Decorative automotive interior trim articles with cast integral light stable covering and process for making the same
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B32B-027/40
B32B-007/22
C08J-005/00
출원번호
US-0676773
(2003-10-01)
발명자
/ 주소
Gardner Jr., John A.
출원인 / 주소
Magna Interior Systems Inc.
대리인 / 주소
Honigman Miller Schwartz and Cohn LLP
인용정보
피인용 횟수 :
1인용 특허 :
43
초록▼
An article including a panel structure mountable in an automobile vehicle to form a part of the vehicle 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 prepare
An article including a panel structure mountable in an automobile vehicle to form a part of the vehicle 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 layered composite structure is united with the reinforcing substrate so that the reinforcing substrate serves to reinforce the outer layer. The exposed exterior surface of the panel 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▼
1. An article comprising a panel structure mountable in an automobile vehicle to form a part of a vehicle interior thereof, the panel structure having an exterior surface, at least a portion of which is exposed to the vehicle interior, and an interior surface, said panel structure comprising:a reinf
1. An article comprising a panel structure mountable in an automobile vehicle to form a part of a vehicle interior thereof, the panel structure having an exterior surface, at least a portion of which is exposed to the vehicle interior, and an interior surface, said panel structure comprising:a reinforcing substrate; a layered composite structure comprising an outer layer defining at least a portion of said exterior surface of the panel structure and an inner layer, said layered composite structure being united to a surface of said reinforcing substrate; said outer layer 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, and at least one heat-activated crosslinking monomer or agent; and said inner layer being formed directly on said outer layer such that said inner layer has an outer surface adjacent an inner surface of said outer layer, said inner layer comprising a thermoplastic polyurethane resin material having at least one ethylenically unsaturated bond in its backbone, at least one pendent hydroxyl group, or a combination thereof, wherein an interfacial chemical bond is formed between at least one of an unreacted functional group of said at least one light-stable aliphatic thermoplastic polyurethane and an unreacted functional group of said at least one heat activated crosslinking monomer or agent of said outer layer and at least one of said at least one ethylenically unsaturated bond and at least one pendent hydroxyl group of said inner layer. 2. An article according to claim 1, wherein the heat-activated crosslinking agent is carbodiimide.3. An article according to claim 2, further comprising a relatively rigid polyurethane cellular foam interposed between said layered composite structure and said reinforcing substrate that adheres said layered composite structure to said reinforcing substrate, wherein said outer layer is provided with a compressing feel by said relatively rigid polyurethane cellular foam and said inner layer.4. An article according to claim 3, wherein said outer layer has a thickness in a range of from about 1.0 mils to about 1.5 mils.5. An article according to claim 3, wherein said inner layer has a thickness in a range of from about 40 mils to about 60 mils.6. An article according to claim 3, wherein said at least one light-stable aliphatic thermoplastic polyurethane and said heat-activated crosslinking agent can be premixed and stably stored for at least up to 24 hours at room temperature.7. An article according to claim 3, wherein said-panel structure is a door panel.8. An article according to claim 3, wherein said panel structure is an instrument panel.9. An article according to claim 1, wherein said outer layer comprises a water-dispersed composition having a water concentration of from about 10% by weight to about 80% by weight.10. An article according to claim 1, wherein said outer layer comprises a water-dispersed composition having a solvent concentration of from about 9% by weight to about 15% by weight.11. An article according to claim 10, wherein the solvent is N-methyl pyrrolidone.12. An article according to claim 11, wherein the water-dispersed composition further comprises at least one member selected from the group consisting of glycol ether acetate and xylene.13. A process for making a panel structure mountable in an automobile vehicle to form a part of a vehicle interior thereof, the panel structure comprising a reinforcing substrate and a layered composite structure, 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 first composition onto a first mold surface, said first 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, and at least one heat-activated crosslinking monomer or agent to form said outer layer of said layered composite structure; and casting a second composition comprising a thermoplastic polyurethane resin material having at least one ethylenically unsaturated bond in its backbone, at least one pendent hydroxyl group, or a combination thereof onto an inner surface of the outer layer while on the first mold surface to form said inner layer of said layered composite structure, whereby an interfacial chemical bond is formed between at least one of an unreacted functional group of said at least one light-stable aliphatic thermoplastic polyurethane and an unreacted functional group of said at least one heat activated crosslinking monomer or agent of said outer layer and at least one of said at least one ethylenically unsaturated bond and at least one pendent hydroxyl group of said inner layer. 14. A process according to claim 13, wherein the heat-activated crosslinking agent is carbodiimide.15. A process according to claim 13, further comprising the steps of:transferring the layered composite structure from the first mold surface to a second mold surface; and providing the reinforcing substrate on a third mold surface having a complementary surface to an interior surface of the panel structure. 16. A process according to claim 13, further comprising the steps of:transferring the layered composite structure from the first mold surface to a transparent surface of a holding platform; detecting and reinforcing rupturable portions of the layered composite structure for preventing failure of the same during said uniting step; transferring the layered composite structure from the transparent surface to a second mold surface; and providing the reinforcing substrate on a third mold surface having a complementary shape to an interior surface of the panel structure. 17. A process according to claim 13, wherein said first composition comprises a water-dispersed composition that is substantially dried prior to said casting step.18. A process according to claim 13, wherein the outer layer has a thickness in a range of from about 1.0 mils to about 1.5 mils.19. A process according to claim 13, wherein the inner layer has a thickness in the range of from about 40 mils to about 60 mils.20. A process according to claim 13, further comprising the step of precoating the first mold surface with a microcrystalline wax mold releasing agent.21. A process according to claim 13, wherein the light-stable aliphatic thermoplastic polyurethane and the heat-activated crosslinking agent can be premixed and stably stored prior to said applying step for at least up to 24 hours at room temperature.22. A process according to claim 13, wherein the first mold surface is heated during said applying step.23. A process according to claim 13, wherein the first mold surface has a complementary shape to an exterior surface of a door panel.24. A process according to claim 13, wherein the first mold surface has a complementary shape to an exterior surface of an instrument panel.25. A process for making a panel structure mountable in an automobile vehicle to form a part of a vehicle interior thereof, the panel structure comprising a reinforcing substrate and a layered composite structure, 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:providing a microcrystalline wax mold releasing agent on a first mold surface, the first mold surface being heated to a first temperature for melting and dispersing the microcrystalline wax mold releasing agent; applying a first composition onto the first mold surface containing the microcrystalline wax mold releasing agent dispersed thereon, first 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, and at least one heat-activated crosslinking agent, the first mold surface being heated to a second temperature for inducing at least a partial crosslinking of the light-stable aliphatic thermoplastic polyurethane with the heat-activated crosslinking agent; substantially drying the water-dispersed first composition while on the first mold surface by heating the first mold surface to a third temperature for forming the outer layer with an exterior surface; casting a second composition comprising a thermoplastic polyurethane resin material having at least one ethylenically unsaturated bond in its backbone, at least one pendent hydroxyl group, or a combination thereof onto an inner surface of the outer layer while on the first mold surface to form the inner layer, whereby an interfacial chemical bond is formed between at least one of an unreacted functional group of said at least one light-stable aliphatic thermoplastic polyurethane and an unreacted functional group of said at least one heat activated crosslinking monomer or agent of said outer layer and at least one of said at least one ethylenically unsaturated bond and at least one pendent hydroxyl group of said inner layer; and uniting the layered composite structure with the reinforcing substrate so that the reinforcing substrate reinforces the outer layer while retaining a touch, color, and configuration of the exposed portion. 26. A process according to claim 25, wherein the heat-activated crosslinking agent is carbodiimide.27. A process according to claim 26, wherein the first temperature, second temperature, and third temperature are in a range from about 140° F. to about 160° F.28. An article according to claim 13, wherein said unreacted functional groups of said outer layer comprises said at least one heat-activated crosslinking monomer or agent.29. A process according to claim 13, wherein said unreacted functional groups of said outer layer comprises said at least one heat-activated crosslinking monomer or agent.30. A process according to claim 25, wherein said unreacted functional groups of said outer layer comprises said at least one heat-activated crosslinking monomer or agent.
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