DE102007008557B3 - Plastic molded part manufacturing method for motor vehicle, involves attaching lining material piece to molded part using groove, heating molded part within area of groove, and partially welding side walls of groove with each other - Google Patents

Abstract

The method involves attaching a lining material piece to a molded part (36) using a groove (42) of the molded part such that an edge section of the lining material piece is taken up in the groove. The molded part is deformed within the groove area, when the groove is partially pressed together with lining material, where the edge section of the lining material piece lies in the pressed part of the groove. The molded part is heated within the area of the groove, and side walls of the groove are partially welded with each other. Independent claims are also included for the following: (1) a device for manufacturing a molded part (2) a plastic molded part covered with a lining material.

Description

The invention relates to a method and an apparatus for producing a molded part and a molded part produced according to the method. More particularly, the invention relates to a method of manufacturing a molded article laminated with a cladding material, according to the preamble of claim 1. Such a method is known from EP 1 211 051 A2 known.

The DE 697 19 506 T2 describes a method of making a molded article laminated with a facing material, wherein the molding has a groove and the trim piece of material is applied to the molding such that an edge portion of the trim material is received in the groove. The side walls of the groove are connected together by means of a mechanical fastener.

method for laminating moldings with a cladding material as well correspondingly laminated moldings are used in particular in the motor vehicle industry for the Interior of passenger compartments used. Interior paneling, such as interior door panels, dashboards, vehicle roof and the like, are formed by moldings to which a Cladding material, such as a foil, a textile fabric, a leather or artificial leather, is applied. The cladding material can for example, a fleece, a carpet, a slush skin, a PUR spray skin or a grained surface be. In the prior art, it is known to moldings with a uniform Cladding material or with different cladding materials to conceal, with the interface between the two different Covering materials usually covered by a trim strip or in a groove. The cladding materials themselves are usually applied to the molding via a back coating, for example polyolefin foam or polyolefin film to obtain a hot melt adhesive composition applied. The seams between the same or different Covering materials are usually by thermal welding, Gluing or sewing, realized.

The EP 1 211 051 A2 describes a method for producing a connection between two cover materials for a trim part. The trim part comprises a carrier and two different covering materials which do not have to be joined together but are adhesively adhesively bonded to the carrier independently of one another by a hot-melt adhesive contact adhesion. The connection of the two covering materials is taken up by a groove-shaped recess of the carrier, which is closed by pressing using a molding device. The forming apparatus includes a horizontally movable ram that forms a press nip relative to a protruding edge of a stationary mold. A press blade cooperates with a counter-clamping blade to clamp the carrier and the connection of the cover materials and then to press into the press nip. The press blade is then withdrawn while the ram closes the press nip by pressing to form a narrowed recess in the carrier. The connection of the two covering materials thus disappears in the press nip. In the process of EP 1 211 051 A2 For example, the groove for receiving the edge portions of the cover materials is produced from an undeformed straight support plate in a cold forming process. For this purpose, on the one hand, the press blade and the counter clamping blade, which are vertically movable, and on the other hand, the horizontally movable press ram necessary. This necessitates precise control of the dies in the vertical and horizontal directions and places considerable demands on the elasticity and dimensional stability of the backing material.

The WO 96/017719 A1 describes a method for producing a laminated with a Kaschierungsgewebe metal part for the inner lining of a motor vehicle. The Kaschierungsgewebe is glued directly to a still undeformed metal sheet and formed in this state in a deep-drawing process, wherein in the overlap region of superimposed covers a bead is formed in the metal sheet, in which the edge regions of the Kaschierungsgewebes are miteingezogen. This bead is then pressed together, whereby the edge regions of the Kaschierungsgewebes are clamped. The reason for the production of such a laminated metal part is that the use of additional moldings for the interior lining of motor vehicles should be avoided.

It It is an object of the invention, a method and an apparatus for producing a laminated molding and a manufactured according to the method Specify a molding in which one with one or more different Cladding materials laminated molding in a simple way can be made with a clean appearance. This task is achieved by a method having the features of claim 1, a device having the features of claim 9 and a Molded part according to claim 11 solved.

With the method according to the invention, a molded part is produced, which is laminated with a cladding material, wherein the molded part has a groove which receives edge portions of the cladding material. According to the method, a first Cladding material piece is applied to the molding such that an edge portion of the cladding material piece is received in the groove, the molding is heated in the region of the groove and then deformed by at least partially compressing the groove, wherein the edge portion of the cladding material piece in the compressed part of the groove to lie comes. The heating of the molding in the region of the groove and the pressing pressure are chosen so that the side walls of the groove are at least partially permanently welded during compression. As a result, a very dimensionally stable, narrow groove can be formed, which receives the edge portion of the cladding material and securely holds between the pressed side walls of the groove. The molded part can be a plastic injection molded part with a preformed groove, wherein the flanks of the groove are welded during the pressing operation and the molded part receives additional stability by the pressing and welding of the groove.

By the welding the side walls of the Groove is guaranteed that the two sections of the molding on both sides of the groove relative to each other not are mobile and that the Groove the edge portions of the cladding material securely fixed.

In a preferred embodiment According to the invention, a second piece of lining material is so on applied to the molding, that too an edge portion of the second trim piece of material in the Groove is received, wherein the first and the second piece of lining material piece on opposite Sides of the groove opposite lie. The two trim pieces of material may be the same or different Be made of materials. This can be a lamination in a simple way for a Molded part are made, which has a two-tone effect, wherein the different panel materials different shades or too different surface structures to have. For example, it is possible to provide a cladding material on one side of the groove, while the other side of the groove is grained.

In an advantageous embodiment The invention is the groove first essentially U- or V-shaped is formed and is only in a lower bottom portion of the groove welded. However, the groove may also have a different geometric shape, they may be interrupted and / or over their length is different Have depths. The compression and joining of the groove can be so be controlled that the Groove in its upper area where it enters the surface of the laminated molding opens, an opening with has defined distance while the side walls the groove are firmly connected in its lower region, where appropriate irregularities the welding on the surface of the Laminated molding do not come to light.

The Cladding material can be glued to the molding, laminated, pressed, laminated or sprayed on or otherwise applied.

In an advantageous embodiment the invention, the molding is heated by means of infrared radiation, wherein the radiation during of pressing and welding the groove is removed so as not to interfere with the pressing process and a rapid and defined cooling of the molding die after the Pressing and welding to enable. Also a warming the molding by means of hot air or other suitable heating is within the scope of the invention.

It is useful the laminated with the cladding material for heating and Pressing into a pressing tool inserted, wherein in an advantageous embodiment of the invention, the pressing tool tempered in advance, that is to a defined temperature the ambient temperature is brought to the most uniform process parameters for the pressing and welding process, and in particular a predetermined temperature profile over the Time to achieve. Especially with difficult geometric shapes the molding can be warming also outside of the pressing tool respectively. Even if the pressing tool designed so that a radiator for reasons of space can not be accommodated, it would be appropriate to the press tool (Fastening tool) to connect a heating station.

The invention also provides an apparatus for carrying out this method. This apparatus comprises a lower die having a fixed press block and at least one movable press block and an upper die which also has a fixed press block and at least one movable press block. The molding is inserted between the lower die and the upper die so that the groove comes to rest between each of the fixed and movable blocks, and the respective movable blocks are moved toward the fixed blocks to press the groove and connect their flanks , In a preferred embodiment of the invention, guide elements are formed in the surface of the upper tool or of the lower tool facing the molded part, which can be brought into engagement with corresponding guide elements formed on the molded part. For example, guide webs are formed on the non-laminated side of the molding in the vicinity of the groove and substantially parallel to the groove. The guide bars are by correspond de guide grooves in the lower tool or upper tool and ensure that in the merging of the fixed and the movable press blocks, the molded part is defined entrains. Instead of guide webs and grooves z. As well as round pins, domes or other formations, such as retainers, corners and edges of the molding, take over the task of defined entrainment of the molding with the joining tool.

The The invention also provides a molded part which is provided with a cladding material is laminated. This molding has a groove, and an or several pieces of lining material are applied to the molding so that edge portions of the lining material pieces in the Groove are included. The molding is compressed in the region of the groove, and the side walls the groove are at least partially permanently welded together to the Edge portions of the trim pieces of material in the compressed part to hold and hide the groove.

The Cladding material can be glued to the molding, laminated, pressed, laminated or sprayed or applied in any other way. The cladding material is for example a film, a textile fabric, a leather or a synthetic leather. Other conceivable paneling materials are fleece, carpet, slush skin, PU spray or a grained surface.

In the preferred embodiment The invention is the molding for the interior trim of a motor vehicle used, for example, the interior trim of a vehicle door, a Dashboard or the vehicle sky.

The Invention is in the following with reference to a preferred embodiment with Closer to the drawings explained. In the figures show:

1 a partially sectioned side view of an apparatus for producing a molding according to the invention;

2 an isometric view of the lower tool of the device of 1 ;

3 an isometric view of the upper tool of the device of 1 ;

4 an isometric view of a heater of the device of 1 ;

5 an isometric view of a molding according to the invention prior to deformation;

6 a plan view of the molding of the 5 ;

7 a front view of the molding of the 5 ;

8th a side view of the molding of the 5 ;

9 an isometric view of a molding according to the invention after deformation;

10 a plan view of the molding of the 9 ;

11 a front view of the molding of the 9 ; and

12 a side view of the molding of the 9 ,

With reference to the 1 to 4 In the following, an embodiment of the device according to the invention for producing a laminated molding is described. The device is on a base plate 10 mounted, which carries a lower tool, which has a movable press block 12 and a fixed press block 14 includes. Opposite this is a movable press block 16 and a fixed press block 18 of the upper tool, attached to a cover plate 20 are attached. The cover plate 20 is relative to the base plate 10 over a guide column 22 stored in guide blocks 24 . 26 is held.

On the side of the movable press blocks 12 . 16 is a horizontally movable press stamp 28 arranged, this one over a wedge 30 against the movable press blanks 12 . 16 suppressed. The pressing pressure is via press ram 32 on the press stamp 28 applied. This pressing device is via a mounting block 34 on the cover plate 22 attached and in guide rails 35 guided.

Between the movable and stationary press block 12 . 14 of the lower tool and between the movable and fixed press block 16 . 18 the upper tool is a laminated molding 36 inserted, with further details with respect to the 5 to 12 is described. In the 1 and 3 are guide grooves 38 . 40 indicated, which are engageable with corresponding guide webs on the inside of the molding in engagement with the formed in the molding groove 42 Compress with defined, reproducible force. As explained above, other guide elements may be formed on the molding and the press block, for example pins, dome or other formations on the molding, which are gripped by the press block.

In the 1 and 4 is also a heater 44 shown, for heating the molding 36 before pressing the groove is used. This heater 44 is with more details related to 4 explained. During the pressing process, when the press blocks 12 to 18 are joined together, this heater 44 preferably in a waiting position, as in 44 shown, driven, in which it does not interfere with the pressing process. For heating the molded part 36 However, it is in a position that can be brought in 1 at 44 is indicated. The heater 44 is this along a guide rail 46 traversable. Instead of a heating device integrated in the joining tool, it is also possible to provide a heating device arranged upstream of the joining tool.

Further details of the inventive device for producing the laminated molding are in the 2 to 4 shown, wherein corresponding parts are denoted by the same reference numerals. This shows 2 an isometric view of the lower tool, in relation to 1 is shown from the rear right while 3 an isometric view of the upper tool shows, which in relation to 1 also viewed from the back.

4 shows further details of the heater 44 , which in the embodiment shown three Konturheizstäbe 48 . 50 . 54 includes. Two of the heating elements 48 . 50 are at a plate 52 held and along the guide rail 46 movable in horizontal direction. The third contour heating element 54 is at a distance from the first and the second contour heating element 48 . 50 arranged underneath these and together with the two first Konturheizstäben 48 . 50 along the guide rail 46 movable in horizontal direction. In the embodiment shown, the third Konturheizstab is movable together with the first and second Konturheizstab. In an alternative embodiment, however, these can be moved separately from one another and controllable with regard to their temperature profiles. It is possible that the heating elements are also arranged vertically or obliquely and movable depending on the contour of the molded parts to be processed.

The details of mounting and mounting the guide rail 46 and the Konturheizstäbe 48 . 50 . 54 will not be described in detail here. They emerge from the drawings and beyond that are easily comprehensible for a specialist.

When a molding according to the invention with the in 1 to 4 is first shown a molding as it is in the 5 to 8th is shown, prefabricated and laminated with a cladding material. This molding 36 For example, is made of plastic by injection molding, but it can also be extruded or formed with another suitable molding process. Thus, it is also possible to produce a molded part from a wood fiber material or another natural fiber material by means of a molding press. In the embodiment shown, the molding is used 36 as interior trim of a motor vehicle door, the invention of course is not limited thereto. An essential part of the molding according to the invention is the groove 42 , in which the edge regions of the cladding material are introduced. Before deformation, the molding with the cladding material, z. Example, a textile, a film, leather or artificial leather, laminated, wherein a plurality of different and different trim pieces of material can be applied, the edge regions in the groove 42 be inserted or glued. In the preferred embodiment of the invention, the molded part 36 Guide elements, for. B. guide webs, 56 . 58 have substantially parallel to the side edges of the groove 42 run and on the surface facing away from the cladding material of the molding 36 are formed.

In the method according to the invention for producing the molded part, this is first laminated with the cladding material and then in the in the 1 to 4 shown inserted device. In a first processing step, the molded part is in the region of the groove 42 with the help of the heater 44 heated. For this purpose, the heater 44 along the guide rail 46 move so that the contour heating rods 48 . 50 on one side of the molded part and the contour heating element 54 come to lie on the opposite side of the molding, as in 1 at 44 ' indicated. The contour heating rods give z. B. from an infrared radiation, the invention is not limited thereto. Depending on the contour of the molded part, the heat can also z. B. be introduced by means of hot air.

Due to the heating, the plastic molded part in the groove 42 softens, so that it can be easily deformed afterwards.

The heater 44 is then moved to their waiting position, and the upper tool consisting of the press blocks 16 . 18 is positioned as in 1 shown. Subsequently, the movable press blocks 12 . 16 of the upper or lower tool on the press stamp 28 and the wedge 30 against the stationary press blanks 14 . 18 pressed to the groove 42 compress. Here, the guide webs 56 . 58 in the corresponding guide grooves 38 . 40 of the upper tool, so that on the side walls of the groove 42 a defined pressing force is applied. In an alternative embodiment it would be also possible to drive the movable press blocks not by wedges, but by separate drives, such as hydraulic cylinders.

As in the 5 to 7 is shown in the preferred embodiment of the invention, the groove 42 initially U- or V-shaped, wherein the upper ends of the groove flanks are extended in the vertical direction. In the preferred embodiment, the groove 42 compressed only in a lower portion, so that at the mouth of the groove a clean, defined gap remains, which should be just wide enough to accommodate the cladding material without excessive squeezing. The press blocks 16 . 18 of the upper tool, the in 3 are shown are therefore in the range of the groove 42 formed so that the flanks are brought into contact and welded in the lower portion of the groove in the pressing process, while the groove mouth is indeed pressed together, but not so far that here come the opposite side walls of the groove in contact.

The 9 to 12 show various views of the molding according to the invention after deformation. It can be seen that the groove 42 is largely closed, forming a gap in the region of its mouth with a defined opening width, so that the cladding material can be absorbed without excessive squeezing in the closed groove.

In order to achieve the most uniform possible course of the process with a defined temperature profile of the molded part, in a further embodiment of the invention, the press blocks can be tempered, that is, brought to a defined preheating temperature, so that the molded part before heating with the heater 44 has a defined starting temperature. In the preferred embodiment, all press blocks are heated to achieve a defined extraction temperature after cooling of the molded part.

The in the foregoing description, drawings and claims Features can both individually and in any combination for the realization of the invention in the various embodiments of importance.

10

baseplate

12

Portable Press block of the lower tool

14

fixed Press block of the lower tool

16

Portable Press block of the upper tool

18

fixed Press block of the upper tool

20

cover plate

22

guide column

24 26

guide blocks

28

press ram

30

wedge

32

press ram

34

mounting block

35

guide rail

36

molding

38 40

guide

42

groove

44

heater

44 '

heating position the heater

46

guide rail

48 50

Konturheizstäbe

52

plate

54

Konturheizstab

56 58

guide webs

Claims (17)

Method for producing a plastic molding ( 36 ), which is laminated with a cladding material, wherein the molded part ( 36 ) a groove ( 42 ), in which a first lining material piece so on the molding ( 36 ) is applied, that an edge portion of the lining material piece in the groove ( 42 ) is recorded; and the molded part ( 36 ) in the region of the groove ( 42 ) is deformed by at least partially compressing the groove, wherein the edge portion of the first piece of lining material is located in the compressed part of the groove; characterized in that the molded part ( 36 ) in the region of the groove ( 42 ) is heated; and the side walls of the groove are at least partially welded together during compression. Method according to Claim 1, characterized in that a second piece of lining material is applied to the molded part ( 36 ) is applied, that also an edge portion of the second cladding material piece in the groove ( 42 ), wherein the first and second trim pieces of material on opposite sides of the groove ( 42 ) are opposite. Method according to one of the preceding An claims, characterized in that the groove ( 42 ) is formed substantially U- or V-shaped and permanently connected only in a lower bottom portion of the groove. Method according to one of the preceding claims, characterized in that at least one trim piece of material on the molded part ( 36 ) is glued, laminated or pressed on. Method according to one of the preceding claims, characterized in that at least one piece of trim piece on the molded part ( 36 ) is sprayed on. Method according to one of the preceding claims, characterized in that the molded part ( 36 ) is heated by means of infrared radiation or hot air and the radiation is removed during the pressing process. Method according to one of the preceding claims, characterized in that the molded part laminated with the cladding material ( 36 ) is inserted for heating and pressing in a pressing tool. Method according to claim 7, characterized in that that this Pressing tool is tempered. Device for carrying out the method according to one of the preceding claims, characterized by a lower tool which has a stationary press block ( 14 ) and at least one movable press block ( 12 ) and an upper tool, which has a fixed press block ( 18 ) and at least one movable press block ( 16 ), wherein the molded part ( 36 ) is insertable between the lower tool and the upper tool such that the groove ( 42 ) between the respective fixed ( 14 . 18 ) and moving blocks ( 12 . 16 ) and the respective moving blocks ( 12 . 16 ) in the direction of the fixed blocks ( 14 . 18 ) are movable to the groove ( 42 ) to be pressed and welded. Apparatus according to claim 9, characterized in that in the molded part ( 36 ) facing surface of the upper tool or the lower tool guide elements ( 38 . 40 ) formed with corresponding to the molding ( 36 ) formed guide elements ( 56 . 58 ) are engageable. Plastic molding ( 36 ), which is laminated with a cladding material, wherein the molded part ( 36 ) a groove ( 42 ), in which a first lining material piece so on the molding ( 36 ) is applied, that an edge portion of the lining material piece in the groove ( 42 ) is included; and the molded part in the region of the groove ( 42 ) and the side walls of the groove ( 42 ) are at least partially connected to each other, wherein the edge portion of the first trim piece of material in the compressed part of the groove ( 42 ) and wherein the side walls of the groove are partially welded. Molding according to Claim 11, characterized in that a second piece of lining material is thus applied to the molded part ( 36 ) is applied, that also an edge portion of the second cladding material piece in the groove ( 42 ) is received, wherein the first and the second piece of lining material piece on opposite sides of the groove ( 42 ) are opposite. Molding according to claim 11 or 12, characterized in that the side walls of the groove ( 42 ) are connected only in a lower section. Molding according to one of claims 11 to 13, characterized in that at least one lining material piece on the molded part ( 36 ), laminated or pressed on. Molding according to one of claims 11 to 14, characterized in that at least one piece of lining material is applied to the molded part ( 36 ) is sprayed on. Molding according to one of claims 11 to 15, characterized that this Covering material a foil, a fabric, a leather or a synthetic leather includes. Use of a molding according to one of claims 11 to 16 as part of the interior trim of a motor vehicle.