DE102005052347A1 - Motor vehicle interior panel manufacture involves molding thermoplastic substrate in first tool, enlarging tool cavity and injecting foamable elastomer onto substrate where outer skin is formed against cold tool surface - Google Patents

Abstract

A first plastic material(20) is injected into a first tool cavity(16) to form a molded substrate section of the final panel. A mixture of a thermoplastic elastomer and blowing agent heated under pressure in an injection molding machine is injected into a larger, second tool cavity which contains the substrate molding and molds a cushioning section onto the substrate. The mixture expands when there is no pressure acting on it and a smooth outer skin forms on the mixture as it meets a relatively cold tool surface. The outer skin of the foamed cushioning section forms after contact with a cooled tool surface. Substrates are molded in relatively rigid thermoplastic plastics. The mixture of thermoplastic elastomer and blowing agent is supplied in pellet form. The first tool cavity is formed by two tool parts(12,14) which move relative to each other and in their closed position form the shape of the initial substrate. A second tool cavity is created by removal of the second tool part and adding a third while the substrate remains in the cavity formed by the first tool part. Independent claims are included for the following: (1) a tool(10) for molding an interior panel for a motor vehicle which comprises a first injection molding tool with a first part(12) having an injection point(18) and a second part(14) which together form a cavity(16) for molding a substrate and a second tool formed by the first tool part, the molded substrate and a third tool part, the latter having an injection inlet for a polymer mixture forming the skinned cushioning section of the panel; (2) a motor vehicle interior panel construction comprising a substrate and a cushioned cover part with a smooth outer skin enclosing an expanded core and the thermoplastic elastomer and blowing agent mixture forming the skin and core is melted under pressure in an injection molding machine.

Description

BACKGROUND OF THE INVENTION

1. Field of the invention

The The present invention relates to a process for producing a Interior equipment component, a mold for forming the interior equipment component, and the trim component comprising a substrate portion and a padded cover portion having a smooth Has outer skin, which surrounds an expanded core. The smooth outer skin and the core are made from the same mixture, which there the smooth outer skin trains where it touches the mold, and also the expanded core in the inner sections of the mold formed.

2. Technical background

Interior components for a Vehicle can made of different materials including cloth, plastic and Leather can be produced. There have been numerous different manufacturing processes designed to create a desired surface texture, surface finish and upholstery available to deliver. Cushioned areas of vehicle interior components were originally so made that fabric over a cushioning composite was sewn on. This approach was to a significant extent Replaces manufacturing processes in which outer skins made of plastic by rotational molding were made in closed molds used for this purpose became "balloon-like" cases form, which were then filled with expanded elastomer foam materials. This later developed rotational molding process resulted in significant savings, and facilitated the provision of improved polymeric materials and of Product systems, which reduced the cost of production.

In front Recently, one of the co-inventors of the present application filed US Serial No. 10 / 708,312, entitled "Automotive Interior Equipment Assembly and method with simultaneous injection in two shots "addressed to the holder of the present application has been. This application described the concept of making a Automotive interior trim assembly, wherein a substrate part by injecting a material into a mold, after which a second and a third material simultaneously through a coaxial opening be injected in a mold. The second material forms a Skin layer while the third material forms a foam layer.

One Disadvantage of this procedure is that three materials fed to an injection molding machine Need to become. Costs associated with the provision of additional material, and Costs associated with maintenance, such as rinsing three different materials, and the requirement that a special injection mold for There must be three components that are present belong to the process which is described in the previous application.

With These and other problems and disadvantages are dealt with Applicants' invention as summarized below is reproduced.

SUMMARY THE INVENTION

According to one Aspect of the present invention is a method of preparation an interior equipment field for a vehicle described. The method comprises a first material Injecting into a first injection mold cavity, the mold a substrate portion of the trim panel sets to form the substrate portion. A second material and a Blowing agents are fed to an injection molding machine. In the injection molding machine, the second material is melted under pressure, and mixed with the blowing agent to form a blown elastomer, the even an outer skin formed. That itself an outer skin forming, blown elastomer is placed in a second injection mold cavity injected, which contains a previously formed substrate portion, the to the shape of a padded portion of the trim panel sets. That itself an outer skin forming blown elastomer is injected into the cavity, to form a padded section of elastomeric foam, the smooth outer skin on the outer surface of the padded portion has.

According to others Aspects of the method according to the present invention Invention is the smooth skin section the padded portion of elastomeric foam in contact with a relatively cold mold surface educated. The first material is a thermoplastic material, which forms a relatively rigid substrate portion, and can a material selected from the group consisting of thermoplastic Olefin, acrylonitrile butadiene styrene, styrene maleic anhydride, a Polycarbonate / acrylonitrile butadiene styrene compound, and polypropylene consists. The second material may be a thermoplastic elastomer be, for example, polycarbonate or polypropylene.

According to others Aspects of the invention, as far as it relates to the method can a first injection mold cavity a first mold portion and a second mold section, the relative to each other between one opened Position and a closed position to be moved. In the closed Position, the shape of the substrate portion is set, and a injected thermoplastic olefin to a relatively rigid substrate train. The second injection molding cavity can through the first Mold portion of the first injection mold, the previously formed Substrate portion of the Innenausstattungsfeldes, and a third mold section be formed. A blown, self-forming skin Elastomer is heated and injected into the second injection mold cavity to form a padded portion having a smooth skin.

One Another aspect of the present invention relates to a mold for Formation of an interior trim component of a vehicle. The Mold comprises a first injection mold, which has a first mold section and a second mold portion that is relative to each other between an open one Position and a closed position to be moved. Form the substrate portion is defined by the first and second mold sections, when they are in the closed position. The first Mold section has at least one opening for injecting a first polymer material. A second injection mold comprises the first mold portion of the first injection mold, the previously formed Substrate portion of the interior panel, and a third Mold section. The third mold section has at least one opening to the Injecting a mixture of a second polymer material and a blowing agent, which melted and under pressure in the second Injection mold are injected. The mixture forms, after injection in the form, a smooth outer skin On contact with the chilled ones Mold walls, and a foam core when the blowing agent in the inner section the second injection mold expands.

According to others Aspects of the invention may include the first portion of the second injection mold cavity, while the substrate portion is held relative to the third portion between an open one Position and a closed position are moved to one Cavity for the formation of a padded portion of elastomeric foam set. The mixture of the second polymer material and the Blowing agent is supplied to an injection molding machine in solid form.

According to one Another aspect of the invention is a vehicle interior trim assembly to disposal posed. The vehicle interior trim assembly includes a substrate portion on which a padded cover integrally formed is. The padded cover has a smooth outer skin which surrounds an expanded core. The material for training the smooth outer skin and The core used is a mixture of an elastomer and a blowing agent under pressure in an injection molding machine are melted, and fed to the mold, in which a smooth outer skin On contact formed with cooled mold walls is formed, and the expanded core is formed inside the mold.

These and other aspects of the present invention will become more apparent Reference to the attached Drawings and the following, detailed description of a preferred Embodiment of Invention understandable become.

SUMMARY THE DRAWINGS

1 FIG. 10 is a cross-sectional view of a molding tool for forming a substrate portion of an interior fitting; FIG.

2 Fig. 10 is a cross-sectional view of a mold for forming a foam cushion portion of an interior trim member, showing an initial injection of elastomer itself forming an outer skin;

3 Fig. 10 is a cross-sectional view of a mold for forming a padded portion of an interior trim component after completion of the molding cycle; and

4 FIG. 12 is a cross-sectional view of an interior trim component formed according to the described method. FIG.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

In 1 is a mold 10 shown, which is a first molded part 12 and a second molded part 14 having. The first molded part 12 and the second molding 14 form a substrate mold cavity 16 , An opening 18 for a thermoplastic olefin (TPO) is for injection of TPO 20 provided by a TPO source 22 is pumped out.

In the 2 and 3 is a shaped substrate 24 on the first molding 12 shown. A third molding 26 is shown which engages the first mold part 12 stands. The third molding 26 has an opening 28 for thermoplastic elastomer (TPE), through which a molten mixture of a blowing agent 30 and TPE 32 when a mixture 34 be injected. The mixture 34 is pressurized in an injection molding machine 36 in the cushion formation cavity 38 heated.

Depending on the geometry and size of the part, and the choice of material, the temperature and pressure are set. Typically, thermoplastic polycarbonate or polypropylene olefins are heated to between 200 ° F and 500 ° F at pressures between 1000 and 20,000 psi. The propellant 30 and TPE 32 become the injection molding machine 36 through a feed chute 40 fed in the form of solids or pellets. After injection, this mixture can 34 as a blown elastomer forming an outer skin itself 42 be designated.

The blown elastomer 42 forms a padded section 44 within the cushioning cavity 38 out. An outer skin 48 is due to the blown elastomer 42 trained where it is the relatively cold molding 26 touched. The molded article may be cooled by circulating water or by air, as is well known in the art.

The TPO may be acrylonitrile butadiene styrene, styrene maleic anhydride, a polycarbonate / acrylonitrile butadiene styrene compound, or polypropylene. The thermoplastic elastomer may be polycarbonate or polypropylene. Other thermoplastic elastomers can also be used, provided that they form a smooth outer skin when in contact with the cold molded part 26 are forced. The blown elastomer 42 expands, and comes into contact with the cold molding 26 forced, which quickly mix 42 cools, and forms a smooth outer skin before the propellant can expand significantly.

In 4 a finished interior trim is shown as being a substrate 24 and a cushion section 44 which has the outer skin 48 comprising the blown elastomer.

Though were embodiments illustrated and described the invention, however, these embodiments not all possible forms represent and describe the invention. Instead, the in terms used in the description are descriptive rather than limiting terms, and it is noted that various changes can be made without departing from the spirit and scope of the invention.

Claims (14)

Method of manufacturing an interior fitting for a Vehicle, with: Injecting a first material into one first injection mold cavity, which takes the form of a substrate section the trim panel to form the substrate portion; Heating one Mixture containing a thermoplastic elastomer and a blowing agent contains under pressure in an injection molding machine; Injecting the mixture into a second injection mold cavity containing the substrate portion contains and the shape of a padded portion of the trim panel sets; Formation of an elastomer foam pad section in the second injection mold cavity as the mixture expands, when pressure is no longer exerted on the mixture; and education a smooth outer skin on the surface the mixture, which is a relatively cold wall of the second injection mold cavity touched. The method of claim 1, wherein the smooth Skin section the elastomer foam pad portion is formed after contact with a cooled mold surface becomes. The method of claim 1, wherein the first Material is a thermoplastic olefin, which is a relative rigid substrate portion forms. The method of claim 1, wherein the first Material selected from the group is, which consists of: acrylonitrile butadiene styrene; styrene maleic anhydride; one Mixture off Polycarbonate / acrylonitrile butadiene styrene; and Polypropylene. The method of claim 1, wherein the mixture of the thermoplastic elastomer and the blowing agent of the injection molding machine supplied as solid pellets becomes. The method of claim 1, wherein the first Injection mold cavity through a first mold section and a second mold section is formed, which is relative to each other between an open one Position and a closed position, where in the closed position, the shape of the substrate portion is determined. The method of claim 6, wherein the second injection mold cavity is defined by the first mold portion of the first injection mold, the substrate portion of the trim panel, and a third mold section is formed. Form for forming an interior trim component of a vehicle, wherein are provided: a first injection mold, which has a first mold section and a second mold section, the relative to each other between an open position and a be moved in the closed position, in which the shape of a Substrate section is determined, wherein the first mold section at least one opening for injecting a first polymeric material; a second injection mold, which the first mold section of the first Injection mold, the substrate portion of the trim panel, the is formed from the first polymer material, and a third Mold portion, wherein the third mold portion has at least one opening, through which is a mixture of a second polymer material and a Propellants are injected, the mixture is heated under pressure, whereupon the mixture has a smooth surface on contact with the third mold section forms, and the mixture forms an expanded core, if the propellant expands in an inner portion of the second Injection mold. A mold according to claim 8, wherein the first material a thermoplastic material is a relatively rigid substrate portion formed. A mold according to claim 8, wherein the second material a thermoplastic elastomer. Mold according to claim 8, wherein the first mold section of the second injection mold cavity, while holding the substrate section supports, relative to the third mold section between an open position and a closed position is moved to a cavity for the formation of a Elastomer foam pad section defining a smooth outer skin on the outer surface of the padded portion has. Vehicle interior trim assembly, in which are provided: a substrate part; a padded cover, the one piece is molded onto the substrate part, wherein the padded cover part a smooth outer skin having an expanded core surrounding it and the material that used to form the smooth outer skin and the core is a mixture of an elastomer and a blowing agent, which are melted under pressure in an injection molding machine. Vehicle interior trim assembly according to claim 12, in which the substrate part formed by a first material which is a thermoplastic material that is relatively rigid Substrate portion forms. Vehicle interior trim assembly according to claim 12, in which the elastomer is a thermoplastic elastomer.