CN115746387A - VOC treatment of molded interior trim components for vehicles - Google Patents
VOC treatment of molded interior trim components for vehicles Download PDFInfo
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- CN115746387A CN115746387A CN202111034272.XA CN202111034272A CN115746387A CN 115746387 A CN115746387 A CN 115746387A CN 202111034272 A CN202111034272 A CN 202111034272A CN 115746387 A CN115746387 A CN 115746387A
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- CN
- China
- Prior art keywords
- aminosilane
- interior trim
- layer
- automotive interior
- molded
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J7/00—Chemical treatment or coating of shaped articles made of macromolecular substances
- C08J7/04—Coating
- C08J7/06—Coating with compositions not containing macromolecular substances
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/30—Processes for preparing, regenerating, or reactivating
- B01J20/32—Impregnating or coating ; Solid sorbent compositions obtained from processes involving impregnating or coating
- B01J20/3202—Impregnating or coating ; Solid sorbent compositions obtained from processes involving impregnating or coating characterised by the carrier, support or substrate used for impregnation or coating
- B01J20/3206—Organic carriers, supports or substrates
- B01J20/3208—Polymeric carriers, supports or substrates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/30—Processes for preparing, regenerating, or reactivating
- B01J20/32—Impregnating or coating ; Solid sorbent compositions obtained from processes involving impregnating or coating
- B01J20/3231—Impregnating or coating ; Solid sorbent compositions obtained from processes involving impregnating or coating characterised by the coating or impregnating layer
- B01J20/3242—Layers with a functional group, e.g. an affinity material, a ligand, a reactant or a complexing group
- B01J20/3244—Non-macromolecular compounds
- B01J20/3246—Non-macromolecular compounds having a well defined chemical structure
- B01J20/3257—Non-macromolecular compounds having a well defined chemical structure the functional group or the linking, spacer or anchoring group as a whole comprising at least one of the heteroatoms nitrogen, oxygen or sulfur together with at least one silicon atom, these atoms not being part of the carrier as such
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/30—Processes for preparing, regenerating, or reactivating
- B01J20/32—Impregnating or coating ; Solid sorbent compositions obtained from processes involving impregnating or coating
- B01J20/3231—Impregnating or coating ; Solid sorbent compositions obtained from processes involving impregnating or coating characterised by the coating or impregnating layer
- B01J20/3242—Layers with a functional group, e.g. an affinity material, a ligand, a reactant or a complexing group
- B01J20/3244—Non-macromolecular compounds
- B01J20/3246—Non-macromolecular compounds having a well defined chemical structure
- B01J20/3257—Non-macromolecular compounds having a well defined chemical structure the functional group or the linking, spacer or anchoring group as a whole comprising at least one of the heteroatoms nitrogen, oxygen or sulfur together with at least one silicon atom, these atoms not being part of the carrier as such
- B01J20/3259—Non-macromolecular compounds having a well defined chemical structure the functional group or the linking, spacer or anchoring group as a whole comprising at least one of the heteroatoms nitrogen, oxygen or sulfur together with at least one silicon atom, these atoms not being part of the carrier as such comprising at least two different types of heteroatoms selected from nitrogen, oxygen or sulfur with at least one silicon atom
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
- B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
- B60N3/042—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets of carpets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
- B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
- B60N3/048—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets characterised by their structure
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2375/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
- C08J2375/04—Polyurethanes
- C08J2375/06—Polyurethanes from polyesters
Landscapes
- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Analytical Chemistry (AREA)
- Transportation (AREA)
- Mechanical Engineering (AREA)
- Health & Medical Sciences (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
Abstract
A molded automotive interior trim component comprising at least one layer, wherein at least a portion of an exterior surface of the molded trim component is covered by a network of aminosilane and/or aminosiloxane molecules that are partially hydrogen bonded to an adjacent surface.
Description
Technical Field
The present application relates to a thermoformed automotive trim part comprising at least a polyurethane foam layer or a felt layer, and a method of producing such trim part.
Background
Vehicle occupants recognize that the volatile components are released from the interior components immediately after production of a new vehicle, particularly if they produce a so-called "new vehicle smell". The release may last for a longer period of time and may be accelerated by a car in an environment with an elevated temperature, for example, when parked in the sun or used in an overall warmer climate.
The release of volatile components may pose a minor health hazard, but also produce undesirable odors within the vehicle. Over time, the release may decrease to a level that is not apparent to the vehicle user. However, the use of a closed air conditioning system may extend a significant period.
Among the volatile components, the aldehydes, in particular formaldehyde and acetaldehyde, are the most problematic and can be released from interior trim parts comprising at least a foam layer or a felt layer. Trim parts with foam layers obtained with the in-mold foaming process tend to produce high levels of free formaldehyde and acetaldehyde. In addition, the use of certain mold release agents may increase emission levels. Felt materials, particularly those containing recycled or recycled fiber materials, may increase acetaldehyde levels. While virgin polyester may release volatile components, particularly in the first stage after polyester production.
In addition, trim components can be exposed to exogenous VOCs during production, transportation, and storage, which can be absorbed by the component. These absorbed VOCs can be released again during automotive use, increasing VOC emission levels.
There is a need for automotive interior trim parts having at least a polyurethane foam layer and/or a thermoplastic or natural fiber felt layer with reduced levels of emissions of compounds, especially formaldehyde and acetaldehyde.
The prior art solutions are either unpredictable, may release the compound at a later time, or are difficult to apply or maintain on the part. Furthermore, many proposed solutions capture formaldehyde or acetaldehyde, but not both.
It is therefore an object of the present invention to provide a method of treating an automotive interior trim part having at least a polyurethane foam layer and/or a thermoplastic or natural fiber felt layer to reduce the emission levels of formaldehyde and acetaldehyde without the problems of the prior solutions.
Disclosure of Invention
This problem is solved by a molded interior trim part comprising at least one layer according to the main claim 1 and a method of handling such a molded part according to claim 7.
In particular, by covering at least a portion of the exterior surface of the molded trim part with a network of aminosilane and/or aminosiloxane molecules that are partially hydrogen bonded to adjacent surfaces, nearly equal levels can be achieved to achieve significant reductions in formaldehyde and acetaldehyde emissions. Although the reduced efficacy of one molecule (e.g. formaldehyde) reduces the reduced efficacy of another molecule (e.g. acetaldehyde) by prior art systems, this cannot be observed by the treatment according to the invention. Even more surprising, acrolein emissions are also reduced.
This reduction can be established by specially treated foams, but the full carpet construction also shows a reduction in emissions after at least part of the surface is covered with a network of aminosilane and/or aminosiloxane molecules that are partially hydrogen bonded to the adjacent surface.
The reduction in emissions is defined as the emission of the molecules under test and related molecules into the surrounding air. The emissions were sampled at predetermined times and temperatures using Tedlar bags for VOC testing according to ISO 12219-2 or using a cubic meter chamber (cubic meter chamber). The air is then measured by a suitable method, for example according to DIN ISO 16000-3.
Surprisingly, only small amounts of aminosilane are required to cover the surface and achieve at least a reduction of formaldehyde, acetaldehyde and acrolein to a legally acceptable level. The aminosilane may be present in the network as an aminosiloxane after drying. Thus, the final network may be a combination of aminosilanes and/or aminosiloxanes.
Regardless of the molded shape of the part, the aminosilane is used at a concentration required to be at least 0.02 wt% and not more than 0.1 wt% of the weight of the part to achieve this result. It appears that further addition of aminosilane does not increase or even decreases the expected effect, since the molecules may bind to each other and are no longer available for trapping VOCs.
The molded automotive interior trim part according to the invention may preferably comprise at least one layer selected from the group consisting of polyurethane foam layers and thermoplastic carpet layers and/or natural fiber carpet layers and/or pile carpet layers, such as tufted carpet or needle punched carpet.
The molded automotive interior trim component may comprise additional layers selected from polyurethane foam layers and thermoplastic felt layers and/or natural fiber felt layers and/or pile carpet layers, or perforated or foil layers and nonwoven scrim layers. These other layers may form the outer layer of the molded trim part having a surface treated according to the invention.
All surfaces of the molded automotive interior trim part may be covered by a network of aminosilane and/or aminosiloxane molecules that are partially hydrogen bonded to adjacent surfaces. Surfaces that are not accessible to passengers during normal use are preferred, in particular the back of the floor system may be covered.
Preferably, the aminosilane or aminosiloxane is one of the group of silane compounds having an amino group or a diamino group and at least one alkoxy group.
Preferably, the aminosilane is at least one member selected from the group consisting of: -N- (2-aminoethyl) -3-aminopropyltrimethoxysilane, -N- (aminoethylaminomethyl) phenyltrimethoxysilane, -N- (2-aminoethyl) -3-aminopropyltris (2-ethylhexyloxy) -silane, -aminoethyl-aminopropyl-trimethoxysilane, -3- (dimethoxymethylsilyl) propylamine, -N- (2-aminoethyl) -3-aminopropylmethyldimethoxysilane, -3-aminopropyltrimethoxysilane, trimethoxysilylpropyldiethylenetriamine, -bis (2-hydroxyethyl) -3-aminopropyltrimethoxysilane and the like.
A preferred method of treating a molded automotive interior trim part according to the present invention to obtain coverage of a network of aminosilane molecules that are partially hydrogen bonded to an adjacent surface has the steps of:
(1) Spraying a water-based solution comprising at least one aminosilane on at least one surface of a molded automotive trim part, and
(2) The decorative part thus treated is thermally dried so that water evaporates and the aminosilane forms a molecular network covering at least part of the surface and bonding to adjacent materials.
Surprisingly, a thin coverage of the aminosilane and/or aminosiloxane molecular network is already sufficient to reduce formaldehyde and acetaldehyde emissions by more than 50% over the entire part.
Any molded automotive interior trim part (which contains at least a first layer of polyurethane foam and/or fiber mat molded in its final shape) can be treated with the solution according to the invention to reduce the emission of aldehydes, in particular formaldehyde and acetaldehyde.
Surprisingly, the use of aminosilanes or aminosiloxanes as scavengers for coating on surfaces has been sufficient to reduce aldehyde release from the components.
The aminosilane is preferably applied to at least the rear outer surface of the part, i.e. the surface facing the vehicle body.
Preferably, the aminosilane-containing solution is sprayed in the spray booth predominantly on the rear surface of the part so that overspray and aerosol in the spray booth can also reach other surfaces of the part, for example carpet surfaces, such as tufted or needle-punched surfaces. Thus, the part is completely covered by the solution, preferably the back surface is more covered than the front surface.
Alternatively, the pile surface may be covered or placed in a carrier surface to prevent any overspray and to treat only the back surface of the molded part.
The component may be at least partially sprayed on the rear surface, the entire rear surface, or even part or all of the front surface. Preferably, the main concentration is located in areas that are not accessible to the occupant during normal use of the vehicle, such as the back of the part including the sides, and the area under the seat or the upper area directly under the dashboard, to reduce or prevent the occupant from contacting the treated surface.
Preferably, the trim component comprises at least 0.3% scavenger, based on the weight of the component, sprayed on at least one side of the component. Preferably, the scavenger is sprayed in the form of a water-based solution.
Various interior components can be treated in this manner to reduce VOC emissions, particularly floor components, floor mats, interior front wall (innardash) components, back panels, door panels, and roof panels or ceilings, as well as small trim components for closing small gaps in the overall covering.
The process may also be used to mold foam seat components to reduce emissions from these components, preferably before the seat components are covered with fabric.
Example 1
Each component was tested using at least two 20 gram (same weight and size) polyurethane foam blocks cut from a standard commercial foam. A water-based solution containing this component was sprayed onto the surface of each foam block and the block was dried in a hot air oven immediately after treatment.
The so treated blocks and the untreated blocks from the same foam source were packed in bags for VOC emission testing according to DIN ISO 16000-3.
The blocks were treated with the following components such that there was 0.02gr of the components per 20gr foam block: -SC 1N- (2-aminoethyl) -3-aminopropylmethyldimethoxysilane
-SC 2-aminopropyltrimethoxysilane
-SC3 aminoethyl-aminopropyl-trimethoxysilane
-SC4-3- (dimethoxymethylsilyl) propylamine.
Figure 1 shows the percent reduction in formaldehyde, acetaldehyde and acrolein emissions measured on the samples. Surprisingly, the emissions of all three components can be reduced, by at least 80% for all three components, depending on the aminosilane used. In particular, SC1 and SC2 show high reduction in parallel discharge of the two aldehyde components.
In these and other experiments it was found that the function of the treatment was independent of any residual release agent on the surface of the final part to be treated.
Example 2
Three different carpet flooring systems coming directly from the production line were treated with SC1 on the carpet surface and dried. Each sample was packed into a bag and measured in the same manner as in example 1.
Untreated and treated carpet flooring systems were prepared and compared.
It can also be shown herein that the emission levels of formaldehyde, acetaldehyde and acrolein can be significantly reduced.
For the first polyamide tufted carpet having mainly a nonwoven backing layer and a LEPE and EVA latex layer, a formaldehyde emission reduction of more than 90% can be achieved, in addition to a 70% reduction in acetaldehyde, while acrolein is reduced below detectable levels.
The second was also a polyamide tufted carpet, the layout of which was similar to the first carpet tested. In addition, here formaldehyde emissions are reduced by more than 90%, while acetaldehyde emissions are reduced by nearly 60%.
The final carpet treated was a needle punched nonwoven carpet having layers of EVA latex and LDPE and a nonwoven backing layer. In this case the reduction was similar to the tufted carpet sample. Wherein the reduction amounts were 11% formaldehyde, 67% acetaldehyde, respectively, and below the level detectable for acrolein.
Despite the different layouts of the carpets, they showed a considerable level of reduction, indicating that the system was less dependent on the treated surface and the material used for the floor part.
While it is shown that the flooring system can be treated on a napped surface to achieve good results, it is more preferable to treat surfaces that are not contacted by passengers during normal use. Therefore, preferably, the rear surface of the floor member faces the vehicle body.
Claims (7)
1. A molded automotive interior trim component comprising at least one layer, characterized in that at least a portion of the exterior surface of the molded trim component is covered by a network of aminosilane and/or aminosiloxane molecules that are partially hydrogen bonded to adjacent surfaces.
2. The molded automotive interior trim component of claim 1, wherein the aminosilane is at least 0.02% and not more than 0.1% by weight of the component.
3. The molded automotive interior trim component of claim 1, wherein the at least one layer and/or at least one additional layer is selected from the group consisting of a polyurethane foam layer and a thermoplastic and/or natural fiber felt layer and/or a pile carpet layer, a foil layer, a film layer, and a nonwoven scrim layer.
4. The molded automotive interior trim component of one of the preceding claims, wherein all surfaces of the molded automotive interior trim component are covered with a network of aminosilane or aminosiloxane molecules that are partially hydrogen bonded to adjacent surfaces.
5. The automotive interior trim part according to one of the preceding claims, wherein the aminosilane or aminosiloxane is one of the group of silane compounds having an amino group or a diamino group and at least one alkoxy group.
6. The automotive interior trim part according to one of the preceding claims, wherein the aminosilane or aminosiloxane is preferably at least one member selected from the group consisting of: n- (2-aminoethyl) -3-aminopropyltrimethoxysilane, N- (aminoethylaminomethyl) phenyltrimethoxysilane, N- (2-aminoethyl) -3-aminopropyltris (2-ethylhexyloxy) -silane, aminoethyl-aminopropyl-trimethoxysilane, 3- (dimethoxymethylsilyl) propylamine, N- (2-aminoethyl) -3-aminopropylmethyldimethoxysilane, 3-aminopropyltrimethoxysilane, trimethoxysilylpropyldiethylenetriamine, bis (2-hydroxyethyl) -3-aminopropyltrimethoxysilane and the like.
7. Method of treating an automotive interior trim part according to one of the preceding claims, comprising the steps of:
(1) Spraying a water-based solution comprising at least one aminosilane on at least one surface of a molded automotive trim part, and
(2) The decorative part thus treated is thermally dried so that water evaporates and the aminosilane forms a network of aminosilane and/or aminosiloxane molecules covering at least part of the surface and bonded to adjacent materials.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111034272.XA CN115746387A (en) | 2021-09-03 | 2021-09-03 | VOC treatment of molded interior trim components for vehicles |
| PCT/EP2022/074311 WO2023031327A1 (en) | 2021-09-03 | 2022-09-01 | Voc treatment of moulded interior trim parts for a vehicle |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111034272.XA CN115746387A (en) | 2021-09-03 | 2021-09-03 | VOC treatment of molded interior trim components for vehicles |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN115746387A true CN115746387A (en) | 2023-03-07 |
Family
ID=83362502
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202111034272.XA Pending CN115746387A (en) | 2021-09-03 | 2021-09-03 | VOC treatment of molded interior trim components for vehicles |
Country Status (2)
| Country | Link |
|---|---|
| CN (1) | CN115746387A (en) |
| WO (1) | WO2023031327A1 (en) |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2009090955A1 (en) * | 2008-01-15 | 2009-07-23 | Toyota Jidosha Kabushiki Kaisha | Material for interior automotive trims |
| US20100016151A1 (en) * | 2008-07-18 | 2010-01-21 | Caldwell Kenneth G | Aldehyde reducing coating |
| JP2010173343A (en) * | 2009-01-27 | 2010-08-12 | Nicca Chemical Co Ltd | Vehicular interior material |
| EP2886569A1 (en) * | 2013-12-20 | 2015-06-24 | Politechnika Poznanska | 'Polyoxymethylene composite with reduced formaldehyde emission and method for making and use thereof' |
| CN107735419A (en) * | 2015-06-16 | 2018-02-23 | 赢创德固赛有限公司 | Aldehyde scavenger for polyurethane foam |
| CN112638996A (en) * | 2018-03-08 | 2021-04-09 | 欧拓管理股份有限公司 | Thermoformed automotive product with reduced VOC |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2009090956A1 (en) * | 2008-01-15 | 2009-07-23 | Toyota Jidosha Kabushiki Kaisha | Automotive carpet |
-
2021
- 2021-09-03 CN CN202111034272.XA patent/CN115746387A/en active Pending
-
2022
- 2022-09-01 WO PCT/EP2022/074311 patent/WO2023031327A1/en unknown
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2009090955A1 (en) * | 2008-01-15 | 2009-07-23 | Toyota Jidosha Kabushiki Kaisha | Material for interior automotive trims |
| US20100016151A1 (en) * | 2008-07-18 | 2010-01-21 | Caldwell Kenneth G | Aldehyde reducing coating |
| JP2010173343A (en) * | 2009-01-27 | 2010-08-12 | Nicca Chemical Co Ltd | Vehicular interior material |
| EP2886569A1 (en) * | 2013-12-20 | 2015-06-24 | Politechnika Poznanska | 'Polyoxymethylene composite with reduced formaldehyde emission and method for making and use thereof' |
| CN107735419A (en) * | 2015-06-16 | 2018-02-23 | 赢创德固赛有限公司 | Aldehyde scavenger for polyurethane foam |
| CN112638996A (en) * | 2018-03-08 | 2021-04-09 | 欧拓管理股份有限公司 | Thermoformed automotive product with reduced VOC |
Also Published As
| Publication number | Publication date |
|---|---|
| WO2023031327A1 (en) | 2023-03-09 |
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