Cold lamination of trim skins using microwave/induction in a heated press
A lamination process and press/tooling for bonding a flexible decorative material layer (skin, trim) to a dimensionally stable support using a heat‑activatable adhesive that is cured by irradiating the stack with electromagnetic energy (microwave, RF or induction). The parts are pressed between two rigid mold halves, edges are folded over, local edge radiators heat the fold regions, and coolant channels in the tool prevent unwanted heating. Typical users are suppliers of automotive interior trim and other manufacturers of bonded panels.
(57) What the patent covered
The main independent claim covers a process in which a flexible material layer and a support are pressed together with a heat‑activatable adhesive between them, a portion of the layer projecting at the support edge is folded, the stack and tool are irradiated with electromagnetic radiation from a radiator in one tool half to activate the adhesive (microwave, high‑frequency or induction), the edge region is separately irradiated by a second radiator, and the tool contains coolant channels filled with a coolant that is not excited by the radiation to cool the adhesive.
The distinctive part: Using embedded electromagnetic radiators in the press halves to activate the adhesive directly (including a separate radiator for the folded edge) while actively cooling the tool with a non‑susceptible coolant.
Novelty 4/5. At filing time, press lamination with heated tooling was common; the novel element was replacing conductive heat transfer from the tooling with direct electromagnetic activation of the adhesive and targeted edge irradiation.
Making it
Pressed assembly in rigid mold halves; embed microwave/RF/induction radiators in at least one tool half; apply adhesive to layer and/or support; place and fold projecting edge; close press to apply pressure; energize radiators to directly heat/activate adhesive; circulate non‑susceptible coolant in tool channels for cooling; demold and finish.
Materials: thermoplastic or heat‑reactive adhesive dispersion (aqueous or solventborne), flexible decorative layer: PVC, leather, coated fabric or textile composite (likely), dimensionally stable support: thermoplastic or fiber‑reinforced substrate (e.g., ABS, PP, polyurethane foam carrier), tooling: steel or aluminum mold halves with embedded radiators and coolant channels
Manufacturability 3/5. Requires conventional press tooling with additional integration of electromagnetic radiators and sealed coolant channels; needs RF/microwave components and shielding but uses standard pressed panel handling and folding steps.
Is anyone buying?
We haven't run a demand check on this one yet. Shoppers would likely search for automotive trim laminating press, microwave adhesive activation lamination, heated press for bonded panels; the links on the right open those searches.
Who buys it: automotive interior suppliers and industrial panel laminators
Before you make it
We didn't find any related continuation or divisional patents still in force, although that doesn't rule out design patents, trademarks or unrelated patents covering the same product.
Practical issues include electromagnetic shielding, matching radiation frequency to adhesive chemistry, tooling complexity and safety/EMC compliance; patent has lapsed so check regulatory and process standards rather than patent clearance.
Owners occasionally revive lapsed patents (about 1.5% are), and this page is a research lead rather than legal advice, so get a freedom-to-operate opinion before you manufacture anything.