Method for producing a component provided with a multipart cover layer and said component

• US 8,394,314 B2
• Filed: 03/22/2006
• Issued: 03/12/2013
• Est. Priority Date: 03/22/2005
• Status: Expired due to Fees

• Current Assignee: Faurecia Innenraum Systeme GmbH (Forvia SE)
• Original Assignee: Faurecia Innenraum Systeme GmbH (Forvia SE)
• Inventors: Heinz, Claus, Baumann, Bernhard, Baumont, Sebastien, Beau, Godefroy, Gehring, Andreas, Stoof, Freddy, Neuhard, Thomas, Meyer, Andreas
• Primary Examiner(s): Johnson, Christina
• Assistant Examiner(s): HAUTH, GALEN H
• Application Number:
  US11/909,234
• Publication Number:
  US 20080233359A1
• Time in Patent Office: 2,547 Days
• Field of Search: 264/45.2, 264/511, 264/275, 264/245, 264/241, 264/263, 264/546, 264/46.5
• US Class Current: 264/511
• 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

A component is produced according to the following steps: a) insertion at least of two skins into the second tool half of a tool having a cavity-forming first tool half and second tool half such that the skins overlap in their end regions; b) rear-foaming or rear-spraying of the skins with a foam material or spraying material, c) by exerting low pressure in the region of the overlap, the internally situated end region of the one skin being pressed against the externally situated end region of the other skin in a foam-tight or injection molding-tight manner.

Claims

1. A method for a production of a component in a tool having a cavity-forming first tool half and a second tool half including at least a first channel and a second channel, comprising:

a) inserting at least a first skin and a second skin into the second tool half such that the first skin and the second skin overlap in their end regions and such that the first channel and the second channel of the second tool half lie across from the overlap, wherein the second skin comprises an externally situated end region, which includes at least one skin opening;

b) one of rear-foaming and rear-spraying of the first skin and the second skin with one of a foam material and a spraying material,

c) exerting a first low pressure in a region of the at least one skin opening through the first channel to pressure an internally situated end region of the first skin against the externally situated end region of the second skin in one of a foam-tight manner and an injection moulding-tight manner; and

d) exerting a second low pressure in an edge region between an edge of the externally situated end region and the internally situated end region through the second channel.

2. The method according to claim 1, wherein using the first 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.

3. The method according to claim 1, wherein the externally situated end region of the second skin has continuous openings in the overlapping region for transferring the first low pressure to the internally situated end region of the first skin on which the first low pressure is exerted.

4. The method according to claim 1, wherein the end regions of the first skin and the second skin are melted together at least in regions after insertion of the first skin and the second skin into the second tool half.

5. The method according to claim 1, wherein at least one of the first skin and the second skin is composed of a thermoplastic material.

6. The method according to claim 1, wherein the first skin and the second skin 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.

7. The method according to claim 6, wherein the internally situated end region of the first skin has an inclined sealing lip in an edge region.

8. The method according to claim 1, 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.

9. The method according to claim 1, 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.

10. The method according to claim 9, further comprising:

on the surface of the second tool half in the region of the overlap of the first skin and the second skin, providing an expandable element along the overlapping region; and

pressing the overlapping region against the carrier by means of the element.

11. The method according to claim 10, wherein the element is an elastic hose.

12. The method of claim 1, further comprising:

disposing a rigid carrier in the first tool half; and

inserting the one of a foam material and a spraying material between the first skin and the second skin and the carrier.

13. A method for a production of a component in a tool having a cavity-forming first tool half and a second tool half including at least a first channel and a second channel, comprising:

a) inserting at least a first thermoplastic skin and a second thermoplastic skin into the second tool half such that the first thermoplastic skin and the second thermoplastic skin overlap in their end regions and such that the first channel and second channel of the second tool half lie across from the overlap;

b) one of rear-foaming and rear-spraying of the first thermoplastic skin and the second thermoplastic skin with one of a foam material and a spraying material; and

c) exerting a low pressure in a region of the at least one skin opening through the first channel to pressure an internally situated end region of the first thermoplastic skin against the externally situated end region of the second thermoplastic skin in one of a foam-tight manner and an injection molding-tight manner, where the internally situated end region and the externally situated end region are attached to each other by heating the second tool half.

14. The method according to claim 13, wherein the heating of the tool half and the exerting of the low pressure overlap in time.