DE102005030279A1 - Multi-layer plastic wall lining panel for internal cladding of motor vehicles comprises outer decorative fabric layer, a flexible thermoplastic foam sandwiched between heat insulation layers and an injected plastic rear layer - Google Patents

Multi-layer plastic wall lining panel for internal cladding of motor vehicles comprises outer decorative fabric layer, a flexible thermoplastic foam sandwiched between heat insulation layers and an injected plastic rear layer Download PDF

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Publication number
DE102005030279A1
DE102005030279A1 DE200510030279 DE102005030279A DE102005030279A1 DE 102005030279 A1 DE102005030279 A1 DE 102005030279A1 DE 200510030279 DE200510030279 DE 200510030279 DE 102005030279 A DE102005030279 A DE 102005030279A DE 102005030279 A1 DE102005030279 A1 DE 102005030279A1
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Germany
Prior art keywords
layer
plastic element
plastic
element according
thermal protection
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DE200510030279
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German (de)
Inventor
Herbert Starz
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BLANKE TEXTECH GMBH, DE
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Fritz Blanke GmbH and Co KG
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Priority to DE200510030279 priority Critical patent/DE102005030279A1/en
Publication of DE102005030279A1 publication Critical patent/DE102005030279A1/en
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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
    • 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
    • B29C45/14811—Multilayered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/32—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed at least two layers being foamed and next to each other
    • 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
    • B29C45/0081—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor of objects with parts connected by a thin section, e.g. hinge, tear line
    • 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
    • B29C45/14467—Joining articles or parts of a single 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
    • 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
    • B29C45/14819—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 inserts being completely encapsulated
    • 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
    • B29C45/14836—Preventing damage of inserts during injection, e.g. collapse of hollow inserts, breakage
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0809—Fabrics
    • B29K2105/0818—Fleece
    • 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
    • B29K2713/00—Use of textile products or fabrics for preformed parts, e.g. for inserts
    • 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
    • B29K2715/00—Condition, form or state of preformed parts, e.g. inserts
    • B29K2715/003—Cellular or porous
    • 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
    • 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
    • B29L2031/3038—Air bag covers
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/05—5 or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/025—Polyolefin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/003—Interior finishings

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

The liner (10) comprises a decorative layer (11) outer layer, preferably a fabric, a first heat insulation layer (12), a layer (13) of a high heat resistant and a reversibly flexible thermoplastic foam and a second heat insulating layer (14) comprising a non-woven fleece based on a polypropylene and polyester mixture. A injected plastic layer (15) forms the back of the liner. The decorative layer (11), both heat insulating layers (12,14) and the heat resistant foam layer (13) are heated, preferably by flame lamination, to join them together. Connectors (16) for mounting the lining panel onto a vehicle body are incorporated in the plastic backing layer (15) which may also enclose cables and/or cable channels. Air bags may also be incorporated in the plastic backing layer and in this case the liner (10) features deliberate weak failure lines. An independent claim is included for process for manufacturing the plastic liner in which four layers (11,12,13,14) are heated and joined to form a laminate (10) onto the back of which a plastic is injected in a molding tool.

Description

Die Erfindung betrifft einen mehrschichtige Wandverkleidung für Kraftfahrzeuge, insbesondere Personenkraftfahrzeuge. Solcherlei Kunststoffelemente dienen hauptsächlich zur Abdeckung von Karosserieteilen des Fahrzeuges.The The invention relates to a multi-layer wall cladding for motor vehicles, in particular passenger vehicles. Such plastic elements serve mainly for covering body parts of the vehicle.

Bekannte Wandverkleidungen bestehen aus einer Dekorschicht, die mit einer Wärmeschutzschicht versehen wird. Dahinter kann dann Kunststoff gespritzt werden. Die so entstehenden Formteile werden hauptsächlich zur Abdeckung von Karosserieteilen, wie etwa A- und B-Säulen in Kraftfahrzeugen, verwendet. Als nachteilig hat es sich bei dieser Art von Kunststoffelementen erwiesen, dass sie den Eindruck einer minderwertigen Qualität vermitteln. Dieses liegt hauptsächlich an der harten Oberfläche, die der Käufer mit preiswerten Plastikteilen in Verbindung setzt.Known Wall coverings consist of a decorative layer, which with a Thermal protection layer is provided. Behind this plastic can be injected. The moldings resulting in this way are mainly used to cover body parts, such as A and B columns used in motor vehicles. It is disadvantageous in this type of plastic elements proved to give the impression of a substandard quality convey. This is mainly on the hard surface, the the buyer with cheap plastic parts.

Der Erfindung liegt die Aufgabe zugrunde, ein Kunststoffelement für Wandverkleidungen bereitzustellen, welches nicht die obengenannten Nachteile aufweist. Dieses wird erfindungsgemäß durch die im Anspruch 1 genannten Maßnahmen erreicht, denen nachfolgende besondere Bedeutung zukommt.Of the Invention is based on the object, a plastic element for wall coverings to provide, which does not have the above-mentioned disadvantages. This is inventively the measures mentioned in claim 1 achieved, the following special significance.

Das erfindungsgemäße Kunststoffelement für eine Wandverkleidung besteht aus einer Dekorschicht, einer ersten Schicht zum Wärmeschutz, einer Schicht aus einem hochwärmefesten und zumindest bereichsweise reversibel nachgiebigen Thermoplastschaum, einer zweiten Wärmeschutzschicht sowie einer Unterspritzung aus Kunststoff. Insbesondere die nachgiebige Thermoplastschicht sorgt für ein haptisch hoch qualitatives Gefühl für den Verbraucher. Denn für diesen wird sich die Dekorschicht nachgiebig anfühlen, was er mit hochwertigen Materialien, wie etwa Leder, in Verbindung setzen wird. In einer vorteilhaften Ausgestaltung des erfindungsgemäßen Kunststoffelementes ist die Thermoplastschicht aus Polyethylen-Schaum aufgebaut. Des Weiteren kann eine der Wärmeschutzschichten durch ein Abstandsvlies ersetzt werden. Diese Dreilagen-Vliese weisen einen Kern aus Rezyklaten auf, welcher eingebettet ist in zwei Polypropylen/Polyesterschichten.The Plastic element according to the invention for a wall cladding consists of a decorative layer, a first layer for thermal protection, a layer of a high heat resistant and at least partially reversibly compliant thermoplastic foam, a second thermal protection layer and an injection of plastic. Especially the yielding Thermoplastic layer ensures a haptic high quality feeling for the consumer. Because for this the decorative layer will feel yielding, what he wants with high quality Materials, such as leather, will connect. In a advantageous embodiment of the plastic element according to the invention the thermoplastic layer is made of polyethylene foam. Furthermore can one of the heat protection layers through a spacer fleece are replaced. These three-layer webs exhibit a core of recycled material, which is embedded in two polypropylene / polyester layers.

Weitere Maßnahmen und Vorteile der Erfindung ergeben sich aus den Unteransprüchen, der nachfolgenden Beschreibung und den Zeichnungen. In den Zeichnungen ist die Erfindung in einem Ausführungsbeispiel dargestellt. Es zeigen:Further activities and advantages of the invention will be apparent from the dependent claims, the following Description and the drawings. In the drawings, the invention in one embodiment shown. Show it:

1 den Schichtaufbau des Kunststoffelementes und 1 the layer structure of the plastic element and

2 die Thermoplastlagen in einer Form um mit Kunststoff hinterspritzt zu werden. 2 the thermoplastic layers in a mold to be back-injected with plastic.

In 1 ist ein Schnitt durch das erfindungsgemäße Kunststoffelement 10 gezeigt. Die erste Lage ist die Dekorschicht 11. Sie besteht im Allgemeinen aus einem Gewebe und bildet die Sichtseite des Kunststoffelementes. Die Dekorschicht 11 ist mit einer ersten Wärmeschutzschicht 12 verbunden. Dabei kann es sich um einen Polyethylen-Schaum handeln, der mit der Dekorschicht kaschiert wurde. Auf die Rückseite beiden Schichten aufgebracht ist ein hochwärmefester und zumindest bereichsweise reversibel nachgiebiger Thermoplastschaum 13. Er sorgt dafür, dass die Dekorschicht bei Berührungen durch den Verbraucher sich nachgiebig anfühlt. Denn dieser Thermoplastschaum, welcher beispielhaft aus Polyethylen bestehen kann, ist kompressibel, nimmt aber wieder sein Ausgangsvolumen ein, sobald der Druck nachlässt. Auf die Thermoplast-Schaumschicht 13 ist eine zweite Wärmeschutzschicht 14 aufgebracht. Sie soll den Schaum 13 vor den hohen Temperaturen und Drücken des aufgespritzten Kunststoffes 15 schützen.In 1 is a section through the plastic element according to the invention 10 shown. The first layer is the decorative layer 11 , It generally consists of a fabric and forms the visible side of the plastic element. The decorative layer 11 is with a first heat protection layer 12 connected. It may be a polyethylene foam, which has been laminated with the decorative layer. Applied to the back of both layers is a highly heat-resistant and at least partially reversibly compliant thermoplastic foam 13 , It ensures that the decorative layer feels pliable when touched by the consumer. Because this thermoplastic foam, which may consist of polyethylene by way of example, is compressible, but again assumes its initial volume as soon as the pressure subsides. On the thermoplastic foam layer 13 is a second heat protection layer 14 applied. She should be the foam 13 before the high temperatures and pressure of the sprayed plastic 15 protect.

Je nach Anwendungsort und -zweck kann die Dekorschicht aus unterschiedlichsten Materialien bestehen. Aus produktionstechnischen Gegebenheiten bietet es sich häufig an, hier ebenfalls Thermoplastgewebe, wie etwa Polyester-, Polyvinylchlorid-, Polyurethan- oder Polypropylengewebe zu verwenden. Auch Mischgewebe aus diesen Thermoplasten können vorteilhaft sein. Möchte man besonders hochwertige Dekorflächen schaffen, finden häufig textile Gewebe Verwendung. So bieten sich Baumwolle oder auch Veloursstoffe an. Da die hohen Temperaturen, bei denen der reversibel nachgiebige Thermoplastschaum verarbeitet wird, die Dekorschicht schädigen würden, ist ein direktes Kaschieren nicht möglich. Vielmehr ist zwischen beiden eine Wärmeschutzschicht 12 eingebracht. Sie besteht vornehmlich aus einem Polyethylen-Schaum. Dieser weist einen sehr großes Temperaturintervall auf, in welchem er verarbeitet werden kann. So lässt sich die Dekorschicht 11 bei eher niedrigen Temperaturen auf die Wärmeschutzschicht 12 kaschieren. Diese Schicht ist aber temperaturbeständig genug, um später mit dem reversibel nachgiebigen Thermoplastschaum 13 verbunden zu werden. Folglich wirkt die Schicht 12 nicht nur als Wärmeschutz, sondern auch als Klebeschicht.Depending on the application site and purpose, the decorative layer can consist of a wide variety of materials. For reasons of production technology, it is often advisable to also use thermoplastic fabrics, such as polyester, polyvinyl chloride, polyurethane or polypropylene fabric here. Blended fabrics of these thermoplastics may also be advantageous. If one wishes to create particularly high-quality decorative surfaces, textile fabrics are frequently used. This is how cotton or velor fabrics are made. Since the high temperatures at which the reversibly compliant thermoplastic foam is processed, would damage the decorative layer, a direct lamination is not possible. Rather, a heat protection layer is between both 12 brought in. It consists primarily of a polyethylene foam. This has a very large temperature interval in which it can be processed. This is how the decorative layer works 11 at rather low temperatures on the thermal insulation layer 12 conceal. However, this layer is temperature-resistant enough to later with the reversibly compliant thermoplastic foam 13 to be connected. Consequently, the layer works 12 not only as a thermal protection, but also as an adhesive layer.

In einer vorteilhaften Ausgestaltung des erfindungsgemäßen Kunststoffelementes kann die erste Schicht zum Wärmeschutz 12 auch aus einem Abstandsvlies bestehen. Jene sind im Allgemeinen dreilagig aufgebaut. Ein Kern aus Rezyklat ist an der Ober- und Unterseite mit einem Thermoplastschaum abgedeckt. Im Allgemeinen handelt es sich bei dem Schaum um ein Gemisch aus Polypropylen und Polyester. Der Einbau solcher Abstandsvliese bietet sich aufgrund ihrer Temperaturbeständigkeit sowie Dämmeigenschaften an.In an advantageous embodiment of the plastic element according to the invention, the first layer for heat protection 12 also consist of a spacer fleece. These are generally constructed in three layers. A core of recycled material is at the Ob Covered and underside with a thermoplastic foam. In general, the foam is a blend of polypropylene and polyester. The installation of such spacer fleeces offers itself due to their temperature resistance and insulation properties.

Die Thermoplastschaumschicht 13 sorgt dafür, dass die Oberfläche des Kunststoffelementes 10 zumindest bereichsweise nachgiebig ist. Streicht ein Fahrzeugbenutzer über die Oberfläche des Kunststoffelementes, wird diese seinem Tastdruck leicht nachgeben. Durch das so erzeugte haptische Gefühl vermittelt das Kunststoffelement einen besonders hochwertigen Qualitätseindruck. Die Innenflächen des Fahrzeuges wirken nicht wie einfache harte Kunststoffflächen, sondern eher wie polsterartige Elemente. Der beim Tasten ausgeübte Druck wird vom Kunststoffelement aufgenommen in einer Kompression der Thermoplastschaumschicht 13. Wie bei einem Federkissen expandiert der Thermoplastschaum später wieder in seine Ausgangsgröße zurück. Der Qualitätseindruck des Kunststoffelementes 10 wird somit hauptsächlich durch den reversibel nachgiebigen Thermoplastschaum 13 vermittelt.The thermoplastic foam layer 13 ensures that the surface of the plastic element 10 at least partially compliant. If a vehicle user brushes over the surface of the plastic element, it will yield slightly to its tactile pressure. The haptic feel created in this way gives the plastic element a particularly high quality impression. The interior surfaces of the vehicle do not look like simple hard plastic surfaces, but rather like upholstery-like elements. The pressure exerted during the pressing is absorbed by the plastic element in a compression of the thermoplastic foam layer 13 , As with a feather pillow, the thermoplastic foam later expands back to its original size. The quality impression of the plastic element 10 is thus mainly due to the reversibly compliant thermoplastic foam 13 taught.

Das Aufbringen der Kunststoffschicht 15 auf das mehrlagige Laminat erfolgt unter hohem Druck und hohen Temperaturen. Da diese den Thermoplastschaum 13 schädigen würden, ist auf ihn eine weitere Wärmeschutzschicht 14 aufgebracht. Sie besteht aus einem Gemisch aus Polypropylen und Polyester. Als vorteilhaft haben sich Gemische aus ungefähr 30% Polypropylen und ungefähr 70% Polyester erwiesen. Auch Mischungsverhältnisse, die etwa je die Hälfte Polyester und Polypropylen aufweisen, werden häufig verwendet.The application of the plastic layer 15 on the multi-layer laminate is carried out under high pressure and high temperatures. Since these are the thermoplastic foam 13 would damage him, is another heat protection layer on him 14 applied. It consists of a mixture of polypropylene and polyester. Mixtures of about 30% polypropylene and about 70% polyester have been found to be advantageous. Mixing ratios, which each have about half polyester and polypropylene, are often used.

Die Lagen 11, 12, 13, 14 des Kunststoffelementes 10 werden im Allgemeinen durch Wärmeeinwirkung verbunden. Bekannt ist, diese Schäume mittels Beflammung zu plastifizieren. Dabei werden die Oberflächen mittels einer Flamme erhitzt und anschließend zusammengedrückt. Im Stande der Technik ist es auch bekannt, die Lagen mittels eines Klebstoffes miteinander zu verbinden.The layers 11 . 12 . 13 . 14 of the plastic element 10 are generally connected by the action of heat. It is known to plasticize these foams by means of flame treatment. The surfaces are heated by means of a flame and then compressed. In the prior art it is also known to connect the layers by means of an adhesive.

Wie in 2 dargelegt wird das vierlagige Laminat anschließend in eine Form 20 eingebracht. In diese wird unter hohem Druck und hoher Temperatur Kunststoff eingespritzt 23. Der Kunststoff kann aus unterschiedlichsten, dem Fachmann bekannte Basisstoffen bestehen. Die Form der Matrize bzw. Patrize legen die Gestalt 22 des Kunststoffelementes fest. Die zweite Wärmeschutzschicht 14 sorgt dafür, dass die hohen Drücke und Temperaturen der Hinterspritzung 15 nicht zu einer Schädigung des Laminates führen. In die Kunststoffhinterspritzung 15 können weitere Elemente 16 einbettet werden. Insbesondere bei modernen Fahrzeugen hat es sich eingebürgert, in Abdeckungselementen, wie etwa jene über der B-Säule, Airbagsysteme zu integrieren. Bei einem Unfall entfalten sich die Airbagsysteme dann, um die Insassen zu schützen. Damit eine gleichbleibende, nicht von Zufällen abhängige, Entfaltung des Airbags sichergestellt ist, muss das Kunststoffelement 10 Sollbruchstellen aufweisen. Diese garantieren, dass die Kunststoffelemente 10 an einer definierten Stelle unter einem definierten Druck des sich aufblasenden Airbags bersten, um so den Weg freizugeben.As in 2 set forth the four-ply laminate is then in a mold 20 brought in. In this plastic is injected under high pressure and high temperature 23 , The plastic can consist of a wide variety of basic materials known to the person skilled in the art. The shape of the matrix or patrix shape the figure 22 the plastic element firmly. The second heat protection layer 14 Ensures that the high pressures and temperatures of the back injection 15 not lead to damage to the laminate. In the plastic injection 15 can have more elements 16 be embedded. Particularly in modern vehicles, it has become commonplace to incorporate airbag systems into cover members such as those above the B-pillar. In an accident, the airbag systems then unfold to protect the occupants. So that a consistent, not dependent on chance, deployment of the airbag is ensured, the plastic element 10 Have predetermined breaking points. These guarantee that the plastic elements 10 burst at a defined location under a defined pressure of the inflating airbag, so as to clear the way.

Selbstverständlich könne in das Kunststoffelement 10 auch weitere Elemente 16 eingebettet werden. So bietet es sich an, Verbindungselemente, wie etwa Schrauben, Muttern oder Ösen mit einzugießen. Sie erleichtern die Montage des Kunststoffelementes 10 an die Fahrzeugkarosserie im Rahmen der Produktion erheblich. Auch der Austausch von defekten Elementen 10 nach Unfällen oder sonstigen Beschädigungen ist so einfacher möglich. Gleichfalls können Kabel oder Kabelkanäle in das Kunststoffelement integriert 10 werden. Dieses bietet sich insbesondere bei der Herstellung von Armaturenbrettern an.Of course, in the plastic element 10 also other elements 16 be embedded. So it makes sense to pour fasteners, such as screws, nuts or eyelets with. They facilitate the assembly of the plastic element 10 to the vehicle body as part of the production considerably. Also the replacement of defective elements 10 After accidents or other damage is easier. Likewise, cables or cable channels can be integrated into the plastic element 10. This is particularly useful in the manufacture of dashboards.

Das erfindungsgemäße Kunststoffelement 10 besteht aus einem vierlagigen Laminat, welches in einer Form 20 mit Kunststoff 15 hinterspritzt 23 wird. Das Laminat besteht aus 4 Schichten 11, 12, 13, 14, die vorzugsweise durch Wärmeeinwirkung, wie etwa Flammkaschierung miteinander verbunden werden. Die Besonderheit dieses Kunststoffelementes 10 besteht darin, dass eine der Schichten aus einem zumindest bereichsweise reversibel nachgiebigen Thermoplastschaum 13 aufgebaut ist. Durch die nachgiebige Ausgestaltung des Kunststoffelementes 10 vermittelt es einen besonders hochwertigen Eindruck.The plastic element according to the invention 10 consists of a four-ply laminate, which in a mold 20 with plastic 15 back-injected 23 becomes. The laminate consists of 4 layers 11 . 12 . 13 . 14 , which are preferably bonded together by the action of heat, such as Flammenkaschierung. The special feature of this plastic element 10 is that one of the layers of an at least partially reversibly compliant thermoplastic foam 13 is constructed. Due to the resilient design of the plastic element 10 it gives a particularly high-quality impression.

1010
KunststoffelementPlastic element
1111
Dekorschichtdecorative layer
1212
erste Wärmeschutzschichtfirst Thermal protection layer
1313
ThermoplastschaumThermoplastic foam
1414
zweite Wärmeschutzschichtsecond Thermal protection layer
1515
Hinterspritzung aus KunststoffOvermolding made of plastic
1616
Element in 15 Element in 15
2020
Formshape
2121
Einfüllstutzenfiller pipe
2222
Hohlraum in 20 Cavity in 20
2323
Einspritzung von 15 Injection of 15

Claims (20)

Kunststoffelement (10) für Wandverkleidungen in Fahrzeugen, mit einer Dekorschicht (11), die vorzugsweise aus einem Gewebe besteht, einer ersten Schicht zum Wärmeschutz (12), einer Schicht (13), die aus einem hochwärmefesten und zumindest bereichsweise reversibel nachgiebigen Thermoplast-Schaum aufgebaut ist, einer zweiten Schicht zum Wärmeschutz (14), die aus einem Vlies besteht, welches aus einem Polypropylen/Polyester Gemisch gebildet ist, und einer Hinterspritzung (15) aus Kunststoff.Plastic element ( 10 ) for wall coverings in vehicles, with a decorative layer ( 11 ), which is preferably made of a fabric, a first layer for thermal protection ( 12 ) a layer ( 13 ), which is constructed from a highly heat-resistant and at least partially reversibly compliant thermoplastic foam, a second layer for thermal protection ( 14 ), which consists of a non-woven, which is formed from a polypropylene / polyester mixture, and a back injection ( 15 ) made of plastic. Kunststoffelement nach Anspruch 1, dadurch gekennzeichnet, dass das Gewebe der Dekorschicht (11) Polyester und/oder Polyvinylchlorid und/oder Polyurethan enthält.Plastic element according to claim 1, characterized in that the fabric of the decorative layer ( 11 ) Polyester and / or polyvinyl chloride and / or polyurethane. Kunststoffelement nach Anspruch 1, dadurch gekennzeichnet, dass das Gewebe der Dekorschicht (11) ein Polypropylen-Gewebe ist.Plastic element according to claim 1, characterized in that the fabric of the decorative layer ( 11 ) is a polypropylene fabric. Kunststoffelement nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass das Gewebe der Dekorschicht (11) ein textiles Gewebe ist.Plastic element according to one of claims 1 to 3, characterized in that the fabric of the decorative layer ( 11 ) is a textile fabric. Kunststoffelement nach Anspruch 4, dadurch gekennzeichnet, dass das Gewebe der Dekorschicht (11) aus Velours besteht.Plastic element according to claim 4, characterized in that the fabric of the decorative layer ( 11 ) consists of suede. Kunststoffelement nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass die erste Schicht zum Wärmeschutz (12) aus einem Polyethylen-Schaum aufgebaut ist.Plastic element according to one of claims 1 to 5, characterized in that the first layer for thermal protection ( 12 ) is constructed of a polyethylene foam. Kunststoffelement nach Anspruch 5, dadurch gekennzeichnet, dass der Polyethylen-Schaum der ersten Schicht zum Wärmeschutz (12) als Klebeschicht wirkt.Plastic element according to claim 5, characterized in that the polyethylene foam of the first layer for thermal protection ( 12 ) acts as an adhesive layer. Kunststoffelement nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass die erste Schicht zum Wärmeschutz (12) aus einem Abstandsvlies besteht.Plastic element according to one of claims 1 to 5, characterized in that the first layer for thermal protection ( 12 ) consists of a spacer fleece. Kunststoffelement nach Anspruch 8, dadurch gekennzeichnet, dass das Abstandsvlies dreilagig aufgebaut ist, wobei zwei, aus einem Polypropylen\Polyester Gemisch bestehende Schichten, eine Schicht aus Rezyklat umschließen.Plastic element according to claim 8, characterized in that that the spacer fleece is constructed in three layers, wherein two, from a polypropylene \ polyester blend existing layers, one layer made of recycled material. Kunststoffelement nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass der Thermoplast-Schaum (13) aus Polyethylen-Schaum aufgebaut ist.Plastic element according to one of claims 1 to 6, characterized in that the thermoplastic foam ( 13 ) is constructed of polyethylene foam. Kunststoffelement nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass die zweite Schicht zum Wärmeschutz (14) aus etwa 50% Polypropylen und etwa 50% Polyester gebildet ist.Plastic element according to one of claims 1 to 7, characterized in that the second layer for thermal protection ( 14 ) is made of about 50% polypropylene and about 50% polyester. Kunststoffelement nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass die zweite Schicht zum Wärmeschutz (14) aus ungefähr 30% Polypropylen und ungefähr 70% Polyester aufgebaut ist.Plastic element according to one of claims 1 to 7, characterized in that the second layer for thermal protection ( 14 ) is constructed of about 30% polypropylene and about 70% polyester. Kunststoffelement nach einem der Ansprüche 1 bis 9, dadurch gekennzeichnet, dass die Dekorschicht (11), die erste Schicht zum Wärmeschutz (12), die Schicht (13) und die zweite Schicht zum Wärmeschutz (14) durch Wärmeeinwirkung miteinander verbindbar sind.Plastic element according to one of claims 1 to 9, characterized in that the decorative layer ( 11 ), the first layer for thermal protection ( 12 ), the layer ( 13 ) and the second layer for thermal protection ( 14 ) are connected to one another by the action of heat. Kunststoffelement nach Anspruch 10, dadurch gekennzeichnet, dass die Lagen (11, 12, 13, 14) durch Flammkaschierung verbindbar sind.Plastic element according to claim 10, characterized in that the layers ( 11 . 12 . 13 . 14 ) are connectable by Flammkaschierung. Kunststoffelement nach einem der Ansprüche 1 bis 11, dadurch gekennzeichnet, dass in die Kunststoffhinterspritzung (15) Elemente (16) eingebettet sind.Plastic element according to one of claims 1 to 11, characterized in that in the plastic injection molding ( 15 ) Elements ( 16 ) are embedded. Kunststoffelement nach einem der Ansprüche 1 bis 11, dadurch gekennzeichnet, dass die Elemente (16) ein Verbinden des Kunststoffelements mit der Fahrzeugkarosserie ermöglichen.Plastic element according to one of claims 1 to 11, characterized in that the elements ( 16 ) enable the plastic element to be connected to the vehicle body. Kunststoffelement nach einem der Ansprüche 1 bis 12, dadurch gekennzeichnet, dass die Kunststoffhinterspritzung (15) Kabel und/oder Kabelkanäle umschließt.Plastic element according to one of claims 1 to 12, characterized in that the plastic injection molding ( 15 ) Encloses cables and / or cable channels. Kunststoffelement nach einem der Ansprüche 1 bis 13, dadurch gekennzeichnet, dass das Element (16) ein Airbag-System ist.Plastic element according to one of claims 1 to 13, characterized in that the element ( 16 ) is an airbag system. Kunststoffelement nach einem der Ansprüche 1 bis 14, dadurch gekennzeichnet, dass das Kunststoffelement (10) Sollbruchstellen für das Airbag-System aufweist.Plastic element according to one of claims 1 to 14, characterized in that the plastic element ( 10 ) Has predetermined breaking points for the airbag system. Verfahren zur Herstellung eines Kunststoffelementes für Wandverkleidungen in Fahrzeugen, dadurch gekennzeichnet, dass zuerst ein Laminat (10) erstellt wird, welches aus vier Schichten (11, 12, 13, 14) aufgebaut ist, die durch Wärmeeinwirkung miteinander verbunden werden, mit (i) einer Dekorschicht (11), die aus einem Gewebe besteht, (ii) einer ersten Schicht zum Wärmeschutz (12) aus einem Polyethylen-Schaum, (iii) einer Schicht (13), die aus einem hochwärmefesten und zumindest bereichsweise reversibel nachgiebigen Thermoplast-Schaum aufgebaut ist, und (iv) einer zweiten Schicht zum Wärmeschutz (14), die aus einer Polypropylen/Polyester Vliesschicht gebildet ist, und dieses Laminat (10) anschließend in einer Form (20) mit Kunststoff (15) hinterspritzt (23) wird.Method for producing a plastic element for wall cladding in vehicles, characterized in that first a laminate ( 10 ), which consists of four layers ( 11 . 12 . 13 . 14 ), which are connected to one another by the action of heat, with (i) a decorative layer ( 11 ), which consists of a fabric, (ii) a first layer for thermal protection ( 12 ) of a polyethylene foam, (iii) a layer ( 13 ), which is constructed from a highly heat-resistant and at least partially reversibly compliant thermoplastic foam, and (iv) a second layer for thermal protection ( 14 ), which is formed from a polypropylene / polyester nonwoven layer, and this laminate ( 10 ) subsequently in a mold ( 20 ) with plastic ( 15 ) behind injected ( 23 ) becomes.
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EP3181347A1 (en) * 2015-11-26 2017-06-21 Diehl Aircabin GmbH Sandwich component
FR3069822A1 (en) * 2017-08-03 2019-02-08 Novares France METHOD FOR OVERMOLDING A TRIM PANEL WITH A FRAGILE TEXTILE PROTECTIVE LAYER

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