Method for producing a moulded skin and mould arrangement therefore

• US 8,142,705 B2
• Filed: 07/06/2009
• Issued: 03/27/2012
• Est. Priority Date: 07/05/2008
• Status: Active Grant

• Current Assignee: Recticel Automobilesysteme GmbH
• Original Assignee: Recticel Automobilesysteme GmbH
• Inventors: Breest, Jurgen, De Winter, Hugo, Van Houcke, Geert
• Primary Examiner(s): Lee, Edmund H.
• Application Number:
  US12/994,732
• Publication Number:
  US 20110115127A1
• Time in Patent Office: 995 Days
• Field of Search: None
• US Class Current: 264/309
• CPC Class Codes: B29C 33/306 Exchangeable mould parts, e.g. cassette moulds, mould inserts moulds with exchangeable mould parts for injection moulding B29C45/2673; mounting of exchangeable mould inserts for injection moulding B29C45/2675
• CPC Class Codes: B29C 33/50 elastic or flexible for isostatic pressing B29C43/3642
• CPC Class Codes: B29C 41/08 Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder spray-up of reinforcing fibres B29C70/305
• CPC Class Codes: B29C 41/20 incorporating preformed parts or layers, e.g. moulding inserts or for coating articles
• CPC Class Codes: B29C 41/38 Moulds, cores or other substrates
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/3008 Instrument panels
• CPC Class Codes: B29L 2031/3014 Door linings

Abstract

A method for manufacturing molded flexible plastic skins (9, 24, 27, 34) differing in their shape from each other, each skin being molded against a mold surface (2) of a mold (1), comprises the steps: —providing a mold surface (2) matching the shape of the skin to be molded by using a first mold surface provided by the mold itself or by altering the first mold surface by placing one or more mold inserts covering only a part of the first mold surface onto said mold surface and thereby providing an alternative second mold surface, —applying a plastic compound to be brought to shape by the mold surface (2) provided, —bringing to shape the plastic compound applied to the mold surface (2), and —demolding the molded skin (9) from the effective mold surface (2).

Claims

1. A method for manufacturing a moulded flexible plastic skin and variants thereof, which flexible plastic skins differ in their shape from each other, comprising the steps:

providing an effective mould surface matching the shape of the skin to be moulded by either using a first mould surface to manufacture a skin in a first shape, said first mould surface provided by the base mould or by using a second mould surface to manufacture a skin in a second shape, said second mould surface provided by placing one or more mould inserts onto the first mould surface, said insert covering only a part of the first mould surface, each insert providing a mould surface as part of the effective mould surface, and thereby providing an alternative second mould surface;

applying a plastic compound to be moulded on said effective mould surface provided;

bringing to shape the plastic compound applied to the effective mould surface,

demoulding the moulded skin from the effective mould surface, and

wherein that the at least one mould insert used is flexible, whereas such mould insert is arranged on the first mould surface in that the side surfaces of the insert adjoining its own mould surface abut against a wall of the first mould surface arranged angular to the adjacent first mould surface.

2. The method according to claim 1, wherein the insert is arranged on the first mould surface that its side surfaces abutting such wall of the first mould surface are put under a pre-stress in their abutting engagement to the upstanding wall.

3. The method according to claim 1 wherein the more than one mould insert is used to provide the effective mould surface, whereas the mould inserts are placed on different sections of the first mould surface.

4. The method of claim 1 wherein more than one mould insert is used to provide the effective mould surface, whereas at least one mould insert is arranged on the mould surface of a first mould insert.

5. The method of claim 1 wherein a plastic compound is applied to the effective mould surface of a mould.

6. The method of claim 5, wherein the moulded skin is made of polyurethane.

7. The method of claim 5 wherein a mould insert serves as a support for holding one or more elements to be connected to the moulded skin, which elements remain as part of the moulded skin after separation of the mould insert from the moulded skin.

8. The method of claim 7, wherein the element or elements to be connected to the moulded skin are parts of connectors for connecting objects to the moulded skin.

9. The method of claim 5, wherein a mould insert has an extension projecting through the plastic compound to be applied or terminating flush with it.

10. The method of claim 1 wherein the at least one mould insert is made of silicone or a silicone material.

11. The method of the claim 1 wherein the at least one mould insert this insert is used to provide a texturized surface on the moulded skin.

12. A mould arrangement for moulding a flexible plastic skin and variants thereof, which flexible plastic skins differ in their shape from each other the arrangement comprising:

a base mould with a first mould surface for manufacturing a skin in a first shape;

one or more mould inserts to be arranged on the first mould surface and covering only a part of the first mould surface and when applied to the first mould surface each insert providing a mould surface as part of the effective mould surface thus defining a mould with an alternative effective mould surface for manufacturing a skin in a second shape;

wherein the at least one mould insert is flexible; and

the first mould surface carries one or more walls arranged angular to the adjacent mould surface, in particular upstanding from its first mould surface and the mould inserts abut with their side surfaces adjoining their own mould surfaces against such wall at least in those sections of the insert used for shaping the plastic compound.

13. The mould arrangement of claim 12, wherein the mould insert is arranged on the first mould surface with a pre-stress load in the abutting arrangement of the side surfaces of the insert against such wall of the base mould.

14. The mould arrangement of claim 12 wherein the mould surface of the base mould has discrete sections for mould inserts to be placed.

15. Mould arrangement the claim 12 wherein a first mould insert has a section, onto which a second mould insert may be arranged in such a manner, in which the first mould insert is arranged on the first mould surface of the base mould.