Flexible multi-layer material, vehicle interior component and roll-up cover with such a

Abstract

Flexible multilayer material (1), comprising a decorative layer (10) made of a renewable natural material and / or a textile material, a flexible base layer (20) onto which the decorative layer (10) is applied, and a support structure layer (30) made of a polymer material, which is molded onto the side of the base layer (20) opposite the decorative layer (10), wherein the support structure layer (30) consists of a plurality of adjacent but unconnected rigid segments (31), and wherein the flexible load-bearing layer (20) forms joints between the rigid segments (31) of the support structure layer (30).

Description

[0001] The utility model relates to a flexible multi-layer material and also to components using such a material.

[0002] In the automotive industry, as in other sectors, there is a growing demand for sustainable, environmentally friendly, and low-carbon materials that can replace conventional materials. Natural materials such as wood and plant fibers offer an attractive alternative due to their aesthetics and mechanical properties. However, their integration into industrial processes and their adaptation to complex three-dimensional shapes present a significant technical challenge.

[0003] Current applications of wood in automotive interiors are limited to manually processed flat components, which are time-consuming and expensive to manufacture and offer little design flexibility. Highly curved shapes cannot be achieved with thin-walled structures.

[0004] US 10981309 B2 discloses a method for manufacturing a molded part that incorporates real wood. For this purpose, an in-mold decorative film (IMD film) is placed in a mold and back-injected with plastic. However, the resulting product is not flexible and, for example, not suitable for a roller cover where the cover is guided along a curved path, similar to a roller shutter.

[0005] The invention is based on the objective of providing a remedy for this problem.

[0006] For this purpose, a flexible multilayer material with the features of claim 1 is proposed. Furthermore, a vehicle interior component according to claim 25 and a roll-up cover according to claim 26 are proposed using such a flexible multilayer material. Specific embodiments are the subject of further claims.

[0007] The solution according to the invention enables a thin, multi-layered material with a natural appearance, which, due to its high flexibility, is particularly suitable for highly curved surfaces and can, for example, also be designed to be rolled up like a roll-up cover. After back-injection with plastic, the material can be flexibly applied to a curved surface.

[0008] The support structure layer allows for the adjustment of required stiffness, regardless of the chosen decor.

[0009] For example, a roll-up cover for the center console of a motor vehicle can be designed to be so rigid that a passenger cannot accidentally push it in with their knee.

[0010] Appropriate material selection ensures good separability during recycling. Water-soluble adhesives allow for easy separation of individual layers.

[0011] The invention represents a novel approach to the use of natural fibers for integration into plastic materials with a natural surface, for example, in the automotive industry. The material's weight is reduced by up to 10%. The CO2 footprint can be reduced by more than 20% compared to current materials.

[0012] This flexibility allows for a high degree of design freedom with regard to complex spatial forms that are difficult to achieve with conventional materials. This opens up new possibilities for the interior and exterior design of vehicles.

[0013] Optional backlighting and / or heating can increase functionality and improve the user experience.

[0014] The following section explains in more detail ways of implementing the invention with reference to exemplary embodiments shown in the drawing. The drawing shows in Fig. 1 a schematic representation of the layer structure of a flexible multilayer material according to an embodiment according to the invention, Fig. 2 an exploded view of the layer structure, Fig. 3 a roll-up cover made of a flexible multilayer material according to an embodiment of the invention, and in Fig. 4 another view of the roll-up cover according to Fig. 3.

[0015] The in Fig. 1 An exemplary flexible multilayer material 1 comprises at least a decorative layer 10 made of a renewable natural material, a flexible base layer 20 onto which the decorative layer 10 is applied, and a support structure layer 30 made of a polymer material, which is molded onto the side of the base layer 20 opposite the decorative layer 10.

[0016] Optionally, a preferably transparent coating 40 can be applied to the visible side of the decorative layer 10 as UV protection and / or as wear protection. An encapsulating coating 40 can have a thickness of 1 to 500 µm.

[0017] An adhesive layer 50, preferably made of a water-soluble adhesive, can be provided between the decorative layer 10 and the flexible support layer 20.

[0018] The support structure layer 30 can be injection-molded or thermoformed onto the flexible base layer 20. In the latter case, an adhesive layer is also provided between the flexible base layer 20 and the support structure layer 30.

[0019] The support structure layer 30 has or consists of a multitude of adjacent but unconnected rigid segments 31. The rigid segments 31 are held together by the flexible support layer 20, which primarily provides the flexibility of the multilayer material 1. The material of the support structure layer 30 would be too rigid for this purpose. The flexible support layer 20 thus forms joints between the rigid segments 31 of the support structure layer 30.

[0020] The rigid segments 31 of the support structure layer 30 are preferably configured to reinforce the flexible multilayer material 1.

[0021] Preferably, the support structure layer 30 has a greater thickness than the decorative layer 10. In particular, the support structure layer 30 can have a thickness of 200 µm to 25 mm.

[0022] The flexible multilayer material 1 can be bent significantly and is therefore adaptable to complex geometries. Surfaces with double curvature are possible using appropriately shaped segments.

[0023] Fig. 3 and Fig. Figure 4 shows, by way of example but without limitation, the use as a roll-up cover 100 for an opening made of a flexible multilayer material 1 of the aforementioned type. Such a roll-up cover 100 can, for example, be arranged in the area of ​​a motor vehicle's center console, but can also be used for other purposes.

[0024] In the case of the roller cover 100, the rigid segments 31 are formed from a plurality of rod-shaped segments 101, which are arranged successively parallel to each other with respect to the rolling direction R of the roller cover 100.

[0025] At least some of the rod-shaped segments 101 can form guide projections 102 at their axial ends for engagement in a stationary guide groove.

[0026] The rod-shaped segments 101 provide the roller cover 100 with sufficient rigidity to prevent it from being accidentally dented, for example. The flexible support layer 20 ensures the necessary flexibility for moving the roller cover 100 along a curved path. This support layer 20 also forms the connection to the decorative layer 10, which provides the visual and tactile appearance of the roller cover 100.

[0027] In a variation of the exemplary embodiment, the rigid segments 31 of the support structure layer 30 can also be triangular, square, or hexagonal. Other shapes are also possible in order to cover a surface as completely as possible with a decoration. In particular, rigid segments 31 of different shapes can also be combined with one another.

[0028] In the example case, the roller cover 100 can have a wider handle part 103, to which the parallel rod-shaped segments 101 are successively connected by hinges.

[0029] The visual appearance is primarily determined by the decorative layer 10. This layer can be segmented to facilitate adaptation to curved surfaces. The segments of the decorative layer 10 can be partially or completely separated from one another by incisions.

[0030] Optionally, the segments of the decorative layer 10 can be structured three-dimensionally, as shown in the Fig. 2 to 4 are merely examples, so that, for instance, a somewhat uneven surface with perceptible bumps and depressions results.

[0031] The decorative layer 10 can contain natural fibers in the visible area, creating the impression of a natural material. Wood, in particular, can be used for this purpose. A textile material can also be used, and the invention is not limited to these materials.

[0032] Suitable material thicknesses for the decorative layer 10 are preferably in the range of 100 µm to 5 mm.

[0033] The support layer 20 can comprise a polymer film, a textile material, or a combination thereof. Preferably, the support layer 20 has a thickness of 10 to 750 µm.

[0034] The decorative layer 10 is glued onto the base layer 20, for example using a water-soluble adhesive 50, to improve material separation during recycling.

[0035] Optionally, an adhesion promoter layer can be provided between the base layer 20 and the support structure layer 30, which is applied to the base layer 20.

[0036] Functional components such as lighting and / or heating can also be integrated into the flexible multi-layer material.

[0037] For example, the support structure layer 30 can have lighting means for backlighting which are attached to the support structure layer 30 or embedded in the material of the support structure layer 30.

[0038] Likewise, the support structure layer 30 can have heating means for heating, which are attached to the support structure layer 30 or embedded in the material of the support structure layer 30.

[0039] One possible use of the flexible multilayer material 1 is in the Fig. 3 and Fig. 4 is shown using a roll-up cover 100 for an opening. However, this can also be used in a variety of ways for other surfaces.

[0040] The present invention enables a multilayer plastic composite structure comprising a top layer 10 made of a natural material, such as a sheet of natural long fibers or a natural fiber fabric such as wood, raffia, jute, straw, cork, bamboo, cellulose, hemp or other long-stemmed plants or a continuous wooden sheet with or without micro-cuts or with engraved structures, for example by machining or CNC machining, which is connected to a plastic-based support structure layer 30, thereby enabling the production of a spatially shaped (non-planar) and / or articulated part.

[0041] This structure can be produced by injection molding, lamination, or wrapping and finishing processes.

[0042] The combination of materials offers improved properties, such as higher mechanical strength, improved aesthetics, recyclability and sustainability.

[0043] The flexible multilayer material 1, made of renewable natural material and / or a textile material on the one hand and plastic on the other, can assume flat geometries, curved geometries and complex geometries and adapt to three-dimensional and articulated shapes.

[0044] The multi-layered structure can optionally maintain a sufficient degree of light transmission so that it can be backlit using electroluminescence, LED and OLED technologies.

[0045] Depending on the thickness of the flexible multilayer material 1, it can be equipped with haptic functions.

[0046] The flexible multilayer material 1 can also perform radiant or convection heating functions. Surface heating of vehicle interior components can be achieved primarily through electrical heating systems integrated behind the component, for example, carbon nanotube or graphite heating elements covered by steel or polymer additives in the substrate material or by a coating. These distribute the heat precisely for an efficient and rapid experience, creating thermal islands that provide comfort and a pleasant feel.

[0047] To illustrate the flexible multilayer material 1, methods for its production are explained below.

[0048] The process initially includes the step of selecting suitable plastic and natural materials intended to form a multi-layered, dimensionally stable and at the same time flexible composite structure.

[0049] In a first step, renewable natural materials for the decorative layer 10, in particular natural fiber fabrics, plant textiles, wood or wood veneers, are prepared for their integration into the multilayer structure. For this purpose, the respective natural material is permanently bonded to a woven, non-woven or knitted textile made of natural or synthetic fibers or to a synthetic membrane or film as a flexible support layer 20 in order to increase its mechanical stability and further processing capabilities.

[0050] The manufacturing process includes the provision of an adhesive system 40, which can consist, for example, of natural cellulose adhesives or chemical adhesives and is designed to allow subsequent delamination of layers 10 and 20 to improve recyclability. The layers of the composite material are joined via a co-extrusion or lamination process in which plastic and natural material layers are combined to form a multilayer flat structure.

[0051] Subsequently, the flexible multi-layer structure 1 is produced by an injection molding or thermoforming process, in which the segmented support structure layer 30 is molded onto the base layer 20.

[0052] In a further step, the finished product can be provided with a protective coating 50. This coating 50 can have UV barrier properties and / or protect the surface from abrasion, scratches, and other external influences. It is available in various colors, can compensate for surface irregularities if necessary, and allows for the visual enhancement of older wood surfaces.

[0053] The surface of the final product can be additionally surface-treated to increase moisture resistance, repel bacteria or pests, reduce the risk of fire, achieve intense color effects and / or provide a dynamic texture.

[0054] Finally, an exemplary layer structure is given in detail, whereby the following materials in particular can also be used individually or in combination at the top: Layer 1 (Coating 50 - Surface protection layer) - optional: A plant-based coating comprising a water-based, two-component, thermosetting or solvent-based resin or composite material. The coating has a thickness of 1–500 µm and is designed to improve physical and chemical resistance to environmental influences. Layer 2 (decorative layer 20): A thin sheet of natural fiber fabric, plant fabric, or natural wood veneer, selected from wood veneers with or without laser cutting, wood fabrics, straw fibers / fabrics, bamboo fibers / fabrics, raffia fibers / fabrics, or other cellulose fabrics. The layer thickness ranges from 150 µm to 5 mm. Layer 3 (adhesive layer 40): An adhesive layer formed from natural cellulose adhesives or from water-based, solvent-based, film- or network-shaped adhesives or from two-component adhesives such as PES, PP, PA, Co-PES, Co-PA, acrylic, PUR or PSA. Layer 4 (flexible base layer 20): A textile cover compatible with polymer or resin injection molding processes. The reverse side can be made of paper using an adhesive according to layer 3. woven or knitted textiles, nonwovens, nets, films or adhesive membranes, especially based on PP, PES, PA or acrylic. Layer 5 (carrier layer) - optional: An additional adhesive layer on a dotted film, mesh or membrane consisting of PES, PP, PA, Co-PES, Co-PA, acrylic, PUR, PSA or similar materials. Layer 6 (support structure layer 30 - injection molding layer): A three-dimensional molded part produced by injection molding from PP, PET, PC / ABS, ABS, PC, POM, or PMMA. The choice of material depends primarily on the desired visual appearance, the possibility of backlighting / heating, and the intended application of the final product.

[0055] The utility model has been explained in more detail above with reference to exemplary embodiments and further modifications. In particular, individual technical features, which were explained above in the context of other individual features, can be implemented independently of these features and in combination with other individual features, even if this is not expressly described, as long as this is technically possible. The utility model is therefore expressly not limited to the described exemplary embodiments and modifications, but encompasses all configurations defined by the claims. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 10981309 B2

[0004]

Claims

[1] Flexible multilayer material (1), comprising a decorative layer (10) made of a renewable natural material and / or a textile material, a flexible base layer (20) onto which the decorative layer (10) is applied, and a support structure layer (30) made of a polymer material, which is molded onto the side of the base layer (20) opposite the decorative layer (10), wherein the support structure layer (30) consists of a plurality of adjacent but unconnected rigid segments (31), and wherein the flexible load-bearing layer (20) forms joints between the rigid segments (31) of the support structure layer (30). [2] Flexible multilayer material (1) according to claim 1, characterized by , that the support structure layer (30) is injection molded or thermoformed onto the flexible base layer (20). [3] Flexible multilayer material (1) according to claim 1 or 2, characterized by, that the rigid segments (31) of the support structure layer (30) are configured to reinforce the flexible multilayer material (1). [4] Flexible multilayer material (1) according to any one of claims 1 to 3, characterized by , that the rigid segments (31) are rod-shaped and arranged parallel to each other. [5] Flexible multilayer material (1) according to any one of claims 1 to 3, characterized by , that the rigid segments (31) of the support structure layer (30) comprise triangular segments, square segments or hexagonal segments or a combination thereof. [6] Flexible multilayer material (1) according to any one of claims 1 to 5, characterized by , that the decorative layer (10) is segmented, the segments of which are partially separated from each other by incisions. [7] Flexible multilayer material (1) according to any one of claims 1 to 5, characterized by, that the decorative layer (10) is segmented, the segments of which are completely separated from each other by incisions. [8] Flexible multilayer material (1) according to claim 6 or 7, characterized by , that the segments of the decorative layer (10) are structured three-dimensionally. [9] Flexible multilayer material (1) according to any one of claims 1 to 8, characterized by , that the decorative layer (10) in the visible area contains natural fibers. [10] Flexible multilayer material (1) according to any one of claims 1 to 8, characterized by , that the decorative layer (10) in the visible area consists of wood. [11] Flexible multilayer material (1) according to any one of claims 1 to 8, characterized by , that the decorative layer in the visible area consists of a textile material (10). [12] Flexible multilayer material (1) according to any one of claims 1 to 11, characterized by , that the support layer (20) has a polymer film. [13] Flexible multilayer material (1) according to any one of claims 1 to 12, characterized by , that the supporting layer (20) has a textile material. [14] Flexible multilayer material (1) according to any one of claims 1 to 13, characterized by , that the decorative layer (10) is glued onto the base layer (20). [15] Flexible multilayer material (1) according to any one of claims 1 to 13, characterized by , that the decorative layer (10) is glued to the base layer (20) by means of a water-soluble adhesive (40). [16] Flexible multilayer material (1) according to any one of claims 1 to 15, characterized by , that an adhesion-promoting layer is provided between the base layer (20) and the support structure layer (30), which is applied to the base layer (20). [17] Flexible multilayer material (1) according to any one of claims 1 to 16, characterized by, that the support structure layer (30) has backlighting means which are attached to the support structure layer (30) or embedded in the material of the support structure layer (30). [18] Flexible multilayer material (1) according to any one of claims 1 to 17, characterized by , that the support structure layer (30) has heating means for heating which are attached to the support structure layer (30) or embedded in the material of the support structure layer (30). [19] Flexible multilayer material (1) according to any one of claims 1 to 18, characterized by , that the decorative layer (10) has a thickness of 100 µm to 5 mm. [20] Flexible multilayer material (1) according to any one of claims 1 to 19, characterized by , that the base layer (20) has a thickness of 10 to 750 µm. [21] Flexible multilayer material (1) according to any one of claims 1 to 20, characterized by, that the support structure layer (30) has a greater thickness than the decorative layer (10). [22] Flexible multilayer material (1) according to any one of claims 1 to 21, characterized by , that the support structure layer (30) has a thickness of 200 µm to 25 mm. [23] Flexible multilayer material (1) according to any one of claims 1 to 22, characterized by , that a coating (50) is applied to the visible side of the decorative layer (10) as UV protection. [24] Flexible multilayer material (1) according to claim 23, characterized by , that the encapsulating coating (50) has a thickness of 1 to 500 µm. [25] Vehicle interior component made of a flexible multilayer material (1) according to any of the preceding claims. [26] Roll cover (100) for an opening made of a flexible multilayer material (1) according to one of claims 1 to 24, wherein the support structure layer (30) has a plurality of rod-shaped segments (101) which are arranged successively parallel to each other in the rolling direction (R) of the roll cover (100). [27] Roll-up cover according to claim 26, characterized by , that at least some of the rod-shaped segments (101) form guide projections (102) at their axial ends for engagement in a guide groove.

Images