SK500562011A3 - Structural part, process for producing such structural part and mold pip - Google Patents

Description

Technical field

BACKGROUND OF THE INVENTION The present invention relates to an automotive component having a multilayer base body having at least one cutting edge, to a method for manufacturing an automotive component according to which a multilayer base body is manufactured and to be cut at least partially in the edge area as well as forming a spray or foaming on the cutting edge of the automotive component with the upper mold part and the lower mold part, which in the closed state forms the mold cavity.

BACKGROUND OF THE INVENTION

Such automotive components are now produced in part by compressing the layer structure in the respective mold to form the shape. For this purpose, the pre-planar starting materials of the layer structure are laid over one another as usual and subsequently inserted into a press, whereby the individual layers are also joined in the press at the same time, for example by pressure and temperature.

The layer structure of such components comprises at least one core layer, which may, for example, consist of a foam material or a composite foam, or a so-called honeycomb board of cardboard or plastic, or may comprise a fibrous matrix, for example glass fiber matrix and / or a natural fiber matrix that is mixed with a plastic, such as polypropylene, and a cover on the side facing the viewer, which cover may be formed by a so-called topsheet, for example, carpet, circular knitted fabric, fleece, felt and so on. further.

It is a condition of manufacture that larger sized prefabricates are inserted into the press so that after molding, final shaping occurs. This can occur with the so-called splitting or cutting off of the edge with the shearing tool, for which the molded component is inserted into the shearing tool, or the compression mold already contains the tool. The advantage of this method is that the component can be manufactured in one step. However, it is disadvantageous that the cutting edges have an unclean appearance. Furthermore, the top layer can be frayed at the cutting edges. A further disadvantage is seen in the fact that the tools usually have a short tool life because the quality of the cut deteriorates with increasing use time.

Furthermore, it is known in the art to provide cutting edges by so-called knocking, thereby producing a clean, optically pleasant cutting edge. However, it is disadvantageous that a second, expensive working run with the respective tool is usually required, which entails relatively high tool costs. In addition, even in this method of forming the cutting edge, impure edge cuts can occur many times.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a vehicle component which at least partially removes the problems described above.

To solve this problem, it is proposed according to the invention that the cutting edge is sprayed or foamed with at least one plastic to form an edge element. The advantage here is that it is possible to form the cutting edge cleanly, irrespective of the nature of the surface of the cutting edge, whereby the sprayed plastic can be adapted to the shape of the cutting edge. Consequently, it is further possible to reduce the under-yield. In addition, by means of the connection between the plastics of the edge element and the base body of the component, a higher stability of this cutting edge is achieved, thus preventing later splitting of the visible layer of the base body due to the use of the component. In this way, the cutting edge of the component can also be better protected from

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33946 / H damage or damage during use. In this way, it is also possible, without any further manufacturing step, to make identifications such as the model or part number, the part designation or the material information. Also, the cutting edge may be at least partially provided with a facing layer (of imitation leather) or other design. For example, (rubber) buffers may be provided which serve mainly as protection against clattering. The advantage of the cutting edge foaming is that due to the low pressure, a better optical appearance is obtained, or that this adjustment is easier to accomplish in that the pressure fluctuations play no major role with respect to the resulting edge cutting edge. In addition, sealing of the mold cavity is easier to implement.

The object of the invention is also solved in the foregoing manner in which the cutting edge in the mold with the mold cavity is foamed with a plastic foam formed from a plastic raw material or is sprayed with at least one plastic to form the edge element, effects.

For this purpose, the object of the invention is solved by the aforementioned mold, in which the upper mold part in the closed position is located at a partial distance from the lower mold part to form an intermediate space for positioning the edge region of the cutting edge component. With this narrowing of the cross-section, the component is "pressed" in the peripheral area between the two mold parts, thus achieving a better sealing of the mold cavity in the direction of the component also without additional sealing measures, so that the foamed or sprayed on the base body cleaner and without fringing in the transition area between spraying and foaming respectively. However, it is of course also possible to form an additional sealing plane.

According to a variant embodiment, it is proposed that the edge element at least partially consists of a thermoplastic elastomer or a plastic (in the form of a foam). On the one hand, they are short on account of the thermoplastic properties

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33946 / H production cycle times. On the one hand, it is thus possible to provide a cutting edge or edge element for the base body of the component which has a pleasant grip feeling for the user. In addition, it is possible that the previous compression deformations in the edge region of the component are rebalanced during use as a result of relaxation, i.e. the compression deformations are reverted, thus retaining the original shape for a long period of time, even with correspondingly intensive use. By designing the edge element as a plastic foam, the pressure exerted on the base body during foaming can be better controlled by, for example, limiting the pressure of the foam acting on the cutting edge by using the raw material volume used for the plastic foam and / or directs the volumetric flow to the component.

The base body may have at least partially a cross-sectional taper in the cutting edge region. On the one hand, this allows at least approximately planar formation of the edge region or edge region of the component. On the one hand, this allows the edge element to be formed with a large layer thickness, whereby its stability or mechanical properties can be improved.

In a particular variant of the embodiment, it is proposed that the cutting edge is tapered to the tip, whereby it is possible in the region of the component edge to provide an edge element with a greater or lesser layer thickness. Furthermore, however, there is also the possibility, for example when the edge element is provided with an approximately constant layer thickness, that the component can be better adapted to the manufacturing tolerances of the bodywork or the sub-element or the surrounding car elements due to the decreasing wall thickness in the region of the edge element. whereby, for example, the luggage space can be better covered, i.e. the luggage compartment, in case the component is designed to cover the luggage compartment.

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Fastening elements can be provided on the cutting edge which are connected to the edge element, in particular they are at least partially anchored in the plastic of the edge element. This makes it possible to further simplify the method of manufacturing the edge element by taking into account the fastening elements for positioning the component on the car body during the production of the edge element and by having these fastening elements having a better grip on the structural element by preferential anchoring in the plastic. part.

The edge element may have at least approximately a cross-section of the profile with the arm, the arm having a width which corresponds at least to the maximum thickness of the base body in the injection area. On the one hand, the gripping of the edge element on the cutting edge is improved, and on the other hand, the load-bearing capacity of the cutting edge, i.e. the edge formation of the component, is clearly improved.

However, it is also possible that the width of this arm will be greater or less than the width of the base body.

The base body may have at least two adjacent cutting edges, wherein the transition between the cutting edges is made with a curvature to improve the removability of the component from the mold. Furthermore, this also reduces the wear of the component due to the reduced risk of damage to the corner area or the edge area.

At least one intermediate layer may be positioned between the edge element and the base body in the cutting edge region. The intermediate layer may, according to one embodiment, consist of a plastic (in the form of a foam), or according to another embodiment, it may consist of a metallic material. This can achieve a stiffening of the edge region of the component, on the one hand, by means of a plastic intermediate layer (in the form of a foam) by compressing it during injection of the plastic to form the edge element so that pressure is generated in the edge region of the component is kept with the aid of plastic

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33946 / H of the edge element, thereby obtaining a kind of "stiffening" of the edge area of the component. However, this reinforcement can also be achieved by means of a metal interlayer. In particular, the fastening of the aforementioned fastening elements and their attachment to the component can be improved.

The thickness of the edge element may correspond to at least 10% of the maximum thickness of the base body in the area of the injection or foaming, whereby an increase in the strength in the area of the edge of the component can also be achieved.

In this case, it is possible that the thickness of the edge element corresponds to 20%, in particular at least 30% of the maximum thickness of the base body in the area of injection or foaming.

For the same reason, it is possible that the thickness of the edge element increases over the width of the spray or foaming. In this way, however, it can also be achieved that inaccuracies in the region of the cutting edge of the base member of the component can be better compensated, so that the component can be better adapted to the desired shape and thus again reduce the unevenness.

The edge element may be softer or harder than the base body, thereby improving the grip feel of the component, but also due to the possibility of adapting the edge element to surface inaccuracies or tolerances, the fit of the component in the automobile can be improved. However, a soft or hard edge element also achieves "clatter protection", for example when closing a component or while driving.

An increase in mechanical stability is also achieved when the edge element is reinforced with a fiber.

In order to achieve a better connection of the edge element to the base body of the component, there is the possibility that the base body has at least one, in particular groove, recess in the region of the edge element in which it engages

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33946 / H edge element or interlayer. This can also provide for better positioning of the interlayer in the region of the cutting edge during spraying or foaming, whereby the production of the component can be simplified.

It is also advantageous if the foaming has a hardness of at least 10 Shore A, for example, the hardness is selected from the range of 20 Shore A lower limit, especially 40 Shore A upper limit, and 100 Shore A upper limit, especially 80 Shore A upper limit. “Without losing its properties to accommodate unevenness in the area of abutment of the component, possibly for a user-friendly grip feel.

According to a variant of the process, it is proposed that the foaming is effected by feeding the plastic foam raw material into the mold cavity at a pressure of not more than 300 bar, in particular not more than 250 bar. This also avoids the formation of impure foaming as a result of excessive pressure in the mold, while the pressure applied to the base body during foaming is reduced.

In view of improving wear, it is preferable that the plastic foam is made with a closed surface, so that the plastic foam has an externally formed shell.

In a particularly preferred embodiment of the process, the plastic foam is formed as a polyurethane foam of polyol and isocyanate, the polyol: isocyanate ratio being selected from a range of 100: 20 lower and 100: 50 upper limit. The properties obtained by foaming with respect to strength, wear resistance, flexibility and the like, in this mixture ratio of the components, while at the same time easy to process the components, are clearly superior to that of other mixture ratios.

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It is also possible that an integral foam is formed as a plastic foam, whereby the foaming in the edge layers can be made hard or harder in one production step in comparison with the core layers.

In view of the uniform distribution of the feedstock in the mold cavity, it is preferable for the feedstock to be fed into the mold cavity through an at least partially fan-shaped supply channel, thereby reducing the feed pressure of the feedstock with the advantages described above.

According to a preferred embodiment of the mold, it is proposed that a cross-sectional constriction be provided by the edge of the upper mold part or the lower mold part. This improves the sealing function. In addition, the sealing area may be limited to a small area of the base body.

For better venting of the mold cavity, it may be advantageous if the upper mold part and / or the lower mold part are formed at least in two parts.

Brief Description of the Drawings

For a better understanding of the invention, this is explained in more detail by the following figures.

The drawings in a schematic simplified illustration show:

Fig. 1 is an oblique view of a component;

Fig. 2 shows a detail of a component in the area of the cutting edge in a side sectional view;

Fig. 3 shows a detail of a variant embodiment of a component in the cutting edge region in a side sectional view;

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Fig. 4 shows a cutaway side view of a variant embodiment of a component with a foamed cutting edge;

Fig. 5 shows a side cut-out of the mold;

Fig. 6 shows a sectional side view;

Fig. 7 shows a side view in cross-section of an embodiment of the mold;

Fig. 8 shows a side view of the component.

DETAILED DESCRIPTION OF THE INVENTION

It is stated at the outset that in the various embodiments described, the same parts are provided with the same reference numerals, and the information contained throughout can be meaningfully transferred to the same parts with the same reference numerals. Also, the position data selected in the description, such as up, down, side, and so on, refer to the immediately described as well as the illustrated image and are meaningfully transferred to the new position when the position is changed.

Fig. 1 shows an oblique view of a component 11 in the form of a luggage compartment lid for an automobile, also sometimes referred to as a hat shelf.

It should be noted at this point that a component 1 can also be formed for other purposes in a car. For example, the component 1 may be formed as a (side) trim for a car door, a luggage compartment, for a luggage compartment floor, for a pillar, for example A, B, or C pillars of a car, such as a luggage compartment floor as such and the like.

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The component 1 comprises a base body 2 having at least one face layer 4 on the upper side which, in the closed state of the face element 11, faces upwardly into the passenger compartment, as well as a layer below and preferably attached thereto. 5 cores. Optionally, at least one additional layer may be positioned between the facing layer 4 and the core layer 5, at least one further layer may also be provided on the underside of the component 1, if desired, an additional facing layer may be provided. Such an embodiment of the luggage compartment lid, as is commonly used for station wagons, in which the luggage compartment, i.e. the luggage compartment is separated from the passenger compartment only by means of this component 1, is already known from the prior art.

The component may be formed in one piece, as shown in FIG.

There is also the possibility that it consists of a plurality of parts connected to one another mainly by means of a hinge, so that the component can be folded out or folded. folding. Such embodiments are also known in the art.

As shown in FIG. 1, at least one recess 6 may be located on the upper side 3 of the component 1.

The facing layer 6 may consist of a carpet, fleece, felt, or the like. The core layer 5 may consist of a foam, for example a polyurethane foam, which foam may be a so-called new foam or a bonded foam in which waste and residue foam particles are bonded to the new foam. It is also possible that the core layer 5 is at least partially formed by a honeycomb board, for example of cardboard or plastic, in particular of polypropylene, or the core layer 5 can be a plastic layer, in particular a fiber-reinforced thermoplastic layer.

Such components 1 are usually made by laying the individual layers on top of each other and inserting the laminate into a compression mold followed by compression, the laminate being normally larger than the end structural member.

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33946 / H part 1, so that it is necessary in the region of at least one of the side edges 7 to be trimmed to form a cutting edge 8. In the region of this cutting edge 8 layer structures can then be seen, so that the core layer 5 can be seen. To prevent this, the face layer 4a can be retracted in the region of this cutting edge 8 down over this cutting edge 8 and glued to the core layer 5. In this case, it is necessary for the facing layer 4 to be left with a large overlap, which however requires higher costs in terms of tools, personnel, production equipment and the like.

To avoid this, it is proposed according to the invention that the cutting edge 8 is sprayed with plastic to form the edge element 9.

The base body 2 has at least one cutting edge 8, of course, the base body 2 may have such a cutting edge 8 on several or all side edges and in this case it is possible that more or all of these cutting edges 8 s are sprayed. plastic to form the edge element 9.

In principle, any sprayable or foamable plastic mass (in particular any thermoplastic mass) can be used to produce the edge element 9. Preferably, however, thermoplastic elastomers are used, in particular thermoplastic polyurethanes (TPU) or thermoplastic copolyamides (TPA), wherein olefin-based thermoplastic elastomers or thermoplastic copolyesters are also useful. Mixtures of different plastics are also possible.

In FIG. 2 shows a variant embodiment of the edge element 9 of the component in the region of the cutting edge 8 connected mainly to the base body 2. The base body 2 in this embodiment variant consists of a first, top view layer 4, core layer 5 and another on the bottom side of the view layer 4. wherein both face layers 4 may also consist of different materials. In this embodiment variant, the cutting edge 8 has at least a partially reduced cross-section, so that the base body 2 is in the cross section

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33946 / H tapers towards the side edge 7. It is noted, however, that the presented cross-sectional form of the base body 2 is not limiting to the invention. In particular, this reduction in cross-section need not be provided with a curvature, but there is also the possibility that the base body 2 is chamfered in the region of the cutting edge 8. Further, the reduction in cross-section does not necessarily have to be effected in such a way that it is sharply tapered.

In a first embodiment variant - FIG. 2, a plurality of embodiments are shown - protruding the edge members over the surface of the base body 2, forming a tapered cross-section of the base body 2 in the region of the cutting edge 8.

However, there is also the possibility, as shown in dotted lines in FIG. 2, that the base body 2 has an offset 10 in the region of the edge element 9, which is preferably on both opposite surfaces, i.e. on the upper side 3 and also on its opposite underside, and only one of these surfaces can be provided with an offset 10, has an additional cross-sectional narrowing, so that there is a possibility that the plastic to form the edge element 9 ends at least approximately planar with both surfaces of the base body 2.

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Furthermore, there is a possibility, as in FIG. 2 shown intermittently that the edge element 9 in the cutting edge region does not necessarily copy the contour of the base body 2, but this edge element 9 is formed in the side edge region 7 by at least an approximately rectangular cross-section so that the layer thickness of the edge element 9 in the edge element region is increased 9 facing away from the base body 2, for example to obtain a sub-substrate.

Fig. 3 shows a variant embodiment of the component 1 in the region of the cutting edge 8, in which the base body 2, which again has two face layers 4 as well as a core layer 5, has at least a partial recess 11 on the front side. wherein the edge element 9, i.e. the plastic mass of the edge element 9, reaches up to the groove recess 11, thereby improving the connection between the edge element 9 and the base body 2

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33946 / H of the component 1. Preferably, in particular, the groove recess 11 has a dovetail cross-section or at least one undercut, thereby improving the anchoring or coupling effect between the edge element 4 and the base body 2. However, it is also possible other cross-sectional shapes, such as rectangular or square cross-section. Furthermore, this recess 11, although this is a preferred embodiment, does not necessarily have to be grooved, but several recesses or recesses 11 can be provided in separate locations on the base body 2 on the front side in the region of the cutting edge 8. at least two groove recesses 11.

In a variant of the embodiment, it is still possible that such mainly groove recesses 11 are located not only on the front side in the region of the edge element 9, but also on at least one of the surfaces, i.e. on the upper side 3 or on the underside of the base body 2 in at least one such recess 11 of the same kind and for the same purpose is provided at the cutting edge 8, i.e. in the region of the edge element 9.

As shown in FIG. 1, the component 1 can have at least one fastening element 12 by means of which the component 1 can be fixed, for example, to the rear door of a car. Such fasteners 12 are known in the art and consist, for example, of a clamping device 13, of an element 14 connected thereto, in particular in the form of a cord, and of an annular element 15 connectable to the rear doors, in particular hinged thereon. In a particularly preferred embodiment, the fastening element 12 is not located additionally on the component t on the front side, but rather before the edge element 9 is formed, so that the plastic for spraying the cutting edge 8 at least partially grips the fastening element. 12 and thus the fastening element 12 is partially anchored in this edge element 9. Thereafter, the fastening element 12, i.e. the clamping device 13 in particular, can also have corresponding devices, such as hook elements or the like, which are optionally profiled and / or provided with openings. .

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33946 / H so that an anchoring of the fastening element 12 in the edge element 9 is improved.

In a preferred embodiment of the edge element 9, this is, for example, shown in FIG. 2 and 3 in the form of a profile with a cross-section in the form of a profile and having at least one arm 16, said arm having a width 17 which corresponds at least to the maximum thickness 18 of the base body 5 in the injection area. Thereby a further improvement of the attachment, i.e. the connection of the edge element 9 to the base body 5, is achieved, whereby the mechanical load of this edge connection, i.e. the component 1, can be increased in the region of the edge.

As already mentioned, it is within the scope of the invention that the base body 2 has a plurality of cutting edges 8, wherein at least two such cutting edges 8 are adjacent to each other. In this case, it is advantageous that they are provided with a rounding in the transition between the two cutting edges 8, as shown, for example, in FIG. First

In order to further reinforce the edge of the component, there is the possibility that, although not shown, at least one intermediate layer is disposed in the region of the cutting edge 8, in particular on the face side, on the base body 2, which intermediate layer may consist of plastic foam, or made of metal or cardboard, and again there is also the possibility of combinations, so that, for example, both the plastic foam intermediate layer and the metallic material intermediate layer can be formed. In particular, it is possible that this intermediate layer protrudes at least partially into the groove recess 11, as shown, for example, in FIG. 3, whereby a better attachment or positioning of the intermediate layer during the injection molding to form the edge element 9 can be achieved.

Furthermore, there is the possibility that the edge element 9 is made with a surface of the fine fabric or fleece type, so that this edge element 9 can be better

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33946 / H to be integrated into the optical appearance of the component 1. In addition, this improves the palpation of the component 1 in the region of the edge element 9.

The thickness 19 of the edge element 9 is preferably, as shown in FIG. 2, formed in such a way that it corresponds to the maximum thickness 18 of the base body 2 in the injection area, whereby the thickness 19 of the edge element means the wall thickness, for example the arm 16, if this is formed in the form of a profile. Of course, there is a possibility that the edge element 9 has a layer thickness, i.e. a thickness 19, at least in part, especially on the front side, equal to the thickness 18 of the base body 2, or the thickness 19 of the edge element 9 can also be greater than the thickness. 18 of the base body 2.

In a particularly preferred embodiment of the edge element 9, it is made softer than the base body 2 of the component 1, so that the edge element 9 has a lower hardness than the base body 2, which is normally relatively rigid, so as to allow some minimal load on the objects deposited on the component 1. .

There is also the possibility that the edge element 9 is reinforced with fibers, for example glass fibers or plastic fibers or metal fibers, whereby this mixture of plastic and fibers is pre-mixed and can be injected at the same time, In the peripheral region of the base body 2 in the portions in which the edge element 9 is formed, a fibrous web or a nonwoven fabric is laid before being overmolded and these are injected or foamed to produce the edge element 9 and thereby embedded therein.

Although the component 1 according to the invention can be manufactured in one device, there is a possibility within the scope of the invention, especially in particular embodiments, such as in FIG. 3 that a groove recess 11 or more recesses 11 are formed in the base body 2 or more recesses 11 in a special device before the injection molding or foaming and, accordingly, the injection molding or foaming 20

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33946 / H will be carried out again in its own device, in which case it is also possible to combine devices which allow both the formation of the cutting edge 8 and the production of the recess 11a a subsequent injection or foaming of the cutting edge 8, such devices being understandably expensive.

The device itself may, in the simplest case, consist of a lower tool and an upper tool, both tools being relatively adjustable relative to one another, or one of the two tools being adjustable relative to the other tool, so that a squeezing process can be carried out. In order to allow the edge element 9 to be formed, there is the possibility that the cutting tools for forming the cutting edge 4 or cutting edges 8 are located in the upper tool or in the lower tool at a distance from the tool edge, so that usually the cavity of the takeover mold remains after cutting. The nozzles can be placed in this lateral cavity of the mold by means of which the plastic can be injected into the cavity when the tool is closed. The separated overhang of the base body 2 is separated from the tool, for example by its short-term opening, before the cutting edge 8 is inserted. However, it is also possible that the component 1 is already trimmed prior to the compression process, so that the cutting tool does not necessarily have to be placed in the compression device.

It is pointed out that in principle it is also possible that the joining of the layers for manufacturing the base body 2 can be inserted into the pressing device without interference, so that it fits to what appropriate positioning tools can be used, for example with an appropriate optical pickup device Thus, in these base bodies 2, the cutting edge 8 in the above sense may not be available. Although it is also possible to produce the edge region with the edge element 9 by injection molding the edge region, i.e. the side edge 7 or the side edges 7, so that also in these embodiments the core layers 5 of the base body 2 of the component 1 are positioned Obviously.

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Fig. 4 shows a cut-away from a variant embodiment of the component 7 in the edge region, i.e. in the region of the cutting edge 8. This component 1 again has a base body 2 which is formed in a multi-layer construction. The construction of the layers can be carried out as described above, so that reference is made to these embodiments.

In contrast to the above-mentioned variants of the embodiment of the component 1, in the variant shown in FIG. 4, a foam 20 which overlaps the cutting edge 8 instead of the plastic injection molding. In particular, the foam 20 is made of a thermoplastic foam, preferably polyurethane. Thereby, the foaming 20 can be easily adjusted both for its hardness and for its expansion so that the foaming 20 has both the necessary strength in terms of its use and also improves its production by not causing too much cutting edges 8 during foaming. high pressure. The foaming hardness 20 preferably has a value of at least 10 Shore A, for example a value which is preferably selected from the range of lower limit 20 Shore A and upper limit 100 Shore A, in particular from the lower boundary 40 Shore A and upper bound 80 Shore A.

In this way, however, it is also possible to easily set the other desired mechanical characteristics, these being set mainly on the basis of the mixing ratio of the raw materials for foaming 20. In the case of polyurethane foam, as is customary for polyurethane foams per se single component systems also known from the prior art for polyurethane foams are also applicable, one component being formed by a polyol and the other component being formed by an isocyanate, wherein mixtures of more polyols and / or more isocyanates may also be used. Preferably, the ratio of polyol: isocyanate is selected from the range of the lower limit of 100:20 and the upper limit of 100:50, in particular it is selected between the lower limit of 100:30 and the upper limit of 100:40.

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Polyols and isocyanates known in the art can be used.

Foaming of the polyurethane foam raw material takes place according to the prior art for polyurethane foams, so reference is made in this regard to the relevant literature.

However, other foams of plastic, such as polyethylene foams, polypropylene foams and so on, are also useful for foaming 20, preferably foams having an open cellular structure are used.

CMI

The foaming 20 has, in a variant of the embodiment s + ki 1 according to FIG. 4 an approximately "circular" cross-section, wherein the angle 21 between the froth 20 and the base body 2 on the surface 22 facing upwards is less than the angle 23 between the froth 20 and the surface 24 facing the body 2 downwards as shown Fig. 4. In other words, the foaming 20 extends flat on the underside of the component 1.

However, it should be noted that this in FIG. 4, the cross-section shown is not limiting to the invention, which has certain advantages in terms of use and manufacture of component 1, but foaming 20 with other cross-sections can also be produced and used on component 1, for example those shown in the above figures.

The formation of the overcoat and in particular the foaming 20 preferably takes place in the mold 25, as shown in FIG. 5 and 6, respectively in FIG. 7. It should be noted, however, that other molds may also be formed, in particular also molds for molding the base body 2, as long as they are appropriately equipped to supply one or more raw materials for plastic foam, for example as described in the following. to the molds 25 shown in FIG. 5 to 7.

The mold 25 of FIG. 5 and 6 has a lower mold part 26 and an upper mold part 27. In FIG. 5, only the lower mold part 26 is shown. Both the lower mold part 26 and the upper mold part 27 have recesses 28 and 29, respectively

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33946 / H together form the mold cavity 30 in the closed position of the mold 25. The upper mold part 27 is located in a closed position at a distance from the lower mold part 26 in the region 31 into which the mold cavity 30 is fed into the mold cavity 30, so that the basic body 2 does not have to be completely inserted into the mold 25 as this is shown in FIG. 6, but is immersed in the mold cavity 30 only with an edge region having a cutting edge 8, the mold 25 can thus be made smaller. The intermediate space 32 formed by the spacing can be at least as large in height as the base body can be inserted, in which case a seal is formed between the base body 2 and the mold 25 in the area of the intermediate space 32 to prevent the foam from the plastic However, in the preferred embodiment, the intermediate space 32 has a cross-sectional narrowing such that the base body 2 is clamped between the lower and upper mold parts 26, 27 so that an additional seal can be dispensed with in this region.

Preferably, in the upper mold part 27, but in principle also in the lower mold part 26, a feed channel 33 is provided for supplying the raw material for the plastic foam or possibly also for the plastic - in principle it is also possible 30, which is formed in part by, for example, a bore and in part by further spacing, optionally by a further depression in the upper mold part 27, or by further depressions in the lower mold part 26. However, it is also possible that the supply channel 33 is formed integrally in the upper or lower mold part 27, 26.

In a preferred embodiment of the mold 25, the feed channel 33 in the front end region that opens into the mold cavity 30 is formed in a fan-shaped manner and preferably tapers in cross-section towards the mold cavity 30, as shown in FIG. 5 and 6, wherein it is preferably a continuous process. This achieves a uniform supply of plastic raw material (plastic foam) to the mold cavity 30. However, other inlets into the mold are also possible, for example, die-casting and the like.

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Although in FIG. 5 and 6 only the supply channel 33 is shown, there is of course the possibility that several such channels are located along the length or circumference of the mold 25. By this embodiment, it is monitored that the base body 2 of the component 1 can have a cutting edge 8 on more than one edge region so that the mold 25 can be positioned around at least two edge regions or front regions of the base body 2, that in this case more than one mold 25 is used, or the foaming 20 is produced in several steps.

There is also the possibility that a plurality of fan-shaped inlets are located side by side and are supplied by a common part of the inlet duct 33.

For completeness, FIG. 6, a supply element 34, in particular a pump, by means of which the raw material for the plastic material (foam therefrom) is supplied to the supply duct 33 and flows therein.

It is further noted that although in FIG. 6, there is a feed of plastic material (foam) from above, side feed is also possible, so that the feed channel 33 can also be designed to run in a straight line.

In a further preferred embodiment of the embodiment shown in FIG. 7, the mold 25 again has a lower and an upper mold part 26, 27, between which a mold cavity 30 is formed. In contrast to the variant described above, the cross-sectional narrowing of the intermediate space 32 in which the base body 2 is partially located is formed by the edge 35 of the upper mold part 27 so that the base body 2 is clamped between the upper and lower mold parts 27, 26. This will provide a better seal in this area. The gripping of the base body 2 is preferably not so great that, after being removed from the mold 25, permanent damage to the base body 2 remains. For example, the compression may be between 0.1 mm and 1 mm, in particular between 0.2 mm and 0.5 mm. In FIG. 7 it is further shown that at least one sealing element 36, for example oval, may be placed between the lower and upper mold parts 26, 27.

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33946 / H line in the groove recesses 37, 38 in the lower and upper mold parts 26, 27, which extends along the entire length of the mold 25 (seen in FIG. 7). Such sealing elements 36, in particular sealing cords, for example of silicone, can also be placed to seal the mold cavity 30 between the base body 2 and the upper mold part 26 or the lower mold part 27, and the component 1 can abut against these sealing elements 36. For this purpose, these sealing elements 36 can again be partially located in the respective grooves of the lower and upper mold parts 26, 27.

The dashed line in FIG. 7 shows that the upper mold part 27 can also be made in two or more parts, and the partition can be made mainly in the region of the mold cavity 30, whereby the mold cavity 30 can be vented better during filling with the plastic foam raw material and / or frothing of this raw material. In principle, the lower mold part 26 can also be formed in two parts. Again, it is also advantageous if the partition is formed exclusively on the rear or inner side of the component 1 - in the sense mentioned above, so that the visible side of the component 1 in the installed position does not disturb the unevenness caused by the partition.

It is also possible that at least a portion of the upper mold part 26 and / or the lower mold part 27 is formed as a slide which can slide in the direction of the intermediate component 1 in order to seal the mold cavity 30. Again, the slide may have edges or a tip having a function analogous to the edge 35 described above.

When the component 1 is as in FIG. 4, 6 and 7 provided with a deflected edge region, it is advantageous if the lower mold part 26 has a width 39 which is at least so large that the shoulder region of the base body 2 is also supported. The contour in this region corresponds essentially to the outline of the base body. 2, so that in this region at least approximately completely abuts the lower mold part 26.

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In FIG. 8 shows a detail of a variant embodiment of the component 1. This component 1 has a recess 41 on the side surface 40. The recess 41 is in cross-sectional view according to FIG. 8, in particular having a cross-section at least approximately in the shape of the letter Ω, so that the cross-section starting from the edge 42 widens. The cutting edge 8 thus formed is provided with a foaming 20, which in the illustrated embodiment starts at the transition of the edge 42 into the recess and extends separately in the recess 41 continuously along the entire cutting edge 8. Preferably, it is not between the edge 42 of the component 40, the transition is therefore stepless.

The recess 41 serves to accommodate the pin, for example in a variant of the component 1, as a hat shelf or a luggage compartment lid on which the component 1 can rest. In the prior art, a so-called Ω clip has so far been inserted into the component. When foaming 20 according to the invention, this additional component can be omitted. In addition, with the aid of a foamed notch it is better to reduce or to prevent squeaking and rattling noises. For example, the recess 41 can be made with a side slider as a punching edge.

Of course, it is within the scope of the invention that the recess 41 may have a different cross-sectional shape.

Furthermore, in this embodiment variant, the edge of the component 1, i.e. the cutting edge 8, as mentioned above, can also be foamed in whole or at least in part.

The plastic raw material (foam therefrom) is fed into the mold cavity 30 preferably with a flow rate between 10 g / s and 40 g / s, especially between 20 g / s and 30 g / s. The pressure to which the base body 2 is subjected during foaming is a maximum of 300 bar, while foaming also means filling the mold cavity 30. The pressure at which the polyol is fed may be between 100 bar and 250 bar, for example 170 bar, the pressure at which the isocyanate is fed.

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33946 / H may be between 80 bar and 200 bar, for example 160 bar. The temperature of the polyol / isocyanate mixture may be between 35 ° C and 50 ° C.

Preferably, the plastic foam is formed with a closed surface so that the open pores are formed only below the "shell" surface. Alternatively, however, there is also the possibility that the closed surface is achieved by means of an additional element, for example a plastic layer or a non-woven layer, which is inserted into the mold cavity 30 prior to foaming 20 and joined by foaming 20 to the plastic layer.

According to a further variant of the embodiment, the foaming 20 is determined to be formed by means of integral foam, whereby the foaming 20 is harder in the areas near the surface than in the core area.

In contrast to the spraying of the cutting edge 8, the foaming can also be said to "bypass" the cutting edge 8 with the raw material for the plastic foam.

In FIG. 5 and 6, the riser on the so-called visible side of the component is shown on the left. However, it is also possible to place the spout on the rear side, i.e. on the inside of the component 1, i.e. in FIG. 5 and 6 to the right, as in FIG. 6, so that the visible side has a better appearance without the surface of the component 1 having to be reworked in the area of the boss.

The cutting edge 8 can also be a die cut in the component 1 to form a hole.

The cutting edge 8 does not necessarily have to be made with a cutting tool, but can also be made with a punching tool. In addition, the punching or cutting tool does not necessarily have to carry out a vertical movement, but can be guided to the component 1 at an appropriate angle, e.g.

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33946 / H also perform a horizontal movement, in particular to produce the recess 41 of FIG.

8th

In a preferred embodiment, the edge element 9 extends continuously over the entire circumference, possibly over a portion of the circumference of the base body 2 or the recess 41.

The formation of the foaming 20 has the advantage over the injection molding that the mold 25 can be more easily constructed due to the low pressure, in particular it can be easier to prevent the peripheral regions of the base body 2 along its circumference due to the material supplied to the mold cavity 30 . Special measures in the form to prevent this effect can be dispensed with.

The exemplary embodiments show possible variants of the embodiment of the component L as well as the mold 25, at which point it is pointed out that the invention is not limited to their separately illustrated variants but rather different combinations of individual variants are possible with each other. the knowledge of the technical negotiations with the aid of the present invention within the capabilities of a person skilled in the art.

Finally, for the sake of convenience, it is pointed out that, for a better understanding of the construction of the component 1 and of the mold 25, these or their parts have been partially off-scale and / or enlarged and / or reduced. List of reference numbers used

Claims (6)

PATENT CLAIMS Ing. Zuzana Hôrmannová patent attorney 841 02 Bratislava, Repašského 20 SLOVAK REPUBUC Component (1) for automobiles with a multilayer base body (2) having at least one cutting edge (8), characterized in that the cutting edge (8) is sprayed or foamed with at least one plastic to form edge element (9). Component (1) according to claim 1, characterized in that the edge element (9) consists at least in part of a plastic or a thermoplastic elastomer or a plastic foam. Component (1) according to claim 1 or 2, characterized in that the base body (2) has at least partially a cross-sectional taper in the region of the cutting edge (8). Component (1) according to claim 3, characterized in that the cutting edge (8) is tapered to the tip. Component (1) according to one of Claims 1 to 4, characterized in that at least one fastening element (12) is connected to the cutting edge (8) and is connected to the edge element (9), in particular at least partially. anchored in the plastic of the edge element (9). Component (1) according to one of Claims 1 to 5, characterized in that the edge element (9) has a cross section in the form of a profile with an arm (16), the arm (16) having a width (17) corresponding at least the maximum thickness (18) of the base body (2) in the injection area.