Method for slush moulding articles, such as simulated leather or similar articles, of two or more colours from thermoplastic, thermosetting or elastomeric resins in powder form and apparatus for implementing the method.

Abstract: The method comprises, as a first stage, feeding a thermoplastic, thermosetting or elastomeric resin (10) in solid and preferably powder state into only a part (6) of the suitably preheated mould (2), this being achieved by separating the residual part in which a different colour is to be obtained, by the use of a special gasket (4). Said gasket is prepared by moulding, for example in the same mould (2), and is therefore able to perfectly follow the contour between the two colours. In the stage following the first filling, the mould is filled with powder material of the second colour and then emptied in accordance with the normal procedures of slush moulding. The mould (2), to which the two different colour materials have adhered to the required thickness, then passes to a further stage for completing gelling or fusion, before being cooled for extraction of the finished article.

Description: The method of slush moulding plastisol or PVC powder or other materials is generally known and is described in the literature, of which the following examples can be cited: 1) "PLAST" - Sept. 1979 pp 175-177. 2) "MODERN PLASTIC ENCYCLOPEDIA" 1977-1978 pp 340 onwards. 3) BALL W., Ziebart W., Woite B. (BMW) Mannheim VDI conference "New Requirement for Car Interior Trim" pp 1-18. 4) Pabst H.G., Shaper S., Schmidt H., Terveen A. (AUDI) Mannheim VDI Conference 1978 - "Development and large-scale use of dashboards produced by Slush Moulding PVC". 5) Khue N.N., Kunpers-Martz M., Dankmeier O. (EVC) "Development of optimum powder-blend for slush moulding" IVth international Conference PVC '90 - 24-26 April 1990, Brighton U.K., pp 31/1-31/14. FR-A-1,439,028 (Rhone Poulenc), CH-A-293,508 (J. Croning), FR-A-1,075,378 (Telegraph Construction), FR-A-1,381,850 (Gosudarstvenny), GB-A-905,546 (Plastomatic) US-A-2,736,925 (J.S. Heisler), FR-A-1,131,153 (National Research), GB-A-1,337,962 (Aquitaine Total), GB-A-1,056,109 (Celanese), US-A-3,039,146 (T. Hengel), US-A-2,915,788 (T. Hengel), GB-A-865,608 (T. Hengel), FR-A-916,055 (ICI), GB-A-1,025,493 (M.F. Smith), FR-A-1,560,675 (Goodyear Tire), DE-A-1,554,967 (Vaessen-Schemaker), IT-A-22197 A/80 (ILPEA), DE-A-3,417,727 (YMOS). All these patents or articles describe a substantially similar process, briefly consisting of filling a preheated metal mould with polymer liquid or powder, removing the excess liquid or solid and then heating the mould to complete gelling or fusion of the material which has adhered to it. The mould is then cooled and the final moulding extracted. In the sector involving such articles the problem has recently appeared of obtaining a finished product, such as simulated leather for trimming an automobile dashboard, having two or more sharply divided colours in the exposed part of the moulding. EP-A-0 339 222 describes an apparatus for manufacturing thin-walled hollow shells for parts such as automobile door panels, control and instrument panels and the like including a charge box or powder box for supplying dry thermoplastic material to separate casting surfaces on a heated mold selectively connected to the charge box during a casting process. A selectively pressurizable inflatable seal gasket is connected to the charge box for sealing a division surface on the heated mold which surface separates the casting surfaces of the mold. The inflatable seal gasket includes a base portion fixed to the charge box; an inflatable core with expandable walls to bridge the distance between the charge box and the division surface and a seal bead that sealingly engages the division surface when the seal gasket is inflated to keep the division surface clean for a subsequent application of material to form a connector bond between previously cast two tone colored segments. The Japanese laying open print A-1984-59/159309 discloses a method for forming a multi-coloured skin member in a mould comprising a rib on which a separation wall is coupled and thermally insulated from the mould, such coupling being carried out by the insertion of the rib into a groove in the separation wall. The object of the present invention is therefore to form articles such as thermoplastic, thermosetting or elastomeric resin based simulated leathers or the like, of the type mouldable in an open top mould, such that they comprise two or more different colours in their exposed part, i.e. that part which adheres to the inner surface of the mould. This object is attained according to the invention by a method according to the features of claim 1. In stage d) of the aforesaid method, the material is left in contact with the mould for the time required for it to adhere and partly gel or melt in the part relating to the first colour. The sealing performed by the gasket if necessary can be improved by suitable means, such as for instance by applying vacuum to the system. The mould is then emptied of the excess (powder) material, the gasket is removed and a further filling of material of the second colour is made within the shortest possible time, the material is left in contact with the hot mould for the required time depending on the thickness to be obtained, and the excess is then removed. The mould is heated to complete the total gelling or fusion, after which it is suitably cooled and the finished product is extracted from the mould, which can then start again its production cycle. The characteristics and advantages of the present invention will be more apparent from the description of one embodiment thereof given hereinafter with reference to the accompanying drawings. Figure 1 is a cross-section through a mould of the invention mounted on a slush moulding tank. Figure 2 is a perspective sectional view of a detail of a first embodiment of the gasket mounted on said tank. Figure 3 is a perspective sectional view of a detail of a further embodiment of the gasket of the invention mounted on said tank. Figures 4, 5 and 6 are cross-sectional views showing in succession the stages in the implementation of the method of the present invention. Figure 7 shows a finished article resulting from the method of the invention, and extracted from the mould. Figure 8 shows a form or mould for forming a gasked suitable for the method of the invention. Figure 9 shows a detail of Figure 8. Figure 10 is a section on the line X-X of Figure 8. Figure 11 is a view analogous to figure 10, showing a further embodiment of the invention. In figure 1 the reference numeral 1 indicates a slush moulding tank on which a mould 2 is mounted in an operating position. The tank 1 is divided longitudinally into two parts by a vertical wall 3 which extends into the mould overlying the tank so as to define in this latter two half-spaces indicated by 6 and 7 in Figure 4. The upper profile of the wall 3 extending into the mould substantially reproduces the shape of that region of the mould within which this wall lies. Along that perimeter of the dividing wall 3 which cooperates with the mould 2 there is fixed a gasked 4 for forming a seal between said two half-spaces 6 and 7. This gasket can be of various cross-sections. For example, Figure 2 shows a gasket 4 of substantially trapezoidal cross-section within which a metal insert 6 is incorporated for stiffening the gasket 4'. Figure 3 shows a modified gasket 4' of substantially C-shaped cross-section within which a stiffening insert 6' is provided. To enable the gasket to be fixed onto the dividing wall 3 a fixing section 7 is provided, to be forced over the dividing wall 3 in order to clamp the gasket. Various means can be provided to obtain a perfect seal between the gasket 4 and the corresponding mould line against which the gasket is to act. For example, Figure 1 shows mechanical means 5 mounted on the dividing wall 3 to compress the gasket against the mould wall. In contrast, the means shown in Figures 2 and 3 for compressing the gasket against the mould wall are air chambers 8 into which compressed air is fed via suitable nozzles below the gasket 4 or 4', in order to urge it against the mould wall and hence optimize the seal. Figures 4 and 5 show the operation of the structure of Figure 1 in two successive positions, in which that longitudinal half of said tank 1 corresponding to the half-space 6 of the mould is filled with a first plastic material 10 suitable for slush moulding, said first material constituting said first colour of the article. Figure 6 shows the next operating stage, in which the mould 2 is now mounted on a second tank 9 without a dividing wall and filled with a second plastic material 11 suitable for slush moulding and constituting said second colour of the finished article. In figure 7 the reference numeral 15 shows the finished article leaving the mould, and comprising a layer 12 consisting of the first colour and hence deriving from the material 10, and a layer 13 consisting of the second colour and hence deriving from the material 11. Said two layers 12 and 13 are separated from each other along a separation line 14. Figure 8 shows a form or mould for forming the gasket according to the method of the invention, in which a space 21 is defined between two pairs of half-moulds 17, 18 and 19, 20 which exactly reproduces the profile of the mould 2 of Figure 1 along the line 14 of the finished article 15 show in Figure 7. Figure 10 shows the forming of the gasket 4' in the embodiment of Figure 3, while Figure 11 shows the forming of the gasket 4 in the embodiment of Figure 2. Finally, Figure 9 is a full view of the gasket 4' as obtained from the forming mould of fig. 8, the shape of which exactly reproduces the profile of the forming mould for the finished article. The operation of the structures shown in the aforedescribed figures is as follows. Having defined the separation line 14 between the two colours in the finished article 15 on the basis of production requirements, this line must be made to correspond in terms of its shape and design exactly to the mould profile in that region in which the gasket is to be mounted. To achieve this, the gasket can either be moulded in a form or mould of the type shown in Figure 8 in which the forming space 21 corresponds exactly to the profile of the article mould shown in Figure 1, or be directly formed in the actual mould shown in Figure 1, in the region in which the separation line between the two different colours is defined. The gasket if necessary can be obtained from forms having different dimensions in comparison with those of the mold since this can prove to be helpful. For instance the dimensions of the form can be slightly enlarged. The gasket 4 is obtained by mulding liquid silicone rubber in the mould of Figure 8 or in the mould of Figure 1. Before moulding, stiffening inserts of the type 6 or 6' are embedded in it to better distribute the thrust of the gasket against the mould 2 during the operation when the seal is required. Having prepared the gasket 4 (or 4') it is mounted for operational purposes as shown in Figure 1, 2 and 3, by either forcing it directly onto the dividing wall 3 or fixing it by a fixing means. That half of the tank 1 corresponding to the half-space 6 is then filled with a first plastic material 10, after which slush moulding is carried out as shown in Figures 4 and 5. This manner a first layer 12 is formed of the material 10 constituting the first colour of the finished article. When this first layer 12 has been consolidated, the mould 2 is coupled if required, with the aid of driving means with a second tank 9 as shown in afigure 6, this time completely filled with a plastic material 11 of a different colour from the first. Slush moulding is now carried out with this second material, which is able to adhere to that mould wall remaining uncovered after deposition of the layer 12 of the first material. When moulding is complete the finished article has the form shown in Figure 7, and comprising a first layer 12 and a second layer 13 separated along the line 14. During those stages of the method shown in Figures 4 and 5, gasket thrust means such as the pneumatic means shown in Figures 2 and 3 or the mechanical means shown in Figures 1 and 4, or both types of gasket compressing means, are suitably operated. The sealing performed by the gasket can be further improved by means of suitable devices, such as for instance vacuum means applied to the tank's portion containing the plastic material. It should be noted that the aforesaid description with reference to the accompanying drawings in no way limits the scope of the invention, which can undergo numerous modifications with respect to that described and illustrated in the figures. For example, numerous modifications are possibile in the form of the seal gasket according to the present invention and in the manner of fixing the gasket to the dividing wall provided in the mould for forming the article. The method of the invention is suitable for preparing multi-coloured articles, in which case those modifications necessary to enable successive deposition of a number of layers of different materials of different colour have to be made to the described method. From the aforegoing it is apparent that the method of the invention represents an effective method for moulding articles such as simulated leather products, for example for the automobile industry, with different coloured portions. The method of the invention is highly advantageous in its practical implementation and the articles obtained have very high quality characteristics.

Claims: A method for slush moulding two-colour or multi-coloured articles such as simulated leather products from materials chosen from thermoplastic, thermosetting and elastomeric resins in powder form by using a mould (2) and at least one dividing wall (3) to thus operatively define two separate half-spaces (6 and 7) inside said mould, comprising the following stages: a) moulding a gasket (4) which substantially reproduces the profile line of the mould wall (2) which defines on the moulded article the corresponding separation line (14) between two different colours, b) fixing said gasket (4) onto said dividing wall (3) and placing the dividing wall inside said mould (2) so that said gasket lies along said profile line of the mould wall corresponding to said separation line (14), c) compressing said gasket (4) against said profile line on the mould to provide a perfect seal between said two half-spaces (6 and 7), d) slush moulding a layer (12) of a first material constituting the first of said colours, said layer adhering to the mould only on the walls of the first half-space (6) defined within it, e) consolidating the layer of said first material adhering to the mould, f) removing said dividing wall and the relative gasket from the mould, g) slush moulding a continuous layer (13) of a second material constituting the second of said two or more colours, and so on according to the number of colours required, so that said layer (13) is deposited as a continuous layer over the entire surface of the mould, i.e. including over the walls of said second half-space (7) remained uncovered after deposition of said layer (12) of the first material, and also over said layer (12), the two layers (12) and (13) thus being separated along a sharp separation line (14) on their exposed visible surface, the final article having such sharp separation line (14) being eventually extracted from the mould after appropriate consolidation. A method as claimed in claim 1, characterised in that said stage a) is carried out within said mould (2) used for moulding said article. A method as claimed in claim 1, characterised in that said stage d) is carried out by coupling said mould (2) with a tank (1) divided into two parts by said dividing wall (3) and containing said first material only in the part of the tank which is delimited by the effect of said dividing wall (3) which extends within both said tank and said mould. A method as claimed in claim 1, characterised in that in said stage a) stiffening inserts (6) of rigid material such as metal are embedded in said gasket, and actuated by mechanical means (5) to compress said gasket against the mould all along said profile line. An apparatus for carrying out the method claimed in one or more of the preceding claims, comprising a mould (2) and a dividing wall (3) which operatively extends into the mould defining two half-spaces (6 and 7), further comprising a gasket (4) which substantially reproduces the profile line of the mould wall (2) which defines on the moulded article the corresponding separation line(14) between two different colours and which is fixed onto said dividing wall (3) to hence provide a perfect seal within the mould between said two half-spaces and means for compressing the gasket during the operating stage, a first tank (1) containing a first material for forming the first of said colours, and a second tank (9) to be filled partly or completely with said second material. An apparatus as claimed in claim 5, characterised by comprising a number of tanks equal to the number of materials which are to confer a corresponding different colour on the article. An apparatus as claimed in claim 5, characterised in that said means are pneumatic or mechanical or of both types. An apparatus as claimed in claim 7, characterised in that said means are mechanical means (5) which actuate stiffening inserts (6) of rigid material such as metal which are embedded in said gasket (4).

Inventors: BUZZONI GIANCARLO, CITTADINI PAOLO, BUZZONI, GIANCARLO, CITTADINI, PAOLO
Applicants: ILPEA IND SPA, INDUSTRIE ILPEA S.P.A.
Application year: 1991
Main classification: B29C41
IPC codes: B29C41, B29C33, D06N3, B29K101, B29L9