DE102008064843B3 - Interior trim part and method for producing an interior trim part and foaming tool - Google Patents

Abstract

Method for producing an interior trim part comprising a carrier (2), a skin (4) and a foam layer (3) arranged between the carrier (2) and the skin (4), comprising: a) providing a foaming tool (5) with a first (51) and a second (52) mold half, wherein the carrier (2) is inserted into the first mold half (51) and the second mold half (52) is coated with a silicone layer (53), b) producing the foam layer (3) between the silicone layer (53) and the carrier (2) in the foaming mold (5), wherein the silicone layer (53) covering the second mold half (52) does not bond with the foam layer (3) during manufacture of the foam layer (3) and of this is subsequently solved, c) pulling the skin (4) onto the foam layer (3).

Description

The invention relates to an interior trim part, a method for producing such an interior trim part and a foam tool.

Interior trim parts in the automotive sector, especially for motor vehicles (motor vehicle), are usually built up layered. The interior trim parts have a carrier, a foam layer applied to the carrier and a skin applied to the foam layer. The mounting of skins is usually done by injecting the skin with the foam layer and then applying the carrier.

However, many skins are not suitable for this. This concerns in particular decorative skins such. B. leather surfaces, which usually have to be applied in a further process step either manually or by means of a clamping tool on the interior trim part. When applying such a skin, however, numerous problems arise. A dermis does not have its own stability and therefore often has to be stretched onto the interior trim part. A method for mounting a dermis on an interior trim part is, for example, the document DE 10 2005 003 212 A1 removable. Here, the dermis is applied by means of a complicated machinery on the foam layer to ensure that in the foam layer, which is already arranged on the support, no pressure points, especially in the region of bends such as undercuts for a center console, glove boxes, ventilation ducts or fittings, occur.

Another alternative is given by the fact that the decorative skin is back-foamed directly. Such a method is described for example in the document DE 41 34 951 C1 disclosed in which the decorative skin is sucked to one half of a mold and is foamed with the foam material. However, the method disclosed therein has the disadvantage that the dermis must be made substantially in one piece, which is difficult especially for large areas to be covered. Frequently, leather skins have to be sewn together from several pieces, which results in foam being able to pass through the seams unless special precautions are taken.

Another alternative is to introduce a slush skin such as a PVC skin in a mold, to foam behind and then cover with the carrier. The slush skin itself has a high stability, so that the tensioning of a decorative skin on the interior trim part leaves no pressure points in the foam layer due to the stability of the slush skin. The disadvantage here is that the additional slush skin generates costs and has a high dead weight.

The DE 101 25 074 A1 , which is due to a legal predecessor of the applicant, shows an interior trim part and a method for its preparation. Details of the preparation process are explained in [0025] and [0026] of the cited reference. Accordingly, a slush skin ( 12 ) inserted in a support mold or the like. Then, on the one hand, the slush skin supporting elements, for example in the form of an insert frame ( 4 ) and a substantially dimensionally stable carrier ( 10 ) fixed at a defined distance above the support elements or directly on this and then a foam layer ( 11 ) between slush skin and wearer. This can be done by introducing a corresponding foam-forming substance in the space between Slushhaut and dimensionally stable support and subsequent formation of the foam layer, with a stable connection between slush skin, support elements and support is given by the foam layer. The cited document thus shows exclusively that a fixing / bonding between a slush skin and a carrier is given by producing a foam layer. Finally, in addition to the slush skin sections leather material ( 13 ) (see, for example, DE 101 25 074 A1).

The DE 103 29 259 A1 shows a likewise attributable to a legal predecessor of the applicant document relating to a plastic molding for automotive interiors and a corresponding manufacturing method. There, a decorative surface serving casting polyurethane skin is at least partially backfoamed and thereby brought into contact with a carrier. To distinguish with the present invention, the above applies, since the foam layer always adheres to the casting skin and the carrier and thus firmly connects.

The DE 10 2005 029 865 A1 relates to a method for producing a door trim panel for a door and a correspondingly manufactured article. Specifically shown is a method of manufacturing an interior trim panel for a vehicle door comprising the steps of: forming a frame having a raised portion defining a frame cavity, inserting a frame into a mold, spraying polyurethane onto the mold, and over a side of the frame; to form a skin / frame assembly, inserting the skin / frame assembly and a fiberglass mat into a reaction injection mold, closing the reaction spray form against the raised region to close the frame cavity, injecting polyurethane into the reaction spray mold that connects to the skin / frame assembly and the regions of the fiberglass mat that extend outside of the frame cavity to a glass fiber reinforced part forming, removing the glass fiber mat from the frame cavity, inserting a foam pad in the frame cavity, and attaching a cover over the glass fiber reinforced part and the foam pad to provide the interior trim panel with a padded frame surface. An inventive foaming back of a silicone layer, which is then released from the foam and is replaced by a decorative skin is not shown there.

The DE 10 2005 052 976 A1 relates to a vehicle door trim pad with multi-feel reference and a method of making the same. It is shown how a pad is made in a "two-shot molding" process wherein the substrate is formed in a first shot of the molding operation and the multi-felt cover is formed in the second shot of the molding operation. The production of a foam layer and a detachment of a silicone layer from such a foam layer and a subsequent replacement by a decorative skin is also not addressed here.

Object of the present invention is to allow the production of an interior trim part so that the process is inexpensive and requires little material.

• a) Bereitstellen eines Schaumwerkzeugs mit einer ersten und einer zweiten Formhälfte, wobei der Träger in die erste Formhälfte eingelegt wird und die zweite Formhälfte mit einer Silikonschicht überzogen wird,
• b) Herstellen der Schaumschicht zwischen der Silikonschicht und dem Träger in dem Schaumwerkzeug, wobei die die zweite Formhälfte überziehende Silikonschicht bei der Herstellung der Schaumschicht nicht mit der Schaumschicht bindet und von dieser anschließend gelöst wird,
• c) Aufziehen der Haut auf die Schaumschicht.

The method according to the invention for producing an interior trim part with a carrier and a foam layer arranged between the carrier and the skin comprises the following steps:

• a) providing a foam tool having a first and a second mold half, wherein the carrier is inserted into the first mold half and the second mold half is coated with a silicone layer,
• b) producing the foam layer between the silicone layer and the carrier in the foam tool, wherein the silicone layer coating the second mold half does not bond to the foam layer during the production of the foam layer and is subsequently detached therefrom,
• c) putting the skin on the foam layer.

The inventive method for producing an interior trim part thus comprises at least the following steps: First, the foam layer between support and silicone layer is produced in a foam tool. In this case, preference is given to an additional applied to the foam layer stabilizing skin such. B. omitted a slush skin. This saves weight over the prior art. In a further step, the skin is mounted on the foam layer, wherein the mounting can be done either manually or in a separate clamping tool. As skin especially decorative skins or a leather skin are suitable.

In one embodiment of the method, the first and second regions of the foam layer are produced in a multi-component process. If only two foam materials are used, a two-component process is suitable, in which case the first or the second region is first back-injected with the first or second foam material and then the missing region is supplemented. As a result, a particularly cost-effective production of the interior trim part is possible. In particular, as usual in multicomponent methods, a frame can be used to cover the area not to be back-injected or to be overmoulded. The density and index of the first and second foam materials are selected such that the first foam material is harder than the second foam material.

According to the method, the foam tool has a first and a second mold half, wherein the carrier is inserted into the first mold half and the second mold half is coated with the silicone layer and the silicone layer in the production of the foam layer does not bind to the foam layer and is detachable from this. In this variant, it is possible by means of the additional silicone layer to create a structuring of the foam layer on which the skin is reared later. Furthermore, it is advantageous if the silicone layer is reusable and washable, so that it can be used for producing a plurality of interior trim parts.

A further advantage is that the same foam tool can be used in the manufacture of the interior trim part, which is also used for the production of an interior trim part with a stabilizing skin, wherein the layer need only have the thickness and contours of the stabilizing layer to be replaced. So it is possible to produce with a foam tool both interior trim parts with simple skins and interior trim parts with later applied high-quality decorative skins. Furthermore, geometries can be incorporated in the layer, which are necessary, for example, in a later dermis, in particular in the area of the sutures. This applies, for example, ribs or rib-shaped indentations. These are introduced in such a way that they are in the region of the seams, z. B. an applied dermis lie.

In a further embodiment, the skin of the interior trim part is a decorative skin, preferably a dermis. In particular, leather skins are particularly sensitive. Furthermore, it is difficult to produce these in large dimensions. The fact that when using a leather decorative skin in the aforementioned interior trim part on an underlying slush skin or stabilizing skin can be dispensed with and at the same time no special, complicated in structure jig must be used, the quality of a covered with a leather skin lining interior trim increases greatly over those in the state of Technique known method. In particular, it is possible to apply the decorative skin manually, which further increases the quality of the interior trim part.

The manufacturing process for an interior trim part will now be described in more detail by way of example. Show it:

1a an embodiment of an instrument panel;

1b a foam layer of the instrument panel of the previous figure;

2 a longitudinal section through the instrument panel of 1a ;

3 a cross section through the instrument panel of 1a ;

4 a foam tool for producing an interior trim part as well

5 a foam tool.

The 1a shows an instrument panel 1 which is a carrier 2 , a foam layer 3 and one on the foam layer 3 overlying skin 4 having.

In the instrument panel 1 There is a plurality of openings in which additional elements can be embedded. This concerns, for example, the opening for a center console 11 as well as the recess 12 for a ventilation outlet, the recess 13 for a glove box flap or tab 14 as a sunscreen for an underlying opening area 15 in which fittings are used. It is clear that the skin 4 in the area of the openings 11 . 12 . 13 respectively. 14 and 15 has strong bends, with the bends in the area of the opening 11 as well as the recesses 12 and 13 essentially at 90 ° and the projection to move 180 °, the skin here is essentially along a curve.

In the 1b is the instrument panel 1 of the 1a shown again, the skin 4 not shown, so as to the different areas of the foam layer 3 show. The foam layer 3 is on the carrier 2 arranged. The foam layer 3 has a second area 32 which consists of a polyurethane with a density of 150 g / l. Furthermore, it is a first area 31 present, which the borders 311 . 312 . 313 . 314 . 315 and 316 includes. The first region consists of a higher density polyurethane, here 160 g / l, and has a different index, with the first foam material being harder overall than the second foam material. The hardness of the first region is selected such that no pressure points appear during later application of a skin and when tightening this skin in the region of the bends. The density of the second region foam material is selected to have pleasing haptic properties. Like the size ratios of the first area 31 and the second area 32 it can be seen at approximately uniform thickness of the foam layer 3 along the entire instrument panel, occupies the first area 31 less than 20% of the volume of the foam layer 3 one. Furthermore, the 1b removable, that the first area 31 is applied only at some selected locations, especially in areas with bends, which may be subject to great stress when pulling the skin.

The border 311 the area with bending of the center console allows for a simple mounting of the skin while avoiding pressure points and facilitates the insertion of a center console insert, which due to the greater hardness of the first area 31 this also can not damage. The same applies in the area of the recesses 12 and 13 , which each have a border 312 respectively. 313 in the area with angling of the recess 12 respectively. 13 exhibit. The same applies to the border of the fittings 315 , The border area 314 of the projection 14 is also part of the first section 31 and causes the edge area of the protrusion to have no pressure points when the skin is pulled around the protrusion. Furthermore, the outer border 316 the instrument panel 1 with the first foam material of the first area 31 refilled.

In the 2 becomes the longitudinal section 2 through the instrument panel 1 shown. On the carrier 2 passing through the opening 11 the center console and the recess 12 for the ventilation duct is interrupted, are a first foam material 33 and a second foam material 34 applied. The first foam material 33 is doing with the in the 1b used material identical, as well as the second foam material 34 with the second foam material of 1b is identical. From the representation of 2 is clearly visible that the outline 311 directly on the carrier 2 attaches and extends to the dermis 40 extends. In particular, the areas of angling are 401 and 402 to mention, which are bends about 90 °. From the bends 401 and 402 different are the bends 403 and 404 in the area of the border 312 the recess 12 executed. These are not sharp edges, as the bends have slight curves. Such a rounding is to be understood in the present application as an area with angling. Similar to the areas with angling 403 and 404 is also the area with angling 405 the border 316 educated.

In the 3 is a cross section through the instrument panel 1 of the 1a shown. At the instrument panel 1 it is a self-supporting instrument panel. The first foam material 33 , which forms the first region, is applied in such a way that the surface of the first region is substantially plane-parallel to the applied skin 40 runs. This is especially true at the top of the border 312 described. The surface 3120 the border 312 which of the dermis 40 is facing, is substantially parallel to the level of the dermis 40 in the area of angling 407 , It is not necessarily parallel to the surface of the carrier 3121 , The drawn distances between the dermis 40 and the foam layer 3 are only for better intuition: The dermis 40 lies, as in the other figures directly on the foam layer.

In the 4 is the cross section IV of 1a shown. Again, the first foam material forms 33 the first, the second foam material 34 the second area. The lead 14 indicates at its end facing the driver 140 a portion of the first foam material 33 which stabilizes the area of an angling 408 should contribute. Other stabilizing areas of a bend with first foam material are the areas 141 and 142 ,

In the 5 becomes a foam tool 5 shown, which is a first half of the mold 51 and a second mold half 52 having. For the inventive production of an interior trim part of the carrier 2 in the first half of the mold 51 inserted and the foam tool 5 closed. On the cavity 6 the tool facing surface of the second mold half 52 is a silicone layer 53 arranged, which with the materials to be introduced the foam layer 3 does not bind. After the back of the carrier 2 with the foam layer 3 The tool is opened and the foam layer is removed from the silicone layer 53 solved. The silicone layer 53 is profiled, so that regardless of the formation of the cavity different profiles 54 a foam layer 3 can be produced and facilitate the later Aufziehen a dermis or can absorb the seams. After removing the foam layer 3 from the silicone layer 53 , the silicone layer becomes 53 cleaned and reused in the tool. In case of wear of the silicone layer 53 this is replaced by a new silicone layer or another suitable layer. The layers can be used as skin, e.g. B. be designed as silicone skin.

Although the embodiment shows only an instrument panel, the method can be extended to other interior trim parts such as door panels, airbag covers, center console covers or the like.

Claims (14)

Method for producing an interior trim part with a carrier ( 2 ), a skin ( 4 ) and one between the carrier ( 2 ) and skin ( 4 ) arranged foam layer ( 3 ), comprising: a) providing a foam tool ( 5 ) with a first ( 51 ) and a second (52) mold half, wherein the carrier ( 2 ) in the first half of the mold ( 51 ) is inserted and the second half ( 52 ) with a silicone layer ( 53 ), b) producing the foam layer ( 3 ) between the silicone layer ( 53 ) and the carrier ( 2 ) in the foaming tool ( 5 ), wherein the second half of the mold ( 52 ) covering silicone layer ( 53 ) in the production of the foam layer ( 3 ) not with the foam layer ( 3 ) and is subsequently dissolved by this, c) raising the skin ( 4 ) on the foam layer ( 3 ). Method according to claim 1, characterized in that a first and a second area ( 31 . 32 ) of the foam layer ( 3 ) are produced in a multi-component process. Method according to one of the preceding claims, characterized in that the skin ( 4 ) is a leather decorative skin. Method according to one of the preceding claims, characterized in that the foam layer ( 3 ) Polyurethane or consists of polyurethanes. Method according to one of the preceding claims, characterized in that the silicone layer ( 53 ) is profiled such that independent of a cavity between the first ( 51 ) and second ( 52 ) Mold half different profiles ( 54 ) of the foam layer ( 3 ) can be generated to facilitate the subsequent development of a dermis and / or the absorption of sutures. Method according to one of the preceding claims, characterized in that after removal of the foam layer ( 3 ) of the silicone layer ( 53 ), the silicone layer cleaned and in the foam tool ( 5 ) is used again. Method according to one of claims 1 to 5, characterized in that the silicone layer ( 53 ) by a new silicone layer ( 53 ) is replaced. Method according to one of the preceding claims for producing a first interior trim part with a carrier ( 2 ), a high quality skin ( 4 ) and one between the wearer and the high-quality skin ( 4 ) arranged foam layer ( 3 ), using the same foam tool ( 5 ) also a second interior trim part with a simple skin ( 4 ), the simple skin ( 4 ) the silicone layer ( 53 ) replaced. Method for producing an interior trim part according to one of the preceding claims, characterized in that the interior trim part comprises an instrument panel ( 1 ). Method for producing an interior trim part according to one of claims 1 to 8, characterized in that the interior trim part is a door trim, an airbag cover or a center console cover. Foam tool ( 5 ) for carrying out a method according to one of claims 1 to 10, comprising: a first mold half ( 51 ) and a second mold half ( 52 ), wherein on the one cavity ( 6 ) of the foam tool ( 5 ) facing surface of the second mold half ( 52 ) a silicone layer ( 53 ) is arranged, which is designed such that they are to be introduced with materials of a foam layer ( 3 ) does not bind. Foaming tool according to the preceding claim, characterized in that the silicone layer ( 53 ) is interchangeable. Foaming tool according to one of the preceding two claims, characterized in that the foaming tool ( 5 ) is designed such that, regardless of the formation of the cavity ( 6 ) different profiles ( 54 ) a foam layer ( 3 ) are producible. Foaming tool according to the preceding claim, characterized in that the profile ( 54 ) of the foam layer ( 3 ) is such that seams one on the foam layer ( 3 ) skin to be wound up ( 4 ) are in this recordable.

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