阅读说明：本技术 用于制造装饰部件的方法和可由该方法制造的装饰部件 (Method for producing a decorative part and decorative part producible by the method ) 是由 克劳斯·比涅克 穆阿梅特·萨迪库 于 2021-06-15 设计创作，主要内容包括：本发明涉及一种用于制造装饰部件的方法,该装饰部件包括带有装饰层的可见侧和带有基底层的安装侧,其中将含聚硅氮烷的组合物施加到装饰层的可见侧以形成覆盖层并随后将其固化。本发明还涉及可通过该方法制造的装饰部件。(The invention relates to a method for producing a decorative part comprising a visible side with a decorative layer and a mounting side with a substrate layer, wherein a composition containing polysilazane is applied to the visible side of the decorative layer to form an overlay and subsequently cured. The invention also relates to a decorative part that can be produced by means of said method.)

1. A method for producing a decorative part comprising a visible side with a decorative layer and an installation side with a substrate layer, characterized in that a composition comprising a polysilazane compound is applied to the visible side of the decorative layer to form an overlay layer and subsequently cured.

2. The process according to claim 1, wherein the polysilazane-containing composition comprises perhydropolysilazane or an organopolysilazane or a mixture thereof.

3. The process according to claim 1, wherein the polysilazane in the polysilazane-containing composition is present in an amount ranging from 0.1 to 50 wt.%.

4. Process according to claim 1, characterized in that the polysilazane-containing composition is applied at a temperature of from 10 ℃ to 40 ℃ and a relative humidity of more than 30%.

5. Process according to claim 1, characterized in that the polysilazane-containing composition is cured at a temperature of from 50 ℃ to 100 ℃ and a relative humidity of from 10% to 80%.

6. The method according to claim 1, characterized in that the cured cover layer has a layer thickness of 0.25 μm to 25 μm.

7. Method according to claim 1, characterized in that the decorative layer is cleaned with a gas stream or dry ice blasting before the polysilazane-containing composition is applied.

8. The method of claim 1, wherein said decorative layer is formed from wood veneer, metal, paper, or fabric.

9. The method of claim 1 wherein the decorative layer is formed into a preform prior to applying and curing the overlay layer.

10. The method of claim 1 wherein the decorative layer is bonded to the base layer either before or after the overlay layer is applied and cured.

11. The method according to claim 1, characterized in that the decorative layer is bonded to the substrate layer by a pressing method or an injection molding method.

12. Method according to claim 1, characterized in that at least one intermediate layer of thermoplastic or thermosetting plastic is applied to the decorative layer before the application of the cover layer.

13. Decorative part comprising a visible side with a decorative layer and an installation side with a substrate layer, characterized in that the decorative layer on the visible side is coated with a cured covering layer comprising polysilazane.

14. The trim part according to claim 13, producible by a method according to one of claims 1 to 12.

15. Decorative part according to claim 13, characterized in that the covering layer comprises a cured organic polysilazane.

16. Decorative part according to claim 13, characterized in that at least one intermediate layer of thermoplastic or thermosetting plastic is arranged between the decorative layer and the covering layer.

Technical Field

The invention relates to a method for producing a decorative part, in particular for a vehicle interior, comprising a visible side with a decorative layer and an installation side with a substrate layer, and to a decorative part that can be produced by means of the method.

Background

Decorative parts, in particular for use in the interior of motor vehicles, have to meet high requirements in terms of their visual and tactile quality as well as dimensional accuracy and resistance to environmental influences. For this reason, a design is widely used in which the decorative layer determining the visual appearance is provided with a protective transparent covering layer on the visible side of the decorative part. On the opposite mounting side, a base or base layer is provided which imparts the necessary dimensional stability to the trim part and is provided for fastening the trim part.

Transparent cover layers with high surface quality can be manufactured from, for example, polyester or polyurethane thick film coatings. However, the coating requires a large number of labor-intensive and cost-intensive manual finishing operations. Furthermore, the clear coating can yellow under the influence of light and temperature, which deteriorates the visual appearance of the decorative part over time. The shrinking process may cause the non-smooth surface of the textured decorative layer to develop an undesirable image on the surface of the transparent overlay layer.

In order to avoid the above-mentioned disadvantages, decorative components and corresponding processes are known in which a transparent cover layer is injected onto the decorative layer in the form of a transparent plastic in an injection mold. This reduces the amount of rework required. By choosing a suitable material, the quality of the visible surface side can be maintained for a longer period of time, since the injection-molded plastic material is less sensitive to external influences.

A further development of the process is disclosed in EP 2298528 a 1. The decorative layer is here laminated with a transparent film on its side facing the visible side and with a barrier layer on its side facing the installation side. The laminated decorative layer is formed into a preform which is then overmolded with clear plastic to form the overlay and back injection molded with a carrier plastic to form the substrate. The decorative part is formed in which the transparent film is disposed between the cover layer and the decorative layer, and the barrier layer is disposed between the substrate and the decorative layer. The transparent film is made, for example, of a thermoplastic, in particular Polycarbonate (PC), polymethyl methacrylate (PMMA), polyvinyl butyral (PVB), Thermoplastic Polyurethane (TPU) or a composite of these materials. The cover layer is made of an injection-moldable plastic, in particular polymethyl methacrylate (PMMA).

Another example of a trim part is disclosed in EP 2842742 a 1. The trim part disclosed therein comprises a covering layer applied directly to the substrate, wherein the covering layer consists of polyurethane or polyurea and the substrate consists of a mixture of at least one thermoplastic and at least one urethane-based thermoplastic elastomer.

Another example of a trim part is disclosed in DE 19914092 a 1. The decorative part disclosed therein comprises a decorative layer and an injection molded substrate layer connected thereto.

Disclosure of Invention

The invention is based on the problem of providing a new trim part for a vehicle interior and a method for manufacturing the trim part. The trim part is intended to exhibit a high mechanical resistance, in particular a high scratch resistance and wear resistance. Furthermore, the decorative part is intended to be permanently resistant to external influences, such as mechanical impact or UV radiation, and further allows the use of an inherently sensitive decorative layer.

This problem is solved by a method for producing a decorative part comprising a visible side with a decorative layer and a mounting side with a substrate layer, wherein a composition comprising a polysilazane compound is applied to the visible side of the decorative layer to form an overlay layer and subsequently cured. Furthermore, the problem is solved by a decorative part which can be obtained in particular by this method and comprises a visible side with a decorative layer and an installation side with a base layer, wherein the decorative layer is coated on the visible side with a cured covering layer comprising polysilazane.

Excellent scratch resistance and abrasion resistance are obtained due to the use of a covering layer comprising polysilazane. At the same time, the overlay layer also effectively protects the sensitive decorative layer from external influences without impairing the appearance of the decorative layer. In particular, the cover layer has antifouling properties and is easy to clean. At the same time, the cover is resistant to common detergents.

The trim component described herein includes a substrate layer and a decorative layer applied to the substrate layer. The structure defines a visible side and a mounting side of the trim component. The visible side is the side of the decorative layer from which the decorative surface is visible. The mounting side is the side opposite the visible side, on which the generally flat substrate layer is applied.

The decorative layer may be formed of, for example, a wood veneer, metal, paper, or fabric. Preferably, the wood veneer is a real wood veneer, preferably a precious wood veneer. The wood veneer may be bonded to an additional blind veneer on the mounting side, wherein the decorative wood veneer and the blind veneer are bonded, for example, by a fleece or glue layer impregnated with a phenol-melamine resin. In the case of decorative layers made of metal, aluminum, steel and copper are particularly suitable for this purpose. The metal is preferably designed as a foil. The fabric used may be a woven fabric made of natural or synthetic fibres, glass, carbon, Kevlar fabric, metal or metallised fabric, or a hybrid fabric made of several of the above fabrics, which may tightly or loosely define a mesh (mesh) and thereby make visible the layers behind it, such as a base layer behind a decorative layer.

The thickness of the decorative layer is preferably in the range from 0.1mm to 2mm (and including 2mm), particularly preferably in the range from 0.3mm to 0.7 mm.

The decorative layer preferably has a hydrophilic surface to improve adhesion between the decorative layer and other layers directly bonded to the decorative layer. Furthermore, the decorative layer preferably has an open surface in order to obtain a larger contact surface between the decorative layer and the other layers directly bonded to the decorative layer.

The cover layer according to the invention is produced by applying and curing a composition comprising a polysilazane compound to the visible side of the decorative layer. The overlay layer may be applied directly to the decorative layer, or one or more intermediate layers may be provided between the overlay layer and the visible side of the decorative layer.

In a preferred embodiment, one or more intermediate layers are provided between the overlay layer and the decorative layer. Preferably, at least one intermediate layer made of a thermoplastic or thermosetting plastic is used. For example, a polymethyl methacrylate-containing composition is used as the thermoplastic, and a polyurethane-containing composition is used as the thermosetting plastic. The use of an intermediate layer comprising polymethyl methacrylate is particularly preferred. The intermediate layer is at least partially translucent to ensure visibility of the decorative layer. The intermediate layer may be colorless (colorless) or colored.

The intermediate layer is applied to the visible side of the decorative layer prior to application of the overlay layer. In a subsequent step, a cover layer is applied to the top intermediate layer.

In an alternative embodiment, the overlay layer is applied directly to the visible side of the decorative layer. In this case, the decorative layer preferably has an open-pored surface. Particularly preferably, the cover layer is applied directly to the decorative layer if the decorative layer has a surface made of metal or plastic film.

The polysilazane used may be perhydropolysilazane (inorganic polysilazane), organic polysilazane (organic polysilazane) or a mixture of different polysilazanes. Particularly preferably, at least one organic polysilazane is used.

Suitable polysilazanes are commercially available, for example under the trademark Durazane. Inorganic polysilazanes are available in the Durazane 2000 product range, and organic polysilazanes are available in the Durazane 1000 product range. In particular, methyl-and/or methylvinyl-modified organic polysilazanes are used as organic polysilazanes.

In particular, perhydropolysilazanes form carbon-free, glassy silica networks during curing, which have excellent surface properties. Due to the lower mechanical flexibility of the resulting cover layer, the perhydropolysilazane-containing composition is preferably applied after the decorative layer is formed in the preform.

Preferably, the polysilazane has a number average molecular weight of from 150g/mol to 150000g/mol, more preferably from 1000g/mol to 100000g/mol, most preferably from 2000g/mol to 20000 g/mol.

In addition to polysilazanes, the polysilazane-containing compositions generally comprise one or more solvents, in particular organic solvents, such as xylene, ethylbenzene, di-n-butyl ether, n-butyl acetate and/or tert-butyl acetate. The proportion of polysilazane in the composition is preferably from 20 to 100 wt.%, more preferably from 20 to 80 wt.%, most preferably from 50 to 80 wt.%. The proportion of polysilazane is selected such that the preferred liquid composition has a viscosity suitable for application to the decorative layer. If desired, the viscosity can be adjusted by diluting a commercially available polysilazane composition with a suitable solvent, in particular an organic solvent. In particular, the proportion of polysilazane varies depending on the method of application. If the cover layer is applied by spray application, the polysilazane content is, for example, from 20 to 80 wt.%, particularly preferably from 40 to 60 wt.%. In the case of jet application, the polysilazane content is, for example, from 60 to 100 wt.%, particularly preferably from 70 to 90 wt.%.

Prior to applying the polysilazane-containing composition and any intermediate layer, preferably, the decorative layer is cleaned. This is done by means of, for example, a gas flow, such as compressed air. In a preferred embodiment, cleaning is performed by dry ice blasting, i.e. by shooting (irradiatingling) the surface with a mixture of dry ice particles (CO2 particles) and compressed air. In addition to compressed air, another inert carrier gas may also be used for this purpose. This cleaning removes the microparticles from the surface of the decorative layer and enables the uniform application of the overlay layer and any intermediate layers.

The compositions containing polysilazane are preferably applied in liquid form. This can be done, for example, by dipping, spraying, dipping or casting. In the case of dipping, the decorative part is passed through a bath of the polysilazane-containing composition. In the case of dip coating and casting, the surface of the decorative part is dip-coated with a composition comprising a polysilazane, which can be applied by means of one or more nozzles, in particular dip coating nozzles or rinsing nozzles. The application may be performed, for example, in a continuous flow or a decreasing process.

In a particularly preferred embodiment, the composition comprising polysilazane is applied by spraying. In this way, an extremely uniform coating is obtained while maintaining a low material consumption. It is particularly preferred that the spraying process is applied by jet spraying and is free of paint mist.

In order to avoid premature reaction of the polysilazane, the application is preferably carried out under an inert gas, for example under a nitrogen atmosphere. This is particularly suitable for spray application.

Particularly good results are obtained if the application is carried out at a temperature of from 10 ℃ to 40 ℃ and a relative humidity of 30% or more. Preferably, the temperature is from 20 ℃ to 30 ℃. The relative humidity is preferably from 30% to 80%, particularly preferably from 40% to 70%. Under these conditions, excellent adhesion of the cover layer is achieved.

The applied composition containing a polysilazane compound is then cured to form a covering layer. During curing, polysilazanes react with water, wherein the Si-N bond is hydrolyzed and subsequently condensed to form Si-O-Si units. Curing is preferably carried out at a temperature of from 50 ℃ to 100 ℃ and a relative humidity of from 10% to 80%. Particularly preferably, the temperature is from 60 ℃ to 90 ℃, most preferably from 75 ℃ to 85 ℃. The relative humidity is preferably 40% to 80%. The duration of curing is preferably from 10 minutes to 180 minutes, most preferably from 60 minutes to 120 minutes. Under these conditions, the polysilazane-containing covering layer achieves excellent antifouling properties with high transparency and mechanical stability.

The cured cover layer preferably has a thickness of 0.25 μm to 25 μm, more preferably 6 μm to 10 μm.

The intermediate layer (if provided) may also be applied to the decorative layer by the above-described methods or by other coating methods known in the art.

The substrate layer is preferably formed from a plastic, in particular a thermosetting or thermoplastic plastic. Suitable materials for the substrate layer include polyurethane (TPU), Polycarbonate (PC), Acrylonitrile Butadiene Styrene (ABS), Polyamide (PA), polypropylene (PP), Styrene Acrylonitrile (SAN), Styrene Maleic Anhydride (SMA), polypropylene ether (PPE), polyphenylene oxide (PPO) or mixtures of several of these plastics. For example, blends of PC and ABS, blends of ABS and PA, or blends of PC and SAN are particularly suitable. Particularly preferably, the substrate layer comprises a blend of TPU with one or more other plastics, in particular one or more of the plastics mentioned above.

The plastic of the substrate layer may comprise further additives. For example, the plastic may be reinforced with glass, carbon, or natural fibers. Preferably, the plastic is a glass fiber reinforced plastic. In addition, fillers such as silica or carbon black may be included.

For producing the decorative part, the decorative layer is preferably formed as a preform. The shape of the preform substantially corresponds to the shape of the subsequent decorative component. The preform is manufactured in a suitable pressing mould. The decorative layer may be bonded to the substrate layer before, during, or after such formation. The cover layer may also be applied and cured before or after formation.

The decorative layer and the substrate layer are joined by known methods, in particular by pressing or injection molding methods. For example, the decorative layer can be pressed onto the substrate layer, wherein as pressing method, in particular SMC (sheet molding compound) or GMT (glass mat reinforced thermoplastic) is used. Alternatively, the base layer can also be injection molded onto the decorative layer. The decorative layer and the substrate layer may be bonded before or after application and curing of the overlay layer.

In the case of an injection molding method, the decorative layer is preferably formed into a preform, the shape of which substantially corresponds to the subsequent decorative component, before bonding to the substrate layer. The base layer may then be injected onto a preform, wherein the preform serves as a mold member (die) specifying the final shape of the trim part.

In the case of a pressing process, the formation and bonding of the decorative layer to the substrate layer may be carried out in a single step. For this purpose, the decorative layer and the substrate layer are prepared in flat, planar form and pressed together. Alternatively, the decorative layer may also be formed into a preform prior to bonding to the substrate layer. In this case, in order to enable the decorative layer and the substrate layer to be pressed together, the substrate layer is also preferably formed into a corresponding preform before joining.

In order to increase the adhesion between the decorative layer and the substrate layer, an adhesion promoter is preferably applied to the mounting side of the decorative layer before the decorative layer is bonded to the substrate layer. The adhesion promoter is, for example, a glue or a reactive hot melt adhesive. This is particularly true for decorative layers made of metal. If the decorative layer is a wood veneer with a blind veneer on the mounting side, a fleece impregnated with phenol-melamine resin or glue may also be placed on the mounting side of the decorative layer.

In one embodiment, the overlay layer and any intermediate layer are applied to an initially flat decorative layer and cured, and then the resulting composite of overlay layer, intermediate layer and decorative layer is formed into a preform, and the preform is ultimately bonded to the substrate layer.

However, it is preferred not to apply the cover layer and any intermediate layer before forming the decorative layer, but only on the decorative layer which has been preformed, in order to avoid damage to the cover layer during forming.

Thus, in a preferred embodiment, the decorative layer is first formed as a preform, then the preform is bonded to the base layer, then one or more intermediate layers are applied onto the decorative layer if desired, and finally the cover layer is applied to the decorative layer and cured.

In another preferred embodiment, the decorative layer is first formed as a preform, then any intermediate layer and overlay layer are applied to the decorative layer and cured, and finally the resulting preformed composite of overlay layer, intermediate layer and decorative layer is bonded to the substrate layer.

Detailed Description

The process according to the invention is illustrated by the following examples.

Tempering a preform comprising a decorative layer of wood veneer and a substrate layer of glass fiber reinforced polycarbonate/acrylonitrile butadiene styrene plastic bonded to the decorative layer to a temperature of 23 ℃.

An intermediate layer of polyethyl methacrylate is applied to the visible side of the decorative layer by injection molding.

The visible side of the decorative layer was previously cleaned by dry ice blasting.

The compositions containing polysilazane were applied by spray application at an air temperature of 22 ℃ and a relative humidity of 60%. The composition comprises a sprayable dilute 40% solids organic polysilazane. The spray application was performed using the following process parameters: atomizing air 140NL, horn air (horn air)160NL, application speed 500mm/sec, and application rate 130 ml/min.

Subsequently, the polysilazane-containing composition was cured at a temperature of 60 ℃ and a relative humidity of 50% for 90 minutes.

The covering layers thus obtained exhibit very high mechanical resistance, in particular high scratch resistance and abrasion resistance, and excellent transparency.