DE20312501U1 - Molding apparatus for forming multi-layered interior trim for motor vehicles, has pre-molding and final molding cavities selectively opened based on position of primary auxiliary mold - Google Patents

Abstract

A primary pre-molding cavity is selectively opened and closed when a primary auxiliary mold (4) of intermediate mold assembly (45), is located in working position during primary molding step. The uppermost mold (3) is selectively opened/closed relative to the lowermost mold (6) so as to selectively open/close a final molding cavity, when the primary auxiliary mold is in idle position during secondary molding step. An independent claim is also included for usage method of molding apparatus.

Description

The invention relates to a device with at least two molds for producing molded parts consisting of at least two layers, which are in particular interior trim parts for motor vehicles. Devices for such applications are for example from the US 6,136,415 known and have molds, each with an upper mold half and a lower mold half for the layers to be produced. Other machine components such as B. a machine frame, drives, bearing and guide parts and the necessary control for opening and closing the molds are basically provided. Materials that are three-dimensionally deformable under the influence of temperature and pressure and then thermoplastic can be used as the material for the individual layers that are initially to be produced. Such a material is for example in the EP 0 671 259 described. It is therefore known to produce interior trim parts which comprise a support layer made of polyolefin fibers and natural fibers on the one hand and a decorative or cover layer which are shaped, laminated and bonded in one work cycle, this being done without the addition of chemical binders.

Although the known manufacturing process and the devices therefor are substantially satisfactory work, it is desirable production speed and production security too increase, so that more parts can be produced per unit of time and the workflow if possible is simple.

To solve this task, the Invention before that all Molding tools with their mold halves are aligned with each other that the mold halves relative to each other in vertical direction to open and closing of the molds are movable, that the lower half of the upper mold Mold and the upper mold half of the lower mold across the direction of movement when opening and closing the Forming tools are movable and that the upper one directly mold of the upper mold and the lower mold half of the lower mold to open and closing are movable in the vertical direction relative to each other.

Leave with the help of said features achieve very short working cycles. To do this, the two Layers of a two-layer part first individually using the two mold halves two molds are made and then the molds open, one layer in the upper mold half of the upper mold and the other layer in the lower mold half of the lower mold remain. The two mold halves with the two prefabricated layers are then merged immediately, whereby this can be done without any loss of time since the two are different Forming tools mold halves only have to be moved towards each other in the vertical direction. The short commutes and the associated working hours simplify the Production method and lead hence less problems in practice.

In addition, the short Work cycles a procedure, according to the in one workpiece or heat energy stored in one layer can be used the thermoplastic melting process with the other layer without zusätrlich Heat supply too shape.

In development of the invention provided that the one or other or both upper mold halves additional facilities for precise contour machining of the edges of the layers during their manufacture exhibit. These are preferably stamping elements.

In this context, it is also appropriate if a layer serving as a decorative layer is machined on the edge in this way will that she the edges a layer serving as a base layer can encompass something like This is the case, for example, when folding a larger area around the edge Part around the edges of a smaller area Part is done.

Further features emerge from subclaims and the description in connection with the drawing.

The invention is illustrated below of embodiments, which are shown in the drawing, described in more detail. Show:

1 : partly in section, a schematic representation of essential parts of the device with the mold halves before closing the two molds;

2 : schematically a floor plan of essential parts of the in 1 shown device;

3 : partly in section a schematic representation of the upper mold half of the upper mold and the lower mold half of the lower mold in its closed position and on a larger scale;

4 : a schematic diagram with elements used to seal the molds;

5 : in section a schematic representation of a clamping strip used for sealing, in particular for air-permeable materials in the closed position;

6 : a broken side view of a knife-shaped sealing element for the terminal block according to 5 ;

7 : a schematic view of the terminal block and its sealing element in the separated state;

8th a section through a two-layer, three-dimensionally shaped molded part such as an interior trim part for a motor vehicle;

9 : schematically a view as in 1 from a modified embodiment;

10 : schematically a view as in 3 from the embodiment according to 9 and

11 : schematically a view as in 9 from a third embodiment.

A device 100 for producing an at least two-layer molded part 101 ( 8th ) includes according to the in the 1 - 3 schematically and with respect to its components of interest shown embodiment two molds 1 and 2 , Both molding tools 1 and 2 in turn consist of two mold halves, the molding tool 1 an upper mold half 3 and a lower mold half 4 and the lower mold 2 an upper mold half 5 and a lower mold half 6 exhibit.

Both molding tools 1 and 2 are with their mold halves 3 . 4 such as 5 and 6 in one in 2 indicated machine frame 110 arranged in alignment with each other. Furthermore, drives and bearing and guide elements for the mold halves of the molds are not shown in the figures 1 and 2 and further provided a controller for the drives and so on so that the molding tools 1 and 2 or their mold halves 3 - 6 can be moved towards and away from each other or can be opened and closed according to their function (see double arrows 108 and 109 in the 1 and 3 ).

The lower half of the mold 4 of the upper mold 1 and the upper half of the mold 5 of the lower mold 2 are rigidly connected to each other and movable together according to the embodiment. There are two mold halves 4 and 5 on a plate-shaped support element 7 arranged. A frame 8th is provided and takes the support member 7 with the two molded parts 4 and 5 for cross transport and is available for vertical movements of the two mold halves 4 and 5 free. The support element 7 has roles 9 or sliding blocks, with the help of which the two molded parts 4 and 5 along rails 10 from the in 1 shown working position with the other two mold halves 3 and 6 in a position according to 2 are movable such that the upper mold half 3 of the upper mold 1 and the lower mold half 6 of the lower mold 2 can work together ( 3 ). The length of the rails 10 and the travel path for the two rigidly connected mold halves 4 and 5 is chosen so that the two mold halves 4 and 5 at least completely the working area of the two mold halves movable relative to each other in the vertical direction 3 and 6 can write. The device 100 therefore points for the two mold halves 4 and 5 a working position corresponding to the solid lines and a parking position corresponding to the dashed lines in 2 on, furthermore the directions of movement of the two mold halves using the double arrow P in 2 are specified.

With the help of the device 100 molded part to be produced 101 consists of at least two layers 102 and 103 ( 8th ) in the device 100 with the help of the two molding tools 1 and 2 are initially manufactured separately.

A flat base material is used for this 12 respectively 16 which is three-dimensionally deformable under the influence of heat and pressure. The flat starting material is used in the manufacture of an interior trim part for a motor vehicle 12 to form a base layer or according to 8th to form the situation 103 of the molded part 101 , The other, also flat starting material 16 serves to produce a cover or decorative layer and according 8th to make the situation 102 , With the base layer or layer 103 becomes the necessary strength and rigidity of the three-dimensionally shaped and dimensionally stable molded part as an end product 101 achieved.

How out 1 emerges, it becomes the production of the base layer or the layer 103 serving starting material 12 with the help of a tensioning and carrying device 11 between the mold halves 5 and 6 of the opened, lower mold 2 arranged. In the same way, the flat starting material serving as a decorative or top layer becomes 16 with the help of a tensioning and carrying device 15 between the mold halves 3 and 4 of the upper mold 1 arranged ( 1 ).

To complete the mold halves 3 - 6 are also elements 13 respectively 22 for the precise contouring of the edges of the molds 1 and 2 initially provided separately manufactured parts. Furthermore, the mold halves 3 - 6 channels 17 for targeted heating and cooling before, after or during the molding process. Further holes 18 are in the upper half of the mold 3 of the upper mold 1 provided and end at the inner contour 19 the mold half 3 , The holes 18 are either connected to a vacuum or vacuum generator, not shown, or they serve to hold holding needles 20 for that in the mold 1 part to be manufactured.

The mold half is expedient 3 in the device 100 rigidly arranged while the other three mold halves 4 . 5 and 6 towards the mold half 3 , that is in the vertical direction upwards to close the two molds 1 and 2 are movable. Thereby the between the mold halves 3 - 6 existing layers deformed in the desired manner. The closed position of the two molds 1 and 2 is not shown in the figures. It is sufficient if only the lower mold 6 has a linear actuator (in 1 . 3 not shown).

After the layers 102 and 103 are produced in parallel in the two molds, the molds are 1 and 2 opened and the rigidly connected mold halves 4 and 5 move from the working position to the parking position accordingly 2 , The upper layer, which forms a decorative or cover layer 102 remains in the upper half of the mold when the molds are opened 3 of the upper mold 1 , This is achieved either with the help of point-acting vacuum on the inner contour 19 the upper half of the mold 3 or with the help of holding needles effective there 20 , The bottom layer 103 or the original planar starting material forming the base layer 12 is now three-dimensionally shaped according to the in 1 part shown 14 , This molded and sufficiently heated part 14 remains on the lower half of the mold 6 of the lower mold 2 , The mold half 6 is used to manufacture the complete molded part 101 in the vertical direction upwards with the upper mold half 3 of the upper mold 1 merged or pressed against it ( 3 ). After the two in the mold halves 3 and 6 parts have been thermoplastic bonded together and have cooled sufficiently, that is from the two mold halves 3 and 6 existing form opened. Then the finished molded part 101 be removed.

The part serving as a base layer is expediently 14 ( 1 ) already heated in the first step in such a way that the amount of heat stored in it is sufficient to create a thermoplastic connection with the upper mold that forms the decorative or cover layer 3 of the upper mold 1 located location 102 for the production of a one-piece, multi-layer molded part 101 to create.

The multi-layer molded part 101 forming locations 102 and 103 indicate according to 8th different borders 104 and 105 respectively 106 and 107 on. The design of the edges 106 and 107 the situation 102 is chosen such that it is in a further step around the free ends of the edges 104 and 105 the situation 103 can be placed. This is done by bending the free edges 106 and 107 around the edges 104 and 105 , The two layers receive the necessary shape and form 102 and 103 already in the device 100 using the elements used to edit these margins 13 respectively 22 each in the upper mold halves 3 and 5 of the molds 1 and 2 , The Elements 13 and 22 are, for example, the punching knives of a punching device or other separating elements which act in a suitable manner.

Both molding tools 1 and 2 also have elements for sealing the interacting mold halves 3 and 4 respectively 5 and 6 respectively 3 and 6 on. These sealing elements are particularly important when the starting material 12 respectively 16 is permeable to air.

As shown in 4 has one half of the mold, such as the half of the mold 3 a sealing gap as a sealing element 23 ' on while over the surface of the other mold half 4 a sealing strip as a sealing element 23 protrudes. The sealing strip 23 can in the mold half 4 for example, be supported resiliently. A resilient element such as a rubber body is expediently used for this purpose 24 or similar.

In order to achieve a good seal, it is also expedient if the sealing gap 23 ' in the closed position the free end or the free edge 25 the sealing strip 23 form-fitting.

Another sealing device 26 for molds of the type of interest here comprises according to the 5 to 7 also a sealing strip 30 in one or the other mold half in the area of their mutually facing surfaces 28 . 29 is arranged. According to the embodiment, it is in the mold half 31 not resilient, but rigidly arranged.

To the sealing strip 30 in one half of the mold 31 belongs to a terminal block 32 in the other half of the mold 33 ,

The sealing device is used 26 especially when the raw material to be processed 12 respectively 16 is permeable to air.

When closing the sealing device 26 penetrates the sealing strip 30 with its free edge or end 34 in the cross-sectional terminal strip, for example 32 on ( 5 ).

The terminal block 32 is slotted along its length and consists of a resilient material. When entering the terminal block 32 moves the sealing strip 30 with its free end 34 at the same time the starting material 12 . 16 into the tubular or tubular terminal block 32 through an entry and exit slot 35 , Due to the elastic properties of the terminal block 32 press their edges bounding the entry and exit slots towards each other according to the arrows 36 and 37 ( 7 ) and thereby ensure a complete seal, even if the starting material 12 . 16 is permeable to air. This also applies in particular if according to 5 not just raw material 12 . 13 wrinkled inside the terminal block 32 but also the free margin 34 the sealing strip 30 ,

The sealing strip 30 is expediently knife-shaped and can consist of a metallic material.

When loading with the starting material 12 and 16 are the mold halves 3 . 4 . 5 respectively 6 in four different levels arranged vertically one above the other. The starting measure TERIAL 12 respectively 16 can already be outside the device 100 are heated or heated in the required manner so that the material together with the bores, lines or channels located in the mold halves 17 which each reach the required working temperature between 160 ° C and 220 ° C. For this purpose, as is generally known, hot water or hot oil can flow through the lines.

As a material for a base layer, or mat-shaped Material made from polypropylene fibers and natural fibers or from polypropylene fibers and glass fibers or polypropylene fibers and cellulose fibers. The decorative or cover layers also consist of thermoplastic materials in the form of foils, woven or non-woven textiles and can also contain synthetic foams.

The in the 9 and 10 only partially and schematically shown device 200 basically has the same machine parts and components and so on as the device 100 according to the 1 to 3 , The device 200 therefore also includes the manufacture of a two-layer part 101 ( 8th ) two molds 201 and 202 with two mold halves each 203 . 204 respectively 205 and 206 , All others, in connection with the device 100 described components are present and in the 9 and 10 numbered with the same reference numbers.

A difference between the device 100 and the device 200 is that the upper mold half 203 of the upper mold 201 its own linear actuator 207 and the lower mold half 206 of the lower mold 202 its own linear actuator 208 exhibit. The mold half 203 is therefore with the help of their linear actuator 207 with the necessary pressure against the associated lower mold half 204 movable and the lower half of the mold 206 of the lower mold 202 is with the necessary pressure using the lifting device 208 against the upper half of the mold 205 of the lower mold 206 movable when the two layers first 102 and 103 of the molded part 101 ( 8th ) getting produced. For thermoplastic welding of the two separately produced layers 102 and 103 then again the preferably rigidly connected mold halves 204 and 205 from the side of the work area between the two mold halves 203 and 206 removed so these two mold halves 203 and 206 with the help of their linear actuators 207 and 208 can interact directly ( 10 ).

As in the first embodiment, the upper mold half 203 of the upper mold 201 in a first step with the lower mold half 204 and in a second step with the lower mold half 206 of the lower mold 202 cooperate with the lower mold half 206 in a first step with the upper mold half 204 of the lower mold 202 had worked together.

Each with its own linear actuators 207 and 208 for the two mold halves 203 and 206 bring some advantages over the first embodiment described. For example, it is not necessary that the two mold halves 204 and 205 out of the frame 8th with the rollers or sliding blocks 9 have to be lifted out. Despite a second lifting device, the technical effort is therefore lower than in the case of a single lifting device ( 1 ).

A device 300 according to the third, in 11 schematically illustrated embodiment also includes a complete upper mold 301 and an incomplete lower mold 302 , To the complete upper mold 301 include an upper mold half 303 and a lower mold half 304 as in the two exemplary embodiments described first.

The lower mold 302 can have an upper mold half, but this is not absolutely necessary ( 11 ). According to the exemplary embodiment, the lower mold is 302 only with a lower mold half 306 as in the case of the other two embodiments.

There is also one on the upper half of the mold 303 of the upper mold 301 attacking linear actuator 307 and one on the mold half 306 of the lower mold 302 attacking linear actuator 308 intended.

The two mold halves 303 and 304 of the upper mold 301 in turn serve to produce a flat, three-dimensionally shaped layer 102 for the two-layer molded part 101 ( 8th ), which in the tensioning and carrying device 15 held starting material 16 serves. That for the second layer 103 of the two-layer molded part 101 needed, second prefabricated part 14 is produced in another device, not shown in the figures, and processed or trimmed in the area of its edges. Then this pre-made part 14 on the lower half of the mold 306 of the lower mold 302 placed after the lower half of the mold 304 of the upper mold 301 from the working space between the two mold halves 303 and 306 may have been removed. Then the two of them act on the drives 307 and 308 belonging mold halves 303 and 306 together to form the two-layer molding 101 to be manufactured completely, as has already been described in connection with the other exemplary embodiments.

The prefabricated part 14 can on the lower half of the mold 306 with a handling device or by hand if this makes sense in individual cases. This is especially true if the prefabricated part 14 Because of different quantities or because of special material properties, it is advisable to use another device tion is prefabricated.

Various machine components and configurations shown in the other figures are missing in 11 only because of the better clarity and are also available to the extent necessary.

After all, the invention is not limited to the embodiments shown in the figures, rather are still changes and modifications possible, without the basic inventive idea departing.

Claims (17)

Device with at least two molding tools ( 1 . 2 ) for the production of at least two layers ( 102 . 103 ) existing molded parts ( 101 ), in particular for the production of interior trim parts for motor vehicles, the molding tools ( 1 . 2 ) one upper mold half each ( 3 . 5 ) and a lower mold half ( 4 . 6 ) for each layer ( 102 . 103 ) and where further components such as a machine frame, drives, bearing and guide elements as well as a control and the like for opening and closing the molds ( 1 . 2 ) are provided, and the layers ( 102 . 103 ) Have materials which are three-dimensionally deformable under the influence of temperature and pressure and then thermoplastic can be connected to one another, characterized in that the molding tools ( 1 . 2 ) with their mold halves ( 3 . 4 . 5 . 6 ) are aligned with each other so that the mold halves ( 3 . 4 . 5 . 6 ) relative to each other in the vertical direction for opening and closing the molds ( 1 . 2 ) are movable so that the lower mold half ( 4 ) of the upper mold ( 1 ) and the upper half of the mold ( 5 ) of the lower mold ( 2 ) transverse to the direction of movement when opening and closing the molds ( 1 . 2 ) are movable and that the upper mold half ( 3 ) of the upper mold ( 1 ) and the lower half of the mold ( 6 ) of the lower mold ( 2 ) can be moved relative to one another in the vertical direction for opening and closing. Device according to claim 1, characterized in that the lower mold ( 2 ) to produce a layer serving as a base layer ( 103 ) and that the upper mold ( 1 ) to produce a layer serving as a top layer / decorative layer ( 102 ) are provided. Device according to claim 1, characterized in that the lower mold half ( 3 ) of the upper mold ( 1 ) and the upper half of the mold ( 5 ) of the lower mold ( 2 ) are rigidly connected and can be moved together. Device according to claim 1, characterized in that the lower mold half ( 3 ) of the upper mold ( 1 ) and the upper half of the mold ( 5 ) of the lower mold ( 2 ) on a plate-shaped support element ( 7 ) are arranged. Device according to claim 1, characterized in that additional elements ( 13 ) for precise contour machining of the edges ( 104 . 105 ) when making the layer ( 103 } on the upper half of the mold ( 5 ) of the lower mold ( 2 ) is arranged. Device according to claim 1, characterized in that additional elements ( 22 ) for precise contour machining of the edges ( 106 . 107 ) in the manufacture of the layer ( 102 } on the upper half of the mold ( 3 ) of the upper mold ( 1 ) are arranged. Device according to claim 1, characterized in that the upper mold half ( 3 ) of the upper mold ( 1 ) is arranged immovably in the machine frame and that the other mold halves ( 4 . 5 . 6 ) are movably arranged. Device according to claim 5, characterized in that the elements ( 13 ) for precise contour machining of the edges ( 104 . 105 ) of one location ( 103 ) Include stamping elements. Device according to claim 6, characterized in that the elements ( 22 ) for precise contour machining of the edges ( 106 . 107 ) the other location ( 102 ) Include stamping elements. Device according to claim 1, characterized in that bores / or channels ( 17 . 18 ) in the mold halves ( 3 . 4 . 5 . 6 ) to create a vacuum, to guide holding needles ( 20 ) and / or for the production of compressed air and / or for heating or cooling during the production of the layer ( 102 . 103 } and for the production of the complete molded part ( 101 ) are provided. Device according to claim 3, characterized in that a frame ( 8th ) with wheels ( 9 ) is provided for cross-processing and as a carrier for releasably receiving the mold halves ( 4 . 5 ) serves. Device according to claim 1, characterized in that the mold halves have sealing elements and that the one mold half ( 3 ) a sealing strip ( 23 ) and the other half of the mold ( 4 ) a sealing gap ( 23 ' ) for the sealing strip ( 23 ) having. Device according to claim 1, characterized in that a sealing device ( 26 ) with a sealing strip ( 30 ) on one half of the mold and one with an entry and exit slot ( 35 ) on pointing terminal block ( 32 ) are provided on the other mold half in such a way that the starting material to be processed ( 12 . 16 ) with the help of the sealing strip ( 30 ) in the terminal strip ( 32 ) is movable. Device according to claim 1, characterized in that one lifting drive ( 207 . 208 ) on the upper half of the mold ( 203 ) of the upper mold ( 201 ) and on the lower half of the mold ( 206 ) of the lower mold ( 202 ) attacks. Device with at least two molding tools ( 301 and 302 ) for the production of at least two layers ( 102 . 103 ) existing molded parts ( 101 ), in particular for producing interior trim parts for motor vehicles, the molding tools ( 301 and 302 ) an upper mold half ( 303 ) and two lower mold halves ( 304 and 306 ) and where further components such as a machine frame, lifting drives ( 307 and 308 ), Bearing and guide elements as well as controls and the like for opening and closing the molds ( 301 and 302 ) are provided, and the layers ( 102 . 103 ) Have materials that are three-dimensionally deformable under the influence of temperature and pressure and then thermoplastic can be connected to each other, the upper mold half ( 303 ) in a first step with a lower mold half ( 304 ) of the upper mold ( 301 ) interacts and the upper half of the mold ( 303 ) in a second step with the mold half ( 306 ) of the lower mold ( 302 ) interacts. Apparatus according to claim 15, characterized in that a lifting drive ( 307 . 308 ) on the upper half of the mold ( 303 ) of the upper mold ( 301 ) and on the mold half ( 306 ) of the lower mold ( 302 ) attack. Apparatus according to claim 15, characterized in that the upper mold half ( 303 ) with the linear actuator ( 307 ) and a first, lower and additionally movable mold half transverse to the lifting device ( 304 ) without linear actuator on the one hand and the upper mold half ( 303 ) with a second, lower mold half ( 306 ) with its own linear actuator ( 308 ) cooperates on the other.