DE102008005103A1 - Method for producing slush-skin by applying plastic film of predetermined film thickness on forming surface of open forming tool by application unit, involves coating partial area of forming surface of forming tool with plastic film - Google Patents

Abstract

The method involves coating a partial area (20) of the forming surface of the forming tool with a plastic film of a predetermined film thickness. The total forming surface of the forming tool is coated with a plastic film of another predetermined film thickness. Same plastic is used for all steps that are carried out for applying a film. Independent claims are included for the following: (1) a method for manufacturing an instrument panel of a vehicle; and (2) a slush skin for forming a surface of a plastic product.

Description

The The invention relates to a method for producing one of its outer Side textured or smooth-textured slush-like skin as an outer layer of various forming products, preferably for an instrument panel in a vehicle interior, which is covered with a slush skin, with the in the preamble of claim 1, and that produced by this method Product, slush skin, with those mentioned in the preamble of claim 16 Features. Furthermore, the invention relates to methods for manufacturing an instrument panel of a vehicle with the in the preamble of Claim 12 mentioned steps and use of a slush skin with the features of claim 13.

It is known to be the impression of the quality feel of a Instrument panel and a center console in the interior of a vehicle crucial for a qualitative assessment of a vehicle through is a user. That is why in recent years of the Vehicle manufacturers have made numerous efforts in particular by producing a so-called slush skin, with the instrument panel is made coated, a Surface of, for example, a natural one Leather with very fine, incorporated into the surface To replicate structures.

It is also known that thin-skinned and large-scale Plastic products with a very fine surface structure preferably in open molds, either by the widespread Method of plastic sintering using centrifugal forces in rotating, heated molds made with plastic are charged in powder form, or by spraying / foaming a made of suitable plastic such as polyurethane become. Such thin plastic products For example, with a very fine surface texture in the interiors of vehicles for the Cladding surfaces used, so-called slush skins. The thin-skinned plastic products thus produced can have a thickness of a few tenths to a few millimeters. The molds are for this purpose in a so-called Galvanoformungsverfahren made of relatively soft metals such as nickel, copper, silver and others by electrodeposition from a liquid solution made on a previously made of wax, rubber or rubber the model of the same shape with the required shape and surface shape galvanically deposited the Galvanoform will, for example, the later molding tool for manufacturing of slush skins. The model form will either by melting, etching in the case of using metallic model forms or mechanically from the finished Galvanoform away.

A Such slush skin is in a preferably open, out of one Nickel, tin, copper, silver or similar galvanic easily produced metals produced Galvanoform in one relatively thin layer, for example 0.8 to 1.5 mm applied and the Galvanoform for the purpose of a uniform Distributing the plastic layer in a specific, for this purpose appropriate rotation and at the same time heated, thereby the plastic, for example PVC or polyurethane in powder form, plasticized and then cured.

The cut out of the Galvanoform and with great care removed slush skin is next in a second Mold inserted, the later for easy demolding a has smooth surface and the given outer Form of the instrument panel, the so-called Strack form, as well as the Galvanoform before, pretending. This can be the slush skin for example, in the mold through fine openings sucked so that it fits exactly and no air bubbles behind you can emerge.

In a parallel process is similar for example with the help of Technology manufactured an instrument panel carrier that a significantly larger, sustainable plastic layer thickness from about 2 to 3 mm. Because its inner surface is smooth may be, he is well demoldable and therefore can in its original Form remain. Alternatively, he can also be removed at this point and be inserted into a second mold again.

The Secondary mold with inlaid slush skin and the mold with the inserted instrument panel support, each forming a mold half, are now assembled together according to the principle of a waffle iron and point in the interior formed by them between the inlaid Slush skin and the instrument panel support a preferably uniform everywhere Distance of for example 8 mm, in the next step preferably foamed with a foaming plastic and is cured. The result is an instrument panel, which is easily demoulded and mechanically stable, by the foaming can be reduced in weight, exactly the predetermined Strack form replicated is and a fine surface texture of a slush skin having.

The thickness of the slush skin is formed by a uniform application of plastic in a Galvanoform relatively equal over the entire surface of the slush skin. Therefore, it must uniformly correspond to a layer thickness, which in only ei is specified in a particularly stressed area for reasons of strength. Such an area may be, for example, the area where an airbag unit is later mounted on the finished instrument panel from its inside. However, this makes the entire area of the slush skin in this same increased thickness, making the slush skin more expensive than necessary. Likewise, the later product made with this slush skin is made more expensive than necessary, because the material of the subsequent foaming is cheaper than the material used for the slush skin when using both plastic materials as a filling of the same layer thickness , which corresponds to the volume to be replaced, compares.

DE 102 29 922 A1 discloses a method for producing a slush skin, in which the application of the mold to the plastic powder is carried out by means of an attachable container by means of a rotation.

WO 2006 / 131154A1 discloses an apparatus and method for producing a slush skin of uniform thickness with the above-mentioned disadvantages.

DE 102 34 375 A1 discloses a method of making a slush skin in a closed mold and uniform thickness.

DE 103 52 581 A1 discloses an interior trim panel provided with a lacquer layer instead of a slush skin.

DE 298 23 765 U1 discloses an interior trim part of a vehicle provided with a uniformly thick slush skin.

DE 198 55 277 C2 discloses an interior trim part and method of making it with a uniformly thick slush skin.

Of the Invention is given the above deficiencies and Disadvantages of the object, a method for producing a Slush skin, which as an outer layer of various shaping Products serves, preferably for an instrument panel in a vehicle interior that has an instrument panel carrier which is covered with a slush skin, so pretend that saved plastic material in the production of slush skin is to thereby reduce manufacturing costs. Furthermore, it is one Object of the invention to propose a slush skin without sacrificing quality is made saving material and a use of this slush skin for cost-saving production of interior trim parts of a Propose vehicle.

• – in wenigstens einem der Schritte nur wenigstens ein Teilbereich der formgebenden Fläche des Formwerkzeugs mit einer Kunststoffschicht von einer ersten vorgegebenen Schichtdicke überzogen wird, und
• – in wenigstens einem der anderen Schritte die gesamte formgebende Fläche des Formwerkzeugs mit einer Kunststoffschicht von einer zweiten vorgegebenen Schichtdicke überzogen wird, sind die Aufgaben der Erfindung realisiert.

Characterized in that in a method for producing a slush skin by applying a plastic layer of predetermined thickness to a forming surface of an open mold with the aid of a coating agent, the application of the slush-forming plastic layer is divided into the mold in at least two steps whose Order is arbitrary, and

• - In at least one of the steps only at least a portion of the forming surface of the mold is coated with a plastic layer of a first predetermined layer thickness, and
• - In at least one of the other steps, the entire forming surface of the mold is coated with a plastic layer of a second predetermined layer thickness, the objects of the invention are realized.

Further preferred embodiments of the invention will become apparent from the others, in the subclaims mentioned features.

• – zuerst der Schritt, in dem nur ein Teilbereich der formgebenden Fläche des Formwerkzeugs mit einer Kunststoffschicht von einer ersten vorgegebenen Dicke überzogen wird, ausgeführt, und
• – danach der Schritt, in dem die gesamte formgebende Fläche des Formwerkzeugs mit einer Kunststoffschicht von einer zweiten vorgegebenen Dicke überzogen wird, ausgeführt.

According to a preferred embodiment of the present invention is in the inventive method

• - First, the step in which only a portion of the forming surface of the mold is coated with a plastic layer of a first predetermined thickness, executed, and
• - Then the step in which the entire shaping surface of the mold is coated with a plastic layer of a second predetermined thickness, carried out.

• – zuerst der Schritt, in dem die gesamte formgebende Fläche des Formwerkzeugs mit einer Kunststoffschicht von einer zweiten vorgegebenen Dicke überzogen wird, ausgeführt, und
• – danach der Schritt, in dem nur ein Teilbereich der über der gesamten formgebenden Fläche des Formwerkzeugs zuvor ausgebildeten Kunststoffschicht mit einer Kunststoffschicht von einer ersten vorgegebenen Dicke überzogen wird, ausgeführt.

And according to a preferred embodiment of the present invention is in the inventive method in reverse order

• - First, the step in which the entire forming surface of the mold is coated with a plastic layer of a second predetermined thickness, executed, and
• - Then the step in which only a portion of the over the entire forming surface of the mold previously formed plastic layer is coated with a plastic layer of a first predetermined thickness, executed.

Thereby may be the thicker coating of the invention in at least one subarea depending on manufacturer-specific requirements first in the mold or subsequently on an already applied Slush skin be introduced. In the subarea with the additional Coating add the layer thicknesses of the general coating and the additional coating to a total layer thickness together, which in principle can not be thinner as the layer thickness of the general slush-skin layer.

According to one Another preferred embodiment of the present invention in the inventive method in all executed steps for applying a layer of the same plastic used. This is the most applicable embodiment, the However, in a further preferred embodiment, so adapted is that with the inventive method at the individual executed steps for application one layer of a different plastic is used.

Of the for applying a respective layer each used plastic may be in a further embodiment of the invention Process of other plastics used in at least one not completely enumerated properties distinguish as: color, composition, hardness, type, Filling material or degree of foaming.

In preferred embodiment of the invention Procedure, the application takes place only the at least one subregion with the plastic using a spraying device. It the same spraying device can be used for the Applying the actual skin is provided.

The Applicator is preferably a spray device, that of an electromechanical, electropneumatic or electrohydraulic powered and electronically controlled positioning over the areas to be sprayed respectively on the shape of shape aligned with the area to be sprayed to be led. Also this positioning unit can do the same thing which is already provided for applying the general slush skin.

According to Another preferred embodiment of the present invention is in the inventive method in a additionally between at least two steps, in which each a plastic layer is applied, executed Step on the sprayed layer a contactless Readable data carrier with data recorded on it placed on top and covered with plastic in the next step.

Of the contactless readable disk with on it recorded data may preferably be an RFID transponder, to resort to existing technologies can and the recorded data can preferably be manufacturing and identification parameters.

• a) zum Herstellen einer Slush-Haut in einem ersten Formwerkzeug,
• b) zum Entnehmen der Slush-Haut aus dem Formwerkzeug,
• c) zum Einlegen der Slush-Haut in ein zweites Formwerkzeug, das als eine Formhälfte ausgebildet ist, aa) zum Herstellen eines Instrumententafelträgers oder zum Einlegen eines vorgefertigten Instrumententafelträgers in einem/in ein Instrumententafelträger-Formwerkzeug, das als eine Formhälfte ausgebildet ist,
• D) zum Zusammenführen des zweiten Formwerkzeugs mit der darin im Schritt c) eingelegten Slush-Haut mit der anderen Formwerkzeughälfte mit dem darin im Schritt aa) ausgebildeten oder eingelegten Instrumententafelträger, und
• E) zum Ausschäumen des in dem im Schritt D) zusammengefügten, geschlossenen zweiteiligen Formwerkzeug ausgebildeten Zwischenraums mit einem Kunststoff, die im Schritt a) hergestellte Slush-Haut nach dem oben beschriebenen erfindungsgemäßen Verfahren zum Herstellen einer Slush-Haut herzustellen.

According to another aspect of the present invention, it is proposed in a method of manufacturing an instrument panel of a vehicle with the steps

• a) for producing a slush skin in a first mold,
• b) for removing the slush skin from the mold,
• c) for inserting the slush skin into a second mold formed as a mold half, aa) for producing an instrument panel support or for inserting a prefabricated instrument panel support into an instrument panel support mold formed as a mold half,
• D) for merging the second mold with the inserted therein in step c) slush skin with the other mold half with the step aa) formed or inserted therein instrument panel carrier, and
• E) for foaming the space formed in the closed two-part molding tool assembled in step D) with a plastic to produce the slush skin produced in step a) according to the above-described method according to the invention for producing a slush skin.

According to one Another aspect of the present invention is a use a slush skin of a first predetermined thickness with at least one formed with a different predetermined layer thickness Part of forming a surface of a plastic product proposed.

The used plastic product is preferably in another Embodiment of the use built in a Fahrzeiginnenraum Form surface assembly and this form surface assembly is preferably in yet a further embodiment of the present invention Invention an instrument panel, the cockpit area of a passenger compartment formed.

According to one Another aspect of the present invention is a slush skin for forming a surface of a plastic product proposed, which has at least two surface areas, each having a different layer thickness.

The Invention will be described below in embodiments the accompanying drawings explained. Show it:

1 a schematic cross-sectional side view through a Galvanoform with Aufsprühvorrichtung and an applied partial area according to the invention;

2 a schematic cross-sectional side view through a Galvanoform with erfindungsge in accordance with applied slush skin;

3 a schematic cross-sectional side view through a two-part mold with an inventive instrument panel therein and

4 a schematic cross-sectional side view through a Galvanoform with according to the invention applied in an alternative order additional coating in a partial area.

1 shows a schematic cross-sectional side view through a Galvanoform 10 with a spraying device 14 and a coated portion of the invention 20 ,

The surface 12 the Galvanoform 10 follows in this example the outer shape, the so-called Strackform the manufactured instrument panel 23 (please refer 3 ) and can be very finely structured.

With a robot arm 16 becomes the spray device 14 held in this example, but it may alternatively be held manually, and at a required distance corresponding to the shape contour of the surface 12 guided and applied a plastic layer according to one of the selected methods according to the prior art. In the first step, for example, this is only a partial area 20 provided with a layer of a predetermined layer thickness. The plastic can either be used as a powder for subsequent sintering by the warmed Galvanoform 10 or applied according to the prior art as a foamed plastic according to an alternative method.

The above the subarea 20 The layer to be applied can be predetermined in its layer thickness, for example by the feed rate, delivery rate or number of layers or the like. The layer thickness can also be within the subarea 20 be varied, for example, to take more account of the intended loads, for example. Furthermore, several subarea 20 with the same or different thickness of plastic over the surface 12 can be applied spread over more than one area particularly robust characteristics of the slush skin 22 pretend.

2 shows a schematic cross-sectional side view through a Galvanoform 10 with a slush skin applied according to the invention 22 , which are also above the sub-area applied in the previous step 20 has been applied. Here, the plastic of the previously applied partial area layer connects 20 with the plastic of the commonly applied slush skin 22 especially good if the sub-area layer 20 has not been completely cured.

3 shows a schematic cross-sectional side view through a two-part tool mold 101 . 24 with an instrument panel 23 in it, for example, a slush skin 22 with a thickened portion 20 , an instrument panel carrier 26 and a foamed plastic filling filled between them, for example 28 having.

Follow the previous steps 1 and 2 manufactured and from the Galvanoform 10 removed slush skin 22 with a thickened portion 20 is in a second mold 101 inserted, which as well as the Galvanoform 10 the outer Strackform corresponds, but preferably has a smooth and therefore easily demoldable surface. Another mold 10 , the instrument panel mold 24 , is with an inserted or produced in it instrument panel support 26 shown.

After the two mutually as tool halves corresponding molds 10 with inlaid slush skin 22 with a thickened portion 20 and instrument panel support 26 are attached to each other, a preferably foamed plastic such as polyurethane is filled via a (not shown) filling opening.

This shows the plastic filling 28 a layer thickness, the respective first and second distance a, b between the plastic filling 28 facing side of the instrument panel molding tool 24 and the plastic filling 28 facing side of the second mold 101 equivalent.

In this case, the instrument panel molding tool 24 be designed so that the second distance b against the additionally thickened portion 20 the slush skin 22 equal to the first distance a is executed by one of the thickening of the partial area 20 corresponding recess in the partial area a corresponding opposite arranged part surface of the instrument panel molding tool 24 is omitted. This ensures that after curing the instrument panel 23 the associated shrinkage of the plastic filling 28 a uniform surface shrinkage of the slush skin 22 on the instrument panel causes. However, the disadvantage is possibly that the instrument panel molding tool 24 This requires a special adaptation, especially if all tools are not created anyway for a new model anyway.

Therefore, in another embodiment of the method according to the invention the instrument panel molding tool 24 be left unchanged, whereby the distance b against the additionally thickened portion 20 the slush skin 22 smaller than the first distance a in the unthickened part of the slush skin. As a result, the plastic filling would shrink during curing shrinkage 28 the slush skin 22 shrink more strongly over the surface area with the distance a due to a larger shrinkage length than in the partial region with the shorter distance b. As a result, the subarea 20 with the extra layer on the slush skin 22 be perceived as a small emphasis. Therefore, this embodiment is suitable for special cases, in which this effect, for example, by using a little shrinking plastic for the plastic filling 28 can be excluded.

4 shows a schematic cross-sectional side view through a Galvanoform 10 with additional coating applied according to the invention in an alternative sequence in a partial region 20 the electroforming surface.

In contrast to the in 1 and 2 In this preferred embodiment according to the invention, a thin slush-skin layer is first produced 22 into the Galvanoform 10 registered and in a further process step, possibly after a small, but preferably incomplete curing phase of this slush-skin layer 22 , over at least a subarea 20 applied an additional layer of plastic predetermined layer thickness. As a result, depending on the circumstances of the production and the plastics used a better adapted sequence can be applied. Thus, for example, in this process sequence shown theoretically, or in longer cooling breaks possibly even, there is no danger that on the slush skin 22 a noticeable burr transition between the additional layer over the subregion 20 and the thin slush-skin layer 22 can be seen, as it is for the design in 1 and 2 could possibly occur.

The previous embodiments of the present invention are by way of example only, and not to be construed as limiting the present invention. The present invention can easily be applied to other applications become. The description of the embodiment is by way of illustration provided and not to the scope of the claims limit. Many alternatives, modifications and Variants are obvious to one of ordinary skill in the art without that he is the scope of the present invention would have to leave the, in the following claims is defined.

10

Mold Galvanoform

12

structured surface

14

Application means, sprayer

16

positioning, Positioning unit, robot arm

18

spray

20

Subregion Layer, subregion layer

22

Slush skin, layer

23

Plastic product, dashboard

24

Instrument panel carrier mold other mold half

26

Instrument panel support

28

Plastic filling, frothed

101

second mold

a

first distance

b

second distance

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 10229922 A1 [0009]
• WO 2006/131154 A1 [0010]
• DE 10234375 A1 [0011]
• - DE 10352581 A1 [0012]
• - DE 29823765 U1 [0013]
• - DE 19855277 C2 [0014]

Claims (16)

Method for producing a slush skin ( 22 by applying a plastic layer of predetermined layer thickness to a shaping surface of an open mold ( 10 ) by means of a contract agent ( 14 ), characterized in that the application of the slush skin ( 22 ) forming plastic layer in the mold ( 10 ) is divided into at least two steps whose order is arbitrary, and - in at least one of the steps only at least one sub-area ( 20 ) of the forming surface of the mold ( 10 ) is coated with a plastic layer of a first predetermined layer thickness, and - in at least one of the other steps, the entire shaping surface of the mold ( 10 ) is coated with a plastic layer of a second predetermined layer thickness. A method according to claim 1, characterized in that - first the step in which only a partial area ( 20 ) of the forming surface of the mold ( 10 ) is coated with a plastic layer of a first predetermined thickness is carried out, and - then the step in which the entire forming surface of the mold ( 10 ) is coated with a plastic layer of a second predetermined thickness is performed. Method according to one of the preceding claims, characterized in that - first the step in which the entire shaping surface of the molding tool ( 10 ) is coated with a plastic layer of a second predetermined thickness is performed, and - then the step in which only a portion ( 20 ) over the entire forming surface of the mold ( 10 ) previously formed plastic layer is coated with a plastic layer of a first predetermined thickness is executed. Method according to one of the preceding claims, characterized in that in all executed steps for applying a layer ( 20 . 22 ) is used the same plastic. Method according to one of the preceding claims, characterized in that in the individual steps executed for applying a layer ( 20 . 22 ) each a different plastic is used. A method according to claim 5, characterized in that the for applying a respective layer ( 20 . 22 ) used plastic differs from others in at least one of the not fully enumerated properties such as: color, composition, hardness, type, filler or degree of foaming. Method according to one of the preceding claims, characterized in that the application of only the at least one subregion ( 20 ) takes place with the plastic by means of a spray device. A method according to claim 7, characterized in that the application means a spray device ( 14 ), which is controlled by an electromechanically, electro-pneumatically or electro-hydraulically driven and electronically controlled positioning unit ( 16 ) is guided over the areas to be sprayed in each case aligned with the shape of the surface to be sprayed. Method according to one of the preceding claims, characterized in that in addition to between at least two steps, in each of which a plastic layer is applied, performed step on the sprayed layer a non-contact readable disk with data recorded on it is launched and subsequently Step covered with plastic. Method according to claim 9, characterized that the non-contact readable disk with data recorded on it is an RFID transponder. Method according to claim 9 or 10, characterized that the recorded data manufacturing and identification parameters exhibit. Method for producing a dashboard of a vehicle comprising the steps of a) producing a slush skin ( 22 ) in a mold ( 10 ), b) for removing the slush skin from the mold ( 10 ), c) for inserting the slush skin into a second mold ( 101 ), which is formed as a mold half, aa) for producing an instrument panel carrier ( 26 ) or for inserting a prefabricated instrument panel carrier ( 26 ) in an instrument panel carrier mold ( 24 ), which is formed as a mold half, D) for merging the second mold ( 101 ) with the slush skin inserted therein in step c) ( 22 ) with the other mold half ( 24 ) with the instrument panel carrier formed or inserted therein in step aa) ( 26 ), and E) for foaming the one in step D) assembled, two-part closed mold formed intermediate space with a plastic ( 28 ), characterized in that the slush skin produced in step a) ( 22 ) is produced by the method according to one of claims 1 to 9. Use of a slush skin ( 22 ) of a first predetermined layer thickness with at least one, formed with a different predetermined layer thickness therein, portion ( 20 ) for forming a surface of a plastic product ( 23 ). Use of a slush skin according to claim 13, characterized in that the plastic product ( 23 ) is a mold surface assembly installed in a vehicle interior. Use of a slush skin according to claim 14, characterized in that the molding surface assembly comprises an instrument panel ( 23 ). Slush skin ( 22 ) for forming a surface of a plastic product, characterized in that the slush skin ( 22 ) has at least two surface areas, each having a different layer thickness.