DE102007061337B4 - Process for producing a component, interior trim part and tool for producing the same - Google Patents

Abstract

Method for producing a component (1), in particular an interior trim part with a decorative skin (9), which comprises the following steps: a) opening a tool (2) with at least two movable and preferably temperature-controlled tool parts (3, 4), b) applying a carrier part (6) which has ventilation holes (7a) and ventilation channels (7b) in an area at the edge and at the edge of an area to be foamed, such that at least one ventilation hole running towards the edge of the carrier part (6) and on a connect venting channels (7b) arranged on the side facing away from the foam for degassing and/or venting, and inserting the skin (9) on the other tool part, c) introducing the foam and closing the tool (2) in an interchangeable sequence, d) expanding the foam (8 ) in the closed mold (2) and degassing and/or ventilation via the ventilation holes (7a) and channels (7b),e) blockage of the ventilation holes (7a) and channels (7b) through exiting foam (8), which changes its material properties due to correspondingly narrow cross sections of the ventilation bores (7a) and channels (7b), f) opening and removing the finished component (1).

Description

The present invention relates to a method for producing a component, in particular an interior trim part with a decorative skin for motor vehicles, an interior trim part produced by means of this method, and a tool for producing the same.

In order to meet the requirements of the automotive industry, interior trim parts of vehicles are usually made up of several layers. A carrier part is usually formed with a mechanically strong material. The visible side of the component is formed by a foil, which can consist of different materials, and there is often a foam layer or another plastic-based layer between the carrier and the foil.

In order to produce these decorative surfaces, in the prior art the skin is laid in the underside of a foaming tool and the carrier is introduced into the upper side of the foaming tool. When the foam components are introduced openly, the foam is applied to the film and/or the carrier with the mold open before the mold is closed. After the mold is closed, the foam components begin to expand and displace the air, which can escape through the open gaps into the side edges. The disadvantage of this method is that seals are required that close the vent gap in a time-controlled manner to prevent the foam from escaping and allow the foam to be compressed. This leads to a skin-foam carrier outlet, which has to be punched in a further work step and leads to a lot of waste.

A method for producing a component is described, for example, in the publication DE 10 2004 023 823 A1 set forth. In this case, a carrier and a skin are arranged in a tool, with the carrier part having a vent hole for venting the component. Foam is then placed between the skin and the wearer and expanded, venting the cavity through the vent hole. An interior trim part produced in this way has a decorative skin, a carrier part and an area of foam lying between them, with the skin and carrier part lying on top of one another in edge regions of the interior trim part, and with the carrier part comprising a vent hole for venting during foam introduction.

A tool for producing such a component is, for example, in the publication DE 10 2005 052 350 A1 shown. This device comprises two tool parts which form a cavity when closed and into which a carrier part and a skin are introduced in order to be back-foamed. Another device for producing a component can be found, for example, in the publication US 4,683,098A can be removed, which has two movable tool parts forming a cavity, and at least one of the tool parts has a device for separating the mold surface into an unsealed and a sealed area.

The object of the present invention is to reduce the waste generated during manufacture and to eliminate or reduce an entire working step. This object is achieved by a method according to patent claim 1, an interior trim part according to patent claim 8 and a tool according to patent claim 10.

1. a) Öffnen eines Werkzeugs mit mindestens zwei beweglichen und vorzugsweise temperierbaren Werkzeugteilen,
2. b) Aufbringen eines Trägerteils, in einem Bereich am Rand und am Rand eines zu schäumenden Bereichs Entlüftungsbohrungen und -kanäle aufweist, derart, dass an mindestens eine Entlüftungsbohrung zum Rand des Trägerteils hin verlaufende und auf einer vom Schaum abgewandten Seite angeordnete Entlüftungskanäle zur Entgasung und/oder Entlüftung anschließen, und Einlegen der Haut auf das andere Werkzeugteil
3. c) Schaumeinbringung und Schließen des Werkzeugs in austauschbarer Reihenfolge,
4. d) Expansion des Schaums im geschlossenen Werkzeug und Entgasung und/oder Entlüftung über die Entlüftungsbohrungen und -kanäle,
5. e) Verstopfung der Entlüftungsbohrungen und -kanäle durch austretenden Schaum, welcher aufgrund der bestehenden engen Querschnitte im Entlüftungsbereich seine Materialeigenschaften ändert,
6. f) Öffnen und Entfernen des fertigen Bauteils.

The invention primarily relates to a method for producing a component, in particular an interior trim part with a decorative skin for motor vehicles, which comprises the following steps:

1. a) opening a tool with at least two movable and preferably temperature-controlled tool parts,
2. b) Application of a carrier part, in an area at the edge and at the edge of an area to be foamed, having ventilation bores and channels, such that at least one ventilation hole running towards the edge of the carrier part and arranged on a side facing away from the foam for degassing and/or or connect vent, and placing the skin on the other tool part
3. c) foam introduction and mold closing in interchangeable order,
4. d) Expansion of the foam in the closed mold and degassing and/or venting via the vent holes and channels,
5. e) Blockage of the ventilation holes and channels by escaping foam, which changes its material properties due to the existing narrow cross-sections in the ventilation area,
6. f) Opening and removing the finished component.

In this case, the skin or carrier part is inserted into corresponding tool parts of a tool.

It is preferably possible that in at least one of the two preferably temperature-controlled tool parts separately temperature-controlled ventilation rich are provided and the carrier part is inserted into the tool in such a way that the ventilation bores and channels are at least partially in the separately temperature-controlled areas of the tool and the clogging by the foam occurs at least also through the temperature control of the tool in the ventilation area.

In terms of the basic idea, however, the blockage is preferably already caused by the geometric conditions of the ventilation bore or channels.

To this end, it is particularly advantageous for the ventilation bores to run through the carrier part, for example “transversely” through the carrier part. In order to then achieve a "lateral offset", it is advantageous that on the side facing away from the skin or the foam area, ventilation channels then connect to the at least one ventilation hole, which run towards the edge of the carrier, in order to thus allow ventilation or degassing to reach. It is advantageous here that these ventilation channels are on the side of the carrier part facing away from the skin or the foam, since there is less soiling of the skin on the edge side and thus the feel and aesthetics are not impaired in the visible area. The change in the material properties of the foam preferably takes place as a result of the particular narrowness of the ventilation bores or the adjoining channels; In a preferred embodiment, this can be further supported by temperature control in this venting area on the tool side.

A special feature here is that one tool part can be temperature-controlled separately, specifically in an area that is provided with the carrier part and there with the ventilation bores and ventilation channels. The foam is then introduced into a cavity between the carrier part and the skin, although this does not necessarily have to take place in the mold, which is closed from the start. It is essential, however, that towards the end of the process, the foam expands in the closed mold, so that venting takes place via the venting holes and channels. The ventilation holes and channels are then clogged by escaping foam, the foam changes its material properties in the regions there due to the different temperature and/or small cross-section compared to other foam areas, so that the foam is prevented from escaping after a very short time and the rest of the foam in the cavity between the skin and the support part is compressed. In addition to the "specific" removal of excess foam, the foam hardens more quickly here due to the small cross-section of the ventilation holes or channels and/or the temperature control in the edge areas "from the edge" and therefore the outflow at the edge is even stronger minimized. As a result, the outlet area at the edge of the interior trim part can be reduced and, if necessary, a trimming can be completely dispensed with.

The advantages are therefore a reduction or avoidance of waste, the reduction or avoidance of a complete work step (trimming), the reduction of material consumption (skin, foam and carrier materials) and a "self-controlled" sealing process (when process parameters are changed, the sealing times are not adjusted necessary, which in turn means a reduction in rejects). A low degree of extraction of deep-drawing foils for large components is also advantageous.

In addition, an interior trim part for motor vehicles is proposed which has a decorative skin, a carrier part and an area made of foam between the skin and the carrier part, with the skin and carrier part lying on top of one another essentially without a gap in the edge regions of the interior trim part. According to the invention, on the side facing away from the decorative surface, the carrier part comprises ventilation bores and ventilation channels in the edge regions for degassing or venting during the introduction of the foam.

Furthermore, a tool for the production of interior trim parts with a decorative skin is also proposed, which has two preferably temperature-controlled tool parts which, when closed, form a cavity with their mold surfaces and, in at least one of the tool parts, a seal for separating the mold surface into an unsealed and a sealed area having. According to the invention, in at least one of the tool parts the unsealed area of the mold surface is provided with a separate cooling and/or heating device for setting a different temperature in the unsealed area compared to the sealed area.

The special feature of the invention is thus reflected in the fact that the material in the edge area (carrier part, skin) can be used more sparingly thanks to the novel venting mechanism. This is due to the narrow cross-section of the ventilation bores and channels within the carrier part or the combination with the separate heatability of the edge and ventilation areas in connection with the material properties of the foam. Venting channels are preferably located in the carrier, adjoining the venting bores of the carrier part part, via which the escaping air and/or gas and/or escaping foam is passed outside of the tool. So that the escaping foam (or air/reaction gases, etc.) does not penetrate between the upper part of the tool and the carrier part, there are preferably sealing mechanisms in the vicinity of the ventilation bores, which only allow the foam to escape via the ventilation channel.

Advantageous developments from the dependent claims are described below for this invention and the independent claims presented above.

The decorative skin is preferably a textile skin, a leather skin or a plastic skin. Slush skins (PVC slush is particularly suitable), polyurethane skins, TPO films, etc. are particularly suitable here. What is favorable about plastic films is their impenetrability to the foam, their regular expansion behavior and their compressibility in the edge area.

The carrier part is preferably made of a thermoplastic material, stability and low costs are important here; reinforced or unreinforced polyolefins or polyamides are particularly suitable here, particularly preferably plastics containing polypropylene. These aforementioned plastics are stable and easy to process, for example the ventilation holes or ventilation channels can also be produced in injection molding processes from the outset, but alternatively they can also be introduced later.

The foam can be introduced in the form of an already finished foam or by adding several reactive components that form a foam. For example, it is advantageous to introduce polyurethane foam, which is produced by the foaming agents polyol and isocyanate in the cavity between the skin and the carrier part.

The ventilation hole is preferably closed by heating. It is advantageous here for the temperature in the ventilation area on the tool side to be between 40 and 100°C, preferably between 45 and 70°C, particularly preferably between 50 and 60°C.

At these temperatures, on the one hand, no damage to the skin or the carrier part is to be expected, and on the other hand, the expansion behavior of the foam can be easily controlled.

A further advantageous development provides that in the edge area of the carrier part and the skin, these two components (i.e. carrier part and skin) lie on top of one another essentially without a gap, with the gap-free area perpendicular to the edge line having a width of less than 100 mm, preferably less than 60 mm , particularly preferably less than 15 mm. This means that the edge area can be selected to be relatively small, so that there is less waste here, but a secure seal is still guaranteed. The ventilation bores are preferably arranged in the carrier part, these bores usually being made perpendicularly to the carrier part (however, the perpendicular is not mandatory, oblique shapes are also possible here). Following the bore, it is advantageous to attach a venting channel to the back of the carrier part (i.e. on the side facing away from the skin), which transports gas and/or air and/or foam from the venting bore through the channel to the outside of the tool or tool. Carrier part transported without thereby damaging the skin.

An advantageous development of the tool provides that the unsealed area of the mold surface of one tool part (preferably the upper part) is separated from the sealed area of the mold surface by an insulating layer. This results in a higher temperature gradient (higher temperature difference) between the preferably separately heated outer area and the “inner area” that is sealed off from it. In addition, this insulation also ensures that the edge area and a heating device or sealing device provided therein can be dismantled.

A further advantageous development provides that one tool part is designed as an upper part and the other as a lower part. In this case, the support part can be attached to the upper part, since during degassing or venting the gas or air first rises and then the foam flows on. However, it is also possible to arrange this the other way round or to arrange the two tool parts vertically (that is to say parallel to one another in the vertical), even if this is not particularly advantageous.

A further advantageous development provides that the upper part has the heating device and that this is also located in the edge area of the upper part.

The seal, which is also preferably arranged in the upper part, can be designed as a rubber seal and/or an inflatable seal. An “active” hydraulic seal or a passive clamp seal is therefore conceivable here.

A further advantageous development provides that a ventilation area for escaping foam outside of the closed course of the seal is present. As a result, the foam is discharged in a particularly targeted manner, and the entire rear side of the carrier part is not contaminated as a result.

However, it should be pointed out that the device is not limited exclusively to the outer edges of the interior trim part; the present invention can also be used with “internal openings” (for example around a ventilation duct).

A further advantageous development provides that the heating device (or also the cooling device) is designed as an arrangement of electrical coils, as a fluid heating or cooling system, preferably operated with water and/or oil, or as a burner system.

• 1a und 1b Schnitte eines erfindungsgemäßen Werkzeugs bei der Durchführung des erfindungsgemäßen Verfahrens zur Erstellung eines erfindungsgemäßen Innenverkleidungsteils, und
• 2 einen Schnitt durch ein erfindungsgemäßes Innenverkleidungsteil.

The invention will now be explained with reference to several figures. Show it:

• 1a and 1b Sections of a tool according to the invention when carrying out the method according to the invention for producing an interior trim part according to the invention, and
• 2 a section through an interior trim part according to the invention.

1a shows the final state of the production of a component 1 according to the invention, in this case an interior trim part for motor vehicles, in a tool 2. A tool 2 is shown here, which has a temperature-controllable upper part 3 and a temperature-controllable lower part 4. On a mold surface 14 of the lower part 4 there is a skin 9, which is designed here as a PVC slush skin with a thickness of 1-2 mm. A carrier part 6 rests on the mold surface 13 of the upper part 3 . the inside 1a The edge area shown on the left between the support part 6 and the skin 9 lies on top of one another essentially without a gap, the gap-free area perpendicular to the edge line presently having a width of 10 mm. As the edge distance increases, a gap or cavity 10 is formed, into which foam 8 is placed. This is a polyurethane foam created by reacting polyol and isocyanate. The mold surface 13 consists of a sealed area 13b (this is a closed inner area, see Fig 1b ) and an unsealed edge area 13a. The unsealed area 13a is separated from the sealed area 13b by an inflatable rubber seal 11 . A separate heating device 12 is fitted radially outside of this closed seal 11, ie towards the edge region of the tool 2 or the component 1, which is designed as a fluid conducting heating device and can, for example, lead to heating. However, it is also possible to cool with this device, so that lower temperatures can then be produced in the edge area than on the rest of the mold surface 13. The edge area is also separated from the rest of the upper part by an insulating layer 15. In the present case, the carrier part 6 is made of a plastic containing polypropylene. The heating device 12 ensures that the edge area or the unsealed area 13a of the mold surface is heated to about 50° C. (the ambient temperature after reactive foaming is assumed to be 25° C. for the rest of the component). The carrier part 6 has a ventilation hole 7a, which is arranged near the gap-free area between the skin 9 and the carrier part 6, but still has full access to the cavity 10. As a result, gas and/or air and/or foam can be guided out of the cavity 10 through the ventilation hole 7a, and this is then discharged further through the ventilation channel 7b in 1a out to the left. This “venting area” at the edge for escaping gas and/or air and/or foam lies outside the closed course of the seal 11 . The same applies here to the heating device 12 , which runs outside the closed area of the seal 11 .

So it is shown in 1a a tool 2 for the production of interior trim parts (alternatively: exterior trim parts) with a decorative skin, which has two tool parts 3, 4 which, when closed, form a cavity 10 with their mold surfaces 13, 14 and in at least one of the tool parts 3, 4 (here a Tool part, which is designed as an upper part 3) has a seal 11 for separating the mold surface 13 into an unsealed area 13a and a sealed area 13b. Here, in the upper part, the unsealed area 13a of the mold surface is equipped with a separate cooling and/or heating device 12 for setting a different temperature in the unsealed area 13a compared to the sealed area 13b.

The production runs as follows as an example.

• Öffnen des Werkzeugs 2 mit mindestens zwei beweglichen temperierbaren Werkzeugteilen 3, 4 und mindestens einem Werkzeugteil separat temperierbaren Rand- bzw. Entlüftungsbereichen (vorliegend das Oberteil 3, Aufbringen des Trägerteils 6, welches mit Entlüftungsbohrungen 7a und Entlüftungskanälen 7b versehen ist, so dass die Entlüftungsbohrungen bzw. Entlüftungskanäle zumindest teilweise in den separat temperierbaren Bereichen des Werkzeugs 2 liegen, Einlegen der Haut 9 auf das andere Werkzeugteil (also Unterteil 4), Schaumeinbringung und Schließen des Werkzeugs 2 (dies kann allerdings auch umgekehrt erfolgen, die Schaumeinbringung ist in das offene, geschlossene oder auch sich schließende Werkzeug 2 möglich). Anschließend erfolgt eine Expansion des Schaums 8 im geschlossenen Werkzeug 2 und eine Entgasung bzw. Entlüftung über die Entlüftungsbohrungen 7a bzw. Entlüftungskanäle 7b. Hiernach kommt es zu einer Verstopfung dieser Bohrungen 7a bzw. Kanäle 7b durch austretenden Schaum 8, welcher aufgrund der dort unterschiedlichen Temperatur des Werkzeugteils 3, 4 im Entlüftungsbereich/Randbereich und/oder der Enge der Entlüftungsbohrungen 7a bzw. -kanäle 7b seine Materialeigenschaften ändert. Anschließend erfolgt das Öffnen und Entfernen des fertigen Bauteils 1.

When manufacturing component 1, the following process steps are carried out, not necessarily in this order:

• Opening of tool 2 with at least two movable temperature-controlled tool parts 3, 4 and at least one tool part with separately temperature-controlled edge or ventilation areas (here the upper part 3, application of the carrier part 6, which is provided with ventilation holes 7a and ventilation channels 7b, so that the ventilation holes or Ventilation channels are located at least partially in the areas of the tool 2 that can be heated separately, placing the skin 9 on the other tool part (i.e. the lower part 4), introducing the foam and closing of the tool 2 (however, this can also be done vice versa, the introduction of the foam is possible in the open, closed or closing tool 2). The foam 8 then expands in the closed tool 2 and is degassed or vented via the vent bores 7a or vent channels 7b. This causes these bores 7a or channels 7b to become clogged by escaping foam 8, which changes its material properties due to the different temperatures of the tool part 3, 4 in the ventilation area/edge area and/or the narrowness of the ventilation bores 7a or channels 7b. The finished component 1 is then opened and removed.

The finished component 1 is, for example, in 2 shown. This is an interior trim part for motor vehicles, with a decorative skin 9 , a support part 6 and an area made of foam 8 between the skin 9 and the support part 6 . Skin 9 and support part 6 lie on top of one another in the edge areas of interior trim part 1 with essentially no gaps, and support part 6 has ventilation bores 7a and ventilation channels 7b in the edge areas on the side facing away from the decorative surface (skin 9) for degassing or venting during foam introduction.

This in 2 The interior lining part 1 shown is characterized in that it not only has an outer edge area that is provided with ventilation holes 7a, but also an inner area that serves, for example, as a later ventilation opening in a motor vehicle, here too the skin 9 and carrier part 6 are essentially in contact gap-free on top of each other. The invention can also be used in this “internal area”; for this purpose, several ventilation bores 7a or ventilation channels 7b are provided.

Claims (18)

Method for producing a component (1), in particular an interior trim part with a decorative skin (9), which comprises the following steps: a) opening a tool (2) with at least two movable and preferably temperature-controlled tool parts (3, 4), b) Application of a carrier part (6), which has ventilation holes (7a) and ventilation channels (7b) in an area at the edge and at the edge of an area to be foamed, such that at least one ventilation hole runs towards the edge of the carrier part (6). and connect ventilation channels (7b) for degassing and/or ventilation arranged on a side facing away from the foam, and placing the skin (9) on the other tool part, c) foam introduction and closing of the tool (2) in an interchangeable order, d) expansion of the foam (8) in the closed mold (2) and degassing and/or venting via the venting bores (7a) and channels (7b), e) blockage of the ventilation holes (7a) and channels (7b) by escaping foam (8), which changes its material properties due to correspondingly narrow cross sections of the ventilation holes (7a) and channels (7b), f) Opening and removing the finished component (1). procedure after claim 1 , characterized in that venting areas that can be heated separately are provided in at least one tool part (3, 4) and the carrier part (6) is placed in the tool (2) in such a way that the venting bores (7a) and venting channels (7b) are at least partially in are located in the areas of the tool (2) that can be heated separately and the clogging by the foam also occurs at least as a result of the temperature control of the tool (2) in the ventilation area. Method according to one of the preceding claims, characterized in that the skin (9) is a textile skin, a leather skin or a plastic skin, preferably a slush skin, and/or that the carrier part (6) consists of a thermoplastic material, for example a reinforced or unreinforced polyolefin, particularly preferably made of a polypropylene-containing plastic. Method according to one of the preceding claims, characterized in that the foam is introduced either in the form of a foam which is already ready or by adding a plurality of reactive components which form a foam. procedure after claim 4 , characterized in that the foaming agents are polyol and isocyanate, and a polyurethane foam is thereby produced. Method according to one of the preceding claims, characterized in that the temperature in the region of the ventilation bores (7a) and channels (7b) on the tool side is between 40 and 100 °C, preferably between 45 °C and 70 °C, particularly preferably between 50 °C and 60 °C. Method according to one of the preceding claims, characterized in that in common edge areas of the carrier part (6) and the skin (9), these lie essentially without a gap, the gap-free area perpendicular to the edge line having a width of less than 100 mm, preferably less than 60 mm, particularly preferably less than 15 mm. Interior trim part for motor vehicles, the interior trim part having a decorative skin (9), a carrier part (6) and an area of foam (8) between the skin (9) and carrier part (6), the skin (9) and carrier part (6) in Edge regions of the interior lining part lie on top of one another, characterized in that the support part (6) on the side facing away from the decorative surface comprises venting bores (7a) arranged in an area at the edge of the support part (6) and at the edge of a foamed area and subsequent to the edge of the support part ( 6) has venting channels (7b) running towards it for degassing and/or venting during the introduction of foam. interior lining part claim 8 , characterized in that the skin (9) and the carrier part (6) lie on top of one another without a gap in the edge regions. Tool (2) for producing interior trim parts with a decorative skin (9), which has two tool parts (3, 4) which, when closed, form a cavity (10) with their mold surfaces (13, 14) and in at least one of the tool parts ( 3, 4) has a seal (11) for separating the mold surface (13) into an unsealed (13a) and a sealed (13b) area, characterized in that in at least one of the tool parts (3, 4) the unsealed area (13a ) the mold surface (13) has a separate cooling and/or heating device (12) for setting a different temperature in the unsealed area (13a) compared to the sealed area (13b). tool (2) after claim 10 , characterized in that the unsealed area (13a) of the mold surface (13) of one tool part is separated from the sealed area (13b) of the mold surface (13) by an insulating layer (15). Tool (2) according to one of Claims 10 or 11 , characterized in that one tool part (3) is designed as an upper part and the other tool part (4) as a lower part. tool (2) after claim 12 , characterized in that the upper part has the heating device (12) and this is located in the edge area of the upper part. Tool (2) according to one of Claims 10 until 13 , characterized in that the seal (11) is designed as a rubber seal and / or inflatable seal. Tool (2) according to one of Claims 10 until 14 , characterized in that a ventilation area for escaping gas and/or air and/or foam runs outside a closed course of the seal (11). Tool (2) according to one of Claims 10 until 15 , characterized in that the heating device (12) extends in such a way that temperature control is possible outside of a closed area of the seal (11). Tool (2) according to one of Claims 10 until 16 , characterized in that the heating device (12) is designed as an arrangement of electric coils, as a fluid heating system, preferably operated with water and/or oil, or as a burner system. Tool (2) according to one of Claims 10 until 16 , characterized in that the temperature of the two tool parts (3, 4) can be controlled.

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