Stock material or miscellaneous articles – Structurally defined web or sheet – Discontinuous or differential coating – impregnation or bond
Patent
1993-08-12
1996-05-07
Lesmes, George F.
Stock material or miscellaneous articles
Structurally defined web or sheet
Discontinuous or differential coating, impregnation or bond
428247, 428286, 428296, 428300, 4283179, 428253, 4283199, 428252, 264DIG65, B32B 700, D03D 300, D04H 104, B27N 310
Patent
active
055144586
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND OF THE INVENTION
The invention relates to large-size paneling parts of a thermoplastic synthetic resin for the interior of an automotive vehicle, and to a process for the production thereof.
Panels for the interior of an automotive vehicle along the lines of this invention are understood to mean, in particular, door side parts, headliners (finished dome liners), seat back linings, hat shelves, and side paneling of thermoplastic synthetic resins.
Molded parts as paneling parts in multilayer structure for uses in automotive vehicle interiors have been known for a long time. Such constructions usually consist of a compact supporting member of thermoplastic or thermosetting synthetic resins filled with various materials, or of fibrous starting materials converted, with the aid of suitable resins, into a mechanically load-bearing composite; see, in this connection, for example DOS 3,842,846.
The actual shaping process takes place according to the conventional methods primarily by press-molding, injection molding or in accordance with the RIM and, respectively, RRIM technology.
The basic components display the joint feature that their surface meets only very low decorative requirements. Decorative paneling members are obtained from these molded parts by joining these basic materials with decorative, flat products during the shaping step or also in separate procedures. These decorative, flat products can be imprinted and embossed plastic sheeting as well as woven, knit textiles or nonwovens.
In case a composite is produced by subsequent lamination, the bond between the decorative and, in some cases, soft and elastic top layer and the supporting molded member must be established with simultaneous application of pressure and heat and with the use of a special laminating material.
In pressing processes, flat products are placed into the tool utilized for the shaping step, and thereafter molded parts are produced having decorative, soft and elastic surfaces. Materials that can be processed according to the presently known techniques, and molded parts manufactured pursuant to such techniques exhibit a number of disadvantages: mat production step ranges above 5-10 bar, in case of injection molding even above several hundred bar. that the conventional molded parts can be recycled only for low-quality products. materials, above 180.degree.-200.degree. C. and therefore leads to thermal damage to the top material in cases where the latter is not especially protected, for example by a film, foam sheet, or a similar material. step in order to produce a rounded border.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a structure for a molded part which no longer exhibits the aforementioned drawbacks of the conventional structures and makes it possible to obtain decorative surfaces of a higher quality.
In order to attain this object, the invention proposes to fashion a paneling member of thermoplastic synthetic resin. The molded parts of this invention are characterized particularly in that, during the process of shaping the molded part, a decorative layer of polymers having predominantly a polyolefinic structure is applied by laminating, this layer consisting of a multilayer knit or woven fabric with incorporated spacers of preferably polyolefinic polymer threads, and having a decorative, textile surface, or being laminated additionally on the topside with a decorative film--predominantly on the basis of olefinic polymers--or, respectively, is additionally laminated on the rear side with a polyolefin film. Another version resides in the use of a two-ply decorative layer of an outside compact layer and foamed sheeting, especially of a polyolefin. Preferred structures of the paneling members are molded parts of several layers (sandwich components), all based on the same polymer (preferably polyolefins) with soft, grained, or textile surfaces. The structure of the molded parts pursuant to the invention here ensures the prerequisites for the intended usage with respect to the prescribed
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Bottger, W.: Three-Dimensional Fiber Reinforcements For Composite Materials, Kunststoffe 79, 1989 vol. 11, pp. 1228-1230.
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Falk Karlheinz
Schulze-Kadelbach Roland
Konrad Hornschuch AG
Lesmes George F.
Shelborne Kathryne E.
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