DE102014107098A1 - MOLDING AND METHOD AND DEVICE FOR PRODUCING SUCH A MOLDED PART - Google Patents

Abstract

The invention relates to a molded part (1) in particular for vehicle interior trim with a user-specific outer contour (10). The molded part (1) has an internal structure formed by at least one insert part (5.1 to 5.7), which defines a basic shape (100) of the molded part (1) at least in regions. Furthermore, the molded part (1) has a thermoplastic material (6) forming the outer contour (10) of the molded part (1), which at least partially encloses the at least one insert (5.1) of the molded part (1) to form a unit to 5.7) surrounds and is connected to this cohesively.

Description

The invention relates to a molded part, in particular for vehicle interior trim, and a method and an apparatus for producing such a molded part.

A molded part of the generic type is used, for example, for lining interior surfaces of vehicle doors, as side panels, dashboard or the like. Of course, however, the present invention is not limited to these specific uses. In particular, it is also conceivable to use a manufactured according to the teachings of the present invention molding, for example, for the cabin and cockpit equipment of an aircraft.

Moldings for vehicle interior trim are usually produced in a tool-based manufacturing process, in which with the help of a molding tool, the molded part to be produced is made. As an example of this, the original molding of, for example, thermoplastic materials using the known injection molding technology called. In this case, the outer contour of the molded part to be produced is achieved with the aid of a corresponding molding tool. The contour of the molded part is specified via the contour of the molding tool.

Since, especially in the automotive industry, the variety of variants, but also the pressure to shorten the development times more and more, are required by the vehicle manufacturers concepts for the production of moldings for vehicle interior lining, in which not only prototypes and illustrative models, but also end products tool-less, flexible and at the same time as fast , can be produced precisely and economically. Such concepts or approaches are currently unknown.

In particular, conventional manufacturing methods, such as milling, turning, casting or forming can not meet these requirements, since in these manufacturing methods, the production costs are strongly coupled to the complexity of the molded part to be produced. In this case, it is usually necessary to initially produce relatively complicated molded part tools in a complex process, so that vehicle manufacturer-specific individualization requests are often not feasible in the short term and profitably.

On the basis of this problem, the present invention seeks to provide a molded part in particular for vehicle interior trim, which can be manufactured in small quantities at short notice and with little effort. Furthermore, a method and an apparatus for producing such a molded part are to be specified.

With regard to the molding, this object of the invention is achieved by the subject matter of the independent claim 1.

Accordingly, in particular a molded part is proposed for vehicle interior trim with a user-specific outer contour, wherein the molded part has an inner structure formed by at least one insert, which at least partially defines a basic shape of the molded part. In addition, the molded part according to the invention has a thermoplastic material forming the user-specific outer contour of the molded part, which at least partially surrounds the at least one insert part that predetermines the basic shape of the molded part and forms a material connection to form a unit.

With regard to the method for producing such a molded part, the object underlying the invention is achieved by the subject matter of the independent patent claim 8. In particular, it is thus proposed that initially at least one insert is provided, wherein with the help of the provided at least one insert then an inner structure of the molded part is formed, in such a way that with the inner structure at least partially a basic shape of the molded part to be produced is formed. In order to be able to form the user-specific outer contour of the molded part, it is proposed to selectively apply a thermoplastic material to the at least one insert forming the inner structure in such a way that the thermoplastic material at least partially surrounds the at least one insert for forming a unit and integrally bonded thereto is.

The advantages that can be achieved with the solution according to the invention are obvious: the fact that the molded part is manufactured by a tool-free method enables a fast, precise and economical production even of complex molded parts, even with smaller series. Here, the advantage is exploited that the coarse outer contour of the molded part can be predetermined by standard inserts in an easy to implement and thus cost-effective manner, wherein then the finished outer geometry of the molded part is realized with an additive manufacturing process. As a result, the complexity and three-dimensional design of the outer contour of the molding for the production time and production costs hardly plays a role.

On the other hand, with the help of standard inserts the three-dimensional basic shape of the molded part can be predetermined, the present invention enables the demand-oriented mass production of molded parts with a user-specific outer contour, in particular also vehicle manufacturer-specific individualization wishes are short-term and profitable feasible, even for small quantities.

In this context, it is conceivable, for example, that the at least one insert part is a prefabricated, three-dimensional injection-molded or molded part. On the other hand comes as an insert but also, for example, a plastic foam or the like in question, in which case the outer contour of the molding defining thermoplastic material forms a corresponding cover layer.

With regard to the at least one insert, it is particularly advantageous if this not only has the function of forming a (coarse) three-dimensional inner structure of the molded part to be manufactured, but also assumes additional functionalities. For example, in this context, it is conceivable that the inner structure formed by the at least one insert part is formed, the impact energy generated in a crash due to a Stoßkraftübertragung and introduced into the molding impact energy in particular by plastic deformation of the at least one insert or by non-ductile destruction thereof at least partially absorb or degrade.

In order to be able to apply the thermoplastic material to the inner structure formed with the aid of the at least one insert, an additive method is particularly suitable, such as, for example, Fused Deposition Modeling (FDM) or Arburg Plastic Freeforming (AKF).

Such additive (generative) manufacturing processes have already found their way into the production of prototypes and illustrative models in industrial product development. Additive manufacturing processes enable the layered production of models directly from CAD data without the use of a tool.

Characterized in that according to the invention, the additive manufacturing method is used in combination with at least one three-dimensional insert, not only a significant reduction in production time and thus an economical production of individual molded parts in small batches is possible.

The invention is not limited only to a molded part and a method for producing such a molded part, but also relates to a corresponding device for producing such a molded part, wherein the device comprises means for pre-positioning and temporary fixing of at least one insert and a device for selective application a thermoplastic material has on the at least one prepositioned and temporarily fixed insert.

Here, the device for pre-positioning and temporary fixing is in particular designed to position the at least one insert so that a basic shape of the molded part to be produced can be predetermined.

Hereinafter, an exemplary embodiment of the present invention will be described in more detail with reference to the drawings.

Show it:

1 a schematic side view of a device for pre-positioning and temporary fixing of inserts in an exemplary embodiment of the device according to the invention for producing a molded part;

2 a schematic side view of the means for pre-positioning and temporary fixing according to 1 together with means for selectively applying a thermoplastic material; and

3 , a schematic side sectional view through an exemplary embodiment of a molding, which with the device according to 2 was made.

Hereinafter, an exemplary embodiment of the inventive solution will be described in more detail with reference to the accompanying drawings. In detail is in 3 in a schematic sectional view of an exemplary embodiment of the molding according to the invention 1 shown. This molding 1 is in particular a molding for vehicle interior trim, such as a molding for lining of inner surfaces of vehicle doors, a molding for side paneling, or even a molding for forming the front panel of a vehicle.

Such a molded part 1 is characterized by the fact that this is a user-specific outer contour 10 having. The term "user-specific outer contour" as used herein means, in particular, the three-dimensional design of the molded part 1 to understand, which is visible to the user in the installed state. This outer contour does not only have to fulfill functional functions, but often also aesthetic aspects, as in the automotive industry, the increasing trend There is also the design of the interior of a vehicle individually. Thus, the outer contour of the molding must 1 to reproduce the user-specific individualization wishes.

As the schematic sectional view according to 3 can be removed, has the molding according to the invention 1 an internal structure made up by a variety of inserts 5.1 to 5.7 is formed. With these inserts 5.1 to 5.7 These are prefabricated (three-dimensional) bodies that have been pre-fabricated, for example, by injection molding or casting. It is conceivable, however, that at least some of the inserts 5.1 to 5.7 are designed as foam body, etc.

The inserts 5.1 to 5.7 showing the internal structure of the molding 1 can each have different shape and / or sizes. Of course, it is also conceivable consistently to use inserts of the same size and type. However, it is conceivable, inserts of different materials and / or with different structural properties, such as pressure resistance, thermal and / or acoustic insulating property, etc., have.

Essential here is solely and solely that it is the inserts 5.1 to 5.7 showing the internal structure of the molding 1 train to standardized standardized components can act. In other words, the inserts 5.1 to 5.7 leading to the formation of the internal structure of the molding 1 are not relevant for the finished, user-specific outer contour 10 of the molding 1 , In particular, therefore, the standard inserts are suitable 5.1 to 5.7 to specify a basic shape for molded parts 1 with different outer contours 10 ,

The schematic sectional view according to 3 It can also be seen that the individual, the internal structure of the molding 1 forming inserts 5.1 to 5.7 at least partially of a thermoplastic material 6 are surrounded, said thermoplastic material 6 the individual inserts 5.1 to 5.7 not only surrounds in some areas, but also connects them firmly together.

As it subsequently with reference to the representations in the 1 and 2 is described in more detail, the invention provides that the thermoplastic material 6 especially additive to the with the help of inserts 5.1 to 5.7 formed inner structure is applied to ultimately the user-specific outer contour 10 of the molding 1 train. As in particular the representation in 3 can be removed, it is necessary that the thermoplastic material 6 partially different thicknesses, so the user-specific outer contour 10 to be able to form.

Hereinafter, with reference to the schematic diagrams in the 1 and 2 the method for producing the in 3 schematically shown molding 1 and an exemplary embodiment of an apparatus for carrying out the method described in more detail.

In detail is in 1 in a side view schematically a first component of the device according to the invention 50 for producing a molded part 1 , in particular one in 3 schematically shown molding 1 shown. This first component is generally indicated in the drawings by the reference numeral " 20 "And serves for pre-positioning and temporary fixing of the individual inserts 5.1 to 5.7 for the formation of the internal structure of a molded part to be manufactured 1 serve.

As shown, this has the first component 20 the device 50 a substantially horizontally extending support structure 21 on, as the basis for a plurality of independently relative to this in the vertical direction (z-direction) extendable plunger 22.1 to 22.7 serves. This is every pestle 22.1 to 22.7 a corresponding insert 5.1 to 5.7 assigned, with the corresponding plunger 22.1 to 22.7 this serves the corresponding assigned insert 5.1 to 5.7 not only to position in the vertical direction, but also to deflect in the x and y direction accordingly.

For this purpose, every pestle 22.1 to 22.7 with a device for temporary fixing of the corresponding associated insert 5.1 to 5.7 Mistake. For this it is conceivable, for example, that every pestle 22.1 to 22.7 at his base 21 remote end portion has a suction cup, for example via a ball joint assembly 23.1 to 23.7 with the appropriate plunger 22.1 to 22.7 is connected, so as to the corresponding insert 5.1 to 5.7 not only in the vertical direction (z-direction) but also in the horizontal plane in the x and y direction in the context of the corresponding plunger 22.1 to 22.7 assigned grid area of, for example, 25 × 25 mm to pivot.

In this way it is possible that with the help of the plunger assembly, the individual inserts 5.1 to 5.7 can be pre-positioned so that the inserts 5.1 to 5.7 a basic form 100 of the molded part to be manufactured 1 pretend. This basic form 100 roughly corresponds to the user-specific outer contour 10 , which ultimately by selective and preferably adaptive application of the thermoplastic material 6 is formed.

In 2 is also schematically indicated in a side view, as in the exemplary embodiment of the device according to the invention 50 for the production of the molding 1 the thermoplastic material 6 selectively on the pre-positioned and temporarily fixed inserts 5.1 to 5.7 is orderable.

Specifically, at the in 2 schematically illustrated exemplary embodiment of a raster arrangement of a plurality of printheads 7 provided, each individual printhead 7 independently in the vertical direction (z-direction) relative to the inserts 5.1 to 5.7 is movable.

Every printhead 7 The plurality of printheads, which are arranged in a raster arrangement in the exemplary embodiment, serve to provide a thermoplastic material 6 selectively on the upper surface of the individual inserts 5.1 to 5.7 ie on the through the inserts 5.1 to 5.7 given basic form 100 apply. It is advantageous if every single printhead 7 not only in the vertical direction (z-direction) relative to the prepositioned inserts 5.1 to 5.7 is movable, but also independently in the horizontal plane in the x and y direction in the context of a corresponding printhead 7 assigned grid surface are movable.

For example, the printhead system may be based on FDM or AKF technology, wherein the thermoplastic material 6 either on coils wound (in FDM technology) or in the form of granules (in AKF technology). In the case of the AKF technology, it is conceivable not to each of the individual printheads 7 to provide a separate plasticizing unit, but a limited number of plasticizing units of a larger number of printheads via hot runners with molten thermoplastic material 6 to feed. In the case of FDM technology, however, every printhead would have to 7 be assigned a separate material coil.

After all, it should be noted that by the use of adaptive manufacturing in the prepositioned and the inner structure of the molding indicating inserts are already feasible for smaller series in an easy to implement, cost-effective and with savings in production time and costs user-specific molding configurations.

The invention is not limited to the exemplary embodiment illustrated in the drawings, but results from a synopsis of all the features disclosed herein.

Claims (19)

Molded part ( 1 ) in particular to the vehicle interior trim with a user-specific outer contour ( 10 ), wherein the molded part ( 1 ) one by at least one insert ( 5.1 to 5.7 ) has formed inner structure, which at least partially a basic shape ( 100 ) of the molded part ( 1 ), and wherein the molded part ( 1 ) Furthermore, the outer contour ( 10 ) of the molded part ( 1 ) forming thermoplastic material ( 6 ), which for forming a unit at least partially, the at least one of the basic form ( 100 ) of the molded part ( 1 ) predetermined insert part ( 5.1 to 5.7 ) surrounds and is connected to this cohesively. Molded part ( 1 ) according to claim 1, wherein the at least one insert part ( 5.1 to 5.7 ) is a prefabricated, 3-dimensional metal, plastic, natural material or composite part, in particular an injection molding, extrusion or compression molding. Molded part ( 1 ) according to claim 1 or 2, wherein the at least one insert part ( 5.1 to 5.7 ) formed inner structure of the molding ( 1 ) is a self-supporting structure. Molded part ( 1 ) according to one of claims 1 to 3, wherein the at least one insert part ( 5.1 to 5.7 ) is formed, the resulting in a crash due to an impact force transmission and in the molded part ( 1 ) initiated impact energy, in particular by plastic deformation or by non-ductile destruction at least partially absorb or degrade. Molded part ( 1 ) according to one of claims 1 to 4, wherein the outer contour ( 10 ) of the molded part ( 1 ) forming thermoplastic material ( 6 ) selectively to the through the at least one insert ( 5.1 to 5.7 ) formed inner structure is applied, in particular in layers, preferably by FDM or AKF. Molded part ( 1 ) according to one of claims 1 to 5, wherein the at least one insert part ( 5.1 to 5.7 ) and / or by the at least one insert ( 5.1 to 5.7 ) formed inner structure are / is to specify a basic form ( 100 ) for molded parts with different outer contours. Vehicle interior trim part, in particular trim part, with at least one molded part ( 1 ) according to one of claims 1 to 6. Method for producing a molded part ( 1 ) to the vehicle interior trim, in particular for producing a molded part ( 1 ) according to one of claims 1 to 6, wherein the method comprises the following method steps: i) providing at least one insert ( 5.1 to 5.7 ); ii) forming an internal structure of the molded part ( 1 ) with the aid of the at least one insert ( 5.1 to 5.7 ) such that with the internal structure at least in regions a basic form ( 100 ) of the molded part ( 1 ) is formed; and iii) selective application of a thermoplastic material ( 6 ) on the at least one, the inner structure forming insert ( 5.1 to 5.7 ) such that the thermoplastic material ( 6 ) to form a unit at least partially, the at least one insert ( 5.1 to 5.7 ) surrounds and is connected to this cohesively. Process according to claim 8, wherein in process step iii) the thermoplastic material ( 6 ) in layers on the at least one insert ( 5.1 to 5.7 ) is applied such that at least in regions with the applied thermoplastic material ( 6 ) a user-specific outer contour ( 10 ) of the molded part ( 1 ) is formed. Process according to claim 8 or 9, wherein in process step iii) the thermoplastic material ( 6 ) is applied by FDM or AKF. Method according to one of claims 8 to 10, wherein in step i) the at least one insert ( 5.1 to 5.7 ) is provided by injection molding or molding. Method according to one of claims 8 to 11, wherein in method step i) a plurality of inserts ( 5.1 to 5.7 ), and wherein in step ii) the inner structure is formed by positioning the plurality of inserts with respect to each other and preferably at least temporarily fixing them. Contraption ( 50 ) for producing a molded part ( 1 ), in particular a molded part ( 1 ) according to one of claims 1 to 6, wherein the device ( 50 ): - a device ( 20 ) for pre-positioning and temporarily fixing at least one insert ( 5.1 to 5.7 ) such that a basic form ( 100 ) of the molded part ( 1 ) can be specified; and a device for the selective application of a thermoplastic material ( 6 ) on the at least one prepositioned and temporarily fixed insert ( 5.1 to 5.7 ). Contraption ( 50 ) according to claim 13, wherein the device ( 20 ) for pre-positioning and temporary fixing at least one and preferably a plurality of independently relative to a base ( 21 ) extendable in the vertical direction plunger ( 22.1 to 22.7 ), wherein the at least one plunger ( 22.1 to 22.7 ) at its base ( 21 ) end region detachably connected to the at least one insert ( 5.1 to 5.7 ) is connectable. Contraption ( 50 ) according to claim 14, wherein the at least one plunger ( 22.1 to 22.7 ) at its base ( 21 ) facing away from a preferably relative to the plunger ( 22.1 to 22.7 ) has a pivotable suction cup. Contraption ( 50 ) according to any one of claims 13 to 15, wherein said means for selectively applying a thermoplastic material ( 6 ) at least one and preferably a plurality of print heads ( 7 ) for selective and additive dispensing of the thermoplastic material ( 7 ) in liquid form. Contraption ( 50 ) according to claim 16, wherein the at least one print head ( 7 ) in the vertical direction relative to a pre-positioned with the means for pre-positioning and temporary fixing insert ( 5.1 to 5.7 ) is arranged movable. Contraption ( 50 ) according to claim 16 or 17, wherein a plurality of arranged in a grid print heads ( 7 ) is provided, wherein the print heads ( 7 ) are independently movable in the vertical direction. Contraption ( 50 ) according to claim 18, wherein each print head ( 7 ) in the horizontal plane in the x and y direction in the context of a corresponding printhead ( 7 ) assigned grid surface is movable.

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