WO2007017072A1 - Method for producing a moulded body - Google Patents

Abstract

The invention relates to a method for producing a moulded body comprising at least one first (2) and one second (3) skin-like moulded body. The first moulded body comprises a first colour and the second moulded body comprises a second colour and the first and second colours are different. The moulded body also comprises a carrier layer (5) and at least one moulded body (2, 3) is connected directly to the carrier layer. The invention also relates to a moulded body and to a work tool which is used to carry out said inventive method and for producing the inventive moulded body.

Description

 METHOD FOR PRODUCING A FORM BODY

The present invention relates to a method for producing a shaped body comprising at least a first and a second skin-like molded body, wherein the first molded body has a first color and the second molded body has a second color and the first and second colors are different and a carrier layer, wherein at least a molded body is connected directly to the carrier layer. Furthermore, the present invention relates to a molding and a tool for carrying out the method according to the invention and for the production of the molding according to the invention.

Nowadays moldings, for example trim parts of the interior of motor vehicles, have very complex structures. For example, trim parts having molded skin surfaces of different colors must be provided. In addition, these molded skin surfaces must still have different haptic properties. For example, a part must feel soft, while in a subsequent part of the haptic impression should be hard.

For the production of these elaborate trim parts, the differently colored molded skin surfaces were first prepared in the past, cut into a specific shape, connected to each other and then glued to a support layer, wherein a foam layer could be partially arranged between the support layer and the Formhautoberfläche. This manufacturing method has the disadvantage that it is very labor-intensive that relatively much waste is produced during the subsequent trimming and that a concise color-separating groove is present between the two color layers. In order to eliminate the last disadvantageous point, DE 40 01 807 proposes integrally forming two sections with different colors. However, this method has the disadvantage that the overlap area between the two sections is very large and that the method is comparatively expensive to perform. It was therefore the object of the present invention to provide a method for producing a shaped body consisting of a first and a second skin-like shaped body, wherein the first shaped body has a first color and the second shaped body has a second color and the first and second colors are different and one Carrier layer, wherein at least one shaped body is connected directly to the carrier layer to provide, which does not have the disadvantages of the prior art.

The object is achieved with a method for producing a shaped body comprising at least a first and a second skin-like shaped body, wherein the first shaped body has a first color and the second shaped body has a second color and the first and the second color are different and a carrier layer, wherein at least one shaped body is directly connected to the carrier layer, in several process steps, in which all manufacturing steps are performed in a tool.

With the method according to the invention moldings can be produced which have a first and a second skin-like molded body, wherein the first molded body has a first color and the second molded body has a second color and these two colors are different. Such skin-like shaped bodies can be produced from any plastic known to the person skilled in the art for this application. For example, the skin-like molded body made of PU (polyurethane) and are produced by casting and subsequent curing. Alternatively, the skin-like shaped bodies can also be produced by means of an injection molding process. The two moldings are made in one piece in the method according to the invention. The skin-like appearance of the skin-like shaped bodies is preferably produced by having scars. The negative of these scars is incorporated into the tool with which the skin-like moldings are made. The structure of the two skin-like shaped bodies can be different.

According to the invention, at least one of these moldings is directly connected to a carrier layer. The carrier layer gives the resulting molded body its mechanical stability and can be made of a natural material or a preferably thermoplastic material. The backing layer may have any size and shape, for example, undercuts. This carrier layer preferably has its final shape.

The production of the two skin-like shaped bodies as well as the connection of at least one of the two shaped bodies with a carrier layer takes place in several process steps. The inventive method is characterized in that all manufacturing steps are carried out in a tool, whereby the inventive method is very simple and very time-saving and thus inexpensive to perform. Intermediates, such as the skin-like moldings, do not have to be transferred from one tool to another and further processed there, but remain in the mold until they are bonded to the backing in which they have been cast and cured, for example.

Preferably or in accordance with a further subject of the present invention, the manufacturing steps that are required to produce a shaped body consisting of at least two interconnected skin-like moldings and a carrier layer, at least partially parallel. Parallel within the meaning of the invention means that the next process step is already started, although a previous process step has not yet ended. For example, a foam layer is already arranged on the back side of the first skin-like molded body, although the skin-like molded body has not yet fully cured, or the second skin-like molded body is cast although the first skin-like molded body and / or the foam layer are not yet cured. If the intermediates had to be removed from the mold, such a parallel production would not be possible or only with difficulty. This subject or this preferred embodiment of the present invention has proven to be particularly time-saving and therefore cost.

Preferably, a first curing molding compound is filled in a first cavity of the tool, where the curing begins. Furthermore, preference is given to a carrier layer on the inside of the molding compound to produce a cavity arranged and filled this cavity with a hardening foam. The other cavities, which are present between the carrier layer and the tool, are filled with further curing molding compounds. Preferably, at least one of these molding compounds is a material from which a second skin-like shaped body can be produced which integrally connects with the first skin-like shaped body. A third cavity can serve, for example, for producing a connection and / or a seal of the resulting molded part in relation to other components of the interior trim of a motor vehicle.

With the method according to the invention moldings can be produced which have both a soft and a hard haptic appearance. Furthermore, multicolor surface designs are possible with the method according to the invention without a color separation groove in the direct field of vision of the occupants of a motor vehicle, for example, being recognizable. The scar configuration, which as a rule has skin-like shaped bodies, can be freely designed and may be different in the first skin-like shaped body than in the second skin-like shaped body.

The inventive method allows a cost-effective production of moldings, for example, interior parts of motor vehicles. There is no material loss due to, for example, edge trimming. The inventive method allows a high reproducibility and a consistent product quality.

Another object of the present invention is a molded body comprising at least a first and a second skin-like molded body, wherein the shaped body has a first color and the second molded body has a second color and the first and the second color are different, in which the molded body only touch along a separation surface. Preferably, this separation surface is behind a color separation groove.

Preferably or according to a further aspect of the present invention, the shaped body has a carrier layer which is connected to at least one of the plurality of skin-like shaped bodies. Furthermore, this shaped body is characterized in that it has no adhesions and the skin-like shaped bodies have no cutting edges.

The shaped body according to the invention preferably has a cushion layer, preferably a foam layer, which is connected to only one of the two skin-like shaped bodies. Preferably, this cushion layer is arranged between the carrier layer and one of the two skin-like shaped bodies. This preferred embodiment of the present invention has the advantage that the molded body has a haptic soft and a tactile hard area. As foam material, all known foam materials are used, which are used in the cladding. Preferably, the foam is first a molding compound, which then hardens in conjunction with other parts of the molding according to the invention. For example, the foam is a PUR foam.

Preferably, on the inside of the skin-like shaped body, d. H. arranged on the side invisible to the viewer, a sealing geometry, which cooperates with the tool, is produced with the molding according to the invention. This sealing geometry can be used for example for the arrangement of the cushion layer.

The support layer preferably has recesses, in particular holes, which serve as a sprue / injection opening for liquid plastic from which the skin-like shaped bodies or other shaped bodies are produced or which serve as degassing openings during casting spraying or foaming.

Preferably seals or other connection means are arranged, preferably cast, on the molded body according to the invention, which cooperate with other components of the interior of the interior of a motor vehicle.

The molded body according to the invention is suitable for the interior lining of a vehicle of any kind. Preferably, however, the shaped body is the curb of a door trim, an instrument panel, a center console, a glove box and / or an armrest. The shaped body according to the invention has the advantage that it has two haptically different areas and that a multi-colored surface design without visible color separation groove is possible. The molding according to the invention is simple, inexpensive and reproducible to produce.

Another object of the present invention is a tool for carrying out the method according to the invention and for producing the shaped body according to the invention, which has a one-piece mold cavity with a projection. This projection serves to separate the two differently colored areas of the skin-like shaped body and to design the color separation groove. Preferably, the projection with a lid having a seal, sealingly cooperates, so that the plastic material for producing the first skin-like shaped body does not reach into the region of the mold cavity, in which the second skin-like molded body is to be produced.

Preferably, the mold cavity has, at least in some areas, a surface structure which allows the production of grained skin-like moldings.

In a preferred embodiment of the present invention or according to another aspect of the present invention, the mold cavity is covered with a lid which can receive a carrier layer.

The tool according to the invention is simple and inexpensive to manufacture and can be used individually.

In the following the invention will be explained with reference to Figures 1 to 4. These explanations are merely exemplary and do not limit the general inventive concept. The explanations apply equally to all articles of the present invention.

FIG. 1 shows the shaped body according to the invention, FIG. 2 shows the method steps a) -d) of the method according to the invention,

FIG. 3 shows the method steps e) - g) of the method according to the invention and

FIG. 4 shows the method steps h) -j) of the method according to the invention.

1 shows an embodiment of the shaped body according to the invention in the present case, a curb of a door panel having on the side facing the passenger compartment two skin-like moldings 2, 3 and on the body side facing a carrier layer 5. Between the skin-like shaped body 2 and the carrier layer 5, a foam layer 14 is arranged. The skin-like shaped body 2, 3 are designed differently colored and made in one piece. They only touch each other along a very small connection region, preferably a parting line 23, preferably behind the color separation groove 20, which is not in the direct field of vision of the occupant of the vehicle. The color design of the two skin-like shaped body may be different. The two skin-like shaped bodies are preferably produced as PU cast skin. The fact that the foam is arranged only in the region of the molded skin 2 results in two haptically different regions, namely a soft region behind the molded body 2 and a haptically hard-looking region behind the molded article 3, which is connected directly to the backing layer 5. The visual and haptic appearance of the molding according to the invention is very high quality.

FIG. 2 shows the process steps ad of the process according to the invention for producing the shaped body according to the invention. First of all, as can be seen under a), a tool 8 is provided which has a mold cavity 15, for example a galvano dish or the like. In this mold cavity 15, a projection 16 is arranged, which divides the mold cavity into two different areas and which is used as shown later for the design of the color separation groove. The tool 8 can be made tempered. The mold cavity 15 may have a structure for producing scars in the resulting molded body. As can be seen under b), a lid is in the mold cavity 15 17 lowers until as under c) visible whose preferably elastic seals 19, 21 with the tool 8 sealingly engage. The lid 17 may also be designed to be tempered. The lid 17 and the tool 8 define a cavity 9 which, according to method step d), is filled with a hardening mass 2 ^' , preferably by casting, which forms the skin-like shaped body 2. The cover 17 has, as is particularly well visible according to method step c), a recess 22 which serves to produce a sealing geometry on the inside, ie the side of the skin-like shaped body 2 which is not visible to the vehicle occupant. The person skilled in the art recognizes that the cover 17, in particular directly adjacent to the seals 19, 21, can have one or more vents in order to avoid air pockets or the like.

FIG. 3 shows the method steps e) -g) of the method according to the invention. After the molding compound 2 'is at least partially cured, the cover 17 is removed and, as is visible in accordance with method step f), replaced by a cover 18 which carries on its underside the carrier layer 5 of the molding 1 according to the invention. The molded body 2, in the present case a casting skin, remains during the change in the tool. Between the carrier layer 5 and the inside of the skin-like body 2, a cavity 10 is formed, which is filled with a moldable and curable foam material 14, for example polyurethane foam, which cures in this cavity. It can be clearly seen that a seal between the carrier layer 5 and the first casting skin is formed and thus forms the clearly defined hollow chamber, in which the reactive foam finds its shape bed.

FIG. 4 shows the method steps h) -j) of the method according to the invention. After the carrier layer 5 has been lowered into its final position within the tool 8, the slider 4 is moved to the right to reduce the size of the cavity 11, which is localized by the tool 8 and the carrier layer 5 and the molding 2 , so that moldings 1 can be produced with undercuts by the method according to the invention. Another cavity 12 is formed between the lid 18, the tool 8, the molded body 2 and the carrier layer 5. The sealing points the lid 18, the tool 8 and the first molded body 2 are preferably also as idealgeometrische plant in executed the fine structure to prevent escape of the respective Formasse from the respective cavity. As can be seen in accordance with method step i), the cavities 11 and 12 are filled with the molding compounds 3 ^* and 13 ', preferably by casting. The molding compound 13 ^' is used to produce a Randangußes a window bar, which may have a different color than the skin-like moldings 2, 3. This is preferably during at least one of the two molding materials 2' or 14 'still hardens, so that the inventive method very time-saving is to perform. Since the first skin-like shaped body 2 is still fresh due to the process sequence described and has no contamination, a stable material connection between the first and the other skin-like moldings is given, whereby a subsequent material separation is avoided. After all the molding compositions of the molding 1 are sufficiently cured, the slider 4 is moved to the left and the finished molded part 1 is removed from the mold. At best, this must be subjected to minor reworking in the form-separation area. Due to the fact that in the method according to the invention the entire production takes place in a tool 8 and / or the molding compounds to be cured are at least partially filled into the tool in parallel and / or hardened, the method according to the invention is very time-saving. Since neither the skin-like shaped bodies 2, 3 nor the foam layer 14 are cut to size, the shaped body according to the invention has no cutting edge. Furthermore, the molded body has no adhesive surfaces by an additional adhesive, since the skin-like molded body 3 and the foam 14 connect during curing with the carrier layer 5. With the method according to the invention, it is possible to foam behind only a portion of the skin-like shaped bodies 2, 3, so that two haptically different areas arise. The transition region between the two skin-like shaped bodies 2, 3 has no color overlays, for example due to film formation, especially in the visible, directly visible area of the finished shaped body 1, since the first skin-like shaped body 2, the casting skin, has remained in the mold cavity and thus no material between the mold cavities first mold body and the mold cavity passes, because an idealgeometrische plant is also in the fine structure (eg graining). In addition, the molded body 2 is pressed by the carrier 5 against the mold cavity, whereby the resulting reaction pressure of the materials is derived by sealing stable elements to each other. Preferably a special pressure-receiving sealing geometry of the carrier to the first molded body 2 with direct support to the mold cavity 15 is provided.

All parts of the disclosure apply equally to all subjects of the invention.

LIST OF REFERENCE NUMBERS

1 shaped body

2, 3 skin-like shaped bodies, casting skin

2 ^' , 3 ^' curing molding compounds

4 slides

5 carrier layer

6 inside of the molded body 2

7 sealing geometry

8 tool

9 first cavity

10 - 12 cavity

13 ^' hardening molding compound

14, 14 ^' padding layer, hardening foam

15 mold nest

16 advantage

17 cover I

18 lid Il

19 seal

20 color separation groove

21 seal

22 indentation

23 dividing line a-j method steps

Claims

claims: 1. A method for producing a shaped body comprising at least a first and a second skin-like shaped body (2, 3), wherein the first molded body (2) has a first color and the second molded body (3) has a second color and the first and the second Color are different and a carrier layer (5), wherein at least one shaped body (2, 3) is directly connected to the carrier layer (5) in several process steps (a - j), characterized in that all manufacturing steps (a - j) in one Tool (8) are performed. 2. A method for producing according to the preamble of claim 1 or claim 1, characterized in that the manufacturing steps (a - j) run at least partially in parallel. 3. The method according to any one of the preceding claims, characterized in that a first curing molding compound (2 ^' ) in a first cavity (9) of the tool (8) is filled and where the curing begins. 4. The method according to claim 3, characterized in that preferably before the complete curing of the molding compound (2 ^' ) behind the inside (6) to produce at least one cavity (10 - 12) a carrier layer (5) is arranged. 5. The method according to claim 4, characterized in that the cavity (10) between the carrier layer (5) and the molded part (2) with a thermosetting foam (14) is filled. 6. The method according to claim 3 or 4, characterized in that the cavities (11, 12) with a second or third curing molding compound (3 ^' , 13 ^' ) are filled. 7. The method according to any one of the preceding claims, characterized in that the molded part (1) is removed from the mold. 8. Shaped body (1) comprising at least a first and a second skin-like shaped body (2, 3), wherein the shaped body (2) has a first color and the second shaped body (3) has a second color and the first and the second color differently are, characterized in that the shaped bodies (2, 3) touch only along a very small connection area, preferably a parting line (23). 9. Shaped body according to claim 8 or according to the preamble of claim 8, characterized in that it comprises a carrier layer which is connected to one of the skin-like shaped bodies (2, 3) and that it contains no adhesive and the skin-like shaped bodies (2, 3) have no cut edges. 10. Shaped body according to claim 8 or 9 and according to the preamble of claim 8, characterized in that it comprises a cushion layer (14) which is connected only to one of the skin-like shaped body (2, 3). 11. Shaped body according to claim 10, characterized in that a cushion layer (14) between the carrier layer (5) and the skin-like shaped body (2) is arranged. 12. Shaped body according to one of the preceding claims, characterized in that the skin-like shaped body (2, 3) has an inner side (6) and that on the inside a sealing geometry (7) is arranged. 13. molded body, characterized in that it is an interior trim part of a vehicle, preferably the curb of a door trim, an instrument panel, a center console, a glove box and / or an armrest. 14. Tool for carrying out the method and for the production of the shaped body according to one of the preceding claims, characterized in that it comprises a one-piece mold cavity (15) with a projection (16). 15. Tool according to claim 14, characterized in that it comprises at least one cover (17) and that the lid (17) has a seal (19) which cooperates with the projection (16). 16. Tool according to one of the preceding claims or according to the preamble of patent claim 15, characterized in that the mold cavity (15) of a lid (18) can be covered, which receives a carrier layer (5).