Methods of forming a layered article
| Title: | Methods of forming a layered article |
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| Patent Number: | 7,837,911 |
| Publication Date: | November 23, 2010 |
| Appl. No: | 10/805760 |
| Application Filed: | March 22, 2004 |
| Abstract: | A method of forming a layered article, the method comprises thermoforming a substrate sheet to form a shaped substrate, wherein the shaped substrate is a fiber-reinforced plastic material having a void content sufficient to allow a vacuum to be applied through the shaped substrate; pulling a vacuum through the shaped substrate; and pulling a film layer onto a surface of the shaped substrate to form the layered article. |
| Inventors: | Bristow, Paul Anthony (Brighton, MI, US); Davis, Scott Michael (Lee, MA, US); Hipwell, Jesse Guy (Grand Blanc, MI, US); Myers, Randall Todd (Pittsfield, MA, US); Teutsch, Erich Otto (Richmond, MA, US) |
| Assignees: | Sabic Innovative Plastics IP B.V. (NL) |
| Claim: | 1. A method of forming a layered article, the method comprising: thermoforming a substrate sheet to form a shaped substrate, wherein the shaped substrate is a fiber-reinforced plastic material having a void content sufficient to allow a vacuum to be applied through the shaped substrate, wherein the void content is greater than or equal to about 5 vol. %, based on the total volume of the shaped substrate; pulling a vacuum through the shaped substrate; pulling a film layer onto a surface of the shaped substrate to form the layered article; wherein the shaped substrate is foraminated. |
| Claim: | 2. The method of claim 1 , wherein the film layer further comprises a compatible layer. |
| Claim: | 3. The method of claim 1 , wherein the void content is about 10 vol. % to about 50 vol. %. |
| Claim: | 4. The method of claim 3 , wherein the void content is about 25 vol. % to about 50 vol. %. |
| Claim: | 5. The method of claim 1 , wherein the fibers have a fiber diameter of about 6 micrometers to about 25 micrometers, and a fiber length of about 2 millimeters to about 75 millimeters. |
| Claim: | 6. The method of claim 1 , wherein the substrate sheet comprises: about 25 wt. % to about 75 wt. % plastic material; about 25 wt. % to about 75 wt. % fibers; and wherein weight percents are based on a total weight of the substrate sheet. |
| Claim: | 7. The method of claim 6 , wherein the substrate sheet comprises: about 35 wt. % to about 65 wt. % plastic material; and about 35 wt. % to about 65 wt. % fibers. |
| Claim: | 8. The method of claim 6 , wherein the plastic material is selected from the group consisting of polycarbonate, polyester, polyetherimide, polyphenylene ether, polystyrene, polyamide, and combinations comprising at least one of the foregoing. |
| Claim: | 9. The method of claim 1 , wherein the substrate sheet is thermoformed with a membrane assisted vacuum pressure forming method with a plug-assist. |
| Claim: | 10. The method of claim 1 , further comprising disposing a tie-layer between the shaped substrate and the film layer. |
| Claim: | 11. The method of claim 1 , wherein the substrate sheet further comprises a non-woven scrim disposed on a surface of the substrate sheet. |
| Claim: | 12. A method of forming a layered article, the method comprising: thermoforming a substrate sheet to form a shaped substrate, wherein the shaped substrate is a fiber-reinforced plastic material having a void content sufficient to allow a vacuum to be applied through the shaped substrate, wherein the void content is greater than or equal to about 5 vol. %, based on the total volume of the shaped substrate; pulling a vacuum through the shaped substrate; and pulling a film layer onto a surface of the shaped substrate to form the layered article; wherein thermoforming the substrate sheet further comprises heating the substrate to a temperature sufficient to loft the fibers. |
| Claim: | 13. The method of claim 12 , wherein the temperature is about 450° F. (about 232° C.) to about 700° F. (about 371° C.). |
| Claim: | 14. A method of forming a layered article, the method comprising: heating a substrate sheet to a temperature sufficient to loft the fibers of the substrate sheet; disposing the substrate sheet against a membrane assisted pressure box; pushing the substrate sheet onto a mold to form a shaped substrate; heating a film layer; disposing the film layer adjacent to the shaped substrate; pulling a vacuum through the shaped substrate; and pulling the film layer against the shaped substrate to form the layered article; wherein the shaped substrate is a fiber-reinforced plastic material having a void content of greater than or equal to about 5 vol. %, based upon the total volume of the shaped substrate. |
| Claim: | 15. The method of claim 14 , wherein the void content is about 10 vol. % to about 50 vol. %. |
| Claim: | 16. The method of claim 14 , further comprising disposing a tie-layer between the shaped substrate and the film layer. |
| Claim: | 17. A method of forming a layered article, the method comprising: thermoforming a substrate sheet to form a thermoformed substrate, wherein the substrate sheet comprises a fiber-reinforced plastic material having a void content sufficient to allow a vacuum to be applied through the substrate; cooling the thermoformed substrate to form a shaped substrate, pulling a vacuum through the shaped substrate; and pulling a film layer onto a surface of the shaped substrate to form the layered article. |
| Claim: | 18. A method of forming a layered article, the method comprising: thermoforming a substrate sheet to form a shaped substrate, wherein the substrate sheet comprises a fiber-reinforced plastic material having a void content sufficient to allow a vacuum to be applied through the substrate; wherein thermoforming comprises heating the substrate sheet to a temperature sufficient to loft the fibers; pulling a vacuum through the shaped substrate; and pulling a film layer onto a surface of the shaped substrate to form the layered article. |
| Current U.S. Class: | 264/468 |
| Patent References Cited: | 3446686 May 1969 Butler et al. 3938782 February 1976 Robertson 3947315 March 1976 Smith 4166090 August 1979 Green et al. 4201612 May 1980 Figge et al. 4257754 March 1981 Green et al. 4529641 July 1985 Holtrop et al. 4868030 September 1989 Mentzer et al. 5001000 March 1991 Rohrbacher et al. 5215627 June 1993 Willis et al. 5407610 April 1995 Kohama et al. 5601679 February 1997 Mulcahy et al. 5622756 April 1997 Tokoro et al. 5750234 May 1998 Johnson et al. 5854149 December 1998 Nagayama et al. 5968629 October 1999 Masui et al. 6136441 October 2000 MacGregor et al. 6224706 May 2001 Matich 6689474 February 2004 Pickett et al. 2003/0146543 August 2003 Lebrun et al. 2003/0220036 November 2003 Lee et al. 2005/0164023 July 2005 Davis et al. 10110501 August 2002 0324680 July 1989 1 124 878 September 1999 1155794 November 2001 WO 00/69945 November 2000 |
| Other References: | U.S. Appl. No. 10/807,844, filed Mar. 24, 2004, Dunton et al. cited by other Gerald L. Steele, “Thermoforming Tooling”, DuBois and Pribble's Plastics Mold Engineering Handbook. Fifth Edition. Chapter 9. pp. 469-498. cited by other Brister, et al. “Zero Voc Sollx Film for Weatherable, High-Gloss, Chemcial and Scratch Resistant Performance”. Presented at the International Waterborne, High-Solids and Powder Coatings Symposium Feb. 6-8, 2002. New Orleans, LA USA. pp. 261-275. cited by other International Search Report for PCT/US2005/001375; Date of Completion Jul. 27, 2005; Date of Mailing Nov. 8, 2005. cited by other EP 0324680 Publication Date Jul. 19, 1989; “Process for the manufacture of a sheet of reinforced thermoplastic material, and sheet thus obtained.” (Abstract Only). cited by other Patent Abstracts of Japan; Publication No. 01-228824; Publication Date Dec. 9, 1989; “Vacuum Molding of Thermoplastic Material and Molded Article”; 2 pages. cited by other |
| Primary Examiner: | Huson, Monica A |
| Attorney, Agent or Firm: | Cantor Colburn LLP |
| Accession Number: | edspgr.07837911 |
| Database: | USPTO Patent Grants |
| Language: | English |
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