DE102024203946A1 - Method for manufacturing a trim part of a motor vehicle and motor vehicle which is provided with an embossing and/or application in or on a surface - Google Patents

Abstract

The invention relates to a method for manufacturing a fairing part of a motor vehicle provided with an embossing and/or application in or on a surface, as well as the motor vehicle itself.
In the process for manufacturing a fairing part (1) of a motor vehicle provided with an embossing (12) and/or application (11) in or on a surface (2), an embossing (12) and/or an application (11) is applied to or on a surface material (10) that forms at least part of the surface (2) of the fairing part (1), and this surface material (10) provided with the embossing (12) and/or application (11) is used in a lamination process to laminate a carrier element (40).
Furthermore, the invention relates to a motor vehicle.

Description

The invention relates to a method for manufacturing a fairing part of a motor vehicle provided with an embossing and/or application in or on a surface, as well as the motor vehicle itself.

Passenger car users, in particular, desire an appealing interior design. Besides the visual design of surfaces, such as trim and seats, the tactile feel also plays a role.

To strengthen customer brand loyalty and/or for visual design, it is common practice for some vehicle types to include embossing and/or applications on the surfaces of fairings, creating a specific pattern and/or displaying a specific symbol or name.

Surface finishes in the form of embossing and appliqués are already being used on vehicle seat covers. The upper materials, including the embossed or appliquéd finishes, are pulled over the seat cushions. However, the seat cover, including the finishes, is not bonded to a soft, compressible component such as foam or spacer fabric. In some cases, the seat cover with the surface finish is only attached to the soft component by stitching. Consequently, the upper materials, including the finishes, are not fully coated with adhesive, which can lead to delamination.

However, when integrating these finishes into a vehicle's interior trim, such as a door panel, this is absolutely essential to prevent delamination. Furthermore, laminating processes used to manufacture trims place higher demands on the materials and their bonds due to the pressures and temperatures involved.

The US2003175467A1 Disclosing a method for producing a multicolored cover material, comprising: providing at least two sheets, each sheet having a different visual feature; guiding the at least two sheets into a position where the at least two sheets partially overlap; guiding the at least two sheets through an oven, the oven serving to raise the temperature of the at least two sheets to a level sufficient for laminating the at least two sheets onto a substrate; and laminating the at least two sheets together and onto the substrate to form an embossed cover material by passing the at least two sheets and the substrate through an embossing slit, the embossing slit giving the at least two sheets an embossed surface.

The CN1717320 A discloses a textured composite material with a surface area comprising a fibrous outer layer and an adhesive layer, wherein the surface area comprises a concave area and a raised area, wherein the concave area is fibrous, the fibers of the layer are attached to the adhesive layer, and the fibers of the outer surface of the fibrous outer layer are not substantially bound to the adhesive layer in the raised areas.

The present invention is based on the objective of providing a method for manufacturing a fairing part of a motor vehicle with an embossing and/or application in or on a surface, with which a fairing part of high quality can be manufactured in a simple, cost-effective and time-saving manner.

This problem is solved by the method for manufacturing a trim panel of a motor vehicle, provided with an embossing and/or application in or on a surface, according to claim 1. Advantageous embodiments of this method are specified in dependent claims 2-14. Additionally, a motor vehicle comprising a trim panel manufactured according to claim 15, and provided with an embossing and/or application in or on a surface, is provided.

A first aspect of the invention is a method for manufacturing a fairing part of a motor vehicle provided with an embossing and/or application in or on a surface, in which the embossing and/or application is applied in or onto a surface material that forms at least part of the surface of the fairing part, and this surface material provided with the embossing and/or application is used in a lamination process to laminate a carrier element.

The trim panel can be an interior door panel or a component of the interior door panel, but the use of the trim panel as another interior panel of a motor vehicle or a component thereof is also possible. It should not be ruled out that a different interior trim is possible.

An embossing is created in the surface of the trim panel. An application is applied to the surface of the trim panel. An embossing is a so-called volumetric embossing, meaning a depression in the surface material. The application is formed by an additional layer of material.

In the process for manufacturing a cladding part with an embossing and/or application in or on a surface, it is provided that a structure of the surface material used is retained during the lamination process, whereby at least a structure of the surface material surrounding the embossing and/or application is retained.

The presented method makes it possible to laminate a carrier element in a simple, cost-effective and time-saving manner in order to provide a cladding part which is already equipped with an embossing or application after lamination.

The material of the application can be a knitted fabric, woven fabric, microfiber, or synthetic leather. These materials are also suitable for applying the application using the standard lamination process.

The application can be bonded to the surface material, for example, using high-frequency welding. High-frequency welding provides a simple and reliable way to connect the application to the surface material. This bonding process takes place before the lamination process.

The embossing can be applied, for example, using high-frequency embossing. High-frequency embossing allows for the simple and reliable application of the embossing to the surface material. The embossing is applied before the lamination process.

In the lamination process, the surface material can be combined with a haptically compressible component to form a layered structure, whereby the haptically compressible component is connected to the carrier element.

The lamination process of the carrier element is carried out by bonding the haptically compressible component to the carrier element. The carrier element can be made of plastic. The haptically compressible component gives the trim part a pleasant softness.

One embodiment of the method for producing a cladding part provided with an embossing and/or application in or on a surface provides that the surface material is combined with a haptically compressible component and a nonwoven fabric to form a layer structure in the lamination process, wherein the nonwoven fabric is bonded to the carrier element.

When using a nonwoven fabric, it is positioned between the carrier element and the haptically compressible component. A nonwoven fabric on the haptically compressible component enhances the volume effect during embossing. It acts as an anchor for the embossing and also prevents the volume embossing from partially or completely disappearing due to the pressure and heat input of the laminating machine.

For the nonwoven fabric, a polyethersulfone-based random fiber nonwoven with a thickness of 0.2 mm to 0.8 mm (e.g., 0.5 mm) and a basis weight of 40 g/ ^m² to 60 g/ ^m² (e.g., 50 g/m² ⁾ can be used, for example. The surface material can be a textile, synthetic leather, or microfiber. The textile can be a knitted, woven, or twill fabric. Such a textile offers the desired visual appearance and aesthetic appeal.

The compressible component can be a foam or a spacer fabric. This foam could, for example, be polyester foam. Using such a foam allows the requirements for hydrolysis testing to be met. Furthermore, it prevents or significantly reduces delamination.

To fix the haptically compressible component to the carrier element, an adhesive bond can be created between the component and the carrier element. Applying the adhesive over a large area is advantageous. The adhesive bond ensures a permanently strong connection between the haptically compressible component and the carrier element.

To achieve the adhesive bond between the haptically compressible component and the carrier element, the temperature of the haptically compressible component, the carrier element, and/or an adhesive between the haptically compressible component and the carrier element can be set within a range of 80 °C to 140 °C. For example, the The temperature should be set to a range between 100°C and 120°C, for example, 110°C. Heating can be achieved, for instance, using halogen lamps. This ensures good surface quality and adhesion. Excessively high temperatures should be avoided to prevent heat damage to the visible side of the surface material, including any application or embossing.

Furthermore, to achieve the adhesive bond between the haptically compressible component and the carrier element, the layer structure of the surface material, the haptically compressible component, the carrier element, and an adhesive between the haptically compressible component and the carrier element can be compressed such that the thickness of the surface material before compression (d1) is in the following ratio to the thickness of the surface material during compression (d2): d2 = 0.2 ... 0.3 * d1. In an advantageous embodiment of the method, the compression can be maintained for, for example, between 20 and 50 seconds.

The thickness of the surface material is to be determined without the embossing or application.

Performing the lamination process with the aforementioned temperature and/or pressure parameters improves the adaptability of the haptically compressible component and/or the surface material to the contour of the carrier element and thus the realization of a planar connection with the surface of the carrier element.

Additionally, the increased temperature activates the adhesive, resulting in a stronger bond with the carrier element and the haptically compressible component.

Excessive pressure and heat input into the surface material, including any application or embossing, could damage the surrounding structure, regardless of the finishing method. This could result in the loss of the three-dimensional effect of the embossing or cause the application to detach from the surface material. Furthermore, there would be a risk that transition phases, characterized by a height difference between the surface material and the application, would no longer be preserved.

For example, a polyolefin or polyurethane-based adhesive can be used to create the adhesive bond between the haptically compressible component and the carrier element.

To avoid delamination between the haptically compressible component and the carrier element or the fleece, the adhesive that creates the bond should be applied over a large area.

The substrate onto which the material is laminated can be, for example, a polypropylene-based plastic, or made of acrylonitrile butadiene styrene (ABS), or even natural fiber injection molding material.

When using a nonwoven fabric between the haptically compressible component and the carrier element, the same parameters can be set and/or the same materials can be used for the carrier element, the haptically compressible component and the surface material.

To fix the surface material with embossing and/or application and the haptically compressible component, an adhesive bond can be applied between the surface material with embossing and/or application and the haptically compressible component.

This process, in which the haptically compressible component and the surface material are bonded together, can also be described as a second lamination. The adhesive bond ensures a permanently strong connection between the surface material and the haptically compressible component.

The adhesive for bonding between the surface material with embossing and/or application and the haptically compressible component can be arranged at least in the projection area of the embossing or application between the surface material and the haptically compressible component.

The projection area is understood to be the area that corresponds to the surface of a projection of the embossing or application perpendicular to the plane of the surface material in the area of the arrangement of the embossing or application.

However, an advantageous implementation of the method involves the application of adhesive across the entire surface between the surface material and the haptically compressible component.

The bonding between the surface material with embossing and/or application and the haptically compressible component can be either adhesive lamination or hot melt bonding, in which the surface of the foam is bonded. The material is melted by the foam. This bonding in the projection area of the application or embossing ensures that at least the surface material in the area of the application or embossing does not detach from the haptically compressible component.

Before the bond between the surface material and the haptically compressible component is created, the surface material and/or the haptically compressible component can be activated on their respective surfaces by flame or adhesive application.

Activation can enhance the adhesive effect.

The respective activated surface is the surface facing the other material.

The process of surface activation and subsequent bonding can be a continuous process in which the surface material and/or the haptically compressible component is brought together in individual strips via rollers.

The heat and pressure applied during the laminating process puts considerable stress on the surface material, including any finish. However, the surrounding structure and any embossing or application remain completely intact despite the high heat and pressure from the laminating machine.

When bonding the aforementioned components, at least one of the components can be secured in position by means of pins that pass through openings in the respective component. Alternatively or additionally, openings can be provided that bring them close to the surface of one of the components in order to create a clamping effect by generating a vacuum.

A press tool that applies the aforementioned pressure can be designed in such a way that the tool halves, between which the aforementioned components are held, move towards each other until they are in contact, in order to build up the desired pressure on the material layers and, on the other hand, to prevent excessive pressure or excessive deformation of the material layers and thus avoid the reversal of embossings introduced into the surface material and/or the detachment of applications.

The presented method for manufacturing a cladding part with an embossing and/or application in or on a surface enables the lamination of a carrier element and thus the production of a cladding part while maintaining transition phases between the surface of a surface material of the cladding element and an embossing or application placed therein, as well as maintaining the structure of the area of the surface material surrounding the embossing or application.

Another aspect of the present invention is a motor vehicle comprising at least one fairing part produced according to the described method for producing a fairing part provided with an embossing and/or application in or on a surface.

The motor vehicle can, for example, be a passenger car that is at least partially electrically powered and/or autonomously operated.

The invention will be explained below with reference to the exemplary embodiments shown in the accompanying drawings.

• 1: ein Verkleidungsteil einer ersten Ausführungsform in Draufsicht,
• 2: ein Verkleidungsteil einer zweiten Ausführungsform in Draufsicht,
• 3: den Schichtaufbau des Verkleidungsteils der ersten Ausführungsform im Querschnitt, und
• 4: den Schichtaufbau des Verkleidungsteils der zweiten Ausführungsform im Querschnitt.

They show

• 1 : a cladding part of a first embodiment in top view,
• 2 : a cladding part of a second embodiment in top view,
• 3 : the layer structure of the cladding part of the first embodiment in cross-section, and
• 4 : the layer structure of the cladding part of the second embodiment in cross-section.

The 1 and 2 Top views show a trim part 1, which is designed to form a component of an interior door trim of a passenger car.

The in the 1 and 2 The depicted cladding parts 1 have a surface material 10 on their surfaces 2 facing the viewer.

The 1 The illustrated cladding part includes, as part of the surface 2 applied to the surface material 10, an application 11 in the form of a trademark.

The 1 The illustrated cladding part includes, as part of the surface 2, an embossing 12 in diamond shape incorporated into the surface material 10, which forms the visual appearance of quilting.

The two in the 1 and 2 The embodiments shown are not limited to the sole application of an application 11 or the incorporation of an embossing 12, but the cladding part 1 can also have an application 11 together with an embossing 12 on its surface 2.

Not in the 1 and 2 The figure shows a carrier element on which the surface material 10 is applied with the application 11 or the embossing 12.

Such a support element 40 is the 3 and 4 removable, as part of a layer structure 50. The 3 and 4 The sectional view shows different sectional structures 50. In the embodiments shown, these sectional structures 50 each comprise a surface material 10, a haptically compressible component 20 and the support element 40.

The differences lie in the 3 and 4 The layer structures shown are described in some detail below.

The in 3 The layer structure shown comprises an application 11 on the surface material 10, which has already been described using the following methods: 1 As described above, application 11 forms a component of surface 2. In addition to application 11, surface material 10 also forms part of surface 2 in certain areas.

The surface material 10, equipped with application 11, is bonded over its entire surface to a haptically compressible component 20 by means of an adhesive bond 13. The adhesive bond 13 thus forms an adhesive layer between the surface material 10 and the haptically compressible component 20. In the 3 In the illustrated embodiment of a layer structure 50, the haptically compressible component 20 is firmly bonded to the surface of a carrier element 40 by means of a planar adhesive 21. The carrier element 40 is thus laminated by the haptically compressible component 20 and the surface material.

4 Figure 1 shows an alternative embodiment of the layer structure 50 of the cladding part. The surface 2 of this layer structure 50 is formed here solely by the surface material 10, which, as shown in Figure 2, is formed as follows: 2 The surface material 10, as described, may exhibit an embossing not shown here. The surface material 10 is bonded over its entire area to a haptically compressible component 20 by means of an adhesive bond 13. The adhesive bond 13 thus forms an adhesive layer between the surface material 10 and the haptically compressible component 20. On the side of the haptically compressible component 20 facing away from the surface material 10, a nonwoven fabric 30 is arranged as a further layer of the layer structure 50. This nonwoven fabric can also be fixed to the haptically compressible component 20 by means of an adhesive bond.

On the side of the nonwoven fabric 30 facing away from the haptically compressible component 20, it is fixed to the carrier element 40 by means of an adhesive 21. The carrier element 40 is thus laminated by the nonwoven fabric 30, the haptically compressible component 20 and the surface material.

In both in the 3 and 4 In the illustrated embodiments of the layer structure 50, the carrier element 40 imparts sufficient mechanical strength and stability to the entire layer structure 50 for a trim panel of an interior door panel. The haptically compressible component 20 gives the trim panel a pleasant softness, and the surface material 10 with the application 11 gives the trim panel a visually appealing appearance. The in 4 The fleece used (30) ensures a permanent formation of the embossing (12), as shown in 2 is shown.

List of reference symbols

1

Trim panel

2

surface

10

Surface material

11

application

12

Embossing

13

adhesive bond

20

Haptly compressible component

21

Adhesive

30

fleece

40

Support element

50

Layer structure

QUOTES CONTAINED IN THE DESCRIPTION

This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• US 2003175467A1 [0006]
• CN 1717320 A [0007]

Claims (15)

Method for producing a fairing part (1) of a motor vehicle provided with an embossing (12) and/or application (11) in or on a surface (2), in which the embossing (12) and/or application (11) is applied in or on a surface material (10) that forms at least the surface (2) of the fairing part (1) in a certain area, and this surface material (10) provided with the embossing (12) and/or application (11) is used in a lamination process to laminate a carrier element (40). Method for manufacturing a cladding part provided with an embossing and/or application in or on a surface according to Claim 1 , characterized in that the material of the application (11) is a knitted, crocheted, woven, microfiber or artificial leather. Method for producing a cladding part provided with an embossing and/or application in or on a surface according to one of the preceding claims, characterized in that the application (11) is joined to the surface material (10) by means of high-frequency welding. Method for producing a cladding part provided with an embossing and/or application in or on a surface according to one of the preceding claims, characterized in that the embossing (12) is applied by means of high-frequency embossing. Method for producing a cladding part provided with an embossing and/or application in or on a surface according to one of the preceding claims, characterized in that the surface material (10) is combined with a haptically compressible component (20) to form a layer structure (50) in the lamination process, wherein the haptically compressible component (20) is connected with the carrier element (40). Method for manufacturing a cladding part provided with an embossing and/or application in or on a surface according to one of the Claims 1 until 4 , characterized in that the surface material (10) is combined in the lamination process with a haptically compressible component (20) and a nonwoven fabric (30) to form a layer structure (50), wherein the nonwoven fabric (30) is connected to the carrier element (40). Method for producing a cladding part provided with an embossing and/or application in or on a surface according to one of the preceding claims, characterized in that the surface material (10) is a textile, an artificial leather or microfiber. Method for producing a cladding part provided with an embossing and/or application in or on a surface according to one of the preceding claims, characterized in that the haptically compressible component (20) is a foam or a spacer fabric. Method for producing a cladding part provided with an embossing and/or application in or on a surface according to one of the preceding claims, characterized in that an adhesive bond (13) is produced between the haptically compressible component (20) and the carrier element (40) to fix the haptically compressible component (20) on the carrier element (40). Method for manufacturing a cladding part provided with an embossing and/or application in or on a surface according to Claim 9 , characterized in that , in order to realize the adhesive bond (13) between the haptically compressible component (20) and the carrier element (40), a temperature of the haptically compressible component (20), the carrier element (40) and/or an adhesive between the haptically compressible component (20) and the carrier element (40) is set in a range of 80 °C to 140 °C. Method for manufacturing a cladding part provided with an embossing and/or application in or on a surface according to one of the Claims 9 and 10 , characterized in that , to realize the adhesive bond (13) between the haptically compressible component (20) and the carrier element (40), the layer structure (50) of the surface material (10), the haptically compressible component (20), the carrier element (40) and an adhesive between the haptically compressible component (20) and the carrier element (40) is compressed such that a thickness of the surface material (10) before compression d1 is in the following ratio to a thickness of the surface material (10) during compression d2: d2 = 0.2 ... 0.3 * d1. Method for producing a cladding part provided with an embossing and/or application in or on a surface according to one of the preceding claims, characterized in that for fixing the embossing (12) and/or application (11) A bond (21) is formed between the surface material (10) with embossing (12) and/or application (11) and the haptically compressible component (20). Method for manufacturing a cladding part provided with an embossing and/or application in or on a surface according to Claim 12 , characterized in that adhesive for bonding (21) between the surface material (10) provided with embossing (12) and/or application (11) and the haptically compressible component (20) is arranged at least in the projection area of the embossing (12) or application (11) between the surface material (10) and the haptically compressible component (20). Method for manufacturing a cladding part provided with an embossing and/or application in or on a surface according to one of the Claims 12 and 13 , characterized in that , prior to the production of the bond (21) between surface material (10) and haptically compressible component (20), the surface material (10) and/or the haptically compressible component (20) is activated on their respective surfaces by flame or application of adhesive. Motor vehicle, comprising at least one fairing part produced according to the method for manufacturing a fairing part provided with an embossing and/or application in or on a surface according to one of the Claims 1 until 14 manufactured fairing part (1).