Method for producing composite component

Abstract

The invention relates to a method for producing a composite component (1) for a motor vehicle, comprising a polyurethane surface and a decorative and / or functional component (5), consisting of the following method steps: providing a first mold half (2) of an injection mold, which first mold half has an open cavity (3); applying the rear side of the film to a second mold half (4) of the injection mold, the second mold half supporting the film on the entire application surface thereof; joining the second mold half to the first mold half wherein the front side of the film completely covers the open side of the cavity of the first mold half; injecting a first reactive material (10) into the cavity of the first mold half; waiting for curing of the first reactive material; removing the second half mold; joining a further second mold half (6) having a further cavity to the rear side of the film; injecting a second reactive material (11) into the cavity of the further second mold half; waiting for curing of the second reactive material; separating the first mold half from a further second mold half and removing the composite component; and optionally: the protruding portions (9) of the film are removed.

Description

Technical Field

[0001] The invention relates to a method for producing a composite component for a motor vehicle, which consists of at least one reactive material and a decorative and / or functional film. Background Art

[0002] Composite components with decorative and / or functional films are often provided for the design of display and operating elements in motor vehicles.

[0003] As known from document DE 10 2019 008 780 A1, such composite components are produced by the following method steps (production of plastic injection-molded components and subsequent overmolding or dipping with reactive two-component materials such as polyurethane). In order to achieve special decorative or functional properties, films with correspondingly designed surfaces are used.

[0004] The production of composite components using polyurethanes by injection molding is problematic because polyurethanes have such low viscosity before the reaction that sealing of the contours of the composite components is difficult. In the above-mentioned cases, sealing is therefore mainly achieved via plastic injection moldings, which are subsequently overmolded or impregnated with polyurethane. In addition, this procedure only creates a low binding energy due to the properties of polyurethanes after crosslinking (for example, thermosetting). Summary of the invention

[0005] The object is therefore to provide a particularly simple and cost-effective method for producing a decorative and / or functional composite component for a motor vehicle.

[0006] This object is achieved according to the invention by a sequence of method steps according to claim 1 .

[0007] According to the invention, provision is made for the production of a three-dimensional composite component consisting of at least one low-viscosity material, for example polyurethane, which is processed in a high-pressure process and which is filled into a cavity sealed by means of a film. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] An embodiment of the present invention is shown and described below with the aid of the accompanying drawings. In which each is a cross-sectional view:

[0009] Figure 1 The first method step is shown,

[0010] Figure 2 The second method step is shown,

[0011] Figure 3 The third method step is shown,

[0012] Figure 4 A fourth method step is shown,

[0013] Figure 5 A fifth method step is shown,

[0014] Figure 6 shows a composite component with a protruding membrane,

[0015] Figure 7 The final composite component is shown. DETAILED DESCRIPTION

[0016] Figure 7 A prismatic composite component having a crystalline appearance is shown as a potential end product.

[0017] Such composite components can in principle be produced as plastic injection-molded parts, but require additional coatings in order to be scratch-resistant or chemical-resistant.

[0018] The object of the method according to the invention is to produce such a composite component from a low-viscosity reactive material in a high-pressure process.

[0019] like Figure 1 As shown schematically, in a first method step, a first mold half 2 with a cavity 3 is provided. A second mold half 4 is placed opposite the first mold half 2, on which a thin film 5 is fixed. The film 5, shown here in section, is sufficiently large in area to completely cover the opening of the cavity 3 facing the film 5. Preferably, the size of the film 5 is selected so that it protrudes beyond the lateral boundaries of the first and second mold halves 2, 4.

[0020] The back side of the film 5 is against the contact surface 8 of the second mold half 4 (at Figure 3 The second mold half 4 is formed flat so that the film 5 is supported by the entire contact surface 8 of the second mold half 4 .

[0021] The film 5 can be a decorative film and / or a functional film which is coated with a conductive structure. The latter means that the film 5 carries electrical components (such as sensors or display elements) and corresponding wires. In addition, the film 5 can be a multilayer film.

[0022] Furthermore, the film 5 can be partially provided with an adhesive-reducing layer, which facilitates the separation of the parts of the first and second tool parts which are temporarily resting on the film 5. The film 5 can be provided with a metal coating, in particular on one side or on both sides.

[0023] After the film 5 has been joined to the second mold half 4, the mold halves 2 and 4 are closed and the first reactive material 10 is injected into the mold cavity 3 ( Figure 2 ).

[0024] After the first reactive material 10 is cured, the first mold half 2 and the second mold half 4 are separated from each other ( Figure 3 ). The film 5 is now located on the bottom side of the first mold half 2 because it is connected to the solidified first reactive material 10 .

[0025] Next, another second mold half 6 with another cavity 7 is brought to a position relative to the mold half 2 ( Figure 4 ), and the first and further second mold halves 2, 6 are closed with the film 5 sandwiched therein.

[0026] Thereafter, the second reactive material 11 is injected into the mold cavity 7 and reacts and solidifies ( Figure 5 ). The second reactive material 11 can be identical to the first reactive material 10 or can also have different properties. Thus, for example, one of the materials 10, 11 can be a transparent polyurethane and the other material 11, 10 can be composed of a colored polyurethane or of a polyurea.

[0027] After the second reactive material 11 is cured, the completed composite component 1 can be removed.

[0028] Subsequently, the protruding part 9 of the film 5 can be selectively cut off at the edge of the composite component 1 by means of a cutting tool 12 ( Figure 6 ). The protruding part 9 of the film can also remain on the composite component 1 , for example when it is provided as an electrical lead for a functional component of the film 5 .

[0029] Reference numerals list

[0030] 1 Composite components

[0031] 2First half mold

[0032] 3 Cavity

[0033] 4 Second half mold

[0034] 5 films

[0035] 6 Another second half mold

[0036] 7 cavities

[0037] 8. Adhesion surface

[0038] 9. Protruding part

[0039] 10First Reactive Material

[0040] 11 Second Reactive Material

[0041] 12 Cutting tools

Claims

1. A method for producing a composite component (1) for a motor vehicle, comprising at least one reactive material and a decorative and / or functional film (5), comprising the following method steps: a) providing a first half-mold (2) of an injection mold, the first half-mold having an open cavity (3); b) placing the back side of the film (5) against the second half (4) of the injection mold, wherein: The second mold half (4) supports the film (5) over its entire abutment surface; c) joining the second mold half (4) to the first mold half (2), wherein the front side of the film (5) completely covers the open side of the cavity (3) of the first mold half (2); d) injecting a first reactive material (10) into the cavity (3) of the first mold half (2); e) waiting for the first reactive material (10) to solidify; f) removing the second mold half (4); g) joining a further second mold half (6) having a further cavity (7) to the back side of the film (5); h) injecting a second reactive material (11) into the cavity (7) of the further second mold half (6); i) waiting for the second reactive material (11) to solidify; j) separating the first mold half (2) from the further second mold half (6) and removing the composite component (1); k) Optionally: removing the protruding portion (9) of the film (5).

2. The method according to claim 1, characterized in that The first and second reactive materials (10, 11) are polyurethanes or polyureas.

3. The method according to claim 1, characterized in that The film (5) is a decorative film.

4. The method according to claim 1, characterized in that: The film (5) is a functional film which is coated with an electrically conductive structure.

5. The method according to claim 1, characterized in that The reactive materials (10, 11) are processed in a high pressure process.

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