Method in which a vehicle interior trim part with a decor layer comprising paper layers is produced

Patent metadata

Field	Value
Publication number	US-10131128-B2
Application number	US-201514945100-A
Country	US
Kind code	B2
Filing date	Nov 18, 2015
Priority date	Nov 18, 2014
Publication date	Nov 20, 2018
Grant date	Nov 20, 2018

Abstract

A method in which an interior trim part for a vehicle is produced. The method includes the steps of providing a block of material comprising a plurality of paper layers connected to each other by at least one resin, cutting the block into slices, wherein a cutting plane has an angle between 5° and 85° in relation to layer planes of the paper layers, providing a flexible support layer and applying at least one of the slices to the flexible support layer to obtain a flexible composite layer, and providing a rigid carrier and applying the flexible composite layer directly or indirectly to the carrier.

First claim

The invention claimed is:

1. Method in which an interior trim part for a vehicle is produced, comprising the steps:
providing a block of material comprising a plurality of paper layers connected to each other by at least one resin;
cutting the block into slices along a cutting plane that has an angle between 5° and 85° in relation to layer planes of the paper layers, wherein the block is cut with a cutting tool, wherein the cutting tool cuts each paper layer by contacting the paper layer on a first side, then passes through the paper layer and leaves the paper layer again on a second side, wherein the first side of each of the paper layers has a surface normal facing out of the slice to be cut;
providing a flexible support layer and applying at least one of the slices to the flexible support layer to obtain a flexible composite layer; and
providing a rigid carrier and applying the flexible composite layer directly or indirectly to the carrier.

2. Method according to claim 1 , wherein the block of material provided comprises a content of resin which is higher than 10 wt % of a total weight of the block of material and/or a content of cellulose, lignin or a mixture thereof which is lower than 90 wt % of a total weight of the block of material.

3. Method according to claim 1 , wherein the flexible composite layer is laminated onto the rigid carrier.

4. Method according to claim 1 , wherein the carrier is provided and connected to the flexible composite layer in one integral step.

5. Method according to claim 4 , wherein the carrier is provided and connected to the flexible composite layer by back injecting a plastic material into a mold and into contact with the composite layer.

6. Method according to claim 1 , further comprising the step of smoothing a surface of the slices.

7. Method according to claim 1 , wherein the slice cut from the block of material is smoothed after it has been applied to the flexible support layer.

8. Method according to claim 7 , wherein the slice of the block of material is smoothed after the composite layer has been applied to the carrier.

9. Method according to claim 1 , wherein the block of material is cut into slices which comprise a thickness of less than 2 mm.

10. Method according to claim 9 , wherein the thickness is less than 1.5 mm.

11. Method according to claim 10 , wherein the thickness is less than 1 mm.

12. Method according to claim 1 , wherein the block of material is provided by soaking multiple paper layers with resin and pressing the multiple paper layers together.

Assignees

• Faurecia Innenraum Systeme Gmbh

Inventors

• Beau Godefroy
• Piccin Hugo
• Salandre Maxime

Classifications

• B29C45/14631

  Coating reinforcements (fibre reinforcements B29C45/0005) · CPC title

• B32B37/10

  characterised by the pressing technique, e.g. using action of vacuum or fluid pressure · CPC title

• B29C70/78

  Moulding material on one side only of the preformed part · CPC title

• B32B2451/00

  Decorative or ornamental articles · CPC title

• B32B2605/08

  Cars · CPC title