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: (1) jute or natural linen and a second natural cotton fabric (2) or fibrous paper formed by cellulose and synthetic multi-directional microfibers, wherein the cut is made in the appropriate size and shape to the piece to be trimmed; b) impregnating the first (1) and second fabric (2) with an aqueous based adhesive resin and drying it; c) pressing the impregnated fabrics into a resin forming a pressed structure (3) comprising the first (1) and second fabrics (2); d) comprised of the structure to provide the part shape to be trimmed, previously adding an adhesive layer on one of the faces of the pressed structure (3) formed in the previous pressing stage and, on the adhesive layer, a decorative sheet (7); e) applying a primer layer on the decorative sheet (7) of the formed structure in the previous step and drying; f) applying at least one layer of varnish onto the primer layer and drying it. Wherein additionally, the adhesive is acrylic, polyurethane or solvent-based or water-based epoxy; the forming is carried out in a press with hot plates with the required shape, at temperatures between 100 C. and 120 C. and the thickness of the decorative sheet varies between 0.2 and 0.6 mm;

2. A method for trim preparation of car interior parts according to claim 1, characterized since the thickness of the first fabric (1) ranges from 0.1 to 0.8 mm and the thickness of the second fabric (2) ranges from 0.05 mm to 0.1 mm.

3. A method for trim preparation of car interior parts, according to claim 1, characterized since the decorative sheet is made of wood, carbon fiber or plastic material and its thickness varies between 0.2 and 0.6 mm.

4. A method for trim preparation of car interior parts according to claim 1, characterized since the fabrics are impregnated with aqueous based adhesive resin by spray (8) and/or by rollers (9).

5. A method for trim preparation of car interior parts according to claim 1, characterized since the aqueous based adhesive resin is an acrylic, vinyl, polyurethane or epoxy resin.

6. A method for trim preparation of car interior parts according to claim 1, characterized since the drying of the adhesive resin applied in step b) is carried out between 30 C. and 50 C.

7. A method for trim preparation of car interior parts according to claim 1, characterized since the pressing step c) is carried out in a hot plate press at temperatures between 245 C. and 265 C.

8. A method for trim preparation of car interior parts according to claim 1, characterized since the forming step d) is preferably carried out in a hot-plate press (6) at temperatures between 100 C. and 120 C.

9. A method for trim preparation of car interior parts according to claim 1, characterized since the adhesive indicated in step d) is acrylic, polyurethane or solvent-based or water-based epoxy.

10. A method for trim preparation of car interior parts according to claim 1, characterized since the primer may be acrylic, polyurethane or solvent-based or water-based epoxy.

11. A method for trim preparation of car interior parts according to claim 1, characterized since the drying step of the primer is carried out at a temperature between 18-25 C.

12. A method for trim preparation of car interior parts according to claim 1, characterized since the drying of the varnish applied in step f) is carried out in an oven at temperatures between 10 and 110 C. and during 1 and 10 hours.

13. A method for trim preparation of car interior parts according to claim 1, characterized since subsequent to the application and drying of at least one varnish layer, a cutting step is carried out to remove surpluses of material.

14. A method for trim preparation of car interior parts according to claim 13, characterized since the step of trim assembling into the workpiece is subsequently carried out at the trim stage.

15. A method for trim preparation of car interior parts, according to claim 14, characterized since the trim assembled on the article to be trimmed is varnished, sanded and polished.

16. A trim for car interior parts obtained according to the method described in claim 1.

17. Car interior part characterized by comprising a trim as described in claim 16.

18. Car interior part, according to claim 17, characterized since the part is a steering wheel.

Description

DESCRIPTION OF THE FIGURES

[0027] In order to aid in a better understanding of this invention, the following figures are included with illustrative and non-limiting character:

[0028] FIG. 1: shows a cut-away view of the first and second fabrics used in the method of this invention.

[0029] 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.

[0030] FIG. 3 shows a schematic view of a hot plate press used in the forming process of this invention (before and after the forming).

[0031] FIG. 4 shows a schematic view of a primer robot used in the pressing and forming process of this invention.

[0032] 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

[0033] 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.

[0034] 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.

[0035] Once the resin is impregnated, it is allowed to dry at 40 C. for a time varying between 30 minutes and 48 hours.

[0036] 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).

[0037] 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.

[0038] 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.

[0039] Three layers of varnish are applied to the primer layer as follows: [0040] a first layer of varnish and allowed to dry for one hour between 18-25 C., [0041] a second coat of varnish and allowed to dry for two hours between 18-25 C., [0042] a third layer of varnish and allowed to dry for three hours between 18-25 C.

[0043] Finally, the formed trim is placed in the oven for 10 hours at a temperature around 85 C. to completely dry the varnish.

[0044] 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.

[0045] 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.

[0046] To the trim already assembled in the steering wheel, it is applied 3 layers of varnish as follows: [0047] a first layer of varnish and allowed to dry for one hour between 18-25 C. [0048] a second coat of varnish and allowed to dry for one hour between 18-25 C. [0049] a third coat of varnish and allowed to dry for one hour between 18-25 C.

[0050] Finally, the trim is sanded and polished in a polishing robot, thus obtaining the final trimmed steering wheel.