METHOD FOR MANUFACTURING AN INTERIOR TRIM COMPONENT

• US 20120286444A1
• Filed: 01/19/2011
• Published: 11/15/2012
• Est. Priority Date: 01/19/2010
• Status: Active Grant

• Current Assignee: Faurecia Innenraum Systeme GmbH (Forvia SE)
• Original Assignee: Faurecia Innenraum Systeme GmbH (Forvia SE)
• Inventors: Baumann, Bernhard, Vasilj, Ante, Bois, Frederik, Moraes, Pierre-Olivier
• Granted Patent: US 9,493,124 B2
• Time in Patent Office: Days
• US Class Current: 264/46.4
• CPC Class Codes: B29C 44/08 using several expanding or moulding steps
• CPC Class Codes: B29C 44/1233 the preformed parts being supported during expanding
• CPC Class Codes: B29C 44/14 the preformed part being a lining B29C44/1209 takes precedence
• CPC Class Codes: B29C 45/1418 the inserts being deformed or preformed, e.g. by the injection pressure
• CPC Class Codes: B29C 45/1671 with an insert
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29L 2031/3041 Trim panels
• CPC Class Codes: B60R 13/02 Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners B60R13/01 takes precedence ; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18
• CPC Class Codes: Y10T 428/24479 including variation in thickness

Abstract

The invention pertains to a method for manufacturing an interior trim component that features a special injection molding process and a selective back-foaming process.

Claims

1. A method for manufacturing an interior trim component, comprising the following steps:

placing a film onto a first contouring surface of a first molding tool part,

fixing the film on the first molding tool part,

arranging a second molding tool part with a second contouring surface on the first molding tool part in order to realize a closed position relative to one another, wherein the second contouring surface is realized in such a way that it at least regionally extends over the first contouring surface of the first molding tool part in its planar expanse and the first and the second contouring surface jointly form a cavity in the closed position of the molding tool parts, wherein said cavity lies between said contouring surfaces and serves for accommodating material to be injected for the at least sectional in-mold lamination of the film,

carrying out the injection molding process into the cavity between the film and the at least one second molding tool part in order to produce a first trim component section of film and

curing the supporting structure and removing the supporting structure with the film connected thereto as first trim component section,

arranging a second trim component section with an outer side that is sectionally realized in the form of a visible face and a rear side that lies opposite of the outer side in such a way that the trim component section forms a first exposed visible face section and a connecting section that is in contact with a connecting section of the film on the outer side and a cavity for at least sectionally back-foaming and connecting the first and the second trim component section is sectionally formed between the rear side of the second trim component section and the first trim component section, and

sectionally back-foaming and connecting the first and the second trim component section.

2. The method of claim 1, wherein the film has a haptically and/or optically optimized surface at least on the first side that faces the first molding tool part.

3. The method of claim 1, wherein back-foaming material is injected into an intermediate space between the first trim component section and the second trim component section through the first trim component section during the selective back-foaming step.

4. The method of claim 1, wherein the film is pressed against the first molding tool part due to the injection molding process such that at least the surface of the first side that faces this molding tool part is deformed in a plastic fashion.

5. The method of claim 4, wherein the plastic deformation is realized with a first molding tool part, the negative surface structure depth of which is 10% to 30% greater than the positive surface structure depth to be produced on the first trim component section.

6. The method of claim 1, wherein PP GF or PP LGF is used for the injection molding process.

7. The method of claim 1, wherein the film features a layer of TPO at least on the first side that faces the first molding tool part.

8. The method of claim 1, wherein the film is fixed in the first molding tool part before the mold is closed.

9. The method of claim 8, wherein the fixing is realized with the aid of fixing device in the form of adhesive and/or cohesive adhesives.

10. The method of claim 8, wherein the fixing is realized with the aid of fixing device in the form of clamping device.

11. The method of claim 1, wherein the film is provided with cutouts and/or at least one weakening line that, when the film is placed into the mold, corresponds to at least one elevation or depression in the contouring surface of at least one of the molding tool parts, and wherein the region, in which at least part of the elevation or the depression forms, is removed in a process step in order to form an opening in the interior trim component to be manufactured.

12. The method of claim 1, wherein air channels are provided in the first molding tool part in order to generate a vacuum in the volume between the film and the first molding tool part.

13. A device for carrying out the method of claim 1.

14. The device of claim 13, wherein at least the first molding tool part has radii greater than or equal to 0.5 mm.

15. An interior trim component manufactured by the method of claim 1.