Panel for vehicle interior and method for producing said panel

Abstract

The present disclosure relates to a panel (100, 100 ') for a vehicle interior, the panel (100, 100') comprising: a first layer (110) made of a first composite material comprising a first thermoplastic polymer component (112) and a plurality of first natural fibers (111) embedded in the first thermoplastic polymer component (112); and a second layer (120) made of a second composite material comprising a second thermoplastic polymer component (122) and a plurality of second natural fibers (121) embedded in the second thermoplastic polymer component (122). The average length of the first natural fibers (111) is less than the average length of the second natural fibers (121). The present disclosure also relates to a method for producing such a panel (100, 100 ').

Description

Technical Field

[0001] The present disclosure relates to a panel for vehicle interior and a method for producing such a panel. Panels of the type disclosed herein can be used as trim, lining, covering or structural parts of vehicle cockpits, doors, pillars, roofs, trunks or other vehicle compartments and components, for example. Background Art

[0002] The materials used in such panels should ideally be strong, resilient, durable, lightweight and cost-effective. Natural fiber composites, such as natural fiber reinforced thermoplastics, are increasingly being used as a more sustainable alternative or supplement to conventional materials for vehicle interior panels, such as all-plastic materials or synthetic fiber reinforced plastics (including carbon fiber or glass fiber reinforced plastics). Although the use of natural fiber composites can improve the ecological footprint of vehicles, further improvements are still expected. In particular, products and methods that can recycle natural fiber composites or products containing such materials to reduce waste and more efficiently utilize the raw materials contained therein are needed. Summary of the invention

[0003] One object of the present disclosure is therefore to propose a panel for vehicle interiors and a method for producing a panel of this type which enables recycling of natural fiber composite materials or products comprising such materials.

[0004] This object is achieved by a panel according to claim 1 and a method according to claim 9. Specific embodiments are described in the respective dependent claims.

[0005] The panels proposed in this article for vehicle interiors include:

[0006] a first layer made of a first composite material comprising a first thermoplastic polymer component and a plurality of first natural fibers embedded in the first thermoplastic polymer component; and

[0007] A second layer is made of a second composite material comprising a second thermoplastic polymer component and a second plurality of natural fibers embedded in the second thermoplastic polymer component.

[0008] The average length of the first natural fibers is shorter than the average length of the second natural fibers.

[0009] The first natural fibers included in the first composite material may be derived from a precursor material comprising natural fibers having a relatively long average length, for example by grinding or milling the precursor material. The precursor material may be or include a used product, such as a previously used panel, a used product comprising longer natural fibers embedded in a thermoplastic polymer component.

[0010] Thus, when producing panels of the type proposed herein, natural fiber composite materials or products comprising such materials may be recycled in order to reduce waste and utilize the raw materials contained therein more efficiently.

[0011] Some or all of the plurality of second natural fibers may be oriented substantially parallel to one another. Specifically, the plurality of second natural fibers may form at least one of a woven or nonwoven fabric, a tissue, a knitted fabric, a scrim, a laid structure, etc., the woven or nonwoven fabric, the tissue, the knitted fabric, the scrim, the laid structure, etc. comprising at least a subset of the plurality of second natural fibers oriented parallel to one another.

[0012] The first natural fiber and / or the second natural fiber can be oriented in a substantially random orientation relative to each other. Multiple subsets of the plurality of first natural fibers and / or multiple subsets of the plurality of second natural fibers can be oriented in a substantially random orientation relative to each other, each subset comprising one or more fibers. For example, if the first natural fibers contained in the first composite material are derived from a precursor material comprising natural fibers of relatively long average length as described above, in particular by grinding or milling the precursor material, the grinding or milling process produces abrasive particles or particles, which can be processed into the first composite material. If the precursor material comprises natural fibers oriented parallel to each other, the abrasive particles or particles may also comprise multiple groups of mutually parallel fibers. However, the multiple groups of mutually parallel fibers are oriented in a substantially random orientation relative to each other. If the precursor material comprises randomly oriented fibers, the first natural fibers are also oriented in a random orientation.

[0013] The first layer may also comprise filler particles, in particular glass beads and / or wood flour, embedded in the first thermoplastic polymer component. The density of the filler particles may be lower than the density of the first thermoplastic polymer component.

[0014] The first layer may further include gas bubbles embedded in the first thermoplastic polymer component.The first layer may include a blowing agent to generate the gas bubbles.

[0015] The panel may further comprise a support layer. The support layer may be arranged between the first layer and the second layer. The support layer may be arranged on a side of the first layer facing away from the second layer. The support layer may be arranged on a side of the second layer facing away from the first layer. The first layer and / or the second layer may comprise a soft and / or flexible and / or bendable and / or foldable material, which may be supported on the support layer. The support layer may be more rigid than the first layer and / or the second layer. The support layer itself may comprise a soft and / or flexible and / or bendable and / or foldable material; combining the first layer and / or the second layer with the support layer may provide a joint structure with increased rigidity. The first layer and / or the second layer may be a substantially rigid layer. A plurality of support layers may be provided.

[0016] At least one of the first thermoplastic polymer component and the second thermoplastic polymer component may be or include at least one of polypropylene, polyethylene, polylactic acid, and polyetheretherketone. At least one of the first natural fiber and the second natural fiber may be or include at least one of bast fiber, jute fiber, flax fiber, hemp fiber, sisal fiber, kenaf fiber, basalt fiber, coconut shell fiber, rattan fiber, agave fiber, pineapple fiber, and banana fiber.

[0017] The first thermoplastic component may comprise recycled thermoplastic material. The first thermoplastic component may comprise new (non-recycled) thermoplastic material. For example, if the first natural fiber contained in the first composite material is derived from a precursor material comprising fibers and a thermoplastic component as described above, an additional supply of thermoplastic material may be added while the first layer is being produced to supplement the thermoplastic component present in the precursor material. The additional supply may include recycled and / or new thermoplastic material.

[0018] The method proposed herein for producing a panel of the proposed type comprises:

[0019] providing the first composite material, the first composite material produced by a process comprising grinding or milling a third composite material, the third composite material comprising a third thermoplastic polymer component and a plurality of third natural fibers, wherein the first natural fibers have an average length less than an average length of the third natural fibers, wherein grinding or milling the third composite material converts the third natural fibers into the first natural fibers; and

[0020] The first layer is formed from the first composite material.

[0021] The first layer may be formed from the first composite material by extrusion.The method may comprise joining the first layer, the second layer and the support layer, if provided, by a lamination process and / or a calendaring process.

[0022] The panels proposed herein may be further developed by including features equivalent to or resulting from certain steps of the methods proposed herein; or conversely, the methods proposed herein may include additional steps corresponding to optional features of the panels proposed herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The foregoing and other aspects and advantages of the presently disclosed subject matter will become apparent to those skilled in the art from the following detailed description of exemplary embodiments, when considered in light of the accompanying drawings, wherein

[0024] Figure 1A schematically shows a cross-sectional view of a panel for a vehicle interior,

[0025] Figure 1B schematically shows a cross-sectional view of a panel according to another example,

[0026] Figure 2A Schematically showing a method of obtaining fibers from a precursor material,

[0027] Figure 2B Schematically shows the process for producing Figure 1A The panel method uses a device,

[0028] Figure 2C Schematically shows the process for producing Figure 1B A device for use in the method of a panel. DETAILED DESCRIPTION

[0029] Repeated and similar features in the drawings are provided with the same alphanumeric reference numerals.

[0030] Figure 1A The illustrated panel 100 is an exemplary component for a vehicle interior. The panel 100 includes a first layer 110 made of a first composite material including a first thermoplastic polymer component 112 and a plurality of first natural fibers 111 embedded in the first thermoplastic polymer component 112 .

[0031] The panel 100 further includes a second layer 120 made of a second composite material comprising a second thermoplastic polymer component 122 and a plurality of second natural fibers 121 embedded in the second thermoplastic polymer component 122 .

[0032] By using natural fiber composite materials for the first layer 110 and the second layer 120, a panel 100 having improved sustainability and a reduced environmental footprint (particularly a CO2 footprint) is provided compared to the use of conventional materials. Factors contributing to these properties include the recycled / regenerated nature of natural fiber raw materials, and the light weight of natural fiber composite materials (which in turn can reduce fuel or energy consumption and related emissions).

[0033] The average length of the first natural fiber 111 is less than the average length of the second natural fiber 121. (In FIG. 1a , for illustrative purposes, the first natural fiber 111 and the second natural fiber 121 are respectively shown as having a uniform length equal to the average length. In most cases, the lengths of the first natural fiber 111 and the second natural fiber 121 are non-uniform, following a corresponding length distribution.)

[0034] like Figure 2A As shown, the first natural fibers 111 included in the first composite material are derived from a precursor material 140. The precursor material 140 includes a plurality of third natural fibers 141 having a relatively long average length embedded in a third thermoplastic polymer component 142. A process of grinding or milling the precursor material 140 (schematically indicated by arrows) transforms the third natural fibers 141 into the first natural fibers 111. The precursor material 140 may be or include a used product, such as a previously used panel.

[0035] Combining layers with short fibers (layers made of recycled material) and layers with long fibers (layers made of new material) provides a degree of material strength (particularly stiffness, hardness) and robustness (particularly elasticity, durability) that cannot be achieved, for example, with panels consisting entirely of recycled materials. In particular, these properties may be impaired when using materials that only contain short fibers resulting from grinding or milling used products. Therefore, when producing a panel 100 as described above, natural fiber composite materials or products containing such materials can be recycled in order to reduce waste, more effectively utilize the raw materials contained therein, and produce the panel 100 in a cost-effective manner.

[0036] The plurality of second natural fibers 121 form at least one of a woven or nonwoven fabric, a tissue, a knitted fabric, a scrim, a laid structure, etc., which includes a subset of the plurality of second natural fibers 121 oriented parallel to each other. In another example, the plurality of second natural fibers 121 can be oriented in a substantially random orientation relative to each other. In either case, the plurality of second natural fibers 121 serve as a reinforcing component of the panel 100, thereby increasing the aforementioned properties related to material strength and robustness.

[0037] like Figure 1A As shown in , a plurality of subsets of the plurality of first natural fibers 111 are oriented in a substantially random orientation relative to each other, each subset comprising several fibers. In particular, since the first natural fibers 111 included in the first composite material are derived from a precursor material 140 comprising third natural fibers 141 of relatively long average length as described above, in particular by grinding or milling the precursor material, the grinding or milling process produces abrasive particles or particles (see Figure 2A ), which are subsequently processed into a first composite material (see Figure 2B / C). Since in this example, the precursor material 140 includes third natural fibers 142 oriented in parallel to each other, the abrasive particles or particles also include multiple groups of first natural fibers 111 parallel to each other. However, since the abrasive particles or particles are incorporated into the first layer 110 in a random orientation, the multiple groups of first natural fibers 111 parallel to each other are oriented in a substantially random orientation relative to each other. In another example, the third natural fibers 141 can be oriented in a substantially random orientation relative to each other. In this case, the first natural fibers 111 derived from the third natural fibers 141 of the precursor material are also oriented in a substantially random orientation relative to each other.

[0038] The first layer 110 further includes filler particles 113, in particular glass beads and / or wood flour, embedded in the first thermoplastic polymer component 112. The density of the filler particles 113 is lower than the density of the first thermoplastic polymer component 112. The use of filler particles can help achieve desired material properties. In particular, filler particles 113 having a lower density than the first thermoplastic polymer component 112 can reduce the weight of the panel 100 while maintaining the desired mechanical properties, thereby helping to reduce the environmental footprint.

[0039] The first thermoplastic polymer component 112 and the second thermoplastic polymer component 122 are made of polypropylene. However, alternative or additional thermoplastic materials or combinations thereof may be used, such as polyethylene, polylactic acid, or polyetheretherketone. The first thermoplastic polymer component 112 may include a different material combination than the second thermoplastic polymer component 122. The first natural fiber 111 and the second natural fiber 121 are bast fibers. However, alternative or additional natural fibers such as jute fibers, flax fibers, hemp fibers, sisal fibers, kenaf fibers, basalt fibers, coconut shell fibers, rattan fibers, agave fibers, pineapple fibers, or banana fibers may be used. The first natural fiber 111 may be different from the second natural fiber 121.

[0040] Figure 1B The panel 100' shown in FIG. Figure 1A The panel 100 shown in FIG. 1 is generally similar. Therefore, the following description is limited to the differences.

[0041] Instead of filler particles 113 of panel 100, first layer 110 of panel 100' comprises gas bubbles 114 embedded in first thermoplastic polymer component 112. The first layer comprises a blowing agent (see Figure 2C and description thereof) to produce gas bubbles 114. Using gas bubbles 114 instead of filler particles 113 further reduces the weight of panel 100' while potentially providing a different compromise in material properties.

[0042] The rigidity of the first layer 110 and the second layer 120 of the panel 100' is less than that of the first layer and the second layer of the panel 100. In particular, the second layer comprises a soft, bendable material. The panel 100' further comprises a support layer 130 arranged between the first layer 110 and the second layer 120 so as to additionally support the first layer 110 and the second layer 120. The support layer 130 is at least more rigid than the second layer 120. Alternatively, the support layer 130 may be arranged at different positions, for example, on a side of the first layer 110 facing away from the second layer 120 or on a side of the second layer 120 facing away from the first layer 110. A plurality of support layers may be provided.

[0043] In the following, reference Figure 2A and Figure 2B ,right Figure 1A A method of producing the illustrated panel 100 will be described.

[0044] The first step of this method ( Figure 2A ) includes providing a first composite material produced by a process including grinding a third composite material (i.e., precursor material 140), the third composite material including a third thermoplastic polymer component 142 and a plurality of third natural fibers 141, wherein, as described above, the average length of the first natural fibers 111 is less than the average length of the third natural fibers 141.

[0045] The second step of the method ( Figure 2B) includes forming a first layer 110 from a first composite material. The first layer 110 is formed from the first composite material by extruding using an extruder 200. To this end, abrasive particles or particles of a first thermoplastic polymer component 112 containing first natural fibers 111 embedded therein are fed into the extruder 200 together with additional particles of the thermoplastic polymer component 112 (without embedded fibers) and filler particles 113. The additional particles of the thermoplastic polymer component 112 provide an additional supply of thermoplastic material to supplement the third thermoplastic polymer component 142 present in the precursor material 140. The additional particles of the thermoplastic polymer component 112 may include recycled thermoplastic material and / or new thermoplastic material. If the abrasive particles or particles of the first thermoplastic polymer component 112 containing the first natural fibers 111 contain a sufficient amount of the first thermoplastic polymer component 112 to form the first layer 110, the additional particles of the thermoplastic polymer component 112 may be omitted.

[0046] In this example, the material composition of the third thermoplastic polymer component 142 is the same as the first thermoplastic polymer component 112. The material composition of the third natural fibers is the same as the material composition of the first natural fibers 111. In different examples, the first thermoplastic polymer component 112 can include a different material combination than the third thermoplastic polymer component and / or the first natural fibers 111 can be different from the third natural fibers.

[0047] In a third step of the method, the first layer 110 leaves the extruder 200 and is fed into a roller press 300 together with the provided second layer 120 for joining the first layer 110 and the second layer 120 by lamination to form a panel 100 which is conveyed by a conveying mechanism 500 to a further point of use.

[0048] Figure 2B A modified version of the method for producing a panel 100' is shown. The first step is as described above. In the second step, a foaming agent 115 for forming bubbles 114 is fed into the extruder 200 together with the other components described above, instead of the filler particles 113.

[0049] In a third step, after leaving the extruder 200, the first layer 110 is combined with the support layer 130 and fed into a roller press for joining the first layer 110 and the support layer 130 into an intermediate product.

[0050] In a fourth step of the method, the intermediate product is fed into a calender 400 together with the second layer 120 for joining the intermediate product and the second layer 120 by calendering so as to form a panel 100'.

[0051] List of reference numerals:

[0052] 100, 100' panel,

[0053] 110 first floor,

[0054] 111 First Natural Fiber,

[0055] 112 a first thermoplastic polymer component,

[0056] 113 filler particles,

[0057] 114 bubbles,

[0058] 115 foaming agent,

[0059] 120 Second Floor,

[0060] 121 second natural fiber,

[0061] 122 a second thermoplastic polymer component,

[0062] 130 support layer,

[0063] 140 precursor materials,

[0064] 141Third natural fiber,

[0065] 142 a third thermoplastic polymer component,

[0066] 200 extruder,

[0067] 300 roller press,

[0068] 400 calender,

[0069] 500 conveying mechanism.

Claims

1. A panel (100, 100') for a vehicle interior, the panel (100, 100') comprising: A first layer (110) made of a first composite material, the first composite material comprising: a first thermoplastic polymer component (112) and a plurality of first natural fibers (111) embedded in the first thermoplastic polymer component (112); and A second layer (120) made of a second composite material, the second composite material comprising: a second thermoplastic polymer component (122) and a plurality of second natural fibers (121), wherein the plurality of second natural fibers are embedded in the second thermoplastic polymer component (122); The average length of the first natural fibers (111) is smaller than the average length of the second natural fibers (121).

2. The panel (100, 100') according to claim 1, wherein the first natural fibers (111) and / or the second natural fibers (121) are oriented in a substantially random orientation relative to each other, and / or wherein multiple subsets of the plurality of first natural fibers (111) and / or multiple subsets of the plurality of second natural fibers (121) are oriented in a substantially random orientation relative to each other, each subset comprising one or several fibers.

3. The panel (100, 100') according to any of the preceding claims, wherein the first layer (110) further comprises a plurality of filler particles (113), in particular glass beads and / or wood flour, embedded in the first thermoplastic polymer component (112).

4. The panel (100, 100') according to claim 3, wherein the density of the filler particles (113) is lower than the density of the first thermoplastic polymer component (112).

5. The panel (100, 100') according to any one of the preceding claims, wherein the first layer (110) further comprises gas bubbles (114) embedded in the first thermoplastic polymer component (112).

6. The panel (100, 100') according to claim 5, wherein the first layer (110) comprises a blowing agent (115) to generate the gas bubbles (114).

7. The panel (100, 100') according to any one of the preceding claims, further comprising a supporting layer (130).

8. A panel (100, 100') according to any of the preceding claims, wherein at least one of the first thermoplastic polymer component and the second thermoplastic polymer component (112, 122) is or comprises at least one of polypropylene, polyethylene, polylactic acid and polyetheretherketone, and / or wherein at least one of the first natural fiber and the second natural fiber (111, 121) is or comprises at least one of bast fiber, jute fiber, flax fiber, hemp fiber, sisal fiber, kenaf fiber, basalt fiber, coconut shell fiber, rattan fiber, agave fiber, pineapple fiber and banana fiber.

9. The panel (100, 100') according to any one of the preceding claims, wherein the first thermoplastic polymer component (112) comprises recycled thermoplastic material.

10. A method for producing a panel (100, 100') according to any one of the preceding claims, the method comprising: providing the first composite material, the first composite material produced by a process comprising grinding or milling a third composite material, the third composite material comprising a third thermoplastic polymer component (142) and a plurality of third natural fibers (141), wherein the first natural fibers (111) have an average length that is less than an average length of the third natural fibers (141), wherein grinding or milling the third composite material converts the third natural fibers (141) into the first natural fibers (111); and The first layer (110) is formed from the first composite material.

11. The method according to claim 10, wherein the first layer (110) is formed from the first composite material by extrusion.

12. The method according to claim 10 or 11, comprising joining the first layer (110), the second layer (120) and the support layer (130), if provided, by a lamination process and / or a calendaring process.

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