Vehicle interior material and manufacturing method therefor

Patent metadata

Field	Value
Publication number	US-10137669-B2
Application number	US-201515325915-A
Country	US
Kind code	B2
Filing date	Jul 14, 2015
Priority date	Jul 15, 2014
Publication date	Nov 27, 2018
Grant date	Nov 27, 2018

Abstract

Provided is a vehicle interior material comprising coating layers formed on both surfaces of a veneer layer; a back layer on the coating layer of one surface of the veneer layer; and a front layer on the coating layer of the other surface of the veneer layer. Provided is a method of manufacturing a vehicle interior material comprising steps of: providing a veneer layer; forming coating layers on both surfaces of the veneer layer by applying and drying water-dispersible polyurethane dispersion or water-dispersible acrylic polyurethane dispersion on the both surfaces; pre-forming a real wood film layer prepared by forming the coating layers on the both surfaces of the veneer layer; forming a back layer on the coating layer of one surface of the veneer layer by primary insert molding; and forming a front layer on the coating layer of the other surface of the veneer layer by secondary insert molding.

First claim

The invention claimed is:

1. A vehicle interior material comprising:
coating layers formed on both surfaces of a veneer layer, wherein the coating layers are formed from water-dispersible polyurethane dispersion or water-dispersible acrylic polyurethane dispersion, wherein
the water-dispersible polyurethane dispersion or the water-dispersible acrylic polyurethane dispersion comprises a solid content of 10% to 40% by weight,
the water-dispersible polyurethane dispersion or the water-dispersible acrylic polyurethane dispersion further comprises a silica compound, and
the water-dispersible polyurethane dispersion or the water-dispersible acrylic polyurethane dispersion comprises 5 to 30 parts by weight of the silica compound with respect to 100 parts by weight of the solid content of the dispersion;

a back layer on the coating layer of one surface of the veneer layer, and
a front layer on the coating layer of the other surface of the veneer layer,
wherein each of the front layer and the back layer comprises one or more thermoplastic resins, and wherein a thickness of the coating layers is 5 μm to 50 μm.

2. The vehicle interior material of claim 1 , wherein a thickness of the veneer layer is 100 μm to 600 μm.

3. The vehicle interior material of claim 1 , wherein the one or more thermoplastic resins are selected from the group consisting of acrylic resin, polycarbonate resin, acrylonitrile-butadiene-styrene copolymer (ABS) resin, polyester resin, polymethyl methacrylate (PMMA) resin and a combination thereof.

4. A method of manufacturing a vehicle interior material, comprising steps of:
providing a veneer layer;
forming coating layers on both surfaces of the veneer layer by applying and drying water-dispersible polyurethane dispersion or water-dispersible acrylic polyurethane dispersion on the both surfaces;
pre-forming a real wood film layer prepared by forming the coating layers on the both surfaces of the veneer layer;
forming a back layer on the coating layer of one surface of the veneer layer by primary insert molding; and
forming a front layer on the coating layer of the other surface of the veneer layer by secondary insert molding,
wherein the step of forming the coating layers comprises a step of further adding a silica compound to the water-dispersible polyurethane dispersion or the water-dispersible acrylic polyurethane dispersion,
the water-dispersible polyurethane dispersion or the water-dispersible acrylic polyurethane dispersion comprises a solid content of 10% to 40% by weight,
the water-dispersible polyurethane dispersion or the water-dispersible acrylic polyurethane dispersion comprises 5 to 30 parts by weight of the silica compound with respect to 100 parts by weight of the solid content of the dispersion, and
each of the front layer and the back layer comprises one or more thermoplastic resins; and a thickness of the coating layers is 5 μm to 50 μm.

5. The method of claim 4 , wherein the silica compound is formed by a sol-gel process.

6. The method of claim 4 , wherein the step of pre-forming the real wood film layer is carried out at a temperature of 100° C. to 150° C. for 20 seconds to 120 seconds.

7. The method of claim 4 , further comprising a step of cutting unnecessary portions of the real wood film layer after pre-forming the real wood film layer.

8. The method of claim 4 , wherein the primary insert molding and the secondary insert molding are performed at the same time.

9. The method of claim 4 , wherein the primary insert molding and the secondary insert molding are performed at a temperature of 200° C. to 250° C.

Assignees

• Lg Hausys Ltd

Inventors

• Kim Heon-Jo
• Ryu Mu-Seon
• Kim Won-Kook
• Park Chun-Ho

Classifications

• B29K2033/08

  Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate · CPC title

• B32B27/36

  comprising polyesters · CPC title

• B29C45/14819

  the inserts being completely encapsulated · CPC title

• B32B27/10

  of paper or cardboard · CPC title

• B29K2711/14

  Wood, e.g. woodboard or fibreboard · CPC title