Surface decoration for a covering part and method for the production thereof

• US 20060204722A1
• Filed: 07/30/2004
• Published: 09/14/2006
• Est. Priority Date: 07/31/2003
• Status: Abandoned Application

• Current Assignee: Faurecia Innenraum Systeme GmbH (Forvia SE)
• Original Assignee: Faurecia Innenraum Systeme GmbH (Forvia SE)
• Inventors: Franzgrote, Ralf
• Application Number:
  US10/566,567
• Publication Number:
  US 20060204722A1
• Time in Patent Office: Days
• US Class Current: 428/157
• CPC Class Codes: B29C 44/1257 Joining a preformed part and a lining, e.g. around the edges
• CPC Class Codes: B29C 45/14418 Sealing means between mould and article
• CPC Class Codes: B29K 2711/08 Leather
• CPC Class Codes: B29K 2713/00 Use of textile products or fabrics for preformed parts, e.g. for inserts B29K2105/06 takes precedence
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/3041 Trim panels
• CPC Class Codes: B60R 13/0237 Side or rear panels
• CPC Class Codes: B60R 2013/0281 made of a plurality of visible parts
• CPC Class Codes: B60R 2013/0293 Connection or positioning of adjacent panels
• CPC Class Codes: Y10T 428/24488 Differential nonuniformity at margin

Abstract

Described is a surface decoration for a covering part, especially for an inner trim part in a motor vehicle, partially formed by a cast skin. The surface decoration consists of a decorative insert whose edge is adjacent to an area of the surface decoration formed by said cast skin. The edge of the decorative insert is enclosed by the cast skin. Descrived also is a method for the production of a corresponding surface decoration and to a casting tool for the production of said surface decoration. Highly esthetic trim parts can be produced in a highly simple manner.

Claims

1. A surface decor for a trim part which is formed in regions using a cast skin, comprising a first region formed exclusively by a decor inlay, an edging of the decor inlay bordering a second region of the surface decor which is formed by the cast skin, the edging of the decor inlay being enclosed by the cast skin.

2. A surface decor according to claim 1, wherein the trim part is an interior trim part for a motor vehicle.

3. A surface decor according to claim 1, wherein the cast skin consists of polyurethane.

4. A surface decor according to claim 1, wherein the cast skin has an average thickness of between 0.7 mm and 1.5 mm.

5. A surface decor according to claim 1, wherein a viewed surfaced of the cast skin which, when installed remains visible carries at least one of a paint layer and a light-insensitive layer.

6. A surface decor according to claim 1, wherein a viewed surface of the cast skin which, when installed remains visible, consists of a light-insensitive material.

7. A surface decor according to claim 1, wherein the decor inlay consists of one of leather, a textile and a polymeric material.

8. A surface decor according to claim 1, wherein the decor inlay has a thickness of between 0.3 mm and 2 mm.

9. A surface decor according to claim 1, wherein a rear side of the decor inlay which, when installed, is not visible includes a blocking layer.

10. A surface decor according to claim 1, wherein a rear side of the decor inlay which, when installed, is not visible is of a foam-tight nature.

11. A surface decor according to claim 1, wherein the edging of the decor inlay encompassed by the cast skin is closed.

12. A surface decor according to claim 1, wherein the surface decor defines a viewed surface which, when installed remains visible, the surface decor including a groove extending into a region of the viewed surface surrounding the edging so that the edging lies sunk in the groove so that a joint separating a first surface region formed by the cast skin from a second surface region formed by the decor inlay runs substantially parallel to the edging.

13. A surface decor according to claim 12, wherein a width of the joint is no more than approximately 1.5 mm.

14. A surface decor according to claim 12, wherein a width of the joint is no more than approximately 0.7 mm.

15. A surface decor according to claim 1, wherein portions of the cast skin and the decor inlay extending substantially perpendicular to the edging form an overlap of between 1 mm and 5 mm in length.

16. A surface decor according to claim 1, wherein portions of the cast skin and the decor inlay extending substantially perpendicular to the edging form an overlap of between 2 mm and 3 mm in length.

17. A surface decor according to claim 1, wherein the surface decor is adapted for incorporation in a trim part.

18. A surface decor according to claim 17, wherein the surface decor is adapted for incorporation in a trim part for an interior of a motor vehicle.

19. A surface decor according to claim 17, wherein the surface decor is adapted for incorporation in a trim part forming one of a side trim, a door interior trim and a constituent of an instrument panel.

20. A surface decor according to claim 17, including a foam applied to a rear surface thereof, which, when installed, is not visible.

21. A surface decor according to claim 17, the foam includes a polyurethane material.

22. A surface decor according to claim 17, further comprising a carrier.

23. A surface decor according to claim 22, wherein the carrier is manufactured of plastic.

24. A surface decor according to claim 22, wherein the carrier is manufactured of a pressed wood fiber shape material.

25. A surface decor according to claim 12, wherein a joint on the viewed side has a disappearing width.

26. A method for manufacturing a surface decor for a trim part, comprising:

introducing a decor inlay into a space between upper and lower tools of a casting tool;

clamping an edging of the decor inlay between the upper and lower tools so that the edging projects into a cavity formed between the upper and lower tools; and

filling the cavity between the upper and lower tools with a curing material to form a cast skin enclosing the edging after the decor inlay has been clamped between the upper and lower tools.

27. A method according to claim 26, wherein the trim part is an interior trim part for a motor vehicle.

28. A method according to claim 26 wherein the curing material includes polyurethane and wherein the cast skin resulting therefrom has an average thickness of between approximately 0.7 mm and 1.5 mm.

29. A method according to claim 26, further comprising, depositing a paint layer remaining on the cast skin onto a surface of the lower tool before filling the cavity covering a portion of the decor inlay with a mask.

30. A method according to claim 26, wherein the lower tool is divided such that a first region accommodating the decor inlay is lowerable relative to a second region of the lower tool accommodating the cast skin.

31. A method according to claim 26, wherein the lower tool comprises a web along a line separating the cavity from non-edge portions of the decor inlay, wherein the edging of decor inlay is clamped between this web and the upper tool, the upper tool comprising a recess for the web.

32. A method according to claim 31, wherein the web has at least one of (i) a width of between approximately 0.7 mm and 1.5 mm and (ii) a height of between approximately 3 mm and 10 mm.

33. A method according to claim 26, wherein the upper tool is divided such that a first region covering the decor inlay is liftable and lowerable relative to a second region separating non-edge regions of the decor inlay from the cavity.

34. A method according to claim 26, wherein decor inlay is held on one of the upper and lower tools by a vacuum.

35. A method according to claim 26, wherein the upper tool comprises a plurality of positioning pins, wherein the decor inlay is introduced into the casting tool with the edging bearing on the positioning pins.

36. A method according to claim 26, wherein the decor inlay forms a middle region of the surface decor encased peripherally by the cast skin.

37. A method according to claim 26, wherein the decor inlay is formed of one of leather, textile material and a polymer material.

38. A method according to claim 26, wherein a rear side of the decor inlay which is not visible when installed, includes one of a coating, a film and a blocking layer applied thereto.

39. A method according to claim 26, wherein a rear side of the decor inlay which is not visible when installed, consists of a foam-tight material.

40. A method according to claim 31, wherein a joint is created by the web and wherein a region formed between the cast skin and non-edge regions of the decor inlay is pushed together to reduce the joint to a disappearing gap after removal of the surface decor from the casting tool.

41. A casting tool for manufacturing a surface decor for a trim part, comprising:

upper and lower tools which, when closed against one another, form a cavity therebetween, the upper and lower tools being movable toward and away from one another to open and close the cavity, wherein a first region of the cavity forms a space for the introduction thereto of a curing material to form a cast skin and a second region of the cavity forms a space for receiving therein a decor inlay, the first and second regions bordering one another along a sealing gap within which an edging of the decor inlay is clamped when the upper and lower tools are closed against one another, wherein the casting tool at the sealing gap is widened towards the cavity so that the edging of the decor inlay bears on edges of the sealing gap but not on walls of the cavity.

42. A casting tool according to claim 41, wherein the lower tool comprises a web extending along the sealing gap, the web delimiting the cavity and forming an edge of the sealing gap.

43. A casting tool according to claim 41, wherein the sealing gap forms a closed edging of the second region.

44. A casting tool according to claim 41, wherein one of the lower and upper tools is divided such that first and second regions thereof move independently of one another.

45. A casting tool according to claim 41, wherein one of the upper and lower tools comprises openings for applying a vacuum to the second region in a direction toward the other of the upper and lower tools.

46. A casting tool according to claim 41, wherein one of the upper and lower tools includes one of steel and aluminum.