Abstract:
A laminated panel ( 23 ) comprises a fusible layer ( 23 A) having an upper surface. A mesh layer ( 23 A, A 1 ) has an encapsulated portion enclosed in the fusible layer so as to be below the upper surface of the fusible layer ( 23 A). An embossed portion (A 1 ) protrudes from the upper surface of the fusible layer ( 23 A). A method ( 10 ) of forming a laminated panel with the fusible layer and the mesh layer comprises the steps of: i) heating the fusible layer ( 23 A) to fuse a portion of the fusible layer; and ii) pressing only selected portion of the mesh layer against the fusible layer to provide for the formation of an embossed pattern (A 1 ) on the resulting laminated panel ( 10 ).

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present patent application is a divisional of U.S. patent application Ser. No. 11/572,109, filed Jan. 15, 2007, now U.S. Pat. No. 7,879,423 which is U.S. National Phase Entry of PCT/CA2005/001096, bearing an International Filing Date of Jul. 14, 2005, both incorporated herein by reference. The present application claims priority on U.S. Provisional Patent Application No. 60/587,516, filed on Jul. 14, 2004, and on U.S. Provisional Patent Application No. 60/605,138, filed on Aug. 30, 2004, both incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention generally relates to a lamination process and, more particularly but not exclusively, to a process for laminating various layers into a laminated panel, for subsequent use of the laminated panel as a component of a boot quarter, for sporting goods or the like. 
     BACKGROUND ART 
     Laminated panels are found in a plurality of products. Laminated panels typically consist of a plurality of layers, each layer being part of the laminated panels for given properties. Therefore, laminated panels are used as an alternative to well known materials, such as leather and polymers (e.g., vinyl), in the fabrication of goods. 
     The layers constituting laminated panels are chosen for various properties that will suit the subsequent use of the product. For instance, layers having properties such as resilience, impermeability, strength, shock absorption, softness, are combined to be laminated into panels that will have selected characteristics. 
     The lamination processes typically involve a continuous feed of the layers into presses, and therefore involve expensive equipment. Moreover, effects such as embossing are desired on some panels, and this involves further equipment, for instance to synchronize embossing dies with the feed of material in the lamination process. 
     It would thus be desirable to simplify the lamination process and to lessen the cost of equipment involved in the process, for instance when embossing is required in the laminated panels. 
     SUMMARY OF INVENTION 
     Therefore, it is a feature of the present invention to provide a novel method for laminating panels. 
     It is a still further feature of the present invention to provide a novel laminated panel. 
     Therefore, in accordance with the present invention, there is provided a method of forming a laminated panel with at least a fusible layer and a mesh layer, comprising heating the fusible layer to fuse a portion of the fusible layer, and pressing only a selected portion of the mesh layer against the fusible layer to provide for the formation of an embossed pattern of mesh layer projecting above the adjacent fusible layer in which mesh layer is encapsulated, in the resulting laminated panel. 
     Further in accordance with the present invention, there is provided a method of forming a laminated panel, comprising assembling product layers including a fusible polymeric layer, a mesh layer, and a core layer, heating the fusible polymeric layer to fuse a portion of the fusible polymeric layer, and pressing only a selected portion of the mesh layer against the fusible polymeric layer to provide for the formation of an embossed pattern of mesh layer projecting above the adjacent fusible polymeric layer in which mesh layer is encapsulated, in the resulting laminated panel. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       A preferred embodiment of the present invention will now be described with reference to the accompanying drawings in which: 
         FIG. 1  is a flow chart illustrating a lamination process in accordance with a preferred embodiment of the present invention; 
         FIG. 2  is a schematic side view of an assembly of materials prior to being subjected to the process of  FIG. 1 ; 
         FIGS. 3A ,  3 B and  3 C represent a sequence of steps of the process of  FIG. 1 ; 
         FIG. 4  is a top plan view of an embossing die of a process layer of the assembly of materials; and 
         FIG. 5  is a side elevation view of the assembly of materials of  FIG. 2 , after having been subjected to the process of  FIG. 1 . 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring to the drawings and, more particularly, to  FIG. 1 , a lamination process in accordance with a preferred embodiment is generally shown at  10 . The process  10  is used to fuse layers of material (hereinafter product layers) to form a laminated panel, using process layers to facilitate the process and obtain effects, such as embossing, in the laminated panel. 
     Assembly of Product and Process Layers for the Process  10   
     Referring to  FIG. 2 , a typical assembly of the product and process layers that will be used as a batch in the process  10  is generally shown at  20 . The assembly  20  has a pair of antiadhesive sheets  21  between which a remainder of the layers are sandwiched. The antiadhesive sheets  21  are typically fiberglass sheets with both surfaces having an anti-adhesive coating, such as a PTFE coating (i.e., polytetrafluorethylene). The antiadhesive sheets  21  are process layers, in that they will not be part of the laminated panel. 
     As shown in  FIGS. 2 and 4 , an embossing die  22  is adjacent to one of the antiadhesive sheets  21 . The embossing die  22  may be a flat panel made of a material having a relatively high thermal conductivity. Shapes  22 ′ are defined in the panel and these shapes will outline the embossing in the laminated panel that will be produced by the process  10 , as will be described hereinafter. Although a single layer of the embossing die  22  is shown in  FIG. 1 , it is contemplated to provide another embossing die  22  adjacent to the other antiadhesive sheet  21  so as to create embossing on both surfaces of the laminated panel that will be produced by the process  10 . In such a case, guiding templates are typically used to ensure that the embossing dies  22  are aligned with respect to one another. 
     For instance, the embossing die  22  typically consists of aluminum (aluminum plate between 1/16″ and ½″ thickness, as a function of the desired embossing), in which shapes have been defined using laser or abrasive jet cutting techniques. Other materials, such as metals and high thermal conductivity materials, can also be used to constitute the embossing die  22 . A coating may be applied on the embossing die  22 , to reduce adherence of the product layers  23  to the embossing die  22 . The embossing die  22  is also part of the process layers, as it will not be part of the laminated panel. 
     As shown in  FIG. 2 , product layers  23  are positioned between one of the antiadhesive sheets  21  and the embossing die  22 . The product layers  23  will be fused so as to become the laminated panel, with process layers (i.e., the antiadhesive sheets  21  and the embossing die  22 ) being removed following the embossing process  10  ( FIG. 1 ). 
     The Process  10   
     Referring concurrently to  FIGS. 1 and 3A , the process  10  has a first Step  11  of superposing the product and process layers into the assembly  20  ( FIG. 3A ), as described previously. 
     In Step  12 , the product layers  23  are laminated. Step  12  involves positioning the product and process layers in a press  30 . The press  30  is then closed on the assembly  20 , as shown in  FIG. 3B , to apply pressure and heat on the assembly  20 , so as to create a fusing reaction between the various components of the product layers  23 . 
     The temperature, pressure and cycle time settings of the press  30  are selected as a function of the product layers  23  that will be fused into the laminated panel. As will be discussed below, press settings will be described with examples of product layers  23 . Once the cycle is over, the assembly  20  is removed from the press  30 . 
     The embossing die  22  will cause some embossing in the product layers  23 , in that the pressure applied to the product layers  23  will be lower where the shapes are defined in the embossing die  22 . This will cause the product layer  23  to be thicker at the locations, resulting in some embossing in the product layer  23 . This is illustrated in  FIG. 5 , in which embossed portions A 1  of the layer  23  are defined as a result of the process  10 . 
     Referring concurrently to  FIGS. 1 and 3C , in Step  13 , the assembly  20  may undergo a stabilization step in a press  31 , in which a pressure is applied onto the assembly  20 , and in which the assembly  20  is cooled to ambient temperatures. 
     The stabilization step is performed to enable the product layers  23  of the assembly  20  to stabilize into their new fused conditions. As the product layers  23  include various types of materials, such as expanded polymer resins and bonding agents, the product layers  23  may be unstable at the exit of the press  30  in Step  12 . Therefore, Step  13  is provided to enable the product layers  23  of the assembly  20  to stabilize into shape as a whole, according to the desired aspect of the laminated product. 
     Once more, the temperature, pressure and cycle time settings of the press  31  are selected as a function of the product layers  23  of the assembly  20 . 
     The product layer  23  and the process layers assembly  20  may stay together between Steps  12  and  13 . Therefore, the assembly  20  may be carried as a whole from the press  30  to the press  31 . The use of antiadhesive sheets  21  to conceal a remainder of the assembly  20  facilitates the removal of the assembly from the hot press  30 , and its handling toward the cooling press  31  (e.g., using the sheets  21  which overhang the product layers  23  for grip). Moreover, the antiadhesive sheets  21  generally prevent product layer residues to gather on the plates of the presses  30  and  31 , which residues would impede on the efficiency of the presses. It is pointed out that the material and coating of the sheets should be selected so as not to affect the thermal conductivity of the assembly  20 . The presence of the embossing die  22  throughout Steps  12  and  13  helps in producing well defined embossing in the laminated panel. 
     It is also contemplated to provide a single press, equipped with both a heating system and a cooling system, such that the Steps  12  and  13  take place one after the other in the same press, such that the assembly  20  stays assembled as in Step  11 . This satisfies the process in that no alignment is required for the assembly  20  to be cooled after being heated, as is the case if the assembly  20  switches presses (e.g.,  FIGS. 3B and 3C ). 
     In Step  14 , the laminated panel is extracted from the assembly  20 . More specifically, the process layers, namely the antiadhesive sheets  21  and the embossing die  22  are separated from the product layers  23 . The fused product layers  23  define the laminated panel of the preferred embodiment. The process layers are then reusable for subsequent cycles of the process  10 . 
     In Step  15 , the laminated panel is cut in pieces, according to intended use of the laminated panel. For instance, boot quarters may be cut following the outline created by the embossing. Moreover, items such as eyelets, trademark logos and decorative materials may be added to the pieces of laminated panel. 
     It is contemplated to provide curved press surfaces and embossing die  22 , so as to shape the product layers  23  with curvature. 
     It is pointed out that conveyors may be provided, as shown in  FIGS. 3A to 3C , whereby the displacement of the assembly  20  in the process  10  may be automated. 
     The Product Layers  23   
     The product layers  23  may include various materials, according to the type of panel that is desired. As shown in  FIG. 2 , the product layers  23  include an external layer  23 A, core layers  23 B and an internal layer  23 C. 
     The external layer  23 A will constitute one of the exposed layers of the laminated panel. Accordingly, the material constituting the external layer  23 A will be chosen as a function of the intended use of the laminated panel. For instance, the external layer  23 A may consist of fabrics, such as polyester and/or nylon fabrics. 
     Alternatively, the external layer  23 A may be a combination of layers. For instance, to enhance the embossing of the laminated panel, a combination of a mesh layer and a fusible polymeric layer [e.g., polypropylene or polyethylene base material or coating, such as a thermo-plastic olefin (TPO), Surlyn™ 8940, with a thickness of 0.040″] is typically used with the process  10 . In such a case, the mesh layer (e.g., nylon monofilament meshing, with color coating) will be enclosed in the fusible polymeric layer in areas without embossing, while being exposed at embossing portions. In addition to creating a visual effect, the mesh embossing will reinforce the laminated panel. On the other hand, the laminated panel remains relatively flexible, whereby it may be shaped/conformed into various products. One type of mesh layer that may be used in the process  10  is a 355D nylon 6 monofilament (diameter of 0.008″), with 800D nylon mono-ply. 
     The core layers  23 B typically include reinforcement materials having a temperature reactive bonding agent, used to reinforce the fabrics and to bond the external layer  23 A to other layers of the core layers  23 B. The reinforcement materials typically consist of synthetic fiber base materials, such as a non-woven fabric made from a blend of synthetic fibers and impregnated with a filled styrene copolymer with EVA hot melt adhesive. The bonding agent is preferably activated at a given temperature, such as an EVA glue (ethylene-vinyl-acetate). 
     A core material of the core layers  23 B is typically present, and is fused to the external layers  23 A by the reinforcement materials. The core material may be an expanded polymer, such as expanded polypropylene (EPP), expanded polyethylene (EPE), expanded polystyrene (EPS), or similar polymeric foams. The density and thickness of such foams varies according to the type of laminated panel desired. Other types of core material include papers, cardboard, fabrics, wood and the like. As an example, some laminated panels have a core of EPP having a density ranging between 2.5 and 5.5 lb/in 3 , with a thickness ranging between 0.188″ and 0.280″, for given applications. It is contemplated to use cores of other densities and/or thickness in accordance with the contemplated application of the laminated panel. 
     Another layer of reinforcement material may then be provided in the core layers  23 B, to further reinforce the laminated panel. It is pointed out that the reinforcement material may consist in predefined shapes that will cause an embossing effect in a surface of the laminated panel. 
     The internal layer  23 C will constitute an exposed surface of the laminated panel. For instance, when the laminated panel is used as a boot quarter, this surface will constitute an interior of the boot. Accordingly, it is contemplated to use a fabric, such as a polyester, as the internal layer  23 C. A suitable type of polyester that may be used as the internal layer  23 C is a 100% brushed polyester (e.g., 1.96 oz/yd 2 ). 
     It is pointed out that similar materials, and additional layers, may be added to define various configurations of the laminated panel. For the above described materials, suitable fusing results have been obtained heating the press  30  ( FIG. 3C ) to about 170° C. (e.g., 172° C.) with a 4 Psi pressure applied to the assembly  20 , for a cycle of 120 seconds in the press  30 , to compress a 0.40″ of product layers  23  to below 0.37″. 
     The stabilization of Step  13  subsequently took place for another cycle of 120 seconds at pressure of 4 Psi in the cooling press  31 , to compress the 0.37″ of product layers  23  into the laminated panel of 0.25″ of thickness. The temperature of the plates of the press  31  were initially below 16° C., and generally maintained thereat throughout stabilization in Step  13 . 
     As mentioned previously, the temperature, pressure and cycle time settings are dependent on the materials being used, the thickness of the product layers  23 , and their capacity to keep their laminated shape following the process  10 , and the thickness of the process layers (e.g., embossing die  22 ). The above values are given for illustrative purposes. For instance, although the cycle time for the Steps  12  and  13  is the same in the above examples, these cycle time values are independent from one another, and it may be that the stabilization cycle is longer to ensure the embossing keeps its shape. 
     Referring to  FIGS. 2 and 4 , the thickness of the embossing die  22 , in relation to the other factors of the lamination process  10 , may have an effect on the surface texture of the laminated panel. More specifically, a greater thickness of the embossing die  22  (e.g., ¼″ and more), will result in thicker air pockets between the press plates and the product layers  23 . opposite the shapes  22 ′. As air acts has a thermal insulator, heat from the press  31  is transferred to a portion of the layer  23 A that is in contact with the material of the embossing die  22 , whereas the shapes  21 ′ encapsulate air such that the portion of layer  23 A opposite the shapes  21 ′ is subjected to lower temperatures and can thus react differently. 
     Therefore, the thickness of the embossing die  22 ′ is factored in when specific surface texture is required, such as the embossing using a mesh that will be partially encapsulated in a fusible polymeric material. Mesh will show opposite the shapes  21 ′, whereas a lustered polymeric material will encapsulate the mesh opposite the material of the embossing die  22 . 
     Amongst the various possible uses of the laminated panels are the sporting goods industry (quarters for sport shoes/boots, boot quarters for skate boots, padding for various sports, such as shoulder pads, chest protectors, back pads, rib pads, thigh pads, helmet components, playing surfaces), the clothing industry (boot quarters, e.g., military boots), the furniture industry (cushions, seat backrests, wall partitions), the packing industry and the automotive industry (door inner shell, arm rests, decorative components). 
     It is within the ambit of the present invention to cover any obvious modifications of the embodiments described herein, provided such modifications fall within the scope of the appended claims.