CN103998227A - 具有基于植物的天然产物的内饰装配零部件 - Google Patents

具有基于植物的天然产物的内饰装配零部件 Download PDF

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CN103998227A
CN103998227A CN201280047522.6A CN201280047522A CN103998227A CN 103998227 A CN103998227 A CN 103998227A CN 201280047522 A CN201280047522 A CN 201280047522A CN 103998227 A CN103998227 A CN 103998227A
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assembling parts
backing
decorative layer
fiber
arbitrary aforementioned
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S·帕鲁丘里
H·卡拉斯
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Johnson Controls Interiors GmbH and Co KG
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Johnson Controls Interiors GmbH and Co KG
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
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    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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Abstract

本发明涉及用于机动车辆内饰的装配零部件，以及还涉及用于生产装配零部件的方法。

Description

具有基于植物的天然产物的内饰装配零部件
技术领域
本发明涉及用于机动车辆内饰的装配零部件，以及还涉及用于生产装配零部件的方法。
背景技术
国际专利申请WO2010/080967A1公开了一种装配零部件，其具有由天然纤维制成的背衬以及在不使用附加热熔粘合剂的情况下施加到所述背衬表面上的透明外部薄片。
发明内容
本发明基于提供一种装配零部件的目的，所述装配零部件在视觉上具有吸引力，此外其在关于耐擦伤性、耐紫外线性以及成本的方面还具有优异的特性。另一意图是提供用于高效生产装配零部件的方法，所述装配零部件的价格呈现良好的价值且其在视觉上具有吸引力。
该目的通过下述装配零部件来实现，所述装配零部件：
-包括由下述材料制成的背衬，所述材料优选是基于植物的，但其还包括任何所需的天然物质；
-其中由包括天然纤维、优选基于植物的纤维的材料制成的装饰层优选覆盖所述背衬可见侧的至少一部分；以及
-其中所述背衬和/或装饰层至少部分地设有透明或半透明的外层。
关于本发明该主题所提供的描述也同样适用于本发明的其它主题，反之亦然。
所述背衬优选包括作为天然物质的分别通过粘合剂粘结到彼此的木纤维或木材颗粒。所述粘合剂优选是以热固方式变硬的丙烯酸类树脂。此外特别是由聚酯制成的合成纤维能够与背衬材料混合以提高强度。天然物质的比例优选是从重量的50%至85％，特别是重量的约70％。粘合剂的比例优选低于重量的50％，特别是重量的约15％。在一个优选的实施例中，合成纤维的比例是从重量的10%至20％，特别是重量的约15％。
背衬材料、特别是天然物质引入到进一步处理时所处的形式优选是能够被压制和/或已被针刺的毡垫形式。
在另一个优选的实施例中，所述背衬包括天然物质，特别是亚麻、大麻和/或洋麻，在此给出特别优选为洋麻，并包括作为粘合剂的热塑性材料，特别是聚丙烯。本发明的该实施例具有的优点在于其可以优选地省略任何装饰层。背衬的可见侧优选地由透明或半透明的外层所覆盖。其中，热塑性粘合剂所提供的形式同样优选是纤维材料的形式。背衬优选地由占重量40%至60％的天然纤维和占重量60%至40％的热塑性粘合剂构成。然而备选地或另外地，对于背衬层而言，其也可以使用椰子纤维和/或动物鬃毛。所述纤维有利地采取无规则纤维的形式，例如采取非织造材料的形式。
此外，有利的是将至少一种添加剂添加到特别是天然物质的背衬材料，所述添加剂提高天然物质在处理过程中的热稳定性和/或所述添加剂在高温下用光照射的过程中提供足够的色牢度和/或使用寿命。所述背衬实质上决定所述装配零部件的机械性能。然而，另一种有利的可能性是背衬的天然纤维、粘合剂和/或合成纤维优选地在它们被粘结之前为相同或不同颜色的。
所述背衬的价格凭借其中的材料组成而呈现良好的价值，但背衬有时在视觉上不太具有吸引力；其优选至少在一定程度上由装饰层所覆盖。因此，在一个备选方案中，背衬的可见侧具有覆盖装饰层，且所述装饰层（到其所存在的程度）能够在一定程度上或完全地覆盖可见侧。所述装饰层材料有利地包括韧皮纤维，例如亚麻、大麻、洋麻等。然而备选地或另外地，也可以使用椰子纤维和/或动物鬃毛。纤维的直径优选为从5至40微米。纤维的长度优选为从1000至6000微米。纤维有利地采取无规则纤维的形式，例如采取非织造材料或毡的形式，以及在此也给出优选为机织织物或针织织物的布置。此外背衬材料包括粘合剂，优选为以热固方式变硬的丙烯酸类树脂。纤维在装饰层中的比例优选为重量的70%至90％，特别为重量的80%至85％。粘合剂的比例优选是低于重量的30％，特别是低于重量的20％。为了影响机械性能，可以任选添加优选低于重量的10％比例的特别是由聚酯制成的合成纤维。此外，有利的是将至少一种添加剂添加到装饰层材料，所述添加剂提高天然纤维在处理过程中的热稳定性，并且其也增加抗紫外线辐射的抗性。合适的添加剂例如是诸如4-羟基-2,2,6,6–四甲基哌啶氧化物的光稳定剂，或诸如磺化苯并三唑的UV吸收剂，且在每种情况下它们可以单独使用或组合使用。所述装饰层实质上可决定装配零部件的视觉特性。因此装饰层的天然纤维、粘合剂和/或合成纤维有利地优选在其粘结之前是相同或不同颜色的。
背衬的粘合剂或装饰层的粘合剂有利地由热塑性塑料构成，例如由聚丙烯（PP）、丙烯腈-丁二烯-苯乙烯（ABS）、聚碳酸酯（PC）和/或PC/ABS共混物构成。
所用的天然纤维或天然物质例如可以是木材、洋麻、大麻、亚麻、蕉麻、剑麻或具有韧皮纤维茎干的类似植物。对于有关这些纤维或天然物质的进一步信息，参考Wiley-Verlag的出版物“天然纤维的工业应用（Industrial Applications of Natural Fibres）”，第25和26页。所述章节通过引用的方式并入本文，因此被认为是本公开的一部分。
天然纤维或天然物质被处理时的形式例如可以是单根纤维的形式或毡垫或非织造材料的形式。纤维（例如毡垫或非织造材料）例如可被水固结或热粘结，和/或为针刺毡。在一个优选的实施例中，用透明的背衬介质涂覆纤维层。纤维层（例如毡垫和/或非织造材料）优选随后经受成型处理，特别优选地是通过压制进行成型处理。此外优选的是，所述纤维已嵌入到粒状材料内，所述粒状材料通过注射成型来处理以便得到装配零部件。
外层有利地由塑料薄片构成，其至少在一定程度上是透明的，或者至少在一定程度上是半透明的。塑料薄片可有利地由热塑性聚氨酯（TPU）构成，由在可见侧上具有聚氨酯涂层的聚丙烯（PP）构成，或由聚酰胺（PA）构成或由聚碳酸酯（PC）构成。合适薄片的厚度例如可为从20微米至500微米。合适的薄片材料是聚丙烯、聚甲基丙烯酸甲酯（PMMA）、ABS、PC或PC/ABS。此外有利地可将涂层材料层施加到薄片上，所述涂层材料层有利地由可交联的聚氨酯构成，且其厚度优选为从5微米至50微米。此外可将提高抗紫外线辐射的抗性的添加剂添加到外层材料上。在本发明的一个具体实施例中，外层是着色的，并且该颜色可与装饰层的颜色相符或偏离。
优选的是将紫外线防护以单独或组合的方式提供给装配零部件的组件上，所述组件例如是天然纤维、非织造材料、粘合剂、和/或例如薄片的外层。
在第一优选的实施例中，用于得到三维装配零部件的成型处理仅仅在将表面防护施加到设有毡垫和/或非织造材料和/或其它天然纤维的层上之后进行，表面防护特别是施加到装饰层上。在另一优选的实施例中，表面防护仅仅在设有毡垫和/或非织造材料和/或其它天然纤维的装饰层经受成型处理之后进行。通过施加粒状的表面防护，例如粒状外层，尤其是粒状外层薄片，或通过在模具中的粒状效果可获得表面上的粒状效果。在模具中的所述粒状效果被压印到所述外层和/或所述装饰层内。
此外有利的是，装配零部件在表面防护下面、例如在外层下面的可见区域中、特别是在装饰层中进一步包括优选着色的一定含量的天然物质，例如叶、草、角状物（horn）、软木（cork）等。
背衬的厚度有利的是从1.5至3.0毫米，特别是约2.0毫米，并且在此所述背衬的每单位面积的重量优选是从1000至1600g/m2，特别是约1400g/m2。
所述装饰层的厚度有利的是从0.1至1.0毫米，特别是约0.2至0.3毫米，并且在此所述装饰层的每单位面积的重量优选是从200至500g/m2，特别是从300至400g/m2。
所述外层的厚度有利的是从0.03至0.50毫米，特别是从0.05至0.20毫米。
在装配零部件的生产中，优选为用于背衬的毡垫形式的半成品、为用于装饰层的毡垫形式的半成品、以及还有外层放置于彼此的顶部上并且在引入热量的情况下进行压制以便得到二维或三维组件，但优选不使用任何附加的粘合剂。
备选地，特别在装配零部件处于非常明显的三维形状的情况下，也可在起初将装饰层和外层粘结到彼此以便得到多层片材状结构，然后再将这些粘结到背衬。施加到背衬例如可通过层压或包覆模制、特别是用包括热固性粘合剂的材料来实现。在粘结到背衬之前，特别有利的是使得由装饰层和外层制成的复合物经受预成型处理，特别是经由热成型来进行预成型处理。
在生产装配零部件的一个特定实施例中，装饰层另外地由不同的部段、特别是不同颜色的部段组装而成。部段可以如此的方式对接以便在装配零部件中的部段之间形成可辨别出的分界线。然而，当装饰层的各部段施加到背衬上时它们进行重叠是特别有利的，并且如果此时部段具有不同的颜色，则可以通过在过渡区域内的混色来获得引人注目的视觉效果。
如果装配零部件具有多个可见侧，从原则上而言可以用装饰层和外层完全地或在一定程度上覆盖各个所述可见侧。
附图说明
下面参照附图对本发明进行解释说明。这些解释说明仅仅作为实例，但并不限制本发明的一般概念。所述解释说明同样适用于所有主题。
图1示出本发明装配零部件的一个实施例。
图2示出本发明装配零部件的另一个实施例。
图3和图4分别示出了一种装配零部件，其中装饰层包括天然物质。具体实施方式
在图1中所示的用于车辆内饰（例如门包层，仪表板，柱包层，车顶内衬，车辆座椅上的嵌板）的装配零部件1包括背衬2，在此其材料包括相对粗的碎片型木材颗粒3。粘合剂4将木材颗粒3进行粘结。此外将少量的合成纤维5添加到背衬材料2以便提高强度。由随机排列的相对长的天然纤维7和粘合剂8组成的装饰层6覆盖背衬的可见侧，在这种情况下，在其整个面积上进行覆盖。为透明塑料薄片10形式的外层9在装饰层6的整个面积上覆盖装饰层6，且优选使得装配零部件耐刮擦和/或耐紫外线。外层和/或装饰层可具有颗粒效果。本领域技术人员将会理解的是也可以省略装饰层。在该实施例中，其同样是有创造性的，装饰层6直接附连到背衬2的可见侧上。
在图2的实施例中，装饰层6由两个相互重叠的不同颜色的部段11、11'构成，这两个部段一起在它们的整个面积上由外层9所覆盖。重叠区域12在此产生引人注目的视觉效果。
图3示出了一种装饰层，其由为第一颜色的塑料粘合剂、为第二颜色的通过粘结并入的天然纤维、为第三颜色的所添加的角状物成分组成。该组件具有透明的表面防护，其是外层且使得该组件耐刮擦和耐紫外线。装饰层在其背面侧可具有背衬层，所述背衬层增加其稳定性。在当前情况下，装饰层、外层和任选的背衬层用作三维形状的门包层。装饰层通过透明外层对车辆乘员可见。
图4示出类似的装配零部件，软木而不是角状物被引入到其内。在其它方面，可参考图3的描述。
附图标记清单
1 装配零部件
2 背衬
3 木材颗粒
4 粘合剂
5 合成纤维
6 装饰层
7 天然纤维
8 粘合剂
9 外层
10 塑料薄片
11，11' （装饰层的）部段
12 重叠区域

Claims (14)

1.一种装配零部件（1），所述装配零部件：
-包括由下述材料制成的背衬（2），所述材料包括至少一种天然物质（3）；
-其中由包括天然纤维（7）、优选基于植物的纤维的材料制成的装饰层（6）优选覆盖所述背衬的可见侧的至少一部分；以及
-其中所述背衬和/或装饰层（6）已被至少部分地设有透明或半透明的外层（9）。
2.根据权利要求1所述的装配零部件（1），其特征在于，所述背衬（2）包括木材颗粒（3）。
3.根据权利要求1或2所述的装配零部件（1），其特征在于，所述背衬（2）和/或装饰层（6）包括合成纤维（5）。
4.根据任一前述权利要求所述的装配零部件（1），其特征在于，所述天然物质（3）和/或合成纤维（5）已通过粘合剂（4）粘结到彼此。
5.根据任一前述权利要求所述的装配零部件（1），其特征在于，所述纤维（5）采取无规则纤维的形式，优选为非织造材料或毡，或采取机织织物或针织织物的形式。
6.根据任一前述权利要求所述的装配零部件（1），其特征在于，所述外层（9）为薄片。
7.根据任一前述权利要求所述的装配零部件（1），其特征在于，所述装饰层（6）由多个部段组装而成。
8.根据任一前述权利要求所述的装配零部件（1），其特征在于，所述装配零部件（1）包括层（6），特别是装饰层（6），层（6）中存在天然纤维和粘合剂（8），其中所述纤维（7）和/或粘合剂（8）已被着色。
9.根据权利要求8所述的装配零部件（1），其特征在于，所述纤维（7）和所述粘合剂（8）已被不同地着色。
10.一种生产根据任一前述权利要求所述的装配零部件的方法，其特征在于，为半成品形式的装饰层（6）、以及外层（9）被插入到模具内，以及优选地通过引入热量被三维成形并粘结到彼此。
11.根据权利要求10所述的方法，其特征在于，所述外层（9）随后或同时被粘结到背衬（2）。
12.根据权利要求11所述的方法，其特征在于，所述背衬（2）特别通过层压或包覆成型而施加到所述外层（9）上。
13.根据任一前述权利要求所述的方法，其特征在于，在粘结到背衬（2）之前，装饰层（6）和/或所述外层（9）经受成形，优选经受热成型。
14.根据任一前述权利要求所述的方法，其特征在于，所述纤维（7）、所述粘合剂（8）和/或合成纤维（5）被着色，优选是它们粘结之前被着色。
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