An automobile interior part instead of real wood and a paint spraying process thereof

Abstract

This invention belongs to the field of automotive interior parts technology, and particularly relates to an automotive interior part that can replace real wood. It includes a substrate, a primer layer, a color coat layer, and a topcoat layer. The substrate, primer layer, color coat layer, and topcoat layer are arranged sequentially from bottom to top, and the primer layer, color coat layer, and topcoat layer cover the entire surface of the substrate. The substrate surface is flat, and recessed wood grain textures are provided on the flat surface. The primer layer and topcoat layer have uniform thickness on the substrate. The color coat layer is thicker at the wood grain texture areas than at the flat areas. The color of the color coat layer at the wood grain texture areas and edges of the substrate gradually lightens from the center to the outer perimeter. This invention, through a spraying process involving substrate pretreatment, primer spraying and texture curing, base color spraying, staining, topcoat spraying, polishing, and final inspection, accurately reproduces the three-dimensional texture, vascular bundle recesses, natural color differences, and growth ring layers of natural solid wood.

Description

Technical Field

[0001] This invention belongs to the field of automotive interior parts technology, and particularly relates to an automotive interior part that can replace real wood and its painting process. Background Technology

[0002] Existing real wood-effect automotive interior trims have several drawbacks. First, real wood and its processing costs are high, generally limiting their application to high-end automotive interiors. Second, the processing of real wood is complex and has low production efficiency. Furthermore, real wood interior trim products are unstable, prone to problems such as moisture absorption and expansion, shrinkage, cracking, deformation, mold, and insect infestation. Moreover, real wood interior trims are not environmentally friendly or lightweight enough. Summary of the Invention

[0003] To address the aforementioned problems in the existing technology, this invention provides an automotive interior trim component that can replace real wood. By rationally arranging the components on a substrate and then applying a primer layer, a color paint layer, and a topcoat layer, a decorative effect with a sense of layering and three-dimensionality is achieved.

[0004] To achieve the above objectives, the present invention provides an automotive interior trim component that can replace real wood, comprising a substrate, a primer layer, a color paint layer, and a topcoat layer. The substrate, primer layer, color paint layer, and topcoat layer are arranged sequentially from bottom to top, and the primer layer, color paint layer, and topcoat layer cover the entire surface of the substrate. The substrate surface is flat, and the flat surface is provided with recessed wood grain textures. The primer layer and topcoat layer have uniform thickness on the substrate. The thickness of the color paint layer at the wood grain texture on the substrate is thicker than that at the flat surface. The color of the color paint layer at the wood grain texture and the edge of the substrate gradually lightens from the center to the outer perimeter.

[0005] Furthermore, the primer layer has a recessed roller texture, or a skeleton paint layer is sprayed between the primer layer and the color paint layer, and the skeleton paint layer has a wood grain texture.

[0006] Furthermore, the substrate material is ABS / PC plastic or PC and PMMA composite material or glass fiber reinforced composite material, the primer layer material is two-component polyurethane primer or UV primer, the color paint layer material is a semi-transparent gloss stain containing slow-drying solvent, and the topcoat layer material is a high-solids two-component varnish or UV-cured varnish.

[0007] On the other hand, a painting process for automotive interior parts that replaces real wood is provided, applicable to any of the above-mentioned automotive interior parts that replace real wood, including the following steps: Step 1: Substrate Pretreatment The substrate surface is cleaned using plasma treatment or alcohol wiping to remove mold release agent and oil stains. The substrate is usually ABS / PC plastic, PC and PMMA composite material, or glass fiber reinforced composite material. Step 2: Primer application and texture curing (1) Primer spraying: Select two-component polyurethane primer or UV primer, and spray the primer layer on the substrate surface in a dust-free spraying room; (2) Texture curing: If the substrate surface is flat, roll the texture when the primer is half dry or spray a layer of skeleton paint with a three-dimensional texture and a wood grain texture on the primer. The skeleton paint contains imitation wood conduits. (3) Drying: Dry after leveling. If the primer layer uses a UV primer material, it needs to be cured with ultraviolet light. Step 3: Base coat spraying Choose a translucent gloss stain containing a slow-drying solvent according to the wood species, and apply the stain thinly to the substrate surface with a wool brush or spray gun. Step 4: Apply color (1) Staining: In an environment with sufficient temperature, humidity and light that is compatible with the staining agent, use a lint-free cotton cloth or non-woven cloth to first rub the flat surface vigorously to leave a thin layer of staining agent and leave a thick layer of staining agent in the recessed texture to form clear wood grain lines. Then, lightly rub the edges or corners to retain more color and form an antique "black edge" effect. Next, use a clean soft cloth to pat or lightly sweep the color left in the recessed texture and edges or corners to create a natural transition of color from dark to light, imitating the natural gradation of wood. Finally, let it dry naturally to form a colored paint layer. (2) Inspection: Compare with the standard color chart to confirm the clarity and contrast of the texture; Step 5: Topcoat Spraying Choose a high-solids two-component varnish or a UV-curable varnish to spray onto the substrate surface, level it, and then dry it. If a UV-curable varnish is used, it needs to be cured under ultraviolet light to finally form a topcoat layer. Step Six: Polishing and Final Inspection (1) Polishing: The topcoat layer is polished mechanically or manually to remove orange peel and achieve a mirror effect or specified gloss. (2) Final inspection: Check for whitening, graininess, color difference, and perform a full inspection of the texture effect.

[0008] Compared with the prior art, the beneficial effects of the present invention are: 1. The spraying process of this invention uses a three-layer structure of "base color application + manual color rubbing + topcoat protection". Combined with meticulous operations such as manual rubbing and local touch-up, it can accurately restore the three-dimensional texture, pore depth, natural color difference, and growth ring layers of natural solid wood. It can also create distressed, retro and other textures according to needs. Whether it is the visual wood grain texture, light and shadow changes or the warm and textured feel, it is highly consistent with precious solid woods such as walnut, maple and oak. It is difficult to distinguish with the naked eye. It can perfectly replace real wood trim, enhance the luxury and class of car interiors, and meet consumers' demand for natural solid wood interiors. 2. In terms of cost, this invention uses low-cost substrates such as ordinary plastics and metals, without the need for expensive natural solid wood materials. Moreover, the processing steps only require four core processes: pretreatment, base color spraying, manual rubbing, and topcoat spraying. There is no need for complex cutting, insect prevention, and anti-corrosion treatments. The material cost and processing cost are far lower than those of real wood ornaments. Compared with high-end water transfer printing and in-mold decoration processes, rubbing does not require special molds and printing films, resulting in low modification costs and short cycles, further reducing production costs. 3. In terms of efficiency, this invention has a simple process, controllable production rhythm, low rework rate, and high yield. It can flexibly switch between mass production and small-batch customization, taking into account both production efficiency and product quality, and greatly improving the production efficiency of enterprises. 4. The real wood effect car trim produced by this invention has more stable quality. Combining the sealing effect of the base color layer and the protective effect of the topcoat layer, it can effectively isolate the influence of external factors such as moisture, air, and chemicals, avoiding common problems of real wood trim such as moisture absorption and expansion, shrinkage, cracking, deformation, mold, and insect infestation. The topcoat layer has excellent wear resistance and scratch resistance, good weather resistance and UV resistance. The paint layer is tightly bonded to the base color layer and the substrate, and is not easy to peel off or flake. The service life can reach 8-10 years, far exceeding that of real wood and water transfer printing process trim, reducing the later maintenance costs for consumers. 5. The spray painting process of this invention breaks through the design limitations of traditional real wood, transfer printing, and in-mold decoration processes, and has a very high degree of design freedom; 6. This invention can effectively reduce the exploitation of precious forest resources and protect the ecological environment. Moreover, the staining agent and topcoat used are low-VOC formulas that meet national environmental protection standards, reducing pollution to the environment during the production process and reducing the impact on the health of production workers and consumers. At the same time, the base material used in this invention is lighter than real wood, which can reduce the weight of automotive interior parts by more than 50%, significantly reducing the overall weight of the car. Attached Figure Description

[0009] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a flowchart of the painting process of the present invention. Detailed Implementation

[0010] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0011] like Figure 1As shown, the present invention provides the following technical solution: an automotive interior part that replaces real wood, comprising a substrate 1, a primer layer 2, a color paint layer 3, and a topcoat layer 4. The substrate 1 needs to be pre-treated to remove release agent and oil stains to ensure the adhesion of subsequent coatings. The substrate 1, primer layer 2, color paint layer 3, and topcoat layer 4 are arranged sequentially from bottom to top and cover the entire surface of the substrate 1. The surface of the substrate 1 is flat and has recessed wood grain texture 5. The primer layer 2 and topcoat layer 4 have uniform thickness on the substrate 1. The thickness of the color paint layer 3 at the wood grain texture 5 on the substrate 1 is thicker than that at the flat surface. This can both preserve the base color of the wood and highlight the wood grain with a darker color at the wood grain texture 5. The color of the color paint layer 3 at the wood grain texture 5 and the edge of the substrate 1 gradually becomes lighter from the center to the outer perimeter, which creates a natural transition from dark to light color, imitating the natural gradation of wood. This invention accurately reproduces the three-dimensional texture, pore depth, natural color difference, and growth ring layers of natural solid wood. It can also create distressed, retro, and other textures according to needs. Whether it is the visual wood grain texture, light and shadow changes, or the warm and textured feel, it is highly consistent with precious solid woods such as walnut, maple, and oak, and is difficult to distinguish with the naked eye. It can perfectly replace real wood trim, enhance the luxury and class of car interiors, meet consumers' demand for natural solid wood interiors, and avoid many of the drawbacks of real wood. In this invention, the sealing effect of the primer layer 2 and the protective effect of the topcoat layer 4 are combined to effectively isolate the influence of external factors such as moisture, air, and chemicals, and avoid common problems of moisture absorption and expansion, shrinkage, cracking, deformation, mold and insect infestation in real wood trim. It can adapt to the temperature and humidity changes of the car interior and has excellent dimensional stability. This invention replaces natural solid wood ornaments, reducing the exploitation of precious forest resources; Compared to natural solid wood trim, this invention can reduce the weight by more than 50%, significantly reducing the overall weight of the car.

[0012] Specifically, if the mold itself does not have a wood grain design, resulting in no recessed wood grain texture 5 on the substrate 1 after injection molding, then a recessed rolling texture is set on the primer layer 2, or a skeleton paint layer is sprayed between the primer layer 2 and the color paint layer 3. The skeleton paint layer has a recessed wood grain texture, thus creating a texture effect.

[0013] Specifically, the substrate 1 is made of ABS / PC plastic, PC and PMMA composite material, or glass fiber reinforced composite material. The substrate 1 has the advantage of being lightweight. The primer layer 2 is made of two-component polyurethane primer or UV primer. The color paint layer 3 is made of semi-transparent gloss varnish containing slow-drying solvent. The topcoat layer 4 is made of high-solids two-component clear varnish or UV-cured clear varnish. The topcoat layer 4 has high hardness and excellent wear resistance and scratch resistance, which can resist friction and minor scratches in daily use. Moreover, the topcoat layer 4 has good weather resistance and UV resistance, which prevents color fading and aging caused by direct sunlight. It is also resistant to corrosion from sweat, alcohol, car cleaners and other chemicals, does not easily yellow, and has strong adhesion. The color paint layer 3 is tightly bonded to the primer layer 2 and the substrate 1, making it less prone to peeling and flaking. Its service life can reach 8-10 years, far exceeding that of decorative parts made of real wood, water transfer printing and other processes, thus reducing the later maintenance costs for consumers. The materials used in the color paint layer 3 and the topcoat layer 4 are all low-VOC formulas that meet national environmental protection standards, reducing environmental pollution during the production process and minimizing the health impact on production workers and consumers.

[0014] like Figure 2 As shown, a painting process for automotive interior parts that replace real wood, applicable to any of the aforementioned automotive interior parts that replace real wood, includes the following steps: Step 1: Pretreatment of Substrate 1 Clean the surface of substrate 1 using plasma treatment or alcohol wiping to remove mold release agent and oil stains. The substrate is usually ABS / PC plastic, PC and PMMA composite material, or glass fiber reinforced composite material. Step 2: Primer application and texture curing (1) Primer spraying: Select a two-component polyurethane primer or UV primer, and spray primer layer 2 on the surface of substrate 1 in a dust-free spraying room; (2) Texture curing: If the surface of the substrate 1 is flat, roll the texture when the primer layer 2 is half dry, or spray a layer of skeleton paint with a three-dimensional texture and a wood grain texture on the primer layer 2. The skeleton paint contains imitation wood conduits. (3) Drying: After leveling, dry. If the primer layer 2 uses a UV primer material, it needs to be cured with ultraviolet light. Step 3: Base coat spraying Select a translucent gloss stain containing a slow-drying solvent according to the wood species, and apply the stain thinly to the surface of substrate 1 with a wool brush or spray gun. Step 4: Apply color (1) Staining: In an environment with sufficient temperature, humidity and light that is compatible with the staining agent, use a lint-free cotton cloth or non-woven cloth to first rub the flat surface vigorously to leave a thin layer of staining agent and leave a thick layer of staining agent in the recessed texture to form clear wood grain lines. Then, lightly rub the edges or corners to retain more color and form an antique "black edge" effect. Then, use a clean soft cloth to pat or lightly sweep the recessed texture and the color left on the edges or corners to create a natural transition of color from dark to light, imitating the natural gradation of wood. Finally, let it dry naturally to form a color paint layer 3. (2) Inspection: Compare with the standard color chart to confirm the clarity and contrast of the texture; Step 5: Topcoat Spraying Select a high-solids two-component varnish or a UV-curable varnish to spray onto the surface of substrate 1, level it, and then dry it. If a UV-curable varnish is used, it needs to be cured under ultraviolet light to finally form the topcoat layer 4. Step Six: Polishing and Final Inspection (1) Polishing: The topcoat layer 4 is polished mechanically or manually to remove orange peel and achieve a mirror effect or specified gloss. (2) Final inspection: Check for whitening, graininess, color difference, and perform a full inspection of the texture effect.

[0015] The purpose of pretreating the substrate 1 in this invention is to ensure the adhesion of the subsequent coating. The gloss rub is an oil-based or water-based paste or liquid colorant containing a slow-drying solvent, which provides sufficient time for manual operation. The color is usually dark brown, black, or reddish-brown.

[0016] In terms of cost, this invention uses low-cost substrates such as ordinary plastics and metals, eliminating the need for expensive natural solid wood materials. The processing involves only four core steps: pretreatment, base coat spraying, manual staining, and topcoat spraying. It eliminates the need for complex cutting, insect-proofing, and anti-corrosion treatments. Both material and processing costs are significantly lower than those of genuine wood veneers. Compared to high-end water transfer printing and in-mold decoration processes, staining does not require special molds or printing films, resulting in low modification costs and short cycles, further reducing production costs. In terms of efficiency, the invention features simple processes, controllable production rhythm, low rework rate, and high yield. It allows for flexible switching between mass production and small-batch customization, balancing production efficiency and product quality, and significantly improving enterprise production efficiency.

[0017] This invention's spraying process breaks through the design limitations of traditional real wood, transfer printing, and in-mold decoration processes, offering extremely high design freedom. Regarding texture and color, it can simulate the texture of any wood species (walnut, maple, oak, etc.) according to the needs of automotive interior design, adjusting color depth and contrast. It can also achieve personalized effects such as distressing, gradients, and mix-and-match, adapting to different interior styles such as luxury, sporty, and retro. In terms of gloss, different gloss levels such as gloss, semi-gloss, and matte can be selected to match the overall texture of the interior. Regarding adaptability, the rubbing process uses manual rubbing, allowing for precise application to complex curved surfaces, irregularly shaped parts, blind holes, ribs, and other difficult-to-process areas. It avoids the misalignment and wrinkling problems of transfer printing and is not limited by the molds of in-mold decoration processes. It can meet the decoration needs of various automotive interior components (instrument panels, center consoles, steering wheels, door panel trims, etc.), providing more possibilities for interior design.

[0018] Finally, it should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A type of automotive interior trim that replaces real wood, characterized in that, The substrate (1) includes a base coat (2), a color coat (3) and a topcoat (4). The base coat (1), base coat (2), color coat (3) and topcoat (4) are arranged sequentially from bottom to top and cover the entire surface of the base coat (1). The surface of the base coat (1) is flat and has recessed wood grain texture (5). The base coat (2) and topcoat (4) are of uniform thickness on the base coat (1). The thickness of the color coat (3) at the wood grain texture (5) on the base coat (1) is greater than that at the flat surface. The color of the color coat (3) at the wood grain texture (5) and the edge of the base coat (1) gradually becomes lighter from the center to the outer perimeter.

2. The automotive interior trim component that replaces real wood according to claim 1, characterized in that, The primer layer (2) has a recessed rolling texture, or a skeleton paint layer is sprayed between the primer layer (2) and the color paint layer (3), and the skeleton paint layer has a wood grain texture.

3. The automotive interior trim component that replaces real wood according to claim 2, characterized in that, The substrate (1) is made of ABS / PC plastic, PC and PMMA composite material, or glass fiber reinforced composite material. The primer layer (2) is made of two-component polyurethane primer or UV primer. The color paint layer (3) is made of semi-transparent gloss varnish containing slow-drying solvent. The topcoat layer (4) is made of high-solids two-component varnish or UV-cured varnish.

4. A painting process for automotive interior parts that replace real wood, applicable to automotive interior parts that replace real wood as described in any one of claims 1 to 3, characterized in that, Includes the following steps: Step 1: Substrate (1) Pretreatment The substrate (1) surface is cleaned by plasma treatment or alcohol wiping to remove mold release agent and oil stains. The substrate is usually ABS / PC plastic or PC and PMMA composite material or glass fiber reinforced composite material. Step 2: Primer application and texture curing (1) Primer spraying: Select a two-component polyurethane primer or UV primer, and spray a primer layer (2) on the surface of the substrate (1) in a dust-free spraying room. (2) Texture curing: If the surface of the substrate (1) is flat, roll the texture when the primer layer (2) is half dry or spray a layer of skeleton paint with a three-dimensional texture and a wood grain texture on the primer layer (2), and the skeleton paint is provided with wood-like conduits. (3) Drying: Dry after leveling. If the primer layer (2) uses a UV primer material, it needs to be cured with ultraviolet light. Step 3: Base coat spraying Select a translucent gloss stain containing a slow-drying solvent according to the wood species, and apply the stain thinly to the surface of the substrate (1) using a wool brush or spray gun. Step 4: Apply color (1) Staining: In an environment with sufficient temperature, humidity and light that is compatible with the staining agent, use a lint-free cotton cloth or non-woven cloth to first rub the flat surface vigorously to leave a thin layer of staining agent and leave a thick layer of staining agent in the recessed texture to form clear wood grain lines. Then, lightly wipe the edges or corners to retain more color and form an antique "black edge" effect. Next, use a clean soft cloth to pat or lightly sweep the recessed texture and the color left on the edges or corners to create a natural transition of color from dark to light, imitating the natural gradient of wood. Finally, let it dry naturally to form a colored paint layer (3). (2) Inspection: Compare with the standard color chart to confirm the clarity and contrast of the texture; Step 5: Topcoat Spraying Select a high-solids two-component varnish or a UV-curable varnish and spray it onto the surface of the substrate (1). After leveling, dry it. If a UV-curable varnish is used, it needs to be cured with ultraviolet light to finally form a topcoat layer (4). Step Six: Polishing and Final Inspection (1) Polishing: The topcoat layer (4) is polished mechanically or manually to remove orange peel and achieve a mirror effect or specified gloss. (2) Final inspection: Check for whitening, graininess, color difference, and perform a full inspection of the texture effect.

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