Patent Application
20230110728
The present application generally pertains to coated substrates and more particularly to roll or spray coating of a vehicular interior trim apparatus.
Traditionally, automotive vehicle instrument panel skins are made from a variety of polymeric materials including polyvinyl chloride (“PVC”), thermoplastic polyurethane (“TPU”), thermoplastic polyolefin (“TPO”) and thermoplastic elastomers (“TPEs”). These skins can be made by methods such as slush rotational molding and thermoforming. Examples are disclosed in U.S. Patent Publication No. 2017/0240736 entitled “Polyvinylchloride for Seamless Airbag Doors” invented by Farrar, and U.S. Pat. No. 7,560,515 entitled “PVC Alloy for Use in Air Bag Doors” which issued to Tansey on Jul. 14, 2009, both of which are incorporated by reference herein.
Furthermore, it is known to spray paint onto interior trim panels of automotive vehicles. For example, U.S. Patent Publication No. 2005/0096421 entitled “Aqueous Metallic Paint for Automobile Interior Materials and Coated Article” which published to Watanabe et al., teaches spraying a metallic colored paint onto a polypropylene, polyethylene, acrylonitrile-butadiene-styrene, polyvinyl chloride and polyurethane substrate. This patent publication merely includes titanium oxide, carbon black, iron oxide or chromium oxide inorganic pigments, organic pigments or conductive carbon pigments, in addition to a mica pigment, a water solvent, optionally an organic solvent, and additives. The Watanabe patent publication is incorporated by reference herein. This conventional spray paint is primarily aesthetic in nature rather than providing a functional benefit.
In accordance with the present invention, an apparatus and manufacturing method include a coating, including graphene particles, sprayed or rolled onto a base material. In another aspect, a coating, including antimicrobial or antiviral material, is sprayed or rolled onto a base material. A further aspect applies an antimicrobial material within a polymeric matrix onto a vehicular interior trim panel apparatus by roll-coating or spraying. Yet another aspect includes creating a flexible polymeric skin, curing the skin, applying a liquid polymeric and graphene layer on an outer surface of the cured skin, attaching the skin to a rigid substrate before or after the layer is applied, and optionally placing foam between the skin and the substrate before or after the layer is applied.
In an exemplary aspect, the antimicrobial material has antiviral activity and includes a polymeric matrix and graphene particles dispersed in the polymeric matrix at a concentration of greater than or equal to about 0.05 wt. % to less than or equal to about 10 wt. % based on the total weight of the antiviral material. In a further exemplary aspect, the antimicrobial material includes metal oxide particles dispersed in the polymer matrix, the metal oxide particles including at least one of cuprous oxide (Cu2O) particles or zinc oxide (ZnO) particles. In another exemplary aspect, the base material is flexible and includes a polymer including flexible and/or rigid polyvinyl chloride (PVC), a thermoplastic elastomer (TPE), or a combination thereof, wherein the TPE includes a thermoplastic polyurethane (TPU), a thermoplastic polyolefin (TPO), thermoplastic vulcanizates (TPV), or combinations thereof. In yet another exemplary aspect, the base material is rigid and includes a polymer including polypropylene (PP), acrylonitrile butadiene styrene (ABS), polycarbonate (PC), PC/ABS, PC/PP, a thermoplastic elastomer (TPE), or combinations thereof.
The apparatus is useful as a Class-A surface of an automotive vehicle interior trim panel selected from the group consisting of an A-pillar, a B-pillar, a C-pillar, an instrument panel, a steering wheel skin, an airbag cover, a door trim panel, a center console, a knee bolster, a seat mechanism cover, and a sun visor. In an alternative example, the apparatus is also useful in non-automotive vehicle applications, such as for a seat, a bench, an exercise bench, a bicycle handle, a motorcycle handle, a vital signs monitor, hospital equipment, a door hand panel, a door foot panel, a door knob or handle, a door opening actuator, an airplane cabin wall, an airplane storage bin, an airplane seat, an airplane tray table, a cruise ship surface, a counter top, a flooring, a matt, an electrical device, a ski lift chair or rail, or a sports locker. In another example, the apparatus may be used to create a Class-A accessible, outer surface of a skin or cover material that resembles artificial leather for cushions or furniture such as a sofa, couch or chair. A method of applying a coating by rollers or spraying a polymeric matrix, including an antimicrobial material, to a base material is also provided.
The present apparatus and method are advantageous over conventional devices and materials. For example, the present apparatus and method use less antimicrobial and graphene material when roll-coated or sprayed, as compared to compounded into the skin or base materials. It is also beneficial to spray or roll-coat after the base material is formed since it may be desirable to not expose the antimicrobial coating to the same temperatures or pressures employed during base material forming. The present apparatus and method are also expected to be more cost effective at higher volume production. Because the present antimicrobial material has antiviral activity, it is especially useful for surfaces that are often touched by human subjects. Accordingly, the antimicrobial material is useful for destroying viruses, including coronaviruses, and decreasing risks of viral infection when contacting polymeric surfaces that are commonly encountered.
Moreover, severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2) epidemic has changed the way hygiene is managed and maintained in public and other shared spaces. SARS-CoV-2, which causes coronavirus disease 2019 (COVID-19), and other deadly microbes can transmit through direct person-to person contact, from the uptake of contaminated airborne droplets, or even from contact with contaminated surfaces such as vehicle interiors. For example, traditional interiors of rental cars, taxis and other shared vehicles are affected by SARS-Covid-2, as the virus can be easily transmitted by coming in contact with it. Therefore, the present spray or roll-coating of antiviral polymeric materials on an accessible outer surface of a vehicular interior trim apparatus can beneficially significantly diminish the amount of virus present thereon. The present use of antiviral materials is an effective way to inactivate viral particles in the environment, which prevents viral transmission, thus lowering the risk of infection. Additional advantages and features of the present application will become apparent from the following description, attached drawings and appended claims.
The present apparatus and method include a layer or coating of an antimicrobial polymer on vehicular interior parts. Preferably, the vehicles are passenger automotive vehicles but the vehicles may alternately be aircraft vehicles such as airplanes, watercraft vehicles such as boats, and mass transportation wheeled vehicles such as buses, trains and subways. The automotive vehicle interior trim panels are preferably instrument panels, center floor consoles and door trim panels. Alternately, the automotive interior trim apparatuses may include soft skins, seating materials, class-A hard trim components, map-pockets, A-pillars, B-pillars, C-pillars, knee bolsters, seat mechanism covers, sun visors and the like.
More specifically with reference to
When used as an instrument panel 11, a section of skin 13 acts as an integral airbag door 23 behind which is an airbag assembly including a chute 25. Airbag door 23 hinges or pivots about upper and lower flexure lines adjacent generally horizontally elongated substrate edges 27 when an expanding airbag bursts tear seams 29 in skin 13. A “seamless” or hidden style of skin 13 is preferred whereby tear seams 29 are on the backside surface thereof and are not visible to the vehicle occupant or user. Tear seams 29 preferably have an H-shape, although other configurations such as U-shapes, and X-shapes can be employed.
Soft skins 13 for automotive interiors are made from a variety of polymeric materials including flexible PVC, TPU, TPO, and TPEs, by way of nonlimiting examples. These skins can be produced by methods such as slush rotational molding, injection molding, thermoforming, and from cut and sew applications.
An elongated pillar trim panel, door trim panel, or alternately an exterior door handle apparatus 41, is shown in
Coating layer 21 includes an antimicrobial material or particles in a polymeric matrix. The antimicrobial material preferably includes graphene particles disposed and/or embedded in the polymeric matrix, including at an exposed exterior surface thereof. As used herein, the term “antimicrobial” preferably provides antiviral properties, antibacterial properties and/or antifungal properties. As such, when a virus contacts the antimicrobial material, the virus is disabled, inactivated, destroyed, or “killed” such that the virus is no longer capable of infecting a subject. Similarly, when the antimicrobial material has antibacterial properties, the bacterium is killed when a bacterium contacts the antimicrobial material. The term “antiviral” provides that the antiviral material disables, inactivates, destroys, or “kills” at least SARS-CoV-2, and in some aspects, also kills other viruses, including other coronaviruses. More specifically, the present antimicrobial material exhibits antiviral activity due to its ability to disrupt virus host cell recognition by denaturing protein structures on viral surfaces, leading to the inactivation of viruses regardless of the presence of a viral envelope. As nonlimiting examples, the antimicrobial material disables, inactivates, destroys, or “kills” greater than or equal to about 90%, greater than or equal to about 95%, greater than or equal to about 98%, greater than or equal to about 99%, such as about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96%, about 97%, about 98%, about 99%, or about 99.9%, of SARS-CoV-2 viral particles or plaque forming units (PFUs) in less than or equal to about 4 hours, less than or equal to about 3 hours, less than or equal to about 2 hours, less than or equal to about 1 hours, less than or equal to about 45 minutes, less than or equal to about 30 minutes, or less than or equal to about 15 minutes.
As used herein, a “polymeric matrix” preferably includes a water solvent and a water based polymeric material such as polyurethane, within which the antimicrobial particles, such as the graphene particles, are embedded or suspended. In the pre-cured and application condition, the polymeric matrix is in a liquid and flowable state, but after heat or UV curing, the polymeric matrix has a solid state. Depending on the use, such as on the instrument panel, the cured antimicrobial material preferably is flexible and soft, but it may alternately be relatively rigid. The hardness, rigidness, and flexibility of the antimicrobial material is provided by the polymer in the polymer matrix. For example, for applications requiring soft and flexible materials, such as for a synthetic leather or skin, as non-limiting examples, the polymer of the polymer matrix includes polyvinyl chloride (PVC), a thermoplastic elastomer (TPE), or a combination thereof. The TPE includes a thermoplastic polyurethane (TPU), a thermoplastic polyolefin (TPO), thermoplastic vulcanizates (TPV), or combinations thereof. Non-limiting examples of TPUs include reaction products of aromatic or aliphatic isocyanates with a polyether or polyester polyol, such as TEXIN® 3042 TPU (Covestro). Non-limiting examples of TPOs include olefin block copolymers (OBCs), INFUSE™ olefin block copolymer resins (Dow), ENGAGE™ polyolefin elastomer resins (Dow), styrene-ethylene-butylene-styrene (SEBS) polymer, such as KRATON™ SEBS polymer (Kraton), and the like. For applications requiring rigid materials, the polymer of the polymer matrix 312 includes polypropylene (PP), acrylonitrile butadiene styrene (ABS), polycarbonate (PC), PC/ABS, PC/PP, a TPE, or combinations thereof. Non-limiting examples of TPUs include aliphatic and aromatic TPUs, such as TEXIN® TPUs (Covestro). Non-limiting examples of hard TPEs include OBCs, INFUSE™ olefin block copolymer resins (Dow), ENGAGE™ polyolefin elastomer resins (Dow), styrene-ethylene-butylene-styrene (SEBS) polymer, such as KRATON™ SEBS polymer (Kraton), and the like.
The graphene particles are antimicrobial particles or flakes including graphene or a graphene derivative, such as graphene oxide as a non-limiting example, that provide at least the antiviral activity. The graphene particles have greater than or equal to 1 to less than or equal to 10 layers or greater than or equal to 6 to less than or equal to 10 layers, wherein each layer includes carbon atoms arranged in a two-dimensional honeycomb-shaped lattice. In various aspects, the graphene particles have 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 of the layers. The graphene particles each have a diameter of greater than or equal to about 750 nm to less than or equal to about 250 μm, greater than or equal to about 1 μm to less than or equal to about 100 μm, or greater than or equal to about 1 μm to less than or equal to about 50 μm.
Details on the antiviral composition can be found in commonly owned U.S. patent application Ser. No. 17/411,415, filed on Aug. 25, 2021, and entitled “Graphene-Based Antiviral Polymer” which is incorporated by reference herein. Further details can be found in commonly owned U.S. patent application Ser. No. 16/802,830, filed on Feb. 27, 2020, entitled “Urethane and Graphene Interior Trim Panel” which is also incorporated by reference herein.
Without being bound by theory, the antimicrobial properties of graphene, and graphene-derivatives (e.g., graphene oxide), are attributed to their electron movement towards microbes. This migration causes cytoplasmic efflux, decreases metabolism, affects lipid membrane, induces oxidative stress, produces reactive oxygen species (ROS), loss of glutathione, and finally causes microbial death. As non-limiting examples, graphene can be used to kill different coronaviruses, including SARS-CoV strains.
In some aspects, the antimicrobial material includes an additional antimicrobial agent. By way of example, the antimicrobial material further includes metal oxide particles, wherein the metal oxide particles also provide at least antiviral activity. The metal oxide particles may optionally include cuprous oxide (Cu2O) particles, zinc oxide (ZnO) particles, silver oxide (Ag2O), or combinations thereof. These metal oxide particles release antimicrobial ions, such as Cu1+, Ag1+ and/or Zn2+, and are used to prepare antimicrobial surfaces. Graphene and/or graphene oxide can promote antimicrobial activities of these ions further and improve the effectiveness. The metal oxide particles each have a diameter of greater than or equal to about 100 nm to less than or equal to about 100 μm, greater than or equal to about 200 nm to less than or equal to about 10 μm, greater than or equal to about 250 nm to less than or equal to about 5 μm, or greater than or equal to about 250 nm to less than or equal to about 1.8 μm.
The graphene particles and the metal oxide particles are individually uniformly dispersed throughout the polymeric matrix of coating layer 21. By “individually uniformly dispersed,” it is meant that the graphene particles and the metal oxide particles are blended within the polymer matrix, including the solvent, without respect to each other. Inasmuch as some graphene particles and metal oxide particles may be in contact with each other, the contact is random and an artifact of a mixing step of a fabrication method for the antimicrobial material. Therefore, contact between a portion of the graphene particles and a portion of the metal oxide particles is not intended, but may be present.
Moreover, coating layer 21 can also include adjunct agents, such as solvent (water/urethane) plasticizers, compatibilizers, impact modifiers, light an UV stabilizers, heat stabilizers, color pigments, fillers (e.g., glass fibers), talc, minerals, glass, physical or chemical foaming agents, and combinations thereof. The graphene particles have a concentration in the coating layer of 60-100 wt. %, and if optionally present, the Cuprous and/or Zinc Oxide particles have a concentration of 5-40 wt. %, based on the total weight of the antimicrobial material in the coating layer. Preferably, the antimicrobial material is about 1-20% of the total coating material. Furthermore, coating layer 21 (including the antimicrobial material, PU polymer matrix and water solvent) is about 0.5 wt % to 5 wt % of the entire coated skin combination 21 and 13, by way of nonlimiting example.
The manufacturing methods will now be discussed. First,
In one embodiment, a third step includes pre-forming the interior trim panel by slush molding the skin in a liquid state within rotating and heated molds from a TPU, PVC or TPO material, or vacuum thermoforming into an open mold is employed, which is then cured and cooled. A rigid substrate or frame is also injection molded from an ABS, PP, nylon or other polymeric material within molds and then cured and cooled. Subsequently, the pre-formed skin is placed over a portion of the pre-formed substrate, and optionally, a pliable foam is injected therebetween and cured, which secures the skin onto the substrate. In this processing embodiment, the antimicrobial coating layer matrix is fed, in a primarily liquid state, from one or more holding tanks to an applicator via one or more elongated hoses. The coating layer matrix is sprayed onto an outer surface of the pre-formed skin via the applicator, here a robotic or hand-held spray gun 51 as shown in
In a second processing embodiment more completely shown in
A third processing embodiment is illustrated in
For any of the embodiments herein, the curing is preferably done by moving the coated skin through an oven. Such an oven may be heated by internal radiant resistive wire coils, convection heating, microwave emitters and/or infrared heaters.
Thereafter, the coated skins are placed onto an open mold 91 (see
While various features of the present invention have been disclosed, it should be appreciated that other variations may be employed. For example, the coating of the present apparatus and method may alternately be applied to other base materials such as synthetic leather, gym equipment, flooring, wallets, medical instruments or medical plastics, electronics (e.g., touch screen, buttons, housings, keyboards, laptops, and the like), public transit surfaces such as benches and handrails, cruise ship interior surfaces, sports equipment, and plastic door handles/pads, among others. An automotive interior trim panel, created by spraying or roll coating an antimicrobial or antiviral material onto a generally flat or three-dimensionally shaped polymeric skin, is also envisioned herein. Each and all of the above-disclosed components and method steps can be combined or re-ordered in any combination. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described; the dependent claims may also be multiply dependent on each other in any combination. Variations are not to be regarded as a departure from the present disclosure, and all such modifications are intended to be included within the scope and spirit of the present invention.
