WO2003039765A1

WO2003039765A1 - Electrostatic application of loose fiber to substrates

Info

Publication number: WO2003039765A1
Application number: PCT/US2002/024355
Authority: WO
Inventors: Steven G. Brown; Guy W. Boitos
Original assignee: Bbi Enterprises, L.P.
Priority date: 2001-11-02
Filing date: 2002-08-01
Publication date: 2003-05-15

Abstract

A method for decorating a vehicle component (20) with loose fibers (12) is disclosed. A plurality of loose fibers (12) is ionized and sprayed toward a component (20) in order to adhere the loose fibers (12) to the component (20). A grounding field (218) is applied to the component (20) to attract the charged loose fibers (12) to the component (20). The loose fibers (12) are affixed to the component (20) to orient the fibers (12) in a uniform pattern.

Description

Electrostatic Application of Loose Fiber to Substrates

BACKGROUND OF THE INVENTION 1. Field of the Invention This invention relates generally to a method of decorating vehicle components.

More specifically, this invention relates to a fibrous decorative coating for a vehicle component.

2. Description of the Prior Art During assembly of a vehicle, such as, for example, a passenger vehicle, metal components are welded together to form a body. A roof is supported by several pillars extending from sides of the vehicle. A floor pan defines the bottom of the vehicle body and typically extends rearward to form a load floor of a storage compartment that may or may not be separately enclosed from the passenger compartment. Doors are pivotally attached to the body to provide access for passengers to an interior compartment defined by the body. While assembling the vehicle, interior components are affixed to the sheet metal both to provide decoration and function to the interior compartment for the passengers. Initially, carpeting is spread over the floor pan to cover the floor pan and any electrical wires that have been routed throughout the body. An instrument panel is mounted in the forward section of a vehicle compartment and typically supports the steering wheel and other functional items such as, for example, the radio and various storage compartments. Door pads are mounted on the doors of the body and shield functional components such as the window mechanisms and door handles and locks from the passenger compartment. A headliner is affixed to the roof of the vehicle and is typically formed of a fibrous material. Mouldings are affixed to the pillars extending between the body sides and the roof of the vehicle and to provide a decorative function along with protecting the passengers from contact with the pillars. In the case of a sedan, a package shelf is fixed to the rearward section of the vehicle and typically supports speaker grills. To complete construction of the interior compartment, seats and consoles are fixed to the floor pan, and occasionally, a console is affixed to the roof. Trunk trim may also be spread throughout the storage compartment to cover the sheet metal defining the storage compartment. rn order to provide differentiation and unique decorative features to each of these components, fabric is often glued over the visible surfaces providing an esthetically pleasing appearance. Occasionally, the same fabric will be used to cover adjacent components to provide a uniform appearance. Also, carpeting is known to be glued to the door pads, package shelf, and consoles to provide a uniform appearance and transition to the floor carpeting. These fabrics and carpeting are also used to improve the noise absorbing properties of the various components.

The addition of these fabrics and carpeting have proven to be an expensive step in the manufacture of these components. These materials need to be glued to the surface of the various components, and frequently delaminate as the vehicle ages. Therefore, it would be desirable to provide a decorative coating to these interior components that provides the feel and esthetic appearance of fabrics and carpeting presently glued to the surface of the components without having the associated costs and labor.

Other methods of decorating the visible surface of the interior components have been utilized. One such method, known as flock coating, includes decorating the surface of the components with loose fibers. Flock coating has been utilized on weather stripping to reduce the friction coefficient of the weather strip and, occasionally, in storage compartments to eliminate rattling. During the flock coating process, loose fibers, typically cut to a uniform length, are sprayed onto a component surface that has been coated with an adhesive. The fibers adhere to the surface of the component in a random fashion, as shown in Figure 1, presenting a non-uniform appearance. Therefore, decorating the surface of the highly visible components such as, for example, a headliner, sun visors, pillar moldings, door panels, an instrument panel, a rear shelf, floor covering, and consoles has not heretofore been accomplished. The non-uniform appearance does not provide the esthetically pleasing appearance required of these types of components. Therefore, the cost and efficiency benefit of applying a flocked fiber coating to these components rather than fabrics and carpeting has not been realized.

SUMMARY OF THE INVENTION AND ADVANTAGES A method of decorating a vehicle component using loose fibers is disclosed. A plurality of loose fibers precisely cut to a uniform length are provided to an application device. The loose fibers are ionized and released adjacent a vehicle component being decorated. A grounding field is applied to the vehicle component to attract the ionized loose fibers. The loose fibers are affixed to the component and are subjected to an electrostatic field to orient the fibers in a uniform pattern. The inventive method of decorating a vehicle component described above eliminates the labor and cost associated with gluing fabrics or carpeting to various vehicle components. By applying an electrostatic field to the ionized fibers, the uniform pattern is presented that is consistent even when the fibers are applied to different component substrates such as, for example, fiberglass composites, polymer composites, and natural fiber composites. This provides the benefit of a uniform appearance between components not having the same substrate. For example, a fiberglass headliner abutting to a polymer molding can present a uniform appearance due to the uniform orientation of the fibers affixed to each of the components.

BRIEF DESCRIPTION OF THE DRAWINGS

Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

Figure 1 is a sectional view of the flocked coating of the prior art; Figure 2 is a schematic view of the present inventive loose fiber coating application process;

Figure 3 is a cross-sectional view of a component substrate having a loose fiber decorative coating applied using the present inventive application process;

Figure 4 is a schematic view of an alternative embodiment of the inventive loose fiber application process;

Figure 5 is a schematic view of a further alternative embodiment of the inventive loose fiber application process; and

Figure 6 is a cross-sectional view of a vehicle showing components decorated with the loose fibers using the inventive application process. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to Figure 2, a schematic of an apparatus for applying loose fibers is generally shown at 10. Loose fibers 12 are stored within a container 14 enclosed on one side with a grid 16. An electric source 18 provides an electrostatic charge to the grid 16 in order to transfer the charge to the loose fibers 12.

A substrate 20 is attached to a grounding contact 22 so that an electrostatic field 24 is generated between the grid 16 and the component 20. Preferably, the electrostatic field 24 is aligned in a substantially perpendicular orientation to a surface 26 of the component 20 to which the loose fibers 12 are to be attached, the purpose of which is explained below. The loose fibers 12 are attracted to the grounded substrate 20 via the electrostatic charge transferred to the fibers 12 from the grid 16. Alternatively, pneumatic pressure (not shown) may be used to propel the loose fibers toward the substrate 20. The electrostatic field 24 is preferably generated by a DC electrical current. DC current has proven to generate an electrostatic field 24 providing a more precise alignment of the loose fibers than does an AC current. However, it should be understood that AC current may be used in certain circumstances.

Prior to charging the container 14 with the loose fibers 12, the fibers 12 are ionized to improve the transfer of the electrostatic charge from the electric source 18 to the fibers 12. Preferably, the loose fibers 12 are treated with a solution ionized with sea salt after the fibers 12 have been cut to a desired length. However, other equivalent ionizing solutions known to those with skill in the art may also be used. Once the loose fibers 12 have been ionized, the transfer efficiency of the fibers 12 to the component 20 is improved due to the ionic attraction to the grounded component 20. Further, the fibers 12, having been ionized, are now more readily oriented according to the electrostatic field 24 as will be explained further below.

Referring to Figure 3, a sectional view of a component 20 having the inventive decorative coating applied is shown. The surface 26 of the component 20 being decorated with the loose fibers 12 is pre-treated prior to the application of the fibers 12. Initially, the surface is sealed to provide a non-porous base enabling the loose fibers 12 to be affixed to the surface 26 in a uniform pattern. Several alternatives are contemplated to pre-treat the surface 26 of the component 20. A thin film of plastic 27 may be adhered to the surface 26 to provide a desirable substrate to accept the loose fibers 12. Further, heating or plasma treating the surface 26 of the component 20 may be used. Still further, primer may be applied to the surface 26 to provide a desirable substrate. It should be understood by those of skill in the art that different substrates may accept different of the pre-treatments better than other of the substrates.

An adhesive 28 is subsequently applied to the surface 26 over the pre-treatment 27 to adhere the loose fibers 12 to the surface 26. Preferably, the adhesive is chosen for compatibility with the substrate material. The adhesive is also preferably chosen to meet the physical specifications of the component 20. For example, a door pad, which is typically shaded, may have different adhesive requirements than an instrument panel, which is subject to high levels of ultra violet light. Therefore, an adhesive known to have superior UV durability should be selected for the instrument panel. Further, some adhesives are known to bond to different substrates better than other substrates. An adhesive selected for a polypropylene substrate may not be suitable for a fibrous substrate. Still further, adhesives known to provide a scratch resistant surface is preferably applied to components known to receive a significant amount of wear.

The electrostatic field generated between the grid 16 and the surface 26 of the substrate 20 causes the ionized fibers 12 to orient longitudinally with the field 24. As stated above, the electrostatic field 24 is preferably oriented perpendicular to the surface 26 of the substrate 20. Therefore, the fibers 12 are affixed to the surface 26 in a perpendicular orientation as directed by the ionic field upon contacting the surface 26.

Because the components 20 do not generally include a linear surface, the grid 16 is preferably movable relative to the surface 26 so that the ionic field 24 is maintained at a perpendicular relationship to the surface 26. However, the fibers 12 will orient relative to the surface 26 of the component 20 at any angle defined by the electrostatic field 24. In this embodiment, the grid 16 is large relative to the surface 26 being decorated and preferably would be used to decorate components 20 where it is desirable to decorate the entire visible surface 26. Therefore, it is desirable to mount the grid 16 to a robotic arm (not shown) as is known to those of skill in the art of coating vehicle components. Therefore, the orientation of the fibers 12 regardless of the contours in the surface 26 of the component 20 will always be perpendicular providing a uniform appearance along the entire surface 26 of the component 20.

Subsequent to applying the fibers 12 to the surface 26 of the component 20, the adhesive 28 is cured, preferably with infrared curing equipment. However, an oven or equivalent heat projecting device, such as, for example, a high temperature lamp may be used. Alternatively, a rapid air drying adhesive may also be used. After the adhesive 28 has cured, the fibers 12 are permanently affixed to the surface 26 of the component 20. However, excess fibers 12 that did not come into contact with the adhesive 28 may be removed from the surface 26 through impingement with compressed air or by vibrating the component 20. These loose fibers 12 are preferably recovered and recycled for application to subsequent components 20 so that the material waste is maintained at a minimum.

An alternate apparatus 110 is generally shown in Figure 4. In this embodiment, the loose fibers 12 are fluidized by pressurized air delivered through an air hose 120 from a compressor (not shown). The loose fibers 12 are propelled through a grid 124 by the pressurized air toward the component 20 being decorated. A electrical charge is applied to the grid 124 or other conductive element of the apparatus 110 from an electrical source 126. The component 20 is grounded so that the electrostatic field 24 may be generated between the grid 124 and the surface 26 of the component 20. Therefore, the fibers released through the grid 124 receive an ionized charge causing the fibers 12 to be attracted to the grounded surface 26 of the component 20.

As stated above, the electrostatic field also aligns the loose fibers 12 as well as facilitating the transfer of the fibers to the component 20. In this embodiment, the grid through which the fibers 12 are released, is significantly smaller than the surface 26 of the component 20 being decorated. The container 122 is preferably mounted on a robot arm (not shown) and manipulated around the component 20 to maintain the grid 124 in a perpendicular orientation to the surface 26 being decorated even if the surface is contoured. Therefore, the electrostatic field 24 is also maintained in a perpendicular orientation to the surface 26. Accordingly, the ionized fibers 12 applied to the surface 26 will be aligned in a perpendicular orientation with the surface 26 of the component 20, regardless of the contours in the surface. Another advantage of the smaller grid 124 is that a precise application of the fibers 12 may be achieved. Therefore, if only a certain section of the component 20 is desired to be decorated with the fibers 12, the robot arm may manipulate the grid 124 in that section only, thereby allowing for a two tone appearance on the component 20.

A still further embodiment of the apparatus is generally shown in Figure 5 at 210. Frequently, the component being decorated with the loose fibers 12 are formed from non- conductive materials. In order to generate the electrostatic field 24 and to attract the loose fibers 12 to the surface 26 of the component 20 being decorated, the component 20 must still be grounded. The fibers 12 are maintained in a container 212 similar to that disclosed in the earlier embodiments. A grid 214 or other conductive element of the container 212 is charged with an electrical source 216 to generate the electrostatic field 24 and to ionize the loose fibers 12. A contact plate 218 is disposed behind the non-conductive component 20. The contact plate 218 is grounded so that the electrical field is generated between the contact plate 218 and the grid 214. The non-conducting component 20 is positioned within the electrostatic field 24 between the contact plate 218 and the grid 214. Therefore, the fibers 12 released through the grid 214, having been electrostatically charged by the electrical source 216, are attracted to the non-conducting substrate of the component 20 by virtue of the electrostatic field 24 generated between the grid 214 and the contact plate 218. Preferably, the electrostatic field 24 is generated at a perpendicular orientation to the contact plate 218. Therefore, the surface 26 of the component 20 having a non-conducting substrate is oriented in the electrostatic field 24 in a direction selected to attach the fibers 12 in a substantially perpendicular alignment to the surface 26. However, it should be understood that the contact plate 218 and the surface 26 of the component 20 may be oriented at angles not substantially perpendicular to the electrostatic field 24.

Referring now to Figure 6, a sectional view taken longitudinally of a passenger vehicle is generally shown at 310. As is known to those of skill in the art, the components affixed to the body within the passenger compartment include the instrument panel 312 located in the forward section of the vehicle. An A-pillar molding 314 abuts the instrument panel at its lower end and a headliner 316 at its upper end. A B-pillar molding 318 abuts a central portion of the headliner 316 and is disposed between a front door pad 320 and a rear door pad (or quarter panel pad) 322. A C-pillar molding 324 abuts the headliner 316 at its upper end and a rear shelf 326 at its lower end. A carpet 328 covers the floor pan (not shown) of the vehicle. Rearward in the vehicle is a storage compartment 330 wherein storage compartment trim 332 covers nearly the entirety of the vehicle body defining the storage compartment 330. Also located within the storage compartment is a spare tire cover 334 or equivalently a load floor. By utilizing the inventive process of decorating these components with the loose fibers 12, a transition can be made between abutting of these components that provides a uniform appearance. For example, loose fibers may be applied to the headliner 316, the moldings 314, 318, 324 and upper surface of the instrument panel 312 and the rear shelf 326.

Frequently, these components are formed from different substrates. For example, the headliner 316 may be formed from a fiberglass composite, the moldings 314, 318, 324 may be formed from polypropylene or other polymer composite, and the shelf 326 may be formed from a natural fiber composite. By applying the loose fibers 12 to each of the substrates using the inventive process set forth above, each of these substrates can present a uniform decorative surface within the interior compartment. Further, the components located in the storage compartment 330 can each be decorated with the loose fibers 12 also presenting a uniform appearance within the storage compartment. As shown on the door pads 320, 322, it may be desirable only to decorate portions of the surface with the loose fibers 12. This is easily achieved using the inventive process set forth in the second embodiment. By robotically moving the smaller grid 124 along a predetermined path, a precisely located fiber 12 decorated coating may be achieved without the need to mask the area of the component mat being decorated.

The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described.

Claims

CLAIMSWhat is claimed is:

1. A method of decorating a vehicle component comprising the steps of: providing a plurality of loose fibers; ionizing said plurality of loose fibers; spraying said plurality of loose fibers toward said component in order to adhere said loose fibers to said component; applying a grounding field to said component thereby attracting said loose fibers to said component; affixing said loosed fibers to said component; and applying an electrostatic field to said component thereby orienting said fibers in a uniform pattern.

2. A method of decorating a vehicle component as set forth in claim 1, wherein said step of ionizing said fibers is further defined by treating said fibers with an ionizing solution.

3. A method of decorating a vehicle component as set forth in claim 2, wherein said step of treating fibers with an ionizing solution is further defined by treating said fibers with a solution comprising sea salt.

4. A method of decorating a vehicle component as set forth in claim 1, further including the step of treating the surface of said component thereby reducing the porosity of said component.

5. A method of decorating a vehicle component as set forth in claim 1, further including the step of applying an adhesive to said component thereby affixing said loose fibers to said component.

6. A method of decorating a vehicle component as set forth in claim 5, further including the step of curing said adhesive thereby securing said fibers to said component in said uniform pattern.

7. A method of decorating a vehicle component as set forth in claim 1, wherein said step of applying an electrostatic field to said component is further defined by aligning said electrostatic field generally perpendicular to the surface of said component being decorated.

8. A method of decorating a vehicle component as set forth in claim 1, further including the step of recycling fibers not adhered to said component.

9. A method of decorating a vehicle component as set forth in claim 8, wherein said step of recycling said fibers is further defined by reusing said fibers to decorated additional of said vehicle components.

10. A method as set forth in claim 1, wherein said step of applying a grounding field to said component is further defined by said component including conductive properties thereby enabling said component to be electrically grounded.

11. An assembly as set forth in claim 1, wherein said step of applying a grounding field to said component is further defined by said component including non- conductive properties whereby said grounding field is transmitted onto said component thereby grounding said component.

12. A method of decorating an interior compartment of a vehicle body comprising the steps of: providing a plurality of loose fibers capable of being adhered to a vehicle component; providing a plurality of vehicle components having a visible surface and being mountable to said vehicle body in said interior compartment; mounting said plurality of components to said vehicle body thereby concealing said vehicle body from said interior compartment; and said method characterized by applying a coating of loose fibers in a uniform pattern to at least said visible surface of at least some of said plurality of components thereby providing a uniform decorative appearance to said at least some of said plurality of components.

13. An assembly as set forth in claim 12, wherein said step of applying a coating of loose fibers in a uniform pattern to at least some of said plurality of vehicle components is further defined by applying said coating of loose fibers to at least the entirety of said visible surface of said components.

14. An assembly as set forth in claim 12, wherein said step of providing a plurality of vehicle components is further defined by providing at least a headliner, sun visors, pillar moldings, door panels, an instrument panel, a rear shelf, floor covering, and consoles.

15. An assembly as set forth in claim 12, wherein said step of providing a plurality of vehicle components is further defined by providing vehicle components made from fiber glass composite, polymer composites, and natural fiber composites.

16. An assembly as set forth in claim 15, further including the step of mounting components having different of said fiber glass composite, polymer composite, and natural fiber composite in an adjacent relationship, each having said loose fibers applied thereto in a uniform pattern thereby providing a uniform decorative appearance between adjacent of said components.

17. A vehicle comprising: a body; an interior compartment defined by said body; a plurality of components each having at least a visible surface and being affixed to said body within said interior compartment thereby decorating said interior compartment; and at least some of said plurality of components characterized by having a plurality of loose fibers affixed to at least a portion of said visible surface, wherein said loose fibers are oriented in a uniform pattern thereby providing a uniform decorative appearance to at least some of said plurality of components.

18. An assembly as set forth in claim 17 wherein said components include a headliner, sun visors, pillar moldings, door panels, an instrument panel, a rear shelve, floor covering, and consoles.

19. An assembly as set forth in claim 17 wherein said components are formed from fiber glass composite, polymer composites, and natural fiber composites.

20. An assembly as set forth in claim 17 wherein said plurality of components include a pretreatment thereby sealing said visible surface of said plurality of components.

21. An assembly as set forth in claim 17 wherein said visible surface of said plurality of components includes an adhesive for affixing said loose fibers to said visible surface.

22. An assembly as set forth in claim 17 wherein said visible surface of at least some of said plurality of components having said loose fibers attached thereto abut providing a uniform appearance to said at least some of said plurality of components.

23. An assembly as set forth in claim 17 wherein said component comprises at least on of fiber glass composite, polymer composites and natural fiber composites.