Molding system and decorative component

Abstract

The utility model relates to a forming system and a decorative part. The forming system is used for producing a decorative part with a three-dimensional forming surface starting from a blank and comprises a forming mold and an auxiliary foil. The forming mold includes first and second tool halves and a mold cavity. In the state that the blank fixedly connected with the auxiliary foil is arranged in the mold cavity, the mold cavity is divided into a first formed part and a second part subjected to pressure action by the auxiliary foil in a fluid sealing mode, and therefore the blank in the first part of the mold cavity is introduced into a preset position and posture through the auxiliary foil. In the predetermined position and posture, the blank is completely arranged in the mold cavity and is fixed by the auxiliary foil. The forming die is configured to be able to press the auxiliary foil toward one side of the second portion such that the pressed auxiliary foil presses the blank in a forming manner toward the wall of the first portion, whereby the blank is formed into a layered body having a shape corresponding to the three-dimensional forming surface.

Description

Technical Field

[0001] The utility model relates to a system composed of a forming mold and an auxiliary foil and a decorative component. The system is used for forming a material, which is provided in a sheet form and has no fluid tightness, in particular, no gas tightness. Background Art

[0002] Not only in the automotive sector, but also in other application areas, decorative parts originally used sheet materials such as aluminum foil or veneer as a decorative layer to determine the visual appearance.

[0003] Since these decorative parts or their visible surfaces as well as the decorative layers are usually designed to be three-dimensional and therefore do not extend in just one plane, the foil or veneer must be stretched from an initial sheet shape (i.e. essentially flat and horizontal) to a three-dimensional shape or stretched geometry suitable for the decorative part.

[0004] In the prior art, high pressure forming is usually used for this forming, for example known from EP 0 371 425 A2. According to this known process and the tool or system for it, the sheet material is clamped in the mold cavity of the forming mold, as known from DE 4113 568 C1, and is subjected to high pressure from one side by gas or air, so that the material is pressed against the forming part of the mold cavity in a deformed manner.

[0005] However, for veneers, i.e. very thin wood in the form of veneers, and generally rigid, porous and / or crack-prone materials, the problem with the method proposed in EP 0 371 425 A2 is that the material itself is not, or at least not permanently, airtight. Therefore, when subjected to high pressure, the material cannot be pressed reliably or at least not sufficiently against the shaped part of the mold cavity, so that the material cannot be geometrically shaped in the desired manner and in a process-safe manner and can be damaged unintentionally.

[0006] Therefore, EP 2 322 339 A2 proposes to use an auxiliary foil which is loosely laid on the sheet material and seals it so that high pressure can act on the sheet material through the auxiliary foil. In order to position the sheet material in the mold cavity, it is clamped between the tool halves of the forming mold, and predetermined breaking points and / or shrinkage areas are provided by cuts in the sheet material, through which the sheet material can be deformed as desired despite being fixed in the mold cavity by the tool halves.

[0007] However, this method and the system provided therefor have the disadvantage that the blanks which must be provided by the sheet material or the molding material are relatively large, because they must extend out of the mold cavity to fix the blank in the mold cavity. Another disadvantage is that the blanks made of sheet material are prone to cracking and must be arranged along the sealing surface of the molding die, thereby increasing the difficulty of sealing the mold cavity.

[0008] These disadvantages cause material waste on the one hand and require relatively complex sealing of the mold cavity on the other hand, which leads to higher overall manufacturing costs and increased maintenance costs. Utility Model Content

[0009] The object of the present invention is therefore to overcome the above-mentioned drawbacks and to provide a system for cost-effectively and easily producing decorative parts with a three-dimensionally shaped surface, starting from a sheet-like and non-fluid-tight material, in particular one that is prone to cracking.

[0010] The utility model provides a molding system, which is used for producing a decorative component with a three-dimensional molding surface from a blank formed by a sheet-shaped and non-fluid-tight material. The molding system comprises a molding die and an auxiliary foil, wherein the molding die comprises a first tool half and a second tool half, and the molding die has a mold cavity formed by combining the first tool half and the second tool half. When the blank fixedly connected to the auxiliary foil is arranged in the mold cavity, the auxiliary foil is configured to exceed the blank on each side in a plane and surround the blank in a frame shape through a free portion, and the mold cavity is surrounded by the auxiliary foil. The blank is separated into a first formed part and a second part under pressure in a fluid-tight manner, whereby the blank in the first part of the mold cavity is introduced into a predetermined position and posture by the auxiliary foil, in which the blank is completely arranged in the mold cavity and fixed by the auxiliary foil, and the molding die is configured to be able to pressurize the auxiliary foil toward one side of the second part, so that the pressurized auxiliary foil presses the blank against the wall of the first part in a forming manner, and the wall of the first part corresponds to the three-dimensional molding surface of the decorative component, whereby the blank is molded into a layered body having a shape corresponding to the three-dimensional molding surface.

[0011] In an optional solution, an injection mold is further included, wherein the injection mold is configured to receive the laminate with the auxiliary foil removed, so as to perform back injection molding or over-injection molding on the laminate to form a support layer for stabilizing and reinforcing the laminate.

[0012] In another optional solution, an injection mold is further included, wherein the injection mold is configured to receive the laminate with the free portion removed, so as to perform back injection molding or over-injection molding on the laminate with the auxiliary foil to form a support layer for stabilizing and reinforcing the laminate.

[0013] In another optional solution, the first tool half defines a first portion of the mold cavity, and the second tool half defines a second portion of the mold cavity.

[0014] The auxiliary foil is configured to be able to be pressed between sealing surfaces provided on the first tool half and the second tool half and to seal the first tool half and the second tool half relative to each other.

[0015] In another optional solution, corresponding alignment aids are provided on the forming die and the auxiliary foil, by means of which the auxiliary foil and the blank are introduced into a predetermined position and posture of the first part of the mold cavity.

[0016] In another alternative, the auxiliary foil is a disposable sacrificial foil.

[0017] In another alternative, the blank is configured to be adhered to the auxiliary foil using an adhesive and / or an adhesive tape.

[0018] In another optional embodiment, the first tool half and the second tool half each have a sealing surface that is in direct contact with the auxiliary foil, and the first tool half and the second tool half are configured to be pressed against the auxiliary foil so that the first tool half and the second tool half are sealed relative to each other and seal the mold cavity into the first part and the second part in a fluid-tight manner.

[0019] The utility model also provides a decorative component, which has a three-dimensional molded surface, wherein the three-dimensional molded surface has a visible side and a back side facing away from the visible side, wherein the visible side of the decorative component has a layered body formed in three-dimensional correspondence with the three-dimensional molded surface of the decorative component, and the back side has a supporting layer for stabilizing and reinforcing the layered body, wherein the layered body is molded from a sheet-like and non-fluid-tight material, wherein the layered body is porous and / or has cracks.

[0020] The object is achieved by the following combination of features.

[0021] According to the utility model, a system for producing decorative parts is proposed, wherein the decorative parts have a three-dimensionally formed surface, and the method is based on a material, which exists in the form of a plate and is at least not permanently fluid-tight or permanently airtight. The material is preferably a porous, rigid and / or crack-prone material, in particular a natural material, more particularly wood. Therefore, this material can be a veneer. The term "sheet-like" or "in the shape of a sheet" can be understood as a material that initially exists as a thin layer, such as a piece of paper, and extends substantially in one plane, so that the extension length of the material on the plane is several times the extension length of the material in a direction orthogonal to the plane. The method performed by the system according to the utility model comprises at least the following steps, which are preferably performed in a given order:

[0022] a. Cutting the material into a blank close to the final contour, or cutting a blank close to the final contour from the material, wherein the blank extends in one plane;

[0023] By way of explanation, it should be pointed out that cutting into or cutting out may also mean the profiling of the material, as the material is given the contour of the blank. Furthermore, close to the final contour is to be understood as meaning that, in particular after the subsequent pressing of the blank and the associated shaping of the blank into a laminar body, no further cutting or separation of a relatively large amount of material is necessary or is essentially not necessary. For example, "close to the final contour" may be understood as meaning that the area of ​​the blank is equal to the area of ​​the laminar body of the decorative part, or is only slightly larger than the area of ​​the laminar body of the decorative part, for example 1% to 10% or 1% to 5% larger.

[0024] b. arranging the blank on a fluid-tight, particularly airtight auxiliary foil and aligning the blank with respect to the auxiliary foil so that the auxiliary foil extends beyond the blank on each side in a plane and surrounds the blank in a frame shape, particularly by the free portion of the blank;

[0025] In order to align the blank to the auxiliary foil or to align the blank relative to the auxiliary foil, positioning marks can be provided on the auxiliary foil or, for example, printed on the auxiliary foil, or positioning aids such as positioning gauges can be used. The auxiliary foil itself is a film made of a material such as plastic, which can be deformed elastically or plastically, but still maintains its fluid-tightness or gas-tightness when deformed as desired.

[0026] c. connecting the auxiliary foil and the blank aligned therewith into a unit;

[0027] By connecting the auxiliary foil to the blank, for example using an adhesive mentioned below, the blank is fixed on the auxiliary foil so that the pressure acting on the airtight or fluid-tight auxiliary foil can act on the blank. Therefore, the blank itself is still not airtight or fluid-tight.

[0028] d. Arranging the blank connected to the auxiliary foil in a mold cavity of a forming mold, wherein the mold cavity is divided into a first forming part and a second pressure-acting part in an airtight or fluid-tight manner by the auxiliary foil. In addition, the blank is introduced into a predetermined position and posture of the first part of the mold cavity through the auxiliary foil, wherein the blank is arranged in a position and orientation posture in the mold cavity and fixed by the auxiliary foil;

[0029] It is important here that the blank is completely arranged inside the mold cavity and, in particular, cannot extend between the sealing surfaces of the forming tool, as will be mentioned below. In contrast, the auxiliary foil can extend between the sealing surfaces and thus act as a sealing lip in its entirety. Furthermore, the blank is preferably free on all sides within the mold cavity in relation to its planar extension and, at least initially, in particular does not rest directly against the forming tool.

[0030] e. introducing a fluid, in particular a gas, more particularly air, into the second part of the mould cavity so that the auxiliary foil is compressed on its side facing the second part. The pressurized or high-pressure auxiliary foil presses the blank on its side facing its first part in a deforming manner against the wall of the first part of the mould cavity, which wall corresponds to the three-dimensional moulding surface of the decorative part, thereby moulding the previously flat blank into a layered body having a shape corresponding to the three-dimensional moulding surface.

[0031] In summary, the invention relates to a system for carrying out a method for producing a decorative part with a three-dimensionally shaped surface starting from a sheet-like and non-fluid-tight material. The contour of a blank close to the final contour is formed from a sheet-like material, which is then integrally connected to a fluid-tight auxiliary foil, wherein the formed unit is arranged in a forming mold or its mold cavity, so that the blank is completely arranged in the mold cavity of the forming mold and is freely arranged in the mold cavity of the forming mold at its side. The auxiliary foil is then pressurized with a fluid on its side facing away from the blank, so that the blank is pressed against the forming wall of the forming mold and formed into a layered body.

[0032] Prior to forming, the sheet material is first formed into a contour of the blank close to the final contour, and no waste is generated after forming or the amount of waste generated is significantly reduced. Therefore, compared with the prior art, more laminates or more decorative parts can be produced with a given amount of material.

[0033] Furthermore, the blank is not liquid-tight or gas-tight like the starting material, which is arranged completely inside the mold cavity, so that the tool halves can be sealed more easily, as described below, possibly with the aid of an auxiliary foil.

[0034] The production process is therefore both resource-saving and cost-effective.

[0035] An advantageous further development of the system also provides that the following steps can be performed, preferably in the order given:

[0036] f remove the laminate having an auxiliary foil from the forming mold;

[0037] g. Remove the auxiliary foil from the laminate, in particular the entire auxiliary foil;

[0038] h. Arranging the layered body in the injection mold;

[0039] i. Injection molding or overmolding a support layer on the back side of the laminate to stabilize and reinforce the laminate.

[0040] Back injection molding is understood to mean that the support layer is injection molded onto the back side of the laminate body without extending onto the visible side of the subsequent decorative component or onto the visible side of the laminate body.

[0041] In contrast thereto, overmolding means that the support layer is arranged both on the rear side of the layer body and at least partially on the visible side of the layer body and can also extend into the layer body in order to fill cracks.

[0042] Depending on the visual effect to be achieved, the laminate can be back-molded or over-molded, for example, with a colorless, preferably transparent and / or translucent plastic.

[0043] Alternatively, the system may also be provided for executing the following steps, preferably in the order given:

[0044] f remove the laminate having an auxiliary foil from the forming mold;

[0045] g. Remove the free portion of the auxiliary foil from the laminate, in particular only the free portion;

[0046] h. Arranging the layered body having the auxiliary foil in the injection mold;

[0047] i. Injection molding or overmolding a support layer on the back side of the laminate to stabilize and reinforce the laminate.

[0048] As mentioned above, colorless, preferably transparent and / or translucent plastics can be used for back molding or overmolding.

[0049] According to this system variant, the auxiliary foil, which cannot be reused in any case, remains in the manner of a sandwich between the layer body and the support layer, whereby the penetration of plastic into the layer body during the back injection molding process can be effectively prevented.

[0050] Furthermore, the auxiliary foil can also be used in its entirety to seal the injection mold and / or to separate the visible surface of the layered body from the back, so that during overmolding or backmolding, material cannot inadvertently penetrate the visible side.

[0051] For example, in the case of overmolding it can also be provided that the support layer also surrounds only edge regions of the layered body so that these regions are surrounded by the support layer, without the need for trimming the layered body, since projections on the blank which also occur in the layered body and are intended to increase process reliability are located within the support layer.

[0052] Also advantageously, a further embodiment of the system further provides that the forming die has a first tool half and a second tool half, wherein the first tool half defines a first part of the mold cavity and the second tool half defines a second part of the mold cavity. The auxiliary foil is arranged between the sealing surfaces on the first tool half and the second tool half before step e, in particular during or in step d, and is pressed between the two sealing surfaces by closing the tool halves. The sealing surfaces are preferably arranged on the walls of the tool halves surrounding the mold cavity. The auxiliary foil arranged between the sealing surfaces seals the first tool half and the second tool half relative to each other, in particular the mold cavity. Therefore, the auxiliary foil also has the function of a sealing device, in particular the function of a sealing lip that seals the mold cavity. Therefore, it is not absolutely necessary and also not preferred to provide an additional sealing device between the tool halves to seal the mold cavity.

[0053] In order to facilitate the placement of the auxiliary foil and the blank arranged on the auxiliary foil and fixed in the mold cavity, corresponding alignment aids or alignment elements may be provided on the forming mold and the auxiliary foil. For example, a protrusion designed as a pin, for example, may be provided on the forming mold, especially on the first tool half, and a recessed portion corresponding to the protrusion, for example, designed as an elongated hole may be provided on the auxiliary foil as an alignment aid, through which the auxiliary foil and its blank are introduced into a predetermined position and posture of the first part of the mold cavity in step d.

[0054] Furthermore, the alignment aids or the projections and the associated recesses can also be coded so that the auxiliary foil can only be arranged in a predetermined manner on the tool half.

[0055] Although the alignment element may be disposed within the sealing surface, it is beneficial to improve the sealing performance if the alignment element on the molding die is arranged outside the sealing surface and outside the mold cavity.

[0056] The auxiliary foil is preferably a sacrificial foil which is disposable and non-reusable, but can also be recycled.

[0057] In step b, the blank is preferably bonded to the auxiliary foil using an adhesive and / or tape, wherein the adhesive or tape is preferably temperature-resistant so that it can withstand the temperatures generated during the pressing process and the blank does not fall off the auxiliary foil.

[0058] The adhesive does not necessarily have to be applied in the form of an adhesive tape or double-sided adhesive tape, but can also be applied, for example, in the form of a spray-on film to the blank or the auxiliary foil and thus be arranged between them in the form of a sandwich.

[0059] Another aspect of the utility model relates to a decorative component with a three-dimensionally shaped surface, the decorative component having a visible side and a back side facing away from the visible side, wherein the decorative component or a part of the decorative component is preferably produced by the system proposed according to the utility model. The visible side of the decorative component has a layered body, whose three-dimensional shape corresponds to the surface of the decorative component, and the back side has a support layer for stabilizing and reinforcing the layered body. The layered body is formed by a material that is initially sheet-shaped and non-fluid-tight, in particular non-airtight, such as wood, in particular veneer. The layered body is preferably porous and / or cracked, wherein the openings formed in the layered body can be closed by, for example, a protective layer or a support layer on the visible side.

[0060] In addition, the system consisting of a forming die and an auxiliary foil of the utility model is used for forming or three-dimensionally stretching a sheet-like and non-fluid-tight, particularly non-airtight material, as explained, which is particularly porous and / or prone to cracking. In order to be able to form such a non-fluid-tight or non-airtight material or a blank made thereof by applying high pressure by a fluid, it is provided that the forming die has a mold cavity consisting of two parts, a first tool half defining the first part of the mold cavity and a second tool half defining the second part of the mold cavity. The first tool half and the second tool half respectively have sealing surfaces in direct contact with the auxiliary foil, which are designed to press the auxiliary foil and seal the tool halves relative to each other, and divide the mold cavity into two parts in a fluid-tight manner. Thus, the blank can be completely arranged in the mold cavity, and pressure is applied to press the second part of the mold cavity through the auxiliary foil. In addition, other sealing elements, particularly sealing lips or similar sealing elements, are preferably not required on or between the tool halves.

[0061] The manufacturing of the decorative component proposed in the utility model preferably uses the proposed forming mold. In any case, the physical characteristics of the forming mold explained in relation to the method are also applicable to the forming mold included in the system.

[0062] As long as it is technically feasible and not contradictory, the above features can be combined as needed. BRIEF DESCRIPTION OF THE DRAWINGS

[0063] Other advantageous embodiments of the utility model are described in the dependent claims or are described in detail below together with the description of the preferred embodiments of the utility model with reference to the accompanying drawings. The drawings show:

[0064] Figures 1 to 9 The steps of a method of producing a trim component that can be performed by the system are shown;

[0065] Fig.10 A unit consisting of an auxiliary foil and a blank is shown;

[0066] Fig.11An auxiliary foil having a layered body is shown;

[0067] Fig.12 Decorative parts are shown. DETAILED DESCRIPTION

[0068] The figures are schematic examples. The same reference numerals in the figures represent the same functions and / or structural features.

[0069] Figures 1 to 9 The steps of the method that can be performed by the system according to the utility model are shown, in particular for producing Fig.12 The method of decorating a component 10, wherein Figures 1 to 9 The steps are shown in a preferred order, Fig.10 and Fig.11 Show according to Fig.12 The method for producing the trim component 10 shown results in an intermediate product.

[0070] For example, Fig.12 As shown, the decorative element 10 has a multilayer structure and a three-dimensionally shaped surface 11, i.e. a surface extending in a plane. In addition to the back support layer 70 and the visible decorative layer formed by the laminar body 50, the decorative element 10 can also have other layers, and in particular a visible side protective layer covering the laminar body 50 and being transparent.

[0071] If a sheet-like natural material such as wood, in particular in the form of a veneer, is used as the starting material for the layered body 50, the problem is usually encountered that such materials do not have, or at least cannot permanently or reliably have, fluid tightness, in particular air tightness. Therefore, these materials cannot be reliably formed into the desired shape using the deep drawing processes known and widely used in the prior art for high-pressure forming, for which air tightness is an essential prerequisite.

[0072] In the method that can be implemented by the system according to the utility model, according to step a, a blank 20 close to the final contour can be formed by cutting the raw material into the blank 20 or cutting the blank 20 out of the raw material. Since the blank 20 is close to the final contour and has the same surface area as the layered body 50 in the finished decorative part 10 or only slightly larger surface area, more blanks 20 can be provided with a given amount of natural material compared to a large number of methods known in the prior art.

[0073] According to steps b and c, the blank 20 is arranged on the auxiliary foil 30, aligned with the auxiliary foil and connected so that the blank 20 and the auxiliary foil 30 form a unit, such as Figure 1 As can be seen in Fig.10The auxiliary foil 30 extends in the plane of the blank 20 to a greater extent than the blank 20 , so that the auxiliary foil 30 surrounds the blank 20 with a free portion 33 in the shape of a frame.

[0074] According to step d, Figure 1 and Figure 2 As shown, the unit consisting of the auxiliary foil 30 and the blank 20 is arranged in a forming mold 40 or in a mold cavity of the forming mold 40, so that the mold cavity is divided into a first part 41 and a second part 42 by the auxiliary foil 40. In this arrangement, it is most important that the blank 20 is arranged in the first part 41 of the mold cavity by the auxiliary foil 30 so that the blank 41 is free on all (four) sides in the plane in which it extends. Therefore, the edge 21 of the blank 20 has a predetermined distance from the wall of the forming mold 40 forming the mold cavity.

[0075] To illustrate this feature, the blank 20 is completely arranged in the mold cavity and is free on all sides in the plane. Fig.10 4 , an imaginary inner wall edge 48 of the wall of the forming die 40 defining the mould cavity is shown, which clearly shows that the blank 20 in particular does not extend between the sealing surfaces 46 of the forming die 40 , as will be explained below.

[0076] In order to be able to simply and quickly arrange the blank in a predetermined position in the first cavity portion 41 in step d, in this example, alignment aids 37, 47 are also provided in the form of pins 47 provided on the forming die 40 and corresponding oval recesses 37 on the auxiliary foil 30. Thus, by guiding the auxiliary foil 30 with the recesses 37 onto the pins 47, the blank automatically enters the predetermined position and posture.

[0077] The alignment aids 37, 47 are exemplarily Figure 1 and Fig.10 For example, the pin 47 can be arranged inside the sealing surface 46 of the forming mold 40, such as Figure 1 As shown on the right side, or arranged outside the sealing surface 46 of the forming mold 40, as shown in FIG. Figure 1 As shown on the left, the advantage is better sealing.

[0078] Fig.10 These different variations are also indicated in the figure by imaginary lines of the inner wall edge 48 and the outer wall edge 49. On the right side of the figure, the recess 37 is arranged on the inner side of the sealing surface 46 defined by the inner wall edge 48 and the outer wall edge 49, while on the left side of the figure, the recess 37 is arranged on the outer side of the sealing surface 46 defined by the inner wall edge 48 and the outer wall edge 49.

[0079] Once the blank 20 has entered the predetermined position in the first part 41 of the mold cavity, the two tool halves 44 and 45 of the forming mold 40 are closed, so that the auxiliary foil 30 extends between the sealing surfaces 46 of the forming mold 40 and seals the mold cavity from the outside. Thus, the auxiliary foil 30 can serve as a sealing lip for sealing the mold cavity, whereby it is not necessary to provide an additional sealing device on the forming mold 40 for this purpose.

[0080] like Figure 2 As shown, a fluid, in particular a gas, more particularly air, is then introduced into the second portion 42 of the mold cavity, so that the fluid-tight auxiliary foil 30 is pressurized at its second side 32. The pressure acting on the second side 32 of the auxiliary foil is transferred to the blank 20 through the first side 31 of the auxiliary foil 30, so that the blank is pressed into the first portion 41 of the mold cavity together with the auxiliary foil 30, and as shown in FIG. Figure 3 As shown, it is pressed against the forming wall 43, the shape of which corresponds to the surface 11 of the decorative part 10. Depending on the characteristics of the starting material, the pressure can be kept constant or, if necessary, further steps can be performed until the blank 20 molded against the forming wall 43 is permanently formed into a layered body 50, the shape of which corresponds to the surface 11 of the decorative part 10.

[0081] Regardless of whether the original material has leaked before being implemented by the method according to the system of the present invention, or whether leakage occurs during processing due to cracking or the like, the deformation and forming process will be carried out.

[0082] The still existing unit consisting of the auxiliary foil 30 and the blank 20 formed into a laminate 50 is removed from the forming mold 40, as shown in FIG. Figure 4 and Fig.11 shown.

[0083] According to the method that can be performed by the system according to the utility model, Figure 5 As shown, the unit is now disassembled and the laminar body 50 is separated from the auxiliary foil 30. The auxiliary foil 30 is preferably a sacrificial film which can only be used once but is recyclable for disposal or recycling after separation from the laminar body 50.

[0084] Then, if Figure 6 As shown, the now separated laminate 50 can be placed between mold halves 61 and 62 of an injection mold 60, the mold halves 61 and 62 are closed to form a mold cavity 63, and as shown in FIG. Figure 7 For this purpose, the injection molding material, in particular plastic, enters the mold cavity 63 through the feed line 67, thereby forming a support layer 70 in the mold cavity 63 or the injection mold 60, which is integrally connected to the layered body 50 and reinforces the layered body.

[0085] like Figure 8As shown, the unit consisting of the layer body 50 and the supporting layer 70 can be removed from the injection mold 60 .

[0086] exist Fig. 9 In the drawing, the unit consisting of the laminar body 50 and the supporting layer 70 is again shown separately, which essentially already corresponds to the decorative element 10, the surface 11 of the decorative element 10 being determined on the visible side by the laminar body 50 and, if necessary, supplemented by a protective layer (not shown).

[0087] The present invention is not limited to the preferred embodiments described above. On the contrary, many variants are conceivable which utilize the proposed solution even in fundamentally different designs.

Claims

1. A molding system, characterized in that: The molding system is used to produce a decorative component (10) having a three-dimensionally molded surface (11) starting from a blank (20) formed of a sheet-like and non-fluid-tight material, the molding system comprising a molding die (40) and an auxiliary foil (30), The molding die (40) comprises a first tool half (44) and a second tool half (45), and the molding die has a mold cavity formed by the combination of the first tool half (44) and the second tool half (45). In a state where the blank (20) fixedly connected to the auxiliary foil (30) is arranged in the mold cavity, the auxiliary foil (30) is constructed to extend beyond the blank (20) on each side in a plane and surround the blank (20) in a frame shape via a free portion (33), the mold cavity being divided into a first molded portion (41) and a second portion (42) under pressure by the auxiliary foil (30) in a fluid-tight manner, whereby the blank (20) in the first portion (41) of the mold cavity is introduced into a predetermined position and posture by the auxiliary foil (30), in which the blank (20) is completely arranged in the mold cavity and fixed by the auxiliary foil (30), The molding die (40) is configured to pressurize the auxiliary foil (30) toward one side (32) of the second portion (42), so that the pressurized auxiliary foil (30) presses the blank (20) toward the wall (43) of the first portion (41) in a molding manner, and the wall (43) of the first portion (41) corresponds to the three-dimensional molding surface (11) of the decorative component (10), thereby molding the blank (20) into a layered body (50) having a shape corresponding to the three-dimensional molding surface (11).

2. The molding system according to claim 1, characterized in that: The invention also comprises an injection mold (60) configured to receive the laminate (50) with the auxiliary foil (30) removed, so as to perform back injection molding or over-injection molding on the laminate (50) to form a support layer (70) for stabilizing and reinforcing the laminate (50).

3. The molding system according to claim 1, characterized in that: The invention also comprises an injection mold (60) configured to receive the layered body (50) with the free portion (33) removed, so as to perform back injection molding or over-injection molding on the layered body (50) with the auxiliary foil (30) to form a support layer (70) for stabilizing and reinforcing the layered body (50).

4. The molding system according to any one of claims 1 to 3, characterized in that: The first tool half (44) defines a first portion (41) of the mold cavity, and the second tool half (45) defines a second portion (42) of the mold cavity, The auxiliary foil (30) is configured to be pressed between sealing surfaces (46) provided on the first tool half (44) and the second tool half (45) and to seal the first tool half (44) and the second tool half (45) relative to each other.

5. The molding system according to any one of claims 1 to 3, characterized in that: Mutually corresponding alignment auxiliary devices (37, 47) are provided on the forming die (40) and the auxiliary foil (30), through which the auxiliary foil (30) and the blank (20) are introduced into a predetermined position and posture of the first part (41) of the mold cavity.

6. The molding system according to any one of claims 1 to 3, characterized in that: The auxiliary foil (30) is a sacrificial foil that can be used once.

7. The molding system according to any one of claims 1 to 3, characterized in that: The blank (20) is configured to be adhered to the auxiliary foil (30) using an adhesive and / or an adhesive tape.

8. The molding system according to any one of claims 1 to 3, characterized in that: The first tool half (44) and the second tool half (45) each have a sealing surface (46) in direct contact with the auxiliary foil (30), and the first tool half (44) and the second tool half (45) are configured to be pressed against the auxiliary foil (30) so that the first tool half (44) and the second tool half (45) are sealed relative to each other and seal the mold cavity into the first part (41) and the second part (42) in a fluid-tight manner.

9. A decorative component, characterized in that: The decorative component (10) has a three-dimensionally shaped surface (11), the three-dimensionally shaped surface having a visible side (S) and a back side (R) facing away from the visible side, The decorative component (10) has a layered body (50) formed three-dimensionally corresponding to the three-dimensionally formed surface (11) of the decorative component (10) on the visible side (S), and a supporting layer (70) for stabilizing and reinforcing the layered body (50) on the back side (R). The layered body (50) is formed of a sheet-like and non-fluid-tight material. The layered body (50) is porous and / or has cracks.

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