EP0571617A1 - Panneau en matieres thermoplastiques pour l'habillage interieur de vehicules a moteur et son procede de fabrication - Google Patents

Panneau en matieres thermoplastiques pour l'habillage interieur de vehicules a moteur et son procede de fabrication

Info

Publication number
EP0571617A1
EP0571617A1 EP93901676A EP93901676A EP0571617A1 EP 0571617 A1 EP0571617 A1 EP 0571617A1 EP 93901676 A EP93901676 A EP 93901676A EP 93901676 A EP93901676 A EP 93901676A EP 0571617 A1 EP0571617 A1 EP 0571617A1
Authority
EP
European Patent Office
Prior art keywords
decorative layer
film
decorative
molding
tool
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
EP93901676A
Other languages
German (de)
English (en)
Inventor
Roland Schulze-Kadelbach
Karlheinz Falk
Wolfgang Lucius
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Konrad Hornschuch AG
Original Assignee
Konrad Hornschuch AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Konrad Hornschuch AG filed Critical Konrad Hornschuch AG
Publication of EP0571617A1 publication Critical patent/EP0571617A1/fr
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/026—Knitted fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B2037/148—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers whereby layers material is selected in order to facilitate recycling of the laminate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/025—Polyolefin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2398/00—Unspecified macromolecular compounds
    • B32B2398/20—Thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/65—Processes of preheating prior to molding
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249986—Void-containing component contains also a solid fiber or solid particle
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249987—With nonvoid component of specified composition
    • Y10T428/249991—Synthetic resin or natural rubbers
    • Y10T428/249992—Linear or thermoplastic
    • Y10T428/249993—Hydrocarbon polymer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/10—Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
    • Y10T442/184—Nonwoven scrim
    • Y10T442/195—Including a foam layer
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3325—Including a foamed layer or component
    • Y10T442/3341—Plural foam layers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3325—Including a foamed layer or component
    • Y10T442/335—Plural fabric layers

Definitions

  • the invention relates to large-area cladding parts made of thermoplastic material for the automotive interior and a method for their production.
  • Cladding parts for the motor vehicle interior in the sense of this invention are understood in particular to mean door side parts, headlining (finished roof lining), rear seat cladding, hat racks and side cladding made of thermoplastic materials.
  • Molded parts have long been known as trim parts in a multilayer structure for applications in the interior of motor vehicles.
  • Such constructions generally consist of a compact carrier part made of thermoplastic or thermosetting plastics filled with different materials or of fibrous starting products which have been converted into a mechanically resilient composite with the aid of suitable resins, see for example DE-OS 38 42 846.
  • the actual shaping process takes place according to the known methods predominantly by pressing, injection molding or according to the RIM or RRIM technology.
  • the basic parts have in common that their surface is only very low decorative requirements are sufficient.
  • Decorative cladding parts are obtained from these molded parts in that these base materials are combined with decorative surface products during the shaping process or in separate processes.
  • These decorative surface products can be printed and embossed plastic films as well as woven, knitted textiles or nonwovens.
  • the pressure s to be applied for the nonwoven process during pressing is above 5 to 10 bar, even higher than a few hundred bar during injection molding.
  • the materials used generally do not belong to a uniform polymer base, so that the known molded parts 0 can only be recycled for inferior products.
  • the melt temperature during the molding process is above 180 to 200 ° C for thermoplastic materials and therefore leads to thermal damage to the upper material ⁇ in cases where it is not particularly protected, for example by a film, foam film or the like.
  • the object of the present invention is to achieve a molded part structure which no longer has the disadvantages of the known structures mentioned and which enables decorative surfaces of higher quality.
  • the invention proposes the design of a trim part according to claim 1.
  • the molded parts according to the invention are characterized in particular in that a decorative layer of primarily polyolefinic polymers is laminated on during the molded part formation process, which consists of a multi-layer knitted fabric or woven fabric with spacers made of preferably polyolefinic polymer threads, has a decorative, textile surface or additionally on the top with a decoratively designed film - primarily based on olefinic polymers - is laminated or additionally laminated on the back with a polyolefin film.
  • Another variant consists in the use of a two-layer decorative layer consisting of an outer compact layer and a foamed film, in particular of a polyolefin.
  • Preferred structures of the cladding parts are molded parts from several layers (sandwich parts), all based on the same polymer (preferably polyolefins with soft, grained or textile surfaces.
  • the molded part structure according to the invention guarantees the conditions for the intended use with regard to the prescribed technical specifications according to the current state of the art
  • the process described for the production of the molded parts is efficient and advantageous.
  • the optical and taste design of the surfaces is ensured by the process and offers a wide range of variations.
  • the invention achieves a reduction in the total weight of the sandwich part (support plus decorative layer) for trim parts by at least 50%.
  • the present invention solves the recycling problem for these parts by using only components r 1 di based on a common recyclable polymer base.
  • a compact film is preferably used as the decorative material
  • Plastic granules for the base material of the carrier This eliminates the additional application of an adhesion promoter layer as a lamination layer between the decorative layer and the carrier part.
  • foamable plastic granules As a base material for the load-bearing layer, known foamable plastic granules (beads) are used, which are made of thermoplastic materials, possibly with portions of propellant gas, and are pre-expanded. Suitable 5 thermoplastics are, for example, medium-density polyethylene (PE) and polypropylene (PP), which may optionally contain further auxiliaries, such as stabilizers, pigments, fillers, etc., and copolymers of polyolefins or Co pounds from homo- and co-polymers.
  • the size of these pre-expanded granules is about 2 to 5 mm.
  • the shape of these granules is spherical or approximately spherical.
  • the same plastic is preferably used for the base material and the film.
  • the tool used according to the invention is made of a microporous material which has the desired surface structure on the inside as a negative of the later molded part.
  • Foam beads and the subsequent vapor pressure are produced. Due to the specified working temperatures and working method, a thermostable embossing or structuring of the surface is not to be expected. The use of a microporous shape is also described in this specification, but only for extracting air and moisture.
  • a positive shape is used according to the method according to the invention, in the surface of which the grain structure of the finished part is present.
  • galvanoforms are used for this purpose, which are produced in accordance with patent specification DE 37 43 809 C2.
  • the granules (beads) are filled in a cold or slightly preheated state into a tool which has steaming nozzles through the superheated steam at a temperature of approx. 130 ° C. and below Pressure of approx. 6 bar can be injected.
  • the tool After filling, the tool is locked and the granules are heated, inflated and welded using a known method.
  • An essential feature of this invention is the use of a decorative layer based on a moldable material, such as a fleece or woven or knitted fabric, optionally with spacers or a foamed polyolefin or one which consists of a multilayer film layer which is a laminate of compact and foamed polyolefin films, the grain of which is produced on the decorative side by deep drawing in correspondingly designed vacuum molds which are embossed with the negative embossing.
  • a moldable material such as a fleece or woven or knitted fabric
  • the decorative layer primarily forms a knitted fabric made of polyolefin fibers of different titers, also known as spacer fabrics. Fibers with a titer between 0.5 and 1.5 dtex are preferably used.
  • the knitted fabric is produced so that its thickness is between 0.4 to 2.5 mm and the density is below 0.5 g / cm 3 .
  • the spacer fabric consists of at least two knitted layers, which are connected to one another with pile threads, the so-called spacers, which are produced according to known methods of Raschel technology.
  • the spacers which are produced according to known methods of Raschel technology.
  • the elasticity, elasticity and strength of such a knitted fabric can be set within wide limits.
  • spacer fabrics are optionally laminated on one side with a film of polyolefins (thermo-coated) and embossed in the same operation using a structured microporous vacuum mold as a tool.
  • the embossing depth is between 60 and 150 ⁇ m.
  • the color of the film can be adjusted as desired.
  • the foil can either be embossed beforehand engraved steel rollers under pressure or in the tool with a corresponding surface and using vacuum.
  • the top film can also be dispensed with.
  • knitted or woven fabrics are used, the upper side of which is already provided with a corresponding design when knitted.
  • unembossed, smooth foils can be used, which can then be embossed in conjunction with the knitted fabric or the foamed foil, for example using vacuum technology.
  • the overall structure of the decorative layer corresponds in its properties to the PVC foam foils used today, but in contrast to this is completely made from a polymer base, for example polyolefins, and thus fulfills the material uniformity in the sense of this invention.
  • Shaped part for use as a trim part is shown in Figure 1.
  • the base part namely the carrier part
  • Layers 3, 4 form the decorative layer with a back side
  • trim part consist, for example, of a carrier part 1, film 2 and knitted fabric 3 with a textile decorative surface.
  • a a further variant is represented, for example, by a covering part comprising a carrier part 1 and a decorative layer 4.
  • the trim part is a laminate, consisting of a carrier layer 1 made of PP particle show, an intermediate layer 6 made of extruded PP foam film and a compact PP decorative film 4.
  • the individual layers are glued to one another by suitable adhesives 7, the decorative film (top layer) is also included Matt 8 sealed.
  • the particle foam and the decorative layers are produced in different processes and connected to one another in a further process.
  • PP foam layer 6 and the decorative layer 4 are connected and, after the front side has been sealed and the adhesive or a primer has been applied to the rear side, are vacuum-deformed in accordance with the shape of the carrier layer 1. In the same operation, this composite is connected to the carrier layer 1.
  • a decorative layer consisting of a knitted spacer, which is laminated with a decorative foil based on a polyolefinic compound, is inserted, preheated, preferably to about 110 to 130 ° C. and then with a negative pressure of about 0.8 bar sucked into the tool surface through the microporous walls of the same.
  • the edges and corners of this decorative layer had previously been turned inwards and provisionally fixed to one another.
  • the granules were filled into the microporous tool and combined with steam at a temperature of 142 ° C. and a pressure of 3.5 bar to form a flat molded part 1, the granules simultaneously foaming.
  • a decorative layer consisting of a spacer fabric that was laminated with an unstructured polyolefin film was inserted into a microporous tool with a structured surface.
  • the film with the spacer fabric was drawn into the microporous tool in such a way that the structuring of the tool surface was permanently imprinted on the film. Then, as described in Example 1, the molding was finished.
  • a knitted spacer fabric which was designed on the upper side by the action of a decorative design and was laminated on the back with a thin film as a sealing layer made of polypropylene, was placed in a microporous tool and then sucked in and preformed until it touched the tool surfaces. Thereafter, as described in Example 1, the molded part was formed by filling in polypropylene foam granules with subsequent foaming.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

Des panneaux en matières thermoplastiques pour l'habillage intérieur d'un véhicule à moteur ou pour des applications similaires comprennent un support en mousses de particules de polyoléfines sur lequel est contrecollée pendant le moulage du panneau une couche décorative en polymères essentiellement polyoléfiniques. Cette couche décorative est constituée d'un tissu ou d'un tricot à couches multiples à pièces d'écartement incorporées, en fibres polymères de préférence polyoléfiniques, comprend une surface textile décorative ou porte sur sa face supérieure une pellicule décorative stratifiée essentiellement à base de polymères oléfiniques ou porte en outre sur sa face postérieure une pellicule stratifiée en polyoléfines.
EP93901676A 1991-12-13 1992-12-12 Panneau en matieres thermoplastiques pour l'habillage interieur de vehicules a moteur et son procede de fabrication Ceased EP0571617A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE4141113A DE4141113A1 (de) 1991-12-13 1991-12-13 Grossflaechige verkleidungsteile aus thermoplastischen kunststoffen fuer dfen kfz-innenbereich und verfahren zu deren herstellung
DE4141113 1991-12-13

Publications (1)

Publication Number Publication Date
EP0571617A1 true EP0571617A1 (fr) 1993-12-01

Family

ID=6446962

Family Applications (1)

Application Number Title Priority Date Filing Date
EP93901676A Ceased EP0571617A1 (fr) 1991-12-13 1992-12-12 Panneau en matieres thermoplastiques pour l'habillage interieur de vehicules a moteur et son procede de fabrication

Country Status (5)

Country Link
US (1) US5514458A (fr)
EP (1) EP0571617A1 (fr)
JP (1) JPH06505451A (fr)
DE (1) DE4141113A1 (fr)
WO (1) WO1993011927A1 (fr)

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DE4141113A1 (de) 1993-06-17
US5514458A (en) 1996-05-07
WO1993011927A1 (fr) 1993-06-24

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