DE102013224757A1 - A process for producing a multilayer composite component and supports for use in such a process - Google Patents

Abstract

The invention relates to a method for producing a multilayer composite component, comprising the following steps: a) the carrier (2) is attached to a first tool part (13) and the skin (3) to a second tool part (14) of the opened foaming tool (15) b) the first tool part (13) and the second tool part (14) are moved relative to each other to form a cavity (16) between the carrier (2) and the skin (3), one in an edge region of the carrier (2 ) between the carrier (2) and the skin (3) arranged semipermeable seal (7) limits the cavity (16) with closed foaming tool (15), c) a foam layer (4) forming plastic foam (18) is formed before the relative movement of the two tool parts (13, 14) introduced into the open Schäumwerkzeug (15) or is introduced after the relative movement of the two tool parts (13, 14) in the cavity (16) of the closed Schäumwerkzeuges (15), d) the plastic foam (18) expands in the cavity (16) of the closed Schäumwerkzeuges (15), wherein the displaced by the expansion of the plastic foam (18) in the cavity (16) displaced gas (20) and / or the displaced air (20) by at least one micro-channel (10 ) in the seal (7) passes out of the cavity (16), while an entry of the plastic foam (18) into the microchannel (10) and / or leakage of the plastic foam (18) from the cavity (16) through the microchannel (16) 10) in the seal (7) due to a relative to the gas (20) and / or the air (20) greater viscosity of the plastic foam (18) is prevented, e) the plastic foam (18) fills the cavity (16) between the Carrier (2) and the skin (3) and the foaming tool (15) is opened by a relative movement of the two tool parts (13, 14) and the multilayer composite component produced is removed from the opened foaming tool (15).

Description

The invention relates to a method for producing a multilayer composite component, comprising a carrier, a skin and a foam layer arranged between carrier and skin, in a foaming tool consisting of at least two tool parts that are movable relative to one another. Furthermore, the invention relates to a carrier for use in such a method.

To meet the requirements of the automotive industry today are molded parts in the interior of a vehicle, such as dashboards or vehicle interior trim parts, such as interior trim, door sills or door side panels, door and pillar trim, center consoles, glove box lid or handles, in the Usually constructed as multilayer composite components. These multilayer composite components usually consist of a carrier part made of a mechanically solid material, a film formed as a skin, which forms the visible side of the component and may consist of different materials, and arranged between the carrier and the skin foam layer of a foamed plastic.

In the present case, there is a method for producing a multilayer composite component made of different plastic components, wherein the different layers of the composite component each have different material properties. The carrier gives the entire structure the necessary support or mechanical strength. The skin or foil forming the visible side of the composite component provides a desired décor or a desired surface texture or feel. The skin is connected to the carrier via the foam layer, which preferably consists of a polyurethane foam material.

In the preparation of such moldings, a reaction mass consisting of polyol and isocyanate is introduced into a cavity or a gap between the skin and the carrier. By a chemical reaction of the two reactants of the registered reaction mass, a plastic foam (PUR) forms, which expands and evenly fills the space between the skin and the carrier. In order to obtain a soft pressure haptic of the skin or the skin surface, the thickness of the foam layer is preferably a few millimeters. During foaming, the carrier is held in or on a first tool part and the skin is held in or on a second tool part of a foaming tool. The second tool part, on the contour of which the skin rests, generally forms the lower part of the tool during back-foaming, so that the registered plastic foam securely adapts to the contour of the skin, in particular penetrating into depressions. The carrier is held by the first tool part during foaming of the liquid, foam-forming plastic. The first tool part is preferably located above the skin and holds the wearer against the foam pressure.

After applying the reaction mass between the carrier and the skin, the plastic foam produced in the chemical reaction expands in the cavity. As a result of progressive expansion of the foam material, the air present in the cavity is increasingly displaced. The displaced air must be able to escape from the cavity between the carrier and the skin or from the foaming tool in order to avoid air pockets in the workpiece. To ensure that the air escapes, the foaming tool usually has a plurality of inflatable contour seals, which at least in sections must remain open until the expanding plastic foam approaches. Thereafter, the contour seals of the foaming tool must be able to perform their sealing function within a very short time, so that the spreading plastic foam can not escape from the cavity or the tool.

Important controls of this method are thus formed as silicone tube seals contour seals, which extend along an edge region of the composite component to be produced and are integrated in the foaming. Overall, depending on the size and complexity of the composite component about 10 to 12 individual seals provided, which are each controlled individually, the process variables of the individual seals associated sealing circuits for a complete foaming process must be determined in advance empirically. In addition, the process variables must be detected during the process and also controlled and adjusted depending on external disturbances, such as the hall temperature. The contour seals are very maintenance-intensive and must be regularly checked as a function of wear, maintained and replaced if necessary.

Such contour seals are for example from the DE 20 2009 012 903 U1 known.

In the DE 10 2009 054 893 A1 Another method for producing a multilayer composite member consisting of a backing, a skin, and a foam layer is disclosed. When closing the existing of two tool parts foaming presses a the upper part of the tool assigned contour projection sealing the skin in the region of the contour projection in the deformable carrier. As a result, the cavity between the carrier and the skin is sealingly closed.

Moreover, by the DE 10 2007 061 337 A1 a method for producing a multilayer composite component, consisting of a carrier, a skin and a foam layer known as an intermediate layer. In this case, the carrier and the skin are first arranged in a foaming tool consisting of two tool parts in such a way that they rest on each other without gaps in an edge region. A plastic foam introduced into a cavity between the carrier and the skin expands in the closed foaming tool and the air or displaced gas displaced by the expanding plastic foam is conveyed via a ventilation bore arranged in the carrier and a ventilation channel which extends between the carrier and the adjacent tool part extends, removed from the cavity or from the foaming tool. The vent hole and the vent channel lie in a temperature-controlled and sealed by an inflatable seal area of the foaming tool. The plastic foam changes in the vent or in the vent channel due to the preset temperature in the temperature range its material properties, as a result of which there is a clogging of the vent hole and the vent channel through the exiting or flowing through plastic foam. As a result, an outflow of plastic foam through the vent hole can be prevented after a short time. In addition, excess foam can be selectively removed or discharged from the cavity or the foaming tool through the vent hole and the venting channel.

This proves to be disadvantageous in that a ventilation bore passing through the support over its entire component thickness and additionally a ventilation duct between the support and the adjacent tool part are required in order to remove the air from the cavity or from the foaming tool. These must be introduced in upstream operations in the carrier or the corresponding tool part. Furthermore, a complex and thus costly foaming tool with a sealed by an inflatable seal and temperature range is required. In order to prevent leakage of plastic foam through the vent hole and the vent channel, the inflatable seal and the temperature range must be in accordance with the process progress or depending on the rate of expansion of the plastic foam and / or depending on the position of the application of the plastic foam and other disturbances, such as the ambient temperature in the hall, are controlled. This requires a not inconsiderable control effort. In addition, it must be ensured that the vent hole is arranged in an edge region delimiting the cavity immediately adjacent to the contact area between the carrier and the skin, since the plastic foam could otherwise close the vent opening, even before the air contained in the cavity could be completely removed from the cavity. As a result, the gap or the cavity between the skin and the carrier is not completely filled with the plastic foam, but contains air bubbles, which affect the mechanical stability or strength and the visual appearance of the composite component significantly negative, so it is no more than interior trim part can be installed. The result is an increased proportion of rejects and low process reliability of the process.

Against this background, the object of the invention is to provide a simple and process-reliable method for producing a multilayer composite component which requires a small tool investment volume and low control effort. In addition, it is an object of the invention to provide a carrier for use in such a method.

The first object is achieved by a method according to the features of claim 1. The dependent claims 2 to 6 relate to particularly expedient developments of the invention.

• a) der Träger wird an ein erstes Werkzeugteil und die Haut an ein zweites Werkzeugteil des geöffneten Schäumwerkzeuges angelegt,
• b) das erste Werkzeugteil und das zweite Werkzeugteil werden zur Bildung einer Kavität zwischen dem Träger und der Haut relativ zueinander bewegt, wobei eine in einem Randbereich des Trägers zwischen dem Träger und der Haut angeordnete semipermeable Dichtung die Kavität bei geschlossenem Schäumwerkzeug begrenzt,
• c) ein die Schaumschicht bildender Kunststoffschaum wird vor der Relativbewegung der beiden Werkzeugteile in das geöffnete Schäumwerkzeug eingebracht oder wird nach der Relativbewegung der beiden Werkzeugteile in die Kavität des geschlossenen Schäumwerkzeuges eingebracht,
• d) der Kunststoffschaum expandiert in der Kavität des geschlossenen Schäumwerkzeuges, wobei das durch die Expansion des Kunststoffschaumes in der Kavität verdrängte Gas und/oder die verdrängte Luft durch zumindest einen Mikrokanal in der Dichtung hindurch aus der Kavität austritt, während ein Eintreten des Kunststoffschaumes in den Mikrokanal und/oder ein Austreten des Kunststoffschaumes aus der Kavität durch den Mikrokanal in der Dichtung hindurch aufgrund einer gegenüber dem Gas und/oder der Luft größeren Viskosität des Kunststoffschaumes verhindert wird,
• e) der Kunststoffschaum füllt die Kavität zwischen dem Träger und der Haut aus, das Schäumwerkzeug wird durch eine Relativbewegung der beiden Werkzeugteile geöffnet und das hergestellte mehrschichtige Verbundbauteil wird aus dem geöffneten Schäumwerkzeug entnommen.

According to the invention, therefore, a method for producing a multilayer composite component consisting of a carrier, a skin and a foam layer arranged between the carrier and the skin is provided in a foaming tool comprising at least two relatively movable tool parts, comprising the following steps:

• a) the carrier is applied to a first tool part and the skin to a second tool part of the opened foaming tool,
• b) the first tool part and the second tool part are moved relative to one another to form a cavity between the carrier and the skin, wherein a semi-permeable seal arranged in an edge region of the carrier between the carrier and the skin limits the cavity when the foaming tool is closed,
• c) a plastic foam forming the foam layer is introduced into the open foaming tool before the relative movement of the two tool parts introduced or is introduced after the relative movement of the two tool parts in the cavity of the closed foaming tool,
• d) the plastic foam expands in the cavity of the closed foaming tool, wherein the gas displaced by the expansion of the plastic foam in the cavity and / or the displaced air exits the cavity through at least one microchannel in the seal, while an entry of the plastic foam in the Microchannel and / or leakage of the plastic foam from the cavity through the microchannel in the seal is prevented due to a relative to the gas and / or air greater viscosity of the plastic foam,
• e) the plastic foam fills the cavity between the carrier and the skin, the foaming tool is opened by a relative movement of the two tool parts and the multilayer composite component produced is removed from the opened foaming tool.

The method according to the invention for producing a multilayer composite component has a much greater process reliability than the methods described in the publications mentioned above. At the same time, no expensive, cost-intensive foaming tools with temperature-controllable regions or contoured seals that can be integrated into the foaming tools are required. Due to the omission of the contoured seals and the temperature-controllable area, the expense of detecting, identifying and controlling the respective sealing circuits or process manipulated variables is also eliminated. Maintenance or replacement of contoured seals is not required. As a result, compared to the known methods significantly reduced tool investment volume and a reduction of the influence of external and fluctuating disturbances on the process flow. In the method according to the invention, a semipermeable seal is used, which is permeable to the displaced air or the displaced gas and at the same time impermeable to the expanding plastic foam. A change in material properties to block the microchannel, as in DE 10 2007 061 337 A1 described is not required. The plastic foam is hindered from entering the microchannel solely by a combination of the small cross-sectional area of the microchannel and greater viscosity than the gas or air. However, due to the lower viscosity, the displaced air can pass through the microchannel in the seal or escape from the cavity. The inventive method, the production of multi-layer composite components of changing process variables, such as the hall temperature or location, the shape or amount of application of the plastic foam in the foaming mold, as well as different expansion speeds of the plastic foam is decoupled, so that component errors can be avoided and thereby the reject rate is reduced overall.

A particularly advantageous embodiment of the method according to the invention is also provided in that the escape of the plastic foam is prevented by a microchannel having a cross-sectional area of 0.1 to 100 μm ² . In the case of a cross-sectional area in this size range, it is ensured that the air or the gas can escape from the cavity or from the foaming mold without being impaired by the microchannel, while the plastic foam does not enter the microchannel due to the greater viscosity compared to the air this can pass through. In this case, the cross-sectional area may have any desired shape, wherein a rectangular or square, a circular or an oval shape of the microchannel has proven to be particularly suitable from a functional point of view.

Another particularly expedient development of the invention is also achieved in that the microchannel is produced by a contact of the seal to the skin during the relative movement of the two tool parts, wherein the microchannel by a groove in the contact surface of the seal adjacent to the skin and an opposite Part of the skin is limited. The arranged in the contact surface of the seal groove can have any shape, but from a manufacturing point of view, a rectangular, V-shaped, halbkreisfömige or from a circular section or segment existing groove shape particularly useful. Such groove shapes can be reliably incorporated in the contact surface of the seal in a simple manner.

According to the invention, it is further provided that a contact pressure of the seal produced by the relative movement between the two tool parts of the foaming tool on the skin during or after the expansion of the plastic foam is increased such that the partial section of the skin delimiting the microchannel at least partially reduces the cross-sectional area of the microchannel the groove arranged in the seal is pressed. The skin is flexible and deforms elastically under high contact pressure. Depending on the height of the contact pressure or depending on the choice of material and material thickness of the skin and the shape of the groove in the seal, the skin can also be pressed into the groove so that the microchannel completely, so also for the displaced by the expanding plastic foam air, is closed. As a result, the cycle times for the production of the composite component can be reduced in this case it must be ensured that possibly still contained in the cavity air or gas bubbles are arranged in a region immediately adjacent to the seal and thereby can be separated in a subsequent punching or cutting process of the composite component.

A further advantageous embodiment of the method according to the invention is also provided in that the seal and the carrier are applied as a one-piece assembly to the first tool part. This ensures a defined positioning of the seal relative to the carrier and the skin and optimizes the process reliability of the method. An additional operation for positioning and fixing the seal between the carrier and the skin is not required, so that the cycle time for the production of the composite component can be shortened overall. Advantageously, both the carrier and the gasket are made of the same material, such as a glass fiber reinforced plastic (PP-GF), so that the assembly consisting of the carrier and the gasket can be made in a single injection mold. It proves to be particularly advantageous that the groove in the contact surface of the seal in the same injection mold during injection molding of the assembly is introduced into the seal. In this way, the assembly can be used immediately after removal from the injection mold, without downstream processing steps, in the inventive method.

Subsequent to the production of the multilayer composite component, at least sections of protruding edge sections of the composite component are separated from the composite component by a cutting, milling or punching process. Here, usually, the edge portion is separated together with the seal to provide a composite member in which the gap between the support and the skin is completely filled with the plastic foam. However, a particularly advantageous embodiment of the method according to the invention results from the fact that excess edge portions of the multilayer composite component produced are removed in the foaming tool or after removal from the foaming tool by a cutting or stamping process, wherein the seal remains on the multilayer composite component. By remaining on the multilayer composite component seal the composite component is stiffened on the one hand and on the other hand, the removed waste contains only a small proportion of the material of the wearer. At the same time, the waste contains no portion of the plastic foam, as it can not pass through the seal and thus does not reach the region of the edge portion, which is separated by the cutting or punching process of the composite component.

The second object is achieved with a carrier according to the features of claim 7. The dependent claims 8 to 10 relate to particularly expedient developments of the invention.

According to the invention, therefore, a carrier is provided for use in a method for producing a multilayer composite component consisting of the carrier of a skin and a foam layer arranged between the carrier and the skin, which is connected in an edge region with a semipermeable seal which is permeable to air or gas and impermeable to an expanding plastic foam used in the process. During the process for producing the multilayer composite component, the seal allows the escape of displaced air or of displaced gas, while the expanding plastic foam can not enter into the microchannel or pass through the microchannel due to the greater viscosity relative to the air. Preferably, the carrier and / or the seal of a mechanically solid material, for example of a glass fiber reinforced plastic (PP-GF).

It has proven to be particularly advantageous that the gasket has at least one microchannel with a cross-sectional area of 0.1 to 100 μm ² . By a cross-sectional area in the specified order of magnitude ensures that although the air can pass through the microchannel, which does not have a viscosity greater than air-containing plastic foam. Here, the cross-sectional area is selected as a function of the viscosity of the reacting plastic foam mass. The lower the viscosity, the lower the cross-sectional area of the microchannel should be. The length of the microchannel should preferably be between 0.5 and 5.0 mm, the length of the microchannel essentially corresponding to the dimensions of the seal, in particular the seal width.

The microchannel can be placed anywhere in the seal. However, it has proven to be advantageous from a production engineering and procedural point of view that the microchannel is formed as a groove and is arranged in a contact surface of the seal facing the skin. This makes it possible that the microchannel is formed only by a closing movement of the two tool parts. The microchannel is then delimited by the wall surfaces delimiting the groove and a section of the skin opposite the groove. By such a design, it is also possible, a cross-sectional area of the To reduce micro-channel by an increased contact pressure of the seal on the skin, namely by pressing the skin into the groove. As a result, the microchannel can be closed in a sealed manner for the escaping air.

In addition, it is provided that the carrier and the seal are integrally connected to each other. The carrier is made by injection molding and consists of plastic and a glass fiber reinforcement (PP-GF). The semipermeable seal is produced in the injection molding process together with the carrier, so that carrier and seal form a one-piece or one-piece and jointly manageable unit. Consequently, the seal is also made of a glass fiber reinforced plastic. The assembly consisting of the carrier and the seal takes place by injection molding in a single injection mold, wherein an already existing injection mold for the production of the carrier must be supplemented by the negative contour of the semipermeable seal. Advantageously, the microchannel at least partially forming groove on a contact surface of the seal is also introduced during the manufacture of the assembly in this, so that no subsequent steps for introducing the microchannel are required.

The invention allows numerous embodiments. To further clarify its basic principle, one of them is shown in the drawing and will be described below. This shows in

1 a sectional view of a multilayer composite component produced by the process according to the invention;

2 a carrier according to the invention with a semi-permeable seal in a plan view;

3 a perspective and enlarged view of the in 2 illustrated carrier with a micro-channel having semipermeable seal;

4 another perspective view of the in 2 illustrated carrier with a semipermeable seal and a microchannel in a second embodiment;

5 an existing two tool parts open foaming tool with a pickled carrier and inserted skin at the beginning of the process according to the invention;

6 the closed foaming tool during expansion of the plastic foam in the cavity between the carrier and the skin;

7 this in 6 illustrated foaming tool with a first embodiment of the microchannel in a view according to XX;

8th this in 6 illustrated foaming tool with a second embodiment of the microchannel in a view according to XX;

9 the view according to 7 with a reduced cross-sectional area microchannel;

10 the view according to 8th with a reduced cross-sectional area microchannel;

11 a composite component produced by the process according to the invention without a seal;

12 a composite component produced by the process according to the invention with a seal.

1 shows a prepared by the process according to the invention multilayer composite component 1 which consists of a carrier 2 , a skin 3 and one between the wearer 2 and the skin 3 arranged foam layer 4 consists, wherein the foam layer 4 a gap 5 between the carrier 2 and the skin 3 completely filled out. The gap 5 is through one with the carrier 2 connected and at one bottom 6 of the skin 3 fitting semi-permeable seal 7 locked. The multilayer composite component 1 is made by a polyurethane foaming process. The foam layer 4 made of foamed polyurethane is firmly bonded to the carrier 2 made of a glass fiber reinforced plastic and cohesively with the skin made of PVC 3 connected. One of the foam layer 4 opposite decorative top 8th of the skin 3 forms the visible side of the formed as interior trim part for a motor vehicle multilayer composite component 1 ,

2 shows a plan view of the carrier according to the invention 2 with the in a border area 9 of the carrier 2 arranged semipermeable seal 7 , The seal 7 is circumferentially formed and integral with the carrier 2 connected. Accordingly, there is both the seal 7 as well as the carrier 2 from the same material, namely a glass fiber reinforced plastic, in particular PP-GF. The carrier 2 and the seal 7 So form a one-piece or one-piece and together manageable unit.

The with the carrier 2 bonded semipermeable seal 7 points, as in particular in the 3 and 4 is shown, several micro channels 10 on, in which 3 and 4 each only a single microchannel 10 can be seen. In fact, there are a variety of microchannels 10 on the scope of in 2 illustrated circumferential seal 7 arranged distributed. The in the 3 and 4 illustrated microchannel 10 is as a groove 11 trained and in one of the bottom 6 of the skin 3 facing contact surface 12 the seal 7 arranged. In the 3 pictured groove 11 is semicircular and the in 4 pictured groove 11 is rectangular. Of course, other Nutformen are conceivable.

The following is based on the 5 and 6 the inventive method for producing the multilayer composite component 1 in one of at least two relatively movable tool parts 13 . 14 existing foaming tool 15 described. As in 5 is shown in an open foaming tool 15 first the carrier 2 with the semipermeable seal 7 as a one-piece assembly to the first tool part 13 and the skin 3 to the second tool part 14 created. Here are the carrier 2 and the skin 3 for example, by negative pressure in their respective desired positions on the respective tool part 13 . 14 fixed.

Subsequently, the two tool parts 13 . 14 moved relative to each other, that with the carrier 2 bonded semipermeable seal 7 a cavity 16 between the carrier 2 and the skin 3 closes. This is the contact surface 12 the seal 7 with a predetermined contact pressure (F) on the opposite underside 6 of the skin 3 brought to the plant and pressed ( 6 ). By the plant of the contact surface 12 the seal 7 on the bottom 6 of the skin 3 form through the groove 11 and one of the groove 11 opposite section 17 of the skin 3 limited semipermeable microchannel 10 or the microchannels 10 out (see 7 and 8th ). The microchannel 10 has a cross-sectional area of 0.1 .mu.m to 100 .mu.m ² and can be rectangular ( 7 ) or semicircular ( 8th ) be formed. The length of the microchannel 10 corresponds to the width of the seal 7 and should preferably be between 0.5 mm to 5.0 mm ( 3 and 4 ).

A the foam layer 4 plastic foam 18 is prior to the relative movement of the two tool parts 13 . 14 into the opened foaming tool 15 introduced or the plastic foam 18 is after the relative movement of the two tool parts 13 . 14 into the cavity 16 between the carrier 2 and the skin 3 in the closed foaming tool 15 brought in. Through a chemical reaction, the plastic foam expands 18 in the cavity 16 , what in 6 by a directional arrow 19 is shown. This is also in the cavity 16 contained air 20 or contained gas 20 through the microchannel 10 in the seal 7 through the cavity 16 and from the foaming tool 15 dissipated what was in 6 through the directional arrow 21 is shown. Because of the gas 20 or the air 20 greater viscosity of the plastic foam 18 and the small cross-sectional area of the microchannel 10 can the air 20 or the gas 20 through the microchannel 10 escape while the plastic foam 18 on entering the microchannel 10 or at a passage through the microchannel 10 is prevented.

After the plastic foam 18 the whole in the cavity 16 contained air 20 through the microchannel 10 through the cavity 16 or the foaming tool 15 has pushed out and thus the entire cavity 16 between the carrier 2 and the skin 3 through the plastic foam 18 is filled, the foaming tool 15 , preferably if the plastic foam 18 has reached a sufficient dimensional stability, by a relative movement of the two tool parts 13 . 14 transferred to the open position and the multilayer composite component produced 1 can from the opened foaming tool 15 be removed.

A modification of the method according to the invention provides that the contact pressure F of the seal 7 onto the skin 3 during the expansion of the plastic foam 18 or shortly before completion of the complete filling of the cavity 16 with the plastic foam 18 is increased so that the the micro-channel 10 limiting section 17 of the skin 3 so in the opposite groove 11 in the seal 7 is pressed in, that the cross-sectional area of the microchannel 10 reduced. This allows the microchannel 10 also be completely closed, so that the air 20 or the gas 20 no longer through the microchannel 10 can pass through.

Finally, the in 1 shown excess edge portion 22 the produced multilayer composite component 1 in the foaming tool 15 or after removal from the foaming tool 15 by a cutting, milling or punching operation of the composite component 1 removed and disposed of. It is possible that the seal 7 together with the corresponding edge section 22 from the composite component 1 is separated ( 11 ) or that the seal 7 on the composite component 1 remains ( 12 ). By the on the composite component 1 remaining seal 7 becomes the mechanical stability of the composite component 1 improved and the proportion of the carrier material or the foam layer on the waste to be disposed of can be kept low.

LIST OF REFERENCE NUMBERS

1

 composite component

2

 carrier

3

 skin

4

 foam layer

5

 gap

6

 Underside (skin)

7

 poetry

8th

 Top (skin)

9

 Edge area (carrier)

10

 microchannel

11

 groove

12

 contact area

13

 first tool part

14

 second tool part

15

 foaming

16

 cavity

17

 part Of

18

 Plastic foam

19

 Directional arrow (foam)

20

 Air / Gas

21

 Directional arrow (gas / air)

22

 edge section

F

 contact pressure

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 202009012903 U1 [0007]
• DE 102009054893 A1 [0008]
• DE 102007061337 A1 [0009, 0014]

Claims (10)

Method for producing a multilayer composite component ( 1 ), consisting of a carrier ( 2 ), a skin ( 3 ) and one between carriers ( 2 ) and skin ( 3 ) arranged foam layer ( 4 ), in one of at least two relatively movable tool parts ( 13 . 14 ) existing foaming tool ( 15 ), which comprises the following steps: a) the carrier ( 2 ) is attached to a first tool part ( 13 ) and the skin ( 3 ) to a second tool part ( 14 ) of the opened foaming tool ( 15 ), b) the first tool part ( 13 ) and the second tool part ( 14 ) are used to form a cavity ( 16 ) between the carrier ( 2 ) and skin ( 3 ) is moved relative to one another, wherein one in an edge region ( 9 ) of the carrier ( 2 ) between the carrier ( 2 ) and skin ( 3 ) arranged semipermeable seal ( 7 ) the cavity ( 16 ) with closed foaming tool ( 15 ), c) a foam layer ( 4 ) forming plastic foam ( 18 ) is (before the relative movement of the two tool parts ( 13 . 14 ) into the opened foaming tool ( 15 ) or after the relative movement of the two tool parts ( 13 . 14 ) into the cavity ( 16 ) of the closed foaming tool ( 15 ), d) the plastic foam ( 18 ) expands in the cavity ( 16 ) of the closed foaming tool ( 15 ), which is due to the expansion of the plastic foam ( 18 ) in the cavity ( 16 ) displaced gas ( 20 ) and / or the displaced air ( 20 ) by at least one microchannel ( 10 ) in the seal ( 7 ) through the cavity ( 16 ), while an entry of the plastic foam ( 18 ) into the microchannel ( 10 ) and / or leakage of the plastic foam ( 18 ) from the cavity ( 16 ) through the microchannel ( 10 ) in the seal ( 7 ) due to one opposite the gas ( 20 ) and / or the air ( 20 ) greater viscosity of the plastic foam ( 18 ), e) the plastic foam ( 18 ) fills the cavity ( 16 ) between the carrier ( 2 ) and skin ( 3 ) and the foaming tool ( 15 ) is due to a relative movement of the two tool parts ( 13 . 14 ) and the multilayer composite component ( 1 ) is removed from the opened foaming tool ( 15 ). A method according to claim 1, characterized in that the escape of the expanding plastic foam ( 18 ) through a microchannel ( 10 ) is prevented with a cross-sectional area of 0.1 to 100 microns ² . Process according to claims 1 or 2, characterized in that the microchannel ( 10 ) by an installation of the seal ( 7 ) to the skin ( 2 ) during the relative movement of the two tool parts ( 13 . 14 ), the microchannel ( 10 ) through a groove ( 11 ) in the on the skin ( 3 ) contact surface ( 12 ) of the seal ( 7 ) and an opposite section ( 17 ) of the skin ( 3 ) is limited. Method according to at least one of the preceding claims, characterized in that a contact pressure (F) of the seal ( 7 ) to the skin ( 3 ) during or after the expansion of the plastic foam ( 18 ) is increased in such a way that the microchannel ( 10 ) limiting subsection ( 17 ) of the skin ( 3 ) at least partially the cross-sectional area of the microchannel ( 10 ) reducing in the in the seal ( 7 ) groove ( 11 ) is pressed. Method according to at least one of the preceding claims, characterized in that the seal ( 7 ) and the carrier ( 2 ) as a one-piece assembly on the first tool part ( 13 ). Method according to at least one of the preceding claims, characterized in that the excess edge portions ( 22 ) of the multilayer composite component produced ( 1 ) in the foaming tool ( 15 ) or after removal from the foaming tool ( 15 ) are removed by a cutting, milling or punching operation, wherein the seal ( 7 ) on the multilayer composite component ( 1 ) remains. Carrier ( 2 ) for use in a process for producing a multilayer composite component ( 1 ) consisting of the carrier ( 2 ), a skin ( 3 ) and one between the carrier ( 2 ) and skin ( 3 ) arranged foam layer ( 4 ) according to at least one of claims 1 to 6, characterized in that the carrier ( 2 ) in a peripheral area ( 9 ) with a semipermeable seal ( 7 ), which for air ( 20 ) or gas ( 20 ) permeable and for an expanding plastic foam used in the process ( 18 ) is impermeable. Carrier ( 2 ) according to claim 7, characterized in that the seal ( 7 ) at least one microchannel ( 10 ) having a cross-sectional area of 0.1 to 100 μm ² . Carrier ( 2 ) according to claim 7 or 8, characterized in that the microchannel ( 10 ) as a groove ( 11 ) and in one of the skin ( 3 ) facing contact surface ( 12 ) of the seal ( 7 ) is arranged. Carrier ( 2 ) according to at least one of claims 7 to 9, characterized in that the carrier ( 2 ) and the seal ( 7 ) are integrally connected.

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