Motor vehicle interior trim and methods of manufacture

Abstract

A multi-layered interior trim panel for a vehicle comprising a cover layer, first adhesive layer, cushion layer, second adhesive layer and a carrier layer wherein each of the layers are composed of greater than 50.0% (wt.) of polyolefin. In addition, methods of recycling such multi-layered interior trim panel are described.

Description

MOTOR VEHICLE INTERIOR TRIM AND METHODS OF MANUFACTUREFIELD

[0001] The present disclosure relates to motor vehicle, particularly automobile, interior trim panels such as instrument panels, having multi-layer construction, with improved recyclability, composed primary of polyolefin material.BACKGROUND

[0002] Motor vehicle interior trim panels typically are prepared from several different polymeric resins. In addition, such panels typically involve different structural components where each must provide their own individual performance requirements. This type of construction involving many different polymer resins can render recycling relatively more difficult. It stands to reason that an on-going need exists to identify a multi-layered vehicle interior trim panel construction that is more readily suitable for recycling, by providing a multilayered panel that is primarily sourced from one family of polymer resin, and which then improves or optimizes circularity, namely optimizing the use of the polymeric material and recovering such polymer material into the same or similar trim panel products.BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The above-mentioned and other features of this disclosure, and the manner of attaining them, will become more apparent and better understood by reference to the following description of embodiments described herein taken in conjunction with the accompanying drawings, wherein:

[0004] FIG. 1 is a diagram of an interior trim panel material structure as known in the art;

[0005] FIG. 2 is a diagram of an interior trim panel material structure according to the present disclosure;

[0006] FIG. 3 is a diagram of another interior trim panel material structure according to the present disclosure;

[0007] FIG. 4 is a diagram of a recycling process as known in the art for the interior trim material structure as shown in FIG. 1 ;

[0008] FIG. 5 is a diagram of a recycling process according to the present disclosure for the interior trim material structure as shown in FIG. 3; and

[0009] FIG. 6 is a diagram of a manufacturing process according to the present disclosure for the interior trim material structure as shown in FIG. 3 which includes a closed loop recycling process according to the present disclosure.SUMMARY

[0010] A multi-layered interior trim panel for a vehicle comprising a cover layer, first adhesive layer, cushion layer, second adhesive layer and a carrier layer, wherein each of the layers are composed of greater than 50.0 % (wt.) of polyolefin.

[0011] A method for producing a multi-layer trim panel for a vehicle comprising: (a) providing a first multi-layer trim panel comprising a cover layer, first adhesive layer, cushion layer, second adhesive layer and a first carrier layer, wherein each of the layers are composed of greater than 50.0 % (wt.) of polyolefin; (b) mechanically grinding said first multi-layer trim panel into a form for injection molding and injection molding a second carrier layer; and (c) forming a second multi-layer trim panel comprising a cover layer, first adhesive layer, cushion layer, second adhesive layer, and said second carrier layer, wherein each of the layers are composed of greater than 50.0% of polyolefin.DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0012] It may be appreciated that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention(s) herein may be capable of other embodiments and of being practiced or being carried out in various ways. Also, it may be appreciated that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting as such may be understood by one of skill in the art.

[0013] Referring to the figures, FIG. 1 is diagram of a prior art interior trim panel 100, having a cover 110 and a cushion 130 are adhesively bonded by an adhesive 120, and the cushion 130 and a carrier 150 are adhesively bonded by an adhesive 140.

[0014] As shown, the cover 110 is an artificial leather in a form of a sheet. The cover 110 is formed of a decorative skin 112 having an outer topcoat 111 disposed thereover and a backing113 disposed underneath. The decorative skin 1 12 is formed of polyvinyl chloride (PVC), while the topcoat 111 is formed of a polyurethane (PU) coating and the backing 113 is formed of a polyethylene terephthalate (PET) textile (e.g. knitted fabric).

[0015] The cushion 130 is in a form of a sheet, and is formed of a polyethylene terephthalate (PET) spacer textile (e.g. spacer fabric), while the carrier 150 is injection molded and formed of polypropylene with 20% long glass fiber by weight (PP-LGF20).

[0016] The cover 110 and the cushion 130 are adhesively bonded by an adhesive 120, which is a reactive polyurethane (PUR) hotmelt. Similarly, the cushion 130 and a carrier 150 are adhesively bonded by an adhesive 140, which is also a reactive polyurethane (PUR) hotmelt.

[0017] Referring to FIG. 2, the structure and method of manufacture are the same as FIG. 1, except the skin 111 formed of polyvinyl chloride (PVC) has now been replaced with a skin 212 formed of thermoplastic polyolefin (TPO) or crosslinked polyolefin (XPO). Reference to a polyolefin herein is reference to the use of olefins or alkenes as a monomer for polymerization which therefore include, e.g., ethylene, propylene, 1 -butene, 1 -hexene, 4-methyl-l -pentene, 1- heptene, 1 -octene, 1 -nonene, and 1 -dodecene. Polyolefins therefore can have the repeating unit -[CH2-CH(R)]- where R is either hydrogen or an alkyl group, and in a commercial sense, are dominated by polyethylene and polypropylene type resins.

[0018] Referring to FIG. 3, which now presents a preferred embodiment of the present invention, and in comparison to FIG. 1, the backing 113 of the cover 110 formed of the polyethylene terephthalate (PET) textile (e.g. knitted fabric) has been replaced with a backing 313 formed of a polyolefin (PO) textile (e.g. knitted fabric), such as polypropylene (PP) and polyethylene (PE). Similarly, the cushion 130 formed of a polyethylene terephthalate (PET) spacer textile (e.g. spacer fabric) has been replaced with a cushion 330 formed of a polyolefin (PO) (e.g. polypropylene (PP)) spacer textile (e.g. spacer fabric). Lastly, both adhesives 120, 140 formed of reactive polyurethane (PUR) hotmelt have been replaced with adhesives 320, 340 formed of reactive polyolefin resin (POR), preferably a silane-modified reactive polyolefin resin. A reactive polyolefin resin is a polyolefin with reactive groups that enable chemical curing / cross-linking which can occur during heating or exposure to moisture. In the preferred adhesive, the silane groups (e.g., methoxy silane groups) can react with moisture to form silanols which can react with other silanols to form covalent bonds between the polymer chains. As may therefore be appreciated, polyolefin is common to the cover layer 310

[0019] In the embodiment of FIG. 3, the cover 310 may preferably be configured to have an overall thickness which is a range of 0.6 mm to 1.5 mm in thickness and an area weight in a range of 420-1050 grams / square meter (g / nr). More specifically, the topcoat 311 can have a thickness in the range of 0 to 100 pm (thereby it is optional but preferred), the decorative skin 312 preferably has a thickness in the range of 0.2 mm to 1.0 mm and the backing 313 preferably has a thickness in the range of 0.2 mm to 1.0 mm. As can be appreciated, in the foregoing, the range of thickness for the topcoat, decorative skin and backing can be selected to provide the preferred overall thickness in the range of 0.6 mm to 1.5 mm.

[0020] The skin 312 herein is preferably a thermoplastic polyolefin (TPO) or crosslinked polyolefin (XPO). In the case of the thermoplastic polyolefin, such preferably contains polyethylene and / or polypropylene in combination with an elastomer, preferably an ethylenepropylene elastomer, optionally including additives such as flame retardants, colorants, or impact modifiers. Preferably, the TPO is described in WO2019 / 154354, hereby incorporated by reference, which identifies a composition that contains the following components in parts by mass: 20-50 parts of polyethylene, 30-60 parts of polypropylene, and 20-50 parts of an elastomer (e.g. preferably the rubber elastomer may be selected from ethylene propylene diene monomer) wherein the total amount of the polyethylene, the polypropylene and the elastomer is 100 parts by mass and the composition optionally contains 5-50 parts of an anti-static agent. The topcoat is preferably a thermoplastic or thermoset polyurethane.

[0021] In the embodiment of FIG. 3, cushion 330 may preferably be a spacer textile, such as a spacer fabric which may be a knitted fabric having a thickness in a range of 1.4 mm to 5 mm and an area weight in a range of 70 g / m2to 575 g / m2. As illustrated, the spacer is also preferably a polyolefin based spacer textile composed of polypropylene.

[0022] Also in the embodiment of FIG. 3, the carrier 350 may preferably be formed of Sabie Stamax 20YK270EE, a fiber filled polypropylene with properties from data sheet revision 20210414, which is hereby incorporated by reference. While 20.0 % (wt.) to 30.0 % (wt.) fiber may be preferred, the fiber reinforcement may be in a range of 10 % (wt.) to 40% (wt.), and the fiber is preferably glass fiber or carbon fiber. Fiber length is preferably in a range of 0.1 mm to 22.0 mm. As illustrated, once again, the carrier is preferably a polyolefin based carrier, preferably fiber-filled, and more preferably, composed of fiber-filled polypropylene.

[0023] Also in the embodiment of FIG. 3, the first adhesive layer 320 and second adhesive layer 340 may more preferably be a reactive silane-modified polyolefin (POR) from Jowat Adhesives and available under the designation of Jowatherm-Reaktant 628.32. The adhesive 320, 340 may have an area weight in a range of 40 g / m2to 200 g / m2- and a thickness in a range of 0.05 mm to 3 mm. It should therefore be understood that preferably, the first adhesive layer and second adhesive layer may be composed of any reactive or non-reactive polyolefin hot melt. Reference to a reactive polyolefin hot melt may be understood as having a polyolefin that has reactive groups which enable chemical curing, for example, by crosslinking of the polyolefin chains.

[0024] Referring to FIG. 4, there is shown a recycling process known in the art for the interior trim panel 100 of FIG. 1, in which the cover 110, cushion 130 and the adhesives 120, 140 are incinerated. Note that if the material is recycled, it is typically used in a downcycling application. However, due to the relatively complexity of what is shown in FIG. 4, and for commercial reasons, the downcycling is not often employed and in a number of cases, there is incineration of the recovered shredded (grinded) materials.

[0025] Referring now to FIG. 5, in contrast, there is shown a recycling process according to the present disclosure for the preferred trim panel 300 of FIG. 3, in which the incineration has been eliminated, and the trim panel 300, including the cover 310, first adhesive 320, cushion 330, second adhesive 340 and the carrier 350 are recycled. In FIG. 5, the mechanical separation is a reference to the removal of metal. Moreover, as then shown in FIG. 6, the trim panel 300 is preferably recycled back into the manufacturing process from which it originated. In such regards, the components of the trim panel 300 may preferably exhibit a weight percentage in the recyclate as follows:

[0026] The recyclate illustrated in FIG. 6 may then optionally be used as shown with a fiber containing virgin polypropylene (e.g., PP-LGF20), at a weight ratio of 1.0 % (wt.) recyclate / 99.0 % (wt.) virgin PP containing fiber to 99.0 % (wt.) recyclate / 1.0 % (wt.) virgin PP containing fiber, where again, the level of fiber in such virgin PP may preferably be in the range of 10.0% (wt.) to 40.0 % (wt.) .

[0027] As can now be appreciated from the above, the present invention is directed at a multilayered trim panel component that includes a cover layer, first adhesive layer, cushion layer, second adhesive layer, and a carrier, wherein each of the layers is composed primarily of a polyolefin component, but where each layer provides its own unique structural or performance requirements. Polyolefin is reference to the use of polypropylene and / or polyethylene. Reference to the feature that a layer is primarily a polyolefin is reference to the feature that the polymer composition of such layer is preferably greater than 50.0 (wt.) % polyolefin, including all values and ranges therein. Accordingly, in preferred embodiment, the cover layer, first adhesive layer, cushion, second adhesive layer and carrier may each preferably be composed of, e.g., greater than 55.0 (wt.) %, or greater than 60.0 % (wt.), or greater than 65.0 % (wt.), or greater than 70.0 % (wt.), or greater than 75.0 % (wt.), or greater than 80.0 % (wt.), or greater than 85.0 % (wt.), or greater than 90.0 % (wt.), or greater than 95.0 % (wt.) of polyolefin.

[0028] Expanding on what is disclosed in FIG. 6, as can be seen in the top portion of the figure, one can initially prepare the cover 310 composed of the optional polyurethane top coat 311, skin layer 312 containing greater than 50% (wt.) to 95% (wt.) polyolefin, and polypropylene backing containing greater than 50% (wt.) to 95 % (wt.) polyolefin. Such cover 310 can then be adhered with adhesive 340 to a first carrier 360 where the adhesive is again one that contains greater than 50% (wt.) to 95 % (wt.) polyolefin.

[0029] As for the carrier 360, as can also now be seen, it can now be preferably formed by taking the initially formed trim panel 300 that has been mechanically ground or shredded to form particles which can then be injection molds. It is, however, a preferred option to extrudesuch particles and mechanically form them into granulate that is particularly suitable in size and geometry for feeding into an injection molding machine. For example, granulate that provides relatively uniform pellet size for injection molding with a length in the range of 0.1 mm to 8.0 mm at a diameter in the range of 0.5 mm to 6.0 mm. Optionally, at this step of extrusion, one may introduce into the extruder other components, such as virgin polyolefin resin in order to achieve a selected level of recycled material in combination with the virgin polyolefin resin in the injection molded granulate which is identified in FIG. 6 as recyclate. One may also optionally introduce into the extruder selected additives such as processing aids or stabilizers.

[0030] Accordingly, either the ground trim panel 300 in particle form, or such trim panel particles when preferably converted into injection molded granulate, may next be injection molded into another (second) carrier layer 360, which then can be used in the formation of subsequent and another trim panel 300, now containing the recylate. In addition, as noted above, when forming a second carrier composed of recyclate according to the bottom portion of FIG. 6, one can optionally include in the formation of such second carrier layer of recyclate, a fiber containing virgin polypropylene (e.g., PP-LGF20), at a weight ratio of 1% recyclate / 99% virgin fiber containing PP to 99% recyclate / 1% virgin fiber containing PP. In addition, one may, in lieu of using a recycled carrier, elect to form and utilize a carrier that is sourced from only virgin fiber filled polypropylene.

[0031] It is worth noting that by composing a multi-layer trim panel where attention is directed at the composition of each layer, to ensure that polyolefin is common to each layer, but not necessarily exclusive to each layer, it is contemplated that the recycling of the trim panel will be relatively more efficient. In that sense, it is contemplated herein the improved recycling and circularity can be achieved by again, ensuring that each layer is primarily polyolefin based.

[0032] While a preferred embodiment of the present invention(s) has been described, it should be understood that various changes, adaptations and modifications can be made therein without departing from the spirit of the invention(s) and the scope of the appended claims. The scope of the invention(s) should, therefore, be determined not with reference to the above description, but instead should be determined with reference to the appended claims along with their full scope of equivalents. Furthermore, it should be understood that the appended claims do not necessarily comprise the broadest scope of the invention(s) which the applicant is entitled toclaim, or the only manner(s) in which the invention(s) may be claimed, or that all recited features are necessary.

[0033] Listing of reference characters:100, 200, 300 interior trim panel 110, 210, 310 cover111, 211, 311 topcoat112. 212. 312 skin113. 213. 313 backing120, 220, 320 adhesive 130, 230, 330 cushion140, 240, 340 adhesive150, 250, 350, 360 carrier

Claims

Claims.

1. A multi-layered interior trim panel for a vehicle comprising a cover layer, first adhesive layer, cushion layer, second adhesive layer and a carrier layer, wherein each of the layers are composed of greater than 50.0 % (wt.) of polyolefin.

2. The multi-layer trim panel of claim 1 wherein each of the layers are composed of greater than 70.0 % (wt.) polyolefin.

3. The multi-layer trim panel of claim 1 wherein each of the layers are composed of greater than 75.0 % (wt.) polyolefin.

4. The multi-layer trim panel of claim 1 wherein each of the layers are composed of greater than 80.0 % (wt.) polylolefin.

5. The multi-layer trim panel of claim 1 wherein each of the layers are composed of greater than 85.0 % (wt.) polyolefin.

6. The multi-layer trim panel of claim 1 wherein each of the layers are composed of greater than 90.0 % (wt.) polyolefin.

7. The multi-layer trim panel of claim 1 wherein each of the layers are composed of greater than 95.0 % (wt.) polyolefin.

8. The multi-layered interior trim panel of claim 1 wherein the cover layer is present at 5.0 % (wt.) to 12.0 % (wt.), the first adhesive layer is present at 0.5 % (wt.) to 3.0 % (wt.), the cushion layer is present at 1.0 % (wt.) to 6.0 % (wt.), the second adhesive layer is present at 0.5 % (wt.) to 3.0 % (wt.) and the carrier layer is present at 80.0 % (wt.) to 93.0 % (wt.).

9. The multi-layer trim panel of claim 1 wherein the cover layer has a thickness of 0.6 mm to 1.5 mm and an area weight in the range of 420 g / m2to 1050 g / m2.

10. The multi-layer trim panel of claim 9 wherein the cover layer optionally includes a polyurethane top coat at a thickness of 0 to 100 pm, a skin layer has a thickness of 0.2 mm to 1.0 mm and a backing at a thickness of 0.2 mm to 1.0 mm.

11. The multi-layer trim panel of claim 1 wherein said first and second adhesive layer comprise reactive silane modified reactive polyolefin.

12. The multi-layer trim panel of claim 1 wherein said cushion layer comprises a polyolefin textile fabric.

13. The multi-layer trim panel of claim 1 wherein said earner comprises a fiber filled polypropylene having 10.0 % (wt.) fiber to 40.0 % (wt.) fiber.

14. The multi-layer trim panel of claim 13 wherein the fiber comprises glass fiber or carbon fiber, and said fiber has a length in the range of 0.1 mm to 22.0 mm.

15. A method for producing a multi-layer trim panel for a vehicle comprising: a. providing a first multi-layer trim panel comprising a cover layer, first adhesive layer, cushion layer, second adhesive layer and a first carrier layer, wherein each of the layers are composed of greater than 50.0 % (wt.) of polyolefin: b. mechanically grinding said first multi-layer trim panel into a form for injection molding and injection molding a second carrier layer; and c. forming a second multi-layer trim panel comprising a cover layer, first adhesive layer, cushion layer, second adhesive layer, and said second carrier layer, wherein each of the layers are composed of greater than 50.0% of polyolefin.

16. The method of claim 15 wherein in step (b), the first multi-layer trim panel is present at a level of 1.0 % (wt.) to 99.0 % (wt.) and is ground into particulate in combination with 99.0 % (wt.) to 1.0 % (wt.) virgin polypropylene containing fiber.

17. The method of claim 15 wherein each of the layers in the first multi-layer trim panel are composed of greater than 70.0 % (wt.) polyolefin.

18. The method of claim 15 wherein each of the layers in the first multi-layer trim panel are composed of greater than 75.0 % (wt.) polyolefin.

19. The method of claim 15 wherein each of the layers in the first multi-layer trim panel are composed of greater than 80.0 % (wt.) polyolefin.

20. The method of claim 15 wherein each of the layers in the first multi-layer trim panel are composed of greater than 85.0 % (wt.) polyolefin.

21. The method of claim 15 wherein each of the layers in the first multi-layer trim panel are composed of greater than 90.0 % (wt.) polyolefin.

22. The method of claim 15 wherein each of the layers in the first multi-layer trim panel are composed of greater than 95.0% (wt.) polyolefin.

23. The method of claim 15 wherein said first multi-layer trim panel comprises a cover layer that is present at 5.0 % (wt.) to 12.0 % (wt.), the first adhesive layer is present at 0.5 % (wt.) to 3.0 % (wt.), the cushion layer is present at 1.0 % (wt.) to 6.0 % (wt.), the second adhesive layer is present at 0.5 % (wt.) to 3.0 % (wt.) and the first carrier layer is present at 80.0 % (wt.) to 93.0 % (wt.).

24. The method of claim 15 wherein in said first multi-layer trim panel, said first and said second adhesive layer comprise a silane modified reactive polyolefin.

25. The method of claim 15 wherein said first carrier layer comprises a fiber filled polypropylene having 10.0 % (wt.) fiber to 40.0 % (wt.) fiber.

26. The method of claim 15 wherein said mechanically grinding of said first multi-layer trim panel into a form for injection molding comprises first mechanically grinding said multi-layer trim panel into particles and extruding said particles and converting into granulate for injection molding.

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