CA2021777C - Method of producing lined mouldings - Google Patents
Method of producing lined mouldingsInfo
- Publication number
- CA2021777C CA2021777C CA002021777A CA2021777A CA2021777C CA 2021777 C CA2021777 C CA 2021777C CA 002021777 A CA002021777 A CA 002021777A CA 2021777 A CA2021777 A CA 2021777A CA 2021777 C CA2021777 C CA 2021777C
- Authority
- CA
- Canada
- Prior art keywords
- support member
- mould
- lining
- coating material
- coating
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
- B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
- B27N7/00—After-treatment, e.g. reducing swelling or shrinkage, surfacing; Protecting the edges of boards against access of humidity
- B27N7/005—Coating boards, e.g. with a finishing or decorating layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2711/00—Use of natural products or their composites, not provided for in groups B29K2601/00 - B29K2709/00, for preformed parts, e.g. for inserts
- B29K2711/14—Wood, e.g. woodboard or fibreboard
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
- B29L2031/3041—Trim panels
Abstract
A method of producing lined mouldings for internally covering the passenger compartments of motorcars is described, which comprise a temperature-independent, inherently stable support member of compressed wood fibre materials or the like containing binding agents and a lining on the visual side, firmly bonded to said support member. The lining, at least in sections, con-sists of a thermoplastically deformable material and is applied by coating the heated support member in an enclosed injection moulding tool via injection moulding. For this purpose, the support member is heated to 120 -180° Centigrade.
Description
The invention relates to a method of producing lined mouldings for internal lining of passenger spaces of automobiles.
It is known to line such mouldings by using bonding agents in connection with thermoplastically deformable foils, preferably by sucking the heated thermoplastic foil to the support members. For this purpose, the support members and/or the foil are coated with a bonding agent. Even in case several coating materials are provided, this procedure, hitherto, has been maintained. When a cloth insert is to be inserted in a foil lining, the insert, at first, is specifically lined upon as a blank with the aid of a bonding agent; thereafter, the entire moulding, together with a thermoplastic foil, is lined over by means of the mentioned vacuum deep-drawing procedure and, in a subsequent operation, foil and fabric are welded to the contour of said cloth insert, in case said fabric should be weldable. Advantageously, use is made, in this connection, of high-frequency welding. Then, the foil above the fabric is removed, this process being designated as so-called mirroring.
This method is expensive and waste-intensive. In addition to that, it ought to be applied only when both lining materials are weldable. Moreover, methods have become known in which the waste was reduced by pre-bonding the various lining materials prior to lining (European Patent Specification 0 145 832). A further known method, at least, provides fixing two blanks of the various lining materials on the moulding by special holding devices during lining (German Laying-open Specification 31 09 338), the thermoplastic lining being a pre-fabricated foil from which blanks are made so that, if possible, material can be saved hereby. Nevertheless, considerable production waste may occur therewith. In the knswn cases, the lining operation is performed with the aid of a bonding agent, increasing 40 ~s not only the production cost but _ - 2 also - in case of bonding agents containing solvents -affecting the environment. For lining with thermoplastic foils, PVC foils are employed almost exclusively which, due to the perspirations of the softening agents and due to their adverse effect on the environment, can be disposed of only very expensively. The determining factor for their employment, in this connection, resides in their excellent weldability which enables the formation of neat welded joints and ornamental seams along the line of separation, above all during lining with various materials. The employment of alternative materials, desirable as such, hitherto has proven unavailing, above all due to their insufficient weldability.
Departing from this state of the art, it is the object of the present invention to reduce the waste during lining of mouldings according to the method specified in the method specified hereinafter by at least partially using thermoplastic materials, to enable replacement of the problematic PVC materials by other lining materials and to reduce the overall cost of the production of the moulding.
In accordance with an embodiment of the present invention there is provided a method for manufacturing laminated moulded articles for internal lining of passenger spaces of automobiles. The method comprising: providing a support member to be laminated wherein the support member has binder-containing compressed wood fiber materials and retains its dimensional stability at temperatures greater than 180C; heating the support member to a temperature in the range of about 120 to 180C; inserting the support member into a mould; heating a coating material; injecting the coating material into the mould to coat the support member; and removing the support member from the mould while warm.
The lining of mouldings with thin coats by the nearly wasteless coating during the injection moulding process has 40 ~ hitherto been considered impossible since long flow ~ ,~
paths extending over the present large surfaces are required and the thickness of the coating is relatively low. Under these conditions, flow resistances are to be reckoned with during injection moulding that are so high that performing the procedure was considered out of the question. Surprisingly, it was found now that the flow resistances, by heating the support members, could be lowered to such an extent that also a large-surface coating of corresponding mouldings during the injection moulding process becomes possible when certain conditions are observed, provided, of course, that the support member still remains sufficiently inherently stable at the temperatures to be applied, as is the case with compressed wood materials containing binding agents.
Performing said method comprises heating the support members to 120-180 Centigrade, inserting said support members in an injection mould, one mould half thereof rearwardly backing the support member, whereas the other mould half includes the desired visual surface contour of the lining. In this connection, a possible different thickness of the lining coat providing a distance, has to be incorporated into the injection moulding tool, resulting in a considerable advantage with regard to the product, as compared to foil lining. After closing the mould, the heated and plasticised thermoplastic material of the lining is injected. The location(s) of the injection is/are shifted to areas of said moulding, in which cutouts are produced later on by punching operations so that the "sprue" on the finished part does not disturb. Removal of said moulding now finish-coated by injection moulding may be effected shortly after completion of the injection with the support member still in warm condition.
~ir ~1~, ~
Since the support member remains inherently stable even under heat and stabilises the thermoplastic coat, setting of the same by cooling need not be waited for so that coating can be effected at short time intervals.
The described method may be further developed to advantage.
For instance, it is possible to design the mould half of the injection moulding tool, constituting the visual side, in a relief-like manner, e.g. in the form of a leather grain.
Compared to the employment of pre-grained lining foils, as proposed by the state of the art, this results in the substantial advantage that there will be no drawing of patterns during lining, as is usual and disturbing with deep-drawing of the deep-drawing foils. Another advantageous possibility resides in that individual areas of the visual side - such as e.g. grip troughs, piercings for window cranks, map cases and the like - may be optically emphasised by annular beads, bead webs or similar design elements. Consequently, there is a wider variety of design possibilities, as compared to the employment of a deep-drawing foil according to the state of the art. The additional effort of using assembly parts such as e.g. ornamental rings, which is still customary nowadays, is not necessary any more.
Often, "cushioning effects" are desired on the mouldings of the described kind, which, above all, have hitherto been produced by mounting or foaming foam mouldings onto said moulding, which, then, will have to be lined over. Such cushion areas, with the method according to the invention, can be produced in a simplified manner by correspondingly designing the injection moulding tool and by seeing to it that the thermoplastic coating material contains a foaming agent at least for the respective ~?,- ~f .p , ~:...
areas. While there is no foaming of the thermoplastic in the thin layer of the surface-coating of said moulding when a corresponding mixture for injection moulding is continuously used, the desired "cushioning effect" is obtained in those tool areas which are contoured with a greater distance.
Another advantage results when the method according to the invention is further developed in that the contour of said injection moulding tool is designed in such a way that the support member may be circumferentially coated. On the one hand, bowing over of said lining foil, which, hitherto, has been relatively laborious with regard to process engineering, becomes superfluous hereby; on the other hand, deburring of said support member may be dispensed with since possibly present bur irregularities are injected or injection-moulded around, respectively. The production cost can be considerably reduced thereby.
The method according to the invention presents advantages also in case of linings of various materials when, at first, the area in which a lining which cannot be injection-moulded, e.g.
a fabric, is provided in sections of the surface to be lined is lined with a blank of said lining material in a manner known per se, lining being carried out with a blank of said lining material that cannot be injection-moulded, which is slightly larger than its subsequent visual area. In accordance with the present method, this visual area is separated from the injection area of the injection moulding tool by a sealing ledge following its contour and resembling a knife-edge, an excess length of the preliminary lining projecting into the injection space of said ~r ,~;,~j,,, injection moulding tool so that said excess length is embedded in the paste used for injection moulding and neatly defined.
Joint seams produced by welding can be dispensed with, desired ornamental seams can be incorporated into the injection moulding tool and are extruded. Such a procedure may involve the use of all thermoplastically deformable materials which are suitable for lining and which can be injection-moulded. The condition sine qua non that the lining tools must be able to carry out welding operations, a condition which, with the state of the art, still confined the material selection, has become obsolete. With an appropriate combination of a lining tool known per se with the corresponding injection moulding tool, both partial linings may be effected approximately at the same time.
The invention will be described and explained hereinafter merely by way of example and with reference to the attached Figures.
Fig. 1. shows a schematic sectional representation of the overall configuration with coating by injection moulding according to the invention with a uniform coating material; and Fig. 2 illustrates the possibility to combine a cloth insert which covers only sections of the moulding with coating by injection moulding of the remaining surfaces.
As shown in Figure 1, the upper half 1 of the injection moulding tool includes the visual contour of the finish-coated ~, moulding. The lower half 2 of said injection moulding tool positively receives the support member 3 in supporting manner.
The contour of said upper half 1 follows the contour of said support member 3 only partially. In the areas 4', the gap used for injection moulding is larger than in the remaining areas of the moulding in order to realize a cushion support at this point, which has a good feel. This is, above all, of advantage in cases where the coating material contains foaming agents. The moulding illustrated in section belongs to the lateral covering of the door of a motorcar. In area 4", the contour of the upper half 1 likewise deviates from the contour of the proper moulding, an annular bead being formed around the piercing of said moulding at this point by the coating material. The injection channel 5 through which injections are made in the direction of the arrow is conveniently arranged within those areas of the moulding in which piercings are provided later on. In the border area 6 of said moulding, the injection moulding tool likewise shows contour deviations such that the coating material surrounds the edge of said support member. Even the area 4" of the window crank is formed in a similar edge-surrounding manner. This measure is of advantage for several reasons. On the one hand, deburring of the support member is not necessary any more; on the other hand, this edge-surrounding area can be designed in such a way that it takes the form of sealing lips and, therefore, provides for a tight fit to the motorcar body free from creaking and clattering. In addition thereto, the edge-surrounding coating seals the intersecting edges against influences of moisture. In Figure 1, structural elements such as e.g. guiding supports of said injection moulding tool, channels for heating media or coolants and similar structural elements are not shown for the sake of clarity.
, .
Fig. 2 explains the possibility to combine coating by injection moulding with a cloth insert, and that with reference to two cut-away portions. The designations of the structural elements are identical with those of Fig. 1. As has already been described, the lower tool half 2 supports the support member 3 which in a section (that is shortened for the sake of clarity), carries the cloth insert 7 as preliminary lining. In the area of this preliminary lining, the upper tool half 1 has a window-like opening 8, the edge of which follows the subsequent separation contour of the cloth insert and the coating produced by injection moulding. The upper tool half 1 following the contour of said cloth insert is formed with a squeezing edge 1' which provides for sealing the insert area against the injection area. The high surface pressure of said squeezing edge 1' prevents the coating material from penetrating into the fabric.
Therewith, the cloth insert, together with the excess length 9, projects into the injection space of the injection moulding tool so that this excess length, with accurate contours, is neatly embedded and fixed in the coating produced by injection moulding.
An additional welded joint between the two coating materials, as is the case with the state of the art, is omitted here.
Moreover, another possibility of injecting the coating material is explained in Fig. 2:
In this Figure, the runner 5 is incorporated into the lower half 2 of said injection moulding tool and coating is effected by the support member 3 provided, at this point, with a piercing so that the gate mark is subsequently arranged on the back of the finished moulding. Due to the window-like piercing 8 in the upper tool half, the cloth insert, therewith, is not subjected to any mechanical stress and does not come into contact with any of the tool parts. The cloth texture is not damaged and contamination of said insert by the upper tool half remains out of the question.
Figs. 1 and 2 are to be considered as examples; other arrangements are possible. For instance, it may be appropriate to provide several sprue openings. Another advantageous possibility resides in that a lining die is guided through the window opening 8 in Fig. 2 in such a way that insert lining and injection moulding can be carried out approximately at the same time.
Apart from the already described approach according to the invention for applying the thermoplastically deformable material, it is also possible to carry out lining of said moulding by introducing a not yet cross-linked polymer portion which may be given by the desired thickness of the lining to be produced into the one half of a press, comprising bottom die and top die, in which case said polymer portion may then be compressed together with said support member. In this connection, it is of advantage to heat at least that tool half of said press which is filled with the polymer and/or to warm up the support member itself to an appropriate temperature of 120 to 180 Centigrade. Upon closing the press, the polymer on the subsequent visual side of said moulding is distributed over the same, the elevated temperature of the appertaining tool half and the support member, respectively, reducing the viscosity of said polymer in such a ~^~
~021 777 way that also relatively large surface areas of said support member may be provided with very thin lining coats. The elevated temperature, in addition thereto, provides for a considerable abbreviation of the cross-linking time of the plastic. Generally speaking, all commercially available polymers may be employed for this kind of lining of support members by pressure-coating. It is, however, of special advantage to make use of elastomers for this purpose since, due to their surface properties, the pleasant feel, their resistance to tear even with high mechanical stress, elastomers usually meet modern market requirements in an optimum manner.
The aforementioned good feel of elastomeric materials may be enhanced still by adding foaming agents to them which, e.g.
in the area of the armrests, provide for a sufficient cushioning effect. The gas permeability of the wood fibre materials from which the support members are made here additionally favours bubble-free foaming of such cushion areas.
Finally, a further developing feature of this procedure resides in that the polymer is introduced into one of the tool halves of the press only after the surface of which has been provided with a layer of lacquer and sufficient pre-drying of the same was effected. In this case, a lacquer is used to advantage which possesses sufficient affinity for the respective polymer or which, in other words, forms a sufficient adhesive bond with said polymer, pressure-distributed over the visual side of said support member, after suitable pre-drying. The special advantage of this approach resides in that the surface properties of the coated moulding may be separated irrespectively of the material ~ . -qualities of the coating polymer. The scope of optimisation ofthe method according to the invention is substantially expanded hereby.
Using a pre-dried, i.e. adhesive, coat of lacquer for a tool half together with support members which are inherently stable even under heat offers the additional advantage that a premature removal of the coated moulding from the mould is possible even if the proper polymer coating is not yet fully cured. Inherent stability, in this case, is ensured by the support member, the pre-dried layer of lacquer protects the not yet fully cured polymer surface. The abbreviation of the cycle time thus made possible constitutes a substantial economic advantage of the method according to the invention.
, ....
-
It is known to line such mouldings by using bonding agents in connection with thermoplastically deformable foils, preferably by sucking the heated thermoplastic foil to the support members. For this purpose, the support members and/or the foil are coated with a bonding agent. Even in case several coating materials are provided, this procedure, hitherto, has been maintained. When a cloth insert is to be inserted in a foil lining, the insert, at first, is specifically lined upon as a blank with the aid of a bonding agent; thereafter, the entire moulding, together with a thermoplastic foil, is lined over by means of the mentioned vacuum deep-drawing procedure and, in a subsequent operation, foil and fabric are welded to the contour of said cloth insert, in case said fabric should be weldable. Advantageously, use is made, in this connection, of high-frequency welding. Then, the foil above the fabric is removed, this process being designated as so-called mirroring.
This method is expensive and waste-intensive. In addition to that, it ought to be applied only when both lining materials are weldable. Moreover, methods have become known in which the waste was reduced by pre-bonding the various lining materials prior to lining (European Patent Specification 0 145 832). A further known method, at least, provides fixing two blanks of the various lining materials on the moulding by special holding devices during lining (German Laying-open Specification 31 09 338), the thermoplastic lining being a pre-fabricated foil from which blanks are made so that, if possible, material can be saved hereby. Nevertheless, considerable production waste may occur therewith. In the knswn cases, the lining operation is performed with the aid of a bonding agent, increasing 40 ~s not only the production cost but _ - 2 also - in case of bonding agents containing solvents -affecting the environment. For lining with thermoplastic foils, PVC foils are employed almost exclusively which, due to the perspirations of the softening agents and due to their adverse effect on the environment, can be disposed of only very expensively. The determining factor for their employment, in this connection, resides in their excellent weldability which enables the formation of neat welded joints and ornamental seams along the line of separation, above all during lining with various materials. The employment of alternative materials, desirable as such, hitherto has proven unavailing, above all due to their insufficient weldability.
Departing from this state of the art, it is the object of the present invention to reduce the waste during lining of mouldings according to the method specified in the method specified hereinafter by at least partially using thermoplastic materials, to enable replacement of the problematic PVC materials by other lining materials and to reduce the overall cost of the production of the moulding.
In accordance with an embodiment of the present invention there is provided a method for manufacturing laminated moulded articles for internal lining of passenger spaces of automobiles. The method comprising: providing a support member to be laminated wherein the support member has binder-containing compressed wood fiber materials and retains its dimensional stability at temperatures greater than 180C; heating the support member to a temperature in the range of about 120 to 180C; inserting the support member into a mould; heating a coating material; injecting the coating material into the mould to coat the support member; and removing the support member from the mould while warm.
The lining of mouldings with thin coats by the nearly wasteless coating during the injection moulding process has 40 ~ hitherto been considered impossible since long flow ~ ,~
paths extending over the present large surfaces are required and the thickness of the coating is relatively low. Under these conditions, flow resistances are to be reckoned with during injection moulding that are so high that performing the procedure was considered out of the question. Surprisingly, it was found now that the flow resistances, by heating the support members, could be lowered to such an extent that also a large-surface coating of corresponding mouldings during the injection moulding process becomes possible when certain conditions are observed, provided, of course, that the support member still remains sufficiently inherently stable at the temperatures to be applied, as is the case with compressed wood materials containing binding agents.
Performing said method comprises heating the support members to 120-180 Centigrade, inserting said support members in an injection mould, one mould half thereof rearwardly backing the support member, whereas the other mould half includes the desired visual surface contour of the lining. In this connection, a possible different thickness of the lining coat providing a distance, has to be incorporated into the injection moulding tool, resulting in a considerable advantage with regard to the product, as compared to foil lining. After closing the mould, the heated and plasticised thermoplastic material of the lining is injected. The location(s) of the injection is/are shifted to areas of said moulding, in which cutouts are produced later on by punching operations so that the "sprue" on the finished part does not disturb. Removal of said moulding now finish-coated by injection moulding may be effected shortly after completion of the injection with the support member still in warm condition.
~ir ~1~, ~
Since the support member remains inherently stable even under heat and stabilises the thermoplastic coat, setting of the same by cooling need not be waited for so that coating can be effected at short time intervals.
The described method may be further developed to advantage.
For instance, it is possible to design the mould half of the injection moulding tool, constituting the visual side, in a relief-like manner, e.g. in the form of a leather grain.
Compared to the employment of pre-grained lining foils, as proposed by the state of the art, this results in the substantial advantage that there will be no drawing of patterns during lining, as is usual and disturbing with deep-drawing of the deep-drawing foils. Another advantageous possibility resides in that individual areas of the visual side - such as e.g. grip troughs, piercings for window cranks, map cases and the like - may be optically emphasised by annular beads, bead webs or similar design elements. Consequently, there is a wider variety of design possibilities, as compared to the employment of a deep-drawing foil according to the state of the art. The additional effort of using assembly parts such as e.g. ornamental rings, which is still customary nowadays, is not necessary any more.
Often, "cushioning effects" are desired on the mouldings of the described kind, which, above all, have hitherto been produced by mounting or foaming foam mouldings onto said moulding, which, then, will have to be lined over. Such cushion areas, with the method according to the invention, can be produced in a simplified manner by correspondingly designing the injection moulding tool and by seeing to it that the thermoplastic coating material contains a foaming agent at least for the respective ~?,- ~f .p , ~:...
areas. While there is no foaming of the thermoplastic in the thin layer of the surface-coating of said moulding when a corresponding mixture for injection moulding is continuously used, the desired "cushioning effect" is obtained in those tool areas which are contoured with a greater distance.
Another advantage results when the method according to the invention is further developed in that the contour of said injection moulding tool is designed in such a way that the support member may be circumferentially coated. On the one hand, bowing over of said lining foil, which, hitherto, has been relatively laborious with regard to process engineering, becomes superfluous hereby; on the other hand, deburring of said support member may be dispensed with since possibly present bur irregularities are injected or injection-moulded around, respectively. The production cost can be considerably reduced thereby.
The method according to the invention presents advantages also in case of linings of various materials when, at first, the area in which a lining which cannot be injection-moulded, e.g.
a fabric, is provided in sections of the surface to be lined is lined with a blank of said lining material in a manner known per se, lining being carried out with a blank of said lining material that cannot be injection-moulded, which is slightly larger than its subsequent visual area. In accordance with the present method, this visual area is separated from the injection area of the injection moulding tool by a sealing ledge following its contour and resembling a knife-edge, an excess length of the preliminary lining projecting into the injection space of said ~r ,~;,~j,,, injection moulding tool so that said excess length is embedded in the paste used for injection moulding and neatly defined.
Joint seams produced by welding can be dispensed with, desired ornamental seams can be incorporated into the injection moulding tool and are extruded. Such a procedure may involve the use of all thermoplastically deformable materials which are suitable for lining and which can be injection-moulded. The condition sine qua non that the lining tools must be able to carry out welding operations, a condition which, with the state of the art, still confined the material selection, has become obsolete. With an appropriate combination of a lining tool known per se with the corresponding injection moulding tool, both partial linings may be effected approximately at the same time.
The invention will be described and explained hereinafter merely by way of example and with reference to the attached Figures.
Fig. 1. shows a schematic sectional representation of the overall configuration with coating by injection moulding according to the invention with a uniform coating material; and Fig. 2 illustrates the possibility to combine a cloth insert which covers only sections of the moulding with coating by injection moulding of the remaining surfaces.
As shown in Figure 1, the upper half 1 of the injection moulding tool includes the visual contour of the finish-coated ~, moulding. The lower half 2 of said injection moulding tool positively receives the support member 3 in supporting manner.
The contour of said upper half 1 follows the contour of said support member 3 only partially. In the areas 4', the gap used for injection moulding is larger than in the remaining areas of the moulding in order to realize a cushion support at this point, which has a good feel. This is, above all, of advantage in cases where the coating material contains foaming agents. The moulding illustrated in section belongs to the lateral covering of the door of a motorcar. In area 4", the contour of the upper half 1 likewise deviates from the contour of the proper moulding, an annular bead being formed around the piercing of said moulding at this point by the coating material. The injection channel 5 through which injections are made in the direction of the arrow is conveniently arranged within those areas of the moulding in which piercings are provided later on. In the border area 6 of said moulding, the injection moulding tool likewise shows contour deviations such that the coating material surrounds the edge of said support member. Even the area 4" of the window crank is formed in a similar edge-surrounding manner. This measure is of advantage for several reasons. On the one hand, deburring of the support member is not necessary any more; on the other hand, this edge-surrounding area can be designed in such a way that it takes the form of sealing lips and, therefore, provides for a tight fit to the motorcar body free from creaking and clattering. In addition thereto, the edge-surrounding coating seals the intersecting edges against influences of moisture. In Figure 1, structural elements such as e.g. guiding supports of said injection moulding tool, channels for heating media or coolants and similar structural elements are not shown for the sake of clarity.
, .
Fig. 2 explains the possibility to combine coating by injection moulding with a cloth insert, and that with reference to two cut-away portions. The designations of the structural elements are identical with those of Fig. 1. As has already been described, the lower tool half 2 supports the support member 3 which in a section (that is shortened for the sake of clarity), carries the cloth insert 7 as preliminary lining. In the area of this preliminary lining, the upper tool half 1 has a window-like opening 8, the edge of which follows the subsequent separation contour of the cloth insert and the coating produced by injection moulding. The upper tool half 1 following the contour of said cloth insert is formed with a squeezing edge 1' which provides for sealing the insert area against the injection area. The high surface pressure of said squeezing edge 1' prevents the coating material from penetrating into the fabric.
Therewith, the cloth insert, together with the excess length 9, projects into the injection space of the injection moulding tool so that this excess length, with accurate contours, is neatly embedded and fixed in the coating produced by injection moulding.
An additional welded joint between the two coating materials, as is the case with the state of the art, is omitted here.
Moreover, another possibility of injecting the coating material is explained in Fig. 2:
In this Figure, the runner 5 is incorporated into the lower half 2 of said injection moulding tool and coating is effected by the support member 3 provided, at this point, with a piercing so that the gate mark is subsequently arranged on the back of the finished moulding. Due to the window-like piercing 8 in the upper tool half, the cloth insert, therewith, is not subjected to any mechanical stress and does not come into contact with any of the tool parts. The cloth texture is not damaged and contamination of said insert by the upper tool half remains out of the question.
Figs. 1 and 2 are to be considered as examples; other arrangements are possible. For instance, it may be appropriate to provide several sprue openings. Another advantageous possibility resides in that a lining die is guided through the window opening 8 in Fig. 2 in such a way that insert lining and injection moulding can be carried out approximately at the same time.
Apart from the already described approach according to the invention for applying the thermoplastically deformable material, it is also possible to carry out lining of said moulding by introducing a not yet cross-linked polymer portion which may be given by the desired thickness of the lining to be produced into the one half of a press, comprising bottom die and top die, in which case said polymer portion may then be compressed together with said support member. In this connection, it is of advantage to heat at least that tool half of said press which is filled with the polymer and/or to warm up the support member itself to an appropriate temperature of 120 to 180 Centigrade. Upon closing the press, the polymer on the subsequent visual side of said moulding is distributed over the same, the elevated temperature of the appertaining tool half and the support member, respectively, reducing the viscosity of said polymer in such a ~^~
~021 777 way that also relatively large surface areas of said support member may be provided with very thin lining coats. The elevated temperature, in addition thereto, provides for a considerable abbreviation of the cross-linking time of the plastic. Generally speaking, all commercially available polymers may be employed for this kind of lining of support members by pressure-coating. It is, however, of special advantage to make use of elastomers for this purpose since, due to their surface properties, the pleasant feel, their resistance to tear even with high mechanical stress, elastomers usually meet modern market requirements in an optimum manner.
The aforementioned good feel of elastomeric materials may be enhanced still by adding foaming agents to them which, e.g.
in the area of the armrests, provide for a sufficient cushioning effect. The gas permeability of the wood fibre materials from which the support members are made here additionally favours bubble-free foaming of such cushion areas.
Finally, a further developing feature of this procedure resides in that the polymer is introduced into one of the tool halves of the press only after the surface of which has been provided with a layer of lacquer and sufficient pre-drying of the same was effected. In this case, a lacquer is used to advantage which possesses sufficient affinity for the respective polymer or which, in other words, forms a sufficient adhesive bond with said polymer, pressure-distributed over the visual side of said support member, after suitable pre-drying. The special advantage of this approach resides in that the surface properties of the coated moulding may be separated irrespectively of the material ~ . -qualities of the coating polymer. The scope of optimisation ofthe method according to the invention is substantially expanded hereby.
Using a pre-dried, i.e. adhesive, coat of lacquer for a tool half together with support members which are inherently stable even under heat offers the additional advantage that a premature removal of the coated moulding from the mould is possible even if the proper polymer coating is not yet fully cured. Inherent stability, in this case, is ensured by the support member, the pre-dried layer of lacquer protects the not yet fully cured polymer surface. The abbreviation of the cycle time thus made possible constitutes a substantial economic advantage of the method according to the invention.
, ....
-
Claims (12)
1. A method for manufacturing laminated moulded articles for internal lining of passenger spaces of automobiles comprising:
providing a support member to be laminated wherein said support member has binder-containing compressed wood fiber materials and retains its dimensional stability at temperatures greater than 180°C;
heating said support member to a temperature in the range of about 120 to 180°C;
inserting said support member into a mould;
heating a coating material;
injecting said coating material into said mould to coat said support member; and removing said support member from said mould while warm.
providing a support member to be laminated wherein said support member has binder-containing compressed wood fiber materials and retains its dimensional stability at temperatures greater than 180°C;
heating said support member to a temperature in the range of about 120 to 180°C;
inserting said support member into a mould;
heating a coating material;
injecting said coating material into said mould to coat said support member; and removing said support member from said mould while warm.
2. A method according to claim 1, wherein said mould is a mould half constituting a visual side of the support member and wherein said mould half is designed in the form of a leather grain in a surface-contoured, relief-like manner.
3. A method according to claim 1, wherein said mould is a mould half constituting a visual side of the support member and wherein said mould half is designed with annular beads, bead webs or similar design elements in areas such as grip troughs and piercings for window cranks, in a relief-like manner,
4. A method according to claim 1, wherein said mould is a mould half constituting a visual side of the support member and is maintained at an increased distance between the support member and the coating material in the areas with cushioning effect for the laminated moulded article and that, at least for these areas, a foaming agent is added to the coating material.
5. A method according to any one of claims 1 to 4 wherein said the mould is appropriately contoured to circumferentially coat said support member.
6. A method according to claim 1 wherein said mould has at least one half which is tempered.
7. A method according to claim 1, including the further step of providing a lining blank to line an area in which the coating material cannot be injection moulded, such as a fabric, wherein said lining blank is slightly larger than the area and the area is separated by a sealing ledge.
8. A method according to claim 1, further including a lining tool adapted to cooperate with the mould in such a manner that both partial linings are effected approximately at the same time.
9. A method according to claim 1, wherein said coating material is a polymer.
10. A method according to claim 9, wherein said polymer is an elastomer.
11. A method according to claim 10, wherein a foaming agent is added to said elastomer.
12. A method according to claim 1, further including the step of coating a visual side of said support member with a layer of lacquer and pre-drying prior to injecting said coating material.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DEP3924751.1 | 1989-07-26 | ||
| DE3924751 | 1989-07-26 | ||
| DE4023209A DE4023209C2 (en) | 1989-07-26 | 1990-07-19 | Laminated molded part and process for its production |
| DEP4023209.3 | 1990-07-19 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2021777A1 CA2021777A1 (en) | 1991-01-27 |
| CA2021777C true CA2021777C (en) | 1996-01-09 |
Family
ID=25883432
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002021777A Expired - Fee Related CA2021777C (en) | 1989-07-26 | 1990-07-23 | Method of producing lined mouldings |
Country Status (7)
| Country | Link |
|---|---|
| EP (1) | EP0410553B1 (en) |
| JP (1) | JPH0822560B2 (en) |
| CN (1) | CN1051009A (en) |
| AT (2) | ATE119455T1 (en) |
| CA (1) | CA2021777C (en) |
| ES (2) | ES2071755T3 (en) |
| MX (1) | MX173368B (en) |
Families Citing this family (16)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1993015888A1 (en) * | 1992-02-05 | 1993-08-19 | Weyerhaeuser Company | Surfaced cellulosic composite panel and panel forming method |
| FR2701420B1 (en) * | 1993-02-10 | 1995-05-05 | Pierre Laurence | Method of manufacturing wind instruments and instruments obtained according to this method. |
| US5635248A (en) * | 1995-06-07 | 1997-06-03 | Rohm And Haas Company | Method of producing coating on reconstituted wood substrate |
| US20060097544A1 (en) * | 2004-11-09 | 2006-05-11 | Cowelchuk Glenn A | Automotive interior trim assembly and method |
| EP1986841A1 (en) * | 2006-02-13 | 2008-11-05 | Koninklijke Philips Electronics N.V. | Method of manufacturing a product part by using a composite fibre sheet and applying plastic to this sheet |
| US8685307B2 (en) | 2006-09-29 | 2014-04-01 | Sumitomo Chemical Company, Limited | Method for producing multilayer article |
| CN102211376A (en) * | 2011-03-03 | 2011-10-12 | 华伟表面处理技术（上海）有限公司 | Automobile interior trim part having 3D texture and manufacturing process thereof |
| KR20120115617A (en) * | 2011-04-11 | 2012-10-19 | 삼성디스플레이 주식회사 | Stamper and method of manufacturing the same |
| CN104908674B (en) * | 2014-03-11 | 2018-06-22 | 上海通用汽车有限公司 | Interior coating member and its manufacturing process |
| CN104002360B (en) * | 2014-05-30 | 2016-02-03 | 项林 | Pressing assembly |
| EP2965882B1 (en) * | 2014-07-08 | 2018-02-28 | Universität Stuttgart Institut für Tragkonstruktionen und Konstruktives Entwerfen | Flexible high-density fiberboard and method for manufacturing the same |
| CN105437441A (en) * | 2014-09-02 | 2016-03-30 | 鸿富锦精密工业（深圳）有限公司 | Film formation apparatus |
| CN107484053A (en) * | 2016-06-08 | 2017-12-15 | 星锐安应用材料股份有限公司 | The wearable electronic installation of wearing comfort and its preparation method |
| CN106696138A (en) * | 2017-01-17 | 2017-05-24 | 英诺莱比（北京）科技有限公司 | surface line etching method for trial production piece |
| DE102017108984A1 (en) * | 2017-04-26 | 2018-10-31 | ACO Severin Ahlmann GmbH & Co Kommanditgesellschaft | Molding, method of making a molded article, method of bonding a molded article to an article, and use of a fabric or scrim |
| US20220347900A1 (en) * | 2019-06-21 | 2022-11-03 | Magna Exteriors Inc. | Three dimensional overmolding |
Family Cites Families (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3576049A (en) * | 1968-12-18 | 1971-04-27 | William J Williams | Apparatus for plastic capping a wooden broom block by injection molding |
| US3914475A (en) * | 1973-01-10 | 1975-10-21 | Carl A Napor | Method and means for forming composite plastic and wooden members |
| JPS54132660A (en) * | 1978-04-06 | 1979-10-15 | Marugo Gomu Kougiyou Kk | Method of making composite molding |
| JPS6135921A (en) * | 1984-07-30 | 1986-02-20 | Nissan Motor Co Ltd | Manufacture of car fitting |
| JPS61246056A (en) * | 1985-04-25 | 1986-11-01 | 豊田合成株式会社 | Resin molded shape having soft skin and manufacture thereof |
| FR2587271B1 (en) * | 1985-09-13 | 1987-12-18 | Peugeot | PROCESS FOR MOLDING PARTS OF PLASTIC MATERIAL COMPRISING A METAL INSERT AND PRODUCTS OBTAINED BY THIS PROCESS |
| JPS6360719A (en) * | 1986-08-30 | 1988-03-16 | Toyoda Gosei Co Ltd | Manufacture of steering wheel |
| EP0288130B1 (en) * | 1987-04-20 | 1993-03-17 | Davidson Textron Inc. | Interior trim foam product and method of fabrication thereof |
| JPS6416318U (en) * | 1987-07-21 | 1989-01-26 | ||
| JPS6464817A (en) * | 1987-09-07 | 1989-03-10 | Takashi Oguri | Monolithic molding of wooden body and thermoplastic resin body by means of injection molding |
-
1990
- 1990-07-23 CA CA002021777A patent/CA2021777C/en not_active Expired - Fee Related
- 1990-07-25 ES ES90250191T patent/ES2071755T3/en not_active Expired - Lifetime
- 1990-07-25 AT AT90250191T patent/ATE119455T1/en not_active IP Right Cessation
- 1990-07-25 AT AT93250346T patent/ATE162453T1/en not_active IP Right Cessation
- 1990-07-25 ES ES93250346T patent/ES2112383T3/en not_active Expired - Lifetime
- 1990-07-25 MX MX2203590A patent/MX173368B/en unknown
- 1990-07-25 EP EP90250191A patent/EP0410553B1/en not_active Expired - Lifetime
- 1990-07-26 CN CN90107260A patent/CN1051009A/en active Pending
- 1990-07-26 JP JP2198957A patent/JPH0822560B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CN1051009A (en) | 1991-05-01 |
| MX173368B (en) | 1994-02-23 |
| ES2112383T3 (en) | 1998-04-01 |
| CA2021777A1 (en) | 1991-01-27 |
| ES2071755T3 (en) | 1995-07-01 |
| ATE119455T1 (en) | 1995-03-15 |
| EP0410553A3 (en) | 1992-04-08 |
| JPH0822560B2 (en) | 1996-03-06 |
| EP0410553B1 (en) | 1995-03-08 |
| JPH03218808A (en) | 1991-09-26 |
| ATE162453T1 (en) | 1998-02-15 |
| EP0410553A2 (en) | 1991-01-30 |
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| Date | Code | Title | Description |
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| EEER | Examination request | ||
| MKLA | Lapsed | ||
| MKLA | Lapsed |
Effective date: 20010723 |