Interior trim panel, preparation method thereof and automobile

Abstract

The invention discloses an interior trimming panel, a preparation method thereof and an automobile, and belongs to the technical field of automobiles. When the interior trimming panel is prepared, the composite substrate, the heating sheet, the hot melt adhesive film and the facing layer are sequentially stacked to form a first structure. The composite substrate comprises a thermoplastic resin matrix and a fiber material compounded on the thermoplastic resin matrix, and heating the first structure to soften the thermoplastic resin matrix and the hot melt adhesive film. During pressing and compounding, the softened thermoplastic resin and the hot melt adhesive can be in full contact with the contact structure, and the stable interior trimming panel can be obtained after cooling and curing. The heating piece is arranged in the interior trimming panel, the temperature of the facing layer of the interior trimming panel can be stably increased through the heating effect of the heating piece, and then the problem of ice-cold feeling of the inner wall of an automobile cabin can be solved. By the adoption of the preparation method, the heatable interior panel can be formed at a time, and the production efficiency is improved.

Description

Technical Field

[0001] This application relates to the field of automotive technology, and more specifically, to an interior panel, a method for its preparation, and an automobile. Background Technology

[0002] With increasingly frequent international trade, some vehicle models are exported to frigid regions. The extremely low external temperatures in these regions typically necessitate more powerful air conditioning systems to improve passenger comfort. However, existing air conditioning systems lack the necessary capabilities to maintain a stable cabin temperature, resulting in a cold sensation for the driver when touching the interior sidewalls. Furthermore, high-powered air conditioning systems can increase fuel consumption.

[0003] Therefore, it is necessary to provide a heated interior panel that, by incorporating heating elements into the interior, can both ensure user comfort when touching it and reduce energy consumption. Summary of the Invention

[0004] In view of the above-mentioned shortcomings, this application provides an interior panel, a method for its preparation, and an automobile, which improves the problem of coldness in the interior walls of the automobile cabin by installing an interior panel with heating elements in the automobile cabin.

[0005] This application is implemented as follows: In a first aspect, an example of this application provides a method for preparing an interior trim panel, comprising: sequentially stacking a composite substrate, a heating element, a hot melt adhesive film, and a decorative layer to form a first structure, wherein the composite substrate comprises a thermoplastic resin matrix and a fibrous material composited thereon. The first structure is then heated to soften the thermoplastic resin matrix and the hot melt adhesive film, pressed and laminated, and cooled to obtain the interior trim panel.

[0006] In the above process, the first structure formed by stacking the composite substrate, heating element, hot melt adhesive film and decorative layer in sequence is heated to partially soften the thermoplastic resin in the composite substrate and the hot melt adhesive material in the hot melt adhesive film. When the first structure is pressed and laminated, the composite substrate can fully contact the heating element through the softened thermoplastic resin, and the decorative layer can fully contact the heating element through the softened hot melt adhesive film. After subsequent cooling, the softened thermoplastic resin and hot melt adhesive material can be cured in situ, thereby bonding the corresponding structures into a whole to obtain a stable interior panel.

[0007] Because a heating element is incorporated into the interior trim panel, when installed in the car cabin, the heating element can be connected to an external circuit. The heating effect of the element raises the temperature of the trim layer, thus mitigating the cold feeling of the car interior in cold regions and improving comfort. Furthermore, this embodiment uses a composite substrate made of fiber material and thermoplastic resin matrix as the support structure for the interior trim panel. This composite substrate not only possesses excellent mechanical properties but also boasts lightweight characteristics, ensuring the durability of the interior trim panel while better meeting the lightweight requirements of automobiles.

[0008] According to the preparation method provided in the embodiments of this application, the composite substrate, heating sheet, hot melt adhesive film and decorative layer are directly heated together until the thermoplastic resin matrix and hot melt adhesive film soften. The composite is pressed in one step, which not only reduces the thermal resistance between the heating sheet and the decorative layer and improves the heating performance, but also allows the interior panel of a set shape to be formed during the pressing and composite process, avoiding multiple molding and multiple adhesive application, thereby improving production efficiency and reducing production costs.

[0009] In conjunction with the first aspect, in an optional embodiment of this application, the heating element includes a graphene heating element.

[0010] Optionally, the graphene heating element includes at least one of aramid fabric graphene heating element or basalt fabric graphene heating element.

[0011] In the above implementation process, aramid fabric graphene heating sheets or basalt fabric graphene heating sheets are used as heating elements for interior panels. Graphene heating sheets have good heating effect, while aramid fabric and basalt fabric have good thermal conductivity, insulation properties, and corrosion resistance, as well as good flexibility. This can improve the heating efficiency, safety, and durability of the heating sheets, and also improve the tactile comfort of users when touching the interior panel trim layer.

[0012] In conjunction with the first aspect, in an optional embodiment of this application, the edge of the heating element is provided with a wiring solder joint, which protrudes beyond the circumferential edge of the composite substrate.

[0013] In the above implementation process, wiring solder joints are set on the edge of the heating element and extend beyond the circumferential edge of the composite substrate so that external circuits can be connected to the heating element through the wiring solder joints, thereby using the heating element to heat the interior panel.

[0014] In conjunction with the first aspect, in optional embodiments of this application, the fiber material includes at least one selected from bamboo fiber, hemp fiber, glass fiber, carbon fiber, and basalt fiber. And / or, the thermoplastic resin matrix material includes at least one selected from polyethylene, polypropylene, or thermoplastic polyurethane.

[0015] In the above-mentioned process, the thermoplastic resin and the fiber material are combined to form a composite substrate, which can improve the mechanical properties of the composite substrate and reduce its weight, thus better meeting the lightweight requirements of automobiles.

[0016] In conjunction with the first aspect, in optional embodiments of this application, the material used to prepare the hot melt adhesive film includes at least one of PP hot melt adhesive, PE hot melt adhesive, EVA hot melt adhesive, or APAO hot melt adhesive.

[0017] Optionally, the composite substrate comprises a thermoplastic polyurethane matrix and glass fiber composited with the thermoplastic polyurethane matrix. When the material for preparing the hot melt adhesive film includes PP hot melt adhesive, the first structure 10 can be heated to 150~200°C to soften the thermoplastic polyurethane and PP hot melt adhesive.

[0018] In the above implementation process, the hot melt adhesive film formed by the above-mentioned PP hot melt adhesive, PE hot melt adhesive, EVA hot melt adhesive or APAO hot melt adhesive is used to bond the heating sheet and the decorative layer, which can improve the structural stability of the interior panel.

[0019] In addition, by using glass fiber and thermoplastic polyurethane to form a composite substrate and using PP hot melt adhesive to prepare a hot melt adhesive film, the first structure can be heated to 150~200℃, so that the composite substrate and the hot melt adhesive film can be partially softened. After pressing and cooling the first structure, a stable heatable interior panel can be formed.

[0020] In conjunction with the first aspect, in an optional embodiment of this application, the first structure further includes a nonwoven fabric layer disposed between the heating element and the hot melt adhesive film.

[0021] In the above implementation process, a non-woven fabric layer is placed between the heating element and the hot melt adhesive film. The non-woven fabric has a certain porous structure, allowing the hot melt adhesive film to soften and fully contact the non-woven fabric, heating element, and decorative layer when the first structure is heated. This enables the heating element, non-woven fabric layer, and decorative layer to be bonded together after subsequent pressing, lamination, and cooling, resulting in a stable interior panel. Furthermore, the non-woven fabric layer between the heating element and the decorative layer can mask the color of the heating element, mitigating the impact of the heating element's dark color on the appearance of the interior panel.

[0022] In conjunction with the first aspect, in optional embodiments of this application, the thickness of the composite substrate is 4-8 mm. And / or, the thickness of the heating element is 0.3-0.7 mm. The thickness of the hot melt adhesive film is 0.1-0.3 mm. And / or, the finishing layer includes leather or fabric.

[0023] In the above implementation process, a composite substrate with a thickness of 4-8mm is used as the supporting structure for the interior trim panel, which can reduce the weight of the interior trim panel while maintaining good mechanical properties. Incorporating heating elements with a thickness of 0.3-0.7mm into the interior trim panel can ensure its heatability while minimizing the impact of the heating elements on the appearance or feel of the interior trim panel.

[0024] In conjunction with the first aspect, in an optional embodiment of this application, the compression bonding method includes: placing the heated first structure in a cold-press mold and applying pressure for bonding, wherein the molding pressure is 20~25 bar / m. 2 The molding time should be no less than 60 seconds.

[0025] In the above process, the first structure is placed in a cold-press mold and pressurized for composite bonding at 20~25 bar / m. 2 The molding pressure is applied for more than 60 seconds, which can stably bond the first structure into a whole and improve the durability of the interior panel.

[0026] In a second aspect, an example of this application provides an interior panel prepared according to the preparation method provided in the first aspect.

[0027] In the above-described process, the interior trim panel is prepared according to the preparation method provided in the first aspect. Heating elements can be introduced into the interior trim panel. When the interior trim panel is installed in the car cabin, the heating elements can be connected to an external circuit. The heating effect of the heating elements raises the temperature of the trim layer, thus improving the cold feeling of the car interior in cold regions. Furthermore, the embodiments of this application use a composite substrate made of fiber materials and thermoplastic resin as the supporting structure of the interior trim panel. This composite substrate not only has good mechanical properties but also is lightweight, meeting the lightweight requirements of automobiles.

[0028] In a third aspect, an example of this application provides an automobile, including a vehicle body, wherein at least a portion of the inner wall of the vehicle body compartment is connected to a composite substrate of the interior trim panel provided in the second aspect.

[0029] In the above implementation process, the interior panel provided in the second aspect of this application is disposed on at least a portion of the inner wall of the vehicle cavity. Since a heating element is provided in the interior panel, it can be heated to improve the coldness of the panel and enhance the user's tactile comfort. Furthermore, this application uses a composite substrate made of fiber material and thermoplastic resin as the support structure for the interior panel. This composite substrate not only possesses good mechanical properties to improve the durability of the interior panel but also has a lightweight characteristic to meet the lightweight requirements of automobiles. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below.

[0031] Figure 1 A process flow diagram for manufacturing interior panels provided in the embodiments of this application; Figure 2 This is a first schematic diagram of a first structure provided in an embodiment of this application; Figure 3 This is a second schematic diagram of the first structure provided in an embodiment of this application.

[0032] Icons: 1-Interior panel; 10-First structure; 101-Composite substrate; 102-Heating element; 103-Hot melt adhesive film; 104-Finishing layer; 105-Non-woven fabric layer. Detailed Implementation

[0033] The embodiments of this application will be described in detail below with reference to examples. However, those skilled in the art will understand that the following examples are for illustrative purposes only and should not be considered as limiting the scope of this application. Unless otherwise specified in the examples, conventional conditions or conditions recommended by the manufacturer shall apply. Reagents or instruments whose manufacturers are not specified are all commercially available conventional products.

[0034] With increasingly frequent international trade, some vehicle models are exported to frigid regions. The extremely low external temperatures in these regions necessitate more powerful air conditioning systems to ensure passenger comfort. However, existing air conditioning systems lack the necessary capabilities to maintain a stable cabin temperature, resulting in a cold sensation for the driver when touching the interior sidewalls. Furthermore, high-powered air conditioning systems also tend to lead to higher fuel consumption.

[0035] The inventors discovered that by using an integrated heated interior panel, which directly integrates the heating element into the vehicle's interior panel, a comfortable tactile experience can be provided to passengers.

[0036] Compared to using a high-power air conditioning system, the temperature of the integrated heated interior trim panel is more uniform, and the energy consumption of direct heating by the heating element is lower than that of the air conditioning system.

[0037] In addition, integrating heating elements into vehicle interior components has the following advantages: (1) It can achieve “seamless integration”: the heating element is embedded in the interior panel, which can maintain the original appearance design of the interior panel.

[0038] (2) It can "respond quickly": the heating element can heat the surface of the interior panel to the ideal temperature in a short time. Compared with the air conditioning system, the interior panel with integrated heating element heats up faster.

[0039] (3) Facilitates "zonal control": Multiple interior panels can be installed in different areas of the car cabin interior wall, and the heating elements in each interior panel can heat each other independently, thus enabling independent temperature control in different areas of the car cabin. Compared with the air conditioning system, the temperature control of interior panels with integrated heating elements is more precise.

[0040] Therefore, it is necessary to provide a heated interior panel that, by incorporating heating elements into the interior, can both ensure user comfort when touching it and reduce energy consumption.

[0041] To fabricate a heatable interior trim panel, the inventors attempted a post-processing method, using adhesive bonding or ultrasonic welding to attach heating elements to the back of the trim panel. However, they discovered that fixing the heating elements to the back of the trim panel resulted in more heat being blocked by the panel's substrate, leading to lower efficiency in heat transfer to the panel's surface.

[0042] To further improve heating efficiency and reduce energy consumption, the inventors further explored an embedded method: first, a substrate is molded, then a heating element is attached to the surface of the substrate, and finally, the fabric is attached. The inventors found that while this embedded method could improve heating performance, the production process was complex, the production cost was high, and the production efficiency was low.

[0043] Based on this, this application provides a method for preparing interior trim panels, which can produce heatable interior trim panels, improve the cold feeling of the interior walls of automobile cabins, and also simplify the preparation process and improve production efficiency. To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings.

[0044] Please see Figure 1 This application provides a method for preparing an interior panel 1, comprising: S1. The composite substrate 101, heating element 102, hot melt adhesive film 103 and decorative layer 104 are stacked sequentially to form a first structure 10. The composite substrate 101 includes a thermoplastic resin matrix and a fiber material composited with the thermoplastic resin matrix.

[0045] S2. The first structure 10 is heated to soften the thermoplastic resin matrix and hot melt adhesive film, then pressed and laminated, and cooled to obtain the interior panel 1.

[0046] A schematic diagram of the first structure 10 formed by sequentially stacking the composite substrate 101, heating element 102, hot melt adhesive film 103, and decorative layer 104 is shown below. Figure 2 .

[0047] The first structure 10, formed by sequentially stacking a composite substrate 101, a heating element 102, a hot melt adhesive film 103, and a decorative layer 104, is heated to partially soften the thermoplastic resin in the composite substrate 101 and the hot melt adhesive material in the hot melt adhesive film 103. Therefore, when the first structure 10 is pressed and laminated, the composite substrate 101 can fully contact the heating element 102 through the softened thermoplastic resin, and the decorative layer 104 can fully contact the heating element 102 through the softened hot melt adhesive film 103. After subsequent cooling, the softened thermoplastic resin and hot melt adhesive material can be cured in situ, thereby bonding the corresponding structures into a whole to obtain a stable interior panel 1.

[0048] Since the interior panel 1 is equipped with a heating element 102, when the interior panel 1 is installed in the car cabin, the heating element 102 can be connected to an external circuit. The heating effect of the heating element 102 can be used to increase the temperature of the trim layer 104, thus improving the cold feeling of the car interior in cold regions.

[0049] According to the preparation method provided in the embodiments of this application, the composite substrate 101, heating element 102, hot melt adhesive film 103, and decorative layer 104 are directly heated together and pressed into composite in a one-time molding process. This reduces the thermal resistance between the heating element 102 and the decorative layer 104, improving heating performance. Moreover, compared to pressing the substrate separately and then attaching the heating element 102 and decorative layer 104 separately, the one-time molding method used in this application avoids the problems of low production efficiency and high production costs caused by multiple molding and adhesive application processes.

[0050] In step S1, the present application embodiment uses a composite substrate 101 made of fiber material and thermoplastic resin matrix as the supporting structure of interior panel 1. The composite substrate 101 not only has good mechanical properties, but also has the characteristics of light weight, which can ensure the durability of interior panel 1 while better meeting the lightweight requirements of automobiles.

[0051] Thermoplastic resins are resin materials that soften when heated and harden when cooled. They do not undergo any chemical reaction during the softening and hardening process and can maintain this property even after repeated heating and cooling.

[0052] This application does not limit the specific material of the thermoplastic resin matrix in the composite substrate 101. In some embodiments, the material of the thermoplastic resin matrix includes at least one of polyethylene, polypropylene, or thermoplastic polyurethane.

[0053] Furthermore, in step S1, this application does not limit the specific type of fiber material in the composite substrate 101. In some embodiments, the fiber material includes at least one of bamboo fiber, hemp fiber, glass fiber, carbon fiber, and basalt fiber.

[0054] By combining the above-mentioned thermoplastic resin matrix with the above-mentioned fiber material to form a composite substrate 101, the mechanical properties of the composite substrate 101 can be improved and the weight of the composite substrate 101 can be reduced, thus better meeting the lightweight requirements of automobiles.

[0055] As an example, a composite substrate 101 can be formed by combining a thermoplastic polyurethane matrix with a fiber material.

[0056] As an example, a composite substrate 101 can be formed by combining glass fiber and thermoplastic polyurethane. By combining glass fiber and thermoplastic polyurethane to form the composite substrate 101, the composite substrate 101 can also have certain sound absorption and heat insulation properties.

[0057] As an example, a composite substrate 101 can be formed by combining hemp fiber and thermoplastic polyurethane. By combining hemp fiber and thermoplastic polyurethane to form the composite substrate 101, not only can the composite substrate 101 have certain sound absorption and heat insulation properties, but it can also make the composite substrate 101 more green and environmentally friendly.

[0058] Furthermore, this application does not limit the specific form of the fiber material. In some embodiments, the above-mentioned fiber material can be woven into a fiber web, fiber felt, or fiberboard.

[0059] As an example, thermoplastic polyurethane can be heated to a molten state and mixed with glass fiber in a mold, and then cured under pressure to form a composite substrate 101.

[0060] As an example, thermoplastic polyurethane foam material can be sprayed onto hemp fiber felt and then foamed and cured to form a composite substrate 101.

[0061] As an example, a composite substrate 101 with a prepreg sheet structure consisting of glass fiber mat as a reinforcing skeleton and polypropylene as a matrix can be fabricated using the GMT (Glass Mat Reinforced Thermoplastics) process.

[0062] Furthermore, the embodiments of this application do not limit the mass ratio of thermoplastic resin and fiber material in composite substrate 101. In some embodiments, the mass ratio of thermoplastic resin in composite substrate 101 can be 40% to 50%, and the mass ratio of fiber material in composite substrate 101 can be 50% to 60%.

[0063] Furthermore, the embodiments of this application do not limit the specific thickness of the composite substrate 101. In some embodiments, the thickness of the composite substrate 101 can be 4~8mm.

[0064] As an example, the thickness of the composite substrate 101 can be one or more of 4 mm, 4.5 mm, 5 mm, 5.5 mm, 6 mm, 6.5 mm, 7 mm, 7.5 mm or 8 mm, or any combination thereof.

[0065] As an example, the thickness of the composite substrate 101 can be 4.5~7.9 mm. As an example, the thickness of the composite substrate 101 can be 5.8~6.8 mm; as an example, the thickness of the composite substrate 101 can be 6.6~7.4 mm.

[0066] Furthermore, this application does not limit the specific shape of the composite substrate 101, and it can be adjusted accordingly according to the needs of the vehicle compartment. As an example, corresponding windows, positioning holes, or mounting hole structures can be formed in the composite substrate 101. The composite substrate 101 can be a flat structure, and can be shaped into a shape corresponding to the vehicle compartment during subsequent pressing and lamination, such as a shape with a certain curvature.

[0067] In step S2, the heating element 102 is stacked on the composite substrate 101 so that the heating element 102 and the composite substrate 101 can be bonded and fixed together during the subsequent composite pressing.

[0068] This application does not limit the specific type of heating element 102. In some embodiments, the heating element 102 includes a graphene heating element 102. A graphene heating element 102 refers to a heating element 102 that uses graphene as a heating element.

[0069] As an example, the graphene heating element 102 includes at least one of aramid fabric graphene heating element 102 or basalt fabric graphene heating element 102.

[0070] Aramid fabric graphene heating element 102 refers to a heating element with aramid fabric as the base material and its surface coated or composited with graphene material. Similarly, basalt fabric graphene heating element refers to a heating element with basalt fabric as the base material and its surface coated or composited with graphene material. Aramid fabric graphene heating elements and basalt graphene heating elements are also available for purchase.

[0071] Using aramid fabric graphene heating elements 102 or basalt fabric graphene heating elements 102 as the heating element of the interior panel 1, graphene has excellent heating performance, while aramid fabric and basalt fabric have excellent thermal conductivity, insulation properties, and corrosion resistance, which can improve the heating efficiency, safety, and durability of the heating elements 102. If resistance wire heating elements or the like are used as the heating element of the interior panel 1, a foreign object sensation may easily occur when the user touches the surface layer 104 of the interior panel 1, which will affect the user's touch comfort.

[0072] Furthermore, the embodiments of this application do not limit the specific thickness of the heating element 102. In some embodiments, the thickness of the heating element 102 can be 0.3~0.7mm.

[0073] As an example, the thickness of the heating element 102 can be one of 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm or 0.7 mm or any combination thereof.

[0074] Furthermore, the embodiments of this application do not limit the specific shape of the heating element 102, but make corresponding adjustments according to the shape of the composite substrate 101.

[0075] In some embodiments, when the composite substrate 101 has a window, positioning hole or mounting hole, the heating element 102 can be provided with a corresponding window or hole structure at the position corresponding to the window, positioning hole or mounting hole of the composite substrate 101.

[0076] By providing a window or hole structure corresponding to the composite substrate 101 at the corresponding position of the heating element 102, the heating element 102 can be prevented from being exposed at the window or hole structure of the composite substrate 101, thereby improving the safety of the interior panel 1.

[0077] This application is not intended to limit the heating element 102 to fully covering the composite substrate 101. In some embodiments, the heating element 102 covers a portion of the surface of the composite substrate 101.

[0078] Furthermore, wiring solder joints can be provided on the edge of the heating element. When the heating element is stacked on the composite substrate 101, the wiring solder joints protrude from the circumferential edge of the composite substrate 101 so that they can be connected to external circuits after composite pressing.

[0079] In step S1, a hot melt adhesive film 103 is laid on the surface of the heating element 102. The hot melt adhesive film 103 can soften partially after being heated to a certain temperature. After subsequent pressing, lamination and cooling, the hot melt adhesive film 103 can be used to bond the heating element 102 and the decorative layer 104 together.

[0080] This application does not limit the specific material of the hot melt adhesive film 103. In some embodiments, the material used to prepare the hot melt adhesive film 103 includes at least one of PP hot melt adhesive, PE hot melt adhesive, EVA hot melt adhesive or APAO hot melt adhesive.

[0081] By using the hot melt adhesive film 103 formed by the above-mentioned PP hot melt adhesive, PE hot melt adhesive, EVA hot melt adhesive or APAO hot melt adhesive to bond the heating sheet 102 and the decorative layer 104, the structural stability of the interior panel 1 can be improved.

[0082] As an example, PP hot melt adhesive film 103 can be used. Alternatively, PE hot melt adhesive film 103 can be used.

[0083] Furthermore, this application does not limit the specific thickness of the hot melt adhesive film 103. In some embodiments, the thickness of the hot melt adhesive film 103 can be 0.1~0.3mm. As an example, the thickness of the hot melt adhesive film 103 can be 0.1mm.

[0084] Furthermore, the shape of the hot melt adhesive film 103 can be adjusted according to the shape of the composite substrate 101 to bond the heating element 102 and the decorative layer 104 together. It is understood that when the size of the heating element 102 is smaller than the size of the composite substrate 101, the portion of the hot melt adhesive film 103 outside the heating element 102 is also used to bond the composite substrate 101 and the decorative layer 104.

[0085] The finishing layer 104 is used to form the surface of the interior panel 1. It is understood that the finishing layer 104 needs to completely cover the heating element or composite substrate 101 located underneath it.

[0086] This application does not limit the specific type of the trim layer 104, and it can be adjusted accordingly based on the needs of the vehicle cabin. In some embodiments, the trim layer 104 may be formed of leather or fabric.

[0087] Furthermore, in order to improve the influence of the color of the heating element 102 on the color of the finishing layer 104, in some embodiments, a non-woven fabric layer 105 may be provided between the heating element 102 and the hot melt adhesive film 103.

[0088] A non-woven fabric layer 105 is disposed between the heating element 102 and the hot melt adhesive film 103. The non-woven fabric has a certain porous structure. When the first structure 10 is heated, the hot melt adhesive film 103 softens and can bond with the non-woven fabric, the heating element 102, and the decorative layer 104. Subsequently, after pressing, laminating, and cooling, the heating element 102, the non-woven fabric layer 105, and the decorative layer 104 can be bonded together to obtain a stable interior panel 1. Furthermore, the non-woven fabric layer 105 disposed between the heating element 102 and the decorative layer 104 can mask the color of the heating element 102, improving the impact of the excessively dark color of the heating element 102 on the appearance color of the interior panel 1.

[0089] A schematic diagram of the first structure 10 formed by sequentially stacking composite substrate 101, heating element 102, non-woven fabric layer 105, hot melt adhesive film 103, and decorative layer 104 is shown below. Figure 3 .

[0090] In step S2, it is understood that softening refers to the ability of the corresponding polymer to soften and deform, not that melting it into a liquid state allows the first structure to be heated to the softening temperature of the corresponding polymer material, thereby softening the thermoplastic resin matrix and hot melt adhesive film. Softening temperature refers to the temperature at which an amorphous polymer (including plastics, rubber, fibers, etc.) transitions from a highly elastic state to a viscous flow state. The softening temperature is typically a range determined by the polymer material itself. For example, to soften polypropylene, it can be heated to its softening temperature of 130-160°C.

[0091] The first structure 10, after being stacked, is heated so that the thermoplastic resin in the composite substrate 101 and the hot melt adhesive material in the hot melt adhesive film 103 can be partially softened. Therefore, when the first structure 10 is pressed and laminated, the composite substrate 101 can fully contact the heating element 102 through the softened thermoplastic resin, and the decorative layer 104 can fully contact the heating element 102 through the softened hot melt adhesive film 103. After subsequent cooling, the softened thermoplastic resin and hot melt adhesive material can be cured to bond the corresponding structures into a whole, thereby obtaining a stable interior panel 1.

[0092] As an example, when the composite substrate 101 contains glass fiber and thermoplastic polyurethane composited with the glass fiber, and the material for preparing the hot melt adhesive film 103 includes PP hot melt adhesive, the first structure 10 can be heated to 150~200°C.

[0093] Furthermore, this application does not limit how the first structure 10 is pressed and laminated. In some embodiments, the heated first structure 10 can be placed in a cold press mold and pressed and laminated. The molding pressure is 10~15MPa and the molding time is not less than 60s.

[0094] As an example, the cooling method for cold-pressed molds can be water cooling.

[0095] As an example, the first structure 10 can be pressed into a specific shape using a cold-pressing mold to meet the shape requirements of an automotive cavity. Using a cold-pressing mold for one-time molding allows for the composite of various structural layers and also enables the molding of corresponding shapes as needed, simplifying the process.

[0096] As an example, the molding pressure can be 20~25 bar / m. 2 As an example, the molding pressure can be 23 bar / m. 2 .

[0097] As an example, the molding time can be around 60 seconds.

[0098] Secondly, embodiments of this application provide an interior trim panel 1 prepared according to the above method. The interior trim panel 1 prepared according to the above method has a heating element 102. When the interior trim panel 1 is installed in the car cabin, the heating element 102 can be connected to an external circuit. The heating effect of the heating element 102 increases the temperature of the trim layer 104, thus improving the cold feeling of the car interior in cold regions. Furthermore, embodiments of this application use a composite substrate 101 made of fiber material and thermoplastic resin matrix as the supporting structure of the interior trim panel 1. This composite substrate 101 not only has good mechanical properties but also is lightweight, meeting the lightweight requirements of automobiles.

[0099] The interior panel 1 provided in this application embodiment can be provided with corresponding window or hole structures as needed, and the first structure 10 can be pressed and composited into the required shape of the interior panel 1 as needed, such as a plate-like structure with an arc shape corresponding to the side wall of the car cabin.

[0100] In a third aspect, embodiments of this application provide an automobile, including a vehicle body. At least a portion of the inner wall of the vehicle body compartment is connected to the composite substrate 101 of the interior trim panel 1 provided in the second aspect. This application does not limit how the composite substrate 101 of the interior trim panel 1 is connected to the inner wall of the vehicle body compartment. In some embodiments, it can be bonded by an adhesive, fixed by fasteners such as screws, or snapped together by an interference fit.

[0101] As an example, the interior panel 1 provided in this application embodiment can be fixedly installed on the side walls of the front and rear compartments of the vehicle body.

[0102] The interior panel 1 of this application will be further described in detail below with reference to the embodiments.

[0103] Example 1 Example 1 provides an interior trim panel, the preparation method of which is as follows: (1) The composite substrate, heating element, hot melt adhesive film, and decorative layer are stacked sequentially to form the first structure. The composite substrate is a composite material of glass fiber and thermoplastic polyurethane (glass fiber reinforced thermoplastic polypropylene sheet) with a thickness of 6 mm. The heating element is an aramid fabric graphene heating element, purchased from Jiangsu Junyuan New Material Co., Ltd. (carbon fiber heating element (flexible) TY-LVH-600RS5-H), with a thickness of 0.4 mm. The hot melt adhesive film is a PP hot melt adhesive film, purchased from Jiangsu Sibote Textile Co., Ltd., with a thickness of 0.1 mm. The decorative layer is a printed nonwoven fabric, purchased from Jiangsu Kuangda, with a thickness of 1 mm.

[0104] (2) The first structure is heated to 220±5℃ for 180s, placed in a water-cooled mold, pressed and laminated, and cooled to obtain the interior panel; the molding pressure is 23 bar / m2 The molding time is approximately 60 seconds.

[0105] The interior panel provided in Example 1 was subjected to a heating test: at room temperature, the wiring solder joints of the heating element were connected to the external circuit, and the surface temperature of the trim layer was measured. The test showed that the surface temperature of the trim layer was higher than the room temperature, indicating that the interior panel provided in this example is a heatable interior panel.

[0106] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A method for preparing an interior trim panel, characterized in that, include: A first structure is formed by sequentially stacking a composite substrate, a heating element, a hot melt adhesive film, and a decorative layer; wherein, the composite substrate comprises a thermoplastic resin matrix and a fiber material composited with the thermoplastic resin matrix; The first structure is heated to soften the thermoplastic resin matrix and the hot melt adhesive film, then pressed and laminated, and cooled to obtain the interior panel.

2. The preparation method according to claim 1, characterized in that, The heating element includes a graphene heating element; Optionally, the graphene heating element includes at least one of aramid fabric graphene heating element or basalt fabric graphene heating element.

3. The preparation method according to claim 2, characterized in that, The heating element has a wiring solder joint on its edge, which protrudes beyond the circumferential edge of the composite substrate.

4. The preparation method according to claim 1, characterized in that, The fiber material includes at least one of bamboo fiber, hemp fiber, glass fiber, carbon fiber, and basalt fiber; and / or, the thermoplastic resin matrix is ​​made of at least one of polyethylene, polypropylene, or thermoplastic polyurethane.

5. The preparation method according to claim 1, characterized in that, The materials used to prepare the hot melt adhesive film include at least one of PP hot melt adhesive, PE hot melt adhesive, EVA hot melt adhesive, or APAO hot melt adhesive; Optionally, the composite substrate comprises a thermoplastic polyurethane matrix and glass fiber composited with the thermoplastic polyurethane matrix; the material for preparing the hot melt adhesive film includes PP hot melt adhesive; the first structure is heated to 150~200°C to soften the thermoplastic polyurethane matrix and the PP hot melt adhesive.

6. The preparation method according to claim 1, characterized in that, The first structure further includes a nonwoven fabric layer disposed between the heating element and the hot melt adhesive film.

7. The preparation method according to any one of claims 1 to 6, characterized in that, The thickness of the composite substrate is 4-8 mm; and / or the thickness of the heating element is 0.3-0.7 mm; and / or the thickness of the hot melt adhesive film is 0.1-0.3 mm; and / or the finishing layer includes leather or fabric.

8. The preparation method according to claim 7, characterized in that, The compression composite method includes: The heated first structure is placed in a cold press mold and pressure is applied for composite molding at a pressure of 20~25 bar / m. 2 The molding time should be no less than 60 seconds.

9. An interior panel prepared by the method according to any one of claims 1 to 8.

10. A car, characterized in that, The vehicle includes a vehicle body, wherein at least a portion of the inner wall of the vehicle body's compartment is connected to the composite substrate of the interior panel of claim 9.

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