Automobile interior sheet using waste TPO (thermoplastic olefin) composite sheet and method of manufacturing same

Patent metadata

Field	Value
Publication number	US-12343963-B2
Application number	US-202218088371-A
Country	US
Kind code	B2
Filing date	Dec 23, 2022
Priority date	Mar 28, 2022
Publication date	Jul 1, 2025
Grant date	Jul 1, 2025

Abstract

An vehicle interior sheet, particularly a vehicle interior sheet using a waste TPO composite sheet capable of preventing environmental pollution by recycling industrial waste, and a method of manufacturing the same includes manufacturing a powder by pulverizing a waste TPO composite sheet, manufacturing recycled TPO resin pellets by processing the powder using an extruder, and manufacturing a recycled TPO layer by subjecting the recycled TPO resin pellets to calendering or extrusion molding.

First claim

What is claimed is:

1. An vehicle interior sheet comprising:
a recycled Thermoplastic olefin (TPO) layer comprising a recycled TPO resin, wherein the recycled TPO resin is obtained from a waste TPO composite sheet;
a foam layer disposed under the recycled TPO layer;
a surface treatment layer disposed above the recycled TPO layer;
a backside treatment layer disposed under the foam layer,
wherein the waste TPO composite sheet comprises a crosslinked TPO sheet,
wherein the crosslinked TPO sheet further comprises an ethylene-propylene diene monomer,
wherein the recycled TPO layer further comprises a non-recycled TPO resin, a weight ratio of the recycled TPO resin:non-recycled TPO resin is 1:0.1 to 1:9
wherein the surface treatment layer and the backside treatment layer comprises a polyurethane resin.

2. The vehicle interior sheet of claim 1 , wherein the recycled TPO resin comprises at least one of polypropylene, polyethylene, a polypropylene copolymer comprising alpha-olefins having 2 to 12 carbon atoms, a polypropylene terpolymer comprising alpha-olefins having 2 to 12 carbon atoms, a polyethylene copolymer comprising alpha-olefins having 2 to 12 carbon atoms, a polyethylene terpolymer comprising alpha-olefins having 2 to 12 carbon atoms, a diene-based rubber or any combination thereof.

3. The vehicle interior sheet of claim 1 , wherein the crosslinked TPO sheet comprises a composite resin comprising polyethylene, polypropylene, sulfur, oil, a reinforcing filler, a vulcanization activator, a vulcanization accelerator, and an antioxidant.

4. The vehicle interior sheet of claim 3 ,
wherein the vulcanization activator comprises 1 to 5 parts by weight of zinc oxide and 0.1 to 2 parts by weight of stearic acid, based on 100 parts by weight of the composite resin,
wherein the vulcanization accelerator is N-(1,3-dimethyl) N′-phenyl-p-phenylenediamine included in amount of 0.1 to 2 parts by weight based on 100 parts by weight of the composite resin,
wherein the antioxidant is polymerized 2,2,4-trimethyl-1,2-dihydroquinoline included in an amount of 0.1 to 2 parts by weight based on 100 parts by weight of the composite resin.

5. The vehicle interior sheet of claim 1 , further comprising:
a cover layer disposed between the recycled TPO layer and the surface treatment layer;
wherein the cover layer comprises at least one of polypropylene, polyethylene, a polypropylene copolymer comprising alpha-olefins having 2 to 12 carbon atoms, a polypropylene terpolymer comprising alpha-olefins having 2 to 12 carbon atoms, a polyethylene copolymer comprising alpha-olefins having 2 to 12 carbon atoms, a polyethylene terpolymer comprising alpha-olefins having 2 to 12 carbon atoms or any combination thereof.

6. The vehicle interior sheet of claim 1 , wherein the foam layer comprises base resin of polypropylene, polyethylene and further comprises ethylene-propylene rubber,
wherein the ethylene-propylene rubber is included in an amount of 10 to 30 wt %,
wherein a weight average molecular weight of the ethylene-propylene rubber is 150,000 to 300,000 g/mol,
wherein the foam layer comprise a capsule foaming agent in an amount of 3 to 20 parts by weight, based on 100 parts by weight of the base resin.

7. The vehicle interior sheet of claim 1 , wherein the recycled TPO layer has a thickness of 0.1 to 0.6 mm,
wherein the surface treatment layer has a thickness of 1 to 20 μm,
wherein the foam layer has a thickness of 1.0 to 4.0 mm,
wherein the backside treatment layer has a thickness of 1 to 5 μm.

Assignees

• Hyundai Motor Co Ltd
• Kia Corp

Inventors

• Noh Eun Ju
• Han In Soo
• Lee Kyung Min
• Jung Yong Bae
• Woo Jae Hoon
• Son Gyu Il
• Dong Gyeong Pil

Classifications

• C08L23/12 Primary

  Polypropene · CPC title

• B29K2023/12

  PP, i.e. polypropylene · CPC title

• B29K2023/06

  PE, i.e. polyethylene · CPC title

• B29C48/07

  Flat, e.g. panels · CPC title

• B29C48/0011

  combined with compression moulding · CPC title