DE102016217927A1 - Material carrier, method for producing a material carrier for a structural component and method for producing a structural component for a motor vehicle - Google Patents

Abstract

The present invention relates to a material carrier (20) for use in a foaming process for producing a structural component (1) for a motor vehicle, comprising a base body (21) having at least one recess (23) and a sealing film (22) which comprises the at least one recess (23) seals, wherein by the sealing film (22) and the at least one recess (23) at least one sealed and correspondingly closed cavity (24) in the material carrier (20) is configured. Furthermore, the invention relates to a method for producing a material carrier (20) according to the invention and for producing a structural component (1) for a motor vehicle using the material carrier according to the invention.

Description

The present invention relates to a material carrier for use in a foaming process for producing a structural component for a motor vehicle. Furthermore, the invention relates to a method for producing a material carrier for use in a foaming process for producing a structural component for a motor vehicle. Moreover, the invention relates to a method for producing a structural component for a motor vehicle.

In the case of back-foamed components, for example so-called skin-foam-carrier structures, a closed support or material carrier is required so that there is no foam ejection during the backfoaming process or when closing a foaming tool. After foaming, through a trimming process, such as punching, breakthroughs are introduced. Thereafter, further components are connected to the carrier. The other components are usually welded to the carrier.

By trimming the back-foamed carrier is at least divided into three parts. In addition, at least one additional component is required, which is welded to connect the divided carrier or the respective support pieces with these. This requires a high logistical, technical tooling and processing technical effort.

A prior integration of the additional components or add-on parts, which may be a function carrier, in the support to be foamed is currently not possible or is not carried out since core areas are necessary with a view to removal from the mold in the injection molding tool. In a subsequent foam backing such core areas can not be kept foam-free or only with great effort.

Object of the present invention is to at least partially overcome the disadvantages described above. In particular, it is an object of the present invention to provide a material carrier for use in a foaming process for producing a structural component and a method for producing a material carrier or for producing a structural component for a motor vehicle, wherein the logistical, technical tooling and processing technical effort in manufacturing a foam-backed structural component can be kept as low as possible.

The above object is solved by the claims. In particular, the above object is achieved by the material carrier according to claim 1, the method according to claim 6 and the method according to claim 10. Further advantages of the invention will become apparent from the dependent claims, the description and the drawings. In this case, features and details that are described in connection with the material carrier apply, of course, also in connection with the method according to the invention and in each case vice versa, so that with respect to the disclosure of the individual aspects of the invention always reciprocal reference is or may be.

According to a first aspect of the present invention, there is provided a material carrier for use in a foaming process for manufacturing a structural component for a motor vehicle. The material carrier has a base body with at least one depression and a sealing foil which seals the at least one depression, wherein at least one sealed and correspondingly closed cavity in the material carrier is configured by the sealing foil and the at least one depression.

If such a material carrier is now used in a foaming process, in particular in a foam-back process with semi-rigid foam, for producing a structural component, it is possible reliably to prevent foaming material from penetrating into the depression or the cavity formed therein. After completion of the foaming process in which the material carrier has been coated with a covering material via the foaming material, the foam-backed material carrier coated with the covering material can be opened in the area of the sealing foil. That is, in a region of the sealing film, a sandwich section with the sealing film, the foaming material and the covering material can subsequently be separated out of the foam-backed material carrier.

As a result, a method for producing the structural component can be significantly simplified. A subsequent connection of the separate carrier parts with the function carrier is no longer necessary. Since the function carrier does not have to be stored or moved in the meantime, the logistics effort for producing the structural component can be reduced by using the material carrier according to the invention.

In the present case, the carrier material is preferably to be understood as a carrier on which material, for example in the form of a decoration, can be applied.

The sealing of the depression is to be understood as meaning a sealing of the depression with respect to an environment of the depression. The sealing foil preferably seals the recess air- and liquid-tight or substantially air- and liquid-tight from the environment of the depression. Thus, it can be reliably prevented during the foaming process that foaming material which is applied in the environment or in the immediate vicinity of the depression enters the depression. For sealing the at least one depression, the sealing film can be clamped or pressed against the base body.

The material carrier is not limited for use in a foaming process for manufacturing a structural component for a motor vehicle. Thus, the material carrier can also be used for use in a foaming process, in particular in a backfoaming process, for producing a structural component which is also suitable for purposes other than for use in a motor vehicle.

Under the sealing film is a flat, in particular flexible and correspondingly elastically deformable wall portion, at least considered separately, to understand. For sealing the depression, the sealing film is preferably stretched over an opening region of the depression. The sealing film preferably has a wall thickness of less than 5 mm, in particular less than 2 mm.

The sealing film provides a particularly space-saving and cost-effective cover element which, despite its thin-walled structure, offers sufficient protection against foaming material which could penetrate into the cavity.

The sealed depression preferably has a diameter of several centimeters, for example in a range between 5 cm and 50 cm, in an opening region of the depression. Correspondingly large or slightly larger, the sealing film is dimensioned. On this scale, a particularly favorable cost / benefit factor can be achieved in the production of the structural component. In the context of the present invention, it is also possible to seal larger areas or depression openings. Thus, it is conceivable in principle also to seal or cover opening area of a depression or depressions having a size of one meter or several meters by means of a correspondingly dimensioned sealing film.

The recess is preferably designed as a function carrier. That is, the recess has in the later structural component at least partially a defined function. The sealing film seals the depression or cavity against gases such as air, in particular propellant gas, foaming materials and liquids at a pressure of up to 2 bar, preferably at a pressure of up to 3 bar. According to the invention, the recess can also be configured as an opening or a passage opening or have an opening, in particular in a bottom section of the recess. In this case, the at least one opening can be sealed by the sealing film.

According to one embodiment of the present invention, it is possible that the sealing film has the same material as the main body. As a result, the sealing film and the base body can be connected to one another particularly easily and reliably in a material-locking manner. In a cohesive bonding of the sealing film to the base body, it is not necessary to pay attention to the different material properties of the respective components. With the consideration of correspondingly few material parameters, a compound can be produced particularly inexpensively. In addition, compared to a case in which different materials are used, fewer problems occur with respect to the composite material. Accordingly, a tightness of the cavity can be better ensured.

Furthermore, it is possible with a material carrier according to the invention, that the sealing film for the sealing of the at least one recess or for designing the at least one closed cavity with the main body is materially connected. Due to the cohesive connection, a particularly high density, in particular with respect to gases such as carbon dioxide, foaming materials and liquids, can be achieved. To produce the integral connection, the sealing film in the region of the depression is preferably welded to the base body. By a weld, the cavity or the recess can be sealed by the sealing film particularly effective. Alternatively, it is possible for the sealing film to be adhesively bonded to the base body in the region of the depression in order to produce the integral connection. An adhesive bond can be made more cost-effectively than a welded joint, as an adhesive bond can in principle be made with cheaper fasteners or bonding tools than a welded joint. The application of a sealing film in the form of an adhesive strip, manually or mechanically, is more favorable, for example, than the welding of the sealing film to the base body by means of welding tongs. By the material connection is advantageous also a positive connection between the sealing film and the base body.

Moreover, it is possible according to the present invention that in a material carrier, the base body has a plurality of recesses and the recesses are sealed with a coherent sealing film, whereby correspondingly a plurality of closed cavities in the material carrier are configured. With a single continuous sealing film several wells can be sealed simultaneously and thereby saving time accordingly. By saving time and corresponding costs can be saved. In this case, the coherent film may, for example, cover the plurality of depressions and in each case be air-tight and liquid-tight, in particular materially bonded, only in an opening region of the depressions with the main body. That is, in a portion of the body between the opening portions of the recesses, the continuous sealing film is in this case only on the body. The targeted sealing connection of the coherent sealing film with the main body can be saved compared to, for example, a complete bond or welding costs.

In the context of the present invention, it is also conceivable that in an upper edge region of the recess, a projection is configured by a surface of the base body, wherein the projection is at least partially covered with the sealing film. The projection may, in a foaming process in which the material carrier is mounted in a tool half of a closed tool, press over the sealing foil onto a cover material which is mounted in the other tool half of the tool. The sealing film is in this case clamped between the cover material and the projection of the base body. As a result, slippage of the sealing film during the foaming process from the depression or the opening region of the depression can be counteracted. The desired foaming process for producing the structural component can be carried out correspondingly reliably with such a material carrier. The projection may be configured in the shape of an annular or ring segment, in this case angled and / or round, at least in sections around the opening region of the recess. This allows a uniform pressure to be built on the sealing film. However, the projection may also have a plurality of projection portions which are arranged spaced from each other. As a result, weight, material and corresponding costs can be saved.

• – Herstellen eines Grundkörpers des Materialträgers in einem Spritzgussprozess, wobei in dem Grundkörper wenigstens eine Vertiefung ausgestaltet wird, und
• – Abdichten der wenigstens einen Vertiefung des Grundkörpers mittels einer Abdichtfolie, wobei durch das Abdichten der wenigstens einen Vertiefung wenigstens ein geschlossener Hohlraum im Materialträger ausgestaltet wird.

According to a further aspect of the present invention, a method for producing a material carrier as described above is provided. In particular, a method for producing a material carrier for use in a foaming process for producing a structural component for a motor vehicle is provided. The method comprises the following steps:

• - Producing a body of the material carrier in an injection molding process, wherein in the body at least one recess is configured, and
• - Sealing the at least one recess of the base body by means of a sealing film, wherein by sealing the at least one recess at least one closed cavity in the material carrier is configured.

The method according to the invention produces a material carrier as explained in detail above. Thus, the inventive method brings the same advantages as they have been described in detail with respect to the material carrier.

In a method according to the invention, it may be advantageous if the sealing film for sealing the at least one recess or for forming the at least one closed cavity is welded to the base body. By welding can be created in a quick and easy way, a particularly reliable gas, foam material and liquid-tight connection between the sealing film and the body. The sealing film is preferably welded by welding tongs to the base body.

It is advantageous in this case if, in a method according to the invention, a sealing film is selected which has the same material or essentially the same material as the basic body, for example polypropylene, or consists of this or substantially consists. Two identical materials could be welded together much more easily than two different materials. As a result, a particularly reliable seal can be created.

Moreover, in a method according to the invention, it is possible for a plurality of depressions in the main body to be configured during the production of the main body and for the depressions to be sealed with a coherent sealing film, wherein a plurality of closed cavities in the material carrier are configured accordingly by the sealing of the depressions. As mentioned above, when sealing a plurality of holes with one and the same sealing film, time and thus cost can be saved.

• – Öffnen eines Werkzeugs, das eine erste Werkzeughälfte und eine zweite Werkzeughälfte aufweist,
• – Positionieren eines wie vorstehend beschriebenen Materialträgers oder eines Materialträgers, der nach einem wie vorstehend beschriebenen Verfahren hergestellt wurde, derart in der ersten Werkzeughälfte, dass die Abdichtfolie in Richtung der zweiten Werkzeughälfte positioniert ist,
• – Positionieren eines Deckmaterials zum wenigstens abschnittsweise Bedecken des Materialträgers in der zweiten Werkzeughälfte,
• – Einbringen eines Schäumwerkstoffs in das Werkzeug zwischen den Materialträger und das Deckmaterial und/oder zwischen die Abdichtfolie und das Deckmaterial,
• – Schließen des Werkzeugs,
• – Aufschäumen des Schäumwerkstoffs zum Herstellen einer Sandwich-Struktur, in welcher der aufgeschäumte Schäumwerkstoff zwischen dem Materialträger und dem Deckmaterial und zwischen der Abdichtfolie und dem Deckmaterial positioniert ist, und
• – Heraustrennen zumindest eines Sandwich-Strukturabschnitts aus der Sandwich-Struktur, in welchem der aufgeschäumte Schäumwerkstoff zwischen der Abdichtfolie und dem Deckmaterial positioniert ist und dadurch Herstellen des Strukturbauteils.

According to a further aspect of the present invention, a method for manufacturing a structural component for a motor vehicle is provided. The method comprises the following steps:

• Opening a tool having a first tool half and a second tool half,
• Positioning a material carrier or a material carrier as described above, which was produced according to a method as described above, in such a way in the first mold half that the sealing film is positioned in the direction of the second mold half,
• Positioning a cover material for at least partially covering the material carrier in the second tool half,
• Introducing a foaming material into the tool between the material carrier and the covering material and / or between the sealing foil and the covering material,
• - closing the tool,
• Foaming the foaming material to produce a sandwich structure in which the foamed foaming material is positioned between the material carrier and the covering material and between the sealing foil and the covering material, and
• - Separating at least one sandwich structural portion of the sandwich structure in which the foamed foaming material is positioned between the sealing film and the cover material and thereby producing the structural component.

By using the material carrier according to the invention, this method according to the invention also brings about the same advantages as have been described in detail with reference to the device according to the invention. The sandwich structure section is preferably separated out of the sandwich structure by an attachment cut. As a result, the desired sandwich structure or structural component is retained and only the salient sandwich structure section is produced.

For the cover material is preferably a decor, in particular a decoration for a vehicle interior trim, for example, an instrument panel of the motor vehicle used. The foaming material used is preferably a semi-rigid foam, in particular semi-rigid polyurethane foam. When introducing the foaming material, it is preferably applied to the covering material, in particular directly onto the covering material.

When and / or after closing the tool, pressure is applied by the foaming foaming material both to the material carrier or the base body and the sealing foil and to the covering material. The foaming material foams until the material carrier, the foamed and possibly hardened foaming material and the covering material are materially bonded to form a unit or the sandwich structure. The method is not limited to producing a structural component for a motor vehicle.

According to a further embodiment of the present invention, it is possible that in one method, the projection is dimensioned such that an at least partially covered with the sealing film end face of the projection presses at least partially on the cover material with a closed tool with the sealing film. As a result, the sealing film can be clamped between the cover material and the projection of the base body. As a result, slippage of the sealing film during the foaming process from the depression or the opening region of the depression can be counteracted. A risk of avoidable penetration of foaming material into the recess or the cavity during the manufacture of the structural component can thus be effectively counteracted. The end face or the sealing film presses to hold the sealing film of course only on the cover material and not through this. Alternatively or additionally, it is possible in the context of the present invention for a projection to project from the cover material in the direction of the first tool half or in the direction of the material carrier from a cover material surface or to be designed accordingly. Also, by such a projection, the sealing film can be advantageously fixed between the material carrier and the cover material.

Further, measures improving the invention will become apparent from the following description of various embodiments of the invention, which are shown schematically in the figures. All of the claims, description or drawings resulting features and / or advantages, including constructive details and spatial arrangements may be essential to the invention both in itself and in the various combinations.

Each show schematically:

1 a main body in a method step according to the invention for producing a material carrier,

2 a material carrier according to a first embodiment, which was produced by a method according to the invention,

3 a material carrier according to a second embodiment, which was produced by a method according to the invention,

4 a material carrier according to a third embodiment, which was produced by a method according to the invention,

5 to 12 an inventive method for producing a structural component.

Elements with the same function and mode of action are in the 1 to 12 each provided with the same reference numerals.

Regarding 1 and 2 Subsequently, a method for producing a material carrier according to the invention 20 for use in a foaming process for producing a structural component 1 described for a motor vehicle. In a first step, first a basic body 21 of the material carrier 20 produced in an injection molding process of polypropylene or substantially of polypropylene. The in 1 illustrated basic body was with a recess 23 , which is to serve as a function carrier in an instrument panel of the motor vehicle, designed. Then the depression 23 of the basic body 21 , as in 2 represented by means of a sealing film 22 sealed. By sealing the recess 23 becomes in the material carrier 20 a closed cavity 24 designed.

For sealing the recess 23 or for designing the at least one closed cavity 24 becomes the sealing film with the main body 21 welded by welding tongs. This is a sealing film 22 selected, which is like the main body 21 also made of polypropylene.

In 2 is a material carrier 20 according to a first embodiment of the present invention. The sealing foil 22 of the material carrier 20 is by welding to the body 21 according to cohesive with the body 21 connected.

In 3 is a material carrier 20a represented according to a second embodiment of the invention. According to the second embodiment, the main body 21 a first and a second recess 23 on. The two wells 23 were using a coherent sealing film 22 sealed, by sealing the two wells 23 correspondingly two closed cavities 24 . 25 in the material carrier 20a were designed. The depression 23 of the first closed cavity 24 points in a bottom portion of the recess 23 an opening 27 on.

Such an opening 27 can also in any other recess 23 be configured or each well 23 can be configured in the form of a passage opening.

4 shows a material carrier 20b according to a third embodiment of the invention. At the in 4 shown material carrier 20b is in an upper edge area of the recess 23 or the cavity 24 a lead 26 from a surface of the main body 21 designed, with the projection 26 through the sealing film 22 is covered. The lead 26 is of course not limited to the form shown.

Regarding 5 to 12 Subsequently, a method for producing a structural component is schematically illustrated 1 described in the form of an instrument panel for a motor vehicle.

In 5 is an open tool 10 with a first tool half 11 and a second tool half 12 shown. As in 6 is displayed in the open tool then as in 2 illustrated material carrier 20 so in the first half of the mold 11 positioned that the sealing film 22 in the direction of the second tool half 12 is positioned or pointing in this direction. Also, in the second tool half 12 a cover material 30 at least partially covering the material carrier 20 introduced in the form of a decor.

After that, as in 7 shown between the material carrier 20 and the cover material 30 or between the sealing film 22 and the cover material 30 a foaming material 40 in the tool 10 introduced, more precisely on the cover material 30 applied. After that, as in 8th shown the tool 10 closed. In this case and / or after the foaming material foams 40 on or is brought to foaming.

In 9 is the foaming material 40 shown in a foamed state, in which he between the material carrier 20 and the cover material 30 and between the sealing film 22 and the cover material 30 is present. This will create a corresponding sandwich structure 50 formed, consisting of the material carrier 20 and the cover material 30 as two sandwich cover layers and the foaming material 40 that sandwiched between the material carrier 20 and the cover material 30 is included.

In 9a is a material carrier 20b according to the third embodiment with a projection 26 shown, with the projection 26 was dimensioned such that one with the sealing film 22 covered front of the tab 26 with a closed tool 10 with the sealing foil 22 in sections on the cover material 30 pushes, causing the sealing film 22 between the front of the projection 26 and the cover material 30 is fixed. Since it is from the sectional view according to 9a not directly indicated, it should be noted that the opening area of the recess 23 and the lead 26 in front of and behind the plane shown at least in sections of foaming material 40 are surrounded.

To explain the further process, however, again on the material carrier 20 according to the first embodiment.

After the sandwich structure 50 is designed, the tool, as in 10 illustrated, opened and the sandwich structure 50 is taken. Then, as in 11 and 12 shown by a cutting tool 2 by means of essay section a sandwich structure section 51 , in which the foamed foaming material 40 between the sealing film 22 and the cover material 30 is positioned from the sandwich structure 50 separated out. This will be the structural component 1 finally completed.

LIST OF REFERENCE NUMBERS

1

structural component

2

cutting tool

10

Tool

11

first tool half

12

second tool half

20, 20a, 20b

 material support

21

body

22

sealing film

23

deepening

24

cavity

25

cavity

26

head Start

27

opening

30

cover material

40

Schäumwerkstoff

50

Sandwich structure

51

Sandwich section

Claims (11)

Material carrier ( 20 ) for use in a foaming process for producing a structural component ( 1 ) for a motor vehicle, comprising a base body ( 21 ) with at least one depression ( 23 ) and a sealing film ( 22 ), which the at least one depression ( 23 ), whereby through the sealing film ( 22 ) and the at least one depression ( 23 ) at least one sealed and correspondingly closed cavity ( 24 ) in the material carrier ( 20 ) is configured. Material carrier ( 20 ) according to claim 1, characterized in that the sealing film ( 22 ) the same material as the main body ( 21 ) having. Material carrier ( 20 ) according to one of the preceding claims, characterized in that the sealing film ( 22 ) for sealing the at least one recess ( 23 ) or for designing the at least one closed cavity (FIG. 24 ) with the basic body ( 21 ) is integrally connected. Material carrier ( 20 ) according to one of the preceding claims, characterized in that the basic body ( 21 ) several depressions ( 23 ) and the depressions ( 23 ) with a coherent sealing film ( 22 ), whereby correspondingly a plurality of closed cavities ( 24 . 25 ) in the material carrier ( 20 ) are configured. Material carrier ( 20 ) according to one of the preceding claims, characterized in that in an upper edge region of the depression ( 23 ) a lead ( 26 ) from a surface of the base body ( 21 ), the projection ( 26 ) is at least partially covered with the sealing film. Method for producing a material carrier ( 20 ) for use in a foaming process for producing a structural component ( 1 ) for a motor vehicle, comprising the steps of: - producing a basic body ( 21 ) of the material carrier ( 20 ) in an injection molding process, wherein in the base body ( 21 ) at least one depression ( 23 ), and - sealing the at least one recess ( 23 ) of the basic body ( 21 ) by means of a sealing film ( 22 ), wherein by sealing the at least one recess ( 23 ) at least one closed cavity ( 24 ) in the material carrier ( 20 ) is configured. A method according to claim 6, characterized in that the sealing film ( 22 ) for sealing the at least one recess ( 23 ) or for designing the at least one closed cavity (FIG. 24 ) with the basic body ( 21 ) is welded. Method according to one of the preceding claims 6 to 7, characterized in that a sealing film ( 22 ), which are the same material or substantially the same material as the basic body ( 21 ) having. Method according to one of claims 6 to 8, characterized in that during manufacture of the base body ( 21 ) several depressions ( 23 ) in the main body ( 21 ) and the depressions ( 23 ) with a coherent sealing film ( 22 ) are sealed, by sealing the wells ( 23 ) correspondingly more closed cavities ( 24 . 25 ) in the material carrier ( 20 ) are configured. Method for producing a structural component ( 1 ) for a motor vehicle, comprising the steps of: - opening a tool ( 10 ), which is a first tool half ( 11 ) and a second mold half ( 12 ), - positioning a material carrier ( 20 ) according to one of claims 1 to 5, or which has been produced by a process of claims 6 to 9, in such a way in the first mold half ( 11 ), that the sealing film ( 22 ) in the direction of the second tool half ( 12 ), - positioning a cover material ( 30 ) for at least partially covering the material carrier ( 20 ) in the second half of the mold ( 12 ), - introducing a foaming material ( 40 ) into the tool ( 10 ) between the material carrier ( 20 ) and the cover material ( 30 ) and / or between the sealing film ( 22 ) and the cover material ( 30 ), - closing the tool ( 10 ), - foaming of the foaming material ( 40 ) for producing a sandwich structure ( 50 ), in which the foamed foaming material ( 40 ) between the material carrier ( 20 ) and the cover material ( 30 ) and between the sealing film ( 22 ) and the cover material ( 30 ), and - separating at least one sandwich structure section ( 51 ) from the sandwich structure ( 50 ), in which the foamed foaming material ( 40 ) between the sealing film ( 22 ) and the cover material ( 30 ) and thereby producing the structural component ( 1 ). Method according to claim 10, characterized in that the projection ( 26 ) is dimensioned such that at least in sections with the sealing film ( 22 ) covered front side of the projection ( 26 ) with a closed tool ( 10 ) with the sealing film ( 22 ) at least in sections on the cover material ( 30 ) presses.

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