초록 ▼

The method of this invention is particularly suitable for forming a permanently deep drawn contour in a laminate, such as a self-supporting polymer backed carpet laminate utilized by the automotive industry. The method includes forming a generally planar laminate wherein the carpet or cloth finish s

The method of this invention is particularly suitable for forming a permanently deep drawn contour in a laminate, such as a self-supporting polymer backed carpet laminate utilized by the automotive industry. The method includes forming a generally planar laminate wherein the carpet or cloth finish sheet is spaced from the sides of the polymer sheet, releasably clamping the polymer backing sheet to the side members of a frame assembly including a portion which is hingedly attached to the side members adjacent the area where the deepest draw is to be formed in the laminate. The laminate is then heated in the frame assembly and formed in a die press having at least one die member which is received in forming contact with the laminate between the side members. In the die forming step, the carpet or finish sheet floats on the polymer backing sheet and the hinged portion of the frame assembly floats relative to the side members to approximately mid way between the areas of greatest and least contour of the die member, such that stretching of the carpet-polymer laminate is minimized.

대표청구항 ▼

A method of forming a permanently deep drawn contour in a laminate having a woven finish sheet permanently bonded on a thermoplastic sheet, said method comprising the following steps: (a) forming a laminate by bonding a woven finish sheet having outer sides along at least two opposed sides on a larg

A method of forming a permanently deep drawn contour in a laminate having a woven finish sheet permanently bonded on a thermoplastic sheet, said method comprising the following steps: (a) forming a laminate by bonding a woven finish sheet having outer sides along at least two opposed sides on a larger thermoplastic sheet having outer sides along at least two opposed sides, said woven finish sheet having a width which is less than the width of said thermoplastic sheet, whereby said outer sides of said woven finish sheet are spaced apart from said outer sides of said thermoplastic sheet to separate said woven finish sheet from said thermoplastic sheet by side margins of said thermoplastic sheet on opposed sides of said woven finish sheet; (b) releasably clamping said thermoplastic sheet in a frame assembly, said frame assembly having opposed spaced side members, clamping means releasably clamping said side margins of said thermoplastic sheet to said side members and said frame assembly including a hinged portion hingedly attached to said side members independently supporting a portion of said laminate, said frame assembly hinged portion located adjacent the area where the deepest draw is to be formed in said laminate; (c) heating said laminate in said frame assembly to soften said thermoplastic sheet to the forming temperature; (d) placing said frame assembly and heated laminate in a die press having at least one contoured die member, said die member receivable between said frame assembly side members and said die member having an area of greatest contour adjacent said frame assembly hinged portion; (e) relatively moving said die member into forming engagement with said heated laminate between said frame assembly side members, said woven finish sheet floating on said thermoplastic sheet as said thermoplastic sheet is formed by said die member and said frame assembly hinged portion moving relative to said side members to approximately midway between the areas of greatest contour of said die member; and (f) cooling to harden said laminate in the contoured shape of said die member.