• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    A method of forming a trim panel is provided. The method comprises the steps of: heating a nonwoven material to a predetermined temperature; applying a decorative film having perforations to a first surface of the heated material to create a two-layer laminate; placing the two-layer laminate in a cavity of a tool so that the decorative film is facing the cavity; heating the cavity; and injecting a thermoplastic resin into the tool so that the thermoplastic resin is adhered to a second surface of the material, the second surface being opposed to the first surface.
    公开号:FR3056440A1
    申请号:FR1758692
    申请日:2017-09-20
    公开日:2018-03-30
    发明作者:Kevin Mark Lyons；Edward J. Wenzel
    申请人:Inteva Products LLC；
    IPC主号:
    专利说明:

    ® FRENCH REPUBLIC
    NATIONAL INSTITUTE OF INDUSTRIAL PROPERTY © Publication number: 3,056,440 (to be used only for reproduction orders)
    ©) National registration number: 17 58692
    COURBEVOIE © Int Cl 8 : B 29 C 70/68 (2017.01), B 29 C 70/40, 45/14, B 60 R 13/02
    A1 PATENT APPLICATION
    ©) Date of filing: 20.09.17. © Applicant (s): INTEVA PRODUCTS, LLC— US. © Priority: 23.09.16 US 62398765. @ Inventor (s): LYONS KEVIN MARK and WENZEL EDWARD J .. (43) Date of public availability of the request: 30.03.18 Bulletin 18/13. ©) List of documents cited in the report preliminary research: The latter was not established on the date of publication of the request. (© References to other national documents ® Holder (s): INTEVA PRODUCTS, LLC. related: ©) Extension request (s): ® Agent (s): CABINET GERMAIN & MAUREAU.
    104 / METHOD AND APPARATUS FOR NON-WOVEN TRIM PANELS.
    FR 3 056 440 - A1
    A method of forming a trim panel is provided. The method includes the steps of: heating a nonwoven material to a predetermined temperature; applying a decorative film having perforations to a first surface of the heated material to create a two-layer laminate; placing the two-layer laminate in a cavity of a tool so that the decorative film faces the cavity; heating the cavity; and injecting a thermoplastic resin into the tool so that the thermoplastic resin is bonded to a second surface of the material, the second surface being opposite the first surface.
    i
    METHOD AND APPARATUS FOR NON-WOVEN TRIM PANELS
    BACKGROUND This invention relates to a method and an apparatus for forming nonwoven trim panels and trim panels formed by the method. More particularly, this invention relates to a method and an apparatus for forming trim panels for automobile interiors.
    Recent requests from the industry have been directed towards reducing vehicle weights despite the many components used in a vehicle. One of the areas of interest for achieving reduced vehicle weight is the vehicle interior area, which can include large interior substrate panels.
    Consequently, it is desirable to provide a vehicle interior trim piece which is aesthetically pleasing while also ensuring the required durability and structural integrity.
    SUMMARY OF THE INVENTION A method of forming a trim panel is provided. The method includes placing a nonwoven material in a heating press; heating the nonwoven material to a predetermined temperature; applying a decorative film to a first surface of the heated nonwoven material to create a two-layer laminate; where the decorative film has perforations having a surface area of 6.5 × 10 9 to 25.8 × 10 9 square meters, a density of perforations of 310,000 to 542,500 perforations per square meter, and a porosity of 0.25% to 0.90% ; placing the two-layer laminate in a cavity of a forming tool so that the decorative film faces the cavity; heating the cavity; to close the forming tool; and injecting a thermoplastic resin into the forming tool so that the thermoplastic resin is bonded to at least part of a second surface of the nonwoven material, the second surface being opposite the first surface.
    Another method of forming a trim panel includes placing a nonwoven material in a heating press; heating the nonwoven material to a predetermined temperature;
    insert a decorative film into a cavity of a forming tool where the film has perforations having an area of 6.5 × 10 ' 9 to 25.8 x 10 9 square meters, a density of perforations from 310Q00 to 542,500 perforations per square meter and a porosity of 0.25% to 0.90%; heating the cavity of the forming tool; inserting the heated nonwoven material between half of the forming tool and the decorative film so that a first surface of the nonwoven material comes into contact with the decorative film; to close the tool; and injecting a thermoplastic resin into the forming tool so that the thermoplastic resin is bonded to at least part of the second surface of the material, the second surface being opposite the first surface.
    In addition to one or more characteristic lines described above, or as an alternative to one of the preceding embodiments, the trim panel may be a part of a vehicle interior.
    In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the decorative film can be applied to the material via a contact roller of a roller system.
    In addition to one or more of the features described above, or as an alternative to one of the previous embodiments, the decorative film can be a thermoplastic olefin.
    [0009] In addition to one or more of the characteristics described above, or as an alternative to one of the preceding embodiments, the injection pressures of the thermoplastic resin can be limited by using a sequential opening control / closing the valve, foaming agents or agents promoting flow in order to significantly reduce the injection pressure.
    In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the predetermined temperature can be in the range from 200 to 210 degrees Celsius.
    A trim piece formed by one of the preceding embodiments is also described here.
    In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, a trim panel comprises a nonwoven material; a decorative film applied to a first surface of the nonwoven material in which the film has perforations having a surface area of 6.5 × 10 −9 to 25.8 × 10 9 square meters, a density of perforations of 310,000 to 542,500 perforations per square meter, and a porosity of 0.25% to 0.90%; and a thermoplastic resin (33) attached to at least a portion of a second surface of the nonwoven material, the second surface being opposite the first surface.
    In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the trim panel can be a part of a vehicle interior.
    In addition to one or more of the features described above, or as an alternative to one of the preceding embodiments, the trim panel can be a part of a vehicle door.
    BRIEF DESCRIPTION OF THE DRAWINGS Other characteristics, advantages and details appear, only by way of example, in the following description of embodiments, the description referring to the drawings in which;
    Figures 1 to 10 illustrate a method and an apparatus for forming a decorative trim panel according to a non-limiting embodiment of the disclosure; and [0017] Figures 11 to 20 illustrate a method and an apparatus for forming a decorative trim panel according to another non-limiting embodiment of the disclosure.
    Although the drawings represent various embodiments and features of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to illustrate and explain exemplary embodiments of the present invention. The exemplification set forth herein illustrates several aspects of the invention, in one form, and such exemplification should not be construed as limiting the scope of the invention in any way.
    DETAILED DESCRIPTION With regard now to the drawings, where as far as possible, similar reference numbers are used to designate similar components in all of the various views, in FIGS. 1 to 10 it can be seen that a method and apparatus for forming a decorative trim panel according to the nonlimiting embodiments of the disclosure are presented. According to various embodiments, a method of producing a first finished nonwoven surface directly by the compression / injection tool is disclosed. As such, secondary tooling and secondary processes are now required only for local coating and final assembly operations.
    In one embodiment, a decorative film of thermoplastic olefin (such as a compact sheet of TPO) is used to obtain a hard, grainy surface finish of the product or of the trim piece. In a first step, a nonwoven material 12 is heated to an appropriate treatment temperature, which can be, for example, from 200 to 210 degrees Celsius. Temperatures above or below the above range are considered to be within the scope of various embodiments.
    The heating can be carried out by contact, with hot air or by IR heating. The nonwoven material can be heated to a first temperature on a first side and a second temperature on a second side where the first temperature is not equal to the second temperature.
    The fibers of the nonwoven material 12 can include natural fibers, synthetic fibers or a combination of the two, with a high length to width ratio and characteristics suitable for processing in the material. Some types of exemplary non-limiting fibers may be polypropylene, polyester, kenaf, hemp, linen, jute, sisal, glass, carbon and combinations thereof. In some embodiments, the fibers are a combination of flax fibers and polypropylene fibers. The nonwoven material, before heating, may have a thickness of 5 to 25 millimeters (mm), or, from 7 to 20 mm. The nonwoven material, before heating, can have a surface weight of 600 to 2,500 grams per square meter (g / m 2 ), or from 700 to 2,000 g / m 2 .
    In one embodiment and as illustrated in Figure 1, the nonwoven material 12 is placed between a pair of plates 14 of a contact heating press or an oven 16. In Figure 2, the press is closed and the material 12 is heated.
    Once the nonwoven material 12 is heated to the desired temperature, a decorative film 18 is applied to the heated nonwoven material 12. The film can be applied by a contact roller 20 or a roller system 22 having a contact roller 20 and a reel supplying the decorative film 18. The film 18 is perforated to aid in the release of trapped air or gases between the film 18 and the nonwoven material 12 during forming.
    In certain embodiments, the decorative film 18 is a thermoplastic olefin (such as a compact sheet of TPO) in order to obtain a hard, grainy surface finish of the product or of the trim piece. In some embodiments, the decorative film 18 is a coextruded film having a layer of TPO and a layer of polypropylene. The decorative film may have a total thickness of 0.1 to 1.1 millimeter (mm), or 0.2 to 0.7 mm, or 0.2 to 0.5 mm.
    The film has perforations (holes). The perforations may have any suitable shape. In some embodiments, the perforations are round or ovoid. The perforations can have an area of 6.5x10 ' 9 to 25.8xt0' 9 square meters. When the perforation area is discussed here, it is the area of a single perforation, unless otherwise indicated. The density of the perforations can be from 310,000 to 542,500 perforations per square meter. The perforations can be arranged in an appropriate pattern, such as offset rows. The film can have a total open area (porosity) of 0.25-0.90%. The total open area is defined as the total area of the holes divided by the total area of the film. The perforated film may have a tensile strength and a tensile modulus suitable for making a trim panel.
    In certain embodiments, the decorative film 18 is a layer of thermoplastic olefin laminated on a layer of foam. The thickness can be from 0.6 mm to 4.7 mm.
    The decorative film 18 now coating the nonwoven material 12 is illustrated in the form of two-layer laminate 26 which is then transferred to a forming tool 28, illustrated in at least Figures 5 to 8. The two-layer laminate 26 is placed between the two complementary halves 30 of the forming tool 28. In one embodiment, the cavity 32 of one of the halves 30 is heated. The half cavity 30 of the heated tool 28 is heated near the presentation surface of the part (e.g. the decorative film 18) in order to provide a uniform gloss and a constant reproduction of the grain depth on the entire game surface. In FIG. 5, the forming tool 28 is closed and the graining and forming of the two-layer laminate 26 occurs to form a shape of the end part. The use of heat in the cavity provides a modular shine to the presentation surface of the game. This is partly due to the depth of the grain cavities in the tool of the cavity 32. The gloss of the presentation surface is greater for smaller depths of grain cavities while a lower gloss is provided with a higher grain cavity depth. In addition, a more homogeneous gloss also results from a more uniform and precise polymer reproduction of the tool surface which has a high temperature, and therefore, the homogeneity of the gloss is ensured regardless of the type or depth of grain. Thus, changing the grain depth is not necessary in order to achieve desired visual improvements to the presentation surface.
    In some embodiments, the cavity is porous or has small ventilation holes to allow any gas released to escape from the materials being molded. In some embodiments, the tool is closed, briefly opened to allow any released gas to escape, and then closed to complete the molding operation.
    Shortly after the tool is closed, a thermoplastic resin 33 is injected behind the nonwoven material, producing reinforcing ribs and rear fixing elements for the part being formed. The tool can be either heated or cooled at this stage. This is illustrated in at least Figure 6.
    During the next step and as illustrated in at least Figure 7, edge processing slides 34 are activated and pushed laterally in the direction of the arrows 36 in order to complete the finishing of a peripheral edge of the part being formed. This step is performed when the tool is unheated or cold.
    In the next step and as illustrated in at least Figure 8, the tool is opened and a formed part 38 is removed from the mold. In the demolded part, the combination of the nonwoven material and the decorative envelope may have a thickness of 0.5 to 2.5 mm, or from 0.9 to 1.5 mm. In one embodiment, the formed part 38 may be a part of a vehicle interior such as a trim panel, console, door panel or dashboard or any other product which has a presentation surface. and requires structural integrity and light weight requirements. As soon as it is removed from the mold, the formed part 38 is transferred to a secondary tool (not shown) for lining the internal openings, applying localized coatings and final assembly. The compression / injection process described above produces a film-coated nonwoven portion which emulates a color molded seed injection molded thermoplastic to a significantly reduced mass.
    In some embodiments, the injection pressures need to be limited in order to eliminate any visible marking of the elements injected back onto the presentation surface 40 of the formed part 38 as well as to ensure filling with these elements. The use of a sequential valve opening / closing control for injection drops and thermoplastic materials with a higher melt index are typical for minimizing injection pressure. In one embodiment, foaming agents (chemical or physical) are used in the thermoplastic material to significantly reduce the injection pressure while allowing the use of a high charge thermoplastic resin as required to achieve the desired level of mechanical properties of the thermoplastic material.
    As indicated above, the variation in gloss on the presentation surface of the part resulting from incoherent injection and forming pressures is eliminated by the use of the rapid heating and cooling technology incorporated in half. cavity of the forming tool. Raising the temperature of the tool cavity during compression ensures that the tooling surface will be reproduced uniformly on the part and the fibers will be contained under the surface 40 of the part 38. The high temperature of the tool can be maintained during the feedback phase as needed to further improve the surface appearance. The tool is then cooled sufficiently before the back injection and the subsequent release of the part.
    Referring now to Figure 10, a method 50 of forming the component or the trim portion 38 according to a non-limiting embodiment is illustrated. As mentioned above and in step 52, a nonwoven material is placed between the plates of a contact heat press.
    Thereafter and in step 54, the press is closed and the material is heated to a forming temperature (typically 200 to 210 degrees C). Subsequently and in step 56, the heated nonwoven material is removed from the contact heat press and a film is applied through a roller system to form the two-layer laminate. Subsequently and in step 58, the two-layer laminate is placed between the halves of the tool and the tool cavity is heated. Thereafter and in step 60, the press is closed and the nonwoven material coated with heated film is formed and compressed between the halves of the forming tool while the tool cavity is heated. Thereafter and in step 70, a thermoplastic resin is back-injected behind the two-layer laminate while the tool cavity is heated. Thereafter and in step 72, edge processing slides are activated to line the periphery of the part and the tool cavity is cold or unheated. In step 74, the finished product is removed from the tool and is ready for internal hole filling and secondary assembly operations.
    As illustrated in Figures 11 to 20, an alternative embodiment is illustrated. First, a nonwoven material 12 is heated (by contact or by IR heating) in an oven 16 to an appropriate treatment temperature (Figures 11 and 12). A decorative film 18 is placed in the tool cavity 32 (Figure 13). In some embodiments, the tool cavity is heated before placing the decorative film in the cavity. In some embodiments, the decorative film is heated after being placed in the cavity and before contact with the nonwoven material.
    The heated nonwoven material 12 is placed in the tool cavity 32 adjacent to the decorative film 18 and the tool is closed (Figures 14 and 15). In some embodiments, the cavity 30 is porous or has small ventilation holes to allow any released gas to escape from the materials being molded. In some embodiments, the forming tool is closed, briefly opened to allow any released gas to escape, and then closed to complete the molding operation. After the forming tool is closed, the embossing and forming of the decorative film 18 on the nonwoven material 12 occurs and the resulting two-layer laminate is formed into a shape of the end part. The decorative film is perforated to help release trapped gases.
    The film has perforations (holes). The perforations may have any suitable shape. In some embodiments, the perforations are round or ovoid. The perforations can have an area of 6.5 × 10 9 to 25.8 × 10 9 square meters. The density of the perforations can be from 310,000 to 542,500 perforations per square meter. The perforations can be arranged in an appropriate pattern, such as offset rows. The film can have a total open area (porosity) of 0.25-0.90%. The total open area is defined as the total area of the holes divided by the total area of the film. The perforated film may have a tensile strength and a tensile modulus suitable for making a trim panel.
    Shortly after the forming tool is closed, a thermoplastic resin 33 is injected behind the nonwoven material 12, producing reinforcing ribs and rear fasteners (Figure 16). In FIG. 17, the edge processing slides 34 are activated in the direction of the arrows 36 to finish the peripheral edge of the part 38 while the tool is cold or cools.
    In Figure 18, the tool-opens and the part 38 is removed from the mold. Referring now to Figure 20, a method 100 of forming the packing component or part 38 according to a non-limiting embodiment is illustrated. As mentioned above and in step 102, a nonwoven material is placed between the plates of a contact heat press. Thereafter and in step 104, the press is closed and the material is heated to a forming temperature (typically 200 to 210 degrees C). Subsequently and in step 106, a decorative film is loaded between the halves of the forming tool such as a compression mold. Thereafter and in step 108, the heated nonwoven material is placed between the halves of the forming tool adjacent to the decorative film, and the tool cavity is heated. Subsequently and in step 110, the tool is closed, the forming and compression of the heated nonwoven material and the decorative film between the halves of a forming tool are carried out and the tool cavity is heated. Thereafter and in step 112, a thermoplastic resin is back-injected behind the two-layer laminate formed while the tool cavity is heated. Thereafter and in step 114, edge processing slides are activated to line the periphery of the part and the tool cavity is cold or unheated. In step 116, the finished product is removed from the tool and is ready for internal hole filling and secondary assembly operations.
    In one of the above embodiments, a barrier layer can be applied to the second surface of the nonwoven material before injecting the thermoplastic resin. The barrier layer may be a thermoplastic material having a higher melting temperature than that of the thermoplastic material which is injected into the tool. Without being bound by theory, it is believed that the barrier layer can help isolate the decorative layer from the temperature and pressure of the injection molded material thereby improving the finish of the final part. The barrier layer may have a thickness of 0.1 to 1.1 mm.
    Some advantages of the embodiments of this invention include: an improved appearance; a uniform surface gloss, bright rays and a well-defined grain; a first surface finish produced without the need for a secondary IMG laminating step; a surface briHant adjustable by adjusting the surface temperature of the tool cavity; cost reductions: a product formed with a first finished surface, back-injected, and trimmed around the perimeter in one tool no adhesive between a top coating (film or spray) and the substrate or nonwoven material; the mass of the product is reduced to a minimum; a top coat of minimum thickness required when formed with a nonwoven substrate; a light weight nonwoven material per unit area with back-injected ribbing.
    The method and the article are also described by the following embodiments.
    Embodiment 1: a method of forming a trim panel (38), comprising: placing a nonwoven material (12) in a heating press (16); heating the nonwoven material (12) to a predetermined temperature; applying a decorative film (18) to a first surface of the heated nonwoven material (12) to create a two-layer laminate (26); where the film has perforations having a surface area of 6.5x10 ' 9 to 25.8x10' 9 square meters, a density of perforations of 310,000 to 542,500 perforations per square meter, and a porosity of 0.25% to 0.90% ; placing the two-layer laminate (26) in a cavity (32) of a forming tool (28) so that the decorative film (18) faces the cavity (32); heating the cavity (32); closing the forming tool (28); and injecting a thermoplastic resin (33) into the forming tool (28) so that the thermoplastic resin is bonded to at least part of a second surface of the nonwoven material (12), the second surface being opposite at the first surface.
    Embodiment 2: The method of Embodiment 1, wherein the trim panel (38) is a part of a vehicle interior.
    Embodiment 3; The method according to embodiment 1 or 2, in which the decorative film (18) is applied to the material via a contact roller (20) of a roller system (22).
    Embodiment 4: The method according to any one of embodiments 1 to 3, in which the decorative film (18) is a thermoplastic olefin.
    Embodiment 5: The method according to any one of embodiments 1 to 4, in which the injection pressures of the thermoplastic resin (33) are limited using a sequential opening / closing control of the valve, foaming agents or agents promoting flow in order to significantly reduce the injection pressure.
    Embodiment 6: The method according to any of embodiments 1 to 5, wherein the predetermined temperature is in the range of 200 to 210 degrees Celsius.
    Embodiment 7: A trim piece (38) formed by one of the methods of embodiments 1 to 6.
    Embodiment 8: A trim panel (38), comprising: a nonwoven material (12); a decorative film (18) applied to a first surface of the nonwoven material (12) where the film has perforations having a surface area of 6.5 × 10 -9 to 25.8 × 1 0 * 9 square meters, a density of perforations of 310000 to 542,500 perforations per square meter, and a porosity of 0.25% to 0.90%; and a thermoplastic resin (33) attached to at least a portion of a second surface of the nonwoven material (12), the second surface being opposite the first surface.
    Embodiment 9: The trim panel according to Embodiment 8, wherein the trim panel (38) is a part of a vehicle interior.
    Embodiment 9: The trim panel according to Embodiment 8 or 9, wherein the trim panel is a part of a vehicle door.
    Embodiment 10: A method of forming a trim panel (38), comprising: placing a nonwoven material (12) in a heating press (16); heating the nonwoven material (12) to a predetermined temperature; inserting a decorative film (18) into a cavity (32) of a forming tool (28) where the film has perforations having a surface of 6.5 × 10 -9 to 25.8 × 10 9 square meters, a density perforations of 310,000 to 542,500 perforations per square meter; and a porosity of 0.25% to 0.90%, heating the cavity (32) of the forming tool; inserting the heated nonwoven material between the forming tool half and the decorative film so that a first surface of the nonwoven material comes into contact with the decorative film; closing the forming tool (28); and injecting a thermoplastic resin into the forming tool so that the thermoplastic resin is bonded to at least part of the second surface of the material, the second surface being opposite the first surface.
    Embodiment 11: The method in embodiment 11 in which the trim panel (38) is a part of a vehicle interior.
    Embodiment 12: The method according to embodiment 11 or 12, in which the decorative film (18) is a thermoplastic olefin.
    Embodiment 13: The method according to any one of embodiments 11 to 13, in which the injection pressures of the thermoplastic resin (33) are limited by using a sequential opening / closing control of the valve, foaming agents or agents promoting flow in order to significantly reduce the injection pressure.
    Embodiment 14: The method according to any of embodiments 11 to 14, wherein the predetermined temperature is in the range of 200 to 210 degrees Celsius.
    Embodiment 15: A trim piece (38) formed by the method of any one of embodiments 11 to 15.
    As used herein, the terms first, second, and the like, here do not indicate any order, quantity, or importance, but rather are used to distinguish one item from another. In addition, it should be noted that the terms lower and upper are used here, unless otherwise indicated, simply for convenience of description, and are not limited to any position or any spatial orientation. The numerical ranges described here are nonlimiting ranges. Values outside the non-limiting ranges described are considered to fall within the scope of various embodiments.
    The modifier approximately used in relation to a quantity includes the specified value and has the meaning dictated by the context (for example, includes the degree of error associated with the measurement of the particular quantity).
    Although the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes can be made and that some of its elements can be substituted by equivalents without deviate from the scope of the invention. In addition, many modifications can be made to adapt a particular situation or a particular material to the teachings of the invention without departing from the essential scope thereof. Consequently, it is intended that the invention is not limited to the particular embodiment disclosed as being the best mode envisaged for the implementation of this invention, but that the invention will include all of the embodiments falling under the scope of this application.
    权利要求:
    Claims (16)
    [1" id="c-fr-0001]
    1. A method of forming a trim panel (38), comprising the fact:
    placing a nonwoven material (12) in a heating press (16); heating the nonwoven material (12) to a predetermined temperature;
    applying a decorative film (18) to a first surface of the heated nonwoven material (12) to create a two-layer laminate (26); where the film has perforations having a surface area of 6.5x10 ' 9 to 25.8x10' 9 square meters, a density of perforations of 310,000 to 542,500 perforations per square meter, and a porosity of 0.25% to 0.90% ;
    placing the two-layer laminate (26) in a cavity (32) of a forming tool (28) so that the decorative film (18) faces the cavity (32);
    heating the cavity (32); to close the forming tool (28); and injecting a thermoplastic resin (33) into the forming tool (28) so that the thermoplastic resin is bonded to at least part of a second surface of the nonwoven material (12), the second surface being opposite at the first surface.
    [2" id="c-fr-0002]
    2. The method of claim 1, wherein the trim panel (38) is a part of a vehicle interior.
    [3" id="c-fr-0003]
    3. Method according to claim 1 or 2, wherein the decorative film (18) is applied to the material via a contact roller (20) of a roller system (22).
    [4" id="c-fr-0004]
    4. Method according to any one of claims 1 to 3, wherein the decorative film (18) is a thermoplastic olefin.
    [5" id="c-fr-0005]
    5. Method according to any one of claims 1 to 4, in which the injection pressures of the thermoplastic resin (33) are limited by using a sequential opening / closing control of the valve, of the foaming agents or of the agents promoting flow in order to significantly reduce the injection pressure.
    [6" id="c-fr-0006]
    The method according to any of claims 1 to 5, wherein the predetermined temperature is in the range of 200 to 210 degrees Celsius.
    [7" id="c-fr-0007]
    7. trim piece (38) formed by one of the methods of claims 1 to 6.
    [8" id="c-fr-0008]
    8. A trim panel (38), comprising: a nonwoven material (12);
    a decorative film (18) applied to a first surface of the nonwoven material (12) where the film has perforations having a surface area of 6.5 × 10 5 * 25 to 25.8 × 10 9 square meters, a density of perforations from 310,000 to 542,500 perforations per square meter, and a porosity of 0.25% to 0.90%; and a thermoplastic resin (33) attached to at least a portion of a second surface of the nonwoven material (12), the second surface being opposite the first surface.
    [9" id="c-fr-0009]
    The trim panel according to claim 8, wherein the trim panel (38) is a part of a vehicle interior.
    [10" id="c-fr-0010]
    A trim panel according to claim 8 or 9, wherein the trim panel is a part of a vehicle door.
    [11" id="c-fr-0011]
    11. A method of forming a trim panel (38), comprising the fact:
    placing a nonwoven material (12) in a heating press (16); heating the nonwoven material (12) to a predetermined temperature;
    inserting a decorative film (18) into a cavity (32) of a forming tool (28) where the film has perforations having a surface of 6.5 × 10 -9 to 25.8 × 10 9 square meters, a density perforations of 310,000 to 542,500 perforations per square meter; and a porosity of 0.25% to 0.90%, heating the cavity (32) of the forming tool;
    inserting the heated nonwoven material between half of the forming tool and the decorative film so that a first surface of the nonwoven material comes into contact with the decorative film;
    to close the forming tool (28); and injecting a thermoplastic resin into the forming tool so that the thermoplastic resin is bonded to at least part of the second surface of the material, the second surface being opposite the first surface.
    [12" id="c-fr-0012]
    The method of claim 11, wherein the trim panel (38) is a part of a vehicle interior.
    [13" id="c-fr-0013]
    13. The method of claim 11 or 12, wherein the decorative film (18) is a thermoplastic olefin.
    [14" id="c-fr-0014]
    14. Method according to any one of claims 11 to 13, in which the injection pressures of the thermoplastic resin (33) are limited
    5 by using a sequential valve opening / closing control, foaming agents or agents promoting flow in order to significantly reduce the injection pressure.
    [15" id="c-fr-0015]
    15. The method of any of claims 11 to 14, wherein the predetermined temperature is in the range of 200 to
    10,210 degrees Celsius.
    [16" id="c-fr-0016]
    16. A trim piece (38) formed by the method of any one of claims 11 to 15.
    1/10
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    同族专利:
    公开号 | 公开日
    DE102017121842A1|2018-03-29|
    FR3056440B1|2020-11-27|
    US20180085978A1|2018-03-29|
    CN107867033A|2018-04-03|
    US10377068B2|2019-08-13|
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    法律状态:
    2018-08-13| PLFP| Fee payment|Year of fee payment: 2 |
    2019-08-15| PLFP| Fee payment|Year of fee payment: 3 |
    2020-02-28| PLSC| Search report ready|Effective date: 20200228 |
    2020-08-12| PLFP| Fee payment|Year of fee payment: 4 |
    2021-09-13| PLFP| Fee payment|Year of fee payment: 5 |
    优先权:
    申请号 | 申请日 | 专利标题
    US201662398765P| true| 2016-09-23|2016-09-23|
    US62398765|2016-09-23|
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