CN108602283B - 密封接缝区域的方法和塑料外皮 - Google Patents

密封接缝区域的方法和塑料外皮 Download PDF

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CN108602283B
CN108602283B CN201780010802.2A CN201780010802A CN108602283B CN 108602283 B CN108602283 B CN 108602283B CN 201780010802 A CN201780010802 A CN 201780010802A CN 108602283 B CN108602283 B CN 108602283B
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skin
plastic skin
plastic
seam
back side
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CN108602283A (zh
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O·迈斯鲍姆
J·博伊姆克
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Frimo Group GmbH
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Abstract

本发明涉及一种方法，通过该方法将塑料外皮(10)、特别是PVC或TPU外皮中的接缝区域内的针脚开口密封，所述PVC或TPU外皮被设置用于设有发泡部件。这种类型的发泡部件尤其用作汽车制造领域中的内饰部件，例如用作仪表盘。本发明还涉及包含所述类型的接缝的PVC或TPU外皮。

Description

密封接缝区域的方法和塑料外皮
技术领域
本发明涉及一种方法，通过该方法将塑料外皮、特别是PVC(聚氯乙烯)或TPU(热塑性聚氨酯)(搪塑)外皮中的接缝区域内的针脚开口密封，所述PVC或TPU外皮被设置用于发泡部件。这种发泡部件尤其用作汽车制造领域中的内饰部件，例如用作仪表盘、门板、中央控制台。本发明还涉及包含这种接缝的PVC或TPU外皮。
背景技术
已知在塑料外皮中引入接缝(螺线/纱线)以积极地影响这种外皮的光学设计。外皮首先设有这样的纱线，然后置于发泡工具中并在发泡过程中连接到尺寸稳定的载体上。
由于所述外皮模仿例如在其可见侧上的皮革外观，实际的接缝进一步增强了以这种方式制造的仿皮革，因为例如预期用于连接单独的皮革外皮的接缝区域被建议给观察者。
然而，在发泡过程中通常在接缝区域出现杂乱(complication)，因为如果针脚开口没有被相应的纱线节段充分密封，则泡沫材料在发泡过程中可以通过针脚开口朝外皮的可见侧逸出，由此纱线穿过PVC或TPU外皮。这种质量缺陷是不可接受的，并且会导致高废品率。
因此，在现有技术中已经采取了各种措施，以便在发泡过程之前密封在结合接缝时出现的针脚开口。
例如，已知文献US 2013/0260086 A1，其涉及具有装饰性接缝的泡沫填充面板。由此可以密封针脚，以防止泡沫在载体和外皮之间注入时逸出。US 2013/0260086 A1提出通过沿着针脚的长度粘附膜来密封针脚，从而覆盖开口。作为另一种备选措施，提出了使用可扩展的纱线。因此，纱线可以在湿气的影响下增加其直径。以这种方式密封针脚。
另一个已知文献是DE 10 2014 107 108 A1，其显示了一种为多层模塑体配备装饰性接缝的方法。模塑体具有至少一个芯部和一个盖部。由此假定工具的有效区域至少部分地通过盖部引入到芯部中，其中纱线材料的接缝区域布置在有效区域中。此外，假定工具的有效区域从模塑体中移除，使得接缝区域保留在芯部中，并且在芯部和接缝区域之间以这样的方式激活连接，从而确保维持了接缝区域在芯部中的位置。所述芯材料可包括热激活的连接部分，特别是热激活的热熔粘合剂，其中通过加热至少芯部来激活芯部和接缝区域之间的连接。在一个实施方式中，至少在连接激活之前提供热激活的连接部分，作为在纱线材料上的涂层，在另一个实施方式中，至少在连接激活之前将热激活的连接部分机织成纱线材料作为纱线。
此外，还已知文献DE 10 2015 106 964 A1，其显示了具有密封的针脚接缝的内部面板。由此，在覆盖层的不可见侧上形成泡沫层之前，借助于弹性材料密封缝合针孔，以防止膨胀的泡沫通过针孔泄漏并在面板的可见侧上变得可见。弹性材料最初作为配制成固化的粘性液体施用，并且可以通过喷涂施加，这允许针脚线沿着面板的复杂轮廓定位。例如，乳液是这种粘稠液体的一种合适类型。
发明内容
本发明的目的是提供将塑料外皮、特别是PVC或TPU外皮中的针脚开口密封的简单且廉价的方法。
权利要求1的主题是这种方法。在从属权利要求中规定了进一步优选的实施方式。
本发明提供将塑料外皮、特别是PVC或TPU(搪塑)外皮(聚氯乙烯或热塑性聚氨酯)中的接缝区域内的针脚开口密封的方法。因此，针脚开口优选基本上垂直于塑料外皮的背侧并经过塑料外皮的背侧延伸，并且纱线穿过针脚开口。
该方法包括以下步骤：提供塑料外皮，其具有可见侧和背侧，并设有至少一条纱线，即以此方式使塑料外皮的背侧可触及(accessible)，并加温、加热或熔化接缝区域中的塑料外皮的背侧，使得塑料外皮在针脚开口的区域中接触纱线。例如，塑料外皮在可见侧上具有具纹理的表面(grained surface)。
术语“纱线”在本发明的范围内使用。术语“纱线”在概念上包括此背景下的螺线。术语“螺线”可代替术语“纱线”。纱线/螺线可由多根纤维机织、编织、针织或成簇。
本发明的方法可用于加工用于汽车的面板部件的塑料外皮。然而，以此方式加工的外皮的使用不限于汽车领域。其通常可以是面板部件，仅作为飞机内部的实例。
塑料外皮优选为所谓的搪塑外皮(slush skin)。搪塑外皮在初级成型过程中由塑料材料制成。在本发明的范围内，优选使用PVC或TPU作为塑料材料。
本发明的方法具有的优点是，由于局部热影响，当在外皮中引入纱线时产生的针脚开口被牢固地密封。由此发现，即使局部加热，例如通过火焰或通过热空气，也会导致接缝区域中外皮的永久变形，因此外皮接触纱线，并在较高温度的情况下可能粘附在其上而不必在接缝区域中施加另外的密封剂或覆盖膜。由于除了用于引起热影响的装置之外不需要另外的辅助装置，因此可以大大简化密封接缝区域的方法。这尤其适用于PVC或TPU外皮的情况，其由于热影响(加温/加热)而暂时变得有弹性，并因此可以接触穿过针脚开口的纱线。
根据一个实施方式，优选的是，塑料外皮的加温/加热通过加热装置进行，其中在加热装置和外皮之间提供相对移动。以这种方式可以以一致的质量实现针脚开口的密封。根据一个备选方案，加热装置在塑料外皮保持静止的同时移动。
就此而言，优选的是加热装置为气体燃烧器、电热源或热空气源。气体燃烧器、电热源和热空气源允许相对精确地计量施加到塑料外皮的热量。气体燃烧器还具有以下优点：热输入区域在视觉上是可感知的，因此在程序期间可以识别出是否有足够大的区域受到热影响。热空气源是相对成本有效的加热装置，其在使用期间非常可靠，对其操作仅需要提供电能。
也可以另选使用带有热源的压辊或带有热源的压垫。这些装置的优点在于，除了热量之外，压力也同时施加在外皮上，因此发生机械诱导的变形。
作为另一种可能性，可以使用红外线源、加热元件或加热板或激光器。这些允许特别精确的过程控制。
对于至少一条纱线优选的是耐热或耐火纱线。以此方式，由于加热的方法步骤，可靠地防止纱线在塑料外皮的背侧被断开。
根据本发明的另一实施方式，提供了在制备塑料外皮的步骤期间，将塑料外皮以可见侧向下置于平坦的支撑物、特别是工作台(machine table)上。以此方式可以实现极其可靠的过程控制。
根据另一个备选方案，例如，将塑料外皮置于发泡工具中。因此，可在密封接缝区域之后进行发泡过程。
具体而言，当加热接缝区域中的塑料外皮的背侧时，外皮至少部分熔化。由于塑料外皮、特别是由PVC(聚氯乙烯)制成的外皮的局部熔化，其变形得以实现，使得可以密封在针脚开口区域中塑料外皮和纱线之间可能存在的任何狭缝。
根据本发明的一个备选方案，塑料外皮设有彼此间隔开的两条纱线，其限定共同接缝区域，其中塑料外皮的背侧在共同接缝区域中的加热单程(single pass)进行。因此，可以使用本发明的方法快速加工包括两个平行延伸纱线的所谓装饰性接缝。
本发明还涉及使用一个上述实施方式制造的塑料外皮制造汽车用内部面板部件的方法。
优选的是，当加热接缝区域中的塑料外皮的背侧时或者在其后，在所述接缝区域中施加机械影响，特别是通过压辊或压垫施加。由于加热而更具弹性或已经熔化的塑料外皮的节段可以以这种方式额外变形，从而密封接缝区域。
如已经说明的那样，压力效应因此可以通过具有热源的组合压辊/压垫或者通过单独的装置来实现，特别是压辊/压垫和加热装置如气体燃烧器、热空气源、红外线源、加热元件、烙铁或激光器。
进一步优选的是将塑料外皮的表面区域加热至至少80℃的温度，优选至少100℃。可以至少在接缝区域的节段中选择例如至少110℃的温度。加热区域以此方式变得有弹性，从而接触纱线。
根据本发明的一个目的，在此可以在即将制造内部面板部件的过程之前使塑料外皮经受上述过程。特别有可能的是，将带有纱线的塑料外皮插入用于制造内部面板部件的工具中并使其在其中经受本发明的用于将塑料外皮的接缝区域密封的方法。以此方式可确保相对短的加工时间。
根据本发明的另一个目的，将塑料外皮的接缝区域密封的方法和使用此塑料外皮制造内部面板部件的方法在空间和时间方面彼此分开地进行。
本发明还涉及PVC或TPU外皮，优选具有可见侧和背侧的PVC或TPU外皮，所述可见侧具有具纹理的表面，PVC或TPU外皮具有带纱线的接缝区域，所述纱线分段穿透PVC或TPU外皮，并且在接缝区域中存在PVC或TPU外皮的熔化并再固化的节段，使得PVC或TPU外皮在针脚开口的区域中接触纱线。
使用一个上述实施方式的方法具体制造的这种PVC或TPU外皮可具有上面已引用的其它特征。PVC或TPU外皮尤其可以设有耐火纱线。
附图说明
图1是引入了纱线的PVC外皮的区域的示意性截面图。
图2是引入了纱线的外皮的下侧的透视俯视图。
具体实施方式
下面借助于附图详细描述本发明的优选实施方式。在该上下文中引用的某些特征的进一步修改可以各自单独组合以形成新的实施方式。
图1所示的截面示意性地示出了PVC或TPU搪塑外皮10(在本实施方式的范围内，于下文中也称为“外皮”)的接缝区域。外皮10包括可见侧10a以及背侧10b，可见侧10a通常设有带纹理的图案，例如以模仿皮革表面。背侧10b在设有外皮10的发泡部件中形成不可见的内侧。
在所述实施方式中，纱线20以彼此一定距离缝合到外皮10中，纱线20沿着其从可见侧10a到背侧10b交替经过针脚开口的进程穿过外皮10，反之亦然。因此，纱线20由耐火材料或具有低可燃性的材料形成。此外，在外皮10的可见侧10a(图1的底部)上设置有凹槽11，在该区域中，外皮10具有凹陷，以模仿两片外皮之间的连接区域。
在本发明的过程中，外皮10置于支撑物30上，其可见侧10a面朝下，使得在随后的发泡过程中与泡沫材料(优选聚氨酯)或热塑性弹性体接触的外皮10的背侧10b可触及。
为了密封接缝的针脚开口，现在通过加热装置50施加局部热影响。在本实施方式中，这种热影响通过火焰、烙铁或通过热空气的方式进行。因此，加热装置50被构造为气体燃烧器、烙铁或热空气鼓风机。
出于此目的，沿着外皮10的接缝区域引导加热装置50，从而在该区域中加热外皮10。由于加热，在接缝区域中外皮10暂时软化，使得外皮10接触纱线20并因此密封针脚开口。
根据进一步的改进，还可以使用组合的压力和加热装置，例如具有热源的压辊/压垫。
也可以首先加热接缝区域，然后在接缝区域中的外皮至少部分仍处于加热状态的同时施加压力。
由此可以将外皮10加热至至少80℃，优选至少100℃，进一步优选至少120℃。最高温度范围例如是2000℃。
一旦外皮冷却，它就保持在这种状态，以便在随后外皮10通过特别是聚氨酯连接到尺寸稳定的载体上的发泡过程中，没有泡沫材料能渗透到可见侧。
尽管根据所描述的优选实施方式优选的是将外皮10置于设为静止的支撑物上并且移动加热装置50，但根据另一备选方案可以将外皮10置于可移动的支撑物(可移动的桌台)上，并以这种方式在外皮10和加热装置之间产生相对移动。此外，根据另一备选方案，支撑物和外皮与加热装置都能够移动。

Claims (18)

1.制造面板部件的方法，其使用塑料外皮(10)，其中所述塑料外皮(10)包含接缝区域，其中由于在所述塑料外皮(10)中引入纱线，所以在所述接缝区域内的所述塑料外皮中存在针脚开口，其中密封所述接缝区域包括以下步骤：
提供塑料外皮(10)，其具有可见侧(10a)和背侧(10b)，并设有至少一条纱线(20)，使得所述塑料外皮(10)的所述背侧(10b)能够触及，
加热所述接缝区域中的所述塑料外皮(10)的所述背侧(10b)，使得所述塑料外皮(10)在所述针脚开口的所述区域中接触所述纱线(20)，
其中制造所述面板部件包括以下步骤：
将所述塑料外皮(10)和尺寸稳定载体置于模塑工具中，
将填充材料插入所述塑料外皮(10)的所述背侧(10b)和所述尺寸稳定载体之间的区域。
2.如权利要求1所述的方法，其特征在于，所述塑料外皮(10)的加热通过加热装置(50)进行，其中在所述加热装置(50)和所述外皮(10)之间提供相对移动。
3.如权利要求2所述的方法，其特征在于，所述加热装置(50)是加热元件。
4.如权利要求2所述的方法，其特征在于，所述加热装置(50)是气体燃烧器、热空气源、红外线源、烙铁、带热源的压辊或带热源的压垫、激光器。
5.如权利要求1或2所述的方法，其特征在于，所述至少一条纱线(20)是耐火纱线。
6.如权利要求1或2所述的方法，其特征在于，在制备所述塑料外皮(10)的步骤中，将所述外皮以可见侧(10a)面向下置于支撑物(30)上，或置于发泡工具的一半中。
7.如权利要求6所述的方法，其特征在于，所述支撑物(30)是工作台。
8.如权利要求1或2所述的方法，其特征在于，当加热所述接缝区域中的所述塑料外皮(10)的所述背侧(10b)时，所述塑料外皮至少部分熔化。
9.如权利要求1或2所述的方法，其特征在于，所述塑料外皮(10)设有彼此间隔开的两条纱线(20)，其限定共同接缝区域，其中在共同接缝区域中的所述塑料外皮(10)的所述背侧的加热单程进行。
10.如权利要求1或2所述的方法，其特征在于，所述针脚开口基本上垂直于所述塑料外皮(10)的所述背侧(10b)并经过所述塑料外皮(10)的所述背侧(10b)延伸。
11.如权利要求1或2所述的方法，其特征在于，所述接缝区域中的所述外皮至少部分加热到至少80℃的温度。
12.如权利要求10所述的方法，其特征在于，所述接缝区域中的所述外皮至少部分加热到至少100℃的温度。
13.如权利要求11所述的方法，其特征在于，所述接缝区域中的所述外皮至少部分加热到至少110℃的温度。
14.如权利要求1或2所述的方法，其特征在于，当加热所述接缝区域中的所述塑料外皮(10)的所述背侧(10b)时或者在其后，在所述接缝区域中施加机械影响。
15.如权利要求14所述的方法，其特征在于，所述施加机械影响通过压辊或压垫施加。
16.如权利要求1所述的方法，其特征在于，所述面板部件是内部面板部件。
17.如权利要求1所述的方法，其特征在于，所述填充材料是聚氨酯泡沫或热塑性弹性体。
18.如权利要求1所述的方法，其特征在于，所述塑料外皮(10)是PVC或TPU搪塑外皮。
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