DE102009036678A1 - Method for providing predetermined joint pattern of molded skin of interior trim part of motor vehicle, involves generating wrap-around region of decorative film section, which partially encompasses omega-shaped bar of molded skin tool - Google Patents

Abstract

The method involves providing a molded skin tool (3) with a bar (4) that partially limits an intended region (3'), where cross section of the bar is formed in omega-shape. A decorative film section (2) is precisely produced corresponding to the intended region of the molded skin tool from a decorative film by cutting- and molding processes. A wrap-around region (2') of the decorative film section is generated, where the decorative film section partially encompasses the omega-shaped bar of the molded skin tool. The wrap-around region is inserted into the molded skin tool. Independent claims are also included for the following: (1) a molded skin tool for implementing a method for providing a predetermined joint pattern of a molded skin (2) an interior trim part comprising a decorative film section.

Description

The The invention relates to a method with which a predetermined joint image a molded skin are provided with an integrated decorative film section can. Furthermore, the invention relates to a Formhautwerkzeug for implementation of the method and an interior trim part of a motor vehicle, the comprises a molded skin with an integrated decorative film section, between which the predetermined joint image is provided.

to Production of interior panels, for example in the dashboard area cockpit or for door panels Formed skins that have an optical and haptic structure provide. For multi-part structures offers it depends, the viewing surfaces differently to shape, for example by the integration of decorative elements in the form skins. From the state of the art are composite components known, consisting of several layers arranged in layers, Supporting and cushioning layers as well as decorative surfaces consist.

In this context, the describes EP 00 99 56 67 B1 a composite component for vehicle bodies with an outer skin, on the inside of a plastic layer is foamed with a non-rigid reinforcement, which has a fabric which points into the interior of the vehicle. Also the DE 10 16 17 45 A1 describes a vehicle body component with an outer skin, on the inside of which a foamed plastic layer is applied, which is additionally provided with a foamed reinforcing layer, which is spaced from the outer skin defined.

In the DE 199 56 930 A1 a vehicle outer skin part is disclosed, the outside paint film is backed with a plastic foam layer and which is arranged on a support member.

A Variety of fonts refers to the production of multipart composite surfaces, in particular of molded skins, wherein decorative surfaces are connected to carrier systems.

A method for the production of moldings for a motor vehicle interior trim is in the DE 100 62 825 A1 disclosed. The moldings consist of a multicolored cast skin, a carrier part and an intermediate foam layer. The mold used has a color separation projection which serves to delineate the different colors.

The WO 2008/012247 A1 refers to a spray polyurethane system from which a carrier layer for moldings can be formed.

From the EP 01 112 838 A1 For example, decorative composite parts having an elastomeric surface layer of a sprayable elastomer composition are known.

A component with a decorative surface made of plastic, behind which a foam layer is arranged, is in the DE 100 23 384 A1 discloses, wherein a separately manufactured decorative part is connected to a support member having a formed as a plastic skin decorative surface.

An instrument panel of a vehicle describes the DE 10 2007 007 387 A1 comprising a support member and a separate cover member.

From the DE 10 2006 008 386 A1 is a single or multilayer plastic skin known as a surface covering of coated objects, are embedded in the form and / or decorative elements.

The DE 10 2006 036 535 A1 relates to a cladding comprising two adjacent skins, a carrier and an intermediate foam layer, the carrier having a groove extending along the border region of the two skins into which angled edge regions of the skins are partially inserted.

A method for producing a skin from a thermoplastic material by an injection molding method is disclosed in U.S.P. DE 10 2006 057 126 A1 described in which the thermoplastic material is injected into a mold.

The DE 10 32 92 59 B4 discloses a plastic molding for automotive interiors with serving as a decorative surface casting polyurethane and a carrier, being formed by back-foaming the casting skin closed chambers, which are separated by sealing profiles and filled with different materials.

The DE 10 2005 014 085 B4 discloses a plastic component having a decorative surface and a carrier and an intermediate foam layer. The decorative surface is formed by two adjacent decorative films and in the foam layer protrudes into a web of the wearer, in which the end portions of the decorative films are flat over each other and are connected.

A method for manufacturing vehicle interior parts with a carrier and openings is in DE 10 00 21 91 A1 disclosed, wherein the carrier is backfoamed and provided with a decorative film becomes.

A method for producing automotive interior trim with a carrier which is coated with a film is shown in DE 198 14 956 A1 described. The visible film is backfoamed and connected to the carrier.

The DE 10 00 83 59 A1 describes an apparatus for producing vehicle interior parts from a carrier and a decorative film which is back-foamed. Also the DE 10 2007 025 884 A1 discloses a foam back method for bonding a planar or flat decorative piece to a carrier.

A decorative skin for the interior of a vehicle for covering a first component is in the DE 10 2005 01 08 62 A1 described, wherein the decorative skin bridges a variable gap between the first component and a second component.

A method for producing a lining part, in which the discharge of the air to be displaced in the case of back-foaming takes place by means of a foam-tight, but not gas-tight structure of the support, is disclosed in US Pat DE 10 211 683 B4 disclosed.

The DE 10 2005 038 082 A1 describes a wall lining in the vehicle interior with a non-deformable support and a deformable insert pad arranged in a molding.

The DE 10 2006 052 900 A1 refers to a sound absorbing component for covering aggregates in the engine compartment. This sound absorber is formed by a foam body, which is foamed on a surface element. Such a surface element may be a thermoforming sheet, a sprayed skin and a pouring skin.

A method for producing self-supporting cladding elements is in the EP 00 64 24 11 B1 described, which are multilayered of polyurethanes and a rigid carrier.

The EP 01 510 322 A1 discloses a method of manufacturing a composite trim panel for the interior of a motor vehicle having a flexible skin, a rigid support substrate, and an intermediate layer that is a foam layer.

The DE 10 2006 049 913 A1 relates to molded parts with decorative and / or functional surfaces, in which a sign off of possible structures of the surface of the plastic support member is avoided through the film layer.

In the JP 3347850 B2 For example, two skins with angled end regions are arranged against each other, wherein the end region of the one skin has a protuberance and the end region of the other skin has a corresponding opening or bulge, so that the end regions of the skins can intermesh.

A process that provides sufficient foam tightness in the boundary between two films and ensures good reproducibility and that can be carried out with a short process time, describes the DE 10 2006 044 710 B3 by the manufacturing process of a component with two juxtaposed films and a foam layer applied on the back, the end regions of the films being angled in a U-shape in a tool mold, so that a foam-tight coincidence of the U-shaped angled end regions of the films during foaming Tool mold is provided.

The task of DE 10 2006 056 535 A1 lies in the provision of a method with which composite parts of a multi-part cover layer of foils can be backfoamed under uncomplicated arrangement, whereby a tightness during the back-foaming is ensured. The arrangement of the end regions of the cover layers is also directed away from the tool surface, in which case a negative pressure is applied in the region of the angled end regions, so that they are pressed against each other in a planar manner during backfoaming.

Finally, that describes EP 1 648 741 B1 a surface decoration for trim parts and a method for its production, which is partially formed by a cast skin and has a decorative inlay, the boundary of which is enclosed by the casting skin. For this purpose, the decorative insert is introduced into the casting tool and clamped in the region of the boundary between an upper tool and a lower tool of the casting tool, so that in the formation of the casting skin, the edge of the decorative insert is enclosed.

at Such multipart composite of decorative elements and molded skins Structures can show visible irregularities between the individual components in the joint and possibly noise arise at the joints.

outgoing From this prior art, it is desirable to improved method for providing a predetermined joint image to provide a molded skin with an integrated decorative film section, that with regard to the effect and visibility of a joint bottom and a geometry extending between the decorative film section and the surrounding form skin extending fugue cheaper is.

These The object is achieved by a method having the features of the claim 1 solved.

further developments the method of the invention are in the subclaims executed.

Further it is desirable to provide a mold skin tool with which a procedure can be carried out, the predetermined joint pattern of the molded skin with an integrated decorative film section can provide. This task is done by the form skin tool solved with the features of claim 8.

The Design of a corresponding interior trim part of a motor vehicle, in which a predetermined joint pattern between the molded skin and the Decorative film portion is formed by the interior trim part realized with the features of claim 9.

A Embodiment of the invention Process with which a joint pattern between a molded skin and a provided therein decor sheet portion provided predetermined requires a mold skin tool that has an area, which is intended to receive the decorative film section. Further becomes a forming skin forming material in the Formhautwerkzeug with introduced the inserted decorative film section. According to the invention to the Formhautwerkzeug designed such that the for receiving the Decorative film portion provided area partially or completely is limited by a web, which in cross-section substantially has the shape of the Greek letter Omega. Corresponding the omega-shaped bridge that limits the intended area, the decorative film section is tailored by trimming and forming steps Made on a decorative foil, so that between the inserted Decorative foil section and the mold skin tool no gaps occur. Due to the fact that in the tailor-made production of the decorative film section A Umgriffbereich is generated, which is the omega-shaped The bridge of the molded skin tool more or less surrounds, that can desired joint pattern are generated, and the joint bottom lend the desired effect or visibility become. At the same time, by the design of the grip area the strength of the decorative film section integrated in the molded skin be varied.

A manufactured by the method according to the invention Joint also prevents the formation of noise. Furthermore, it is possible by the inventive Procedures to reduce manufacturing steps and by using a decorative foil on expensive natural To dispense derivatives and earth derivatives such as wood, metal and stone, so that the manufacturing cost of an interior trim part at the same time increased variability of the foil decor can be lowered.

In an embodiment of the invention Method, the material that forms the skin, in such the Formhautwerkzeug be introduced, that both the inserted Film section as well as the area that the for the decorative film section surrounding area, and the one molded-skin viewing area forms, be covered.

By the tailor - made production of the decorative film section must be in the Form skin tool can not be pinched or fixed and more advantageous Thus, the molded skin can thus also over the entire surface the decorative film section are formed.

In an alternative embodiment, a first Formhautschicht be formed in the Formhautwerkzeug by first the area provided for the decorative sheet portion masked is the mold skin forming material in the mold skin tool is introduced in a first layer, wherein the molded skin view area, which surrounds the decorative film section, is covered with the material, whereupon after removal of the masking the decorative film section can be inserted accurately into the intended area and another layer of the molded skin forming material in the Formhautwerkzeug can be introduced, in turn, the entire surface both Cover the decorative film section as well as the surrounding area.

In yet another alternative embodiment of the method the inserted decorative film section is covered with a mask, the dimensions of which are smaller than the dimensions of the decorative film section, so that the decorative film section in the edge region or the Umgriffbereich remains free. Now this will be the form skin Material introduced into the mold skin tool, wherein the masking a full-surface cover prevents and only the Formhautsichtbereich and the remaining margin Covering area covered by the forming skin forming material be and thus only in the edge or Umgriffbereich the Decorative film section is a connection to the molded skin. After all the mask is removed.

These three alternative embodiments for the formation of the molded skin layer and of the integrated decorative film section allow a variation of the hardness of the decorative film section, in which the tailoring of the decorative film section by the formation of the grip region a corresponding formation of the mold skin layer to be introduced is provided. Furthermore, the hardness of the decorative film section still depends on a foam-backed layer, which is applied after production of the molded skin on the side facing away from the visible side. The introduction of the foam can either be done directly in the Formhautwerkzeug as well as be carried out by means of a Hinterschäumwerkzeugs.

moreover For example, the hardness of the decorative sheet portion of a substrate layer hang behind the foamed layer becomes. This affects both the arrangement of the layers in their Order as well as in their relative positioning in relation on the decorative foil section, if not full surface are formed, its hardness. In addition, the Hardness of decorative sheet section depending on one Material choice as well as a thickness of the decorative film section itself as well as the mold skin possibly arranged behind it, the foamed layer and the substrate layer.

A Embodiment of the invention relates to a molded skin tool, with the method of the invention carried out can be. For this purpose, the mold skin tool has an area which is intended to receive a decorative film section. A second area of the Formhautwerkzeugs serves to the viewing area form the skin, in which thus introduced a material can be that forms the skin. Between these two areas the Formhautwerkzeug has a web on which the area is provided for receiving the decorative film section, partially or very limited. This bridge has a substantially omega-shaped Cross-section on.

Further An embodiment of the invention relates to a Interior trim part of a motor vehicle, which consists of a molded skin and an integrated decorative film section is formed between which a predetermined joint image is provided by the production of which is a mold skin tool according to the invention is used. In addition, the decorative film section corresponds exactly to the provided for receiving the area of the Formhautwerkzeugs and an edge or grip area of the decorative film section is shaped so that it has the omega-shaped bridge the mold skin tool more or less surrounds and the predetermined Grout picture provides.

The These and other advantages will become apparent from the following description with reference to the accompanying figures.

Of the Reference to the figures in the description is for assistance the description and the easier understanding of the Object. Objects or parts of objects, which are essentially the same or similar be provided with the same reference numerals. The figures are merely a schematic representation of an embodiment of the Invention.

there demonstrate:

1a - 1f FIG. 2 a schematic cross-sectional detail view of the omega-shaped web of the molded skin tool with differently shaped encompassing regions of the decorative film section, FIG.

2 a perspective view of a cross section of an interior trim part, consisting of the joint-forming molded skin with inserted decorative film section and foam backing and backing material layer,

3 a view accordingly 2 but according to an alternative method with a different layer sequence,

4 a corresponding 2 However, according to an alternative method embodiment with a different layer sequence, respectively hardness running.

Essential for high process quality during production the decor sheet embedded in the molded sheet under provision the desired joint pattern is the seal between the inserted decorative film section and the mold skin tool.

Out 1a to 1f , in each case a section of the mold skin tool 3 with the omega-shaped footbridge 4 to see the, for the decorative film section 2 intended area 3 ' as well as the molded skin viewing area 3 '' Connect, are different custom-made decorative foil sections 2 to see their encompassing area 2 ' different lengths and differently shaped around the bridge, or on the bridge 4 extends.

While the decorative film sections 2 in 1a . 1b . 1d , on the jetty 4 only on side of the intended area 3 abut, the molded skin forming material (not shown here) is the web 4 enclose and thus form the bottom of the joint. In 1c and 1f extends the Umgriffbereich 2 ' over the vertex of the jetty 4 , so that here the joint bottom will be provided by the decorative film section. In 1e ends the Umgriffbereich 2 ' of the decorative film section 2 at about the top of the jetty 4 , so that both decorative film section and molded skin are visible here in the later formed joint bottom.

On the one hand, this is the omega-shaped bridge 4 provided mold skin tool 3 as well as the desired joint pattern corresponding, different trimming and the formation of the decorative film to form the decorative film section 2 and the grip area 2 ' the prerequisites for carrying out the method according to the invention.

This procedure is carried out with the form skin tool, which corresponds to the 1a to 1f the omega-shaped bridge 4 one, the one for the decorative film section 3 ' provided area of a visual range for the molded skin 3 '' demarcates. In this case, it is also possible for a plurality of decorative film sections to be provided in one tool, which are each delimited by omega-shaped webs from a molded-skin viewing region. First, however, a release agent is applied to the mold skin tool in order to be able to detach the molded skin from the mold skin tool after the end of the process.

A Decorative film, the tailor-made production of decorative film section may be used, preferably a plastic film, the according to the prior art by various printing steps with a Variety of decors can be equipped and by pruning and thermoforming formed in the exact shape with the Umgriffbereich can be. But instead of a plastic film can also be a Metal foil can be used, which is accurately made in the intended Area can be inserted. Not excluded, even if associated with additional costs, but also according to customer requirements, the use of a natural derivative such as wood or Stone, as well as woven fabric made of natural or synthetic fibers and leather or artificial leather. Advantageously, exist between the custom-made decorative foil section and the mold skin tool no room for maneuver. Regarding the application of the Release agent, it is important that this is not on the decorative film section itself arrives later to a good adhesion of the molded skin to the To ensure decorative foil section.

in the Next step is the material that the molded skin forms, applied, wherein the decorative film section completely can be coated with the molded skin.

This embodiment is in 2 shown in the the form skin 1 over the entire surface of the decorative film section 2 is formed, whereby the secure bond between decorative film section 2 and surrounding skin 1 is given, so that no noise can occur while the Umgriffbereich 2 ' of the decorative film section 2 gives the desired joint image. The molded skin may be ^® process, a spray skin, a cast skin, a slush skin, a RIM / ROM skin or a skin after Skinform according to the prior art.

To form, for example, an interior trim part for a motor vehicle then the molded skin 1 with the integrated decorative foil section 2 For example, foamed with a PU foam, which can be done directly in the Formhautwerkzeug, or after the skin has been removed from the Formhautwerkzeug and then transferred to a separate tool. With the foamy PO layer 5 will the molded skin 1 and the integrated decorative foil section 2 on a substrate layer 6 arranged, whereby the interior trim part is finished.

The application of the molded skin, or of the material forming the molded skin, can also take place in layers, so that for the production of the in 3 shown interior trim component first the area that for the decorative film section 2 is provided, covered with a mask. Now the visible layer of the molded skin becomes 1 introduced into the mold skin tool, and subsequently removed the mask. Next, the decorative sheet section 2 inserted and a completely covering layer behind the visible layer of the molded skin 1 and decorative film section 2 applied. This layer can, as in 3 shown a foamy PO layer 5 However, it may also be another layer of the form skin forming material. The finally arranged carrier material layer 6 provides the finished interior trim component. At the in 3 shown inner lining component is the joint image through the visible layer of the molded skin 1 determined because the Umgriffbereich behind the visual layer comes to rest.

In yet an alternative embodiment, the decorative film section is first inserted into the mold skin tool again, but the decorative film section is covered with a mask whose dimensions are smaller than that of the decorative film section itself. Now, if the forming skin forming material, so there is only in the edge region, or in Umgriffbereich, the decorative film section a connection to the molded skin. This in 4 The interior trim part shown was manufactured by initially using a masking of the intended area of the visual range of the molded skin 1 was formed, the decorative film section 2 was inserted and covered with a mask. Now, the foamed layer was applied directly, but only behind the layer area of the molded skin 1 , whereupon immediately the carrier material layer 6 was arranged, thus directly behind the decorative film section 2 comes to the plant. In the 2 . 3 and 4 illustrated different embodiments of the interior trim parts By differently executed process steps offer a realization of different hardnesses, respectively haptic levels of the decorative film section. While that in 3 Interior lining part shown by the direct foam backing with PO foam 5 a minimum hardness for the decorative film section 2 provides, so in 4 shown embodiment, in which the carrier material layer 6 directly behind the decorative film section 2 comes to rest, a maximum hardness ready. The geometry of the carrier 6 is designed so that when joining no cavity between decorative film section 2 and the carrier 6 results. Here, the foam backing with the PO foam layer 5 also after the arrangement of the carrier 6 on the decorative film section 2 , For example, by direct gluing or compression, so that in the remaining cavity between the molded skin 1 and carriers 6 is foamed.

This in 2 Interior lining part shown offers a hardness that is between the hardnesses in 3 and 4 depends primarily on the decorative film thickness, the mold skin thickness, the PO foam thickness and the carrier position.

The varying hardness for the decorative film section is due to the arrangement and positioning of different layers influenced, especially by different types of masking. By using a perforated masking is now on the defined open spaces that have no masking, the form skin applied.

By the inventive method can be a variety of high-quality decorative sections, the a more precise joint pattern, increased strength and have no noise, at the same time extremely variable selection of various optical and haptic properties of the decorative sheet portion are provided.

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

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Claims (9)

Method for providing a predetermined joint pattern of a molded skin ( 1 ) with an integrated decorative film section ( 2 ), wherein the decorative film section ( 2 ) into a mold skin tool ( 3 ) in a designated area ( 3 ' ) is inserted and a the molded skin ( 1 ) forming material into the mold skin tool ( 3 ) with the inserted decorative film section ( 2 ), comprising the steps of: - providing the molded skin tool ( 3 ) with a designated area ( 3 ' ) at least partially delimiting bridge ( 4 ), whose cross section is substantially omega-shaped, - tailor-made finishing of the decorative film section ( 2 ) according to the intended area ( 3 ' ) of the mold skin tool ( 3 by trimming and shaping from a decorative film, comprising creating a grip region ( 2 ' ) of the decorative film section ( 2 ), the omega-shaped bridge ( 4 ) of the mold skin tool ( 3 ) at least partially encompasses. Method according to claim 1, comprising the step: during the introduction of the molded skin ( 1 ) forming material covering the intended area ( 3 ' ), in which the decorative film section ( 2 ) and a molded skin panel ( 3 '' ), which covers the intended area ( 3 ' ) surrounds. Method according to claim 1 or 2, comprising the steps before inserting the decorative film section ( 2 ) into the mold skin tool ( 3 ): - Mask the intended area ( 3 ' ), - introducing a first layer of the molded skin ( 1 ) forming material into the mold skin tool ( 3 ), wherein the molded skin viewing area ( 3 '' ), - removing the masking and inserting the decorative film section ( 2 ) in the designated area ( 3 ' ). The method of claim 1, wherein the introduction of the molded skin ( 1 ) forming material into the mold skin tool ( 3 ) comprises the steps: - before introducing the molded skin ( 1 ) forming material covering the inserted decorative film section ( 2 ) with a mask whose dimensions are smaller than the dimensions of the decorative film section ( 2 ), whereby at least the encompassing region ( 2 ' ), - Forming the skin ( 1 ) over a molded-skin viewing area ( 3 '' ), which covers the intended area ( 3 ' ) and over at least the grip area ( 2 ' ) of the decorative film section ( 2 ) by the introduction of the molded skin ( 1 ) forming material, and - removing the mask. Method according to at least one of claims 1 to 4, wherein the tailor-made finishing of the decorative film section ( 2 ) adjusting a hardness of the decorative film section ( 2 ), wherein adjusting the hardness of the decorative film section ( 2 ) comprises: - defining a sequence of layers of at least the decorative film section ( 2 ), the molded skin ( 1 ) and a foamed layer ( 5 ) and / or a substrate layer ( 6 ), - arranging the layers with respect to their relative positioning to the decorative film section ( 2 ), - determining a thickness of the decorative film section ( 2 ), the molded skin ( 1 ), the foamed layer ( 5 ) and the substrate layer ( 6 ). A method according to claim 5, wherein arranging the foamed layer ( 5 ) comprises the step: foam-back of the molded skin ( 1 ) with the integrated decorative film section ( 2 ), wherein a foam for forming the foamed layer ( 5 ) - directly into the mold skin tool ( 3 ) or - after transfer into a foam tool in the molded skin ( 1 ) is introduced. Method according to claim 5 or 6, comprising the step: arranging the foam-backed molded skin ( 1 ) with the integrated decorative film section ( 2 ) on the substrate layer ( 6 ). Form skin tool ( 3 ) for carrying out a method according to at least one of claims 1 to 7, wherein the molded skin tool ( 3 ) a first area ( 3 ' ), in which a decorative film section ( 2 ) and at least one second area ( 3 '' ), in which a the molded skin ( 1 ) forming material is introduced, characterized in that the Formhautwerkzeug ( 3 ) a footbridge ( 4 ) having a substantially omega-shaped cross-section which at least partially covers the first region ( 3 ' ) limited. Interior trim part of a motor vehicle, the one in a molded skin ( 1 ) integrated decorative film section ( 2 ), wherein a predetermined joint pattern between the molded skin ( 1 ) and the decorative film section ( 2 ) using a mold skin tool ( 3 ) according to claim 8, characterized in that the decorative film section ( 2 ) fit the first area ( 3 ' ) of the mold skin tool ( 3 ), wherein a grip region ( 2 ' ) of the decorative film section ( 2 ) and the omega-shaped web ( 4 ) of the mold skin tool ( 3 ) at least partially encompasses.

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