Method For Producing a Component Provided With a Multipart Cover Layer and Said Component

• US 20080233359A1
• Filed: 03/22/2006
• Published: 09/25/2008
• Est. Priority Date: 03/22/2005
• Status: Active Grant

• Current Assignee: Faurecia Innenraum Systeme GmbH (Forvia SE)
• Original Assignee: Faurecia Innenraum Systeme GmbH (Forvia SE)
• Inventors: Stoof, Freddy, Baumont, Sebastien, Heinz, Claus, Meyer, Andreas, Beau, Godefroy, Gehring, Andreas, Bauman, Bernhard, Neuhard, Thomas
• Granted Patent: US 8,394,314 B2
• Time in Patent Office: Days
• US Class Current: 428/192
• CPC Class Codes: B29C 44/1209 by impregnating a preformed part, e.g. a porous lining
• CPC Class Codes: B29C 44/1257 Joining a preformed part and a lining, e.g. around the edges
• CPC Class Codes: B29C 44/143 Means for positioning the lining in the mould in general B29C33/12
• CPC Class Codes: B29C 44/351 Means for preventing foam to leak out from the foaming device during foaming
• CPC Class Codes: Y10T 428/233 Foamed or expanded material encased
• CPC Class Codes: Y10T 428/24488 Differential nonuniformity at margin
• CPC Class Codes: Y10T 428/24496 Foamed or cellular component
• CPC Class Codes: Y10T 428/24777 Edge feature

Abstract

The invention relates to a method for the production of a component having a multipart cover layer and also to a component having a multilayer cover layer.

The method according to the invention for the production of a component comprises the steps: a) insertion at least of two skins (3, 4; 20, 21; 41, 42; 81, 82) into the second tool half of a tool having a cavity-forming first tool half (1) and second tool half (2; 27; 40; 60; 80) such that the skins overlap in their end regions (5, 6; 22, 23; 43, 44; 83, 84); b) rear-foaming or rear-spraying of the skins with a foam material (7, 24) or spraying material, c) by exerting low pressure in the region of the overlap, the internally situated end region (6; 23; 44; 84) of the one skin (4; 21; 42; 82) being pressed against the externally situated end region (5; 22; 43; 83) of the other skin (3; 20; 41; 81) in a foam-tight or injection moulding-tight manner.

Claims

1-15. -15. (canceled)

16. A method for a production of a component in a tool having a cavity-forming first tool half and a second tool half, comprising:

a) inserting at least two skins into the second tool half such that the at least two skins overlap in their end regions;

b) one of rear-foaming and rear-spraying of the at least two skins with one of a foam material and a spraying material,

c) exerting a low pressure in a region of the overlap to pressure an internally situated end region of a first skin of the at least two skins pressed against an externally situated end region of a second skin of the at least two skins in one of a foam-tight manner and an injection moulding-tight manner.

17. The method according to claim 16, wherein using the low pressure, the internally situated end region of the first skin in the region of the overlap is pressed at least in regions in a direction of a surface of the second tool half.

18. The method according to claim 16, wherein the externally situated end region of the second skin has continuous openings in the overlapping region for transferring the low pressure to the internally situated end region of the first skin on which the low pressure is exerted.

19. The method according to claim 16, wherein a low pressure is exerted in a region of an edge of the externally situated end region of the second skin.

20. The method according to claim 16, wherein the end regions of the at least two skins are melted together at least in regions after insertion of the at least two skins into the second tool half.

21. The method according to claim 16, wherein at least one of the at least two skins is composed of a thermoplastic material.

22. The method according to claim 16, wherein the at least two skins are formed in their overlapping region in such a manner and are disposed in such a manner that the latter are pressed together by the pressure of one of the foam material and the spraying material during one of the rear-foaming and the rear-spraying.

23. The method according to claim 22, wherein the internally situated end region of the first skin has an inclined sealing lip in an edge region.

24. The method according to claim 16, wherein the first skin has a recess which abuts against the surface of the oppositely situated second skin in the overlapping region for receiving one of the foam material and the spraying material.

25. The method according to claim 16, further comprising:

disposing a rigid carrier in the first tool half; and

closing the tool to bring the carrier in contact in a planar manner with the internally situated end region of the first skin in the region of the overlapping region.

26. The method according to claim 25, further comprising:

on the surface of the second tool half in the region of the overlap of the at least two skins, providing an element which changes in its expansion and extends along the overlapping region; and

using the element, pressing the overlapping region against the carrier.

27. The method according to claim 26, wherein the element is an elastic hose.

28. A component, comprising:

at least two adjacently disposed skins which overlap in their end regions;

the least two skins including a first skin and a second skin; and

a layer including one of a foam layer and an injection moulding layer, the layer being situated behind the at least two skins, an externally situated end region of the first skin has a continuous openings in the region of the overlap.

29. The component according to claim 28, wherein an internally situated end region of the second skin has an inclined sealing lip in an edge region of the end region.

30. The component according to claim 28, wherein the second skin has a recess which abuts against a surface of the first skin in the overlapping region.

31. The component according to claim 28, further comprising:

a carrier touching the internally situated end region of the second skin in a region of the overlap in a planar manner.