Integral skin molded article and method of preparing integral skin molded article and laminate having skin

• US 20090075084A1
• Filed: 09/17/2008
• Published: 03/19/2009
• Est. Priority Date: 09/19/2007
• Status: Active Grant

• Current Assignee: Sumika Bayer Urethane Co., Ltd (Covertro Deutschland AG), Nihon Plast Company Limited
• Original Assignee: Sumika Bayer Urethane Co., Ltd (Covertro Deutschland AG), Nihon Plast Company Limited
• Inventors: Fujita, Naohiro, Ido, Hiroaki, Nishikawa, Shinji, Suwama, Takahiro, Kochi, Eiju
• Granted Patent: US 8,071,208 B2
• Time in Patent Office: Days
• US Class Current: 428/409
• CPC Class Codes: B29C 44/0461 by having different chemical compositions in different places, e.g. having different concentrations of foaming agent, feeding one composition after the other
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2307/71 Resistive to light or to UV
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 2605/003 Interior finishings
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 5/20 foamed in situ
• CPC Class Codes: C08G 18/6685 with compounds of group C08G18/3225 or polyamines of C08G18/38
• CPC Class Codes: C08G 18/6688 with compounds of group C08G18/3271
• CPC Class Codes: C08G 18/7664 containing alkylene polyphenyl groups
• CPC Class Codes: C08G 2110/0033 having integral skins
• CPC Class Codes: C08G 2110/0058 ≥50 and <150kg/m3
• CPC Class Codes: C08J 2203/06 CO2, N2 or noble gases
• CPC Class Codes: C08J 2375/04 Polyurethanes
• CPC Class Codes: C08J 9/122 Hydrogen, oxygen, CO2, nitrogen or noble gases
• CPC Class Codes: C08J 9/34 Chemical features in the manufacture of articles consisting of a foamed macromolecular core and a macromolecular surface layer having a higher density than the core
• CPC Class Codes: Y10T 428/24273 including aperture
• CPC Class Codes: Y10T 428/249988 : Of about the same composition as, and adjacent to, the void-containing component
• CPC Class Codes: Y10T 428/249989 : Integrally formed skin
• CPC Class Codes: Y10T 428/249991 : Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249992 : Linear or thermoplastic
• CPC Class Codes: Y10T 428/249993 : Hydrocarbon polymer
• CPC Class Codes: Y10T 428/31 : Surface property or characteristic of web, sheet or block

Abstract

The present invention provides an integral skin molded article used for vehicle internal parts, which enables good production efficiency and cost reduction and has good external appearance, and a method of preparing an integral skin molded article, and also provides a laminate with a skin comprising the integral skin molded article and a core material, and a method of preparing a laminate with a skin. Disclosed are an integral skin molded article obtained by injecting a polyurethane foam for a skin into a die after injecting a high density polyurethane resin for a core, containing a high density polyurethane resin for a skin, containing a polyol component, 1-methyl-3,5-diethyl-2,4-diaminobenzene and/or 1-methyl-3,5-diethyl-2,6-diaminobenzene, and a blowing agent into the same die; and a method of preparing a laminate with a skin comprising a skin molded article and a core material.

Claims

1. An integral skin molded article comprising a skin of a high density polyurethane resin and a core of a polyurethane foam, which is molded in a die using a reaction injection molding process, wherein

the high density polyurethane resin comprises a polyol mixture (I) comprising a polyol (I-1), a chain extender (I-2), a catalyst (I-3) and, if required, an auxiliary agent (I-4), and a polyisocyanate compound (II);

the chain extender (I-2) contains 0.7 to 4.5 parts by weight of 1-methyl-3,5-diethyl-2,4-diaminobenzene and/or 1-methyl-3,5-diethyl-2,6-diaminobenzene based on 100 parts by weight of the polyol mixture (I);

the polyurethane foam comprises a polyol mixture (III) comprising a polyol (III-1), a chain extender (III-2), a catalyst (III-3), a blowing agent (III-5) and, if required, an auxiliary (III-4) agent, and a polyisocyanate compound (IV);

the blowing agent (III-5) contains a liquefied carbon dioxide gas; and

a surface hardness of the high density polyurethane resin is from 50 to 90 measured with an Asker A hardness meter, a density of the polyurethane foam is from 0.20 to 0.70 g/cm³ and has a hardness of 20 to 70 measured with an Asker C hardness meter, and the hardness on the skin of the integral skin molded article is from 30 to 70 measured with an Asker A hardness meter.

2. A laminate with a skin, comprising a high density polyurethane resin, a polyurethane foam and a core material, wherein

the high density polyurethane resin and the polyurethane foam comprise the integral skin molded article according to claim 1, and the core material is bonded to the skin of the high density polyurethane resin.

3. The laminate with a skin according to claim 2, wherein a designated rupture section is provided in the core material so as to form an airbag aperture.

4. A method of preparing an integral skin molded article in which a polyurethane foam is present in a core of a skin of a high density polyurethane resin formed on a die inner surface, the method comprising the steps of:

adjusting a gel time of a liquid mixture of a mixture polyol (I) and a polyisocyanate compound (II) of the high density polyurethane resin to 10 to 30 seconds;

adjusting a cream time of a liquid mixture of a mixture polyol (III) and a polyisocyanate compound (IV) of a polyurethane foam to 3 seconds or less; and

injecting the liquid mixture of the polyurethane foam into a die at 1 to 30 seconds after completing injection of a high density polyurethane resin liquid mixture into the die so that a skin thickness of the high density polyurethane resin is 0.1 to 2.0 mm.

5. The method of preparing an integral skin molded article according to claim 2, the method comprising the steps of:

adjusting a gel time of a liquid mixture of a mixture polyol (I) and a polyisocyanate compound (II) of the high density polyurethane resin to 10 to 30 seconds;

adjusting a cream time of a liquid mixture of a mixture polyol (III) and a polyisocyanate compound (IV) of a polyurethane foam to 3 seconds or less; and

injecting the liquid mixture of the polyurethane foam into a die at 1 to 30 seconds after completing injection of a high density polyurethane resin liquid mixture into the die so that a skin thickness of the high density polyurethane resin is 0.1 to 2.0 mm, wherein the method further comprises the step of preliminarily installing the core material in the die prior to injecting the high density polyurethane resin liquid mixture, and a laminate with a skin has a high density polyurethane resin skin formed on the surface of the core material and the die inner surface and a core of polyurethane foam.