CA2151090C - Method of manufacturing a lined moulded part - Google Patents
Method of manufacturing a lined moulded part Download PDFInfo
- Publication number
- CA2151090C CA2151090C CA002151090A CA2151090A CA2151090C CA 2151090 C CA2151090 C CA 2151090C CA 002151090 A CA002151090 A CA 002151090A CA 2151090 A CA2151090 A CA 2151090A CA 2151090 C CA2151090 C CA 2151090C
- Authority
- CA
- Canada
- Prior art keywords
- carrier portion
- tool
- lining
- shaped
- overhang
- 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
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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
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/12—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels
-
- 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
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
- B29C43/40—Moulds for making articles of definite length, i.e. discrete articles with means for cutting the article
-
- 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
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
-
- 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
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/30—Moulds
- B29C51/32—Moulds having cutting means
-
- 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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/78—Moulding material on one side only of the preformed part
-
- 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
- B29C2793/00—Shaping techniques involving a cutting or machining operation
-
- 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
- B29C2793/00—Shaping techniques involving a cutting or machining operation
- B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
-
- 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
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
- B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
-
- 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
- B29L2009/00—Layered products
- B29L2009/001—Layered products the layers being loose
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Laminated Bodies (AREA)
Abstract
Described is a method of manufacturing a lined moulded part, preferably a moulded part for internal trimming of a vehicle. Such moulded parts comprise a dimensionally stable carrier portion and, connected therewith on the visible side a lining of film, textiles or similar decorative lining material.
According to the method, heated blanks of fibrous materials containing binders are shaped to form a carrier portion in a cold tool, and simultaneously connected with the lining. In a first process step, the lining material is inserted with an overhang relative to the contour of the carrier portion into a multi-function tool, and clamped and secured peripherally along the contour of the carrier portion.
Thereafter the heated material of the carrier portion is inserted into the multi-function tool and shaped by closing the tool and connected in the region of the surface of the moulded portion with the lining material, an overhang of the carrier portion material being separated by shearing along the edge of the carrier portion. In a third process step, the overhang of the lining is finally trimmed peripherally by a trimming knife. Thereafter the multi-function tool is opened and the lined carrier portion is removed, whereupon the overhang of lining may be bent over about the edge of the moulded part.
According to the method, heated blanks of fibrous materials containing binders are shaped to form a carrier portion in a cold tool, and simultaneously connected with the lining. In a first process step, the lining material is inserted with an overhang relative to the contour of the carrier portion into a multi-function tool, and clamped and secured peripherally along the contour of the carrier portion.
Thereafter the heated material of the carrier portion is inserted into the multi-function tool and shaped by closing the tool and connected in the region of the surface of the moulded portion with the lining material, an overhang of the carrier portion material being separated by shearing along the edge of the carrier portion. In a third process step, the overhang of the lining is finally trimmed peripherally by a trimming knife. Thereafter the multi-function tool is opened and the lined carrier portion is removed, whereupon the overhang of lining may be bent over about the edge of the moulded part.
Description
METHOD OF MANUFACTURING A LINED MOULDED PART
The invention relates to a method of manufacturing a laminated moulded part having a carrier portion and a lining material and to a tool for carrying out this method.
Shaping of mixtures of polypropylene and wood particles is known in the expert world by the title HMPP (wood flour polypropylene). In this case the material mixture is produced in panel form by extrusion (if necessary with additional calenderingy, the wall thickness of the panels corresponding to the thickness of the later moulded part.
These HMPP panels are heated, preferably by radiant heating, to the softening temperature of the polypropylene, and thereafter shaped to form the respectively required moulded part by means of shaping processes known per se such as vacuum deep-drawing, pressing in a tool comprising male and female mould parts or the like. In this case the tool temperatures lie below the softening temperature of the polypropylene, so that the material cools during shaping and the moulded part can be removed in a dimensionally stable manner from the tool.
There is described in DE-OS 2~ 95 117 a method of producing panel material, which may be pressed to form moulded parts, of cellulose-containing material and at least one thermoplastic binding agent, the cellulose-containing material and the thermapl~st:ic binder being mixed, and the mixture being shaped into the panel material in a heated condition. The method is characterised in that the cellulose-containing material is pulped to provide fibrous material. and mixed with the thermoplastic binders, a fleece being formed from the mixture and this fleece being compressed by the action of heat and pressure to form ~>anel material.
The aim in this case is to propose a method which permits the manufacture of panel material in a simple and cost-effective way, which is characterised by good homogeneity and mechanical properties, and which may be subjected to final pressing in a simple way in order to produce high-quality moulded parts.
Polyethylene, polypropylene, polyimide or the like may be used as thermoplastic binders, conventionally with a proportion by weight of more than 40'x, preferably 50 -605. The high proportion of therrnopl.astic binders is feasible for reasons of cost and technology (softening temperature) in present prior art on1_y with. the use of polypropylene. Subsequent lining of the moulded parts in one working procedure along with shaping is the aim.
In this case however the lining cannot be unbent overdo i.e. laid around the edge of the moulded part, a factor which severely restricts the range of application of the moulded parts, and thus also the range of application of the method proposed, In DE-OS 28 45 117 the following statement is made regarding this problem:
~~a further advantageous possibility ~_onsists ir.
connecting a surface layer, for example a film, preferably a textile layer (fleec~, textile, knitted fabric) with the moulded part before pressing. Because of the proportion of thermoplastic plastics in the moulded part, the surface layer is welded thereto during pressing in one operation. TY~us such layers may be directly laminated on to the moulded parts, or, for example, a carpet may be pressed on. As heating of the pressing tool is not necessary, and operation is frequently carried out even with cold pressed tools, the surface layer may be selected from an optional number of types and may even comprise a thermoplastic film, which would :immediately melt in a hot press tool r~ .
Bending over during the one~shot process was regarded as impossible for two reasons;
1. Trimming of a moulded part durin~~ or after pressing and lamination had to be effected "oz-i the linings, as an overhang of the lining is requires: for bending over;
in view of the normal manufacturing thickness tolerances of the carrier portions, this was not regarded as feasible, and 2. the previously necessary content of more than 50~
by weight of thermoplastic binders, rxbove all when polypropylene is used as a ~.~inder, renders difficult adhesion of the bent-over portion of the edge by the action of parting compounds.
Proceeding from this point the purpose underlying the present invention is to indicate a method of the type already described, by means of which bent-over lined moulded parts may also be produced in the one-shat process, and to indicate a mufti-function foal for carrying out the method.
In accordance with an embodiment: of. the present invention there is provided a method of manufacturing a laminated moulded part, comprising a dimensionally stable carrier portion and, connected therewith on a visible side, a decorative lining material, in which a heated blank of a mat-shaped or panel-shaped semi-product comprising cellular material containing binding agents is shaped in a cold tool to form a carrier portion, and is simultaneously connected to the lining layer, the method comprising the steps of:
inserting the lining material into a mufti-function tool with an overhang relative to the contour of the carrier portion, the lining material being clamped and secured peripherally along the contour C>f the carrier portion such that the overhang of the lining material is angled to a surface position of an edge of the carri.~~r portion inserting the heated mat-shaped or plate-shaped material of the carrier portion into the mufti-function tool and shaping by closing the tool, t~~e heated mat-shaped or plate-shaped material of the carrier portion is connected in the region of the surface of the moulded pardon with the lining material, an overhang of the carrier portion material being separated along the edge of the carrier portion by shearing;
trimming the overhang of lining material by a trimming knife, which is integrated in the mufti-function tool, and which is operated separately from the shearing of the ~J
overhang of the carrier portion materials removing the lined carrier portion by opening the multi-function tool after consolidation of the carrier portion; and bending over the overhang of lining material around the edge of the moulded portion in a separate tool.
In accordance with another embodiment of the present invention there is provided in a method of manufacturing a lined moulded part comprising a dimensionally stable carrier portion and, connected therewith on a visible side, a decorative lining, in which a heated blank of a mat-shaped or plate-shaped semi-product of cellular materials containing binding agents is shaped to form the carrier portion in a cold tool, and is simultaneously connected to the lining, and in which the carrier portion is trimmed in a multi-function tool by means of shearing, and the lining is trimmed by trimming knives, in such a way that the lining forms an overhand which is capable of being bent over, the improvement comprising the steps of: inserting the lining material into the mult.i.-function tool with an averhang relative to the contour of the carrier portion, and peripherally clamping and securing along the contour of the carrier portion in such a way that the overhang of lining is angled to the surface position of the edge of the carrier portion; and trimming the lining material by a trimming knife integrated into the multi-function tool, and which is operated separately.
By virtue of the fact that the bending-over overhang of the lining material is clamped and secured after its insertion into the multi-function tool, in such a way that it is angled to the surface position of the carrier portion, i.e., peripherally along the contour of the caz~rier portion, this region in which the carrier portion must be trimmed during its manufacture, remains accessible, and the overhang of the lining remains protected. Use of a multi-function tool in which the lining material and the mat-shaped or panel-shaped semi-product is shaped and lined, and in which all trimming procedures are carried out on sate without transfer, gives rise to the advantage of a perfect adjustment of lining and carrier portion with specific bending-over material, so that the subsequent bending-over procedure may be effected in a mechanised manner.
The lining material in this case may be fed in as a raw blank, but also in the form of a strip withdrawn from a roll, in that case for example with the aid of clip chains.
Feed of the heated mat-shaped or panel-shaped semi-product for the carrier portion to be shaped may be effected in the same way and in the subsequent process Step in which the semi-produce is also shaped and connected to the lining material. In this respect the overhang of the carrier portion material is peripherally trimmed, e.g. by a conventional cutting edge (overrun cutter). Such a separating procedure is on the one hand independent of any thickness tolerance '~0 of the shaped carrier portion, and on the other hand the shearing forces are fully supported on the lower tool, and do not stress the bending-over overhang of the lining. As the lateral region of the carrier portion in the method according to the invention is directly accessible, no constructive difficulties arise in the design of the trimming cutting edge.
The third process step includes the final trimming of the lining to the bending-over dimensions, by means of a rotating trimming knife which is integrated into the mufti-function tool, and which may be operated separately. The advantages of combination of all the method steps up to the actual ~~bending-over9~ in a single mufti-function tool have already been stated as regards the overall outlay and tool and manufacturing precision. zn a fourth method step, which terminates the manufacture of the moulded part., the moulded part, after it has cooled and has thus become dimensionally stable, is removed from the mufti-function tool, transferred into a conventional bending-over tool, in which the overhang of the lining is adhered about the edge of the moulded part (is bent aver).
Thus the method according to the invention enables lined moulded parts to be produced in the one-shot process in an advantageous way, and to be "bent-over~~
in a proven fashion, and at only a slight added expenditure for the mufti-functian tool.
Separate lining using environmentally-unfriendly solvents can be eliminated.
The method according to the invention can be advantageously further developed in that the moulded part may be provided with punched apertures simultaneously with the bending-over procedure in the bending-over tool, fox' example for door handles, ash-trays or similar components which are to be applied. Thus transfer and manufacturing time can be economised.
In the case of complex shaping and/or sensitive lining materials, these may be used in a pre-shaped form in areas and/or by approximation. The range of application of the method according to the invention can thus be considerably extended. Lining materials which are capable of deep-drawing may naturally also be pre-shaped directly in the multi-function tool. fhe peripheral securing, after heating the lining material in a known way, permits vacuum deep-drawing directly in the mult.i-function tool, when its cavity is designed to be evacuated, a feature which provides no problems.
The application of additional components to the rear side, such as clips and retainers, is possible along with the shaping of the carrier portion. The adhesive attachment of these components is possible either by means of binders intrinsic to carrier portion or also by the use of auxiliary adhesives, for example hot-melt adhesives.
An appropriate multi-function tanl for carrying out the method usable in a vertical press, comprises a base plate 1 which is blocked stationary with the aid of the distance sleeves 4 of the clamp ring ~, further comprising the lower tool 6 which is movable with the aid of the lifting device l~
towards the clamp ring 3, the lower gaol 6 including a trimming knife, which may be aperated separately by means of the lifting device.
It further comprises the head plate 2 with the upper tool 5, the stroke-restricting stop means 12 and centering bolts 10, the range of penetration (C in Figure 5) of the upper tool 6 inta the clamp ring 3 being in the form of a cutting edge.
Such a construction is easily monitored and serviced.
Even vacuum deep-drawing of the lining material may be integrated into this tool just as simply as transport members, by means of which the lining and/or carrier portion materials may be fed in strip form.
The invention is naw e~cplained and described in more detail with references to Figures 1 - ~, which show:
Figures 1 - 6: the functional sequence in steps of the multi-function tool in a cross-sectional view through the lateral area of the tool;
Figures 4 - 6: according to an enlarged partial detail of Figures 1 - 3, the shearing and trimming sequence in the case of carrier portion and lining.
In Figure 1 the base plate is indicated by 1., the top plate by 2. With the aid of these plates, between which all the components of thp mufti-function tool are m located, the tool is clamped in a simply-operating vertical press. Blocked stationary by means of distance sleeves 4, there is the clamp ring 3, which carries on its upper side the centering bolts 10 and the stroke-restricting stop means 12, and which is formed in the region "C" as a cutting edge. The lower tool 6, which presents the visible side of the moulded part, may be moved up and down with the aid of the lifting device 11. The trimming knife 7, which is movable up and down separately by the lifting device 8, is an integral component of the lower tool 6; in its inoperative position tshown in Figures 1 - 3) it follows the lifting movements thereof.
The upper tool 5 is secured to the upper plate 2.
During the press stroke, its area "C" operates along with the corresponding area of the clamp ring 3 as a cutting edge for tximming the material of the carrier portion 15. The arrows in Figure 1 indicate these possible movements of the corresponding components.
Figure 1 shows the state of the tool after insertion of the lining material 1~.
Figure 2, with the same nomenclature of the components, shows how, by means of the upper movement of the lower tool 6 in the direction of the arrow, the lining material 1~ is clamped and ~;ecured between the clamp ring 3 and lower tool 6, and the heated mat-shaped material 15 far the carrier portion is inserted.
Figure 3 shows the upper tool 5, moved by the press stroke in the direction of the arrow into its final position defined by the stops 12. The carrier portion is shaped and lined on its visible side. The overhang of the carrier portion material ~5~ is separated by shearing; the bending-over trimming of the lining material 14 has not yet been carried out.
Figures 4 - 6 are enlarged details of Figure 3, in which are shown the shearing-off of the overhang of the carrier portion material 15, and trimming of the lining material 14. In this case the components are supplied with the same numbers as in Figures 1 -3, and the respective directions of movement are indicated by arrows.
Figure 4 illustrates the start of the shearing procedure in the carrier portion material 15, which has not yet been shaped into the carrier portion. The mutual operation of the cutting edges can be seen, and also the fact that the bending-over region of the lining material 14 is not mechanically stressed by the shearing procedure.
In the illustration in Figure 5, the shearing procedure is terminated, and the overhang 15' of the carrier portion material 15 is separated. The semi-product 15 is shaped to form the Linished carrier portion 15'~
(and finally compressed, as a semi-product capable of compression form the basis of these illustrations).
Finally, Figure 6 shows the final tri~riming of the lining material 15, by means of which the bending-over area «B~~ is specifically shown, by means of the downward movement o.f the trimming knife '7 in the direction of the arrow. The trimming waste 1.4°, which is not required, is in this case cut off.
Figures 1 - ~ explain a construction by way of example of a multi-function tool according to the invention;
variations, for example the application of replaceable cutting edges and cutting strips on the components 3 and 5, are likewise possible, as are different geometries, by means of which the method according to the invention may be realised.
The invention relates to a method of manufacturing a laminated moulded part having a carrier portion and a lining material and to a tool for carrying out this method.
Shaping of mixtures of polypropylene and wood particles is known in the expert world by the title HMPP (wood flour polypropylene). In this case the material mixture is produced in panel form by extrusion (if necessary with additional calenderingy, the wall thickness of the panels corresponding to the thickness of the later moulded part.
These HMPP panels are heated, preferably by radiant heating, to the softening temperature of the polypropylene, and thereafter shaped to form the respectively required moulded part by means of shaping processes known per se such as vacuum deep-drawing, pressing in a tool comprising male and female mould parts or the like. In this case the tool temperatures lie below the softening temperature of the polypropylene, so that the material cools during shaping and the moulded part can be removed in a dimensionally stable manner from the tool.
There is described in DE-OS 2~ 95 117 a method of producing panel material, which may be pressed to form moulded parts, of cellulose-containing material and at least one thermoplastic binding agent, the cellulose-containing material and the thermapl~st:ic binder being mixed, and the mixture being shaped into the panel material in a heated condition. The method is characterised in that the cellulose-containing material is pulped to provide fibrous material. and mixed with the thermoplastic binders, a fleece being formed from the mixture and this fleece being compressed by the action of heat and pressure to form ~>anel material.
The aim in this case is to propose a method which permits the manufacture of panel material in a simple and cost-effective way, which is characterised by good homogeneity and mechanical properties, and which may be subjected to final pressing in a simple way in order to produce high-quality moulded parts.
Polyethylene, polypropylene, polyimide or the like may be used as thermoplastic binders, conventionally with a proportion by weight of more than 40'x, preferably 50 -605. The high proportion of therrnopl.astic binders is feasible for reasons of cost and technology (softening temperature) in present prior art on1_y with. the use of polypropylene. Subsequent lining of the moulded parts in one working procedure along with shaping is the aim.
In this case however the lining cannot be unbent overdo i.e. laid around the edge of the moulded part, a factor which severely restricts the range of application of the moulded parts, and thus also the range of application of the method proposed, In DE-OS 28 45 117 the following statement is made regarding this problem:
~~a further advantageous possibility ~_onsists ir.
connecting a surface layer, for example a film, preferably a textile layer (fleec~, textile, knitted fabric) with the moulded part before pressing. Because of the proportion of thermoplastic plastics in the moulded part, the surface layer is welded thereto during pressing in one operation. TY~us such layers may be directly laminated on to the moulded parts, or, for example, a carpet may be pressed on. As heating of the pressing tool is not necessary, and operation is frequently carried out even with cold pressed tools, the surface layer may be selected from an optional number of types and may even comprise a thermoplastic film, which would :immediately melt in a hot press tool r~ .
Bending over during the one~shot process was regarded as impossible for two reasons;
1. Trimming of a moulded part durin~~ or after pressing and lamination had to be effected "oz-i the linings, as an overhang of the lining is requires: for bending over;
in view of the normal manufacturing thickness tolerances of the carrier portions, this was not regarded as feasible, and 2. the previously necessary content of more than 50~
by weight of thermoplastic binders, rxbove all when polypropylene is used as a ~.~inder, renders difficult adhesion of the bent-over portion of the edge by the action of parting compounds.
Proceeding from this point the purpose underlying the present invention is to indicate a method of the type already described, by means of which bent-over lined moulded parts may also be produced in the one-shat process, and to indicate a mufti-function foal for carrying out the method.
In accordance with an embodiment: of. the present invention there is provided a method of manufacturing a laminated moulded part, comprising a dimensionally stable carrier portion and, connected therewith on a visible side, a decorative lining material, in which a heated blank of a mat-shaped or panel-shaped semi-product comprising cellular material containing binding agents is shaped in a cold tool to form a carrier portion, and is simultaneously connected to the lining layer, the method comprising the steps of:
inserting the lining material into a mufti-function tool with an overhang relative to the contour of the carrier portion, the lining material being clamped and secured peripherally along the contour C>f the carrier portion such that the overhang of the lining material is angled to a surface position of an edge of the carri.~~r portion inserting the heated mat-shaped or plate-shaped material of the carrier portion into the mufti-function tool and shaping by closing the tool, t~~e heated mat-shaped or plate-shaped material of the carrier portion is connected in the region of the surface of the moulded pardon with the lining material, an overhang of the carrier portion material being separated along the edge of the carrier portion by shearing;
trimming the overhang of lining material by a trimming knife, which is integrated in the mufti-function tool, and which is operated separately from the shearing of the ~J
overhang of the carrier portion materials removing the lined carrier portion by opening the multi-function tool after consolidation of the carrier portion; and bending over the overhang of lining material around the edge of the moulded portion in a separate tool.
In accordance with another embodiment of the present invention there is provided in a method of manufacturing a lined moulded part comprising a dimensionally stable carrier portion and, connected therewith on a visible side, a decorative lining, in which a heated blank of a mat-shaped or plate-shaped semi-product of cellular materials containing binding agents is shaped to form the carrier portion in a cold tool, and is simultaneously connected to the lining, and in which the carrier portion is trimmed in a multi-function tool by means of shearing, and the lining is trimmed by trimming knives, in such a way that the lining forms an overhand which is capable of being bent over, the improvement comprising the steps of: inserting the lining material into the mult.i.-function tool with an averhang relative to the contour of the carrier portion, and peripherally clamping and securing along the contour of the carrier portion in such a way that the overhang of lining is angled to the surface position of the edge of the carrier portion; and trimming the lining material by a trimming knife integrated into the multi-function tool, and which is operated separately.
By virtue of the fact that the bending-over overhang of the lining material is clamped and secured after its insertion into the multi-function tool, in such a way that it is angled to the surface position of the carrier portion, i.e., peripherally along the contour of the caz~rier portion, this region in which the carrier portion must be trimmed during its manufacture, remains accessible, and the overhang of the lining remains protected. Use of a multi-function tool in which the lining material and the mat-shaped or panel-shaped semi-product is shaped and lined, and in which all trimming procedures are carried out on sate without transfer, gives rise to the advantage of a perfect adjustment of lining and carrier portion with specific bending-over material, so that the subsequent bending-over procedure may be effected in a mechanised manner.
The lining material in this case may be fed in as a raw blank, but also in the form of a strip withdrawn from a roll, in that case for example with the aid of clip chains.
Feed of the heated mat-shaped or panel-shaped semi-product for the carrier portion to be shaped may be effected in the same way and in the subsequent process Step in which the semi-produce is also shaped and connected to the lining material. In this respect the overhang of the carrier portion material is peripherally trimmed, e.g. by a conventional cutting edge (overrun cutter). Such a separating procedure is on the one hand independent of any thickness tolerance '~0 of the shaped carrier portion, and on the other hand the shearing forces are fully supported on the lower tool, and do not stress the bending-over overhang of the lining. As the lateral region of the carrier portion in the method according to the invention is directly accessible, no constructive difficulties arise in the design of the trimming cutting edge.
The third process step includes the final trimming of the lining to the bending-over dimensions, by means of a rotating trimming knife which is integrated into the mufti-function tool, and which may be operated separately. The advantages of combination of all the method steps up to the actual ~~bending-over9~ in a single mufti-function tool have already been stated as regards the overall outlay and tool and manufacturing precision. zn a fourth method step, which terminates the manufacture of the moulded part., the moulded part, after it has cooled and has thus become dimensionally stable, is removed from the mufti-function tool, transferred into a conventional bending-over tool, in which the overhang of the lining is adhered about the edge of the moulded part (is bent aver).
Thus the method according to the invention enables lined moulded parts to be produced in the one-shot process in an advantageous way, and to be "bent-over~~
in a proven fashion, and at only a slight added expenditure for the mufti-functian tool.
Separate lining using environmentally-unfriendly solvents can be eliminated.
The method according to the invention can be advantageously further developed in that the moulded part may be provided with punched apertures simultaneously with the bending-over procedure in the bending-over tool, fox' example for door handles, ash-trays or similar components which are to be applied. Thus transfer and manufacturing time can be economised.
In the case of complex shaping and/or sensitive lining materials, these may be used in a pre-shaped form in areas and/or by approximation. The range of application of the method according to the invention can thus be considerably extended. Lining materials which are capable of deep-drawing may naturally also be pre-shaped directly in the multi-function tool. fhe peripheral securing, after heating the lining material in a known way, permits vacuum deep-drawing directly in the mult.i-function tool, when its cavity is designed to be evacuated, a feature which provides no problems.
The application of additional components to the rear side, such as clips and retainers, is possible along with the shaping of the carrier portion. The adhesive attachment of these components is possible either by means of binders intrinsic to carrier portion or also by the use of auxiliary adhesives, for example hot-melt adhesives.
An appropriate multi-function tanl for carrying out the method usable in a vertical press, comprises a base plate 1 which is blocked stationary with the aid of the distance sleeves 4 of the clamp ring ~, further comprising the lower tool 6 which is movable with the aid of the lifting device l~
towards the clamp ring 3, the lower gaol 6 including a trimming knife, which may be aperated separately by means of the lifting device.
It further comprises the head plate 2 with the upper tool 5, the stroke-restricting stop means 12 and centering bolts 10, the range of penetration (C in Figure 5) of the upper tool 6 inta the clamp ring 3 being in the form of a cutting edge.
Such a construction is easily monitored and serviced.
Even vacuum deep-drawing of the lining material may be integrated into this tool just as simply as transport members, by means of which the lining and/or carrier portion materials may be fed in strip form.
The invention is naw e~cplained and described in more detail with references to Figures 1 - ~, which show:
Figures 1 - 6: the functional sequence in steps of the multi-function tool in a cross-sectional view through the lateral area of the tool;
Figures 4 - 6: according to an enlarged partial detail of Figures 1 - 3, the shearing and trimming sequence in the case of carrier portion and lining.
In Figure 1 the base plate is indicated by 1., the top plate by 2. With the aid of these plates, between which all the components of thp mufti-function tool are m located, the tool is clamped in a simply-operating vertical press. Blocked stationary by means of distance sleeves 4, there is the clamp ring 3, which carries on its upper side the centering bolts 10 and the stroke-restricting stop means 12, and which is formed in the region "C" as a cutting edge. The lower tool 6, which presents the visible side of the moulded part, may be moved up and down with the aid of the lifting device 11. The trimming knife 7, which is movable up and down separately by the lifting device 8, is an integral component of the lower tool 6; in its inoperative position tshown in Figures 1 - 3) it follows the lifting movements thereof.
The upper tool 5 is secured to the upper plate 2.
During the press stroke, its area "C" operates along with the corresponding area of the clamp ring 3 as a cutting edge for tximming the material of the carrier portion 15. The arrows in Figure 1 indicate these possible movements of the corresponding components.
Figure 1 shows the state of the tool after insertion of the lining material 1~.
Figure 2, with the same nomenclature of the components, shows how, by means of the upper movement of the lower tool 6 in the direction of the arrow, the lining material 1~ is clamped and ~;ecured between the clamp ring 3 and lower tool 6, and the heated mat-shaped material 15 far the carrier portion is inserted.
Figure 3 shows the upper tool 5, moved by the press stroke in the direction of the arrow into its final position defined by the stops 12. The carrier portion is shaped and lined on its visible side. The overhang of the carrier portion material ~5~ is separated by shearing; the bending-over trimming of the lining material 14 has not yet been carried out.
Figures 4 - 6 are enlarged details of Figure 3, in which are shown the shearing-off of the overhang of the carrier portion material 15, and trimming of the lining material 14. In this case the components are supplied with the same numbers as in Figures 1 -3, and the respective directions of movement are indicated by arrows.
Figure 4 illustrates the start of the shearing procedure in the carrier portion material 15, which has not yet been shaped into the carrier portion. The mutual operation of the cutting edges can be seen, and also the fact that the bending-over region of the lining material 14 is not mechanically stressed by the shearing procedure.
In the illustration in Figure 5, the shearing procedure is terminated, and the overhang 15' of the carrier portion material 15 is separated. The semi-product 15 is shaped to form the Linished carrier portion 15'~
(and finally compressed, as a semi-product capable of compression form the basis of these illustrations).
Finally, Figure 6 shows the final tri~riming of the lining material 15, by means of which the bending-over area «B~~ is specifically shown, by means of the downward movement o.f the trimming knife '7 in the direction of the arrow. The trimming waste 1.4°, which is not required, is in this case cut off.
Figures 1 - ~ explain a construction by way of example of a multi-function tool according to the invention;
variations, for example the application of replaceable cutting edges and cutting strips on the components 3 and 5, are likewise possible, as are different geometries, by means of which the method according to the invention may be realised.
Claims (14)
1. A method of manufacturing a laminated moulded part, comprising a dimensionally stable carrier portion and, connected therewith on a visible side, a decorative lining material, in which a heated blank of a mat-shaped or panel-shaped semi-product comprising cellular material containing binding agents is shaped in a cold tool to form a carrier portion, and is simultaneously connected to the lining layer, the method comprising the steps of:
inserting the lining material into a multi-function tool with an overhang relative to the contour of the carrier portion, said lining material being clamped and secured peripherally along the contour of the carrier portion such that the overhang of the lining material is angled to a surface position of an edge of the carrier portion;
inserting the heated mat-shaped or plate-shaped material of the carrier portion into the multi-function tool and shaping by closing the tool, said heated mat-shaped or plate-shaped material of the carrier portion is connected in the region of the surface of the moulded portion with the lining material, an overhang of the carrier portion material being separated along the edge of the carrier portion by shearing;
trimming the overhang of lining material by a trimming knife, which is integrated in the multi-function tool, and which is operated separately from the shearing of the overhang of the carrier portion material;
removing the lined carrier portion by opening the multi-function tool after consolidation of the carrier portion; and bending over the overhang of lining material around the edge of the moulded portion in a separate tool.
inserting the lining material into a multi-function tool with an overhang relative to the contour of the carrier portion, said lining material being clamped and secured peripherally along the contour of the carrier portion such that the overhang of the lining material is angled to a surface position of an edge of the carrier portion;
inserting the heated mat-shaped or plate-shaped material of the carrier portion into the multi-function tool and shaping by closing the tool, said heated mat-shaped or plate-shaped material of the carrier portion is connected in the region of the surface of the moulded portion with the lining material, an overhang of the carrier portion material being separated along the edge of the carrier portion by shearing;
trimming the overhang of lining material by a trimming knife, which is integrated in the multi-function tool, and which is operated separately from the shearing of the overhang of the carrier portion material;
removing the lined carrier portion by opening the multi-function tool after consolidation of the carrier portion; and bending over the overhang of lining material around the edge of the moulded portion in a separate tool.
2. The method according to claim 1, wherein the moulded part is provided with punched apertures simultaneously with the bending-over step.
3. The method according to claim 1 or 2, wherein the lining material is pre-shaped in sections and/or by approximation.
4. The method according to claim 1 or 2, wherein the lining material, after being secured, is pre-shaped in the multi-function tool.
5. The method according to claim 1 or 2, wherein in the same press stroke with shaping of the carrier portion and its lining, constructive components are attached and adhesively secured to a rear side of the carrier portion.
6. The method according to any one of claims 1 to 5, wherein the overhang of lining material is angled relative to the surface position of the dge of the carrier portion by approximation in the direction of the normal of the surface.
7. The method according to any one of claims 1 to 6, wherein the heated mat-shaped or plate-shaped material of the carrier portion is inserted in strip form into the multi-function tool.
8. The method according to any one of claims 1 to 6, wherein the heated mat-shaped or plate-shaped material of the carrier portion is inserted into the multi-function tool as a blank.
9. The method according to claim 2, wherein the punching of apertures is carried out together with the bending over step in a bending-over tool
10. In a method of manufacturing a lined moulded part comprising a dimensionally stable carrier portion and, connected therewith on a visible side, a decorative lining material, in which a heated blank of a mat-shaped or plate-shaped semi-product of cellular materials containing binding agents is shaped to form the carrier portion in a cold tool, and is simultaneously connected to the lining, and in which the carrier portion is trimmed in a multi-function tool by means of shearing, and the lining is trimmed by trimming knives, in such a way that the lining forms an overhang which is capable of being bent over, the improvement comprising the steps of:
inserting the lining material into the multi-function tool with an overhang relative to the contour of the carrier portion, and peripherally clamping and securing along the contour of the carrier portion in such a way that the overhang of lining is angled to the surface position of the edge of the carrier portion; and trimming the lining material by a trimming knife integrated into the multi-function tool, and which is operated separately.
inserting the lining material into the multi-function tool with an overhang relative to the contour of the carrier portion, and peripherally clamping and securing along the contour of the carrier portion in such a way that the overhang of lining is angled to the surface position of the edge of the carrier portion; and trimming the lining material by a trimming knife integrated into the multi-function tool, and which is operated separately.
11. A mufti-function tool adapted for carrying out the method according to claim 1 and usable in a vertical press, comprising:
a base plate which is blocked stationarily with the aid of distance sleeves of a clamp ring, a lower tool movable with the aid of a lifting device towards the clamp ring, the lower tool including a trimming knife which is operable separately by means of the lifting device; and a top plate with an upper tool, a stroke limiting stop means and centring bolts, said upper tool having a range of penetration into the clamp ring in the form of a cutting edge.
a base plate which is blocked stationarily with the aid of distance sleeves of a clamp ring, a lower tool movable with the aid of a lifting device towards the clamp ring, the lower tool including a trimming knife which is operable separately by means of the lifting device; and a top plate with an upper tool, a stroke limiting stop means and centring bolts, said upper tool having a range of penetration into the clamp ring in the form of a cutting edge.
12. The method of any one of claims 1 to 10, wherein the moulded part is for internal trimming of a vehicle.
13. The method of any one of claims 1 to 10, wherein the lining material is a film or textile.
14. The method of claim 5, wherein the constructive components are restrainers or clips.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DEP4419908.2 | 1994-06-07 | ||
| DE4419908A DE4419908C2 (en) | 1994-06-07 | 1994-06-07 | Process for producing a laminated molded part |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2151090A1 CA2151090A1 (en) | 1995-12-08 |
| CA2151090C true CA2151090C (en) | 2003-08-12 |
Family
ID=6520014
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002151090A Expired - Fee Related CA2151090C (en) | 1994-06-07 | 1995-06-06 | Method of manufacturing a lined moulded part |
Country Status (5)
| Country | Link |
|---|---|
| EP (1) | EP0686476B1 (en) |
| JP (1) | JP2617900B2 (en) |
| CA (1) | CA2151090C (en) |
| DE (2) | DE4419908C2 (en) |
| ES (1) | ES2133617T3 (en) |
Families Citing this family (21)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB9708151D0 (en) * | 1996-12-04 | 1997-06-11 | Robobond Ltd | Method of forming ornamented plastics articles |
| DE29700524U1 (en) * | 1997-01-14 | 1997-05-07 | Helsa-Werke Helmut Sandler GmbH & Co. KG, 95482 Gefrees | Device for reducing or eliminating odorants, especially in new vehicles |
| US6136415A (en) * | 1997-05-27 | 2000-10-24 | R + S Technik Gmbh | Vehicle interior trim panel with a soft-touch foam layer, and a method and apparatus for making the same |
| DE19819134A1 (en) * | 1998-04-29 | 1999-11-11 | Behr Gmbh & Co Kg Erwin | Method for producing an interior fitting for vehicles and interior fitting manufactured thereafter |
| DE19949263A1 (en) * | 1999-10-13 | 2001-04-19 | Bayerische Motoren Werke Ag | Plastic component manufacturing process uses a single tool to produce a molded product from flat sheet |
| DE10059247A1 (en) * | 2000-11-29 | 2002-06-13 | Seeber Ag & Co | Fastening method for retainer on inside of internal panelling part for motor vehicle, uses two cooperating stops to urge retainer into adhesive applied to this part |
| ITVR20010132A1 (en) * | 2001-12-11 | 2003-06-11 | Isap Omv Group Spa | PROCESS AND EQUIPMENT FOR THE MOLD CUTTING OF THERMOFORMED OBJECTS REMOVABLE FROM THE MOLD WITHOUT WITHDRAWAL PLATE. |
| DE10315231B4 (en) * | 2003-04-03 | 2006-07-06 | Hero Kunststofftechnik Und Formenbau Gmbh | Apparatus and method for producing a decorative material preform |
| DE10329182B4 (en) * | 2003-06-27 | 2015-06-25 | Johnson Controls Interiors Gmbh & Co. Kg | Half shell, equipment part, method and device |
| DE10357386A1 (en) * | 2003-12-09 | 2005-07-14 | Peguform Gmbh & Co. Kg | Composite component with decorative layer and associated production method |
| FR2872083A1 (en) * | 2004-06-23 | 2005-12-30 | Peguform France Sa | METHOD FOR MANUFACTURING A VEHICLE PART BETWEEN A PUNCH AND A MATRIX |
| DE102004045399B4 (en) * | 2004-09-18 | 2007-11-22 | Faurecia Innenraum Systeme Gmbh | Method for producing a component from at least two layers and a device for carrying out the method |
| BRPI0515550A (en) * | 2004-09-18 | 2008-07-29 | Faurecia Innenraum Sys Gmbh | pressure molding tool as well as process for manufacturing a component through pressure molding |
| DE102004045398B3 (en) * | 2004-09-18 | 2006-05-04 | Faurecia Innenraum Systeme Gmbh | The press to bond and shape different layers, as a carrier and a decorative layer, has a clamping frame assembly and a cutter to trim a layer which projects through shaping distortion |
| DE102004045400B3 (en) * | 2004-09-18 | 2006-05-11 | Faurecia Innenraum Systeme Gmbh | The press to bond and shape different layers, as a carrier and a decorative layer, has a clamping frame assembly and a cutter to trim a layer which projects through shaping distortion |
| JP2006327043A (en) * | 2005-05-26 | 2006-12-07 | Kasai Kogyo Co Ltd | Manufacturing method of trim element for car |
| JP4737530B2 (en) * | 2005-11-02 | 2011-08-03 | 河西工業株式会社 | Manufacturing method for interior parts for automobiles |
| DE102005052913B3 (en) * | 2005-11-03 | 2007-03-15 | Illig Maschinenbau Gmbh & Co. Kg | Mold for forming containers from thermoplastic film, includes upper and lower mold parts, stretching aid and head and stretching aid plates fixed together to inhibit wear on incorporation in molding station |
| DE102006022040A1 (en) | 2006-05-08 | 2007-11-15 | Faurecia Innenraum Systeme Gmbh | Process for producing a laminated molding |
| NL2011625C2 (en) | 2013-10-16 | 2015-04-20 | Bosch Sprang Beheer B V | A THERMO FORM MACHINE, THERMO FORM MACHINE, AND METHOD FOR THERMO FORMING A PRODUCT. |
| CN111361074B (en) * | 2020-04-20 | 2022-03-04 | 南通力威模具制造有限公司 | Back-off forming and punching mechanism arranged in die |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB1111525A (en) * | 1964-06-18 | 1968-05-01 | Keyes Fibre Co | Thermoplastic coating of molded pulp |
| DE2010260A1 (en) * | 1970-03-05 | 1971-09-23 | Haeberle Hab O Mat | Deep drawing machine for hollow thermoplastics |
| DE2365895A1 (en) * | 1973-12-21 | 1977-05-12 | Kiss Consulting Eng | Continuous fibre mat moulding - by steaming double mat layer with intermediate core before stamping out and pressing |
| SE7905318L (en) * | 1978-06-28 | 1979-12-29 | Gor Applic Speciali Srl | PROCEDURE AND DEVICE FOR MANUFACTURE OF CASHED MATERIALS |
| DE2845117C2 (en) * | 1978-10-17 | 1985-03-07 | Casimir Kast Gmbh & Co Kg, 7562 Gernsbach | Process and plant for the production of sheet material which can be pressed into molded parts |
| DE3138442C2 (en) * | 1981-09-24 | 1984-01-26 | Günter Hans 1000 Berlin Kiss | Arrangement for lamination of molded parts |
| EP0127035B1 (en) * | 1983-05-25 | 1991-10-30 | Gustav Stange | Process for securely fixing the edge zone of a sheathing applied to a flat substrate, and apparatus therefor |
| IT1186919B (en) * | 1985-07-31 | 1987-12-16 | Gor Applic Speciali Srl | MOLD FOR COATING AND SPINNING OF PLASTIC PRODUCTS |
| JPS62257827A (en) * | 1986-05-02 | 1987-11-10 | Mitsubishi Monsanto Chem Co | Manufacture of molded product provided with rear boss |
| GB2195940B (en) * | 1986-10-03 | 1990-01-10 | Polistock Nv | A molding method for producing laminated panels and apparatus for carrying out the method |
| CH673253A5 (en) * | 1987-10-29 | 1990-02-28 | Automatisierte Werkzeuge Ag | |
| JPH02227236A (en) | 1989-02-28 | 1990-09-10 | Nissan Motor Co Ltd | Manufacture of trimming material |
| FR2644389B1 (en) * | 1989-03-16 | 1991-07-05 | Solvay | METHOD FOR ASSEMBLING BY MOLDING A RIGID DEFORMABLE SUPPORT AND A FLEXIBLE AND MOLDED DECORATIVE COATING FOR THEIR PRODUCTION |
| DE4417836C2 (en) * | 1994-05-20 | 1996-03-28 | Lignotock Gmbh | Process for the production of molded parts |
-
1994
- 1994-06-07 DE DE4419908A patent/DE4419908C2/en not_active Expired - Fee Related
-
1995
- 1995-05-19 EP EP95107729A patent/EP0686476B1/en not_active Expired - Lifetime
- 1995-05-19 DE DE59506452T patent/DE59506452D1/en not_active Expired - Fee Related
- 1995-05-19 ES ES95107729T patent/ES2133617T3/en not_active Expired - Lifetime
- 1995-06-06 CA CA002151090A patent/CA2151090C/en not_active Expired - Fee Related
- 1995-06-07 JP JP7163100A patent/JP2617900B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| DE4419908A1 (en) | 1995-12-14 |
| DE59506452D1 (en) | 1999-09-02 |
| JP2617900B2 (en) | 1997-06-04 |
| EP0686476A2 (en) | 1995-12-13 |
| EP0686476A3 (en) | 1996-06-05 |
| EP0686476B1 (en) | 1999-07-28 |
| ES2133617T3 (en) | 1999-09-16 |
| JPH07329164A (en) | 1995-12-19 |
| DE4419908C2 (en) | 1997-03-20 |
| CA2151090A1 (en) | 1995-12-08 |
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| EEER | Examination request | ||
| MKLA | Lapsed | ||
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Effective date: 20100607 |