Method for trim preparation of car interior parts and trim as prepared

Abstract

A method for trim preparation of car interior parts includes the steps of cutting out templates of natural jute or linen fabric primer and a second natural cotton fabric or fiber paper, and impregnation of the fabrics with a water-based adhesive resin in each of the fabrics and drying thereof. The method also includes the steps of fabric pressing, forming a structure by adding an adhesive layer and a decorative sheet, applying primer on the decorative layer and drying it, and applying at least one layer of varnish onto the primer layer and drying it.

Claims

1. A method for trim preparation of car interior parts characterized by the following steps: cutting a first fabric (1) made of jute or natural linen and a second fabric (2) made of natural cotton or fibrous paper formed by cellulose and synthetic multi-directional microfibers, wherein the cut is made in an appropriate size and shape to the part to be trimmed; impregnating the first fabric (1) and the second fabric (2) or fibrous paper with an aqueous based adhesive resin and drying them; pressing the impregnated first fabric (1) and the impregnated second fabric (2) or fibrous paper together to form a pressed structure (3) comprising the first fabric (1) and the second fabric (2) or fibrous paper; adding an adhesive layer on one of the faces of the pressed structure (3) and adding a decorative sheet (7) on the adhesive layer and forming a formed structure in a required shape of the part to be trimmed; applying a primer layer to the decorative sheet (7) of the formed structure and drying the primer layer; applying at least one layer of varnish onto the primer layer and drying the varnish; wherein, the adhesive layer is acrylic, polyurethane, solvent-based epoxy or water-based epoxy; the forming is carried out in a press with hot-plate press (6) at temperatures between 100° C. and 120° C., and the thickness of the decorative sheet varies between 0.2 and 0.6 mm.

2. The method of claim 1, wherein the thickness of the first fabric (1) ranges from 0.1 to 0.8 mm and the thickness of the second fabric (2) or the fibrous paper ranges from 0.05 mm to 0.1 mm.

3. The method of claim 1, wherein the decorative sheet is made of wood, carbon fiber or plastic material and its thickness varies between 0.2 and 0.6 mm.

4. The method of claim 1, wherein the first fabric (1) and the second fabric (2) or the fibrous paper are impregnated with aqueous based adhesive resin by spray (8) and/or by rollers (9).

5. The method of claim 1, wherein the aqueous based adhesive resin is an acrylic, vinyl, polyurethane or epoxy resin.

6. The method of claim 1, wherein the drying of the adhesive resin is carried out between 30° C. and 50° C.

7. The method of claim 1, wherein the pressing step is carried out in a hot plate press at temperatures between 245° C. and 265° C.

8. The method of claim 1, wherein the primer is acrylic, polyurethane, solvent-based epoxy or water-based epoxy.

9. The method of claim 1, wherein the drying step of the primer layer is carried out at a temperature between 18-25° C.

10. The method of claim 1, wherein the drying of the varnish is carried out in an oven at temperatures between 10 and 110° C. and during 1 and 10 hours.

11. The method of claim 1, wherein subsequent to the application and drying of at least one varnish layer, a cutting step is carried out to remove surpluses of material.

Description

DESCRIPTION OF THE FIGURES

(1) In order to aid in a better understanding of this invention, the following figures are included with illustrative and non-limiting character:

(2) FIG. 1: shows a cut-away view of the first and second fabrics used in the method of this invention.

(3) FIG. 2: A) shows a schematic view of impregnation # with water-based resin in the fabrics by means of rollers, B) shows a schematic view of the water-based resin deposition on the fabrics by spray.

(4) FIG. 3 shows a schematic view of a hot plate press used in the forming process of this invention (before and after the forming).

(5) FIG. 4 shows a schematic view of a primer robot used in the pressing and forming process of this invention.

(6) FIG. 5 shows a schematic view of the coating assembly of this invention in a steering wheel by a hot plate press (a section of the steering wheel is shown).

DETAILED DESCRIPTION OF THE INVENTION

(7) In order to provide a better understanding of this invention, a preferred embodiment is explained in detail as follow. The figures presented illustrate some of the steps of the method.

(8) In order to cover a steering wheel (5) of a car, a trim is prepared by cutting insoles of a first jute fabric (1) of 0.65 mm thick and a second natural cotton fabric (2) of 0.1 mm of thickness. The insoles have the appropriate size and shape to trim the steering wheel. Subsequently, a water-based acrylic adhesive resin with pH 3.5 is impregnated in each of the fabrics, either by rollers (9) or by spray (8) (see FIG. 2). In general, by means of rollers a greater or deeper impregnation of the resin is achieved in the fabrics.

(9) Once the resin is impregnated, it is allowed to dry at 40° C. for a time varying between 30 minutes and 48 hours.

(10) The two fabrics are then pressed in a hot plate press at a temperature of 255° C. for 10 seconds. In this way, a pressed structure (3) is formed that comprises the first (1) and second fabrics (2).

(11) The structure is then formed into a hot platen press (6) in the shape of the workpiece (see FIG. 3). To this end, a layer (4) of acrylic, polyurethane or water-based or solvent-based epoxy adhesive is added to the structure (3) formed in the previous step and, on the adhesive (4), a wooden decorative sheet (7) of 0.5 mm and the required shape is given to the structure in a hot plate press (6) at 110° C. for 350 seconds.

(12) Then an acrylic, polyurethane or solvent-based or water-based epoxy primer is applied by means of a primer robot 8 (see FIG. 4) on the wooden sheet (7) of the structure formed in the previous step. Subsequently, drying is performed at a temperature between 18-30° C.

(13) Three layers of varnish are applied to the primer layer as follows: a first layer of varnish and allowed to dry for one hour between 18-25° C., a second coat of varnish and allowed to dry for two hours between 18-25° C., a third layer of varnish and allowed to dry for three hours between 18-25° C.

(14) Finally, the formed trim is placed in the oven for 10 hours at a temperature around 85° C. to completely dry the varnish.

(15) Once dry, the trim is cut if on material according to the part to be trimmed, in this case, the steering wheel (5) of a car.

(16) To assemble the trim on the steering wheel (5), it is glued on the wheel by a hot plate press at a temperature of about 110° C. In FIG. 5 the trim assembly on the steering wheel is shown in the wheel (5). In this case, two trim pieces would be needed in order to trim the front and back of the steering wheel.

(17) To the trim already assembled in the steering wheel, it is applied 3 layers of varnish as follows: a first layer of varnish and allowed to dry for one hour between 18-25° C. a second coat of varnish and allowed to dry for one hour between 18-25° C. a third coat of varnish and allowed to dry for one hour between 18-25° C.

(18) Finally, the trim is sanded and polished in a polishing robot, thus obtaining the final trimmed steering wheel.