Resin-based compositions for slush molding and composite parts manufactured therefrom
AssigneeCpK Interior Products Inc.
InventorsGregory James Farrar, Murali Mohan Reddy
Life of this patent
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Abstract
A composite part manufactured via a dual cast slush molding technique includes a skin layer having a first side and an opposite second side and a foam layer formed in situ on the second side of the skin layer. The first side of the skin layer defines a Class A surface. The skin layer and the foam layer each comprise a polymer of the same type and are respectively formed from a first resin-based composition and a second resin-based composition. The first resin-based composition and the second resin-based composition each may comprise a polyvinyl chloride (PVC)-based composition or a thermoplastic polyolefin (TPO)-based composition.
Claims30
A method of manufacturing a composite part, the method comprising:
- (a) introducing a first resin-based composition into a mold cavity using a slush molding technique, the mold cavity being defined by a mold surface;
- (b) heating the mold cavity to melt the first resin-based composition and form a skin layer on the mold surface;
- (c) introducing a second resin-based composition into the mold cavity using a slush molding technique;
- (d) heating the mold cavity to melt the second resin-based composition and form a foam layer on the mold surface over the skin layer;
- and
- (e) removing the composite part from the mold cavity,
- wherein, during formation of the foam layer, chemical bonds form between the skin layer and the foam layer that join the skin layer and the foam layer together, and
- wherein the first resin-based composition and the second resin-based composition each comprise:
- (1) a polyvinyl chloride (PVC)-based composition and the second resin-based composition comprises about 51 parts per hundred resin to about 80 parts per hundred resin of a plasticizer, or
- (2) a thermoplastic polyolefin (TPO)-based composition.
A method of manufacturing a composite part, the method comprising:
- (a) slush molding a first resin-based composition in a mold cavity;
- (b) melting the first resin-based composition to form a skin;
- (c) slush molding a second resin-based composition into the mold cavity;
- (d) melting the second resin-based composition to form a foam on the skin;
- and
- (e) removing the composite part having the skin and the foam from the mold cavity,
- wherein the first resin-based composition and the second resin-based composition each comprise:
- (1) a polyvinyl chloride (PVC)-based composition and the second resin-based composition comprises about 51 parts per hundred resin to about 80 parts per hundred resin of a plasticizer, or
- (2) a thermoplastic polyolefin (TPO)-based composition, and
- wherein, during formation of the foam, chemical bonds form between the skin and the foam that join the skin and the foam together.
A method of manufacturing a composite part, the method comprising:
- (a) slush molding a first resin-based composition in a mold cavity;
- (b) melting the first resin-based composition to form a pliable skin;
- (c) slush molding a second resin-based composition into the mold cavity;
- (d) melting the second resin-based composition to form a foam on the skin;
- (e) adding a foaming agent comprising an endothermic chemical foaming agent or an exothermic chemical foaming agent;
- (f) adding an activator comprising a zinc-containing compound;
- (g) when the foaming agent is combined with the activator, the foaming agent is configured to decompose at temperatures greater than or equal to about 150 degrees Celsius to less than about 180 degrees Celsius to release gases of nitrogen, carbon monoxide, carbon dioxide, or combinations thereof;
- (h) removing the composite part, having the skin and the foam, from the mold cavity, the composite part being a vehicular interior part with a Class A surface;
- (i) the first resin-based composition and the second resin-based composition each comprise:
- (1) a polyvinyl chloride (PVC)-based composition and the second resin-based composition comprises about 51 parts per hundred resin to about 80 parts per hundred resin of a plasticizer, or
- (2) a thermoplastic polyolefin (TPO)-based composition;
- (j) forming chemical bonds that join the skin and the foam together;
- and
- (k) wherein a bonding strength between the skin and the foam is greater than 40 Newtons per centimeter as measured by 90° peel testing on a tensile compression testing machine.
Dependencies are inferred from the claim text.