WO2012055575A1

WO2012055575A1 - Composite part and method for producing a composite part

Info

Publication number: WO2012055575A1
Application number: PCT/EP2011/005531
Authority: WO
Inventors: Christian KÖTTER; Andreas Meyer
Original assignee: Faurecia Innenraum Systeme Gmbh
Priority date: 2010-10-27
Filing date: 2011-10-27
Publication date: 2012-05-03
Also published as: DE102010049653B4; DE102010049653A1; CN203496204U; EP2632676A1

Abstract

The invention relates to a composite part (1), in particular an interior lining for a vehicle, comprising a multi-part cover layer (100), which has a visible side, and a foam layer (5) connected to the side of the cover layer facing away from the visible side (S), wherein the cover layer (100) comprises a first skin and a second skin (2, 3; 2', 3'), and an end region (25; 25') of the first skin and an end region (35; 35') of the second skin are angled, and the first and second skins are arranged such that the angled end regions are adjacent to each other and protrude into the foam layer. The invention further relates to a method for producing such a composite part. According to the invention, the second skin has a decorative skin (31; 31') and a sealing layer (36; 36') impervious to foam, wherein the sealing layer is bonded to the decorative skin and is arranged such that it is arranged between the end region of the first skin and the decorative skin in the end region of the second skin and the sealing layer has greater stiffness than the decorative skin.

Description

Composite part and method for producing a

composite part

The present invention is a composite part according to the preamble of claim 1 and a method for producing such a composite part.

Composite parts which are used as interior trim in vehicles are well known in the art. For the most part, these interior parts have a support arranged on a support

Foam layer and on the side facing away from the carrier side of the foam layer on a cover layer, wherein the cover layer has a visible side, which from

Vehicle interior is visible (A side).

The cover layer may for example consist of a closed surface or may be two skins with different properties such as include different colors, different haptics or different materials.

The difficulty in producing such cover layers is the generation of a clearly defined one

Dividing line, allowing color gradients or haptic

Gradients follow the desired geometries of the dividing lines and are not visible to a passenger of the vehicle. In the prior art, essentially two approaches have prevailed.

On the one hand, a first and a second skin of a covering layer are first joined in a tool, for example by welding, melting or gluing adjoining end regions of the first and second skin. Subsequently, the cover layer connected in this way is introduced into a foam mold and foamed back on the side facing away from the visible side of the decorative layer.

On the other hand, it is possible to produce a compound of the first and second skin by the foam backing itself. Such a joining process by means of back-foaming is known, for example, from the printed documents WO 2008/064915 A1, DE 10 2008 012 431 A and US Pat

DE 10 2006 047 355 AI known.

In the aforementioned documents, it is necessary to use skins which consist of a foam-impermeable material. Therefore, untreated high quality materials, such as textiles in woven or knitted form and leather, synthetic leather or Alcantara, often can not be used. This problem can not be solved by a pure impregnation, since the materials deposited with an impregnating layer do not have sufficient rigidity.

The object of the present invention is to improve the processes known from the prior art in such a way that skins which contain decorative materials which are not compatible with the material of the other skin or can only be connected to it with difficulty can be connected in a foamable manner.

The object is achieved by means of a composite part according to claim 1 and a method according to claim 9.

The composite part has a multi-part, preferably two-part cover layer comprising a visible side with a foam layer connected to the side of the cover layer facing away from the visible side. The topsheet comprises first and second skins, wherein an end portion of the first skin and an end portion of the second skin are angled and the first and second skins are disposed such that the angled end portions are adjacent to each other and project into the foam layer.

According to the invention, the second skin comprises a

Decorative skin and a foam impermeable gasket layer. The gasket layer is integrally bonded to the decorative skin and arranged so that it between the end region of the first skin and the

Decorative skin is arranged in the end region of the second skin.

Since the gasket layer lies between the first skin and the decorative skin of the second skin, can be used as the second

Decorative skin a material with uneven upper surface roughness can be used. This is the case in particular with woven or knitted textiles and other materials such as leather or artificial leather or Alcantara.

Using the gasket layer can be a defined

Roughness and structuring of the end region of the first skin facing side of the end portion of the second skin can be achieved. Here, the surface which faces the end region of the first skin can have, for example, a channel-shaped structuring or a smooth surface, so that foam can not escape from the rear side of the cover layer to the visible side of the cover layer during the foam-back process, if a corresponding sealing vacuum is applied is applied in the region of the end regions of the first and second skin.

The "sealing vacuum" is qualitatively different from a "fixing negative pressure". The sealing vacuum is chosen such that two loosely adjacent end portions are sucked together so that they lie against each other foam-tight. By contrast, a fixing negative pressure is selected such that the hides can be fixed in place, for example in a foam tool. The fixing negative pressure may be smaller than the sealing negative pressure.

In order to perform the intended joining process by means of back-foaming, the gasket layer has a higher

Stiffness than the decorative skin on. Due to the increased stiffness in the end region, a sealing vacuum can cause an improved sealing effect between the end regions of the first and second skin. The term "stiffness" here is to be understood to mean that the gasket layer in Connection with the decorative skin under a greater force, which is applied to the surface of the gasket layer, changes its shape, for example by bending. Another measure of the stiffness could be the indentation depth of the decorative skin or the

Seal layer, wherein soft materials have a large depth of depression and hard materials, such as the gasket layer, have a low indentation. Other dimensions, such. As the modulus of elasticity, can also be used when comparing the materials of the gasket layer and the decorative skin.

By means of the material having a higher rigidity, the angled end region can be provided with a specific shape, so that a defined collision of the first and second skin is possible. Although the bonding of the decorative skin and the sealing layer applied thereon is already an independent invention, in a further step after the production of the second skin, it can be introduced into a foaming tool and a first skin and its end region can be introduced to the end region of the second skin be created that when a sealing negative pressure in the region of the end portions of the gap between the end regions is sealed and an incoming foam mass can not reach the visible side.

Alternatively, the composite part can be additionally provided with a carrier.

In one embodiment, the gasket layer comprises a thermoplastic, preferably a polyolefin. One

Thermoplastic has the advantage that in the case of multiple heat and cool once again can be brought back into the desired shape. As a result, gasket layers, which do not meet the quality requirements, can be newly applied to the decorative skin at any time.

In a further embodiment, the sealing layer is materially connected to the decorative layer.

For example, the gasket layer may comprise a plurality of further nozzles, which are arranged on the inside of the nozzle, facing the end region of the decorative skin, by means of a nozzle, which is preferably placed over at least part of the angled end region of the decorative skin. In this way, the injected material can be materially connected to the decorative skin. In particular, the material of the gasket layer penetrates into the structuring of the decorative skin and thus finds firm hold.

The sealing layer can completely cover the decorative skin in the visible end region. In a further embodiment, not only the visible side is completely covered, but also the rear side for improving the shaping and the rigidity of the stiffened by the gasket layer

End region.

In a further embodiment and in particular for the case in which the decorative skin has openings through which foam can pass, a foam-impermeable layer is applied on the rear side of the decorative skin facing away from the visible side. Such a foam-impermeable layer may be formed by means of an impregnating layer, which Foaming prevented, for example, by openings of the decorative skin.

Alternatively, for example, a film can be applied to the back of the decorative skin, wherein the

Foil is impermeable to foam.

Furthermore, the foam tool can comprise a positioning blade, which preferably comprises at least one nozzle for applying the sealing vacuum. The positioning sword is used in the

Area of the dividing line, which is defined by the visible part of the superimposed end portions, a groove formed. The groove is suitable for the viewer not visible to the parting line

"hide". Alternatively to a nozzle, the

Positioning sword made of a porous material or have this. In both cases, the vacuum is caused by a part of the surface of the tool and transferred to the surface of the positioning blade, wherein the part of the suppressor generating surface of the

Positioning sword adjoins. As materials for the positioning blade are ceramics, porous metals, metallic foams, composites or other porous materials in question.

Further embodiments can be taken from the examples given below.

In the embodiments, various elements and features are shown in combination. It should be noted that the omission or the

Adding individual features from one embodiment in another embodiment while omitting features of the other Embodiment also includes an article which is covered by the invention.

Show it:

Fig. 1 is a schematic view of a composite part;

FIGS. 2a-e is a schematic representation of

Production of an embodiment of a composite part;

FIGS. 3a-b show an alternative embodiment of a manufactured composite part.

FIG. 1 shows a composite part 1 with a cover layer 100, which comprises a visible side S and is formed by the first skin 2 and the second skin 3. The cover layer 100 is provided on the back with a foam layer 5, wherein the composite consisting of the cover layer 100 and the foam layer 5 composite part is deposited with a support 6.

Suitable materials for the foam layer 5 are PU foams, PU foams or multi-component foams. As materials for the carrier 6, injection molded polypropylene or glass fiber reinforced polypropylene as well as metals or other composite materials are possible. For example, a first foam-permeable layer and a second foam-impermeable layer applied to the first layer by deep-drawing may be provided as the first skin, for example a thermoplastic olefin film. In this regard, the state of the art as well as the German application filed on the same filing date the same applicant with the same title and the internal file reference 107P 0362 GO / GE.

As materials for the decorative skin of the second skin are leather, synthetic leather, woven, knitted and crocheted textiles and microfiber fabrics such. B. Alcantara in question. 2a, the second skin 3 is shown, which is fixed when placed on the surface 41 of a foam tool 40 by means of the nozzles 42 and the fixing negative pressure applied thereto. The second skin 3 comprises a decorative skin 31 made of a knitted textile. The surface 41 facing away from

Back of the decorative skin 31 is backed with a foam impermeable impregnation layer 32.

The tool 40 comprises a positioning blade 43 with nozzles 44 inserted therein for generating a

Seal vacuum. First, the first skin 3 is aligned on the surface 41 in such a way that it undergoes an angling 33 in the region of the positioning blade 43 and an edge region 34 adjoins an end region 35 adjoining it. Due to the bend 33, the end portion 35 is angled.

For applying a gasket layer, as shown in Fig. 2b, a nozzle 45 on the edge region

34 turned up. Between the edge region 34 and the inner surface of the nozzle 45, a cavity 46 is formed, which by means of not shown finer nozzles, which are located on the surface of the inside of the nozzle 45, with a thermoplastic

Polyolefin is filled. This is shown in more detail in FIG. 2c. The gasket layer 36 can be seen as a dotted surface. The nozzle 45 can be provided in various embodiments. The nozzle may, on the one hand, be configured such that it is slipped over the entire end section 34 extending into and out of the image plane and therefore has a length substantially equal to the length of the parting line of the second skin Length of the dividing line in the image plane into or out of her perpendicular to the alignment of the end portions. Here are, for example, lengths of 20 cm to 3 m, preferably from 50 cm to

2 m, possible. In another alternative, the nozzle is made smaller, for example, with a length of less than 4 cm, preferably less than 2 cm, more preferably less than learning, and is successively driven along the entire length of the dividing line, so that each area of in the image plane extending end portion of the nozzle 45 is traversed. A small nozzle is suitable for carrying out various contouring operations, i. Gradient radii to be able to depart the dividing line. In this case, the groove would not be as shown in FIG. 1 straight, but a curved course.

In Fig. 2d, the detail of Fig. 2c is shown in more detail. It is clear that the

Surface 37 of the decorative skin 31 is highly irregular. Since the decorative skin 31 is a knit fabric, the thermoplastic polyolefin introduced through the nozzle 45 penetrates below at least on the visible side of the end portion of the second skin 3

Surface 37 a. The polyolefin penetrates into a depth 38 and thus ensures a material connection. Furthermore, a smooth surface 39 is formed on the visible side S of the end portion 35.

FIG. 2e shows a finished composite part 1 ', the second skin 3 being designed and arranged as explained in the preceding FIGS. 2a-2d, and a first skin 2 being arranged along the surface 41 of the tool 40 such that its end section 25 adjacent to the decorative layer provided with the end portion 35 of the second skin 3. Since the visible end portion 25 is a smooth surface, a seal in the gap between the end portions 25 and 35 is effected by means of a sealing negative pressure imparted by the nozzles 44. In this case, the surface 39 of the gasket layer 36 bears against the surface of the end section 25. Subsequently, a foam material 51 is introduced into the open foam tool 40 and thus a foam layer 5 is formed.

FIGS. 3 a and 3 b show an alternative embodiment of a second skin. The second skin 3 'comprises a decorative skin 31', which consists of

Leather exists. On the back of the surface 41 of the foam tool 40 is a thin foam-impermeable layer 32 ', which is given by a thermoformed TPO film. In contrast to the embodiment of Figures 2, the in the

Figures 3a and 3b shown end portion 35 'on a further bend, so that this in one

Angle of approximately 30 ° or 150 ° to the upper surface of the positioning blade 43 is arranged. The angles of the end portions cause a bias of the first and second skin, so that the end portions Already touching each other without a sealing negative pressure and so a simplified Aneinanderaugen is possible. The angle can be chosen between 5 ° and 45 °.

The different shape of the angled end region is mediated by means of a differently shaped nozzle 45 'whose mode of operation substantially corresponds to the nozzle 45. Subsequently, a sealing layer 36 'is applied, so that a provided with a sealing layer visible surface of the end portion 35' is formed. In this case, the surface of the gasket layer is provided with a channel-shaped structure, so that, as shown in Fig. 3b, in the case of the superimposed end portions 25 'and 35' foam mass can penetrate into the channel-shaped structure, collapses and crosslinked , so that a cohesive connection between the superimposed sides of the end portions 25 'and 35' is given. The first skin 2 'is a plastisol skin.

As an alternative to applying a foam-impermeable layer made of a material other than the sealing layer on the back side of the decorative skin, the rear side of the decorative skin can be provided completely with a foam-impermeable layer, and then with a sealing layer made of the material of the foam-impermeable layer or another material applied on the visible side in the end region be provided. The subject of the present application includes, inter alia, the following aspects:

Composite part (1), in particular interior trim for a vehicle, having a multi-part cover layer (100) comprising a visible side and a foam layer (5) connected to the side facing away from the visible side (S), the cover layer (100) comprising a first skin and a second skin (2,3; 2 ', 3') and an end portion (25; 25 ') of the first skin and an end portion (35; 35') of the second skin are angled and the first and second skin are arranged are that the angled end portions are adjacent to each other and protrude into the foam layer,

characterized in that the second skin comprises a decorative skin (31; 31 ') and a foam impervious gasket layer (36; 36'), the gasket layer being arranged between the end region of the first skin and the decorative skin in the end region of the second skin is and the gasket layer has a higher rigidity than that

Decorative skin possesses.

Composite part according to aspect 1, characterized in that the gasket layer comprises a thermoplastic, preferably a polyolefin.

Composite part according to one of the aspects 1 or 2, characterized in that the sealing layer in the visible end region has a smooth surface (39) and / or a channel-like structuring. Composite part according to one of the preceding aspects, characterized in that the sealing layer is materially connected to the decorative layer.

Composite part according to one of the preceding aspects, characterized in that the decorative skin is provided on the side facing away from the visible side with a foam-impermeable layer (31, 31 ').

Composite part according to one of the preceding aspects, characterized in that the sealing layer envelops the decorative skin in the end region, preferably completely enveloping it.

Composite part according to one of the preceding aspects, characterized in that the sealing layer is applied exclusively in the end region.

Composite part according to one of the preceding aspects, characterized in that the decorative skin is a woven fabric, a knitted fabric, a leather or an artificial leather.

Method for producing a composite part (1), in particular an interior lining for a vehicle, comprising a multi-part cover layer (100) comprising a visible side and a foam layer (5) facing away from the visible side (S), the method comprising following steps include:

a) arranging a decorative skin (31, 31 ') of a second skin (3, 3') on the surface (41) of a tool (40), so that the decorative skin has an edge region with an angled end and applying a gasket layer (36, 36 ') to the decorative skin, wherein the gasket layer is disposed so as to be disposed on a visible side (S) of the end portion of the decorative skin;

b) arranging a first skin (2, 2 ') and the second skin, each having angled end regions (25, 35, 25', 35 ') on a surface (41) of a foam tool (40) such that the angled end regions of the first and second skin are directed away from the surface of the foam tool and adjacent to each other;

d) applying a sealing negative pressure in the region of the position of the angled end regions, so that the angled end regions are sucked against each other in a planar manner and the sealing layer touches the first skin in the end region;

e) foaming the second layer of the first skin and the second skin with a foam mass (51) such that the end portions of the first and second skin are pressed together.

Method according to aspect 9, characterized in that the gasket layer is applied by means of a nozzle (45; 45 '), wherein the nozzle is preferably placed on at least part of the angled end region of the decorative skin.

A method according to aspect 9 or 10, characterized in that on a side facing away from the visible side of the decorative skin, a foam-impermeable layer (31, 31 ') is applied before the application of the gasket layer. Method according to one of the aspects 9 to 11, characterized in that the gasket layer has a thickness such that a structure present on the decorative skin is smoothed. Method according to one of the aspects 9 to 12, characterized in that the foaming tool comprises a positioning blade (43), which preferably comprises at least one nozzle (44) and / or a porous structure or a porous material for applying the sealing negative pressure.

Claims

claims

characterized in that the second skin comprises a decorative skin (31; 31 ') and a foam impervious gasket layer (36; 36'), the gasket layer being materially bonded to the decorative skin and disposed between the end region of the first skin and the skin the decorative skin is arranged in the end region of the second skin and the gasket layer has a higher rigidity than the decorative skin.

Composite part according to claim 1, characterized in that the gasket layer comprises a thermoplastic, preferably a polyolefin.

Composite part according to one of claims 1 or 2, characterized in that the sealing layer in the visible end region a smooth Surface (39) and / or has a channel-like structuring.

Composite part according to one of the preceding claims, characterized in that the

Decorative skin on the side facing away from the visible side with a foam-impermeable layer (32, 32 ') is provided.

Composite part according to one of the preceding claims, characterized in that the sealing layer envelops the decorative skin in the end region, preferably completely enveloping.

Composite part according to one of the preceding claims, characterized in that the gasket layer is applied exclusively in the end region.

Decorative skin is a woven fabric, a knitted fabric, a leather or a synthetic leather.

Method for producing a composite part (1), in particular an interior trim for a vehicle, with a multipart, one

The cover layer (100) comprising a visible side and a foam layer (5) connected to the side facing away from the visible side (S), the method comprising the following steps:

a) arranging a decorative skin (31, 31 ') of a second skin (3, 3') on the surface (41) of a tool (40) so that the decorative skin has an edge region with an angled end region, and applying a sealing layer (36 36 ') on the decorative skin, the Gasket layer is integrally connected to the decorative skin or is and is arranged such that it is arranged on a visible side (S) of the end portion of the decorative skin;

A method according to claim 8, characterized in that the sealing layer by means of a nozzle (45; 45 ') is applied, wherein the nozzle is preferably placed at least on a part of the angled end portion of the decorative skin.

A method according to claim 8 or 9, characterized in that on a side facing away from the visible side of the decorative skin before the application of the gasket layer, a foam-impermeable layer (32, 32 ') is applied.

11. The method according to any one of claims 8 to 10, characterized in that the gasket layer has a thickness such that a structure present on the decorative skin is smoothed.

12. The method according to any one of claims 8 to 11, characterized in that the foam tool comprises a positioning blade (43), which preferably comprises at least one nozzle (44) and / or a porous structure or a porous material for applying the sealing negative pressure.