/541
• CPC Class Codes: B29C 43/183 the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould
• CPC Class Codes: B29C 43/184 shaped by the compression of the material during moulding
• 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 45/14065 Positioning or centering articles in the mould
• CPC Class Codes: B29C 45/14508 Joining juxtaposed sheet-like articles, e.g. for making trim panels
• CPC Class Codes: B29C 51/26 Component parts, details or accessories; Auxiliary operations
• CPC Class Codes: B29C 70/78 Moulding material on one side only of the preformed part

Abstract

A multilayer molded article comprising a resin body and at least one sheet of a skin material an edge part of which is present in a surface area of the resin body is efficiently produced by clamping an edge part of a skin material or mated edge parts of adjacent skin materials during molding.

Claims

1. A process for producing a multilayer molded article comprising a resin body and at least two sheets of skin materials which are 1a laminated adjacently on one surface of the resin body, which process comprises the steps of:

mating an edge part of one of the skin materials with an adjacent edge part of another of the skin materials;

clamping the mated edge parts of said skin materials with clamping means, said clamping means having a receiving opening for receiving and securing the edge parts of the skin materials therein, wherein the receiving opening includes pins disposed across said opening and through the edge parts of the skin materials so as to secure said edge parts in said clamping means;

inserting said clamping means into an engaging groove provide in a first mold which opposes a second mold;

spreading the skin materials between said first and second molds;

supplying a mass of resin melt between the skin materials and the first mold; and

closing the first and second molds to form the multilayer molded article, wherein said mated edge parts of said skin materials are formed so as to be within the interior of said multilayer molded article;

wherein said receiving opening is a groove having alternating wide and narrow portions, said wide portions being conduits for allowing resin melt to pass therethrough.

3. The method of claim 1, wherein edge portions of the skin material not secured by said clamping means are secured to said first mold with pins.

5. The method of claim 1, wherein the skin material is selected from the group consisting of woven fabrics, non-woven fabrics, metal nets, fiber nets, thermoplastic resin nets, paper, metal foils, thermoplastic resin sheets, elastomer sheets, thermoplastic resin foams, and rubber foams.

7. The method of claim 1, wherein the resin melt is formed from a resin selected from the group consisting of polypropylene, polyethylene, polystyrene, acrylonitrile-styrene-butadiene copolymer, nylon, ethylene-propylene copolymer and styrene-butadiene copolymer.

9. The method of claim 1, wherein said mated edge parts of said skin materials are bonded together with an adhesive or by welding before being clamped by said clamping means.

2. A process for producing a multilayer molded article comprising a resin body and one sheet of a skin material laminated on a part of a surface of the resin body, which process comprises the steps of:

clamping an edge part of the skin material with clamping means, said clamping means having a receiving opening for receiving and securing the edge part of the skin material therein, wherein the receiving opening of said clamping means includes pins disposed across said opening and through the edge part of the skin material so as to secure said edge part in said clamping means;

inserting said clamping means into an engaging groove provided in a first mold which opposes a second mold;

spreading the rest of the skin material between said first and second molds;

supplying a mass of resin melt between the skin material and the first mold; and

closing the male and female molds to form the multilayer molded article, wherein said edge part of said skin material is formed so as to be disposed within the interior or said multilayer molded article;

wherein said receiving opening is a groove having alternating wide and narrow portions, said wide portions being conduits for allowing resin melt to pass therethrough.

4. The method of claim 2, wherein edge portions of the skin material not secured by said clamping means are secured to said first mold with pins.

6. The method of claim 2, wherein the skin material is selected from the group consisting of woven fabrics, non-woven fabrics, metal nets, fiber nets, thermoplastic resin nets, paper, metal foils, thermoplastic resin sheets, elastomer sheets, thermoplastic resin foams, and rubber foams.

8. The method of claim 2, wherein the resin melt is formed from a resin selected from the group consisting of polypropylene, polyethylene, polystyrene, acrylonitrile-styrene-butadiene copolymer, nylon, ethylene-propylene copolymer and styrene-butadiene copolymer.