In-mold-coated automotive interior and other products, and methods for manufacturing same

Abstract

Described are in-mold coated products such as vehicular components, in-mold coating methods, and in-mold coating compositions, involving the use of aqueous acrylic copolymer dispersions, desirably self-crosslinking.

What is claimed is:  
     
         1 . An in-mold coated vehicular component, comprising: 
 an vehicular component having a molded inner polyurethane layer;    a coating adhered to said inner polyurethane substrate;    said coating formed in-mold with said polyurethane layer and comprised of the reaction product of an aqueous acrylic copolymer dispersion.    
     
     
         2 . The in-mold coated vehicular component of  claim 1 , wherein said aqueous acrylic copolymer dispersion comprises acrylic esters.  
     
     
         3 . The in-mold coated vehicular component of  claim 1 , wherein said copolymer has a T g  of less than about 25° C.  
     
     
         4 . The in-mold coated vehicular component of  claim 3 , wherein said copolymer has a T g  of about 5° C. to about 25° C.  
     
     
         5 . The in-mold coated vehicular component of  claim 3 , wherein said copolymer has a T g  of less than about 15° C.  
     
     
         6 . The in-mold coated vehicular component of clam 5, wherein said copolymer has a T g  of about 8° C. to about 15° C.  
     
     
         7 . The in-mold coated vehicular component of  claim 1 , wherein said coating has a textured surface.  
     
     
         8 . The in-mold coated vehicular component of  claim 1 , wherein said copolymer has a T g  of about −45° C. to about 40° C.  
     
     
         9 . The in-mold coated vehicular component of  claim 1 , wherein said copolymer has a core and shell structure.  
     
     
         10 . The in-mold coated vehicular component of  claim 9 , wherein said aqueous copolymer dispersion comprises acrylic esters.  
     
     
         11 . A method of manufacturing a coating for an vehicular component, comprising: 
 providing a mold for making an vehicular component, the mold having a mold surface;    coating the mold surface with an in-mold coating composition, said in-mold coating composition comprising a self-crosslinking, aqueous copolymer dispersion; and    passing a polyurethane composition into the mold and into contact with the in-mold coating composition; and    causing the in-mold coating composition and polyurethane composition to cure, so as to form the coating for the vehicular component.    
     
     
         12 . The method of  claim 11 , wherein said aqueous copolymer dispersion comprises acrylic esters.  
     
     
         13 . The method of  claim 11 , wherein said copolymer has a T g  of less than about 25° C.  
     
     
         14 . The method of  claim 13 , wherein said copolymer has a T g  of about 5° C. to about 25° C.  
     
     
         15 . The method of  claim 13 , wherein said copolymer has a T g  of less than about 15° C.  
     
     
         16 . The method of  claim 15 , wherein said copolymer has a T g  of about 8° C. to about 15° C.  
     
     
         17 . The method of  claim 11 , wherein said coating has a textured surface.  
     
     
         18 . The method of  claim 11 , wherein said copolymer has a T g  of about −45° C. to about 40° C.  
     
     
         19 . The method of  claim 11 , wherein said copolymer has a core and shell structure.  
     
     
         20 . The method of  claim 19 , wherein said aqueous copolymer dispersion comprises acrylic esters.  
     
     
         21 . An elastomeric skin, comprising: 
 a molded elastomeric polyurethane layer; and    a coating formed in-mold with said elastomeric polyurethane layer and comprised of the reaction product of an aqueous acrylic copolymer dispersion.    
     
     
         22 . The elastomeric skin of  claim 22 , adapted for application to an automotive interior component.  
     
     
         23 . An elastomeric skin of  claim 22 , adapted for application to vehicular seating.  
     
     
         24 . An elastomeric skin of  claim 22 , wherein said aqueous acrylic copolymer dispersion comprises acrylic esters.  
     
     
         25 . An elastomeric skin of  claim 22 , wherein said copolymer has a T g  of less than about 25° C.  
     
     
         26 . An elastomeric skin of  claim 22 , wherein said elastomeric polyurethane layer has a density of less than 1000 kg/M 3 , a Shore A durometer hardness of less than 86, a tensile strength of greater than 8.8 MPas and/or a tear strength of greater than 40 kn/m.  
     
     
         27 . A polyurethane product, comprising: 
 a molded polyurethane elastomer foam substrate; and    a coating adhered to said molded polyurethane elastomer foam substrate;    said coating formed in-mold with said polyurethane elastomer foam substrate and comprised of the reaction product of an aqueous acrylic copolymer dispersion.    
     
     
         28 . The product of  claim 27 , wherein said coating is textured.  
     
     
         29 . The product of  claim 27 , wherein said substrate has a surface, and wherein said coating is adhered over the entirety of said surface and thereby encapsulates said substrate.  
     
     
         30 . A method of manufacturing a coated, molded polyurethane elastomer product, comprising: 
 providing a mold for making the product, the mold having a mold surface;    coating the mold surface with an in-mold coating composition, said in-mold coating composition comprising a self-crosslinking, aqueous copolymer dispersion; and    passing a polyurethane elastomer composition into the mold and into contact with the in-mold coating composition; and    causing the in-mold coating composition and polyurethane elastomer composition to cure, so as to form a coated, molded polyurethane elastomer product.