Automobiles and other vehicles usually include finished, upholstered passenger compartments having door and other openings to the exterior. The perimeters of the openings present an interface between the interior and the exterior materials that is exposed to contact by people and objects passing in or out of the compartment. Traditionally, this perimeter area has been protected by sewn leather, molded rubber and/or fabric bumpers or guards. Recently, molded plastic parts have been provided that are fastened to conceal the interface between the interior and exterior materials. Typically, these parts are made by adhering a suitable decorative laminate to a molded structural profile that permits attachment. In one frequently employed example, a laminate of this type comprises a polyolefin film backing and an embossed vinyl decorative face.

While suitably durable and attractive for most uses and for many different environments, failures are not uncommon in use due to negative interactions with ingredients from the underlying materials combined with UV exposure, thermal cycling, heat aging and the like.

It would be desirable to provide alternative processing techniques for preparing parts of this type with a high degree of reliability. There remains a need for simple and efficient processing to produce protective, decorative door trim materials.

Brief Description of the Drawing The invention will be better understood and its advantages will become more apparent from the following description, especially when read in light of the accompanying drawings, wherein: Figure 1 is a schematic, cross-sectional view of a molded structural door trim profile of the invention including a decorative facing sheet material formed in accord with the invention; Figure 2 is a schematic cross section of a decorative facing sheet material formed in accord with the invention; Figure 3 is schematic cross section of one embodiment of the invention wherein a decorative facing layer is continuously cast onto a backing substrate and then shaped by contact with a removable patterned web to form a decorative sheet material of the type illustrated in Figure 1; Figure 4 is a schematic cross section of a decorative facing sheet material similar to that illustrated in Figure 2, but having an adhesive layer formed between the backing layer and the cast facing layer; Figure 5 is schematic cross section of one embodiment of the invention illustrating a process for preparing the facing sheet material illustrated in Figure 4; Figure 6 is another schematic cross section of a decorative facing sheet material formed in accord with the invention; Figure 7 is schematic cross section of one embodiment of the invention illustrating a process for preparing the facing sheet material illustrated in Figure 6; Figure 8 is another schematic cross section of a decorative facing sheet material formed in accord with the invention; Figures 9a and 9b are schematic cross sections of another embodiment of the invention illustrating a two-stage process for preparing the facing sheet material illustrated in Figure 8.

Summary of the Invention It is an object of the invention to provide a simple and effective method for preparing a protective, decorative automotive door trim material.

It is another object of the invention to provide alternative processing techniques for preparing parts of this type with a high degree of reliability.

It is another object of the invention to provide an improved process for providing simple and efficient processing to produce protective, decorative door trim materials.

These and other objects are accomplished by the invention, which provides an improved decorative facing sheet material and a molded structural door trim or other interior profile and processes for preparing them. In one embodiment, the facing sheet material is formed onto a suitable backing by contacting a thermosetting polymer by contact with an embossed, pealable sheet. The decorative facing sheet material eliminates PVC and its associated problems of plasticizer migration and brittleness. In addition, the materials of the invention will be recyclable and lighter than PVC.

The processes and the materials produced have a number of preferred aspects, which are described below and shown in the attached drawing.

Detailed Description of The Invention While the invention has broader utility, the following description will detail materials and methods wherein an improved decorative facing sheet material and extruded interior trim molding employing it are prepared in preferred forms. The drawings illustrate a number of variations, each with its particular advantages.

As used herein, the term"interior trim"is meant to include contoured members made of one or more plastic materials, some with embedded metal reinforcements, designed to be fixed to a vehicle interior, such as an opening in an automobile door. Typically, the interior trim will protect an interface between a metal structure and a decorative covering typical of interior trim.

The term also relates to other interior applications like small electronic devices copying interior and exterior automotive finishes.

In the following embodiments, the facing sheet material is formed onto a suitable backing by contacting a thermosetting polymer by contact with an embossed, pealable sheet. The decorative facing sheet material eliminates PVC and its associated problems of plasticizer migration and brittleness. In addition, the materials of the invention will be recyclable and lighter than PVC.

Figure 1 is a schematic, cross-sectional view of a molded structural door trim profile of the invention including a decorative facing sheet material formed in accord with the invention.

The door trim profile is comprised of a decorative facing material 10 affixed to a molded structural member 11. The specific shape of structure 11 will be determined by the particular application intended and will complement the particular structure to which it will be attached.

Various flanges, e. g., 11 a, bumpers, e. g., lib, and the like are provided for attachment, cushioning and/or decoration.

Figure 2 is a schematic cross section of a decorative facing sheet material 10 formed in accord with the invention. Sheet material 10 is shown comprised of three layers. A first layer 12 is a embossed paper or other material used to impart a pattern to the outer surface of an outer decorative layer 16 which is revealed when layer 12 is stripped from layer 16 as will be described later. Embossed papers of this type can impart any desired surface configuration to the final decorative material, including a leather or fabric appearance among many. Layer 14 is of a suitable backing material such as a polyolefin film, e. g., coextruded trilaminate of polyethylene of 5 mil thickness. The film is preferably of a type that has been oriented and surface treated, such as by corona discharge. Other materials, can also be employed. Intermediate layer 16 of a cast polyester. The cast layer will be the outer surface of the finished article and is of a material capable of withstanding the physical stresses necessary for this purpose. It will have imparted to it a surface configuration complementary with that of the first layer. In addition to polyesters of <BR> <BR> this type, other curable casting resins can be employed, e. g. , polyurethanes, polyurethane polyesters, and the like. The preferred materials are solvent-based. The materials are selected based on their ability to be shaped in the manner described, their durability to abrasion and ultraviolet light, ability to be color matched, processability, stain resistance and resistance to delamination.

Figure 3 is schematic cross section of one embodiment of the invention for forming the decorative facing sheet material illustrated in Figure 2. In this embodiment, a decorative facing layer 10 still has paper on is continuously formed by casting a suitable resin onto a backing substrate 14 fed between rolls 22 and 28'. The paper will preferably be removed prior to attaching the decorative facing sheet to a substrate, such as shown in Figure 1. The coated backing is then passed through a suitable drying oven, when necessary as in the case of solvent-based coatings.

The drawing shows a two-stage oven 34, e. g, with a first zone heated to about 100 to 200° F and a second zone heated to about 150 to 250°F. Following drying, the applied coating is shaped by contacting it with a removable patterned web 12 fed from roll 20. Webs of this type are available <BR> <BR> commercially from S. D. Warren Co. The polyester 26 in liquid form, e. g. , is of the type typically employed for durable, decorative coatings and can be applied by nip fed reverse roll coating apparatus 28, 28', or the like to a suitable thickness to achieve the desired surface shape.

Conveyor rolls 29 can be utilized as needed. The web 12 is pressed against the cast layer 16 and the cast layer against the backing 14, by passing the three layers between pressure rollers 30 and 32, which may be heated or unheated as required. In a preferred form, the lower roller 32 in contact with the backing 14 is chrome-plated and heated to about 200°F, and the upper roller 30 is made of rubber. The combined layers have a thickness suitable for the intended use.

Figures 4 and 5 show a variation of the embodiment illustrated in Figures 2 and 3 above, wherein an adhesive layer 118 is applied to a backing layer 114 prior to application of the polyester layer 116 and subsequent laying of the web layer 112 thereon. The adhesive can be multifunctional, imparting color, texture, matte, barrier properties, tensile strength or the like. The film 14 is supported by roll 22 or the like during application. The additives can impart functional and decorative aspects to the adhesive layer. It should be noted that the last two digits of the reference numbers are assigned to parts or components equivalent in the other figures. Thus, for example, layers 12,112, 212 and 312 in the various figures are equivalent.

The process illustrated in Figure 5 shows a decorative facing layer 110 is continuously formed by coating a suitable adhesive or primer layer by means of roller pair 127 and 127'onto a backing substrate 114 fed from roll 122. The coated backing is then passed through a suitable drying oven 134, when necessary as in the case of solvent-based coatings. Following drying, a suitable film-forming layer 116, e. g., a onto a backing substrate 114 fed from roll 122. The applied coating is dried in oven 134'and shaped by contacting it with a removable patterned web 112 fed from roll 120 utilizing heat from heated chrome roller 132 and pressure applied by this roller and rubber roller 130. The polyester, polyurethane or polyester/polyurethane and like polymers 126 can be applied by nip fed reverse roll coating apparatus 128, 128', or the like to a suitable thickness. The film 114 is supported by conveyor rolls 129'or the like during application.

Figures 6 and 7 show another variation of the embodiment of the invention, wherein the polyurethane layer 216 is applied to the web 212 and dried prior to application of backing layer.

It will be noted that the arrangement of Figure 7 is essentially the same as that of Figure 3, but with the layers reversed. As a last step in this procedure, resulting three layer composite is fed through the nip between rollers 230 and 232, where 230 is rubber and 232 is a heated metal roller.

Figures 8,9a and 9b show a variation of the embodiment illustrated in Figures 6 and 7 above, wherein an adhesive or primer layer 318 is applied to the backing layer 314 prior to application of the polyester layer 316 and subsequent laying of the web layer 312 thereon.

Following drying in oven 334, a release layer is applied from roll 340 prior to passage of the composite between roller pair 332 and 330 and collection onto roller 338. In Figure 9b, the material is unrolled from roll 338 and release layer 342 is stripped and taken up on roll 339. Then, as in the other embodiments, the polyester layer 316 is applied by rollers 328 and 328', the coating is dried in oven 334'and layer 314 is applied from roll 322 prior to compression between rollers 330 and 332 and collection onto roll 342.

A layered composite of a polyolefin backing layer, a textured surface and a texturizing paper web as illustrated in Figure 1, for example, is then formed. The composite can be attached to a decorative trim extrusion profile by contact therewith at the face of an extrusion forming die or immediately adjacent to the die exit in the case of thermoplastic extrusion materials such TPO's (thermoplastic olefin elastomers), TPE's (thermoplastic elastomers), or at the exit of a curing tunnel following extrusion of the profile in the case of thermosetting resins such as EPDM, or the like. Preferably, the paper web is removed prior to attachment to the door trim extrusion profile. In other cases, the trim can be adhered by any suitable means, including various adhesive and molding procedures, to its intended substrate.

The above description is intended to enable the person skilled in the art to practice the invention. It is not intended to detail all of the possible modifications and variations which will become apparent to the skilled worker upon reading the description. It is intended, however, that all such modifications and variations be included within the scope of the invention which is seen in the above description and otherwise defined by the following claims. The claims are meant to cover the indicated elements and steps in any arrangement or sequence which is effective to meet the objectives intended for the invention, unless the context specifically indicates the contrary.