DE102018131722A1 - Forming tool for joining cladding parts with flat decorative materials and a corresponding method - Google Patents

Abstract

The invention relates to a molding tool for joining trim parts with flat decorative materials, preferably for the vehicle and aviation industries, comprising: - a first and a second mold half (1, 2), which can be adjusted to one another between an open position and a closed position, in which A joint gap (5) is formed between the mold halves, and at least one of the mold halves (1, 2) is contoured on a surface (3, 4) delimiting the joint gap (5) and preferably has an embossed pattern of a grain, - a holding frame (6), which is detachably fixed adjacent to the joining gap (5) on a first of the mold halves (1, 2), a clamping receptacle (7) for a folding flag being formed between the first mold half (1) and the holding frame (6) , which opens into the joining gap (5) via an opening (8), characterized in that a cutting device (9) is arranged in the clamping receptacle (7). A corresponding method is also described.

Description

The present invention is based on a mold for joining trim parts with flat decorative materials, preferably for the automotive and aerospace industries, which has a first and a second mold half, which are adjustable relative to one another between an open position and a closed position, the closed position between the Forming halves a joint gap is formed, and wherein at least one of the mold halves is contoured on a surface delimiting the joint gap and preferably has an embossing pattern of a grain. Furthermore, the molding tool has a holding frame, which is detachably fixed adjacent to the joint gap on a first of the mold halves, wherein Between the first mold half and the holding frame, a clamping receptacle for a folding flag is formed, which opens into the joining gap via an opening. Such a device is from the DE 196 27 387 A1 known. A similar device describes the DE 10 2011 015 818 A1 .

Tools and methods are known from the prior art, in which fiber composite mats, sandwich structures with a honeycomb core or foam core with a thermoplastic binder and a decorative material are produced in one tool or method in a one-shot process with a folding flag, the folding flag however only at a later time Is trimmed and folded in one or more other tools.

The DE 196 273 87 A1 discloses a molding tool for the production of plastic carrier materials which have a plastic carrier part and a decorative film pressed thereon. For the production, the plastic carrier part and the decorative film are placed in the mold and pressed between a lower tool and an upper tool. In this case, a folding flag of the decorative film remains in an undercut area of the lower tool in order to trim it in subsequent production steps and to bend the carrier part. However, it has been found that, in particular in the case of complex components, the trimming of the folding flag to the correct length by additional manufacturing steps is complex and the sometimes necessary use of manual labor is also imprecise.

Starting from this prior art, it is the object of the invention to provide a molding tool which reduces the manufacturing outlay for the production of trim parts.

This object is achieved by the molding tool according to claim 1 and the corresponding method according to claim 8. Advantageous refinements are the subject of the dependent claims.

The cutting device can, for example, have a knife which can be adjusted back and forth between a cutting position in which the knife projects into the clamping receptacle and a release position in which the knife is at least partially retracted into one of the holding frame and the associated mold half.

The knife can advantageously be adjustable back and forth perpendicular to the holding frame and / or the mold half assigned to the holding frame.

Furthermore, the knife in the cutting position can penetrate with its cutting edge into a cutting base arranged opposite the cutting edge or can rest against the latter.

The cutting base can be received in a recess, in particular in a groove, which is open towards the clamping receptacle.

It is also conceivable that the cutting base is held in a recess of the holding frame.

In the release position, the knife of the cutting device can be at least partially and preferably completely retracted into the mold half assigned to the holding frame.

The holding frame can have a plunge edge at its end facing the further mold half, on which the holding frame is not releasably fixed, which forms a cutting edge with the further mold half, at least in the closed position.

It is also conceivable that the contoured surface of the first mold half has a contour for graining flat decorative material, for example to imitate a leather look.

Furthermore, the first mold half or the holding frame can have a folding device for folding or for bending a trimmed end section of the flat decorative material around a carrier material joined between the mold halves.

The contoured surface of the further carrier material can advantageously have at least two concave sections and at least one convex section, the convex section being arranged between the two concave sections. As a result, a recessed shoulder is formed on the carrier material produced, on which the folding flag can be fixed.

Furthermore, the first mold half can have an edge at a transition between the clamping receptacle and the contoured surface, around which the folding flag is placed and enters the clamping receptacle.

Between the further mold half and the holding frame, a trimming plane can also be formed parallel to the direction of adjustment of the mold halves, in which a plunge edge of the holding frame lies, wherein the further mold half and the holding frame can lie against one another in the closed position via the trimming plane and the plunge edge.

Furthermore, the further mold half adjacent to the trimming plane can have a trimming edge which forms a cutting edge with the plunge edge of the holding frame. As a result, the edge of a carrier material to be joined can be sheared off when the mold halves are transferred into the closed position.

Furthermore, the holding frame between the contact surface and the clamping receptacle can have an edge which, together with the edge of the mold half forming the clamping receptacle with the holding frame, limits the opening of the clamping receptacle.

Furthermore, the first and / or the second mold half can have a heating device.

Furthermore, the carrier material can be a fiber composite material, for example a multilayer fiber composite material. It can have one of the following layer structures: single-layer structure, microsandwich or multi-layer structure.

The carrier material can also have a core, which can have one of the following core materials: paper honeycomb, foam core (PP, PES, PUR), plastic honeycomb, aluminum core honeycomb. The design and thickness of the honeycomb structure can take on any size and shape and the density of the core can vary locally.

A possible layer structure can have the following structure: decor, support view, core, support view, cover fleece. However, the structure can also include more or fewer layers. For example, less can be used when using a cover made of NF, a core made of PU, PE, PIR or PET foam or structural foam, a back cover made of NF and applied decorative surfaces and optional needling or intermediate layers such as adhesive films for direct back pressing in the thermograin process Pressure is exerted on the film, whereby scarring, glossy spots or uneven radii can be avoided.

It is also conceivable that the carrier material comprises one or more of the following materials: polypropylene-glass fiber reinforced (PP / GF), polypropylene-natural fiber (PP / NF), polyester (PES), PP / NF / PES, glass / PP, glass / PP / PES, Acrodur / glass, Acrodur / natural fiber, PU / glass as pure fiber mat, recycled cotton fibers / PP, Glass Mat Reinforced Thermoplastic (GMT), Sheet Molding Compound (SMC) or long fiber reinforced thermoplastics (LFT). It is also conceivable that the mat weights of the fiber mats are between 200 g / m ² - 3,500 g / m ² and in different mixture compositions have about 30 - 60% PP fibers as binding fibers.

It is conceivable that the fiber composite mats or sandwich structures are bound thermoplastic. However, this tool could also be used to process thermosetting binders such as phenolic, acrylic, Acrodur, PUR, etc.

Furthermore, the flat decorative material can have one or more of the materials listed below: adhesive films, barrier layers, PU sandwiches, PU glass, PU, cover fleeces, decors, knitted fabrics, knitted fabrics, foils, slush skins or spray skins. Decors can be understood to mean all types of decorative surfaces such as needle fleece, foils, TPO foil, leather, deluxe, fabrics, knitted fabrics or knitted fabrics. Here you can also use special decorative surfaces that have special properties such as temperature resistance or special tool cooling or temperature control. An adhesion promoter, such as adhesive, can be used to improve the adhesion of the decorative material to the carrier, in particular the fiber composite material.

Non-grained foils, grained foils, Ibolour, PVC foil or, for example, tufting are also suitable as materials for the decor.

Furthermore, it is conceivable that the joined cladding parts for hat racks, door panels, door inserts, loading floors, trunk lid, side panels, underbody paneling or all interior or exterior paneling parts made of fiber composite materials / mats can be provided with and without a decorative surface.

• - Einlegen eines flächigen Dekormaterials und eines mit dem Dekormaterial zu versehenen Bauteils oder Bauteilhalbzeugs, der ein Träger für das Dekormaterial ist, in ein Formwerkzeug nach einem der vorangegangen Ansprüche, das in der Offenstellung angeordnet ist,
• - Klemmen eines Außenumfangs des flächigen Dekormaterials, vorzugsweise einer Umbugfahne des Dekormaterials in einer oder mehreren Klemmaufnahmen zwischen einer der Formhälften und dem Halterahmen,
• - Fügen des flächigen Dekormaterials mit dem Bauteil oder Bauteilhalbzeug zwischen der ersten Formhälfte und der zweiten Formhälfte, wobei das Formwerkzeug aus seiner Offenstellung in die Schließstellung überführt und das Bauteil oder Bauteilhalbzeug verformt wird,
• - Überführen des Formwerkzeugs aus der Schließstellung in die Offenstellung und Entnehmen des mit dem Dekormaterial gefügten Bauteils,

dadurch gekennzeichnet, dass das Verfahren nach dem Klemmen und vor dem Überführen des Formwerkzeugs aus seiner Schließstellung in die Offenstellung das Beschneiden des Dekormaterials, vorzugsweise der Umbugfahne, in der Klemmaufnahme aufweist. Das Dekormaterial kann bei dem Beschneiden in der Klemmaufnahme entlang seines Umfangs beschnitten werden.In another aspect, the invention relates to a method for producing carrier materials with flat decorative materials. The method can have the following steps:

• Inserting a flat decorative material and a component or semi-finished product to be provided with the decorative material, which is a carrier for the decorative material, into a mold according to one of the preceding claims, which is arranged in the open position,
• - Clamping an outer circumference of the flat decorative material, preferably a folding flag of the decorative material, in one or more clamping receptacles between one of the mold halves and the holding frame,
• Joining the flat decorative material with the component or semi-finished product between the first mold half and the second mold half, the molding tool being transferred from its open position to the closed position and the component or semi-finished product being deformed,
• Transferring the molding tool from the closed position into the open position and removing the component joined with the decorative material,

characterized in that after the clamping and before the transfer of the molding tool from its closed position into the open position, the method comprises trimming the decorative material, preferably the folding flag, in the clamping receptacle. The decorative material can be trimmed along its circumference in the clamping receptacle.

In addition, during trimming, a knife of a cutting device can be transferred from a release position, in which the knife is at least partially retracted into one of the holding frame and associated mold half of the molding tool, to a cutting position, in which the knife protrudes into the clamping receptacle and cuts through the decorative material.

When trimming, the knife can be adjusted perpendicular to the holding frame and / or the mold half assigned to the holding frame.

It is also conceivable that when the knife is transferred to the cutting position, a cutting edge of the knife is introduced into a cutting base arranged opposite the cutting edge or brought to bear against it.

Furthermore, the knife of the cutting device can be at least partially and preferably completely withdrawn from the clamping receptacle into the mold half assigned to the holding frame after the cutting and before the transfer of the molding tool from the closed position into the open position.

Between the trimming of the free ends of the film and the removal of the carrier material, the method can further comprise turning the free ends of the film around the edges of the carrier material.

Furthermore, after the free ends have been turned over, the method can include fixing the free ends of the film on the back of the carrier material.

When joining the flat decorative material with a carrier material, the method can furthermore comprise producing a film grain in one of the mold halves.

The decorative material can be provided as a non-grained film and inserted into the molding tool, a grain being embossed into the decorative material during the transfer of the molding tool from its open position into the closed position.

Furthermore, the method can have at least one of the following production methods: oneshot, in-mold graining (IMG), scars on the surface, thermograin, molding, laminating, laminating, back-injection of functional parts, introduction of openings, over-molding of edges, long fiber injection ( LFI), Reaction Injection Molding (RIM) or High Pressure Resin Transfer Molding (HD -RTM).

In the methods known from the prior art with a plunge frame tool, pre-trimmed blanks are generally used for the decoration in such a way that they form a folding flag after molding. An integration of the edge trimming in the tool is particularly important when three-dimensionally deformed components are manufactured on which the edge flap is difficult to define.

• 1 eine Schnittdarstellung eines Formwerkzeugs gemäß einer Ausführungsform der Erfindung;
• 2 eine Schnittdarstellung der einzelnen Formwerkzeugkomponenten einer Ausführungsform der Erfindung;
• 3 eine Schnittdarstellung des Formwerkzeugs mit eingelegtem Bauteil;
• 4 ein schematisches Ablaufdiagramm des erfindungsgemäßen Herstellverfahrens.

Further details of the invention are described in the figures below. It shows:

• 1 a sectional view of a mold according to an embodiment of the invention;
• 2nd a sectional view of the individual mold components of an embodiment of the invention;
• 3rd a sectional view of the mold with an inserted component;
• 4th a schematic flow diagram of the manufacturing method according to the invention.

1 shows a mold, which is suitable for joining trim parts. The trim parts to be processed, which are preferably used for the vehicle and aerospace industries, can in particular be thermoplastic and / or thermoset bonded fiber composite materials in a single, multi-layer or sandwich construction, which can be combined with a tool graining decorative material, such as a TPO, PVC, or PP film or other decorative lamination materials, are pressed. In order to produce optically appealing component edges, a folding flag is created at the edge of the film or other decorative material in order to cover the trimming edge with a folding.

The molding tool is designed for a “one-shot” process, in which the decorative film can be laminated to the carrier in a single step, with the two components being shaped at the same time, and the structuring, in particular the graining of the decorative film.

The molding tool in 1 has a first mold half 1 as well as a second mold half 2nd on, with a joint gap between the two mold halves 5 is formed, in which a carrier, in particular a fiber composite material, such as a multilayer fiber composite material, is pressed and shaped with a decorative film. For this purpose, the mold halves can be adjusted relative to one another between an open position and a closed position, the flat carrier and the film being able to be inserted in the open position. The second half of the mold 2nd is from the first half of the mold 1 designed to be liftable in the vertical direction. The two mold halves can be used for a visually appealing design of the components to be manufactured 1 , 2nd one contoured surface each 3rd , 4th have, the contoured surface of the mold half 1 can also have means for producing a film grain.

On the mold half 1 continues to border a holding frame 6 which also between an open position and a closed position relative to the first mold half 1 can be adjusted. It is in the closed position between the first half of the mold 1 and the holding frame 6 a clamp receptacle 7 formed, which is suitable for receiving and clamping a film end section or a folding flag. The clamp receptacle 7 opens when the holding frame 6 and the second half of the mold 2nd are in their respective closed positions, in the joint gap 5 . This allows the end portion of one on the contoured surface 3rd decorative material on top 26 , like a foil, on the edge 19th the first half of the mold 1 from the joint gap 5 groundbreaking in the clamping receptacle 7 be clamped.

In the illustrated embodiment, the first mold half has 1 still a cutter 9 in which a knife 10th is recorded, which is between a cutting position in which the knife 10th in the clamp receptacle 7 protrudes, and a release position in which the knife 10th into the cutter 9 is at least partially withdrawn, can be adjusted. In addition to the joining of the carrier material with the decorative film, the trimmings can also be trimmed to a desired length in the same tool. In the illustrated embodiment, the knife is 10th perpendicular to the clamp receptacle 7 arranged the knife 10th or the cutting device 9 can also be arranged at an angle to this. The knife 10th also has a cutting edge 13 on, which serves to detach the folding flag. The knife is for non-destructive work 10th in the cutting position opposite a cutting pad 11 arranged which in a groove 12 through the holding frame 6 extends and to the clamp receptacle 7 is open, is included.

2nd also shows a side view of the molding tool, the illustrative purpose being the holding frame 6 , the first half of the mold 1 and the second half of the mold 2nd are shown contested from each other. In particular, the opening 14 of the joining gap 5 to recognize which by a trimming edge 17th the second half of the mold 2nd as well as through the edge 19th the first half of the mold 1 is limited and which in the opening 8th the clamping receptacle 7 flows. The opening 8th is limited by the edge 19th the first half of the mold 1 as well as an edge 18th of the holding frame 6 . The bleed edge 17th the second half of the mold 2nd is intended to allow possible protrusions or plastic residues on the outer edge of the carrier material to be joined on the contact surface 16 of the holding frame 6 shear off. This shearing process takes place when the second half of the mold is adjusted 2nd their closed position. Are the holding frame 6 and the second half of the mold 2nd in their closed position, limit the contact surface 16 as well as the cropping area 15 the second half of the mold 2nd to each other.

In 3rd is the mold according to the invention in the closed position and with in the joint gap 5 inserted and already molded trim part shown, the cutting device 9 is not shown in this illustration. You can see the flat decorative material 26 which is in the first half of the mold 1 on the contoured surface 3rd fits and is on the edge 19th the first half of the mold 1 in the form of a folding flag in the clamp receptacle 7 extends and is clamped there. In contrast, there is the carrier material 27th , which with the flat decor material 26 has been pressed on the contoured surface 4th the second half of the mold 2nd on. It can be seen in particular that the surface contour 4th from the clamp receptacle 7 starting from a concave section, then a convex section and then again a concave section, which results in the carrier material 27th a recessed shoulder is generated, on which the fold flag is turned and fixed.

4th shows a schematic sequence of a method for producing trim parts with a decorative surface, for example using a mold according to the embodiments described above. This is done in one step 20th a carrier material 27th in the second half of the mold 2nd as well as a slide section 26 in the first half of the mold 1 inserted, the second mold half 2nd as well as the holding frame 6 are each in their open position.

Then the clamping takes place 21st an outer circumference or the edge of the foil 26 in the clamp receptacle 7 between the first half of the mold 1 and the holding frame 6 .

This is followed by joining 22 of the carrier material 27th and the slide 26 between the first half of the mold 1 and the second half of the mold 2nd by the second mold half 2nd is transferred from its open position to the closed position.

A pruning 23 the slide 26 in the clamping receptacle takes place after the film has been joined 26 with the carrier material 27th . The slide 26 in the clamp receptacle 7 cropped along its circumference. This is particularly advantageous in the case of complex components in which the folding flag is difficult to define and in which a trimming of the folding flag after removal of the trim part from the molding tool is difficult and mostly inaccurate due to the angled geometries.

For trimming 23 the folding flag moves the knife 10th the cutting device 9 from a release position in which the knife 10th into the cutter 9 or in the holding frame 6 or the associated mold half of the mold is withdrawn into a cutting position in which the knife 10th in the clamp receptacle 7 protrudes and with the cutting pad 11 is brought into contact with the film 26 severed. In the in the 1-3 In the illustrated embodiments, the knife is trimmed 23 perpendicular to the holding frame 6 adjusted, but are also opposite the clamp receptacle 7 angled cutting directions conceivable.

After pruning 23 can the molding tool in one step 24th transferred from the closed position to the open position and then in one step 25th the carrier material can be removed from the tool.

The features of the invention disclosed in the above description, in the drawings and in the claims can be essential for realizing the finding both individually and in any combination.

Reference symbol list

1

first mold half

2nd

second half of the mold

3rd

Surface of the first half of the mold

4th

Surface of the second half of the mold

5

Joining gap

6

Holding frame

7

Clamp holder

8th

opening

9

Cutting device

10th

knife

11

Cutting pad

12

Recess

13

Cutting edge

14

opening

15

Trim area

16

Contact surface

17th

Bleed edge

18th

Edge of the holding frame

19th

Edge of the first half of the mold

20th

Insert

21st

Clamps

22

Put

23

trimming

24th

Convict

25th

Remove

26

Decorative material

27th

Backing material

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included 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.

Patent literature cited

• DE 19627387 A1 [0001, 0003]
• DE 102011015818 A1 [0001]

Claims (15)

Molding tool for joining components with flat decorative materials, comprising: - a first and a second mold half (1, 2), which can be adjusted relative to one another between an open position and a closed position, a joining gap (5) being formed between the mold halves in the closed position , and wherein at least one of the mold halves (1, 2) is contoured on a surface (3, 4) delimiting the joint gap (5) and preferably has an embossed pattern of a grain, - a holding frame (6) which is adjacent to the joint gap (5 ) is releasably fixed to a first of the mold halves (1, 2), a clamping receptacle (7) for a folding flag being formed between the first mold half (1) and the holding frame (6), said clamping receptacle via an opening (8) in the joining gap (5) opens, characterized in that a cutting device (9) is arranged in the clamping receptacle (7). Mold after Claim 1 , wherein the cutting device (9) has a knife (10) which between a cutting position in which the knife (10) projects into the clamping receptacle (7) and a release position in which the knife (10) at least partially in one of Retaining frame (6) and associated mold half (1) is withdrawn, is adjustable back and forth. Mold after Claim 2 , The knife (10) being adjustable back and forth perpendicular to the holding frame (6) and / or the first mold half (1) assigned to the holding frame (6). Mold after Claim 2 or 3rd , wherein the knife (10) in the cutting position with its cutting edge (13) penetrates into a cutting pad (11) arranged opposite the cutting edge (13) or bears against it. Mold after Claim 4 , The cutting base (11) being received in a recess (12), in particular in a groove, which is open towards the clamping receptacle (7). Mold after Claim 4 or 5 , wherein the cutting base (11) is held in a recess (12) of the holding frame (6). Molding tool according to one of the Claims 2 to 6 , wherein the knife (10) of the cutting device (9) in the release position is at least partially and preferably completely retracted into the mold half (1) assigned to the holding frame (6). Molding tool according to one of the preceding claims, in which the holding frame (6) has at its end facing the further mold half (1, 2), on which the holding frame (6) is not releasably attached, a plunge edge (18) which is at least in the The closed position forms a cutting edge with the other mold half (1, 2). Method for producing and joining components with flat decorative materials, with the steps: - inserting (20) a flat decorative material and a component or semi-finished product to be provided with the decorative material into a mold according to one of the preceding claims, which is arranged in the open position, - Clamps (21) of an outer circumference of the flat decorative material, preferably a folding flag of the decorative material in one or more clamping receptacles (7) between one of the mold halves (1, 2) and the holding frame (6), - Joining (22) of the flat decorative material with the Component or semi-finished product between the first mold half (1) and the second mold half (2), the mold being transferred from its open position to the closed position and the component or semi-finished product being deformed, - transferring (24) the mold from the closed position to the open position and Removing the component joined with the decorative material, characterized in that the Method after clamping (21) and before transferring (24) the molding tool from its closed position to the open position has the trimming (23) of the decorative material, preferably the folding flag, in the clamping receptacle (7). Procedure according to Claim 9 , wherein the decorative material is trimmed (23) in the clamping receptacle (7) along its circumference. Procedure according to Claim 9 or 10th , wherein during the trimming (23) a knife (10) of a cutting device (9) from a release position in which the knife (10) is at least partially retracted into one of the holding frame (6) and associated mold half (1) of the mold, in a cutting position is transferred in which the knife (10) protrudes into the clamping receptacle (7) and cuts through the decorative material. Procedure according to one of the Claims 9 to 11 , wherein the knife (10) is adjusted perpendicular to the holding frame (6) and / or the mold half (1) assigned to the holding frame (6) during trimming (23). Procedure according to one of the Claims 11 or 12 , wherein during the transfer (24) of the knife (10) into the cutting position, a cutting edge (13) of the knife (10) is introduced into a cutting base (11) arranged opposite the cutting edge (13) or brought to bear against it. Procedure according to one of the Claims 11 or 12 , The knife (10) of the cutting device (9) after trimming (23) and before transferring (24) the molding tool from the closed position to the open position at least partially and preferably completely from the clamping receptacle (7) into the holding frame (6 ) assigned mold half (1) is withdrawn. Method according to one of the preceding claims, in which the decorative material is provided as a non-grained film and placed in the mold (20), and in which a grain is embossed into the decorative material from the open position to the closed position during the transfer (24) of the mold.

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