GB2251208A

GB2251208A - Woven fibers in clear matrix finish for automotive interiors

Info

Publication number: GB2251208A
Application number: GB9125424A
Authority: GB
Inventors: Gary E Fulkerson; Robert T Brombacker
Original assignee: Creative Ind Group Inc
Current assignee: Creative Ind Group Inc
Priority date: 1990-12-21
Filing date: 1991-11-29
Publication date: 1992-07-01
Also published as: GB9125424D0; FR2670710A1; IT1250070B; JPH0712615B2; ITRM910917A0; DE4141955A1; AU8811091A; JPH04301414A; KR920011713A; ITRM910917A1

Abstract

Decorative interior trim material (10) for motor vehicles incorporates a mesh of woven fiber (16) embedded in a clear matrix resin material to form a rigid component. A clearcoat top layer (18) may be applied to provide a damage-resistant outer surface, and the woven mesh may be carried on a substrate (12) of fibreglass, also embedded in the resin. The resulting appearance is aesthetically appealing, yet has sufficient structural strength and integrity, and may be used as an alternative to wood. <IMAGE>

Description

- 1 ?.2:, 12,') 8 FINISH FOR AUTOMOTIVE INTERIORS

Background Of The Invention

I. Field of Invention

This invention relates to decorative materials used as trim in vehicle interiors and, in particular, to a woven fiber set in a clear matrix finish molded to the configuration of the desired component to provide a unique interior appearance.

Il. Description of the Prior Art

Rigid trim components of the passenger compartment of an automotive vehicle have historically been manufactured of wood, simulated wood or plastics. Typically, wood trim is used to provide a rich appearance while plastics may be used for more economical applications. Plastics are readily molded to any desired configuration and thickness to accommodate different components. Wood trim is more limited in its applications and is therefore used more sparingly as highlighting trim. The relative scarcity of wood products suitable for luxury applications such as automotive interior trim substantially increases the cost of such interiors.

I Summary Of The Present Invention

The present invention overcomes the disadvantages of the prior known automotive interior trim by providing an aesthetically appealing material which can be formed into various trim products for the passenger compartment.

The decorative trim material for automotive interiors has a substantially rigid complexion which can be initially molded to any required configuration. A preferred embodiment of the aesthetically appealing material comprises a fiberglass substrate which supports the surface material while providing material thickness, decorative woven fibers set within a clear matrix finish such as a polyester, and an outer layer of clearcoat f inish. The woven f ibers may include kevlar, boron arimide, etc., although carbon fiber is preferred. The woven fiber set within the clear matrix finish provides an appealing iridescent hue. The protective overcoat deters scratching and other damage to the trim material. The fiberglass substrate is designed only as a moldable substrate back f or the woven fibers set in the polyester material. In one method of producing the decorative trim, the fiberglass substrate is molded into the desired configuration. Once molded, the interwoven fibers are applied to the substrate and set within the clear polyester matrix. The clearcoat finish can be applied once the materials are set.

Alternatively, the interwoven fibers can initially be molded or formed into the desired configuration and the fiberglass substrate applied thereto. This combination can then be imbedded into the polyester material and allowed to set. Upon removal from the mold the clearcoat finish may be applied to protect the component.

other objects, features and advantages of the invention will be apparent from the following detailed description taken in connection with the accompanying drawings.

Brief Description of the Drawing

The present invention will be more f ully understood by reference to the following detailed description of a preferred

2 embodiment of the present invention when read in conjunction with the accompanying drawing, in which like reference characters refer to like parts throughout the views and in which:

FIGURE 1 is a perspective of a portion of the surface of the decorative trim material of the present invention; and FIGURE 2 is a cross-sectional view of the decorative trim material of the present invention.

Detailed Description Of A Preferred Embodiment of The Present Invention

Referring to the drawing, there is shown plan and cross-sectional perspectives of a segment of the decorative material 10 of the present invention. The material 10 may be molded during manufacture into substantially any configuration making it suitable for the manufacture of vehicle interior trim. The unique aesthetic appearance of the material 10 provides a rich appeal. It is contemplated that the material 10 could be used to provide a unique appearance to vehicle dashboards, consoles, interior door panels, etc., as well as veneer for furniture. The unique appearance and durable nature of the material 10 makes it highly suitable for frequent impact applications.

I Referring now to Figures 1 and 2, the material 10 is a multi-layered composition to facilitate molding into the desired configuration while providing aesthetic appeal and mar resistance. The material 10 includes a substrate 12 which serves as a backing for the mesh 14 of woven f ibers 16. The fibers 16 are cross-woven with alternating fibers 16 disposed above and below the lateral fibers 16. In a preferred embodiment., the fibers 16 are made of carbon which provides 3 the outer surf ace of the material 10 with an iridescent hue. Alternatively, the mesh layer 14 can be f ormed of kevlar, boron or arimide fibers. The woven mesh 14 and the substrate 12 may be molded or formed into the desired configuration. In order to set the substrate 12 and mesh 14, the molded form is set within a clear matrix finish material such as a polyester resin. once the polyester f inish cures, the resulting f orm will have a rigid configuration suitable for mounting within the passenger compartment of a vehicle. The clear matrix f inish material allows the iridescence of the carbon f iber mesh 14 to be viewed thereby providing the component with the appealing aesthetic appearance.

Once set, the molded component can be removed f rom the mold or other support structure. A protective clearcoat or gel coat f inish 18 can be applied to the part to prevent damage to the appearance of the component. Thus, an aesthetically appealing yet damage-resistant component can be manufactured at a substantially reduced cost compared to typical finish materials.

components incorporating the material 10 of the present invention may be molded using several different processes. In preferred method, the fiberglass substrate 12 is molded into the desired configuration. Thereafter, the woven fiber mesh 14 is applied to the substrate 12 and the polyester resin is applied. Once the molded part is set, the clearcoat top layer 18 may be applied. In an alternative method, the mesh layer 14 is positioned within a mold having the desired configuration. The fiberglass mat backing 12 is subsequently molded to the interior surface of the mesh 14. Having formed the basic configuration of the component, mesh 14 and substrate 12 are imbedded within the polyester resin material and allowed to set. Thereafter, the set form is removed from 4 the mold and a clearcoat finish 18 applied to the outer surface of the component.

The foregoing detailed description has been given for clearness of understanding only and no unnecessary limitations should be understood therefrom as some modifications will be obvious to those skilled in the art without departing from the scope and apirw of the appended claims.

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Claims

1. An aesthetic surface material for interior trim components for vehicles, the material comprising:

a decorative f iber woven into a mesh, said mesh molded into the configuration of the component; and a clear matrix resin within which said molded fiber mesh is imbedded wherein upon setting of said resin said material forms a rigid surface for the trim component.

2. The material as defined in claim 1 and further comprising a substrate of fiberglass, said fiberglass substrate molded with said fiber mesh into the configuration of the component and imbedded with said mesh in said resin whereby said substrate forms in inner support surface for said fiber mesh.

3. The material as defined in claim 2 wherein a protective overcoat is applied to the outer surf ace of said fiber mesh set in said resin.

4. The material as def ined in claim 1 wherein said decorative fiber is a carbon fiber providing an iridescent hue to said woven mesh.

5. The material as defined in claim 1 wherein said decorative fiber is a kevlar fiber providing an iridescent hue to said woven mesh.

6. The material as def ined in claim 1 wherein said decorative f iber is a boron f iber providing an iridescent hue to said woven mesh.

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7. The material as defined in claim 1 wherein said clear matrix resin is a polyester resin.

8. An aesthetic surface material for interior trim components for vehicles, the material comprising a substrate of fiberglass; a decorative fiber woven into a mesh, said fiber mesh and fiberglass substrate molded into the configuration of the component, said fiber mesh forming an outer surface back by said substrate; and a clear matrix resin within which said molded fiber mesh and substrate are imbedded wherein upon setting of said resin said material forms a rigid surface for the trim component.

9. The material as defined in claim 8 and further comprising a protective overcoat applied to the outer surface of said material.

10. The material as defined in claim 8 wherein said decorative fiber is a carbon fiber providing an iridescent hue to said woven mesh.

11. The material as defined in claim 8 wherein said clear matrix resin is a polyester resin.

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12. An interior trim component for the passenger compartment of a vehicle, said component comprising:

a decorative fiber woven into a mesh backed by a substrate of fiberglass, said fiber mesh and substrate molded into the configuration of the component and imbedded within a clear matrix resin such that upon setting of said resin said 7 fiber mesh forms a rigid decorative surface for said component.

13. The component as defined in claim 12 and further comprising a protective overcoat applied to an outer surface of said mesh set within said resin.

14. The component as defined in claim 13 wherein said decorative fiber is a carbon fiber providing an iridescent hue to said woven mesh.

15. The component as defined in claim 14 wherein said clear matrix resin is a polyester resin.

16. An interior trim component or material for a vehicle substantially as hereinbefore described with reference to and as shown in the accompanying drawings.

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