Manufacturing process of sheet-like bodies comprising seat parts for vehicles and the like

• US 5,783,009 A
• Filed: 06/22/1995
• Issued: 07/21/1998
• Est. Priority Date: 06/22/1994
• Status: Expired due to Term

• Current Assignee: Fabricacion Asientos Vehiculos Industriales SA (Trainvest SAS)
• Original Assignee: Fabricacion Asientos Vehiculos Industriales SA (Trainvest SAS)
• Inventors: Singla-Casasayas, Juan
• Primary Examiner(s): Ball, Michael W.
• Assistant Examiner(s): Tolin, Michael A.
• Application Number:
  US08/493,777
• Time in Patent Office: 1,125 Days
• Field of Search: 156/228, 156/242, 156/245, 156/267, 156/308.2, 156/309.6, 156/331.6, 156/332, 156/90, 156/212, 156/213, 156/214, 264/320, 428/95, 428/97, 428/284, 428/287, 428/290
• US Class Current: 156/90
• CPC Class Codes: B29C 70/78 Moulding material on one side only of the preformed part
• CPC Class Codes: B29D 99/0092 Producing upholstery articles, e.g. cushions, seats B29C63/025 takes precedence
• CPC Class Codes: D06M 17/04 by applying synthetic resins as adhesives
• CPC Class Codes: D06M 17/06 Polymers of vinyl compounds
• CPC Class Codes: Y10T 156/1031 with preshaping of lamina
• CPC Class Codes: Y10T 156/108 Flash, trim or excess removal

Abstract

It consists of continuous production of a woven or unwoven piece of textile fibers, to whose piece a layer that is going to be the middle one is affixed on the back surface. It is thick enough to offer resistance to the passing of a thermostable material that will be finally affixed to the same, wherein it will remain imbedded. The textile compound formed of the two layers referred to first of all, the second layer being an unwover layer, is subjected to a hot pre-forming process. Then it is inserted in a mold in which the thermostable material formed by a polyester-fiber glass mass is placed, hot pressing the whole and obtaining a rigid and resistance sheet-like body, whose visible surface is covered with the layer of textile compound that is highly resistant to vandalism. If the textile piece is consistent or thick enough, the middle layer could be eliminated, in which case the polyester-fiber glass mass would remainly closely affixed to that textile piece, with the insertion of the respective waterproof adhesive layer.

Claims

1. A manufacturing process of sheet-like bodies to be used as seat parts for vehicles, said process comprising the subsequent steps of:

fastening an adhesive acrylic resin layer (2) on a surface of a base layer (1), said base layer comprising a woven or unwoven piece of textile fibers, thereby obtaining a first object;

die-pressing said first object, thereby obtaining a second object;

pre-molding and corresponding hot forming of the second object, thereby obtaining a third object;

introducing the third object in a mold, placing a first surface of the third object in contact with the walls of the mold, wherein said first surface is a visible surface of the base layer (1);

depositing on said mold a thermostable material mass (5) formed of polyester-fiber glass, in contact with a second surface of said third object, said second surface being essentially complementary to said first surface; and

hot pressing the contents of the mold, thereby obtaining a single molded sheet-like body.

2. The process according to claim 1 wherein in the event the textile fiber base layer is not very consistent, a middle layer formed by an unwoven fiber film (3), provided on its outside or rear surface of a waterproof layer (4), is applied on the outside or rear surface of the adhesive acrylic resin layer (2) of the first object.

3. The process according to claim 1 wherein the textile fiber base layer (1) may be woven or unwoven, with a grammage between 150 and 1000 gr/m².

4. The process according to any of claims 2 or 3 wherein the acrylic resin layer (2) is inserted as an adhesive means between the base layer (1) and the unwoven fiber film (3) has a weighting of between 20 and 80 gr/m².

5. The process according to any of claims 2 or 3 wherein the waterproof layer (4) is made from a fireproof PVC resin layer having a weighting between 40 and 150 gr/m².

6. The process according to any of claims 1, 2 or 3 wherein the first object is die-pressed by means of a hydraulic press with a shearing die.

7. The process according to any of claims 1, 2 or 3 wherein the second object is pre-molded and hot-formed by heat and pressure molding, at a temperature between 90°

and 150°

C. and at a pressure between 1 and 4 kg/cm², for a period of time from 30 to 120 seconds.

8. The process according to any of claims 1 2, or 3 wherein the thermostable material mass (5) comprises an unsaturated polyester resin, mineral fillers, catalysts and glass fibers of a length between 15 and 50 mm.

9. The process according to any of claims 1, 2 or 3 wherein the contents of the mold are hot pressed at a temperature between 130°

and 160°

C. and at a pressure of 70 to 130 kgr/cm².