Patent Number: 6,165,404

Title: Method of producing stratiform articles and products

Abstract: A method of producing self-supporting stratiform articles having a substrate layer formed of a thermoplastic polymer composition and at least one surface portion formed by a layer made of a cover material, such as a textile; the method comprises: providing a mould cavity in conformity with the article that is to be produced and having a female cavity portion and a male cavity portion; the female cavity portion has at least one surface in conformity with the covered surface portion; the method according to the invention is characterized by providing, for each covered surface portion, a preformed laminate comprising the cover layer and a thermoplastic shielding layer; the shielding layer acts as a permeation barrier protecting the cover layer against the hot polymer composition that will be injected for forming the substrate; the shielding layer may also act as a shrinkage buffer; the preformed laminate is substantially self-supporting and provides for safe positioning of its cover layer at a desired portion of the female mould and, hence, of the final article; because the shielding layer is formed of a material that is substantially compatible with the thermoplastic polymer composition of said substrate layer, i.e. can interfuse therewith, a firm bond between the cover layer and the substrate can be formed upon solidification.

Inventors: Savonuzzi; Andrea (Sheboygan, WI)

Assignee: Lear Corporation

International Classification: B29C 45/14 (20060101); B60R 13/02 (20060101); B29C 045/14 (); B29C 061/02 ()

Expiration Date: 12/26/2017