U.S. patent application number 11/972121 was filed with the patent office on 2008-05-15 for interior vehicle trim panel having a sprayed expanded polyurethane layer and method and system of making same.
This patent application is currently assigned to International Automotive Components Group North America, Inc.. Invention is credited to Robert J. Adams, Glenn A. Cowelchuk, Joseph T. Donatti, Randy S. Reed, Kenneth W. Shaner, Nelson E. JR. Williams.
Application Number | 20080113181 11/972121 |
Document ID | / |
Family ID | 34983975 |
Filed Date | 2008-05-15 |
United States Patent
Application |
20080113181 |
Kind Code |
A1 |
Cowelchuk; Glenn A. ; et
al. |
May 15, 2008 |
INTERIOR VEHICLE TRIM PANEL HAVING A SPRAYED EXPANDED POLYURETHANE
LAYER AND METHOD AND SYSTEM OF MAKING SAME
Abstract
Aspects of the present invention include interior vehicle trim
panel having a sprayed expanded polyurethane layer and method of
making same. In at least one embodiment, the method of making the
vehicle interior trim panel comprises providing a skin layer on a
spray tool, spraying expandable polyurethane reactive components
onto the skin layer to form a resilient layer, and securing a rigid
substrate on the resilient layer, such that the resilient layer
extends between and connects the skin layer with the substrate to
form the vehicle interior trim panel.
Inventors: |
Cowelchuk; Glenn A.;
(Chesterfield, MI) ; Adams; Robert J.; (Ypsilanti,
MI) ; Shaner; Kenneth W.; (Howell, MI) ; Reed;
Randy S.; (Fair Haven, MI) ; Williams; Nelson E.
JR.; (Saline, MI) ; Donatti; Joseph T.;
(Howell, MI) |
Correspondence
Address: |
BROOKS KUSHMAN P.C. / LEAR CORPORATION
1000 TOWN CENTER
TWENTY-SECOND FLOOR
SOUTHFIELD
MI
48075-1238
US
|
Assignee: |
International Automotive Components
Group North America, Inc.
Dearborn
MI
48126
|
Family ID: |
34983975 |
Appl. No.: |
11/972121 |
Filed: |
January 10, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10911922 |
Aug 5, 2004 |
7344666 |
|
|
11972121 |
Jan 10, 2008 |
|
|
|
10885154 |
Jul 6, 2004 |
7147808 |
|
|
10911922 |
Aug 5, 2004 |
|
|
|
Current U.S.
Class: |
428/309.9 ;
264/45.6 |
Current CPC
Class: |
B29C 70/78 20130101;
B29C 70/086 20130101; Y10T 428/24996 20150401; B29C 70/30 20130101;
B60R 21/045 20130101; B60R 13/0256 20130101; Y10T 428/24479
20150115; B29K 2075/00 20130101; B29L 2031/30 20130101; B60R 13/02
20130101 |
Class at
Publication: |
428/309.9 ;
264/045.6 |
International
Class: |
B29C 44/06 20060101
B29C044/06; B29C 41/08 20060101 B29C041/08; B29C 41/22 20060101
B29C041/22 |
Claims
1. A method of making a vehicle interior trim panel, the method
comprising: providing a skin layer on a spray tool; spraying
expandable polyurethane reactive components onto the skin layer to
form a resilient layer having 35 to 75 percent closed cell
structures; and securing a rigid substrate on the resilient layer,
such that the resilient layer extends between and connects the skin
layer with the substrate to form the vehicle interior trim
part.
2. The method of claim 1 wherein the resilient layer has a density
of 0.1 to 0.75 g/cm.sup.3.
3. The method of claim 2 wherein a substantial portion of the
resilient layer has a thickness of 0.1 to 8.0 mm and a shore A
hardness of 30 to 50.
4. The method of claim 3 wherein the resilient layer has a first
portion having a first thickness of 0.05 to 4.0 mm and a second
portion having a thickness of 6.1 to 15 mm.
5. The method of claim 3 wherein the expandable polyurethane
reactive components comprise polyol, isocyanate and a blowing
agent.
6. The method of claim 1 wherein the skin layer comprises
polyurethane and the rigid substrate is secured directly to the
resilient layer.
7. The method of claim 3 wherein the step of providing a skin layer
comprises spraying polyurethane reactive components towards the
spray tool.
8. The method of claim 7 wherein one spraying device is provided
for spraying both the polyurethane reactive components and the
expandable polyurethane reactive components.
9. The method of claim 1 wherein the resilient layer comprises an
elastomer.
10. The method of claim 8 further comprising applying a coating on
the tool prior to the spraying steps, the coating forming an
appearance surface of the panel.
11. The method of claim 10 wherein the coating comprises aliphatic
polyurethane, the skin layer comprises aromatic polyurethane, the
resilient layer comprises aromatic polyurethane, and the substrate
comprises rigid polyurethane.
12. The method of claim 1 wherein the securing step comprises
removing the skin layer and the resilient layer from the spray
tool, positioning the skin layer and the resilient layer in a mold,
and injecting material into the mold when the mold is in a closed
position to form the substrate.
13. The method of claim 1 wherein the securing step comprises
removing the skin layer and the resilient layer from the spray
tool, pouring material onto the resilient layer when the mold is in
an open position, and the method further includes closing the mold
to shape the substrate.
14. The method of claim 10 wherein the securing step comprises:
removing the coating, the skin layer and the resilient layer from
the tool; positioning the coating, the skin layer and the resilient
layer in a mold; and securing the rigid substrate on the resilient
layer, such that the resilient layer extends between and connects
the skin layer with the substrate to form the vehicle interior trim
part wherein the coating forms an exterior appearance surface of
the panel.
15. A method of making a vehicle interior trim panel, the method
comprising: applying a coating on a tool; spraying skin layer
forming materials on the coating to form a skin layer on the
coating; spraying expandable polyurethane reactive components
comprising polyol, isocyanate and a blowing agent onto the skin
layer to form a resilient layer having a density of 0.1 to 0.75
g/cm.sup.3; and securing a rigid substrate directly to the
resilient layer, such that the resilient layer extends between and
connects the skin layer with the substrate to form the vehicle
interior trim part.
16. The method of claim 15 wherein the interior trim panel has a
width of 60 to 125 cm and a length of 3.75 to 22 cm resilient layer
has a first portion having a first thickness of 0.05 to 4.0 mm and
a second portion having a thickness of 6.1 to 15 mm.
17. The method of claim 15 wherein the resilient layer has a
density of 0.2 to 0.3 g/cm.sup.3.
18. A vehicle interior trim component for use with a motor vehicle,
the trim component comprising: a skin layer; a sprayed expanded
polyurethane resilient layer secured to the skin layer; and a rigid
substrate secured to the resilient layer.
19. The vehicle interior trim component of claim 18 wherein the
resilient layer has a density in the range of 0.1 to 0.75 grams per
cubic centimeter.
20. A method for making a vehicle interior door part for a vehicle
interior, said part comprising: a base substrate having a show
surface and a back surface; and the vehicle interior trim component
of claim 18 secured to the base substrate so that the show surface
and the skin layer face towards the vehicle interior.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser.
No. 10/911,922 filed Aug. 5, 2004, which is a continuation-in-part
of U.S. application Ser. No. 10/885,154 filed Jul. 6, 2004, the
disclosures of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to interior vehicle trim panel having
a sprayed expanded polyurethane layer, and to a method and system
of making such parts.
[0004] 2. Background Art
[0005] One example of a relatively typical vehicle interior trim
panel comprises a relatively rigid substrate having a relatively
flexible thin plastic skin disposed over at least an interior
facing portion of a surface of the substrate. For some panels where
a softer touch is desired, foam has been provided between the
substrate and the skin. For these types of panels, a foam in place
process is often times used to provide the foam. In this type of
process, the skin and the substrate are positioned spaced apart in
a mold while foam is molded there between. After the foam is
molded, the foam extends between and secures the skin to the
substrate.
[0006] There are occasions where trim panels having a soft feel are
desired but because of design constraints are not easily
manufacturable. One example is of a door panel having a soft feel
above the belt line to match the appearance and feel of the
instrument panel. Another example is of a trim panel, such as a
door panel or instrument panel, that has undercuts, sharp radii, or
other design configuration that results in relatively small, or
somewhat significantly uneven, clearances between the skin and the
substrate. In these, and other, types of designs, foam in place may
have drawbacks that could prevent such a technique from being a
suitable option.
SUMMARY OF THE INVENTION
[0007] Under the invention, a method of making a vehicle interior
trim panel is provided. The method includes the steps of providing
a skin layer on a surface of a spray tool, spraying expandable
polyurethane reactive components onto the skin layer to form a
resilient layer, and securing a rigid substrate to the resilient
layer.
[0008] Further under the invention, a method of making a vehicle
interior trim panel includes applying a coating on the tool prior
to the step of providing a skin layer, wherein the coating forms an
appearance surface of the panel. In at least one embodiment, the
step of providing a skin layer comprises spraying material on the
coating to form the skin layer. In at least one embodiment, the
skin layer comprises aromatic polyurethane.
[0009] The present invention also provides a vehicle interior trim
component for use with a motor vehicle. In at least one embodiment,
the trim component comprises a skin layer, a sprayed expanded
polyurethane resilient layer bonded to the skin layer, and a rigid
substrate bonded to the resilient layer.
[0010] The present invention also provides a method for making a
vehicle interior door part for a vehicle interior. In at least one
embodiment, the method comprises providing a base substrate having
a show surface and a back surface, and securing a vehicle interior
panel described above to the base substrate so that the show
surface and the skin layer faces towards the vehicle interior.
[0011] The present invention also provides a vehicle interior door
part for a vehicle interior. In at least one embodiment, the part
comprises a base substrate having a show surface and a back
surface, and a vehicle interior trim component described above
secured to the base substrate so that the show surface and the skin
layer face towards the vehicle interior.
[0012] While exemplary embodiments in accordance with the invention
are illustrated and disclosed, such disclosure should not be
construed to limit the claims. It is anticipated that various
modifications and alternative designs may be made without departing
from the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a perspective view of vehicle interior including a
door panel and an instrument panel in accordance with at least one
aspect the invention for use with a motor vehicle;
[0014] FIG. 2 is a cross-sectional view of the door panel taken
along line 2-2 of FIG. 1;
[0015] FIG. 3 is similar to FIG. 2 showing another aspect of the
present invention;
[0016] FIG. 4 is a schematic view of a spray tool and spray
assembly for use in forming a panel, wherein the spray assembly is
shown applying material on the tool to form a coating;
[0017] FIG. 5 is a schematic view of the tool showing application
of additional material onto the coating to form a skin layer;
and
[0018] FIG. 6 is a schematic view of the tool showing application
of expandable material onto the skin layer to form a resilient
layer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0019] As required, detailed embodiments of the present invention
are disclosed herein. However, it is to be understood that
disclosed embodiments are merely exemplary of the invention that
may be embodied in various alternative forms. The figures are not
necessarily to scale, some features may be exaggerated or minimized
to show details of particular components. Therefore, specific
structural and functional details disclosed herein are not to be
interpreted as limiting, but merely as a representative basis for
the claims and/or a representative basis for teaching one skilled
in the art to variously employ the present invention. Moreover,
except where otherwise expressly indicated, all numerical
quantities in this description and in the claims indicating amounts
of materials or conditions of reactions and/or use are to be
understood as modified by the word "about" in describing the
broadest scope of this invention. Practice within the numeral limit
stated is generally preferred. Also, unless expressly stated to the
contrary, percent, "parts of," and ratio values are by weight and
the description of a group or class of materials as suitable or
preferred for a given purpose in connection with the invention
implies that mixtures of any two or more members of the group or
class may be equally suitable or preferred.
[0020] FIG. 1 shows a portion of a vehicle interior 6. FIGS. 1 and
2 show an interior vehicle trim component, such as an door 10, in
accordance with at least one aspect of the invention for use with a
motor vehicle 8. The door 10 includes a lower door portion 12 and
an upper door portion 14. Certain aspects of the present invention
will be described below in connection with the door 10, and in
particular the upper door portion 14. However, it should be
understood that other trim products, such as instrument panels,
door covers, console covers, pillar trim panels, shelves, trim
covers and the like can also enjoy the benefits of the present
invention.
[0021] The lower door portion 12 comprises a base substrate 18. The
base substrate 18, in at least one embodiment, is uncovered. In
certain embodiments, such as one where it is uncovered, the base
substrate 18 can be colored and/or textured to provide an aesthetic
appearance.
[0022] As shown in FIGS. 1-3, in at least one embodiment, the upper
door portion 14 includes a rigid substrate 20, a resilient expanded
polyurethane layer 22 attached to the substrate 20, a skin layer 24
attached to the resilient layer 22, and a coating 26 that covers
the skin layer 24 and provides an exterior appearance surface.
[0023] In at least one embodiment, the upper door portion 14 has a
width w of 60 to 125 cm, a length 1 of 3.75 to 22 cm, and at least
a substantial portion having an average thickness t of 0.1 to 8.0
mm. In another embodiment, the average thickness t of the resilient
layer is 0.5 to 5.0 mm, and in yet another embodiment 1.5 to 4.0
mm. In at least this embodiment, the relative length 1, width w,
and clearance t between skin layer 24 and substrate 20 (or
thickness t of the layer 22) can make it difficult to employ a foam
in place process.
[0024] The substrate 20 is a structural member that provides
support for the remainder of the upper door portion 14, and may
comprise any suitable material. For example, the substrate 20, as
well as base substrate 18, may be made of plastic or reinforced
plastic, such as fiberglass reinforced polyurethane (GRU).
Additional examples of suitable plastics, besides polyurethane,
include polypropylene, polyethylene, acrylonitrile butadiene
styrene (ABS), polycarbonate (PC), and ABS/PC blends. In at least
one embodiment, the substrates 18 and 20 may have independent, or
the same, average thicknesses between 0.5 to 5 mm, in another
embodiment 1.0 to 3.5 mm, and in yet another embodiment 2.0 to 3.0
mm.
[0025] The resilient layer 22 is adhered to the substrate 20 and
the skin layer 24 and may be configured to help provide a soft feel
to the upper door portion 14. The resilient layer 22 may comprise
any suitable sprayed expanded polyurethane material. For example,
the resilient layer 22 may comprise an expanded aromatic
polyurethane elastomer. In at least one embodiment, the density of
the resilient layer 22 can be in the range of 0.10 to 0.75 grams
per cubic centimeter (g/cm.sup.3), in another embodiment between
0.15 to 0.5 g/cm.sup.3, and in yet another embodiment 0.2 to 0.3
g/cm.sup.3. In at least one embodiment, the resilient layer may
have a shore A hardness of 30 to 50.
[0026] In at least one embodiment, the resilient layer 22 primarily
may comprise a low permeable, relatively closed cell material. In
at least one embodiment, the resilient layer 22 may comprise 35 to
75 percent closed cell structures, in at least another embodiment
40 to 65 percent closed cell structures, and in yet at least
another embodiment 45 to 55 percent closed cell structures, based
upon the entire resilient layer 22.
[0027] In at least one embodiment, the resilient layer 22 may have
varying closed cell density throughout the resilient layer. In at
least one embodiment, the top portion (the portion closer to the
skin layer 24) and the lower portion (the portion closer to the
substrate 20) may independently comprise at least 85 percent closed
cell structures, in other embodiments between 90 to 100 percent
closed cell structures, and in yet other embodiments between 95 and
100 percent closed cell structures. In at least one embodiment, the
top and bottom portions may independently comprise between 2.5 to
25 percent, in other embodiments between 5 to 20 percent, and in
yet other embodiments between 10 to 15 percent, of the thickness t
of the resilient layer 22. The remaining intermediate layer (the
portion between the top and bottom portion) of the resilient layer
22 may comprise between 40 to 95 percent closed cell structures, in
at least another embodiment between 50 to 90 percent closed cell
structures, and in yet another embodiment between 60 to 85 percent
closed cell structures. In at least one embodiment, the average
cell structure size can vary between 0.05 mm to 3.0 mm, and in yet
other embodiment between 0.5 mm to 1.0 mm.
[0028] As shown in FIG. 3, the upper door portion 14 may have
varying clearances between substrate 20 and the skin 24. Examples
of varying clearances are shown as t1 and t2. Varying clearances t1
can be less than t, and in some embodiments are 0.05 to 4.5 mm.
Varying clearances t2 can conversely be greater than t and in some
embodiments are 6.1 to 15 mm.
[0029] The skin layer 24 is adhered to the resilient layer 22 and
coating 26. Moreover, the skin layer 24 is configured to provide a
covering over the resilient layer 22 and may comprise any
sufficiently dense material. For example, the skin layer 24 may be
a solid layer that comprises an aromatic or aliphatic compound. As
a more specific example, the skin layer 24 may be made of an
elastomer such as polyurethane. Furthermore, the skin layer 24 may
have any suitable thickness and density. For example, the skin
layer 24 may have a thickness in the range of 0.4 to 2 mm, and a
density in the range of 0.85 to 1.2 g/cm.sup.3. In one embodiment
of the invention, the skin layer 24 has a thickness in the range of
0.5 to 1.2 mm, and a density in the range of 0.95 to 1.1
g/cm.sup.3.
[0030] The optional coating 26 may be used to protect the skin
layer 24 and/or to provide a decorative surface for the upper door
portion 14. For example, the coating 26 may be used to inhibit
sunlight and/or other ultraviolet light from reaching the skin
layer 24. As another example, the coating 26 may be used as a paint
to provide a desired color and/or texture to the upper door portion
14. While the coating 26 may comprise any suitable material, in at
least one embodiment of the invention, the coating 26 is made of an
aliphatic polyurethane composition. Furthermore, the coating 26 may
have any suitable thickness, such as a thickness of approximately
0.5 to 1.0 mil.
[0031] Alternatively, the coating 26 may be omitted if not required
for a particular application. For example, the skin layer 24 may be
configured to provide a sufficiently durable and attractive surface
such that the coating 26 is not needed.
[0032] Referring to FIGS. 4-6, a method of manufacturing the upper
door portion 14 will now be described. The method may begin by
spraying an optional mold release agent and then the optional
coating 26 on a spraying mold tool 30 using any suitable device,
such as a robotic low pressure (such as 10 to 40 psi) spray
assembly 32 having one or more moveable spray nozzles. The tool 30
may be heated to any suitable temperature if desired, generally in
the range of 150.degree. C. to 165.degree. C.
[0033] Next, referring to FIG. 5, the method involves spraying skin
layer forming material onto the coating 26 to form skin layer 24,
which bonds to the coating 26. The skin layer forming material may
be any suitable sprayable polyurethane forming material (i.e.,
composition) and may be applied using any suitable device. For
example, the material may be sprayed with a high pressure (such as
400 to 2,000 psi) robotic spray assembly 34 having one or more
movable spray nozzles. In at least one embodiment, the polyurethane
forming material comprises components such as polyol, provided from
polyol source 40 and isocyanate, provided from isocyanate source
42. In at least embodiment, the polyurethane forming materials are
aromatic and provide an aromatic polyurethane skin layer 24. The
polyol and isocyanate, and any other necessary components for
forming polyurethane, in at least one embodiment, can be mixed in
the spray assembly 34 before being sprayed as the polyurethane
forming material onto the coating 26. A CPU 44 can be provided for
controlling this operation.
[0034] As mentioned above, the coating 26 may be omitted from the
upper door portion 14. In such a case, the skin layer forming
material may be sprayed directly onto the tool 30, or onto a mold
release agent that is applied on the tool 30, to form the skin
layer 24. In this embodiment, the polyurethane skin layer 24 is
preferably aliphatic.
[0035] Referring to FIG. 6, the method then involves spraying
expandable polyurethane material onto the skin layer 24 to form
resilient layer 22, which bonds to skin layer 24. The expandable
polyurethane material may be any suitable sprayable expandable
polyurethane material (composition) and may be sprayed in any
suitable manner. For example, the expandable polyurethane material
may comprise polyol from polyol source 40, isocyanate from
isocyanate source 42, and a blowing agent from blowing agent source
48, such as water and/or a readily volatile organic substance, such
as a delayed-action amine catalyst. In certain embodiments,
specific examples of suitable catalysts are the delayed-action
amine catalyst DABCO.RTM. BL-17 and the amine catalyst DABCO.RTM.
BL-22 available from Air Products and Chemicals, Inc. of Allentown,
Pa.
[0036] Furthermore, the expandable polyurethane material may be
sprayed with the same type of robotic spray assembly 36 as used in
FIG. 5, and the material may be allowed to free rise to achieve the
desired density. Alternatively, the same spray assembly 34 as used
in FIG. 5 could be used to spray the expandable polyurethane
material. The blowing agent, may be provided as a "neat" (pure)
component, or may be provided in a premixed stream containing at
least another expandable polyurethane composition component, such
as polyol. If the expandable polyurethane material is sprayed from
the same spray assembly 34 as the polyurethane forming material in
FIG. 5 is, at least one valve 50 can be provided for selectively
controlling, by the CPU 44, whether, and what relative amount the
blowing agent is sent to the spraying assembly 34. If the blowing
agent is to be premixed with one of the expandable polyurethane
composition components, either all or some of that component can be
premixed with the blowing agent. If all of the component is mixed
with the blowing agent, it should be understood that either polyol
source 40 or isocyanate source 42 need not be employed during the
spraying of the expanded polyurethane composition.
[0037] It should be understood that the expandable polyurethane
material may be sprayed to achieve any desired thickness t at any
location, such that the thickness of the resilient layer 22 may
vary as best shown in FIG. 3. Thus, the expandable polyurethane
material may be more lightly applied in certain areas such as t1
where there is less clearance between substrate 20 and skin 24, and
more heavily applied in areas, such as t2 where there is more
clearance between substrate 20 and skin 24.
[0038] Next, the method involves securing the substrate 20 to the
expanded polyurethane layer 22. In one embodiment, this can be done
by removing the coating 26, skin layer 24 and resilient expanded
polyurethane layer 22 from the tool 30 and positioning the layers
22, 24 and 26 in a mold having first and second mold portions. The
mold portions may then be closed together, with material being
injected into the mold through one or more injection passages (not
shown) to form substrate 20, which bonds to the resilient layer 22.
Alternatively, the material may be poured into the mold, and then
the mold portions may be closed together.
[0039] While the substrate material may comprise any suitable
substance or substances, in one embodiment, the material includes
polyol and isocyanate such that the substrate 20 is formed of
polyurethane. Other suitable materials include polypropylene,
polyethylene, ABS, PC, ABS/PC blends, GRU and RRIM.
[0040] Whether the material is injected or poured into the mold,
such a process may be referred to as reaction injection molding
(RIM). Reinforcing material such as milled glass or glass fibers
may also be added during the RIM process to provide reinforcement
to the substrate 20. As another example, a reinforcing mat or
preform, such as a fiberglass preform, may be positioned in the
mold prior to the RIM process. This process may be referred to as
structural reaction injection molding (SRIM). RRIM is the process
where milled glass is mixed with polyol before reacting the polyol
with the isocyanate.
[0041] In at least one embodiment, the substrate 20 could be a
preformed substrate that is secured to the layer 22 by suitable
means, such as adhesively.
[0042] After the substrate 20 has been secured to layer 22, the
lower door portion 12 and the upper door portion 14 can then be
secured to each other by any suitable method, such as by heat
staking, snap fitting or fastening.
[0043] Examples of other vehicle parts that may be manufactured by
the above method include instrument panels, door panels, door
covers, package shelves, pillar trim panels, trim covers, and
console covers.
[0044] Although separate spray assemblies 32 and 34 are shown in
the Figures, the spray assemblies 32 and 34 may be provided as a
single spray assembly.
[0045] Furthermore, if the material to be sprayed includes multiple
substances, the substances may be mixed at any suitable time. For
example, the substances may be mixed upstream of, within, or
downstream of associated spray nozzles.
[0046] While embodiments of the invention have been illustrated and
described, it is not intended that these embodiments illustrate and
describe all possible forms of the invention. Rather, the words
used in the specification are words of description rather than
limitation, and it is understood that various changes may be made
without departing from the spirit and scope of the invention.
* * * * *