DE102018212610A1 - Process for producing a multilayer plastic component - Google Patents

Abstract

The invention relates to a method for producing a multilayer plastic component, in particular an interior trim part for vehicles, the interior trim part comprising a carrier part (10), a decorative layer (12) and an adhesive layer (11) located between the carrier part (10) and the decorative layer (12). with the steps:
- arranging a carrier part (10) in a predetermined position;
- applying an adhesive layer (11) to at least a portion of a surface (10o) of the carrier part (10) to be laminated,
- Arranging the decorative layer (12) on the surface (10o) of the carrier part (10) to be laminated, the decorative layer (12) being in contact with the adhesive layer (11) at least in sections, characterized in that
- A temperature-controlled fluid is passed through at least a section of the carrier part (10) during the activation of at least a section of the adhesive layer (11).

Description

The present invention relates to a method for producing a multilayer plastic component according to the preamble of patent claim 1.

In today's vehicle construction, surfaces in the vehicle interior or in the passenger compartment of motor vehicles are provided with decors. Decorative parts such as those used in particular in the interior of motor vehicles have to meet high demands on their visual and haptic quality. For this purpose, a decorative layer, which shapes the visual appearance, is applied to a carrier, which gives the decorative part the required dimensional stability and is used to fasten the decorative part. Such decors are, for example, in the form of foils with a wood look or carbon look. In addition, it is also known to use skins made of leather or synthetic leather as decorative elements and to mount them on support structures with the aid of press laminating processes in order to produce a leather look. It is customary to apply one or more intermediate layers which influence the haptic properties and to cover this composite with a decorative material which forms the surface which is visible to the vehicle occupants.

Two-component adhesives are used to bond the layers. These consist of two components that harden when mixed in a chemical reaction. In the case of so-called one-component adhesives, a ready-to-use adhesive is applied to the surface to be coated. The adhesive then hardens through a change in environmental conditions, such as changes in temperature.

A particular challenge when laminating high-quality surfaces is to generate the required activation temperature in the adhesive joint without putting excessive strain on the temperature-sensitive decorative material. The thermal energy, i.e. The heat for activating the adhesive is introduced into the adhesive joint via a warm press stamp of the press laminating tool via contact heat through the decor. As a result, the adhesive hardens during the lamination process and bonds the decor to the carrier. Alternatively, the activation energy can be introduced through the decor using an IR radiator. In order to achieve the required activation temperature of 60 ° to 65 ° C in a short time, the decor in both versions has to be subjected to significantly higher temperatures. This is usually made more difficult by an additional, highly insulating intermediate haptic layer. A thermal overload of the decorative layer can lead to visible damage, so that the entire plastic component must be discarded as scrap.

Methods for producing such components are, for example, from the DE 10 2007 060 240 B4 or the DE 198 15 115 C2 known.

Based on this prior art, it is the object of the present invention to specify a production method for multilayer plastic components which is distinguished by particularly high process reliability and which reduces the number of reject parts.

This object is achieved with a method having the features of patent claim 1. Advantageous embodiments and further developments are specified in the dependent claims.

To achieve this object, the invention proposes a method for producing a multilayer plastic component, in particular an interior trim part for vehicles, the interior trim part having a carrier part, a decorative layer and an adhesive layer located between the carrier part and the decorative layer. The method can include at least the steps of: arranging a carrier part in a predetermined position; Applying an adhesive layer at least to a partial section of a surface of the carrier part to be laminated, arranging the decorative layer on the surface of the carrier part to be laminated, the decorative layer being in contact with the adhesive layer at least in sections. During the activation of at least a section of the adhesive layer, a tempered fluid can be passed through at least a section of the carrier part. Alternatively or additionally, a temperature-controlled fluid can be passed through at least a section of the carrier part during the integral connection of the decorative layer to the carrier part. This has the advantage that the thermal energy required to activate the adhesive layer, i.e. the heat is not introduced through the decorative layer, but via the carrier part. The risk of the decorative layer being damaged by the thermal load is thus reduced. In addition, the direct contact of the adhesive layer with the carrier part makes heating much more effective, so that the adhesive can be heated to the required activation temperature in a short time. The predetermined position of the carrier part described above is a position in which the decorative layer and / or the adhesive layer can be applied particularly easily to the carrier part. In such a position the carrier part can e.g. be arranged in a tool.

Heated gases, especially hot air or superheated steam, are particularly suitable as fluids. As an alternative, however, temperable liquids such as water or oils can also be used as the fluid.

Furthermore, the temperature-controlled fluid can flow through only a predetermined section of the carrier part. This has the advantage that the carrier part is only flowed through in certain areas. As a result, for example, only the region of the decorative layer in which a decorative seam is provided can be fixed with the carrier part via the decorative layer. In a previous process step, the decorative seam is first aligned and fixed with a seam sword until the adhesive layer has hardened locally. After the adhesive layer has hardened locally, the seam sword is removed. The decorative layer can then be pressed on with a membrane and the remaining adhesive of the adhesive layer can be activated by exposure to temperature and / or pressure or by waiting for a certain period of time. This variant of the method offers the advantage that the fixed decorative seam means that the seam sword, which could damage the membrane due to its possibly sharp edges, can be removed immediately after the local hardening of the adhesive layer without the decorative layer slipping. This also reduces the risk of marks or marks from the seam sword on the decorative layer.

A carrier part is preferably used which has an inner region which is designed to be permeable to the fluid and which is at least partially surrounded by an outer wall which is not permeable to the fluid.

In addition, the wall of the carrier part can have at least one inlet through which the fluid is introduced into the inner region of the carrier part during the cohesive connection of the decorative layer to the carrier part, and have at least one outlet through which the fluid from the during the cohesive connection flows out of the inner region of the carrier part.

Additionally or alternatively, the carrier part can be formed from a foamable plastic material, the inner region having an open-pore foam structure and being integrally connected to the outer wall. Such a carrier part can preferably be produced in an injection molding integral process (SGI). The SGI method is known from the prior art. To produce so-called SGI components, a foamable plastic mass is introduced into this cavity between two mold halves that form a cavity. The plastic mass essentially fills the cavity completely and solidifies from the outer regions of the plastic mass to the inner region of the plastic mass. As soon as the plastic mass has reached a certain degree of solidification, it loses its foamability. This effect is used in such a way that a predetermined time is first waited until the edge regions have solidified and the outer wall of the carrier part has thus formed. The tool is then moved apart by the so-called SGI stroke, so that the cavity increases in volume. The outer walls are also moved apart, so that the inner area of the plastic compound lying between them increases. In the inner area of the carrier part between the outer walls, the plastic mass that has not yet solidified can foam up. The use of a SGI component as a carrier part in the production of a multilayer plastic component offers the advantage that the inner, foamed area has pores or alveoli or cells through which the fluid can diffuse. Such SGI carrier parts can be designed as a foamed thermoplastic carrier, the foam structure of which can be flowed through with a heating medium. In the patent application DE 102017206304 such a carrier is described. This consists of a dense outer surface or outer wall and a cellular core. At least part of the cellular core is designed as a heat exchange area.

The decorative layer can be a plastic skin, an artificial or real leather layer. Furthermore, the decorative layer can also be designed as a textile product or textile structure, in particular as a woven fabric, knitted fabric and / or knitted fabric. In addition, the decorative layer can also be formed in multiple layers, with a decorative surface layer, which forms a visible surface in the finished component, and a haptic intermediate layer, which is provided on a side of the decorative surface layer facing the adhesive layer. Such an intermediate layer can be designed in particular as a spacer fabric or foam backing.

By passing the fluid through the carrier part, the adhesive layer can be subjected to thermal stress at least in sections.

The adhesive layer can preferably be activated by thermal exposure.

For the purposes of this invention, interior trim parts are, in particular, dashboard supports or dashboard supports, cladding for the A-pillar, B-pillar, C-pillar, cladding for the center console, glove box cover and the like.

The manufacturing method according to the invention thus offers the advantage of being faster Activation of the adhesive layer, which reduces the cycle time of the manufacturing process. In addition, the method also has the advantage of less stress on the temperature-sensitive decorative layer.

The invention will be explained in more detail below with the aid of the description of the figures.

• 1 ein Trägerteil,
• 2 eine Fügevorrichtung mit einem Trägerteil gemäß einer ersten Ausführungsform des Verfahrens,
• 3 eine Fügevorrichtung mit einem Trägerteil gemäß einer zweiten Ausführungsform des Verfahrens, und
• 4 eine weitere alternative Fügevorrichtung gemäß einer dritten Ausführungsform des Verfahrens.

In a schematic representation:

• 1 a carrier part,
• 2 a joining device with a carrier part according to a first embodiment of the method,
• 3 a joining device with a carrier part according to a second embodiment of the method, and
• 4 a further alternative joining device according to a third embodiment of the method.

1 shows an example of an instrument panel support 10 that as a support structure 10 should serve to explain the process. As an alternative to the illustrated I-board support, it can be used as a support structure 10 all the interior trim parts, such as glove boxes, center armrests, panels, armrests in the door panels, door panels, headliner, etc. also serve this dashboard support 10 has a surface 10o which is to be laminated with the help of a decorative layer. This surface can, as in 1 shown, concern only a section, such as the upper surface of the hood of the so-called instrument cluster. The surface to be concealed 10o can, however, also be the part of the surface of the support structure 10 be visible from a vehicle occupant in the interior of the vehicle. Alternatively, the surface can 10o also the entire surface of the support structure 10 include areas of the support structure that are not visible from a vehicle occupant 10 would be concealed.

With reference to 2 , The manufacturing process for manufacturing a multilayer plastic component is to be explained. For this, the carrier part 10 in a lower half of the tool 22 of in 2 shown tool inserted. In the upper half of the tool 21 becomes a decorative layer 12 introduced, which can be perceived by a vehicle occupant in the finished component. Of course, also in the area of the support part 10 that are not visible later when the finished component is installed, a decorative layer 12 be provided. However, it is more efficient to decorate or conceal only the visible areas.

On a surface of the decorative layer 12 that the carrier part 10 is facing, an adhesive layer 11 applied. Alternatively, the adhesive layer 11 on a surface of the carrier part 10 that of the decorative layer 12 is facing to be applied. The adhesive layer connects in the finished plastic component 11 the decorative layer 12 with the support part 10 , After applying the decorative layer 12 and the carrier part 10 the tool with the tool halves 21 and 22 transferred to a closed position so that the decorative layer 12 and the carrier part 10 with the adhesive layer in between 11 come to the plant.

Thermal energy is now applied to the adhesive layer to activate the adhesive 11 directed. For this purpose, a fluid is passed through an inlet opening 23 the lower half of the tool 22 into an inner area 10k of the carrier part 10 directed. The inner area 10k of the carrier part 10 is cellular or porous, the individual cells or pores being fluidly connected to one another. The fluid introduced can thus pass through the inner area 10k flow along the flow direction F. The walls 10w of the carrier part 10 are not permeable to the fluid, so these walls 10w limit the flow of the fluid and thus conduct it. In the wall 10w of the carrier part 10 is at least one inlet opening 10e intended. Through this inlet opening 10e can the fluid in the inner area 10k of the carrier part 10 penetration.

To drain the fluid from the inner area 10k of the carrier part 10 , can have at least one outlet 10a in the wall 10w be provided. The fluid then flows through the outlet 10a from the carrier part 10 into an outlet duct 24 in the lower half of the tool 22 is trained. be connected. While the fluid along the flow direction F through the support member 10 flows through, there is a heat transfer by convection from the fluid into the carrier part 10 , The thermal energy convects through the wall 10w directly into the adhesive layer 11 , This will make the adhesive layer 11 activated and a material connection between the decorative layer 12 and the carrier part 10 generated.

In 3 a second alternative embodiment of the method is shown. The same reference numerals as in 2 concern the same components. Deviating from the representation in 2 , has the support part 10 in 3 several chambers on by webs 10s are separated from each other in a fluid-tight manner. Only the figurative middle chamber has an inlet 10e and an outlet 10a in the wall 10w on. As a result, flows into the carrier part 10 introduced fluid only through this middle chamber along the flow direction, which is represented by the arrow F. Thus there is a convection of heat from the fluid into the adhesive layer 11 only held in this area. In other words, it just becomes the area of the adhesive layer 11 activated, which is located above the middle chamber. This allows local attachment or material connection between the decorative layer 12 and the carrier part 10 will be realized.

4 shows an alternative manufacturing method, the same reference numerals the same components as in the 2 and 3 affect. That in the 4 The manufacturing process shown makes up the dimensional stability or the inherent rigidity of the carrier part 10 to use, so that tool halves can be dispensed with. As with reference to 3 described, the adhesive layer 11 activated locally only in a certain area. This area corresponds to the section of the adhesive layer 11 , which is above the middle chamber of the support part 10 located. In this area the decorative layer shows 12 a - not shown figuratively - seam or decorative seam, which must be positioned precisely in order to meet the desired quality requirements. To keep the seam in the desired position, the decorative layer 12 locally with a seam sword 31 against the carrier part 10 pressed. Alternatively, the decorative seam and thus the decorative layer 12 only be held in this position to prevent an unwanted displacement relative to the carrier part 10 to prevent. Pressing on the decorative layer 12 is not mandatory. The section of the adhesive layer underneath 11 is with the help of the tempered fluid that flows through the central chamber of the support part 10 is activated as with reference to 2 already explained. By activating the section of the adhesive layer 11 in the area below the seam sword and above the middle chamber, the decorative layer 12 in this area to the support part 10 pinned so that an unwanted displacement of the decorative layer 12 relative to the carrier part 10 is prevented. The saber 31 can thus from the decorative layer 12 be removed. The remaining areas of the adhesive layer 12 can then be activated and harden into a material connection.

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 102007060240 B4 [0005]
• DE 19815115 C2 [0005]
• DE 102017206304 [0013]

Claims (8)

Method for producing a multilayer plastic component, in particular an interior trim part for vehicles, the interior trim part having a carrier part (10), a decorative layer (12) and an adhesive layer (11) located between the carrier part (10) and the decorative layer (12), with the Steps: - arranging a carrier part (10) in a predetermined position; - applying an adhesive layer (11) to at least a portion of a surface (10o) of the carrier part (10) to be laminated, - arranging the decorative layer (12) on the surface (10o) to be laminated of the carrier part (10), the decorative layer (12 ) is in contact with the adhesive layer (11) at least in sections, characterized in that - during the activation of at least one section of the adhesive layer (11), a tempered fluid is passed through at least a section of the carrier part (10). Procedure according to Claim 1 , characterized in that only a predetermined section of the carrier part (10) is flowed through by the tempered fluid. Procedure according to one of the Claims 1 or 2 , characterized in that a carrier part (10) is used which has an inner region (10k) which is designed to be permeable to the fluid and which is at least partially surrounded by an outer wall (10w) which is not permeable to the fluid , Procedure according to Claim 3 , characterized in that the wall (10w) of the carrier part (10) has at least one inlet (10e) through which the fluid in the inner region (10k) during the material connection of the decorative layer (12) to the carrier part (10) of the carrier part (10), and - has at least one outlet (10a) through which the fluid flows out of the inner region (10k) of the carrier part (10) during the integral connection. Procedure according to one of the Claims 1 to 4 , characterized in that the carrier part (10) is formed from a foamable plastic material, the inner region (10k) having an open-pore foam structure and being integrally connected to the outer wall (10w). Procedure according to one of the Claims 1 to 5 , characterized in that the decorative layer (12) is a plastic skin, an artificial or real leather layer. Procedure according to one of the Claims 1 to 6 , characterized in that by passing the fluid through the carrier part (10), the adhesive layer (11) is at least partially thermally acted upon. Procedure according to Claim 7 , characterized in that the adhesive layer (11) is activated by thermal exposure.

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