Automobile instrument panel surface material and method of manufacturing same

Patent metadata

Field	Value
Publication number	US-11629457-B2
Application number	US-201716312856-A
Country	US
Kind code	B2
Filing date	Jun 22, 2017
Priority date	Jun 29, 2016
Publication date	Apr 18, 2023
Grant date	Apr 18, 2023

Abstract

An automobile instrument panel surface material includes a microfiber having an average single fiber diameter of 0.3 to 7 μm; and polyurethane, the automobile instrument panel surface material having nap formed of the microfiber, the automobile instrument panel surface material having, of light fastnesses measured according to a light fastness measurement method of JIS L 0843:2006 under conditions of a xenon arc intensity of 110 MJ/m2, a fading by gray scale evaluation of grade 3.5 or higher, the automobile instrument panel surface material having a glass haze of 10.0% or less as measured according to a glass haze evaluation method of ISO 6452:2007 under conditions of a heating temperature of 100° C. and a heating time of 20 hours.

First claim

The invention claimed is:

1. An automobile instrument panel surface material, comprising:
a microfiber having an average single fiber diameter of 0.3 to 7 μm; and
polyurethane containing a UV absorber having a vapor pressure of 5.0×10 E-6 Pa or less at 20° C.; and
0.01 to 0.1% by mass of a silicone oil in mass percentage relative to a total mass of the microfiber and the polyurethane,
wherein the polyurethane containing the UV absorber is coated with the silicone oil and does not contain the silicone oil, and
wherein the automobile instrument panel surface material has 1) a content of the UV absorber of 0.01 to 5% by mass in mass percentage relative to the polyurethane, 2) nap formed of the microfiber,
3) light fastnesses measured according to a light fastness measurement method of JIS L 0843:2006 under conditions of a xenon arc intensity of 110 MJ/m 2 , a fading by gray scale evaluation of grade 3.5 or higher, and
4) a glass haze of 10.0% or less as measured according to a glass haze evaluation method of ISO 6452:2007 under conditions of a heating temperature of 100° C. and a heating time of 20 hours.

2. The automobile instrument panel surface material according to claim 1 , wherein the polyurethane is polycarbonate polyurethane.

3. The automobile instrument panel surface material according to claim 1 , wherein the UV absorber has a vapor pressure of 1.0×10 E-7 Pa or less at 20° C.

4. A method of manufacturing the automobile instrument panel surface material according to claim 1 , the method comprising:
adding a UV absorber having a vapor pressure of 1.0×10 E-7 Pa or less at 20° C. to the polyurethane;
a polyurethane impregnating and adding step of impregnating and adding, to a fibrous base material containing a microfiber, the polyurethane containing the UV absorber added thereto; and after the polyurethane impregnating and adding step, and
adding to the fibrous base material to which the polyurethane is impregnated and added a silicone oil in an amount of 0.01 to 0.1% by mass in mass percentage relative to a total mass of the microfiber and the polyurethane,
wherein the automobile instrument panel surface material has a content of the UV absorber of 0.01 to 5% by mass in mass percentage relative to the polyurethane.

5. A method of manufacturing the automobile instrument panel surface material according to claim 2 , the method comprising:
adding a UV absorber having a vapor pressure of 1.0×10 E-7 Pa or less at 20° C. to the polyurethane;
a polyurethane impregnating and adding step of impregnating and adding, to a fibrous base material containing a microfiber, the polyurethane containing the UV absorber added thereto; and after the polyurethane impregnating and adding step, and
adding to the fibrous base material to which the polyurethane is impregnated and added a silicone oil in an amount of 0.01 to 0.1% by mass in mass percentage relative to a total mass of the microfiber and the polyurethane,
wherein the automobile instrument panel surface material has a content of the UV absorber of 0.01 to 5% by mass in mass percentage relative to the polyurethane.

6. A method of manufacturing the automobile instrument panel surface material according to claim 4 , the method comprising:
adding a UV absorber having a vapor pressure of 1.0×10 E-7 Pa or less at 20° C. to the polyurethane;
a polyurethane impregnating and adding step of impregnating and adding, to a fibrous base material containing a microfiber, the polyurethane containing the UV absorber added thereto; and after the polyurethane impregnating and adding step, and
adding to the fibrous base material to which the polyurethane is impregnated and added a silicone oil in an amount of 0.01 to 0.1% by mass in mass percentage relative to a total mass of the microfiber and the polyurethane,
wherein the automobile instrument panel surface material has a content of the UV absorber of 0.01 to 5% by mass in mass percentage relative to the polyurethane.

Assignees

• Toray Industries

Inventors

• Yanagisawa Satoshi
• Tanabe Akihiro
• Nishimura Makoto

Classifications

• B60K37/20

  Dashboard panels · CPC title

• D06N3/00

  Artificial leather, oilcloth or {other} material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof · CPC title

• D06N2209/1678

  Resistive to light or to UV · CPC title

• D06N3/18

  with two layers of different macromolecular materials (D06N3/08 takes precedence); {(with two layers of the same kind of macromolecular material D06N2213/03)} · CPC title

• D06N3/14 Primary

  with polyurethanes · CPC title