Decorative molded part and method for manufacturing the same
By forming a locking connection around the substrate with decorative pieces and plastic layers, the problems of complex manufacturing process and difficulty in recycling parts for decorative molded parts are solved, achieving rapid and economical production and recycling capabilities, and reducing squeaking noise.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- JOYSONQUIN AUTOMOTIVE SYST GMBH
- Filing Date
- 2023-03-17
- Publication Date
- 2026-05-12
AI Technical Summary
In the prior art, the manufacturing process of decorative molded parts is complex and it is not convenient to reuse the individual parts, especially because the use of adhesives makes it impossible to effectively separate and recycle them.
The system employs a three-layer structure consisting of a decorative sheet, a plastic layer, and a substrate. The decorative sheet and the plastic layer are bent to surround the substrate, with the plastic layer acting as a spacer to prevent direct contact. The substrate is connected to the decorative sheet via injection molding, eliminating the need for adhesives and enabling a fast and economical manufacturing process.
It enables rapid manufacturing and easy separation of decorative molded parts, reduces production costs, supports the recycling of individual components, and reduces the generation of squeaking noise.
Smart Images
Figure CN116766502B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a decorative molded part and a method for manufacturing the decorative molded part.
[0002] In particular, the present invention relates to a decorative molded part used as an interior trim part in a motor vehicle. Background Technology
[0003] Such decorative parts are typically manufactured using multi-part injection molding. For example, a method known from DE 4301444A1 discloses the insertion of a decorative panel as a decorative layer, which is back-molded from plastic, forming the substrate of the decorative molded part on the back side and overmolding the visible side with a transparent coating designed to protect the decorative layer from environmental impacts. This method is well-known and common today. This method offers the advantage that decorative molded parts, which may have previously been formed in three dimensions, can be largely automated and integrated into the substrate or protective layer by injection molding, where the decorative molded part is produced essentially in a single processing step. Typically, only the contours on the outer periphery of the decorative molded part require rework.
[0004] However, overmolding the plastic onto the surface to which the decorative layer will adhere sometimes involves special measures. For example, trim pieces often have a laminated structure on the back side for reinforcement and also for bonding the plastic. Furthermore, the layers of decorative molded parts are bonded to the material after manufacturing, making it impossible to reuse individual components of the decorative molded part. Summary of the Invention
[0005] This invention addresses the problem of providing a decorative molded part and a method for manufacturing the same, a method that allows the individual components of the decorative molded part to be separated by type. However, the method according to the invention should be easy and economical to implement.
[0006] To address the aspect of the present invention relating to methods, the present invention discloses a method having the features described in claim 1.
[0007] In this context, the present invention assumes that the decorative layer is formed from a decorative sheet. This decorative sheet can be a thin sheet made of plastic or metal. All that is required is a degree of flexibility, where thermoforming and cold forming can be considered to implement the invention. The present invention proposes that the substrate be explicitly (positively) surrounded / embedded within the decorative sheet. For this purpose, the edge portions of the decorative sheet that protrude beyond the substrate on both sides are first bent around the substrate, such that the substrate is at least partially surrounded by the decorative sheet on opposite sides. These sides are typically the main side surfaces of the substrate, i.e., those surfaces of the substrate with the largest area. In the following description of the invention, the surface portions extending substantially perpendicular to the main side surfaces and connecting to the main side surfaces in any case are referred to as the perimeter. The decorative molded part according to the invention is formed like a conventional decorative molded part and is therefore relatively thin. The decorative molded part can be used to cover the center console or dashboard inside the vehicle cabin, or the side rails or ceiling or headliner in the doors or doors. Therefore, the decorative molded part is a substantially flat, planar product. The decorative molded part can form the outer surface of a steering wheel.
[0008] The base or carrier of decorative molded parts is typically a plastic part that provides fastening sections for securing the decorative molded parts to the vehicle body. These fastening sections can be integrally formed fastening protrusions and / or fastening sockets, formed from the plastic material providing the carrier and / or from bolts or nuts or other fastening elements, and can be integrally connected to the plastic body of the decorative molded part by overmolding. The fastening sections are formed to interlock with mating surfaces of a part of the vehicle body or mating surfaces of components connected to the vehicle body.
[0009] Therefore, the substrate also has a relatively large spatial extension and a very small thickness. The substrate is preferably used for mounting decorative molded parts on a vehicle. The substrate is preferably manufactured by injection molding. During injection molding, protrusions and other attachment elements are typically injection molded as a single piece on the rear side of the substrate opposite the visible side of the decorative molded part. Connecting elements (such as screws or rivets) can also be attached to the substrate by overmolding.
[0010] In this invention, a plastic layer is disposed between the substrate and the decorative piece. This plastic layer spacees the decorative piece from the substrate. The plastic layer prevents direct contact between the decorative piece and the substrate, and thus prevents squeaking caused by friction between the decorative piece and the rigid substrate. It should be understood that the plastic layer is preferably formed of a relatively soft plastic, particularly preferably of foamed plastic. The substrate, plastic layer, and decorative piece are generally made of the same material. According to the invention, the connection between the three components is generally achieved simply by bending the decorative piece around the substrate while simultaneously surrounding the plastic layer. The bent end section not only clearly accommodates the substrate within the three-dimensional shape of the decorative piece but also accommodates the plastic layer in the same manner.
[0011] Adhesive joints or similar materials can be eliminated. This means the method can be implemented quickly and is therefore cost-effective. For the recycling of the individual parts of the decorative molding, only the curved edge segments must be bent back or cut off. This frees up the substrate and the plastic layer. These three parts can then be recycled by type. This advantage is made possible by the absence of any adhesives / glues configured to connect the decorative piece, substrate, and / or plastic layer to any other adjacent layers of the decorative molding. These layers are simply placed adjacent to each other before being joined by a clearly defined locking connection.
[0012] During the manufacture of decorative molded parts, the surface portion of the decorative piece surrounding the substrate is typically covered with a plastic layer before the decorative piece is bent. Therefore, the plastic layer is deposited only on the decorative piece, specifically on the rear side opposite the visible side.
[0013] The decorative sheet and the plastic layer are preferably prepared as substantially flat semi-finished products before bending, with one placed on top of the other. In this form, the plastic layer and the decorative sheet, aligned relative to each other, are preferably stamped into a profile in a single operation. Thus, the base region of the decorative sheet corresponds to the base region of the plastic layer. The cutting / trimming of the two layers of the decorative molded part is completed in one step, and is therefore cost-effective. Thus, the plastic layer and the decorative sheet are cut into the same profile, preferably by stamping.
[0014] Regarding the simple attachment of decorative molded parts to motor vehicles, according to a preferred further development of the invention, it is proposed that the decorative piece be explicitly placed (i.e., bent) around the substrate, not around at least one rear surface segment of the substrate. This rear surface segment is typically located in the central region of the substrate. The rear surface segment may include the aforementioned attachment pin, which is integrally disposed on the substrate and used for attaching the decorative molded part to the motor vehicle. The preferred configuration ensures that at least some surface area of the substrate is exposed to the exterior of the decorative molded part. In this case, the bent edge segments of the decorative piece ensure that the decorative features are also prominent around the periphery of the decorative molded part. However, the decorative molded part is not limited to this configuration. In principle, the substrate can be completely surrounded by the decorative piece and / or the plastic layer. However, for the attachment of three layers of the decorative molded part, it is sufficient if only certain segments of the corresponding edge segments of the decorative piece are placed around the substrate, these segments protruding beyond the main side surface of the substrate before bending. In this configuration, the substrate is only partially surrounded by the decorative piece. The plastic layer preferably follows the shape of the decorative piece, and the plastic layer is only disposed where it surrounds the gap between the decorative piece and the substrate.
[0015] Considering the good stability of the decorative layer and the substrate layer, it is preferable to make the plastic layer from foam plastic. This construction also improves the anti-squeaking effect of the plastic layer.
[0016] Decorative molded parts will be arranged inside the vehicle's passenger compartment. The decorative molded parts have a decorative panel and a base attached to the panel on the visible side. The base is spaced apart from the decorative panel by a plastic layer. The base is clearly received and secured within the decorative panel via a flanged edge segment. Attached Figure Description
[0017] Further details and advantages will become clear from the following description of the embodiments in conjunction with the drawings. Wherein:
[0018] Figure 1 A schematic cross-sectional view of the various layers of the decorative molded parts before connection is shown, and
[0019] Figure 2 The connection was shown after... Figure 1 A sectional view. Detailed Implementation
[0020] exist Figure 1 In the accompanying drawing, reference numeral 2 denotes a decorative piece, which in this case is made of aluminum. The decorative piece 2 has a visible side 4 and a rear side 6. The visible side 4 can be pre-treated. For example, embossing or a pattern can be provided on the visible side 4 of the decorative piece 2. The decorative piece 2 may also have through-holes stamped in it, such that the top view of the visible side also shows a plastic layer, indicated by reference numeral 8, in which case the plastic layer also has decorative properties. In this case, another decorative layer (e.g., a plastic film or panel) may also be located below the decorative piece 2, which can be seen from the visible side through the through-holes.
[0021] The plastic layer 8 serves at least as a spacer, ensuring that the substrate, indicated by reference numeral 10, does not directly contact the decorative piece 2. The plastic layer 8 is typically formed of plastic foam. If there is another decorative layer beneath the decorative piece 2, the elastic properties of the plastic foam can be adjusted such that it forces the other decorative layer outward through the through-hole, so that it is flush with the visible side of the decorative piece if desired.
[0022] The substrate is manufactured by injection molding. The substrate can be made of plastic, such as PC or ABS. The substrate 10 has an attachment pin 14 extending from the rear side 12 of the substrate 10 and integrally formed thereon by injection molding. The attachment pin 14 is arranged at a distance from the peripheral edge of the substrate 10.
[0023] For manufacturing, decorative sheet 2 and plastic layer 8 are placed on top of each other. The two layers are then stamped to give them the same profile. A separately prepared substrate 10 is then attached to the side of plastic layer 8 facing away from decorative sheet 2.
[0024] Then, Figure 2 The edge segment indicated by reference numeral 18 in the attached drawing is bent. The bent decorative piece 2 causes the plastic layer 8 to be supported along the outer side of the substrate 10 and placed against the outer side of the substrate (see attached drawing). Figure 2 Edge segment 18 defines the base 10 in the circumferential direction. Furthermore, edge segment 18 curves inward beyond the periphery of the base 10. Therefore, edge segment 18 and its free end at least partially protrude beyond the rear side 12 of the base 10. The dimensions of the decorative piece 2 and the plastic layer 8 relative to the dimensions of the base 10 are such that the rear surface segment, indicated by reference numeral 20, remains free on the rear side of the decorative molded part 16. A fastening pin 14 protrudes beyond the decorative piece 2 at the rear side of the decorative molded part 16, protruding from the rear surface segment 20 (see figure 20). Figure 2 ).
[0025] like Figure 2 As shown, the substrate 10 is thus clearly surrounded by the decorative piece 2. In the same manner, the plastic layer 8 is also clearly received between the contact piece 2 and the substrate 10. The plastic layer 8 prevents direct contact between the contact piece 2 and the substrate 10, and thus prevents squeaking due to friction between the two parts.
[0026] Because the plastic layer 8 is formed of plastic foam, compressive stress can be easily avoided. Therefore, even when processing a fairly thin decorative piece 2, bending is not affected by any reaction forces that might be generated from within the plastic layer 8. Thus, the decorative piece 2 can be bent into the desired shape and formed into its final form by processing on the outside of the decorative piece 2. This also results in a tight bond between the layers, because the substrate 10 can also be pressed into the plastic layer 8 at a point or in a section.
[0027] This invention allows the use of different materials to manufacture the decorative molded parts 16. The adhesive properties of these materials to each other are not important. These materials are preferably connected to each other by bending the decorative piece 2 with forced locking. Bending the decorative piece 2 back allows the individual parts of the decorative molded parts 16 to be separated by type, and thus returns the material to the material cycle.
[0028] List of reference numerals
[0029] 2 decorative pieces
[0030] 4 visible side
[0031] 6 rear side
[0032] 8 plastic layers
[0033] 10 matrix
[0034] 12 rear side
[0035] 14 Attached Pin
[0036] 16 decorative parts
[0037] 18 Edge Sections
[0038] 20 rear surface section
Claims
1. A method for manufacturing a decorative molded part (16), the decorative molded part having a decorative piece (2) disposed on a visible side and connected to a base (10), wherein, A plastic layer (8) is disposed between the substrate (10) and the decorative piece (2), and the edge segments (18) of the decorative piece (2) that protrude beyond the substrate (10) on both sides are bent together with the plastic layer (8) around the substrate (10) to clearly enclose the substrate (10) within the decorative piece (2); The substrate (10) and the plastic layer (8) are connected to each other only by a clear enclosure.
2. The method according to claim 1, wherein, Before the decorative piece (2) is bent, the surface portion of the decorative piece (2) surrounding the substrate (10) is covered with a plastic layer (8).
3. The method according to claim 2, wherein, Before bending, the decorative piece (2) and the plastic layer (8) are placed on top of each other as a substantially flat semi-finished product and cut into the outline.
4. The method according to claim 3, wherein, The plastic layer (8) and the decorative piece (2) are cut into the same outline.
5. The method according to claim 1, wherein, The decorative piece (2) is explicitly curved around the substrate (10) but not around at least one rear surface segment (20) of the substrate (10).
6. The method according to claim 1, wherein, The substrate (10) is injection molded into a molded part.
7. The method according to claim 1, wherein, The substrate (10) is at least partially surrounded by the decorative piece (2) by bending.
8. The method according to claim 1, wherein, The substrate (10) is at least partially surrounded by the decorative piece (2) and the plastic layer (8) by bending.
9. The method according to claim 1, wherein, The substrate (10) is at least partially surrounded by the plastic layer (8) by bending.
10. The method according to claim 1, wherein, The plastic layer (8) is formed of foam plastic.
11. The method according to claim 1, wherein, The substrate (10) is formed of foam plastic.
12. The method according to claim 1, wherein, The substrate (10) and the plastic layer (8) are connected to the decorative piece (2) only by a clear enclosure.
13. A decorative molded part (16) disposed in the passenger compartment of a vehicle, the decorative molded part having a decorative piece (2) on a visible side and a base (10) connected to the decorative piece, wherein, The substrate (10) is separated from the decorative piece (2) by a plastic layer (8), and wherein the substrate (10) is clearly contained within the decorative piece (2) by a flanged edge segment (18) of the decorative piece (2); The substrate (10) and the plastic layer (8) are connected to each other only by a clear enclosure.