Method for producing a diaphragm unit

Abstract

Method for producing a panel unit (1), in particular for a vehicle seat, wherein a) in a first method step, a flexible cladding layer (6) is arranged in a tool (2), wherein the tool (2) comprises a first tool part (3) and a second tool part (4), wherein in the first method step, the cladding layer (6) is arranged on an inner side (5) of the first tool part (3), wherein b) in a second method step, a carrier element (7) is arranged on an inner side of the second tool part (4) in the tool (2), wherein the carrier element (7) comprises a rigid plastic carrier, wherein the plastic carrier has openings, wherein the second tool part (4) has on its inner side only a holding and receiving device for holding and receiving the rigid carrier element (7), and wherein c) in the first and second method steps, the cladding layer (6) and the carrier element (7) are arranged in the tool (2) in such a way that a cavity (11) is formed between the cladding layer (6) and the carrier element (7), wherein in an intermediate step the tool (2) is closed, wherein d) in a third method step, a foam (12) is introduced into the tool (2) between the cladding layer (6) and the carrier element (7) in the cavity (11), wherein in the third method step, the foam (12) is first injected into the tool (2) under pressure and then cured to form a foam layer (13), wherein e) the carrier element (7) is at least partially covered with a film (8) on a side facing the cladding layer (6) in the third process step in a zeroth process step carried out before the second process step in order to close the openings (9) in the carrier element (7), whereby the rear side of the carrier element (7) remains free of foam, characterized in that the plastic carrier has stiffening ribs (10) on its side facing away from the foam layer in order to avoid deformations during injection.

Description

Prior ArtThe present invention is based on a method for producing a panel unit, in particular for vehicle seats, according to the preamble of claim 1.It is known from the prior art to provide vehicle seats with panels to give the vehicle seats an aesthetically pleasing appearance. Such panels are preferably designed to be elastic or soft, so that the risk for a vehicle occupant originating from a vehicle seat in the event of an accident is also reduced.Such panels are usually produced by a corresponding trim layer being subsequently fastened to a carrier element of a vehicle seat. Such a method is comparatively complicated and thus cost-intensive, in particular if comparatively complicated contours are to be covered with the cladding layer. Furthermore, the fastening elements are frequently visible from the outside, so that the aesthetic nature of the panel is impaired.EP 0032052 A1 discloses a method for producing a panel unit, wherein in a first method step a cladding layer is arranged in a tool, wherein in a second method step a carrier element is arranged in the tool and wherein in a third method step a foam is introduced into the tool between the cladding layer and the carrier element, wherein in the first method step the cladding layer is arranged on an inner side of a first tool part and / or wherein in the second method step the carrier element is arranged on an inner side of a second tool part, wherein in an intermediate step the tool is closed, wherein in the third method step first the foam is injected under pressure into the tool and subsequently cured to form a foam layer.DE 32 01 089 C2 discloses a method for producing foam moldings having an insert, in which an insert having a predetermined shape is inserted into a mold for foam molding, which is composed of a core block and a cavity block, in order to integrally form a foam layer on one side of the insert by performing a foaming process of a predetermined foamable material in a cavity of the mold, so that an article is obtained from a foam molding having the insert. A film covering the liner adhesively is applied to that side of the liner where the foam layer is formed. A skirt part of the film is pinched at a connecting portion of the two blocks while the foaming operation of the foamable material is carried out. The foam layer is integrally formed on one side of the liner with the film held between the liner and the foam layer to be formed.WO 96 / 22 340 A2 relates to an adhesive film and a method for sealing openings in a rigid thermoplastic substrate, such as an instrument panel holder for a vehicle. The adhesive film consists of an adhesive layer that can adhere to the thermoplastic substrate and a thermoformable base layer. In a preferred embodiment, the adhesive film is heat sealed around the openings of the substrate by a vacuum thermoforming process to prevent polymer foam from leaking through the openings during manufacture of the instrument panel.The object is to provide a method for performing a processIt is therefore an object of the present invention to provide a method for producing a diaphragm unit, in which simple, rapid and cost-effective production is made possible. Furthermore, the realization of comparatively complex contours is to be promoted.SolutionThe object is achieved by a method for producing a panel unit, in particular for a vehicle seat, wherein in a first method step a flexible cladding layer is arranged in a tool, wherein the tool comprises a first tool part and a second tool part, wherein in the first method step the cladding layer is arranged on an inner side of the first tool part, wherein in a second method step a carrier element is arranged on an inner side of the second tool part in the tool, wherein the carrier element comprises a rigid plastic carrier, wherein the plastic carrier has apertures, wherein the second tool part has on its inner side only a holding and receiving device for holding and receiving the rigid carrier element, and wherein in the first and second method steps the cladding layer and the carrier element are arranged in the tool in such a way, a cavity is formed between the cladding layer and the carrier element, wherein in an intermediate step the tool is closed, wherein in a third method step a foam is introduced into the tool between the cladding layer and the carrier element in the cavity, wherein in the third method step the foam is first injected under pressure into the tool and is subsequently cured to form a foam layer, wherein the carrier element is at least partially covered with a film on a side facing the cladding layer in the third method step in a zeroth method step carried out before the second method step, in order to close the apertures in the carrier element, whereby the rear side of the carrier element remains free of foam, The plastic carrier has stiffening ribs on its side facing away from the foam layer in order to avoid deformations during the injection.Because the plastic carrier has reinforcing ribs on its side facing away from the foam layer to prevent deformations during injection, it is ensured that the carrier element is not deformed and bent during injection of the foam.The present invention advantageously enables the production of the carrier material, the cladding material and the filling material in a single method and a single tool, so that the production costs for the panel unit are significantly reduced. In particular, no additional assembly steps are required for fastening the cladding layer to the carrier element, since the cladding layer is connected to the carrier element indirectly or directly by a material bond via the foam. The aperture unit can thus be removed from the tool and installed as a coherent unit. The foam is injected in particular under pressure, so that all the free spaces between the carrier element and the cladding layer are filled with foam material and a stable connection between the cladding layer and the carrier element is thus achieved, even if the shape of the cladding layer should deviate greatly from the shape of the carrier element. In addition, a mechanically loadable surface is achieved by means of the continuous lining of the cladding layer. A further advantage of the present invention is that no mechanical fastening points for fastening the cladding layer are visible from the outside, so that a pleasing surface can be realized. The carrier element comprises in particular a rigid plastic carrier, while the cladding layer preferably comprises a soft or semi-rigid thin decorative layer.Advantageous embodiments and developments of the invention can be derived from the dependent claim and from the description with reference to the drawings.According to the present invention, it is provided that in the first and second method steps, the cladding layer and the carrier element are arranged in the tool in such a way that a cavity is formed between the cladding layer and the carrier element, wherein in the third method step the foam is introduced into the cavity. Advantageously, the shape of the cladding layer and the shape of the carrier element can deviate from one another in any desired manner as long as a cavity is formed between the cladding layer and the carrier element, into which cavity the foam can be introduced, since the foam introduced under pressure then fills the entire cavity. It is also conceivable for a plurality of cavities to be formed between the cladding layer and the carrier element, which cavities are either connected to one another by channels, so that the foam can pass into all the cavities, or which cavities are shielded from one another, wherein in this case the foam has to be introduced into all the cavities in a targeted manner.According to the present invention, it is provided that in the first method step, the cladding layer is arranged on an inner side of a first tool part and / or wherein in the second method step the carrier element is arranged on an inner side of a second tool part, wherein in an intermediate step the tool is closed, for example by bringing the first and second tool parts together, wherein in the third method step the foam is first injected under pressure into the tool and is subsequently cured to form a foam layer. Preferably, the entire tool, the first tool part and / or the second tool part are heated during or after the third method step in order to achieve a more rapid curing of the foam. The first tool part and / or the second tool part are in particular moved relative to one another in the intermediate step in order to produce a hermetically sealed molding chamber. It is conceivable for the molding chamber to be at least partially cooled before the finished panel unit is removed from the mold. The first tool part has on its inner side a first die which comprises a negative mold of the cladding layer to be produced, so that in order to achieve a specific surface shape of the panel unit, the flexurally slack cladding layer is placed on the corresponding negative mold in the first method step. The foam injected under pressure in the third method step ensures that the cladding layer bears positively against the negative mold and, after the foam has cured, forms a dimensionally stable positive mold of the die. The second tool part has on its inner side only one holding and receiving device for holding and receiving the rigid carrier element.According to the present invention, it is provided that the carrier element is at least partially covered with a film on a side facing the cladding layer in the third method step in a zeroth method step carried out before the second method step. The film advantageously serves to prevent foam from escaping through apertures or recesses in the carrier element during the third process step. The film is preferably adhesively bonded, shrunk and / or welded onto the carrier element, so that cost-effective and simple assembly of the film is made possible.According to a preferred embodiment of the present invention, it is provided that in a fourth method step, the unit, which is connected to one another in a materially bonded manner and is composed of the carrier element, foam layer and cladding layer, is removed from the tool as a finished panel unit. Advantageously, the carrier element and the cladding layer form a unit, so that the mounting of the panel unit, for example on a vehicle seat, can be realized comparatively quickly and thus cost-effectively.The method according to the invention produces a panel unit, in particular for a vehicle seat, wherein the panel unit comprises a carrier element and a cladding layer, wherein a foam layer is arranged between the carrier element and the cladding layer. As has already been explained above, the diaphragm unit can be produced in an advantageous manner in a comparatively simple, flexible, quick and cost-effective manner. At the same time, any desired contours, as well as aesthetically pleasing surfaces through which visible fastening elements pass, can be realized.It is provided that a film is arranged between the carrier element and the foam layer, which film covers the side of the carrier element facing the foam layer and is connected to the carrier element in a materially bonded manner. In this way, it is advantageously ensured that the rear side of the carrier element remains free of foam. This ensures in particular simple mounting of the carrier element on structural components of the vehicle seat.It is further provided that a first side of the panel unit comprises the carrier element and wherein a second side of the panel unit partially opposite the first side comprises the cladding layer, wherein the cladding layer is substantially flexible and comprises a decorative layer and wherein the carrier element comprises a rigid plastic carrier, wherein the cladding layer and the carrier element are indirectly or directly connected to one another in a materially bonded manner via the foam layer. Advantageously, no separate fastening elements for fastening the cladding layer to the carrier element have to be realized.According to the present invention, it is provided that the plastic carrier has stiffening ribs on its side facing away from the foam layer, wherein the plastic carrier has apertures which are closed by the film. The stiffening ribs ensure that the carrier element is not deformed and bent during the injection of the foam.Further details, features and advantages of the invention are evident from the drawings and from the following description of preferred embodiments with reference to the drawings. The drawings illustrate only exemplary embodiments of the invention, which do not restrict the essential inventive concept.Brief Description of the DrawingsFIG. 1 is a schematic view of a manufacturing method for manufacturing a shutter unit according to an exemplary embodiment of the present invention. FIG. 2 is an exploded schematic view of a shutter unit manufactured by the manufacturing method according to the exemplary embodiment of the present invention FIG. 3 is a schematic view of the components of a vehicle seat including a visor unit manufactured by the manufacturing method according to the exemplary embodiment of the present inventionEmbodiments of the InventionIn the various figures, identical parts are always provided with the same reference numerals and are therefore generally also designated or mentioned only once in each case.FIG. 1 shows a schematic view of a production method for producing a diaphragm unit 1 according to an exemplary embodiment of the present invention. The production method is carried out by means of a tool 2 which comprises a first tool part 3 and a second tool part 4. The first tool part 3 and the second tool part 4 can be moved relative to each other in order to open and close the tool 2. FIG. 1 shows the tool 2 in the closed state.In order to produce a diaphragm unit 1, the tool 2 is initially transferred into an open state, not shown. The cladding layer 6 is then placed on the inner surface 5 of the first tool part 3 in such a way that the shape of the cladding layer 6 follows the shape of the inner surface 5. The cladding layer 6 comprises a flexurally slack or semi-rigid decorative layer. On the second tool part 4 there is also arranged a carrier element 7 designed as a plastic carrier. On a side facing the cladding layer 6, the carrier element 7 is covered with a film 8 in order to close apertures 9 in the carrier element 7. On a side facing away from the cladding layer 6, the carrier element 7 is provided with stiffening ribs 10 in order to prevent deformation of the carrier element 7, in particular during the production of the panel unit 1. The tool 2 is then closed.A cavity 11 is formed between the cladding layer 6 and the carrier element 7 or the film 8. Foam 12 is now injected under pressure into this cavity 11. The foam 12 fills the cavity and connects itself to the cladding layer 6 in a materially integral manner and indirectly via the film 8 to the carrier element 7. The foam 12 located in the cavity 11 then cures to form a foam layer 13, with the result that the panel unit 1 is produced as a materially integral composite composed of cladding layer 6, foam layer 13, film 8 and carrier element 7. The curing is preferably accelerated by the application of heat.In a final method step, the diaphragm unit 1 is removed from the tool 2. For this purpose, the tool 2 is transferred back into the open state. It is conceivable that the demolding is supported by cooling the tool 2.FIG. 2 illustrates a schematic exploded view of a panel unit 1 produced using the production method explained with reference to FIG. 1, wherein, for illustration purposes, the panel layer 6 and the carrier element 7 are illustrated spaced apart from one another and the foam layer 13, which is arranged between the carrier element 7 and the panel layer 6, is not illustrated. It can be seen that comparatively complicated surface contours can be achieved with the production method according to the invention. In the present example, the panel unit 1 comprises a side panel 14 for a vehicle seat 15, which is usually located at the height of the pivot axis between a seat part and a backrest of the vehicle seat 16.FIG. 3 shows a schematic view of the panel unit 1 designed as a side panel 14 for a vehicle seat 15 mounted on the vehicle seat 15. FIG. 3 shows circles 17 which show the position of the diaphragm unit 1. The vehicle seat 15 includes the normally invisible support structure 19 shown on the left side of FIG. 3 and the normally visible trim structure 20 shown on the right side of FIG. 3 It can be seen that the side panel 14 is part of the vehicle seat 15.LIST OF REFERENCE CHARACTERS1 Panel unit 2 Tool 3 First tool part 4 Second tool part 5 Inner surface of the first tool part 6 Cladding layer 7 Carrier element 8 Film 9 Aperture 10 Reinforcing rib 11 Cavity 12 Foam 13 Foam layer 14 Side panel 15 Vehicle seat 16 Backrest 17 Circles

Claims

Method for producing a panel unit (1), in particular for a vehicle seat, wherein a) in a first method step a flexible cladding layer (6) is arranged in a tool (2), wherein the tool (2) comprises a first tool part (3) and a second tool part (4), wherein in the first method step the cladding layer (6) is arranged on an inner side (5) of the first tool part (3), wherein b) in a second method step a carrier element (7) is arranged on an inner side of the second tool part (4) in the tool (2), wherein the carrier element (7) comprises a rigid plastic carrier, wherein the plastic carrier has apertures, wherein the second tool part (4) has on its inner side only one holding and receiving device for holding and receiving the rigid carrier element (7), and wherein c) in the first and second method steps, the cladding layer (6) and the carrier element (7) are arranged in the tool (2) in such a way that a cavity (11) is formed between the cladding layer (6) and the carrier element (7), wherein in an intermediate step the tool (2) is closed, wherein d) in a third method step a foam (12) is introduced into the tool (2) between the cladding layer (6) and the carrier element (7) into the cavity (11), wherein in the third method step the foam (12) is first injected under pressure into the tool (2) and is subsequently cured to form a foam layer (13), wherein e) the carrier element (7) is at least partially covered with a film (8) on a side facing the cladding layer (6) in the third method step in a zeroth method step carried out before the second method step, A method for closing the apertures (9) in the carrier element (7), whereby the rear side of the carrier element (7) remains free of foam, characterised in that the plastic carrier has stiffening ribs (10) on its side facing away from the foam layer in order to prevent deformations during injection.Method according to claim 1, wherein the film is glued, shrunk and / or welded to the support element (7).

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