초록 ▼

An article including a panel-like structure mountable in an automobile vehicle to form a part of the interior thereof, and a process for making the same are disclosed. According to this process, an outer layer defining at least a portion of the exposed exterior surface of the structure is prepared b

An article including a panel-like structure mountable in an automobile vehicle to form a part of the interior thereof, and a process for making the same are disclosed. According to this process, an outer layer defining at least a portion of the exposed exterior surface of the structure is prepared by applying a water-dispersed composition containing a thermoplastic polyurethane and a heat-activated crosslinking agent onto a mold surface and thereafter drying the composition. Next, a composition comprising (i) a poly(vinyl chloride) resin and at least one plasticizer and/or (ii) a thermoplastic polyurethane resin material is gelled onto an inner surface of the outer layer while on the outer layer is retained on the mold surface. The gelled composition is then fused to form an inner layer interfacially chemically bonded to the outer layer. The inner layer with the outer layer chemically bonded thereto is united with the rigid substrate so that the rigid substrate serves to reinforce the outer layer. The exposed exterior surface of the panel-like structure simulates the appearance and feel of authentic leather, while the inner layer and an optional semi-rigid polyurethane cellular foam intermediate layer provide a compressing feel to the exposed portion.

대표청구항 ▼

[ What is claimed is:] [1.] A process for making a panel structure mountable in an automobile vehicle to form a part of the interior thereof, the panel structure including a rigid substrate and a layered composite structure, the rigid substrate being hidden from the vehicle interior when the panel s

[ What is claimed is:] [1.] A process for making a panel structure mountable in an automobile vehicle to form a part of the interior thereof, the panel structure including a rigid substrate and a layered composite structure, the rigid substrate being hidden from the vehicle interior when the panel structure is mounted in the automobile vehicle, the layered composite structure comprising an outer layer defining at least a portion of an at least partially exposed exterior surface of the panel structure and an inner layer, said process comprising the steps of:applying a water-dispersed composition onto a first mold surface having a complementary shape to an outer surface of the outer layer, the water-dispersed composition comprising at least one light-stable aliphatic thermoplastic polyurethane containing at least one pendent functional group selected from the group consisting of hydroxyl and carboxyl functional groups, at least one coloring agent, and at least one heat-activated crosslinker;applying sufficient heat to induce partial crosslinking of the light-stable aliphatic thermoplastic polyurethane with the heat-activated crosslinker;substantially drying the water-dispersed composition while on the first mold surface so as to form the outer layer;casting a composition comprising poly(vinyl chloride) containing at least one plasticizer onto an inner surface of the outer layer while on the first mold surface to form the inner layer having the plasticizer crosslinked with the polyurethane of the outer layer via residual unreacted functional groups of the heat-activated crosslinker and to interfacially chemically bond the inner surface of the outer layer to an adjacent surface of the inner layer; anduniting the layered composite structure with the rigid substrate so that the rigid substrate reinforces the outer layer while retaining the touch, color, and configuration of the exposed portion.