Crash pad for vehicle and manufacturing method thereof

Abstract

The present invention relates to a crash pad for a vehicle and a manufacturing method thereof. In one embodiment, the method for manufacturing the crash pad for the vehicle comprises a step of injecting a skin foam-forming composition between a lower mold having a color coating layer formed thereon and an upper mold having a core layer formed thereon, foaming the injected skin foam-forming composition to form a skin foam layer, wherein the color coating layer is formed by applying the color coating composition to the inside surface of the lower mold and curing the applied color coating composition.

What is claimed is: 
     
       1. A method of manufacturing a crash pad for a vehicle, the method comprising:
 injecting a skin foam-forming composition between a lower mold having a color coating layer formed thereon and an upper mold having a core layer formed thereon, and 
 foaming the injected skin foam-forming composition to form a skin foam layer, 
 wherein the color coating layer is formed by applying a color coating composition to an inside surface of the lower mold and curing the applied color coating composition, 
 wherein the color coating composition comprises a modified polyester resin, a polycarbonate diol-based resin and an additive, 
 wherein the additive comprises one or more of a pigment, a light stabilizer and a hydrolysis-preventing agent. 
 
     
     
       2. The method of  claim 1 , wherein the color coating composition further comprises a polyester elastomer. 
     
     
       3. The method of  claim 1 , wherein the color coating composition is cured at a temperature between about 40° C. and about 70° C. to form the color coating layer. 
     
     
       4. A method of manufacturing a crash pad for a vehicle, the method comprising:
 injecting a skin foam-forming composition between a lower mold having a color coating layer formed thereon and an upper mold having a core layer formed thereon, and 
 foaming the injected skin foam-forming composition to form a skin foam layer, 
 wherein the color coating layer is formed by applying a color coating composition to an inside surface of the lower mold and curing the applied color coating composition, 
 wherein the lower mold having the color coating layer formed thereon is formed by sequentially applying a release agent and the color coating composition to the inside surface of the lower mold, and curing the applied color coating composition. 
 
     
     
       5. A method of manufacturing a crash pad for a vehicle, the method comprising:
 injecting a skin foam-forming composition between a lower mold having a color coating layer formed thereon and an upper mold having a core layer formed thereon, and 
 foaming the injected skin foam-forming composition to form a skin foam layer, 
 wherein the color coating layer is formed by applying a color coating composition to an inside surface of the lower mold and curing the applied color coating composition, 
 wherein the skin foam-forming composition comprises:
 a base comprising a polyol compound, a chain extender and a foaming agent; and 
 an isocyanate-based curing agent. 
 
 
     
     
       6. The method of  claim 5 , wherein the polyol compound comprises one or more of diol, triol and a polymeric polyol compound,
 wherein the diol comprises one or more of ethylene glycol, diethylene glycol, butanediol, and hexanediol, 
 wherein the triol comprises one or more of glycerin, trimethylolpropane, and 1,2,3-hexanetriol, and 
 wherein the polymeric polyol compound comprises one or more of a polyolefin polyol compound, a polyester polyol compound, a polycaprolactone polyol compound, a polyether polyol compound, and a polycarbonate polyol compound. 
 
     
     
       7. The method of  claim 5 , wherein the chain extender comprises one or more of ethylene glycol, propylene glycol, 1,4-butanediol, glycerin, diethanolamine, and triethanolamine. 
     
     
       8. The method of  claim 5 , wherein the base of the skin foam-forming composition further comprises one or more of a catalyst, a pigment and a light stabilizer. 
     
     
       9. The method of  claim 8 , wherein the light stabilizer comprises one or more of a triazine-based compound, a benzophenone-based compound and a benzotriazole-based compound. 
     
     
       10. The method of  claim 5 , wherein the isocyanate-based curing agent comprises one or more of 4,4′-dicyclohexylmethane diisocyanate, 4,4-diphenylmethane diisocyanate, bis-4-(isocyanate chclohexyl)methane, hexamethylene diisocyanate, xylene diisocyanate, p-phenylene diisocyanate, tolidine diisocyanate, tetramethylene diisocyanate, dimethyl diisocyanate, trimethyl hexamethylene diisocyanate, phenylene diisocyanate, and dimethyl diphenyl diisocyanate. 
     
     
       11. The method of  claim 10 , wherein the isocyanate-based curing agent comprises about 40 wt % to about 88 wt % of a monomeric methylene diphenyl diisocyanate (MDI) having a weight-average molecular weight of about 200 g/mol to about 300 g/mol, about 10 wt % to about 58 wt % of a polymeric methylene diphenyl diisocyanate (MDI) having a weight-average molecular weight of about 350 g/mol to about 600 g/mol, and about 2 wt % to about 20 wt % of a methylene diphenyl diisocyanate (MDI) prepolymer. 
     
     
       12. The method of  claim 5 , wherein the isocyanate-based curing agent is contained in an amount of about 35 parts by weight to about 55 parts by weight based on 100 parts by weight of the polyol compound. 
     
     
       13. The method of  claim 1 , wherein the core layer is formed to have a thickness of about 1 mm to about 6 mm,
 the skin foam layer is formed to have a thickness of about 3 mm to about 10 mm, and 
 the color coating layer is formed to have a thickness of about 10 μm to about 200 μm. 
 
     
     
       14. The method of  claim 1 , wherein the core layer comprises: a matrix resin comprising a polycarbonate-based resin and a styrene-based resin; and an inorganic filler. 
     
     
       15. The method of  claim 1 , wherein the skin foam layer and the core layer are not scored. 
     
     
       16. The method of  claim 1 , further comprising releasing the crash pad having the skin foam layer formed therein from the upper and lower molds, and then scoring the skin foam layer and the core layer,
 wherein the scoring is performed using one or more of a laser, a hot knife, a cold knife, an ultrasonic knife, and milling. 
 
     
     
       17. The method of  claim 4 , wherein the core layer comprises: a matrix resin comprising a polycarbonate-based resin and a styrene-based resin; and an inorganic filler. 
     
     
       18. The method of  claim 4 , wherein the skin foam layer and the core layer are not scored. 
     
     
       19. The method of  claim 4 , further comprising releasing the crash pad having the skin foam layer formed therein from the upper and lower molds, and then scoring the skin foam layer and the core layer,
 wherein the scoring is performed using one or more of a laser, a hot knife, a cold knife, an ultrasonic knife, and milling.