A leather-covered ceiling and a method for manufacturing the same, vehicle

Abstract

The present application provides a kind of leather-covered ceiling and its preparation method, vehicle, belongs to vehicle component technical field.Leather-covered ceiling includes leather fabric layer, adhesive layer and framework layer, leather fabric layer is adhered the surface of framework layer by adhesive layer, leather fabric layer is made of multiple leather fabrics that are sewn together, framework layer surface is provided with suture slot, and the sewing area of leather fabric layer is located in suture slot;Leather-covered ceiling provided in the embodiment of the present application not only can avoid the defect that leather fabric layer and framework layer are not firmly bonded and crack, simultaneously cooperate with the rest leather-covered components, improve the overall quality and touch of vehicle, and at the same time, a variety of different leather fabrics can be used for coating, increase diversity.

Description

Technical Field

[0001] This invention relates to the field of vehicle component technology, and in particular to a genuine leather-covered headliner, its preparation method, and a vehicle. Background Technology

[0002] With the widespread use of automobiles, after vehicles meet people's travel needs, there is also a greater demand for the diversity of vehicle interiors. Therefore, vehicle interiors have begun to adopt surface treatments such as large-area INS (Insert-Mould-Decoration), covering, or electroplating to meet customer needs.

[0003] The headliner is an essential interior component of a vehicle, requiring not only high functionality but also aesthetic appeal. Currently, headliners on the market are generally manufactured using thermoforming or vacuum forming processes, which leaves room for improvement in terms of feel and texture.

[0004] Genuine leather is soft and delicate to the touch and easy to care for, and it is now widely used in some parts of vehicles, such as the steering wheel, seats, door panels, and dashboard. However, due to the large size and complex shape of the vehicle headliner, and because genuine leather has poor stretchability, problems such as material accumulation, wrinkles, poor adhesion between the leather and the substrate, and delamination can occur if genuine leather is used to cover the headliner. Summary of the Invention

[0005] To address the aforementioned technical problems, this invention provides a genuine leather-covered roof, its preparation method, and a vehicle.

[0006] In a first aspect, the present invention provides a genuine leather-covered headliner, the genuine leather-covered headliner comprising a genuine leather fabric layer, an adhesive layer, and a skeleton layer, wherein the genuine leather fabric layer is adhered to the surface of the skeleton layer by the adhesive layer, wherein:

[0007] The genuine leather fabric layer is composed of multiple pieces of genuine leather fabric stitched together, and the surface of the skeleton layer is provided with seam grooves, with the stitching area of ​​the genuine leather fabric layer located in the seam grooves.

[0008] In some embodiments of the present invention, the width of the stitching groove is 2.5-3 times the thickness of the genuine leather fabric layer.

[0009] In some embodiments of the present invention, the depth of the seam groove is 1.5-2 times the width of the cut edge of the sewing area.

[0010] In some embodiments of the present invention, the stitching groove is at least located at the irregular surface of the skeleton layer, or located at a position where the tensile deformation rate of the genuine leather fabric layer exceeds 10-15%.

[0011] In some embodiments of the present invention, the skeleton layer is provided with a sunroof hole, the stitching groove is provided at the seam where the leather covering the four rounded corners of the sunroof hole extends forward or backward to the seam with another piece of leather, and at the seam between the two pieces of leather corresponding to the area of ​​the sunroof hole and the B-pillar of the vehicle, and at the seam between the two pieces of leather corresponding to the area of ​​the headliner and the B-pillar.

[0012] In some embodiments of the present invention, the skeleton layer is integrally pressed and formed.

[0013] In some embodiments of the present invention, the plurality of genuine leather fabrics are cut according to the tensile deformation rate of the genuine leather fabric layers.

[0014] In some embodiments of the present invention, the adhesive layer is a water-soluble adhesive layer.

[0015] In some embodiments of the present invention, the skeleton layer is a polyurethane composite board layer, the polyurethane composite board layer includes a polyurethane board, and reinforcing fiberglass layers are provided on both sides of the polyurethane board. The reinforcing fiberglass layer includes a glass fiber surface felt layer and a non-woven fabric layer, and the glass fiber surface felt layer is located between the non-woven fabric layer and the polyurethane board.

[0016] In some embodiments of the present invention, the thickness of the genuine leather fabric layer is 0.5-1.5 mm.

[0017] In some embodiments of the present invention, the thickness of the adhesive layer is 0.1-0.15 mm.

[0018] In some embodiments of the present invention, the thickness of the skeleton layer is 2.5-6.0 mm.

[0019] Secondly, the present invention provides a method for preparing the dermal-covered headliner described in the first aspect, the method comprising the following steps:

[0020] (I) Multiple pieces of genuine leather fabric are spliced ​​and sewn together to obtain a genuine leather fabric layer;

[0021] (II) A seam groove is formed on the surface of the skeleton layer near the genuine leather fabric layer;

[0022] (III) The genuine leather fabric layer is adhered to the surface of the skeleton layer using an adhesive layer, wherein the sewing area of ​​the genuine leather fabric layer is set in the seam groove to obtain the genuine leather covered canopy.

[0023] In some embodiments of the present invention, in step (I), based on the tensile deformation rate of the genuine leather fabric layer, the area where the tensile deformation rate is greater than the maximum tensile deformation rate of the genuine leather fabric itself is cut to obtain the multiple pieces of genuine leather fabric.

[0024] In some embodiments of the present invention, the width of the stitch groove is 2.5-3 times the thickness of the genuine leather fabric layer, and the depth is 1.5-2 times the width of the cut edge of the sewing area.

[0025] In some embodiments of the present invention, the adhesion method includes hot pressing followed by cold pressing.

[0026] Thirdly, the present invention provides a vehicle comprising the leather-covered headliner as described in the first aspect, or a leather-covered headliner prepared by the preparation method described in the second aspect.

[0027] The technical solution provided by the embodiments of the present invention has the following advantages compared with the prior art:

[0028] The genuine leather-wrapped headliner provided in this embodiment of the invention not only avoids defects such as poor adhesion and cracking between the genuine leather fabric layer and the skeleton layer, but also enhances the overall texture and feel of the vehicle when combined with other genuine leather-wrapped components. In addition, it can be wrapped with a variety of different genuine leather fabrics, increasing diversity. Attached Figure Description

[0029] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with the invention and, together with the description, serve to explain the principles of the invention.

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram of the structure of the genuine leather-covered ceiling described in this invention;

[0032] Figure 2 This is a schematic diagram of the suture groove structure of the skeleton layer described in this invention;

[0033] Figure 3 A schematic diagram of a skeleton layer provided by the present invention;

[0034] Figure 4 This is one of the structural schematic diagrams of the skeleton layer described in this invention;

[0035] Figure 5 This is a simplified flowchart of the preparation of the genuine leather-covered headliner described in this invention;

[0036] in:

[0037] 1-Genuine leather fabric layer; 101-Sewing area; 2-Adhesive layer; 3-Skeleton layer; 301-Sewing groove;

[0038] 31-Polyurethane board; 32-Reinforcing fiberglass layer; 321-Fiberglass surface felt layer; 322-Non-woven fabric layer. Detailed Implementation

[0039] To better understand the above-mentioned objectives, features, and advantages of the present invention, the solutions of the present invention will be further described below. It should be noted that, unless otherwise specified, the embodiments of the present invention and the features thereof can be combined with each other.

[0040] Many specific details are set forth in the following description in order to provide a full understanding of the invention, but the invention may also be practiced in other ways different from those described herein; obviously, the embodiments in the specification are only some embodiments of the invention, and not all embodiments.

[0041] Currently, vehicle headliners are typically decorated by covering the frame layer with knitted fabrics to achieve a decorative effect. Using genuine leather not only enhances the feel and texture of the headliner but also complements other leather-covered interior elements, significantly improving the overall quality of the vehicle. However, current vehicle headliners are generally integrally molded, resulting in irregularly shaped surfaces at the points where they match other vehicle components. Using genuine leather for this integral molding can lead to issues such as material accumulation or wrinkles in the leather covering layer, and also problems like poor adhesion between the leather covering layer and the frame layer, and delamination. Therefore, this invention provides a genuine leather-covered headliner and its preparation method.

[0042] like Figure 1 and Figure 2 As shown, this embodiment of the invention provides a genuine leather-covered headliner, which includes a genuine leather fabric layer 1, an adhesive layer 2, and a skeleton layer 3. The genuine leather fabric layer 1 is adhered to the surface of the skeleton layer 3 through the adhesive layer 2, wherein:

[0043] The genuine leather fabric layer 1 is composed of multiple pieces of genuine leather fabric stitched together. The surface of the skeleton layer 3 is provided with a seam groove 301, and the stitching area 101 of the genuine leather fabric layer 1 is located in the seam groove 301.

[0044] Vehicle roofs typically have multiple irregular surfaces. If the leather fabric layer 1 and the skeleton layer 3 are directly bonded together to form the roof, the leather fabric layer 1 is prone to material accumulation or wrinkles, and problems such as poor adhesion and delamination between the leather fabric layer 1 and the skeleton layer 3 are also likely to occur.

[0045] In this invention, by providing a genuine leather fabric layer 1 made of multiple pieces of genuine leather fabric stitched together, problems such as material accumulation and wrinkles that occur when using a single piece of genuine leather fabric as the genuine leather fabric layer 1 can be avoided; furthermore, this invention introduces a skeleton layer 3 with seam grooves 301, placing the stitching area 101 of the genuine leather fabric layer 1 within the seam grooves 301 (e.g., ...). Figure 2 As shown in the figure, the genuine leather fabric layer 1 and the skeleton layer 3 provided by the present invention have excellent adhesion, and the genuine leather fabric layer 1 and the skeleton layer 3 are not prone to separation. Therefore, the genuine leather covered ceiling provided by the present invention can solve the problems of poor adhesion and easy separation between the genuine leather fabric layer 1 and the skeleton layer 3, avoid problems such as leather accumulation and wrinkles, and the overall coverage is uniform without uneven parts, resulting in a better overall flatness.

[0046] If the seam groove 301 is not provided on the surface of the skeleton layer 3, since the genuine leather fabric layer 1 is made of multiple pieces of genuine leather fabric spliced ​​together and sewn, the sewing area 101 includes double-layer genuine leather fabric, which is relatively thick. It is easy for it to have problems such as poor adhesion and delamination with the skeleton layer 3. Moreover, in terms of appearance, the thickness of the sewing area 101 cannot be consistent with the rest of the parts, resulting in poor flatness.

[0047] Regarding the genuine leather fabric layer 1 described in this invention:

[0048] The genuine leather fabric layer 1 is obtained by stitching together multiple pieces of genuine leather fabric, wherein:

[0049] In some embodiments of the present invention, the plurality of genuine leather fabrics are cut according to the tensile deformation rate of the genuine leather fabric layer 1.

[0050] If genuine leather is directly used to cover the skeleton layer 3, since the skeleton layer 3 is not a simple planar structure but has multiple irregular surfaces, the tensile force and tensile deformation rate of the genuine leather will vary after it adheres to the skeleton layer 3. Areas with excessive tensile deformation rate are prone to poor adhesion and delamination. Therefore, in this invention, the genuine leather layer 1 is cut according to the tensile deformation rate it experiences, and then spliced ​​and sewn. This can solve the problems of material accumulation and wrinkles in the genuine leather, and also avoid problems such as delamination or cracking caused by excessive tensile deformation rate of the genuine leather.

[0051] In some embodiments of the present invention, the thickness of the genuine leather fabric layer 1 is 0.5-1.5 mm, such as 0.5 mm, 0.6 mm, 0.8 mm, 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.5 mm, etc., but the present invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable; preferably, the thickness of the genuine leather fabric layer 1 is 1.0-1.2 mm.

[0052] Regarding the adhesive layer 2 of the present invention:

[0053] In some embodiments of the present invention, the adhesive layer 2 is a water-soluble adhesive layer.

[0054] The adhesive layer 2 described in this invention serves to bond and fix the genuine leather fabric layer 1 and the skeleton layer 3. The genuine leather fabric layer 1 can be fixed to the surface of the skeleton layer 3 by the adhesive layer 2. In the embodiments of this invention, the specific composition of the adhesive layer 2 is not limited. For example, the adhesive layer 2 can be formed by water-soluble adhesives or the like.

[0055] In some embodiments of the present invention, the thickness of the adhesive layer 2 is 0.1-0.15 mm, such as 0.1 mm, 0.11 mm, 0.12 mm, 0.13 mm, 0.14 mm, 0.15 mm, etc., but the present invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable.

[0056] Regarding the skeleton layer 3 described in this invention:

[0057] In some embodiments of the present invention, the skeleton layer 3 is integrally pressed and formed.

[0058] The skeleton layer 3 described in this invention is prepared by an integral pressing molding process. That is, the stitching grooves 301 on the surface of the skeleton layer 3 do not affect the overall thickness of the skeleton layer 3. The skeleton layer 3 still has a uniform thickness. Therefore, in the leather-covered headliner provided by this invention, although the skeleton layer 3 is provided with certain stitching grooves 301, it does not affect the mechanical properties of the headliner and can still meet the application requirements of the vehicle headliner.

[0059] In some embodiments of the present invention Figure 3 A schematic diagram of a skeleton layer provided in an embodiment of the present invention is shown below. Figure 3 As shown, the skeleton layer 3 is a polyurethane composite board layer, which includes a polyurethane board 31. Reinforcing fiberglass layers 32 are provided on both sides of the polyurethane board 31. The reinforcing fiberglass layer 32 includes a glass fiber surface felt layer 321 and a non-woven fabric layer 322. The glass fiber surface felt layer 321 is located between the non-woven fabric layer 322 and the polyurethane board 31.

[0060] It should be noted that the specific preparation process of the skeleton layer 3 is not limited in the embodiments of the present invention. For example, an appropriate processing technology can be selected to process the skeleton layer according to the specific composition of the skeleton layer 3. For example, for the polyurethane composite board of the present invention, a dry production process (also known as the cold molding method) can be used to process its raw materials. Specifically, the polyurethane board 31 can first be heated to a certain temperature, such as 180-200℃, for example, 180℃, 185℃, 190℃, 195℃, 200℃, etc., but the present invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable, so that it reaches a plastic state. Then it is placed in a mold and pressed into shape simultaneously with other raw materials, such as non-woven fabric and glass fiber surface mat, and the adhesive used. Alternatively, a wet production process (also known as the hot molding method) can be used to process the raw materials. Specifically, the polyurethane board 31 can first be fed, then glue is rolled, water is sprayed, and layers are stacked, and finally it is pressed into shape using a mold. The present invention can refer to the above description to adapt the selection of processing technology, but it does not mean that the present invention must choose the above method. The embodiments of the present invention are not limited here.

[0061] In some embodiments of the present invention, the thickness of the skeleton layer 3 is 2.5-6.0 mm, for example 2.5 mm, 2.8 mm, 3.0 mm, 3.2 mm, 3.5 mm, 3.8 mm, 4.0 mm, 4.2 mm, 4.5 mm, 4.8 mm, 5 mm, 5.2 mm, 5.5 mm, 5.8 mm, and 6.0 mm. However, the present invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable.

[0062] In some embodiments of the present invention, the width of the seam groove 301 is 2.5-3 times the thickness of the genuine leather fabric layer 1, such as 2.5 times, 2.6 times, 2.7 times, 2.8 times, 2.9 times, 3 times, etc. However, the present invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable.

[0063] The thickness of the sewn area 101, formed by splicing and sewing multiple pieces of genuine leather, is twice the thickness of the genuine leather fabric layer 1. When it is placed in the seam groove 301, the width of the seam groove 301 needs to accommodate all the fabric of the sewn area 101, that is, genuine leather fabric with a thickness of twice the thickness. At the same time, in order to avoid a certain deviation in the thickness of the genuine leather fabric layer 1, and in order to facilitate the placement of the sewn area 101 into the seam groove 301 during the preparation process, the width of the seam groove 301 is preferably 2.5-3 times the thickness of the genuine leather fabric layer 1. This design can ensure that the sewn area 101 and the seam groove 301 can fit tightly together, and the two have better adhesion, avoiding the problem of poor adhesion between the sewn area 101 and the skeleton layer 3, while also meeting the processing and preparation requirements.

[0064] In some embodiments of the present invention, the depth of the seam groove 301 is 1.5-2 times the width of the cut edge of the sewing area 101, for example, 1.5 times, 1.6 times, 1.7 times, 1.8 times, or 1.9 times. However, the present invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable.

[0065] Currently, after splicing and sewing multiple pieces of genuine leather fabric, the edges are generally trimmed to leave a certain width of trimmed edge. The depth of the seam groove 301 needs to accommodate the entire trimmed edge. Simultaneously, to prevent the seam thread from being exposed, this invention allows the seam thread to be placed within the seam groove 301 (e.g., Figure 2 This operation can also prevent the suture from breaking. Therefore, the present invention limits the depth of the suture groove 301 to 1.5-2 times the cutting edge width of the sewing area 101.

[0066] In some embodiments of the present invention, the stitch groove 301 is at least provided at the irregular surface of the skeleton layer 3, or provided at a position where the tensile deformation rate of the genuine leather fabric layer 1 exceeds 10-15%.

[0067] In some embodiments of the present invention, the skeleton layer 3 is provided with a sunroof hole, the stitching groove is provided at the seam where the leather covering the four rounded corners of the sunroof hole extends forward or backward to the seam with another piece of leather, and at the seam between the two pieces of leather corresponding to the area of ​​the sunroof hole and the B-pillar of the vehicle, and at the seam between the two pieces of leather corresponding to the area of ​​the headliner and the B-pillar.

[0068] In one specific embodiment of the present invention, a schematic diagram of a skeleton layer 3 with a surface provided with stitch grooves 301 is provided, as shown below. Figure 4 As shown:

[0069] Figure 4 This is one of the structural schematic diagrams of the skeleton layer 3 described in this invention, such as... Figure 4As shown, the frame layer 3 is provided with a sunroof to facilitate the subsequent installation of a vehicle sunroof. At the four rounded corners of the sunroof included in the frame layer 3, the surface is stretched greatly, which is prone to defects such as wrinkles and uneven surfaces of the genuine leather fabric. Therefore, the genuine leather fabric layer 1 can add a sewing area 101 for this purpose. In the frame layer 3, the areas where the four rounded corners extend forward or backward can be provided with corresponding seam grooves 301, that is, a seam groove 301 is provided at position a in the figure. The connection point between the sunroof opening and the vehicle's B-pillar, i.e., point b, is an irregularly shaped surface. If genuine leather is used to cover it, the tensile deformation rate at this point will be relatively large, and the genuine leather will easily wrinkle and not fit properly. Ultimately, this can easily lead to problems such as poor adhesion between the genuine leather layer 1 and the frame layer 3, and delamination. Therefore, a sewing area 101 can be added to the genuine leather layer 1 at this point, and a corresponding seam groove 301 can be set in the frame layer 3. At the same time, for ease of operation, a seam groove 301 can be added at point c, i.e., at the seam between the two pieces of genuine leather in the area corresponding to the roof and the B-pillar.

[0070] Figure 4 The skeleton layer 3 is divided into sections using different shades of color. Figure 4 As can be seen, the skeleton layer in the figure is divided into six parts, which can correspond to six pieces of genuine leather fabric. The six pieces of genuine leather fabric are spliced ​​and sewn together to form genuine leather fabric layer 1, and the sewing area 101 is located in the seam groove 301.

[0071] The genuine leather-covered headliner provided in this embodiment of the invention can not only avoid the defects of poor adhesion and cracking between the genuine leather fabric layer 1 and the skeleton layer 3, but also enhance the overall texture and feel of the vehicle when combined with other genuine leather-covered components. In addition, it can be covered with a variety of different genuine leather fabrics, increasing diversity.

[0072] This invention also provides a method for preparing the aforementioned leather-covered headliner, the method comprising the following steps:

[0073] (I) Multiple pieces of genuine leather fabric are spliced ​​and sewn together to obtain a genuine leather fabric layer;

[0074] (II) A seam groove is formed on the surface of the skeleton layer near the genuine leather fabric layer;

[0075] (III) The genuine leather fabric layer is adhered to the surface of the skeleton layer using an adhesive layer, wherein the sewing area of ​​the genuine leather fabric layer is set in the seam groove to obtain the genuine leather covered canopy.

[0076] In some embodiments of the present invention, in step (I), based on the tensile deformation rate of the genuine leather fabric layer, the area where the tensile deformation rate is greater than the maximum tensile deformation rate of the genuine leather fabric itself is cut to obtain the multiple pieces of genuine leather fabric.

[0077] The maximum tensile deformation rate that the genuine leather fabric itself can withstand is about 10-15%. Therefore, in step (I), the preparation method of the multiple sheets of genuine leather fabric includes: adhering the entire sheet of genuine leather fabric to the skeleton layer, analyzing the tensile force on the entire sheet of genuine leather fabric, and cutting at positions where the tensile deformation rate is greater than the maximum tensile deformation rate it can withstand (about 10-15%) to obtain the multiple sheets of genuine leather fabric. In application and production, a cutting template can also be directly designed based on the above method, and the template can be directly used for cutting and processing to obtain multiple sheets of genuine leather fabric, which are then spliced ​​and sewn together.

[0078] The maximum tensile deformation rate described in this invention is around 10-15%, for example, it can be 10.5%, 11%, 11.5%, 12%, 12.5%, 13%, 13.5%, 14%, 14.5%, etc., but this invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable.

[0079] In some embodiments of the present invention, the width of the seam groove is 2.5-3 times the thickness of the genuine leather fabric layer, such as 2.5 times, 2.6 times, 2.7 times, 2.8 times, 2.9 times, 3 times, etc. However, the present invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable. The depth is 1.5-2 times the width of the cut edge of the sewing area, such as 1.5 times, 1.6 times, 1.7 times, 1.8 times, 1.9 times, 2 times, etc. However, the present invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable.

[0080] In some embodiments of the present invention, the adhesion method includes hot pressing followed by cold pressing.

[0081] When bonding the dermal covering layer and the skeleton layer, this invention first uses hot pressing and then cold pressing to ensure the bonding strength between the dermal covering layer and the skeleton layer, and further avoids problems such as the dermal covering layer coming unglued after application.

[0082] In this invention, the adhesive layer is first activated by hot pressing. During the hot pressing process, the leather fabric layer and the skeleton layer are completely bonded together. Then, cold pressing is performed. Cold pressing can quickly cool the adhesive layer and complete the shaping of the leather-covered ceiling. The combination of hot pressing and cold pressing can effectively increase the bonding strength of the leather fabric layer to the skeleton layer.

[0083] In one specific embodiment of the present invention, such as Figure 5 As shown, the present invention provides a specific method for preparing the genuine leather-covered headliner as follows:

[0084] S1: Preparation of the dermal fabric layer

[0085] S11. Pattern making: Design the pattern of the genuine leather fabric layer according to the tensile deformation rate of the genuine leather fabric layer (the part with a tensile deformation rate greater than 10-15% (the maximum tensile deformation rate that the genuine leather itself can withstand) is cut).

[0086] S12. Cutting and sewing: The genuine leather fabric is cut using the pattern drawing. The cut genuine leather fabric is then stitched together according to the corresponding areas of the ceiling. The sewing process uses an edge-cutting technique. The edge width can be selected as 1.4-1.5 mm, such as 1.4 mm, 1.45 mm, or 1.5 mm. However, the present invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable.

[0087] S13. Spraying Adhesive: Apply adhesive to the sewn genuine leather fabric layer at a concentration of 140-180 g / m². 2 Apply adhesive by spraying, with an amount of adhesive of 140-180 g / m³. 2 It can be 140 g / m 2 145 g / m 2 150 g / m 2 155 g / m 2 160 g / m 2 165 g / m 2 170 g / m 2 175 g / m 2 180 g / m 2 However, the present invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable;

[0088] S14. Baking: The genuine leather fabric layer after spraying adhesive is placed in a circulating air oven for baking. The baking temperature is 55-65℃, such as 55℃, 56℃, 57℃, 58℃, 60℃, 62℃, 64℃, etc. However, the present invention is not limited to the listed values. Other unlisted values ​​within this range are also applicable. The time is 120 seconds to remove moisture from the adhesive.

[0089] S2: Preparation of the skeleton layer

[0090] S21. Pressing and forming: Following the conventional pressing process, add seam grooves to the sewing area corresponding to the genuine leather fabric layer to complete the forming of the skeleton layer;

[0091] S22. Spraying adhesive: Apply adhesive to the skeleton layer at a concentration of 140-180 g / m². 2 Apply adhesive by spraying, with an amount of adhesive of 140-180 g / m³. 2 It can be 140 g / m 2 145 g / m 2 150 g / m 2155 g / m 2 160 g / m 2 165 g / m 2 170 g / m 2 175g / m 2 180 g / m 2 However, the present invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable;

[0092] S23. Baking: The skeleton layer after spraying adhesive is placed in a circulating air oven for baking. The baking temperature is 55-65℃, such as 55℃, 56℃, 57℃, 58℃, 60℃, 62℃, 64℃, etc. However, the present invention is not limited to the listed values. Other unlisted values ​​within this range are also applicable. The baking time is 120 seconds to remove moisture from the adhesive.

[0093] S3: Overmolding

[0094] S31. Positioning: Position the baked skeleton layer and genuine leather fabric layer in the sewing area. Align the sewing area of ​​the genuine leather fabric layer with the seam groove of the skeleton layer. At the same time, use a positioning tool to fix it to ensure the straightness of the sewing and fix the skeleton layer to prevent it from moving.

[0095] S32. Hot / Cold Pressing: The mold is heated using a hot water unit to activate the adhesive on the leather fabric layer and the skeleton layer. The hot water unit temperature is 80-90℃, for example, 80℃, 81℃, 82℃, 83℃, 84℃, 85℃, 86℃, 87℃, 88℃, 89℃, 90℃, etc. However, this invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable. The pressing depth is 0.5 mm, and the holding time is 30 s. After holding the pressure, a cold pressing process is performed. The mold is then cooled using a chiller unit to rapidly cool the activated adhesive. The chiller temperature is 15-25℃, for example, 15℃, 16℃, 18℃, 19℃, 20℃, 22℃, 23℃, 25℃, etc. However, this invention is not limited to the listed values, and other unlisted values ​​within this range are also applicable. The pressing depth is 0.5 mm, and the holding time is 30 s. After holding the pressure, subsequent processing steps are performed.

[0096] S33. Edge and corner binding: Bind and bind the edges and corners of the obtained genuine leather-covered headliner, see inspection for acceptance.

[0097] It should be noted that the preparation of the dermal overcoat and the scaffold layer does not have a specific order and can be carried out according to the actual situation.

[0098] In some embodiments of the present invention, the peel strength between the dermal overlay and the skeleton layer is greater than 35 N / m.

[0099] The genuine leather-covered ceiling prepared by the preparation method provided in the embodiments of the present invention has high peel strength, that is, the genuine leather fabric layer and the skeleton layer are firmly bonded and not easy to delaminate.

[0100] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0101] The above description is merely a specific embodiment of the present invention, enabling those skilled in the art to understand or implement the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the present invention is not to be limited to the embodiments described herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A genuine leather-covered ceiling, characterized in that, The genuine leather-covered headliner includes a genuine leather fabric layer, an adhesive layer, and a skeleton layer. The genuine leather fabric layer is adhered to the surface of the skeleton layer through the adhesive layer, wherein: The genuine leather fabric layer is composed of multiple pieces of genuine leather fabric stitched together, and the surface of the skeleton layer is provided with a seam groove, with the stitching area of ​​the genuine leather fabric layer located in the seam groove. The width of the stitching groove is 2.5-3 times the thickness of the genuine leather fabric layer; The depth of the seam groove is 1.5-2 times the width of the cut edge of the sewing area; The seam groove is located at a position where the tensile deformation rate of the genuine leather fabric layer exceeds 10%.

2. The genuine leather-covered ceiling according to claim 1, characterized in that, The frame layer is provided with a sunroof opening. The stitching groove is provided at the seam where the leather covering the four rounded corners of the sunroof opening extends forward or backward to the seam with another piece of leather, as well as at the seam between the two pieces of leather corresponding to the area of ​​the sunroof opening and the B-pillar of the vehicle, and at the seam between the two pieces of leather corresponding to the area of ​​the headliner and the B-pillar.

3. The genuine leather-covered ceiling according to claim 1 or 2, characterized in that, The skeleton layer is integrally pressed and molded; And / or, the multiple sheets of genuine leather fabric are cut according to the tensile deformation rate of the genuine leather fabric layer; And / or, the adhesive layer is a water-soluble adhesive layer.

4. The genuine leather-covered ceiling according to claim 1 or 2, characterized in that, The skeleton layer is a polyurethane composite board layer, which includes a polyurethane board. Reinforcing fiberglass layers are provided on both sides of the polyurethane board. The reinforcing fiberglass layer includes a glass fiber surface felt layer and a non-woven fabric layer. The glass fiber surface felt layer is located between the non-woven fabric layer and the polyurethane board.

5. The genuine leather-covered ceiling according to claim 1 or 2, characterized in that, The thickness of the genuine leather fabric layer is 0.5-1.5 mm; And / or, the thickness of the adhesive layer is 0.1-0.15 mm; And / or, the thickness of the skeleton layer is 2.5-6.0 mm.

6. The method for preparing a genuine leather-covered headliner according to any one of claims 1-5, characterized in that, The preparation method includes the following steps: (I) Multiple pieces of genuine leather fabric are spliced ​​and sewn together to obtain a genuine leather fabric layer; (II) A seam groove is formed on the surface of the skeleton layer near the genuine leather fabric layer; (III) The genuine leather fabric layer is adhered to the surface of the skeleton layer using an adhesive layer, wherein the sewing area of ​​the genuine leather fabric layer is set in the seam groove to obtain the genuine leather covered canopy.

7. The preparation method according to claim 6, characterized in that, In step (I), based on the tensile deformation rate of the genuine leather fabric layer, the area where the tensile deformation rate is greater than the maximum tensile deformation rate of the genuine leather fabric itself is cut to obtain the multiple pieces of genuine leather fabric. And / or, the width of the stitch groove is 2.5-3 times the thickness of the genuine leather fabric layer, and the depth is 1.5-2 times the width of the cut edge of the sewing area; And / or, the adhesion method includes hot pressing followed by cold pressing.

8. A vehicle, characterized in that, The vehicle includes a genuine leather-covered headliner as described in any one of claims 1-5, or a genuine leather-covered headliner prepared by the preparation method described in claim 6 or 7.

Images