Filler or spacer element for use in automotive trim components

Abstract

A filler element for use in an automotive trim component, the filler element having a density of 25 to 150 kg / m 3 1. A filler element comprising oriented thermoplastic terephthalate-based polyester beads.

Description

[Technical Field]

[0001] The present invention relates to filler elements for use in automotive trim members, automotive trim members including such filler elements, and the use of such filler elements in automotive trim members. [Background technology]

[0002] Automotive trim members, or soft trim members as they are also known, are single-layer or multi-layer members that are primarily used in the passenger compartment for a variety of reasons. For example, they are used to cover vehicle body structures such as the floor, inner dash, or sides of the inner dash, around tunnels, under seats, and small areas in the trunk area. These members are called soft trim members because they are composed of one or more layers of relatively soft materials, such as foam or fibrous layers, or combinations of such layers. These may be combined with optionally filled layers of foil, film, or thermoplastic elastomer. Combinations of such layers with different densities or stiffnesses may be used to improve noise attenuation, prevent water intrusion into the member, or achieve an aesthetically pleasing, flat floor or surface.

[0003] In some areas of the trim member, such as areas expected to be subjected to relatively heavy loads, rigid, lightweight elements are required. This may be in the trunk or the area where the passenger steps on the floor. Or, for example, it may be in the area where an occupant parks their foot or feet. These elements may be considered stiffening elements. However, they are also used in areas where no load forces are expected but where a relatively long distance must be filled between the trim member surface and the underlying vehicle body; in this case, they may be considered filler or spacer elements. For clarity, spacer elements, filler elements, or stiffening elements are used for any situation where a rigid, lightweight element or layer is required, and are used interchangeably.

[0004] Oriented polypropylene (EPP), oriented polyethylene (EPE), oriented polystyrene (EPS), or a blend of EPS and EPE, commercially known as Piocelan, are most commonly used to form such rigid filler elements. In most layer combinations, the current rigid block materials used are not compatible with recycling processes, while scrapped waste cannot be reused as blends. Therefore, most of these blocks, or trim pieces containing such blocks, end up in landfills or incineration.

[0005] However, these materials have numerous drawbacks, particularly when incorporated into multi-layer automotive trim components. For example, EPS has been known to be harmful to the environment because it does not biodegrade in landfills and waste incineration produces harmful gases. While EPP is better, it is not compatible with other materials commonly used in automotive trim components, such as polyester felt layers or polyester carpet surfaces.

[0006] The automotive industry is striving for zero-waste production processes and long-term circular material usage. This requires trim components to contain a high level of recycled content and a material mix that is easy to recycle, preferably without the need for layer separation. EPS or EPP blocks may be embedded in a flexible polyurethane foam or a flexible fibrous felt.

[0007] There is a need for alternative materials to oriented polystyrene or oriented polyethylene that can be incorporated into or used in combination with automotive trim components.

[0008] Another problem with EPS and EPP is their incompatibility with other materials. Therefore, it is difficult to bond other layers to their surface, and very often, rigid blocks or spacer elements are mechanically held in place. Additionally, after the blocks are formed, it is nearly impossible to reshape the parts except by mechanical reshaping, e.g., cutting.

[0009] The industry is specifically working towards single-material, multi-layer trim components. Until now, only the main layer has been adapted, but accessories embedded within the floor structure, such as footrests in the form of hard blocks at the driver's position, or filler elements, have remained unchanged. For example, footplates have traditionally been made from metal or acrylonitrile butadiene styrene (ABS) plastic to obtain high impact strength.

[0010] Although the primary flooring system may be formed from a single layer of polyester-based material, the accessories used do not conform to the orientation of such an all-single material.

[0011] To date, the industry has struggled to find alternatives that meet the requirements, particularly the product requirements and waste management requirements, without the need to remove waste from the trim members or the need for waste segregation.

[0012] The aim is to provide an alternative solution for rigid elements such as filler or spacer elements in order to increase the recyclability of the entire trim part, in particular to reduce separation steps and waste streams. Summary of the Invention [Means for solving the problem]

[0013] This object is achieved by a filler element as claimed in claim 1, by an automotive trim part comprising a filler element as claimed in claim 6, and by the use of a filler element in an automotive trim part as claimed in claim 13.

[0014] Specifically, the density is 25 to 150 kg / m 3 Filler elements comprising thermoplastic oriented terephthalate-based polyester beads can form an alternative to currently used materials, are relatively sustainable, and, due to chemical compatibility, provide filler, spacer, or stiffening elements that can be recycled together with other layers and even mixed materials.

[0015] Surprisingly, it is possible to form a molded structure with thermoplastic polyester bead foam that exceeds all of the requirements of filler elements for trim components used in the passenger compartment of an automobile: these components need to be lighter and less stiff than when used externally or as structural parts.

[0016] The filler elements can be used in various trim components arranged in the interior of a motor vehicle, for example, in flooring systems or as footrest blocks integrated into the inner dash, and can be used as spacers or filler blocks to fill relatively wide gaps between the vehicle body and the surface of the trim component.

[0017] The filler elements may be used as such or may be incorporated into one or more additional layers, such as blocks attached to, bonded to, or encapsulated within one or more additional layers, such as at least one of a foam layer, a felt layer, a film layer, a thermoplastic layer, a highly filled thermoplastic elastomer layer, or a carpet.

[0018] Preferably, the filler elements are shaped in a 3D shape, preferably including at least one of ribs, voids, protrusions, channels or domes.

[0019] The filler element may be shaped or curved, or U-shaped, or include recesses for other elements of the trim member to conform to the vehicle body, required surfaces, or other trim members. The filler element may be shaped to provide a cavity for an auxiliary battery, for example, an auxiliary battery used under a seat.

[0020] The filler elements preferably have a higher compressive stiffness than the surrounding layers.

[0021] For example, filler elements may be placed on the body of an automobile and covered with a carpet system. The carpet system is formed by a pile of tufts tufted into a primary backing, whereby the tufts are locked in place by a thermoplastic layer attached to the surface of the primary backing opposite the pile surface, to which a secondary backing is adjacently bonded. To prevent the filler elements from moving, the filler elements may be confined by at least one additional layer, such as a felt and / or foam layer. The blocks may be foamed around their periphery, preferably with polyurethane foam. To further improve the locking of the filler elements in place, the blocks may have a 3D shape that not only fits the space to be filled but also includes ribs, domes, or voids to further improve the locking of the members. The thus-confined stiffening blocks may be adjacent to and bonded to the tufted carpet system, for example, by an enclosing layer during the back-foaming process or by a binder in a fibrous felt layer. Surprisingly, some spacer filler blocks have already been incorporated locally into carpet systems along with a backing layer formed by felt or foam, whereby the blocks increase the compression stiffness enough to allow the flooring system to be stepped on without sinking, while maintaining the thickness and softness of the backing layer required for acoustic properties and reducing the density and overall weight of the complete floor trim member.

[0022] In a preferred solution, the filler element is disposed between two polyester-containing layers, e.g., between layers in the form of fibers, filaments, or bicomponent fibers or filaments, including a low-melting polyester and a high-melting polyester component. Surprisingly, by using a polyester-based layer together with polyester bead foam, it is possible to adhere the fibrous layer to the bead foam, preferably using a steam molding process to form the trim member, without the need for an additional adhesive layer. To further enhance this surprising effect, the bead foam element may be surface-treated, for example, by mechanical treatment such as surface coating, perforation or roughening of the surface, or removal of a surface layer, or by chemical treatment or activation, such as plasma or flame treatment or primer treatment. [Effects of the Invention]

[0023] The trim member thus produced may be used as a filler trim member in a relatively small area of ​​the passenger compartment, or as an inner dash, for example. By adding additional layers or other flooring materials, such as the carpet system described above, it may also be used as a flooring module.

[0024] The filler elements may be produced from oriented thermoplastic terephthalate-based polyester beads using an in-mould foaming process known to those skilled in the art.

[0025] Preferably, aromatic polyester resin foam particles may be used to produce foamed molded articles. The aromatic polyester resin may be a polyester containing an aromatic dicarboxylic acid component and a diol component, such as polyethylene terephthalate, polypropylene terephthalate, polybutylene terephthalate, polycyclohexanedimethylene terephthalate, polyethylene naphthalate, polybutylene naphthalate, and the like, with polyethylene terephthalate being preferred. The aromatic polyester resin may be used alone, in a blend, or as a copolymer with other polyesters.

[0026] As the aromatic polyester resin, not only petroleum-derived products but also recycled products, plant-derived products, products recovered from used PET bottles, or the like, and recycled products may be used.

[0027] The filler elements are produced by in-mold foaming of an aromatic polyester resin containing unexpanded beads and a blowing agent, where the beads expand to fill spaces while partially fusing with neighboring beads to form a solid element composed of bead-expanded particles. A single particle may still be distinguishable by its sphere-like shape with an expanded core and a relatively densely expanded periphery.

[0028] The density of the packing element according to the present invention is 25 to 150 kg / m 3 , preferably 25 to 45 kg / m 3 It may be.

[0029] Preferably, the compressive stiffness of the resulting filler or stiffening element is less than 1500 kPa, preferably between 150 and 1300 kPa, measured according to ISO 844 at a compressibility of always 25%.

[0030] The filler element according to the present invention has low thermal conductivity and excellent dynamic cushioning properties. Therefore, the use of such filler or spacer elements between the vehicle body and the surface of the trim element, preferably in the lower layer of the trim element, i.e., the layer facing away from the passenger compartment, can improve the thermal insulation of the passenger compartment. This is particularly important for battery electric vehicles, where the heating of the passenger compartment is related to the vehicle's energy consumption.

[0031] Preferably, the filler element further comprises a reinforcing element, preferably in the form of at least one of a reinforcing rod, a reinforcing fabric, or a reinforcing grid. The reinforcing element may be adjacent to and bonded to a surface of the filler element and / or at least partially trapped within a bead of the filler element. Preferably, the reinforcing element is incorporated into the filler element during an in-mold foaming process. The reinforcing element preferably comprises the same type of polyester as the filler element, preferably a terephthalate-based polyester.

[0032] Because the filler elements used in automotive trim components can be relatively thin layers, the reinforcing elements can prevent the component from snapping or breaking, particularly in the relatively thin areas.

[0033] Automotive trim members, also known as soft trim, are based on relatively soft materials such as foam and felt to improve occupant comfort while driving. Thus, the additional layers do not directly add any stiffness to the filler or spacer elements, although some increase in stiffness is observed with the effect of multiple layers.

[0034] Additional layers adjacent to the filler elements may be bound by a polymeric binder, such as a hot melt, powder, film, or fiber, having a melting point below 180° C. Binders may also be used within layers to bind the fibers or lock the tufts.

[0035] The additional layers may be porous or non-porous to optimize acoustic properties in absorbent systems with defined airflow resistance, or in spring-mass systems with a filled thermoplastic elastomer layer and a fibrous or foam layer with relatively low compressive stiffness and density.

[0036] An automotive trim member according to the present invention comprises at least one filler element and at least one additional layer, preferably at least one of a foam layer, a felt layer, a film layer, a thermoplastic layer, a highly filled thermoplastic elastomer layer, or a carpet system, at least partially adjacent to and in contact with the filler element, and preferably the filler element is at least partially chemically or mechanically bonded to, encapsulated within, or attached to said at least one additional layer.

[0037] The additional layers may be bonded together through the melting of fibers contained within the layers or through the use of additional films, powders, foils, or layers and adhered during formation of the trim member.

[0038] The filler elements may be bonded to additional layers by binders or adhesives, preferably including films, fibrous layers, hot melts, powders, or reactive systems, such as polyurethane or epoxy-based systems. Surprisingly, the filler elements remain intact despite numerous hot melt adhesives or treatments, such as thermoformed fiber or heated foaming processes, performed in conjunction with the filler elements.

[0039] The filler elements may be treated to improve bonding to adjacent layers by surface roughening, activation by flame or plasma treatment, application of a chemical primer, or inclusion of additional physical binders, such as clips or screws.

[0040] Additionally, the filler element may include protrusions, ribs, and / or holes to improve interlocking with other layers, and / or to conform to the vehicle body, and / or to optimize material usage.

[0041] Use of automotive trim components comprising filler elements according to the present invention as interior trim components, such as inner dashes, carpet systems, storage compartment liners, side trim, and / or other interior soft trim components.

[0042] Filler elements may be used to locally increase stiffness, to fill relatively large spaces between the vehicle body and the surface level required for the function of the component, or simply to reduce cost when the surrounding material is expensive.

[0043] Such a surface system may additionally include optionally attached or welded materials such as heel mats and cargo nets, which will preferably comprise terephthalate-based polyester materials, along with trim members that are entirely terephthalate-based polyester, to make the materials recyclable.

[0044] One example of such a claimed trim member is a surfacing system comprising a nonwoven or tufted terephthalate-based polyester surfacing and a polyester-based backing layer laminated together, and further comprising a heel pad comprising a thermoplastic polyester elastomer (TPEE) material comprising a crystalline polyester and an amorphous polyether.

[0045] The flooring system will preferably comprise substantially terephthalate-based polyester, making the flooring system recyclable as a single part in a closed-loop recycle stream of terephthalate-based polyester. [Brief explanation of the drawings]

[0046] [Figure 1] FIG. 1 shows an embodiment of a filler element according to the present invention used in an automotive trim member. [Figure 2]FIG. 2 shows another embodiment of a filler element according to the present invention for use in an automotive trim piece. [Figure 3] FIG. 3 shows a different configuration of a filler element with a dome according to the invention in an automotive trim piece. DETAILED DESCRIPTION OF THE INVENTION

[0047] In Figure 1, filler element 7 may be placed on the body of an automobile (not shown) and covered with a carpet system formed by a pile of tufts 2 tufted into a primary backing 4, whereby the tufts 3 are locked in place by a thermoplastic layer 5 attached to the surface of the primary backing 4 opposite the pile surface, to which a secondary backing 6 is adjacently bonded.

[0048] The layer 8 surrounding the filler element preferably consists of felt or foam, more preferably felt containing terephthalate-based polyester fibers and a small amount of low-melting bicomponent polyester fibers, and the filler element may be bonded to the felt or foam by an additional adhesion-promoting layer (not shown).

[0049] The filler element may additionally optionally include reinforcing rods or elements (not shown), preferably comprising the same terephthalate-based polyester material as the filler element.

[0050] 2 shows another embodiment of the filler element 7, but with a different aesthetic surface layer, such as a needle-punched or textured thermoplastic surface 13. This surface is bonded to the remainder of the component with an adhesive layer 12 in this embodiment. The adhesive layer 12 may comprise a powder, fiber, or a thermoplastic hot melt formed by melting a coated layer. The layers 10 and 11 surrounding the filler element may comprise, for example, multiple types or densities of felt or foam, and may include additional adhesive layers or treated areas at the interfaces.

[0051] FIG. 3 shows the same component with filler element 7 and aesthetic textured thermoplastic or needle punched surface 13, but the filler element includes ribs, domes, or protrusions 14 to help hold the trim component in place within the vehicle or within itself.

Claims

1. 1. A filler element for use in an automotive trim component, said filler element having a density of 25 to 150 kg / m ３ 1. A filler element comprising oriented thermoplastic terephthalate-based polyester beads.

2. 2. The filler element of claim 1, wherein the polyester beads comprise an aromatic polyester-based resin, preferably the polyester comprises an aromatic dicarboxylic acid component and a diol component, and preferably comprises at least one of polyethylene terephthalate, polypropylene terephthalate, polybutylene terephthalate, polycyclohexanedimethylene terephthalate, polyethylene naphthalate, polybutylene naphthalate, and / or blends or copolymers thereof.

3. 3. The packing element of claim 1 or 2, wherein the element is molded into a 3D shape, preferably a 3D shape comprising at least one of a rib, a void, a protrusion, a channel, a recess, or a dome.

4. 4. The filler element according to any one of claims 1 to 3, wherein the filler element further comprises a reinforcing element, preferably in the form of a reinforcing rod, a reinforcing fabric and / or a reinforcing grid, preferably bonded adjacent to a surface of the filler element and / or at least partially trapped within a bead of the filler element.

5. The packing element according to any one of claims 1 to 4, wherein said packing element comprises at least one of a surface treatment, preferably a mechanical treatment such as coating, drilling, polishing or cutting, or a chemical modification.

6. A trim component for an automobile comprising at least one filler element according to any one of claims 1 to 5.

7. 7. The automotive trim member of claim 6, wherein the filler element has a higher compressive stiffness than the surrounding layers.

8. 8. An automotive trim member according to claim 6 or 7, further comprising at least one additional layer, preferably at least one of a foam layer, a felt layer, a film layer, a thermoplastic layer, a highly filled thermoplastic elastomer layer, or a carpet, at least partially adjacent to and in contact with said filler element, and preferably said filler element being at least partially bonded or attached to said at least one additional layer.

9. 9. An automotive trim member according to any one of claims 6 to 8, wherein the trim member comprises a first additional layer which is a felt layer, a second additional layer which is a foam layer or a felt layer, and at least one filler element, whereby the filler element is at least partially sandwiched between the first and second additional layers.

10. 10. An automotive trim member according to any one of claims 6 to 9, wherein the trim member comprises one or more thermoplastic adhesives, preferably polyester thermoplastic adhesives, within the material near the interfaces between adjacent layers.

11. An automotive trim member according to any one of claims 6 to 10, wherein the filler block includes an outer coating that bonds the filler block to at least one adjacent layer.

12. 12. The automotive trim member according to claim 6, wherein the trim member is formed entirely from polyester or copolyester, and preferably substantially from terephthalate-based polyester.

13. 13. Use of a trim or filler element for a motor vehicle according to any one of claims 1 to 12 as an interior trim element, for example as an inner dash, carpet system, luggage compartment liner, side trim and / or other soft interior trim component, and / or as a spacer or filler block for filling in relatively large gaps between the vehicle body and the surface of the trim element, and / or as a holder for additional components or fixtures.

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