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US 8,133,419 B2Granted
Method for making automotive headliners
AssigneeDow Global Technologies LLC
InventorsStephen R. Burks, Rogelio R. Gamboa, Richard G. McNeil, K. Joanne Bladon, Armando Esau Toledo Gonzalez
Life of this patent
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Abstract
Vehicle headliners are prepared with a core layer of a fiber-reinforced polyurethane foam. The polyurethane foam is prepared from a polyurethane-forming composition that uses water as a blowing agent and polyol or polyol mixture that has a high functionality and an average hydroxyl equivalent weight of 100-130. The selection of polyols permits cycle times to be reduced by allowing for faster demolding and shortened aging times before post-molding heat lamination steps can be performed.
Claims19
A process comprising
- a) applying a foamable polyurethane composition onto a mat of at least one reinforcing fiber to form an impregnated mat;
- b) molding the impregnated mat at an elevated temperature sufficient to cure the polyurethane composition, to form a molded, fiber-reinforced polyurethane foam, and
- c) demolding the fiber-reinforced polyurethane foam,
- wherein the foamable polyurethane composition comprises a polyol or mixture of polyols, a polyisocyanate and about 3.0 to about 5.5 parts of water per 100 parts by weight of polyol(s), the polyol or mixture of polyols having an average of 3.8 to about 8 hydroxyl groups/molecule and a hydroxyl equivalent weight of about 100 to about 135, wherein at least 70% of the hydroxyl groups contained in the polyol or mixture of polyols are secondary hydroxyl groups and the polyol or polyol mixture is substantially devoid of primary or secondary amino groups, and further wherein the polyisocyanate index is from 90 to 130, wherein step c) is performed within 60 seconds of the beginning of step b).
1 more element
A process comprising
- a) applying a foamable polyurethane composition onto a mat of at least one reinforcing fiber to form an impregnated mat;
- b) applying a thermoplastic adhesive film to at least one surface of the impregnated mat;
- c) prior to, simultaneously with or after step b), inserting the impregnated mat into a mold;
- d) molding the impregnated mat at an elevated temperature sufficient to cure the polyurethane composition but below the melting temperature of the thermoplastic adhesive film, to form a molded, fiber-reinforced polyurethane foam having an adhesive film on at least one surface thereof,
- e) demolding the fiber-reinforced polyurethane foam;
- f) applying a show surface to the adhesive film and
- g) heating the adhesive film to a temperature above its melting temperature to bond the show surface to the fiber-reinforced polyurethane foam,
- wherein the foamable polyurethane composition comprises a polyol or mixture of polyols, a polyisocyanate and about 3.0 to about 5.5 parts of water per 100 parts by weight of polyol(s), the polyol or mixture of polyols having an average of 3.8 to about 8 hydroxyl groups/molecule and a hydroxyl equivalent weight of about 100 to about 135, and further wherein the polyisocyanate index is from 90 to 130.
5 more elements
Dependencies are inferred from the claim text.