Interior vehicle trim panel having a sprayed expanded polyurethane layer and method and system of making same

Abstract

Aspects of the present invention include interior vehicle trim panel having a sprayed expanded polyurethane layer and method of making same. In at least one embodiment, the method of making the vehicle interior trim panel comprises providing a skin layer on a spray tool, spraying expandable polyurethane reactive components onto the skin layer to form a resilient layer, and securing a rigid substrate on the resilient layer, such that the resilient layer extends between and connects the skin layer with the substrate to form the vehicle interior trim panel.

1 . A method of making a vehicle interior trim panel, the method comprising: 
 providing a skin layer on a spray tool;    spraying expandable polyurethane reactive components onto the skin layer to form a resilient layer having 35 to 75 percent closed cell structures; and    securing a rigid substrate on the resilient layer, such that the resilient layer extends between and connects the skin layer with the substrate to form the vehicle interior trim part.    
     
     
         2 . The method of  claim 1  wherein the resilient layer has a density of 0.1 to 0.75 g/cm 3 .  
     
     
         3 . The method of  claim 2  wherein a substantial portion of the resilient layer has a thickness of 0.1 to 8.0 mm and a shore A hardness of 30 to 50.  
     
     
         4 . The method of  claim 3  wherein the resilient layer has a first portion having a first thickness of 0.05 to 4.0 mm and a second portion having a thickness of 6.1 to 15 mm.  
     
     
         5 . The method of  claim 3  wherein the expandable polyurethane reactive components comprise polyol, isocyanate and a blowing agent.  
     
     
         6 . The method of  claim 1  wherein the skin layer comprises polyurethane and the rigid substrate is secured directly to the resilient layer.  
     
     
         7 . The method of  claim 3  wherein the step of providing a skin layer comprises spraying polyurethane reactive components towards the spray tool.  
     
     
         8 . The method of  claim 7  wherein one spraying device is provided for spraying both the polyurethane reactive components and the expandable polyurethane reactive components.  
     
     
         9 . The method of  claim 1  wherein the resilient layer comprises an elastomer.  
     
     
         10 . The method of  claim 8  further comprising applying a coating on the tool prior to the spraying steps, the coating forming an appearance surface of the panel.  
     
     
         11 . The method of  claim 10  wherein the coating comprises aliphatic polyurethane, the skin layer comprises aromatic polyurethane, the resilient layer comprises aromatic polyurethane, and the substrate comprises rigid polyurethane.  
     
     
         12 . The method of  claim 1  wherein the securing step comprises removing the skin layer and the resilient layer from the spray tool, positioning the skin layer and the resilient layer in a mold, and injecting material into the mold when the mold is in a closed position to form the substrate.  
     
     
         13 . The method of  claim 1  wherein the securing step comprises removing the skin layer and the resilient layer from the spray tool, pouring material onto the resilient layer when the mold is in an open position, and the method further includes closing the mold to shape the substrate.  
     
     
         14 . The method of  claim 10  wherein the securing step comprises: 
 removing the coating, the skin layer and the resilient layer from the tool;    positioning the coating, the skin layer and the resilient layer in a mold; and    securing the rigid substrate on the resilient layer, such that the resilient layer extends between and connects the skin layer with the substrate to form the vehicle interior trim part wherein the coating forms an exterior appearance surface of the panel.    
     
     
         15 . A method of making a vehicle interior trim panel, the method comprising: 
 applying a coating on a tool;    spraying skin layer forming materials on the coating to form a skin layer on the coating;    spraying expandable polyurethane reactive components comprising polyol, isocyanate and a blowing agent onto the skin layer to form a resilient layer having a density of 0.1 to 0.75 g/cm 3 ; and    securing a rigid substrate directly to the resilient layer, such that the resilient layer extends between and connects the skin layer with the substrate to form the vehicle interior trim part.    
     
     
         16 . The method of  claim 15  wherein the interior trim panel has a width of 60 to 125 cm and a length of 3.75 to 22 cm resilient layer has a first portion having a first thickness of 0.05 to 4.0 mm and a second portion having a thickness of 6.1 to 15 mm.  
     
     
         17 . The method of  claim 15  wherein the resilient layer has a density of 0.2 to 0.3 g/cm 3 .  
     
     
         18 . A vehicle interior trim component for use with a motor vehicle, the trim component comprising: 
 a skin layer;    a sprayed expanded polyurethane resilient layer secured to the skin layer; and    a rigid substrate secured to the resilient layer.    
     
     
         19 . The vehicle interior trim component of  claim 18  wherein the resilient layer has a density in the range of 0.1 to 0.75 grams per cubic centimeter.  
     
     
         20 . A method for making a vehicle interior door part for a vehicle interior, said part comprising: 
 a base substrate having a show surface and a back surface; and    the vehicle interior trim component of  claim 18  secured to the base substrate so that the show surface and the skin layer face towards the vehicle interior.