THERMOPLASTIC FILM

• US 20090269538A1
• Filed: 07/02/2009
• Published: 10/29/2009
• Est. Priority Date: 01/10/2007
• Status: Active Grant

• Current Assignee: Benecke-Kaliko AG (Continental AG)
• Original Assignee: Benecke-Kaliko AG (Continental AG)
• Inventors: Marquardt, Jurgen, Buhring, Jurgen
• Granted Patent: US 8,043,683 B2
• Time in Patent Office: Days
• US Class Current: 428/43
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/30 comprising vinyl (co)polymers; comprising acrylic (co)polymers
• 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 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B60R 21/2165 characterised by a tear line for defining a deployment opening
• CPC Class Codes: Y10T 428/15 Sheet, web, or layer weakened to permit separation through thickness
• CPC Class Codes: Y10T 428/24273 including aperture
• CPC Class Codes: Y10T 428/24479 including variation in thickness
• CPC Class Codes: Y10T 428/24496 Foamed or cellular component
• CPC Class Codes: Y10T 428/24504 Component comprises a polymer [e.g., rubber, etc.]

Abstract

A thermoplastic film for the interior paneling of motor vehicles has a top layer with a structured surface layer and a foamed layer on the underside and with indentations or material weak points introduced on the reverse side. The top layer has a residual thickness of at least 35% in the region of the indentations and the foamed layer has a thickness between 15 and 50% of the density of the compact top layer.

Claims

1. A thermoplastic film, comprising:

an outer compact top layer formed with a three-dimensionally structured upper surface, said outer compact top layer having a given thickness and having a given density;

a foamed layer on an underside of said top layer, wherein said foamed layer and said outer compact top layer are configured to be applied in a shaping processing step to a carrier corresponding to a component shape and to assume the component shape;

the film being formed on a reverse underside facing toward the carrier with indentations or material weak points introduced from the reverse side;

said top layer, in a region of said indentations or material weak points having a residual thickness of at least 35% of the given thickness of said top layer in an unindented, unweakened portion thereof; and

said foamed layer having a density, measured at half a layer thickness of said foamed layer, between 15% and 50% of the given density of said top layer.

2. The thermoplastic film according to claim 1, wherein the given thickness of the unindented, unweakened said top layer is 0.4 to 0.8 mm and the residual thickness at said indentations or material weak points is at least 0.25 mm.

3. The thermoplastic film according to claim 2, wherein the residual thickness at said indentations or material weak points is at least 0.35 mm.

4. The thermoplastic film according to claim 1, wherein said foamed layer has a density, measured at half the layer thickness of said foamed layer, between 25% and 50% of the given density of said top layer.

5. The thermoplastic film according to claim 1, wherein said top layer consists of one or more materials selected from the group consisting of polyolefin, polyurethane, polyvinyl chloride, partly crystalline polymer, and amorphous polymer.

6. The thermoplastic film according to claim 1, wherein said foamed layer comprises a polyolefin foam and a polyethylene component having a melt flow index less than 2 g/10 min.

7. The thermoplastic film according to claim 6, wherein said foamed layer contains a polypropylene component.

8. The thermoplastic film according to claim 1, wherein said foamed layer has a compressive stress of at most 250 kPa at an indentation depth of 25% of a total thickness of the unweakened said foamed layer.

9. The thermoplastic film according to claim 8, wherein said foamed layer has a compressive stress of at most 180 kPa.

10. The thermoplastic film according to claim 8, wherein said foamed layer has a compressive stress hardness of at most 125 kPa.

11. The thermoplastic film according to claim 1, wherein the carrier corresponds to a component shape in a motor vehicle and the thermoplastic film is configured to form an interior paneling of the motor vehicle.

12. An interior paneling part for a motor vehicle, comprising a thermoplastic film according to claim 1, wherein the indentations or material weak points of the film introduced on the reverse side form tear seams of an airbag cover.

13. The paneling part according to claim 12, configured as a dashboard.