Chemical foaming of interior components

Abstract

Chemical foaming of interior components is provided. A method of using chemical foaming agents to manufacture vehicle interior trim wrapped components having reduced weight is disclosed.

Description

Technical Field

[0001] The technical field generally involves vehicle interior trim components and their manufacturing methods. Background Technology

[0002] Vehicle interior trim components have been manufactured using a variety of methods.

[0003] It is desired to provide a method for manufacturing vehicle interior trim components with reduced weight. Furthermore, other desired features and characteristics of patentable variations will become apparent from the following detailed description and appended claims, taken in conjunction with the accompanying drawings and the foregoing introduction. Summary of the Invention

[0004] Multiple variations may include a product comprising: a mixture of a moldable resin and an endothermic chemical foaming agent, the endothermic chemical foaming agent being formulated to generate micropores in a substrate molded from the mixture.

[0005] Multiple variations may include a product wherein the moldable resin includes at least one of thermoplastic polyolefin resin or acrylonitrile butadiene styrene resin.

[0006] Multiple variations may include a product in which the moldable resin comprises about 97 to about 99% by weight of the mixture.

[0007] Multiple variations may include a product in which an endothermic chemical foaming agent comprises about 1 to about 2% by weight of the mixture.

[0008] Multiple variations may include a product, wherein the moldable resin includes thermoplastic polyolefin resins.

[0009] Multiple variations may include a product, wherein the moldable resin includes acrylonitrile butadiene styrene resin.

[0010] Multiple variations may include a product in which the thermoplastic polyolefin resin includes polypropylene, rubber and polyethylene, and in which the endothermic chemical foaming agent includes sodium bicarbonate and citric acid.

[0011] Multiple variations may include a method comprising: mixing a moldable resin and an endothermic chemical foaming agent to provide a mixture; injecting the mixture into an injection molding machine; heating the mixture to activate the endothermic chemical foaming agent to generate micropores in the mixture; pressing the mixture to produce a molded substrate for a vehicle interior trim component having micropores in the molded substrate; and removing the molded substrate for the vehicle interior trim component from the injection molding machine.

[0012] Multiple variations may include a method that further includes controlling the heating of the mixture so that the molded substrate for the vehicle interior trim parts has an outer surface free of bubbles, blemishes, or voids.

[0013] Multiple variations may include a method that further includes wrapping a molded base for vehicle interior trim components with a wrapping material.

[0014] Multiple variations may include a method in which the wrapping material includes at least one of leather, silicone film, vinyl or artificial leather, fabric or suede.

[0015] Multiple variations may include a method in which a molded substrate for a vehicle interior trim component is wrapped with a wrapping material, including at least one of in-situ foam wrapping, in-mold granulation wrapping, in-mold granulation lamination, hand wrapping, or machine wrapping.

[0016] Multiple variations may include a method that further includes depositing an adhesive on at least a portion of the outer surface of the molded substrate before wrapping the molded substrate for the vehicle interior trim component with the wrapping material, such that the wrapping material adheres to at least a portion of the outer surface of the molded substrate.

[0017] Multiple variations may include a method that further includes controlled heating such that the molded substrate for the vehicle interior trim component has micropores present in the molded substrate for the vehicle interior trim component at an amount of at least one million micropores per cubic centimeter.

[0018] Multiple variations may include a method in which the micropores have a width in the range of about 0.1 to about 100 micrometers, and wherein the endothermic chemical blowing agent includes sodium bicarbonate and citric acid.

[0019] Multiple variations may include a product comprising: a vehicle interior trim component including a molded substrate, the molded substrate comprising a molding resin, wherein the molded substrate includes micropores, and the molded substrate has an outer surface free of bubbles, defects, or voids.

[0020] Multiple variations may include a product that further includes a wrapping material on at least a portion of the outer surface of a molded substrate, wherein the wrapping material includes at least one of leather, silicone film, vinyl leather, artificial leather, fabric, or suede.

[0021] Multiple variations may include a product in which the vehicle interior trim components include at least one of thermoplastic polyolefin or acrylonitrile butadiene styrene.

[0022] Multiple variations may include a product in which vehicle interior trim components include dashboards, steering wheels, instrument panels, center consoles, kick panels, armrests, seats, door trim, A-pillars, B-pillars, C-pillars, or headliners.

[0023] Multiple variations may include a product that also includes a vehicle, wherein vehicle interior trim components are installed in the vehicle, wherein the vehicle interior trim components include a dashboard, steering wheel, instrument panel, center console, kick plate, armrest, seats, door trim, A-pillar, B-pillar, C-pillar, or headliner, wherein the vehicle interior trim components include at least one of thermoplastic polyolefin or acrylonitrile butadiene styrene, wherein a wrapping material is on at least a portion of the outer surface of the molded substrate, wherein the wrapping material includes at least one of leather, silicone film, vinyl leather, artificial leather, fabric, or suede, wherein micropores are present in the molded substrate in an amount of at least one million micropores per cubic centimeter of molded substrate, wherein the micropores have a width in the range of about 0.1 to about 100 micrometers. Attached Figure Description

[0024] The illustrative variations will be described below with reference to the accompanying drawings, wherein the same numerals denote the same elements, and wherein:

[0025] Figure 1 It is a flowchart of a method for manufacturing a molded base for use as a vehicle interior trim component according to multiple variations;

[0026] Figure 2 It is a schematic diagram of a molded base for various modified vehicle interior trim components, on which no wrapping material is applied;

[0027] Figure 3 It is based on multiple variations for Figure 2 The diagram shows a molded base for a vehicle interior trim component, with a portion of the molded base having wrapping material.

[0028] Figure 4 This is a partial cross-sectional view of a molded substrate for vehicle interior trim components based on several variations, without any wrapping material, showing microbubbles formed in the molded substrate for vehicle interior trim components.

[0029] Figure 5 It is a schematic diagram of a portion of the vehicle interior, including interior trim components, based on several variations; and

[0030] Figure 6 This is a schematic diagram of a vehicle showing interior trim components based on several variations. Detailed Implementation

[0031] The following detailed description is illustrative in nature only and is not intended to limit application or use. Furthermore, there is no intention to be bound by any express or implied theory presented in the foregoing introduction, description of the figures, summary of the invention, or the following detailed description.

[0032] Figure 1 This is a flowchart of a method 30 for manufacturing a molded substrate for use as an interior trim component in a vehicle. Method 30 may include providing a colorant at box 32, a resin material at box 34, and an endothermic chemical foaming agent at box 36, and placing each of these in a hopper or mixer at box 38. Subsequently, at box 40, the colorant, resin material, and endothermic chemical foaming agent are moved from the hopper or mixer to a spiral rotary mixing device and mixed to provide a mixture. At box 42, an injection mold may be opened at box 42 and then closed at box 44, with or without a mold insert. Subsequently, at box 46, the mixture may be injected into the mold. Subsequently, at box 48, the temperature and pressure of the mold may be controlled to activate the chemical foaming agent to create micropores in the substrate molded in the mold. The temperature of the molding process may be controlled by any of a variety of heat sources, causing the chemical foaming agent to produce carbon dioxide at a certain rate and amount to create micropores in the substrate molded in the mold. Subsequently, at frame 50, the substrate can be demolded, and the mold can be opened to eject the substrate. Then, at frame 52, a wrapping process can be used to wrap the molded substrate, which can be made of materials such as, but not limited to, leather, silicone film, vinyl and artificial leather, fabric, or suede. The molded substrate can be wrapped using methods such as in-situ foaming at frame 54, in-mold granulation or in-mold granulation lamination at frame 56, hand wrapping at frame 58, or machine wrapping at frame 60.

[0033] Figure 2 This is a schematic diagram of a molded base 62 for various modifications of vehicle interior trim components, without any covering material. The molded base 62 may be made of a composition comprising at least one of a thermoplastic polyolefin resin or an acrylonitrile butadiene styrene resin. The thermoplastic polyolefin resin may be a blend of polypropylene, rubber, and polyethylene. The rubber may be an uncrosslinked ethylene propylene diene monomer. The thermoplastic polyolefin resin may include talc, may be heat-stable, may have high stiffness, and / or may have high impact strength properties. The thermoplastic polyolefin resin may comprise about 97 to about 99% by weight of the composition. The acrylonitrile butadiene styrene resin may be UV-stable and / or heat-stable. The acrylonitrile butadiene styrene resin may comprise about 97 to about 99% by weight of the composition.

[0034] The composition may include an endothermic chemical foaming agent that, when activated in a mold, generates micropores 70 in the molding substrate 62. Figure 3 (Best shown in the diagram), and degassing can be avoided, preventing the formation of bubbles, defects, or voids in the outer surface 59 of the molded substrate. The activation of the endothermic chemical agent can be controlled to produce a molded substrate 62 with an outer surface 59 free of bubbles, defects, or voids. Because the outer surface 59 of the molded substrate 62 is free of bubbles, defects, or voids, the wrapping process and the wrapped molded substrate are improved. The micropores in the molded substrate can have a width ranging from about 0.1 to about 100 micrometers. More than one million pores can be present in one cubic centimeter of molded substrate. During the endothermic reaction, the chemical blowing agent can release carbon dioxide and can release trace amounts of water. To deactivate the chemical blowing agent, the mold can be heated such that the injected composition is above the activation temperature of the chemical blowing agent. The activation temperature of the chemical blowing agent can range from about 80 degrees Fahrenheit to about 400 degrees Fahrenheit. The chemical blowing agent can constitute about 1 to about 3% by weight of the composition. Compared to molded substrate products that do not use chemical foaming agents, the use of chemical foaming agents during the molding process can reduce the weight of the molded substrate by up to 25%.

[0035] In several variations, suitable endothermic chemical blowing agents may include sodium bicarbonate and may include citric acid. Suitable chemical blowing agents are commercially available from ID Actives, under the trade names 74837ID FOAM 20MFC and 74979IDFOAM HIGH TEMP ENDO 6672; from Mitsubishi Corporation, under the trade names EIWA H2710 and EIWA HES463; from Trexel Inc., under the trade names TecoCell H1 and TecoCell GTA; and from Avient Corporation, under the trade names Hydrocerol 818 and Hydrocerol HK40.

[0036] Compositions comprising thermoplastic polyolefin resins can be molded at temperatures ranging from about 80 degrees Fahrenheit to about 150 degrees Fahrenheit and can be maintained at pressures ranging from about 20 psi to about 100 psi.

[0037] Compositions comprising acrylonitrile butadiene styrene resin can be molded at temperatures ranging from about 80 degrees Fahrenheit to about 150 degrees Fahrenheit and can be maintained at pressures ranging from about 20 psi to about 100 psi.

[0038] Figure 3 It is based on multiple variations for Figure 2 The diagram shows a molded base 62 for a vehicle interior trim component, on which a covering material 64 is applied. An adhesive (not shown) may be deposited on... Figure 2At least a portion of the molded base 62 for the vehicle interior trim component is shown, and a wrapping material 64 can be placed on an adhesive to attach / adhere the wrapping material 64 to the molded base for the vehicle interior trim component. The ends 61, 65 of the wrapping material 64 can be joined together by stitching 66. The molded base 62 may have an unwrapped portion 68.

[0039] Figure 4 This is a partial cross-sectional view of a molded base 62 for vehicle interior trim components, on which no covering material is applied. According to several variations, microbubbles 70 may be formed in the molded base 62 for vehicle interior trim components.

[0040] Figure 5 This is a schematic diagram of a portion of a vehicle interior including an interior trim component 63, according to several variations. In several variations, the interior trim component 63 may be a dashboard 72, which may include the ends 61, 65 of a covering material 64 joined together by stitching 66. In several variations, the interior trim component 63 may be a steering wheel 74, which has the ends 61, 65 of a covering material 64 joined together by stitching 66. Due to the covering material 64 in each of the dashboard 72 and the steering wheel 74, the molded base 62 for the interior trim component is not visible.

[0041] Figure 6 This is a schematic diagram of a vehicle 76 showing an interior trim component 63 according to several variations. As disclosed herein, it includes a molded base 62 and a covering material 64 thereon (in... Figure 3 and Figure 5 Interior trim components 63 (best visible from the center) may include, but are not limited to, the dashboard 72, steering wheel 74, instrument panel 78, center console 80, kick plate 82, armrest 84, seats 88, door trim 86, A-pillar 90, B-pillar 92, C-pillar 94, and / or headliner 96. Other interior trim components (such as mirrors, sun visors, visors, etc.) may also include a molded base 62 and the covering material 64 thereon.

[0042] While at least one variation has been presented in the foregoing detailed description, it should be understood that numerous variations exist. It should also be understood that one or more variations are merely examples and are not intended to limit the scope, applicability, or configuration of this disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing one or more illustrative variations. It should be understood that various changes can be made to the function and arrangement of the elements without departing from the scope of this disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A product comprising: It includes a mixture of a moldable resin and an endothermic chemical foaming agent, the endothermic chemical foaming agent being formulated to create micropores in a substrate molded from the mixture.

2. The product according to claim 1, wherein, The moldable resin includes at least one of thermoplastic polyolefin resin or acrylonitrile butadiene styrene resin.

3. The product according to claim 2, wherein, The moldable resin comprises about 97 to about 99% by weight of the mixture.

4. The product according to claim 3, wherein, The endothermic chemical foaming agent comprises about 1 to about 3% by weight of the mixture.

5. The product according to claim 2, wherein, The moldable resin includes the thermoplastic polyolefin resin.

6. The product according to claim 2, wherein, The moldable resin includes acrylonitrile butadiene styrene resin.

7. The product according to claim 4, wherein, The thermoplastic polyolefin resin includes polypropylene, rubber, and polyethylene, and wherein the endothermic chemical foaming agent includes sodium bicarbonate and citric acid.

8. A product comprising: Vehicle interior trim components including a molded substrate, the molded substrate comprising a molding resin, wherein the molded substrate includes micropores and has an outer surface free of bubbles, defects, or voids.

9. The product of claim 8, further comprising a wrapping material on at least a portion of the outer surface of the molded substrate, wherein, The wrapping material includes at least one of leather, silicone film, vinyl leather, artificial leather, fabric, or suede.

10. The product according to claim 8, wherein, The vehicle interior trim components include at least one of thermoplastic polyolefin or acrylonitrile butadiene styrene.

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