CN104395060A - 用于制造具有至少一个粘附到其上的插入物的柔性外皮的方法 - Google Patents

用于制造具有至少一个粘附到其上的插入物的柔性外皮的方法 Download PDF

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Publication number
CN104395060A
CN104395060A CN201380033103.1A CN201380033103A CN104395060A CN 104395060 A CN104395060 A CN 104395060A CN 201380033103 A CN201380033103 A CN 201380033103A CN 104395060 A CN104395060 A CN 104395060A
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insert
cortex
back side
die surface
crust
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CN201380033103.1A
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CN104395060B (zh
Inventor
彼得·德怀尔德
让-克里斯托夫·布凯尔特
菲利佩·德斯威夫
弗兰克·德伦斯
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Recticel Automobilsysteme GmbH
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Recticel Automobilsysteme GmbH
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    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract

本发明涉及一种用于制造柔性外皮(1)的方法，所述柔性外皮(1)具有至少一个粘附到其上的插入物(2)。在第一步骤中，外皮在模具表面(6)上被模制。为了将插入物(2)粘附到外皮(1)，首先在外皮中制造开口(13)，开口(13)提供通向插入物(2)的背面(14)的通道。插入物被定位为使其背面紧贴外皮(1)的正面(12)，并且粘附层(17)被设置，粘附层(17)粘附地连接至包围皮层中的开口(13)的皮层(1)背面(18)并且穿过所述开口(13)被粘附地连接至插入物(2)的背面(14)。优选地通过施加可硬化材料层来产生粘附层(17)，所述可硬化材料尤其为可固化合成物。因为插入物(2)的背面(14)接合外皮(1)的正侧(12)，避免了可硬化材料渗透到插入物的正面(24)。

Description

用于制造具有至少一个粘附到其上的插入物的柔性外皮的方法
技术领域
本发明涉及一种用于制造柔性外皮的方法，所述柔性外皮具有至少一个粘附其上的插入物，
所述柔性外皮和所述插入物一起限定出可视正表面；所述柔性外皮由一个或多个皮层构成并且具有正面和背面，所述柔性外皮的正面形成了外皮的可视正表面的第一部分；并且
所述插入物具有背面和正面，所述插入物的背面利用粘附层固定到所述柔性外皮，所述插入物的正面形成了所述可视正表面的第二部分，所述第二部分被布置成邻接所述可视正表面的第一部分。
具有粘附到其上的插入物的柔性外皮通过包括以下相继步骤的方法来制造：
-提供模具表面；
-贴紧所述模具表面模制至少一个所述皮层，所述模具表面具有凸起部分，使得在紧贴模具表面模制的柔性皮层的正面中产生凹入部分；
-将模制的皮层从模具表面移除；
-将所述插入物布置在所述凹入部分中，并且使所述插入物的背面的一部分紧贴模制的皮层；以及
-利用粘附层将插入物的背面粘附到模制的皮层上。
背景技术
这种方法在WO 2010/003915中公开。在所述方法中，通过将可固化聚氨酯合成物喷射到模具表面上来模制皮层。硅树脂模具表面元件被布置在模具表面上的直立边缘之间以限定凸起的模具表面部分。可固化聚氨酯合成物被喷射到模具表面上的连续层中，包括模具表面的由硅树脂模具表面元件限定的部分。因此，在皮层的正面中获得了完全封闭的凸起部分。利用在插入物的背面和皮层的正面之间产生粘附泡沫层的发泡反应混合物将插入物固定到皮层的所述凸起部分中。
该现有技术的方法的优点是插入物不必被定位在用于模制皮层的被加热的模具中并且能够在皮层和插入物的可视表面之间实现间隙自由的连接。在其它现有技术的方法中，例如在WO 02/09977中公开的方法中，插入物实际上在可固化聚氨酯合成物被喷射在所述模具表面之前被定位在被加热模具的模具表面上的直立边缘之间并且被定位在插入物的背面上，以产生具有粘附到其正面的插入物的柔性外皮。所述方法的缺点是紧贴模具表面上的直立边缘的插入物的密封通常由于插入物的尺寸公差(例如，由于被加热模具表面上的插入物的温度增加)而不完美，使得具有较低粘度以便可喷射的可固化聚氨酯合成物能够渗透到直立边缘和插入物的侧面之间。在插入物不被定位在模具表面的水平部分上时尤其如此。所述方法的另一缺点是插入物和皮层的围绕部分之间一直存在间隙。这种间隙能够通过去除模具表面上的直立边缘来避免。例如在US 4 810 452中公开方法的方法中，在该方法中，由于与插入物的侧面接合的直立边缘的存在，导致甚至更难避免可固化聚氨酯合成物渗透到插入物的可视正面上。
DE 103 50 050公开了一种用于在柔性外皮中集成插入物的方法，其中，能够被获得插入物和围绕其的柔性外皮之间的间隙自由过渡。柔性外皮在所述方法中通过热成形工艺来制造，其中，热塑性箔片紧贴被加热模具表面被深拉。插入物在其背面上设置有销，销突出穿过待粘附到背面泡沫层的柔性外皮中的孔。因为模具表面不具有将插入物保持在位的直立边缘，难以将插入物正确地定位在模具中并且难以避免插入物在热成形过程期间移位。插入物还能够在将所述箔片定位在模具之前首先利用其位于孔中的销被固定到热塑性箔片中。然后，热塑性箔片紧贴插入物的背部被模制/热成形，以形成容纳有插入物的凹入部分。所需的压力通过紧贴热塑性箔片的背部注射的发泡合成物或通过真空牵拉被施加到热塑性箔片上。所述方法的缺点是，插入物同样应当被加热以能够使热塑性箔片精确地沿插入物的侧面的方式进行热形成或换而言之以实现外皮的正表面和插入物的正侧之间的性质过渡(qualitative transition)。然而，许多插入物不能够被加热到这种温度。
如上文已经阐明的，皮层的正面和插入物的可视侧之间的间隙自由的连接还能够通过WO 2010/003915中公开的方法实现，其中，插入物通过凹入部分中的粘附泡沫层被粘附到皮层的正面中。因为所述粘附泡沫层由发泡反应产生并且因为封闭的腔(所述封闭的腔必须被粘附泡沫完全充满)在插入物侧的背面和外皮的正面之间形成，所以存在产生的泡沫由于由发泡反应产生的压力而渗透到插入物的侧边和柔性外皮之间的重大风险。此外，当在外皮的凹入部分中或插入物的背面上施加粘附泡沫时，仍存在弄脏柔性外皮的可视正面的风险。
发明内容
本发明的目标在于提供一种用于制造柔性外皮的方法，所述柔性外皮具有至少一个粘附到其上的插入物，所述方法能够实现插入物的可视侧和外皮的正面之间的间隙自由的连接，并且所述方法避免了可固化合成物朝插入物的正面渗透。
为了实现这一目标，本发明的方法的特征在于
皮层设置有至少一个开口，所述开口提供通向所述插入物的背面的通道；并且
在将所述插入物定位为使其背面的一部分紧贴所述皮层的正面之后，通过以如下方式设置的所述粘附层来将所述插入物的背面粘附到所述皮层：所述粘附层粘附地连接至所述皮层的背面的包围所述皮层中的开口的至少一部分上，并且所述粘附层穿过所述开口而被粘附地连接至所述插入物的背面的至少一部分上，所述粘附层所述插入物的背面之上和所述皮层的背面之上延伸以将所述插入物粘附到所述皮层。
所述粘附层能够由粘接到所述插入物的背面和所述皮层的背面的粘附条形成。由于所述皮层的有限厚度，所述插入物能够通过所述胶布被强力地固定到所述外皮。
然而，在优选实施例中，通过将一层可硬化材料层施加到所述插入物的背面和所述皮层的背面上并且允许所述可硬化材料层硬化来产生所述粘附层，所述可硬化材料尤其为熔化的热塑性材料或可固化合成物。
因为可硬化材料未被施加在插入物和外皮之间的封闭的腔中(如WO 2010/003915中的情况)，并且因为皮层以围绕该皮层的提供通向插入物的背面的开口的方式覆盖所述背面，不存在可硬化材料的部分可以沿插入物的侧朝其正面渗透的风险。此外，因为插入物被定位在柔性皮层的凹入部分中，插入物的尺寸能够被设置为恰好安装到该凹入部分中，以实现外皮的正面和插入物的可视侧之间的间隙自由的连接。当然，插入物的尺寸还能够被设置为实现外皮和插入物的正面之间的预定间隙。按照相同的方式，通过插入物的背面和皮层的包围皮层中的开口并接合插入物的背面的部分之间的密封接触来避免可硬化材料渗透到所述间隙中。因为插入物和外皮之间的粘附仅在外皮的背侧上可视并且不穿过插入物和外皮之间的任何间隙(如WO 02/09977中的情况)，在视觉上在外皮的可视侧处将插入物完美地集成到外皮中。
在本发明的方法的优选实施例中，用于产生粘附层的可硬化材料被浇注或喷射到插入物的背面和皮层的背面上，可硬化材料优选地为可固化合成物。
正如所述方法，没有用于将可硬化材料施加到插入物的背侧上的压力被施加到可硬化材料上，使得即使在使用具有较低粘度(尤其是为了可喷射)可固化合成物时，可硬化材料不会或仅最小程度地在皮层的与插入物的背面接合并围绕皮层中开口的部分之间渗透。
在本发明的方法的另一实施例中，用于产生粘附层的可硬化材料被注射到紧贴插入物的背面的模腔中和皮层的背面上，所述可硬化材料尤其为根据反应注射模塑(reaction injection moulding，RIM)工艺被注射到模腔中的可固化合成物。
尽管压力在该实施例中被施加到可硬化材料上，可硬化材料将再次不会或仅最小程度地在皮层的与插入物的背面接合并围绕皮层中开口的部分之间渗透。实际上，由于皮层接合插入物的背面的部分围绕皮层中的开口事实，施加到可硬化材料上的任何压力将抵靠插入物的背面按压皮层并且将因此改进插入物和皮层之间的密封接触。
在本发明的方法中，模制所述皮层的模具表面具有凸起部分以在柔性外皮的正面中产生凹入部分，插入物被固定到所述凹入部分中。在将所述插入物以所述插入物的背面的所述部分紧贴所述皮层的方式定位在皮层的所述凹入部分中之前，将模具表面上产生的皮层从该模具表面移除。
所述方法的优点在于，插入物能够被容易地施加到皮层的凹入部分中。此外，所述方法能够在将插入物粘附到皮层之前对皮层进行质量控制，使得插入物不随着外皮报废而损失。
模具表面(皮层在模具表面上产生)的凸起部分优选地具有侧面，所述侧面显露出至少一个凹槽以在皮层上形成至少一个侧向突出部，所述侧向突出部尤其为柔性唇缘，所述侧向突出部突出到所述凹入部分中，所述插入物以与所述侧向突出部接合的方式被定位在所述凹入部分中。
该实施例的第一优点是，插入物能够容易地被正确定位在外皮的凹入部分中。在插入物和外皮之间必须设置间隙的情况下，皮层上的侧向突出部使插入物被保持在距外皮的正面为所需距离处。另一优点是，该突出部在插入物和外皮之间的间隙中形成密封，从而避免了可固化合成物在插入物和外皮之间的任何渗透并且遮蔽了可能在所述这两个元件之间渗透的任何少量的可硬化材料。最后，该实施例还减小了插入物和外皮之间的间隙的可视深度。
在根据本发明的方法中，衬底层优选地被施加到所述粘附层的背部上，并且优选地在所述粘附层和所述衬底层之间产生居间泡沫层以将所述粘附层固定到所述衬底层，从而产生自支撑部件，自支撑部件尤其为用于汽车的装饰部件。
本发明还涉及通过本发明的方法制造的柔性外皮，所述柔性外皮具有一个或多个粘附到其上的插入物(尤其是位于外皮的凹入部分中)。
附图说明
通过以下对根据本发明的方法和具有插入物的柔性外皮的一些具体实施例的说明，本发明的其它细节和优点中将变得更为清楚。本说明书中使用的附图标记涉及到以下附图，在附图中：
图1示意性地示出了根据本发明的第一实施例的方法的步骤；
图2示意性地示出了根据本发明的第一替代性方法的步骤；
图3示意性地示出了根据本发明的第二替代性方法的步骤；以及
图4示意性地示出了根据本发明的第三替代性方法的步骤。
具体实施方式
本发明通常涉及一种用于制造柔性外皮1的方法，柔性外皮1具有粘附到其上的至少一个插入物2。插入物2尤其为预先制造的插入物，所述插入物2可以由美化元件(例如，皮革、纺织物、木材等)或功能元件(例如，开关、电子元件、照明元件等)或它们的组合构成。柔性外皮1和粘附到其上的插入物尤其用于形成汽车内部的装饰部件3，尤其是诸如仪表盘、车门、操纵台、贮物箱等的内部装饰部件。如图2G中能够看到的，除了柔性外皮1和插入物2之外，装饰部件3包括接合到外皮1的背侧的至少一个衬底层4或坚硬承载体，衬底层4或坚硬承载体通常通过居间的泡沫层5接合到外皮1的背侧。衬底层4给予装饰部件自支撑能力。
柔性外皮1可以为热塑性外皮或箔片，尤其为诸如热塑性聚烯烃(TPO)、聚氟乙烯(PVC)或EV外皮之类的热塑性弹性体(thermoplastic elastomer，TPE)外皮。这种热塑性外皮能够通过热成形工艺或例如搪塑工艺来模制。柔性外皮1还能够从至少一个可固化合成物(尤其是，至少一个可固化聚氨酯合成物)开始制造。所述可固化合成物为可流动材料，可流动材料被施加到模具表面6上并且被允许在该模具表面上固化以产生外皮1或外皮1的层中的一层。
可通过紧贴开口模具7的表面6的喷射工艺来施加可固化合成物或可固化合成物能够被施加到封闭模具中(尤其是被浇注，但是优选地，根据反应注射模塑(reaction injection moulding，RIM)过程被注射)。可使用光稳定的有色聚氨酯(PU)反应混合物。可参考通过引用的方式合并到本文的EP-B-0 303 305，EP-B-0 379 246，WO 98/14492，EP-B-0 929 586以及WO 04/000905。
在一变形实施例中，水基或溶剂基的完成层(尤其是光稳定油漆或所谓的模内涂层)能够被用作紧贴模具表面的第一涂层。该油漆混合涂料与随后施加到其上的一层或多层弹性层一起构成了柔性外皮1。柔性外皮1还能够由各自由可固化合成物产生的两层或多层皮层制成(例如，在WO 2007/137623中描述的)。
优选地，柔性外皮1为弹性外皮。柔性外皮通常具有至少30％的伸长率(根据DIN/EN/ISO 527-3测量)，伸长率优选为至少50％。其弯曲模量优选地小于100MPa(根据ASTM D790-03测量)、更优选地小于75MPa并且最优选地低于55MPa或甚至低于40MPa。通常，柔性外皮的整体密度大于300Kg/m3、优选地大于500kg/m3并且更优选地大于600kg/m3。
与柔性外皮1形成对比，衬底层4相对坚硬并且尤其具有高于500MPa的弯曲模量(根据ASTM D790测量)、所述弯曲模量优选地高于700MPa。尽管衬底层能够由热固性材料制成，例如由优选地通过玻璃纤维或玻璃纤维垫强化的聚氨酯材料制成，但是衬底优选地由热塑性材料制成，所述热塑性材料同样可被强化(尤其是通过玻璃纤维强化)。该热塑性材料优选地选自由聚氨酸酯(polycarbonate，PC)、丙烯腈·丁二烯·苯乙烯(acrylonitrile butadiene styrene，ABS)以及ABS共混物、苯乙烯顺丁烯二酸酐(styrene maleic anhydride，SMA)、聚苯醚(polyphenylene oxide，PPO)、热塑性烯烃(thermoplastic olefin，TPO)、聚缩醛、尼龙、聚酯、丙烯酸以及聚砜，其中，所述ABS共混物尤其为PC/ABS，所述热塑性烯烃尤其为聚丙烯(polypropylene，PP)，所述聚缩醛尤其为聚甲醛(polyoxymethylene，POM)。
衬底层4能够通过单步工艺形成在原位并紧贴外皮1的背部，尤其是开始于通过封闭模具中的结构RIM(Structural RIM，S-RIM)或强化RIM(ReinforcedRIM，R-RIM)工艺或通过开口模具中的喷射技术来施加坚硬PU系统(如在欧洲专利EP-B-0 642 411中公开的)，或衬底层4能够通过两步工艺来紧贴外皮1的背部。
根据本发明的方法的表征特征在于，一个或多个预制插入物2被集成到外皮1中的方式。该方法的第一实施例在图1中示出。
在图1A中示出的第一步骤中，柔性外皮1紧贴模具7的表面6被模制。模具表面6示出了直立边缘8，附加模具表面元件9被布置在直立边缘9之间以提供凸起模具表面部分10。按照这种方式，在外皮1的正面12中产生凹入部分11。附加模具表面元件9优选地为弹性的，使得附加模具表面元件9能够通过直立边缘8之间的一部分压力而被夹紧。附加模具表面元件优选地由硅树脂材料制成。举例而言，通过将可固化聚氨酯合成物喷射到该模具表面6和附加模具表面元件9上并且通过允许可固化聚氨酯合成物在其上固化来产生外皮。为了加速固化过程，该模具表面6优选地被加热到例如大约60℃或更高的温度。
在图1B中示出的第二步骤中，在外皮1中制造开口13(例如通过冲切)，开口13提供了通向插入物2的背面14的通道。开口13还可在该外皮被定位在模具表面上时或在外皮已经从模具表面移除之后被制造在外皮1中。
在下一步骤中，附加模具表面元件9被插入物2取代(参见图1C和1D)。该插入物2优选地同样被定位在直立边缘8之间。图1D中示出的插入物2由覆盖有织物覆盖件16的坚硬芯部15构成。
在已经检查了外皮1的质量之后，外皮1被重新定位在模具表面6上，借此将插入物2定位在外皮1的凹入部分11中。如图1D中能够看到的，插入物2的背面14的一部分在该步骤中被促使与外皮1的正面12(尤其是，与外皮1的正面12的包围外皮1中开口13的那部分)接合。如果该开口13还没有施加到外皮1中，仍可在外皮1已经被定位在插入物2的背部上时将该开口13施加到外皮1中。
在图1E中示出的下一步骤中，利用粘附层17将插入物2的背面14粘附到外皮1上。该粘附层17的施加能够通过简单地将粘附胶条粘到插入物2的背面14和外皮的背面上来进行。然而，在优选实施例中，通过将可硬化材料穿过外皮1中的开口13施加到插入物2的背面14的至少一部分上以及将可硬化材料施加到外皮1的背面18的包围该开口13的至少一部分上来产生该粘附层17。可硬化材料被施加到延伸遍布插入物2的背面14和外皮1的背面18的层中，使得粘附层17(在使可硬化材料硬化之后获得)在插入物2的背面14和外皮1的背面18上延伸并且覆盖外皮1和插入物2之间的边界，从而将插入物2粘附到外皮1。如图3中能够看到的，粘附层17不必覆盖插入物的整个背面14或外皮1的整个背面18。实际上，还能够利用仅沿插入物和外皮之间的边界在外皮的背面和插入物的背面延伸并且覆盖所述边界的粘附层17将该插入物2粘附到外皮1。外皮1中的开口13优选地由外皮中的孔形成，使得插入物2的背面14的穿过该孔而可及的部分完全被外皮1包围。
当可硬化材料被施加到插入物2的背面14和外皮1的背面18上时，插入物2的背面14的位于外皮1中开口13周围的部分接合外皮1的正面12。可硬化材料优选地被喷射或浇注到插入物和外皮的背面上。按照这种方式，插入物2的背面14不必以围绕整个开口13的方式接合外皮1的正面12，由于外皮1的遮蔽作用，可硬化材料将不会在插入物和外皮之间渗透或至多以有限的程度渗透，使得所述可硬化材料从正侧不可见。
如图4D所示，用于产生粘附层17的可硬化材料还能够被注射到封闭模具中。在那种情况下，优选地，利用模制工具19或通过由可硬化材料施加到外皮部分上的压力使该外皮的包围开口13的部分将开口13的整个周缘挤压到插入物2的背面上。
可硬化材料可以是在熔融状态下被施加到插入物的背部和外皮的背部上的热塑性材料。可硬化材料尤其可以是热熔胶。
可硬化材料还可以是如上文所述的用于外皮1的可固化合成物，更优选地为可固化聚氨酯合成物。可硬化材料能够被配制成产生大致非蜂窝状或微蜂窝状的粘附层，或替代性地，可添加发泡剂以产生发泡粘附层，所述发泡粘附层可具有背面泡沫层的作用。此外，可硬化材料还能够在硬化之后(尤其是，固化之后)产生能够充当坚硬衬底的较坚硬的材料。因此，可硬化材料(尤其是，上述的用于衬底层4的可固化合成物)能够被用于产生粘附层17。
粘附层17因此可以具有高于300kg/m3的平均密度、优选地该平均密度高于400kg/m3并且更优选地高于500kg/m3。然而，粘附层17的密度还能够被减小至更低的密度、尤其被减小至300kg/m3的密度、更尤其被减小至低于200kg/m3的密度。
本发明的方法的第二示例在图2中示出。在该示例中，外皮1由两层皮层构成，通过将第一可固化聚氨酯合成物施加到模具表面上来产生第一皮层1A并且通过将第二可固化聚氨酯合成物施加到第一皮层1A的背部上来产生第二皮层1B。第一可固化聚氨酯合成物优选地为脂肪族聚氨酯合成物，而第二可固化聚氨酯合成物优选地为芳香族聚氨酯合成物。如上所述，用于产生这种复合外皮1的适合的可固化聚氨酯合成物已在WO 2007/137623中描述。
在图2A中示出的第一步骤中，第一皮层1A被散布到模具表面6上。在该实施例中，模具表面6的凸起部分10由模具7自身形成并且不像如图1中那样由附加模具表面元件形成。在已经将第一皮层1A从模具表面6移除之后，插入物2被定位在第一皮层1A中(尤其是，被定位在该第一皮层1A的正面中的凹入部分11中)，并且第一皮层1A与包含在其中的插入物一起被定位到另一模具21的表面20上。如图2D和2E中能够看到的，除了模具的凸起表面部分10已经被消除以外，所述另一模具表面20与第一模具表面相对应，使得皮层1A能够被定位在所述另一模具表面20上，皮层1A的凹入部分11被插入物2填充。
在图2E中示出的下一步骤中，用于产生粘附层17的可固化合成物被喷射到第一皮层1A的背面上和插入物2的背面上。该粘附层17大致完全覆盖第一皮层1A的整个背面以形成第二皮层1B。在该情况下，用于产生粘附层17的可固化合成物因此由第二可固化聚氨酯合成物构成，第二皮层1B由第二可固化聚氨酯合成物产生。粘附层17因此由第二皮层1B形成。
形成粘附层的可固化合成物能够附加地包含发泡剂以减小粘附层的密度并且进而还减小第二皮层的密度。这种发泡的第二皮层还在WO 2007/137623中公开。发泡剂添加量能够使得粘附层起背面泡沫层的作用。
如上所述，第二可固化聚氨酯合成物优选地为芳香族聚氨酯合成物，所述芳香族聚氨酯合成物比第一皮层1A的脂肪族聚氨酯合成物的反应性更强。由于第二可固化聚氨酯合成物的更高的反应性，另一模具表面20的最高温度(即，另一模具表面20所达到的最高温度)可以低于在其上产生第一皮层1A的模具表面6的最高温度(即，模具表面6所达到的最高温度)。一个的重要优点是，对温度很敏感的插入物2能够被粘附到外皮1，因为插入物2仅被定位在另一模具表面20上。此外，外皮1和插入物2之间的过渡区域不受插入物和外皮之间可能的热膨胀差异的影响。
图2F和图2G示出了由柔性外皮1制造自支撑装饰部件3的可能的方式。这种部件的衬底层4被附接到上部模具部件23，发泡反应混合物在将模具21封闭之前被浇注到外皮1的背部上,或在已经将模具21、23封闭之后被注射到外皮2的背部和衬底层4之间，并且该发泡反应混合物被允许在封闭模具21、23中发泡和固化以产生居间泡沫层5，所述居间泡沫层5将衬底层4接合到外皮1的背部。
在图2中示出的方法中，插入物2被定位在皮层1B的凹入部分11中，使得插入物2的侧面接合外皮1的凹入部分11的侧面。换而言之，根据本发明的方法能够实现外皮1的正面12和插入物2的正面24之间的间隙自由过渡。
图3示出了所述方法的一个示例，该示例能够在插入物2(现在由一块木材或另一坚硬材料形成)的正面24和外皮1的正面12之间提供具有受控宽度(小的或大的)的间隙。在该方法中，模具表面6(第一皮层1B在模具表面6上产生)的凸起部分10具有侧面25，侧面25显露出凹槽26。按照这种方式，侧向突出部27(具体地，柔性唇缘)在外皮1的凹入部分11的侧面上形成。该突出部27以一距离突出到外皮1的凹入部分11中，该距离使得插入物2以与该侧向突出部27接合的方式被定位在该凹入部分11中。按照这种方式，插入物2自动地被正确定位在外皮1的凹入部分11中。
与图2中示出的方法的另一不同之处是，在图3中示出的方法中，用于产生第二皮层1B的第二可固化聚氨酯合成物在第一皮层1A已经在模具表面6上产生之后立即被施加到第一皮层1A的背部上。开口13随后被制造成穿过皮层1A和1B。如图3E所示，单独的可固化合成物然后被施加到外皮1和插入物2的背面上以按照如图1E中示出的相同的方式产生粘附层17。
图4示出了无需在外皮1中切开开口13的方法。这通过在模具表面6的凸起部分10上提供切断边缘28来实现。这种切断边缘28为具有尖锐顶部的直立边缘，使得喷射到该顶部上的可固化合成物被完全流走或具有仅非常小的厚度，使得能够容易地撕除任何超范围的喷射物。对于关于这种方法的进一步细节，参考WO 2007/023157。
图4D中示出了一种方法，其中，通过反应注射模塑(reaction injectionmoulding，RIM)工艺代替喷射或浇注方法来制造粘附层17。上部模制工具19被用于该工艺。该工具19优选地被定位在外皮1的背面18上，以形成位于插入物2后部的封闭模腔和外皮1的包围外皮1中的开口13的部分，所述开口13提供通向插入物2的背面14的通道。用于产生粘附层17的可固化合成物被注射到该封闭模腔中。
粘附层17能够被产生于仅在插入物的位置处支撑外皮的较小的模具部分中。插入物2于是能够被保持成使其背面14大致水平，使得用于产生粘附层17的可固化合成物能够更容易地被施加到插入物和外皮的背部上。
通过图4D中示出的RIM工艺，还能够在外皮1的整个背面18上产生粘附层17。这通过图2F中示出的RIM模具23完成。当粘附层17为柔性泡沫层时，因此形成用于提供轻柔接触的背面泡沫层。替代性地，粘附层17还能够为坚硬层，该坚硬层给予所述部件自支撑性并且该坚硬层因此形成衬底层4。

Claims (15)

1.一种用于制造柔性外皮(1)的方法，所述柔性外皮(1)具有至少一个粘附到其上的插入物(2)，
所述柔性外皮(1)和所述插入物(2)一起限定出可视正表面；
所述柔性外皮(1)由一个或多个皮层(1A，1B)构成并且具有正面(12)和背面(18)，所述柔性外皮(1)的正面(12)形成所述外皮(1)的可视正表面的第一部分；并且
所述插入物(2)具有背面(14)和正面(24)，所述插入物(2)的背面(14)利用粘附层(17)而被固定到所述柔性外皮(1)上，所述插入物(2)的正面(24)形成所述可视正表面的第二部分，所述第二部分布置成邻接所述可视正表面的所述第一部分，
所述方法包括以下相继步骤：
-提供模具表面(6)；
-紧贴所述模具表面(6)模制至少一个所述皮层(1，1A)，所述模具表面(6)具有凸起部分(10)，使得在紧贴所述模具表面(6)模制的柔性皮层(1，1A)的正面(12)中产生凹入部分(11)；
-将所述模制的皮层(1，1A)从所述模具表面(6)移除；
-将所述插入物(2)定位在所述凹入部分(11)中，使得所述插入物(2)的背面(14)的一部分紧贴所述模制的皮层(1，1A)；以及
-利用粘附层(17)将所述插入物(2)的背面(14)粘附到所述模制的皮层(1，1A)上，
其特征在于
在所述模具表面(6)上模制的所述皮层(1，1A)设置有至少一个开口(13)，所述开口(13)提供通向所述插入物(2)的背面(14)的通道；以及
在将所述插入物(2)定位为使其背面(14)的一部分紧贴所述皮层(1，1A)的正面(12)之后，通过以如下方式设置的所述粘附层(17)来将所述插入物(2)的背面(14)粘附到所述皮层(1，1A)：所述粘附层(17)粘附地连接至所述皮层(1，1A)的背面(18)的包围所述皮层(1，1A)中的开口(13)的至少一部分上，并且所述粘附层(17)穿过所述开口(13)而被粘附地连接至所述插入物(2)的背面(24)的至少一部分上，所述粘附层(17)在所述插入物(2)的背面(14)之上和所述皮层(1，1A)的背面(18)之上延伸以将所述插入物(2)粘附到所述皮层(1，1A)。
2.根据权利要求1所述的方法，其特征在于，通过将一层可硬化材料层施加到所述插入物(2)的背面(14)和所述皮层(1，1A)的背面(18)上并允许所述可硬化材料层硬化来产生所述粘附层(17)，所述可硬化材料尤其为熔化的热塑性材料或可固化合成物。
3.根据权利要求2所述的方法，其特征在于，所述可硬化材料被浇注或喷射到所述插入物(2)的背面(14)上和所述皮层(1，1A)的背面(18)上。
4.根据权利要求2所述的方法，其特征在于，所述可硬化材料被注射到紧贴所述插入物(2)的背面(14)的模腔中和所述皮层(1，1A)的背面(18)上，所述可硬化材料尤其为根据反应注射模塑(RIM)工艺被注射到所述模腔中的可固化合成物。
5.根据权利要求2至4中任一项所述的方法，其特征在于，所述可硬化材料为可固化聚氨酯合成物。
6.根据权利要求1所述的方法，其特征在于，通过将粘附条粘接到所述插入物(2)的背面(14)上和所述皮层(1，1A)的背面(18)上来产生所述粘附层(17)。
7.根据权利要求1至6中任一项所述的方法，其特征在于，当所述插入物(2)的背面(14)被粘附到所述皮层(1，1A)上时，所述皮层(1，1A)的正面(12)和所述插入物(2)的正面(24)被支撑在另一模具表面(20)上；所述插入物(2)在将所述皮层(1，1A)定位在所述模具表面(20)上之前首先被定位在所述另一模具表面(20)上，并借此将所述插入物(2)定位在所述皮层(1，1A)的所述凹入部分(11)中，或者所述插入物(2)在所述皮层(1，1A)被定位在所述另一模具表面(20)上之前就被定位在所述皮层(1，1A)的所述凹入部分(11)中。
8.根据权利要求1至6中任一项所述的方法，其特征在于，当所述插入物(2)的背面(14)被粘附到所述皮层(1，1A)上时，所述皮层(1，1A)的正面(12)和所述插入物(2)的正面(24)被支撑在所述模具表面(6)上；通过使所述模具表面(6)的一部分(10)局部地凸起来设置所述皮层(1，1A)的正面(12)中的所述凹入部分(11)，尤其通过将附加模具表面元件(9)定位在所述模具表面(6)上来设置所述皮层(1，1A)的正面(12)中的所述凹入部分(11)，并且，在所述皮层(1，1A)在所述模具表面(6)上被模制之后，随着尤其通过将所述附加模具表面元件(9)从所述模具表面(6)移除而导致的所述模具表面(6)的所述部分(10)的降低，所述皮层(1，1A)被从所述模具表面(6)上移除并且与所述插入物(2)一起被重新定位在所述模具表面(6)上以支撑所述皮层(1，1A)的所述凹入部分(11)中的所述插入物(2)，所述插入物(2)在将所述皮层(1，1A)定位在所述模具表面(6)之前被首先优选地定位在所述模具表面(6)的降低部分上，借此将所述插入物(2)定位在所述皮层(1，1A)的所述凹入部分(11)中。
9.根据权利要求8所述的方法，其特征在于，通过在所述模具表面(6)上的直立边缘(8)之间将附加模具表面元件(9)定位在所述模具表面(6)上而使得所述模具表面(6)的所述部分(10)凸起，所述附加模具表面元件(9)优选地被夹紧在所述直立边缘(8)之间。
10.根据权利要求1至9中任一项所述的方法，其特征在于，所述模具表面(6)的所述凸起部分(10)具有侧面(25)，所述侧面(25)显露出至少一个凹槽(26)以在所述皮层(1，1A)上形成至少一个侧向突出部(27)，所述侧向突出部(27)尤其为柔性唇缘，所述侧向突出部(27)突出到所述凹入部分(11)中，所述插入物(2)以与所述侧向突出部(27)接合的方式被定位在所述凹入部分(11)中。
11.根据权利要求1至10中任一项所述的方法，其特征在于，在将所述模制的皮层(1，1A)从所述模具表面(6)移除之前，通过将第一可固化聚氨酯合成物施加到所述模具表面(6)上并且允许所述第一可固化聚氨酯合成物固化以产生形成第一弹性聚氨酯皮层(1，1A)的所述皮层(1，1A)来模制所述皮层(1，1A)。
12.根据权利要求1至11中任一项所述的方法，其特征在于，所述柔性外皮(1)包括另一皮层(1B)，通过将第二可固化聚氨酯合成物施加到所述第一弹性皮层(1A)的背部上并且允许所述第二可固化聚氨酯合成物固化以产生第二弹性聚氨酯皮层(1B)来模制所述另一皮层(1B)。
13.根据权利要求12所述的方法，其特征在于，所述第二可固化聚氨酯合成物还被施加到所述插入物(2)的背面(14)的所述部分上，以在固化之后产生所述将所述插入物(2)粘附到所述皮层(1A)上的所述粘附层(17)。
14.根据权利要求1至13中任一项所述的方法，其特征在于，在已经将所述插入物(2)的背面(14)粘附到所述皮层(1，1A)上之后，衬底层(4)被结合到所述粘附层(17)的背部和所述外皮(1)的背部以产生自支撑部件，一方面，所述衬底层(4)优选地通过产生在所述粘附层(17)和所述外皮(1)之间的居间泡沫层(5)接合到所述粘附层(17)的背部和所述外皮(1)的背部，并且另一方面，所述衬底层(4)将所述粘附层(17)和所述外皮(1)固定到所述衬底层(4)。
15.一种柔性外皮(1)，所述柔性外皮(1)具有至少一个粘附到其上的插入物(2)，
所述柔性外皮(1)和所述插入物(2)一起限定出可视正表面；
所述柔性外皮(1)由一个或多个皮层(1；1A和1B)构成并且具有正面(12)和背面(18)，所述柔性外皮(1)的正面(12)形成所述外皮(1)的可视正表面的第一部分；并且
所述插入物(2)具有背面(14)和正面(24)，所述插入物(2)的背面(14)利用粘附层(17)而被固定到所述柔性外皮(1)上并位于所述柔性外皮(1)的正面(12)的所述凹入部分(11)中，所述插入物(2)的正面(24)形成所述可视正表面的第二部分，所述第二部分布置成邻接所述可视正表面的所述第一部分，
其特征在于，具有粘附到其上的所述至少一个插入物(2)的柔性外皮(1)通过根据权利要求1至14中任一项所述的方法来获得。
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