A method for producing an elastomeric skin having visually spotted appearance may include providing a liquid skin forming composition having solid spot forming particles having a longest dimension that is at least 40 μm and spraying the liquid skin forming composition in the form of a spray of droplets onto a mold surface. The provision of solid spot forming particles that are comparable in size to the droplet size may aid in projecting the solid spot forming particles forward upon impact on the mold surface such that a percentage thereof appear visible on the front face of the elastomeric skin after demolding thereby resulting in a front face with a spotted appearance without having to use multiple liquid skin forming compositions.
A method for producing an elastomeric skin having visually spotted appearance comprises providing a liquid skin forming composition comprising solid spot forming particles having a longest dimension that is at least 40 µm and spraying the liquid skin forming composition in the form of a spray of droplets onto a mould surface. The provision of solid spot forming particles that are comparable in size to the droplet size aids in projecting the solid spot forming particles forward upon impact on the mould surface such that a percentage thereof appear visible on the front face of the elastomeric skin after demoulding thereby resulting in a front face with a spotted appearance without having to use multiple liquid skin forming compositions.
A method for producing an elastomeric skin having visually spotted appearance comprises providing a liquid skin forming composition comprising solid spot forming particles having a longest dimension that is at least 40 µm and spraying the liquid skin forming composition in the form of a spray of droplets onto a mould surface. The provision of solid spot forming particles that are comparable in size to the droplet size aids in projecting the solid spot forming particles forward upon impact on the mould surface such that a percentage thereof appear visible on the front face of the elastomeric skin after demoulding thereby resulting in a front face with a spotted appearance without having to use multiple liquid skin forming compositions.
An elastomeric composite polyurethane skin having an average flexural modulus, measured in accordance with ASTM D790-03, smaller than 35 MPa is disclosed. The elastomeric composite polyurethane skin includes a first aliphatic polyurethane layer made from a first polyurethane reaction mixture having at least one isocyanate compound with at least two NCO-groups which are not directly attached to an aromatic group, at least one isocyanate-reactive component (B1), and at least one catalyst component (C1) substantially free of lead, and a second aromatic polyurethane layer made from a second polyurethane reaction mixture having at least one aromatic isocyanate compound (A2), and at least one isocyanate-reactive component (B2).
B60R 13/02 - Trim mouldingsLedgesWall linersRoof liners
C08G 18/12 - Prepolymer processes involving reaction of isocyanates or isothiocyanates with compounds having active hydrogen in a first reaction step using two or more compounds having active hydrogen in the first polymerisation step
C08G 18/24 - Catalysts containing metal compounds of tin
An elastomeric composite polyurethane skin having an average flexural modulus, measured in accordance with ASTM D790-03, smaller than 35 MPa; said elastomeric composite polyurethane skins comprising a first aliphatic polyurethane layer made from a first polyurethane reaction mixture wherein said first polyurethane reaction mixture comprises at least one isocyanate compound (A1) having at least two NCO-groups which are not directly attached to an aromatic group, at least one isocyanate-reactive component (B1) and at least one catalyst component (C1) wherein the catalyst component (C1) is substantially free of lead, and a second aromatic polyurethane layer made from a second polyurethane reaction mixture wherein said second polyurethane reaction mixture comprises at least one aromatic isocyanate compound (A2), and at least one isocyanate-reactive component (B2) characterised in that the elastomeric composite polyurethane skin has a an average areal weight of equal to or less than 750 g/m2 and the second aromatic polyurethane layer has a second average areal weight of less than 300 g/m2.
C08G 18/28 - Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
An elastomeric composite polyurethane skin having an average flexural modulus, measured in accordance with ASTM D790-03, smaller than 35 MPa; said elastomeric composite polyurethane skins comprising a first aliphatic polyurethane layer made from a first polyurethane reaction mixture wherein said first polyurethane reaction mixture comprises at least one isocyanate compound (A1) having at least two NCO-groups which are not directly attached to an aromatic group, at least one isocyanate-reactive component (B1) and at least one catalyst component (C1) wherein the catalyst component (C1) is substantially free of lead, and a second aromatic polyurethane layer made from a second polyurethane reaction mixture wherein said second polyurethane reaction mixture comprises at least one aromatic isocyanate compound (A2), and at least one isocyanate-reactive component (B2) characterised in that the elastomeric composite polyurethane skin has a an average areal weight of equal to or less than 750 g/m2 and the second aromatic polyurethane layer has a second average areal weight of less than 300 g/m2.
C08G 18/24 - Catalysts containing metal compounds of tin
C08G 18/28 - Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
The present invention relates to a method for producing an elastomeric grained skin which comprises at least an elastomeric skin layer and a coating layer overlying the skin layer. The skin has at least a portion which hasa grained surface, which comprises at least one elastomeric skin layer and which has at least one coating layer overlying the skin layer. To produce the skin a coating composition is applied onto at least a portion of a mould surface, which portion is grained, to produce said coating layer; and the elastomeric skin layer is moulded at least against a back side of said coating layer to produce said portion of the elastomeric skin. In order to accent the grain texture so that it stands out more clearly and so that the visibility thereof is less dependent on the direction of the incident light and the position of the viewer use is made of a coating composition which comprises effect pigment particles contained in a transparent or translucent medium.
B29C 41/08 - Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder
B29C 37/00 - Component parts, details, accessories or auxiliary operations, not covered by group or
B29C 41/22 - Making multilayered or multicoloured articles
B32B 33/00 - Layered products characterised by particular properties or particular surface features, e.g. particular surface coatingsLayered products designed for particular purposes not covered by another single class
B29C 41/00 - Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped articleApparatus therefor
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
B29K 75/00 - Use of polyureas or polyurethanes as moulding material
8.
METHOD FOR PRODUCING AN ELASTOMERIC SKIN HAVING A GRAINED SURFACE
The present invention relates to a method for producing an elastomeric grained skin which comprises at least an elastomeric skin layer and a coating layer overlying the skin layer. The skin has at least a portion which hasa grained surface, which comprises at least one elastomeric skin layer and which has at least one coating layer overlying the skin layer. To produce the skin a coating composition is applied onto at least a portion of a mould surface, which portion is grained, to produce said coating layer; and the elastomeric skin layer is moulded at least against a back side of said coating layer to produce said portion of the elastomeric skin. In order to accent the grain texture so that it stands out more clearly and so that the visibility thereof is less dependent on the direction of the incident light and the position of the viewer use is made of a coating composition which comprises effect pigment particles contained in a transparent or translucent medium.
B29C 41/22 - Making multilayered or multicoloured articles
B32B 33/00 - Layered products characterised by particular properties or particular surface features, e.g. particular surface coatingsLayered products designed for particular purposes not covered by another single class
B29C 37/00 - Component parts, details, accessories or auxiliary operations, not covered by group or
9.
Method for manufacturing a flexible skin having at least one insert adhered thereto
The present invention relates to a method for manufacturing a flexible skin which has at least one insert adhered thereto. In a first step, the skin is molded on a mold surface. In order to adhere the insert to the skin, an opening is first made in the skin giving access to the back face of the insert. The insert is positioned with its back face against the front face of the skin and an adhering layer is provided which is adhesively connected to the back face of the skin layer which surrounds the opening in the skin layer and, through this opening, to the back face of the insert. The adhering layer is preferably produced by applying a layer of a hardenable material, in particular a curable polyurethane composition. Since the back face of the insert engages the front side of the skin penetration of hardenable material to the front face of the insert is avoided.
B32B 37/24 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B29C 65/50 - Joining of preformed partsApparatus therefor using adhesives using adhesive tape
B32B 37/14 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
B29C 65/70 - Joining of preformed partsApparatus therefor by moulding
B29C 65/48 - Joining of preformed partsApparatus therefor using adhesives
B32B 1/00 - Layered products having a non-planar shape
B32B 37/12 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B29C 45/16 - Making multilayered or multicoloured articles
B29C 67/24 - Shaping techniques not covered by groups , or characterised by the choice of material
B32B 3/08 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
Method for manufacturing a flexible skin (1) which has at least one insert (2) adhered thereto. In a first step, the skin (1) is moulded on a mould surface (6). In order to adhere the insert (2) to the skin (1), an opening (13) is first made in the skin (1) giving access to the back face (14) of the insert (2). The insert (2) is positioned with its back face against the front face (12) of the skin (1) and an adhering layer (17) is provided which is adhesively connected to the back face (18) of the skin layer (1) which surrounds the opening (13) in the skin layer (1) and, through this opening (13), to the back face (14) of the insert (2). The adhering layer (17) is preferably produced by applying a layer of a hardenable material, in particular a curable polyurethane composition. Since the back face (14) of the insert (2) engages the front side (12) of the skin (1) penetration of hardenable material to the front face (24) of the insert (2) is avoided.
B29C 65/70 - Joining of preformed partsApparatus therefor by moulding
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
B29C 65/48 - Joining of preformed partsApparatus therefor using adhesives
11.
Method for producing a skin layer of a flexible, elastomeric, thermoset, phase-separated polyurethane material
The thermoset, phase-separated polyurethane material of the flexible skin layer is produced from a reactive mixture which is made of one or more isocyanate compounds and isocyanate reactive compounds which include one or more polyol compounds, flexibilizers, chain extenders and/or crosslinkers and amine-initiators. Apart from at least one crosslinking amine-initiator, these amine-initiators further include at least one extender amine-initiator.
C08G 18/28 - Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
The present invention relates to a method for producing a flexible elastomeric composite polyurethane skin wherein a polyurethane reaction mixture is sprayed onto a mold surface and the polyurethane reaction mixture is allowed to cure to produce the skin layer. The polyurethane reaction mixture is composed of components comprising at least an isocyanate component, isocyanate-reactive components and a catalyst component and the isocyanate component is composed of at least one isocyanate having at least two NCO-groups which are not directly attached to an aromatic group. The catalyst component is substantially free of lead, which leads to a lower flexibility. In accordance with the invention, the flexibility of the polyurethane skin is increased by means of at least one flexibiliser which reduces the flexural modulus of the skin and which comprises at least one isocyanate-reactive group. The flexibiliser is preferably a monofunctional flexibiliser which comprises only one isocyanate-reactive group.
The present invention relates to a method of making an elastomeric skin (1) wherein droplets of at least one first skin forming composition (2) are applied onto a mould surface to form a layer of the first skin forming composition thereon and wherein one or more second skin forming compositions (4) are applied at least partially onto the back of the layer of said first skin forming composition (2) to produce the skin (1). In order to obtain a special visual appearance when using of differently colored first and second skin forming materials, or in order to reduce the effect of the first skin forming composition (2) on the overall physical properties of the skin (1), the droplets of the first skin forming composition (2) are applied onto the mould surface and are allowed to coalesce to form a non-continuous layer of the first skin forming composition which comprises a plurality of gaps (3). The second skin forming compositions (4) are applied not only on the back of the first skin forming composition (2) but also in these gaps (3). The first skin forming composition preferably forms islands on the mould surface which are interconnected by means of the second skin forming compositions.
The invention relates to a method for producing a multilayered part which comprises a moulded core (5) and a flexible polyurethane skin layer (4). The core itself comprises a moulded substrate layer (1) which is made of a substrate material, in particular a thermoplastic material, having a Shore A hardness higher than 60. The flexible polyurethane skin (4) is produced by a reaction overmoulding (ROM) process wherein a polyurethane reaction mixture is moulded in a closed mould (11, 12) over at least a first area of the core surface. The moulded core (5) comprises in addition to said substrate layer (1) a softer material which is moulded onto the substrate layer (1) and/or onto which the substrate layer (1) is moulded. This moulded softer material has a Shore A hardness lower than 60 and forms a softer layer (2) between the flexible polyurethane layer (4) and the substrate layer (1) and/or a seal (3) engaging the internal wall of the mould (11, 12) during the ROM process.
B29C 45/14 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
15.
METHOD FOR PRODUCING A SKIN LAYER OF A FLEXIBLE, ELASTOMERIC, THERMOSET, PHASE-SEPARATED POLYURETHANE MATERIAL.
The thermoset, phase-separated polyurethane material of the flexible skin layer is produced from a reactive mixture which is made of one or more isocyanate compounds and isocyanate reactive compounds which comprise one or more polyol compounds, flexibilisers, chain extenders and/or crosslinkers and amine-initiators. Apart from at least one crosslinking amine-initiator, these amine-initiators further comprise at least one extender amine-initiator which has a functionality of 2 and a molecular weight of less than 300 and which corresponds to formula (I) HR1N-R2-OH (I) wherein: R1 is H or a cyclic or acyclic hydrocarbon chain, which is substituted or not and which comprises one or more hetero-atoms or not, R1 being preferably H or a C1 to C6 alkyl group; and R2 is a hydrocarbon chain which is substituted or not, which comprises a hetero-atom or not and which comprises a backbone linking the amino group with the hydroxyl group and containing at least two carbon atoms. The combination of the flexibiliser and the extender amine-initiator was found to have an increased effect on the flexural modulus and the softening temperature of the polyurethane material whilst maintaining the required mechanical properties at a satisfactory level.
C08G 18/18 - Catalysts containing secondary or tertiary amines or salts thereof
C08G 18/28 - Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
A plastic skin 1 for a lining part, such as a trim panel for a vehicle interior application shows at least one decorative element 4, 4.1 resembling a design element of three-dimensional shape. The decorative element 4, 4.1 is formed as part of said skin 1 and has at least at its visible margin towards the adjacent parts of said skin 1 at least partially a coating 14 applied thereon providing a contrasting aspect of the decorative element 4, 4.1 relative to the adjacent parts of the skin 1.
A method for manufacturing molded flexible plastic skins (9, 24, 27, 34) differing in their shape from each other, each skin being molded against a mold surface (2) of a mold (1), comprises the steps: —providing a mold surface (2) matching the shape of the skin to be molded by using a first mold surface provided by the mold itself or by altering the first mold surface by placing one or more mold inserts covering only a part of the first mold surface onto said mold surface and thereby providing an alternative second mold surface, —applying a plastic compound to be brought to shape by the mold surface (2) provided, —bringing to shape the plastic compound applied to the mold surface (2), and —demolding the molded skin (9) from the effective mold surface (2).
B29C 41/08 - Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder
B29C 41/20 - Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped articleApparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. moulding around inserts or for coating articles
The present invention relates to a method of making an elastomeric skin (1) wherein droplets of at least one first skin forming composition (2) are applied onto a mould surface to form a layer of the first skin forming composition thereon and wherein one or more second skin forming compositions (4) are applied at least partially onto the back of the layer of said first skin forming composition (2) to produce the skin (1). In order to obtain a special visual appearance when using of differently coloured first and second skin forming materials, or in order to reduce the effect of the first skin forming composition (2) on the overall physical properties of the skin (1), the droplets of the first skin forming composition (2) are applied onto the mould surface and are allowed to coalesce to form a non- continuous layer of the first skin forming composition which comprises a plurality of gaps (3). The second skin forming compositions (4) are applied not only on the back of the first skin forming composition (2) but also in these gaps (3). The first skin forming composition preferably forms islands on the mould surface which are interconnected by means of the second skin forming compositions.
The present invention relates to a method of making an elastomeric skin (1) wherein droplets of at least one first skin forming composition (2) are applied onto a mould surface to form a layer of the first skin forming composition thereon and wherein one or more second skin forming compositions (4) are applied at least partially onto the back of the layer of said first skin forming composition (2) to produce the skin (1). In order to obtain a special visual appearance when using of differently coloured first and second skin forming materials, or in order to reduce the effect of the first skin forming composition (2) on the overall physical properties of the skin (1), the droplets of the first skin forming composition (2) are applied onto the mould surface and are allowed to coalesce to form a non- continuous layer of the first skin forming composition which comprises a plurality of gaps (3). The second skin forming compositions (4) are applied not only on the back of the first skin forming composition (2) but also in these gaps (3). The first skin forming composition preferably forms islands on the mould surface which are interconnected by means of the second skin forming compositions.
The pressure swirl atomizing nozzle for spraying a curable composition comprises an orifice piece (16), which defines a funnel-shaped cavity and an exit orifice (17), and an injector piece (18) which closing off the funnel-shaped cavity so that the funnel-shaped cavity forms a swirl chamber (19) between a front side of the injector piece (18) and the exit orifice (17). The injector piece (18) comprises at least two swirl ports (20) which end in the swirl chamber (19) for injecting the curable composition therein and for thereby imparting swirl to the curable composition. Compared to the sum of the smallest cross-sectional areas of the swirl ports (20), the side wall (24) of the swirl chamber (19) has a relatively small surface area which is however still large enough to distribute the curable composition so as to achieve a uniform spray pattern. By the reduced size of the swirl chamber (19), the curable composition can be atomized more efficiently. In this way, changes of the relatively low flow rate of the curable composition through the nozzle have less effect on the droplet size and on the stability of the spray pattern.
B05B 17/04 - Apparatus for spraying or atomising liquids or other fluent materials, not covered by any other group of this subclass operating with special methods
21.
METHOD FOR PRODUCING A MOULDED SKIN AND MOULD ARRANGEMENT THEREFORE
A method for manufacturing moulded flexible plastic skins (9, 24, 27, 34) differing in their shape from each other, each skin being moulded against a mould surface (2) of a mould (1), comprises the steps: - providing a mould surface (2) matching the shape of the skin to be moulded by using a first mould surface provided by the mould itself or by altering the first mould surface by placing one or more mould inserts covering only a part of the first mould surface onto said mould surface and thereby providing an alternative second mould surface, - applying a plastic compound to be brought to shape by the mould surface (2) provided, - bringing to shape the plastic compound applied to the mould surface (2), and - demoulding the moulded skin (9) from the effective mould surface (2). The at least one mould insert (7) used is flexible, whereas a mould insert (7) is arranged on the first mould surface in that the side surfaces of the insert adjoining its own mould surface abut against a wall of the first mould surface arranged angular to the adjacent mould surface, in particular an upstanding wall at least in those sections of the insert used for shaping the plastic compound. A mould arrangement for moulding flexible plastic skins (9) differing in their shape from each other, each skin moulded against a mould surface of a mould, the arrangement comprises a base mould with a first mould surface and one or more mould inserts to be arranged on the first mould surface and covering only a part of the first mould surface. Theat least one mould insert is flexible nature and the first mould surface carries one or more walls arranged angular to the adjacentmould surface, in particular upstanding from its first mould surface and the mould inserts abut with their side surfaces adjoiningtheir own mould surfaces against such wall at least in those sections of the insert used for shaping the plastic compound.
B29C 33/50 - Moulds or coresDetails thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling elastic
B29C 41/08 - Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder
B29C 41/20 - Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped articleApparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. moulding around inserts or for coating articles
A method for manufacturing moulded flexible plastic skins (9, 24, 27, 34) differing in their shape from each other, each skin being moulded against a mould surface (2) of a mould (1), comprises the steps: - providing a mould surface (2) matching the shape of the skin to be moulded by using a first mould surface provided by the mould itself or by altering the first mould surface by placing one or more mould inserts covering only a part of the first mould surface onto said mould surface and thereby providing an alternative second mould surface, - applying a plastic compound to be brought to shape by the mould surface (2) provided, - bringing to shape the plastic compound applied to the mould surface (2), and - demoulding the moulded skin (9) from the effective mould surface (2). The at least one mould insert (7) used is flexible, whereas a mould insert (7) is arranged on the first mould surface in that the side surfaces of the insert adjoining its own mould surface abut against a wall of the first mould surface arranged angular to the adjacent mould surface, in particular an upstanding wall at least in those sections of the insert used for shaping the plastic compound. A mould arrangement for moulding flexible plastic skins (9) differing in their shape from each other, each skin moulded against a mould surface of a mould, the arrangement comprises a base mould with a first mould surface and one or more mould inserts to be arranged on the first mould surface and covering only a part of the first mould surface. The at least one mould insert is flexible nature and the first mould surface carries one or more walls arranged angular to the adjacent mould surface, in particular upstanding from its first mould surface and the mould inserts abut with their side surfaces adjoining their own mould surfaces against such wall at least in those sections of the insert used for shaping the plastic compound.
B29C 41/08 - Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder
B29C 33/50 - Moulds or coresDetails thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles with means for collapsing or disassembling elastic
The present invention relates to a method for producing a flexible elastomeric composite polyurethane skin comprising a first and a second flexible polyurethane layer obtained by spraying a first and a second polyurethane reaction mixture onto one another. The first reaction mixture is an aliphatic polyurethane reaction mixture which is free of lead and formulated to produce a polyurethane elastomer having a flexural modulus smaller than 35 MPa. The second reaction mixture is an aromatic polyurethane reaction mixture producing a polyurethane elastomer having a smaller flexural modulus. The thickness of the aliphatic polyurethane layer could be made so small with respect to the thickness of the aromatic polyurethane layer that the composite skin has an average flexural modulus smaller than 30 MPa. Notwithstanding the lower reactivity of the aliphatic polyurethane reaction mixture, especially when using a higher NCO-index to reduce the “rubbery feel” and the emission of VOCs and/or a flexibiliser to achieve a higher flexibility, sufficiently short cycle times can be achieved due to the accelerated curing observed when spraying the aromatic polyurethane sufficiently early against the aliphatic polyurethane layer.
The three-dimensionally shaped sandwich structure is produced starting from a layered material (1) comprising a compressible core layer, in particular a paper honeycomb structure, having two opposite main faces which are each covered with a reinforcing material and with a mouldable material. The layered material (1) is moulded in a compression mould comprising two mutually movable mould sections (7, 9). In order to reduce the formation of cracks, tears or breaks in the core layer, the first mould section (7) is composed of at least two mutually movable mould parts (10 and 11-12). A first portion of the layered material (1) is first deep-drawn by moving the first mould part (10) towards its moulding position so that wrinkles are formed in the layered material and the second mould part (11-12) is moved later and/or more slowly than the first mould part (10) towards its moulding position. In this way the formation of wrinkles by the first mould part (10) is enhanced due to the fact that the layered material (1) is little or not hampered from being drawn by the first mould part to the deep-drawn area. The second mould part may be composed of different subparts (11-13) which are also moved successively towards their moulding position.
B29C 43/18 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
25.
PRESSURE SWIRL ATOMIZING NOZZLE FOR SPRAYING A CURABLE COMPOSITION AND ASSOCIATED METHOD AND USE
The pressure swirl atomizing nozzle for spraying a curable composition comprises an orifice piece (16), which defines a funnel-shaped cavity and an exit orifice (17), and an injector piece (18) which closing off the funnel- shaped cavity so that the funnel-shaped cavity forms a swirl chamber (19) between a front side of the injector piece (18) and the exit orifice (17). The injector piece (18) comprises at least two swirl ports (20) which end in the swirl chamber (19) for injecting the curable composition therein and for thereby imparting swirl to the curable composition. Compared to the sum of the smallest cross-sectional areas of the swirl ports (20), the side wall (24) of the swirl chamber (19) has a relatively small surface area which is however still large enough to distribute the curable composition so as to achieve a uniform spray pattern. By the reduced size of the swirl chamber (19), the curable composition can be atomized more efficiently. In this way, changes of the relatively low flow rate of the curable composition through the nozzle have less effect on the droplet size and on the stability of the spray pattern.
B05B 1/34 - Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means designed to influence the nature of flow of the liquid or other fluent material, e.g. to produce swirl
B29C 41/36 - Feeding the material on to the mould, core or other substrate
26.
Method for manufacturing at least a surface layer of multilayered trim part
The method according to the invention is a moulding method wherein a first layer (21), having a first colour, is produced against a first portion of a mould surface (10) and wherein, in a next step, a second layer (22), having a second colour, is produced against a second portion of the mould surface (10) and at least partially against the back of the first layer (21). The method is intended to obtain a qualitative transition between the colours of the two layers (21, 22) without having to hide the actual colour transition in a groove from view. This object is achieved by applying the material forming the first layer (21) in such a manner on the mould surface (10) that the edge (20) of the first layer (21), which will be situated on the mould surface underneath the second layer (22), is visually sharp and is produced without a mask.
B29C 41/20 - Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped articleApparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. moulding around inserts or for coating articles
B29C 43/18 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
B29C 45/00 - Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mouldApparatus therefor
B29C 41/22 - Making multilayered or multicoloured articles
27.
METHOD FOR PRODUCING A FLEXIBLE COMPOSITE ELASTOMERIC POLYURETHANE SKIN
The present invention relates to a method for producing a flexible elastomeric composite polyurethane skin comprising a first (1) and a second (4) flexible polyurethane layer obtained by spraying a first and a second polyurethane reaction mixture onto one another. The first reaction mixture is an aliphatic polyurethane reaction mixture which is free of lead and formulated to produce a polyurethane elastomer having a flexural modulus smaller than 35 MPa. The second reaction mixture is an aromatic polyurethane reaction mixture producing a polyurethane elastomer having a smaller flexural modulus . The thickness of the aliphatic polyurethane layer could be made so small with respect to the thickness of the aromatic polyurethane layer that the composite skin has an average flexural modulus smaller than 30 MPa. Notwithstanding the lower reactivity of the aliphatic polyurethane reaction mixture, especially when using a higher NCO-index to reduce the 'rubbery feel' and the emission of VOCs and/or a flexibiliser to achieve a higher flexibility, sufficiently short cycle times can be achieved due to the accelerated curing observed when spraying the aromatic polyurethane sufficiently early against the aliphatic polyurethane layer .
C08G 18/28 - Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
The invention relates to a method for producing a multilayered part which comprises a moulded core (5) and a flexible polyurethane skin layer (4). The core itself comprises a moulded substrate layer (1 ) which is made of a substrate material, in particular a thermoplastic material, having a Shore A hardness higher than 60. The flexible polyurethane skin (4) is produced by a reaction overmoulding (ROM) process wherein a polyurethane reaction mixture is moulded in a closed mould (11, 12) over at least a first area of the core surface. The moulded core (5) comprises in addition to said substrate layer (1 ) a softer material which is moulded onto the substrate layer (1 ) and/or onto which the substrate layer (1 ) is moulded. This moulded softer material has a Shore A hardness lower than 60 and forms a softer layer (2) between the flexible polyurethane layer (4) and the substrate layer (1 ) and/or a seal (3) engaging the internal wall of the mould (11, 12) during the ROM process.
B29C 44/08 - Shaping by internal pressure generated in the material, e.g. swelling or foaming for articles of definite length, i.e. discrete articles using several expanding steps
B29C 67/24 - Shaping techniques not covered by groups , or characterised by the choice of material
29.
PROCESS FOR THE PRODUCTION OF A THREE-DIMENSIONALLY SHAPED SANDWICH STRUCTURE
The three-dimensionally shaped sandwich structure is produced starting from a layered material (1) comprising a compressible core layer, in particular a paper honeycomb structure, having two opposite main faces which are each covered with a reinforcing material and with a mouldable material. The layered material (1) is moulded in a compression mould comprising two mutually movable mould sections (7, 9). In order to reduce the formation of cracks, tears or breaks in the core layer, the first mould section (7) is composed of at least two mutually movable mould parts (10 and 11-12). A first portion of the layered material (1) is first deep-drawn by moving the first mould part (10) towards its moulding position so that wrinkles are formed in the layered material and the second mould part (11-12) is moved later and/or more slowly than the first mould part (10) towards its moulding position. In this way the formation of wrinkles by the first mould part (10) is enhanced due to the fact that the layered material (1) is little or not hampered from being drawn by the first mould part to the deep-drawn area. The second mould part may be composed of different subparts (11-13) which are also moved successively towards their moulding position.
B29C 51/08 - Deep-drawing or matched-mould forming, i.e. using mechanical means only
B29C 51/14 - Shaping by thermoforming, e.g. shaping sheets in matched moulds or by deep-drawingApparatus therefor using multilayered preforms or sheets
30.
Method for producing a moulded article comprising a sprayed polyurethane layer
2, S being a value smaller than 1.0, the reaction mixture is sprayed out of the nozzle at a flow rate of between 10×S and 80×S g/sec, and, per gram reaction mixture, an amount of 0.05 to 2.5 mmol of a pressurized gas is sprayed together with the reaction mixture through said spray opening out of the nozzle to increase the kinetic energy of the reaction mixture which is sprayed out of the nozzle. By the addition of a pressurized gas to the reaction mixture, a same or even a better spray pattern can be achieved and the reaction mixture can be sprayed at a smaller flow rate.
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