VOC REDUCING PATCH FOR TREATING AUTOMOTIVE PARTS

Abstract

A volatile organic compound (VOC) reducing patch for treating automotive trim parts, comprising at least one active layer comprising a carrier material and at least one aldehyde scavenger, whereby the aldehyde scavenger is distributed on the surface and/or throughout at least the carrier material, and further comprising an adhesive for connecting the patch to a trim part.

Claims

1. A volatile organic compound (VOC) reducing patch for treating automotive trim parts, comprising at least one active layer comprising a carrier material and at least one aldehyde scavenger, whereby the aldehyde scavenger is distributed on the surface and/or throughout at least the carrier material, characterized in that it further comprises an adhesive for connecting the patch to a trim part.

2. The VOC reducing patch according to claim 1, whereby the adhesive is applied at least partly around the rim of the patch, and/or in discrete points, and/or in a pattern, or as a full coverage of at least one outer surface.

3. The VOC reducing patch according to claim 1, whereby the adhesive is at least one of a natural rubber-based material, a synthetic rubber-based material, like styrene-butadiene rubber, acrylate-based material, methacrylate-based material, polyurethane-based material, or mixtures thereof.

4. The VOC reducing patch according to claim 1, whereby the carrier material is a fiber-based material, like a nonwoven, a scrim, a filter paper or a filter cloth, or a fiber-containing material like a textile, a woven, or a knit, preferably the fibers are staple fibers and/or endless filaments.

5. The VOC reducing patch according to claim 1, whereby the carrier material comprises at least one of polyester, cellulose-based, protein-based, polyolefin, preferably polypropylene or polyethylene, polyamide, or polyurethane, or a mixture thereof.

6. The VOC reducing patch according to claim 1, where the carrier material comprises a filter-paper or filter-cloth type material.

7. The VOC reducing patch according claim 1, whereby the aldehyde scavenger comprises at least one from the group of dihydrazides, preferably succinic acid dihydrazide, adipic acid dihydrazide, isophthalic acid dihydrazide, carbodihydrazide, or from the group of amines, preferably an aminosilane, or from the group of amine salts, or any combination of the aforementioned.

8. The VOC reducing patch according to claim 7, whereby the aldehyde scavenger further comprises at least one substance from the group consisting of urea, preferably ethylene urea, propylene urea.

9. The VOC reducing patch according to claim 7, whereby the aldehyde scavenger further comprises at least one of a silica gel, an aluminum oxide gel, an aluminosilicate, an activated carbon, or combinations thereof.

10. The VOC reducing patch according to claim 1, whereby the active layer is further comprising a binder for binding the scavengers to the carrier material, preferably at least one resin selected from acrylic resins, vinyl chloride/vinyl acetate copolymers, polyesters; polyvinyl butyral resins, ethyl cellulose resins, polyurethane resins, modified rosin resins, polyamide resins, cellulose ether resins, cellulose nitrate resins, poly(maleic anhydride) resins, acetal polymers, styrene/methacrylate copolymers, copolymers of styrene and allyl alcohols, polyhydroxystyrenes and polyketone resins, or any combination thereof.

11. The VOC reducing patch according to claim 1, whereby the patch further comprises at least one cover layer adjacent to and in contact with at least the active layer.

12. The VOC reducing patch according to claim 11, whereby the cover layer comprises an air permeable or microperforated material, preferably chosen from the group of a film, a foil, a nonwoven, a scrim, a textile, or a coating.

13. The VOC reducing patch according to claim 11, whereby the cover layer may comprise the same material as the carrier material, preferably a material chosen from at least a polyester, polyolefin, cellulose, or polyamide, or any combination of the aforementioned.

14. The VOC reducing patch according to claim 1, further comprising a release layer to cover the adhesive layer, whereby the release layer can be removed before the application of the patch to the automotive trim part.

15. An automotive interior trim part comprising at least one VOC reducing patch according to claim 1, whereby the patch is adhered to a surface of the trim part.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0078] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of these inventions.

[0079] FIG. 1 shows a trim part with the patch according to the invention.

[0080] FIG. 2 shows a schematic layout of the trim part according to the invention.

[0081] FIG. 3 shows an alternative embodiment according to the invention.

[0082] FIG. 4 is a schematic of the function of the patch applied on a trim part.

[0083] It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

[0084] FIG. 1 shows an example of a trim part 1 in the form of a flooring part with a cover layer 2, for instance, a tufted or needle punch nonwoven surface layer facing the passenger compartment (not shown), and a foil layer 3 acting as a barrier layer against the back foamed decoupling layer 4. In particular, back foamed in the sense of an in-mold foamed polyurethane layer is a likely source for aldehydes like acetaldehyde and formaldehyde. The trim part is treated on the backside of the part with a patch 5 according to the invention adhered to the trim part with adhesive 8. The patch comprises an active layer 6 and an optional cover layer 7. In this example, the adhesive is placed on the cover layer 7 surrounding the active layer 6. The active layer 6 may be connected to the cover layer by either the same adhesive or by another known version of lamination or may be kept loose within the patch enclosed by the cover layer and the adhesive.

[0085] FIG. 2 shows a patch according to the invention with an optional release layer 11. The patch comprises at least one active layer 6 comprising a carrier material 9 and at least one aldehyde scavenger 10, whereby the aldehyde scavenger 10 is distributed on the surface and/or throughout at least the carrier material 9. The patch is further comprising an adhesive 8 for connecting the patch to a trim part.

[0086] FIG. 3 shows an alternative patch according to the invention with again a carrier layer 9 and an adhesive 8, but in addition, the patch comprises at least one covering layer 7. The adhesive may be applied on either the carrier layer, the covering layer or both. Preferably, the covering layer is extended beyond the size of the carrier layer as shown, and forms a rim around the carrier layer. The adhesive applied to the rim of the cover layer encapsulates the active layer formed by the carrier material and the aldehyde scavenger 10. This further minimizes the risk of contact between the active component and the user. Preferably, the covering layer is hydrophobic; however small aldehyde molecules like formaldehyde or acetaldehyde may freely pass through the covering layer to reach the active component in the carrier layer.

[0087] FIG. 4 illustrates the function of the patch while in use and adhered to a trim part 4. Although the patch illustrated in FIG. 4 uses the patch from FIG. 2, the principle works in the same or similar way for all versions disclosed. The figure shows a patch as applied to a trim part 4 with at least one layer, which may be a foam or a felt. This layer may emit VOCs, including aldehydes, in particular acetaldehyde and formaldehyde.

[0088] In the case the emitting surface is not covered by the patch, the aldehydes are emitted into the adjacent cavity. The concentration of aldehydes in the adjacent cavity is increased and then decreased as they are adsorbed and reacted into the active layer 6 of the VOC removing patch as indicated by the arrow 13.

[0089] In the case the emitting surface is covered by the patch, the aldehydes are directly captured by the substance in the active layer 6, as indicated by the arrow 12.

[0090] Exemplary characteristics of embodiments of the present invention have been described. However, to avoid unnecessarily obscuring embodiments of the present invention, the preceding description may omit several known apparatus, methods, systems, structures, and/or devices one of ordinary skill in the art would understand are commonly included with the embodiments of the present invention. Such omissions are not to be construed as a limitation of the scope of the claimed invention. Specific details are set forth to provide an understanding of some embodiments of the present invention. It should, however, be appreciated that embodiments of the present invention may be practiced in a variety of ways beyond the specific detail set forth herein.

[0091] Modifications and alterations of the various embodiments of the present invention described herein will occur to those skilled in the art. It is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. Further, it is to be understood that the invention(s) described herein is not limited in its application to the details of construction and the arrangement of components set forth in the preceding description or illustrated in the drawings. That is, the embodiments of the invention described herein are capable of being practiced or of being carried out in various ways. The scope of the various embodiments described herein is indicated by the following claims rather than by the foregoing description. And all changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.

[0092] The foregoing disclosure is not intended to limit the invention to the form or forms disclosed herein. In the foregoing Detailed Description, for example, various features of the invention are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed inventions require more features than expressly recited. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the invention. Further, the embodiments of the present invention described herein include components, methods, processes, systems, and/or apparatus substantially as depicted and described herein, including various sub-combinations and subsets thereof. Accordingly, one of skill in the art will appreciate that would be possible to provide for some features of the embodiments of the present invention without providing others. Stated differently, any one or more of the aspects, features, elements, means, or embodiments as disclosed herein may be combined with any one or more other aspects, features, elements, means, or embodiments as disclosed herein.