# US 10,766,175 B2 · Method for producing a trim element with a genuine carbon appearance

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- Number: US 10,766,175 B2
- Document ID: US10766175B2
- Status: Granted
- Kind: B2
- Application number: 15/526,378
- Filed: 2015-11-04
- Published: 2017-12-07
- Granted: 2020-09-08
- Earliest claimed: 2014-11-12
- Assignees: HIB Trim Part Solutions GmbH
- Applicants: Hib Trim Part Solutions GmbH
- Inventors: Bernd Keller
- Web page: https://patentgrep.com/patent/US10766175B2

## CPC

- B29C 45/14786: {Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material}
- B29C 45/14: incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles {(B29C45/1671 takes precedence)}
- B29C 45/14008: {Inserting articles into the mould (B29C45/14827 takes precedence)}
- B29C 45/14811: {Multilayered articles (B29C45/14827 takes precedence)}
- B29C 45/16: Making multilayered or multicoloured articles {(B29C45/0062 takes precedence; feeding colouring materials into the injection unit B29C45/1816)}
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 5/12: characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other}
- B32B 21/10: Next to a fibrous or filamentary layer
- B60R 13/02: {Internal} Trim mouldings {; Internal} Ledges; Wall liners {for passenger compartments}; Roof liners (B60R13/01 takes precedence {; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18})
- C08J 5/042: {with carbon fibres}
- C08J 5/18: Manufacture of films or sheets
- C08J 7/0427: {with only one layer of a composition containing a polymer binder (with more layers C08J7/042)}
- C08J 7/043: Improving the adhesiveness of the coatings per se, e.g. forming primers (adhesives in the form of films or foils characterised by the primer layers between the polymer carriers and the adhesives C09J7/50)
- B29C 2045/14713: {decorations in contact with injected material}
- B29C 2045/1692: {one layer comprising fibres}
- B29K 2707/04: Carbon
- B32B 2307/40: having particular optical properties
- C08J 2331/04: Homopolymers or copolymers of vinyl acetate
- C08J 2333/06: of esters containing only carbon, hydrogen, and oxygen, the oxygen atom being present only as part of the carboxyl radical
- C08J 2375/04: Polyurethanes
- C08J 2400/24: Thermosetting resins
- C08J 2475/04: Polyurethanes
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

## Abstract

The invention relates to a method for producing a trim element for vehicles which has a genuine carbon appearance, comprising a carbon fiber layer which is arranged on an exposed side of the trim element and is visible from the outside, and which is made of a fiber structure composed of prefabricated carbon fibers with interstices, with the method comprising at least the process step of wet impregnating the prefabricated carbon fiber layer with an aqueous polymer dispersion based on polyurethane, acrylate or polyvinyl acetate or a mixture thereof, so that the polymer dispersion penetrates at least partially into the carbon fiber layer, increasing the suitability thereof for penetration of a coating into the interstices of the fiber structure of the carbon layer.

## Claims

### Claim 1

A method for producing a trim element for vehicles which has a genuine carbon appearance, comprising a sized carbon fiber layer which is arranged on an exposed side of the trim element and is visible from the outside, and which is made of a fiber structure composed of prefabricated carbon fibers with interstices, comprising the following process steps:
wet impregnating the prefabricated, sized carbon fiber layer with an aqueous polymer dispersion based on polyurethane, acrylate or polyvinyl acetate or a mixture thereof, so that the polymer dispersion penetrates at least partially into the carbon fiber layer, increasing the suitability thereof for penetration of a coating into the interstices of the fiber structure of the carbon layer, wherein the wet impregnation alters the surface structure of the carbon fibers or carbon fiber filaments of the prefabricated, sized carbon fiber layer, so that the coating becomes cross-linked with the carbon fiber layer and no air pockets remain,
drying the wet impregnated carbon fiber layer,
affixing the carbon fiber layer onto a trim element support, aligned toward the exposed side of the trim element,
applying a coating layer to the carbon fiber layer that is arranged on the trim element support, in order to form a transparent surface layer on the exposed side of the trim element, with coating material penetrating into the interstices of the carbon fiber layer and wherein for wet impregnation, the carbon fiber layer is passed through a dispersion bath as an integral part of the production process,
wherein the carbon fiber layer is mounted onto the trim element support by lamination, and the carbon fiber layer additionally comprises a supporting fabric.

### Claim 2 (depends on 1)

The method according to claim 1 wherein the aqueous dispersion has a solids content of 1-70%.

### Claim 3 (depends on 1)

The method according to claim 1, wherein a coating of primer is applied to the carbon fiber layer to promote adhesion before the carbon fiber layer is placed on the trim element support.

### Claim 4 (depends on 1)

The method according to claim 1, wherein drying is carried out in a drying zone at a temperature of 20-120° C., to a residual moisture of less than 1%.

### Claim 5 (depends on 4)

The method according to claim 4, wherein drying is carried out in the drying zone at a temperature of 60-120° C.

### Claim 6 (depends on 1)

The method according to claim 1, wherein the trim element support is injected onto the back of the carbon fiber layer.

### Claim 7 (depends on 1)

The method according to claim 1, wherein the coating layer is applied by pouring it over the carbon fiber layer.

### Claim 8 (depends on 1)

The method according to claim 1, wherein the carbon fiber layer is conveyed through the dispersion bath at a rate of 0.5-10 m/min, m/min, with an immersion time of 10-60 seconds.

### Claim 9 (depends on 8)

The method according to claim 8, wherein the carbon fiber layer is conveyed through the dispersion bath at a rate of 1-2 m/min.

### Claim 10 (depends on 1)

The method according to claim 1, wherein the carbon fiber layer is composed of individual fibers, fiber bundles or a woven carbon fiber fabric.

### Claim 11 (depends on 10)

The method according to claim 10, wherein the individual fibers, the fiber bundles or the woven carbon fiber fabric in the form of rolled material are wet impregnated in a process integrated into the production process and then cut to size based on the size of the trim element support, for placement of the carbon fiber layer on the trim element support.

### Claim 12 (depends on 1)

The method according to claim 1, wherein the coating layer is composed of a two-component polyurethane.

### Claim 13 (depends on 1)

The method according to claim 1, wherein the aqueous dispersion has a solids content of 10-50%.

### Claim 14

A method for producing a trim element for vehicles which has a genuine carbon appearance, comprising a sized carbon fiber layer which is arranged on an exposed side of the trim element and is visible from the outside, and which is made of a fiber structure composed of prefabricated carbon fibers with interstices, comprising the following process steps:
wet impregnating the prefabricated, sized carbon fibers with an aqueous polymer dispersion based on polyurethane, acrylate or polyvinyl acetate or a mixture thereof, so that the polymer dispersion penetrates at least partially into the carbon fibers, increasing the suitability thereof for penetration of a coating into the interstices of the fiber structure of the carbon layer, wherein the wet impregnation alters the surface structure of the carbon fibers or carbon fiber filaments of the prefabricated, sized carbon fiber layer, so that the coating becomes cross-linked with the carbon fiber layer and no air pockets remain,
drying the wet impregnated carbon fibers,
weaving the wet impregnated and dried carbon fibers into the carbon fiber layer,
affixing the carbon fiber layer onto a trim element support, aligned toward the exposed side of the trim element,
applying a coating layer to the carbon fiber layer that is arranged on the trim element support, in order to form a transparent surface layer on the exposed side of the trim element, with coating material penetrating into the interstices of the carbon fiber layer,
wherein the carbon fiber layer is mounted onto the trim element support by lamination, and the carbon fiber layer additionally comprises a supporting fabric.