METHOD FOR MANUFACTURING AN INTERIOR COMPONENT FOR A VEHICLE AND INTERIOR COMPONENT FOR A VEHICLE

Abstract

A method for manufacturing an interior component (100) for a vehicle is disclosed, comprising the following steps. A foaming tool is provided with a first tool side (220) and a second tool side (230), wherein the two tool sides (220, 230) form a cavity in a closed state, and wherein one of the two tool sides (220; 230) has a first sealing element (221) for sealing to the outside in a specific area. A planar heating element (110) is provided as a precisely cut piece. The heating element (110) is arranged on the first tool side (220), wherein the heating element (110) bears against an inner surface of the first tool side (220) with a first planar side (111). An electrical contact element (116) of the heating element (110) is arranged in the foaming tool, wherein the electrical contact element (116) is guided laterally outwards in the area of ​​the first sealing element (221).A foaming process is carried out, whereby a foam layer (120) is formed on a second flat side (112) of the heating element (110), which is opposite the first flat side (111), and which bonds with the heating element (110), and wherein the first sealing element (221) prevents the foam layer (120) from penetrating outwards in the area of ​​the contact element (116) when the first tool side (220) and the second tool side (230) are closed.

Description

Technical field The present invention relates to a method for manufacturing an interior component for a vehicle and to an interior component manufactured accordingly by the method. State of the art For example, a method for manufacturing an interior trim part is known from DE 10 2022 103 362 A1. In this method, a flat heating element is arranged as a foam mat in a foaming tool. A foam material is introduced into the foaming tool, and the heating element is back-foamed on one flat side, whereby the foam material bonds with the carrier and the flat heating element. In practice, this method has been shown to involve increased process and material costs. Description of the invention One object of the invention is therefore to provide a method for manufacturing an interior component for a vehicle, using the simplest possible means, that is as efficient and resource-saving as possible. The problem is solved by the subject matter of the independent claims. Advantageous embodiments of the invention are specified in the dependent claims, the description, and the accompanying figures. A method according to the invention for manufacturing an interior component for a vehicle comprises the following steps. A foaming tool with a first tool side and a second tool side is provided. In a closed state, the two tool sides form a cavity. One of the two tool sides has a first sealing element for sealing to the outside in a specific area. A flat heating element is provided as a precisely cut piece. The heating element is arranged on the first tool side, with one flat side of the heating element bearing against an inner surface of the first tool side. An electrical contact element of the heating element is arranged in the foaming tool, with the electrical contact element extending laterally outwards in the area of ​​the first sealing element. A foaming process is carried out.This process creates a foam layer on a second flat surface of the heating element, opposite the first flat surface, which then bonds to the heating element. The first sealing element prevents the foam layer from penetrating outwards in the area of ​​the contact element when the first and second tool sides are closed. The process steps are preferably carried out in the specified order, but other sequences are also conceivable. Furthermore, additional process steps can be added. The interior component produced by the process or, if applicable, a subsequent process, may be, for example, an armrest of a door panel or rear side panel, a center panel or a center console of a vehicle, in particular a passenger car or a truck. The first sealing element is preferably arranged at an edge region of the tool side, so that the cavity formed by the tool sides can be sealed to the outside. "Outside" refers to the area outside the tool sides and thus the area surrounding the tool. The first sealing element is made of an elastic material, in particular silicone, or consists entirely of this material. The first sealing element is preferably somewhat wider than the electrical contact element in the area where it extends to the outside. Preferably, the first sealing element extends between 1 mm and 5 mm to the left and right beyond the width of the electrical contact element. When the two tool sides are closed, pressure is applied from one tool side, via the sealing element and the electrical contact element, to the other tool side, so that the foam layer can fill the cavity but does not penetrate to the outside.For the sake of completeness, it should be mentioned that the edge areas of the two tool halves touch directly in the closed state in the areas where no first sealing element is attached, so that the foam layer cannot penetrate to the outside. The flat heating element can also be called a heating mat. All types of flat heating elements can be used, for example, a non-woven stranded heating element, a foil heating element, or heating wires embedded in foam. The thickness of the flat heating element is preferably between 0.2 mm and 6 mm. The flat heating element is supplied as a precision cut. This means that before being positioned on the first side of the tool, it has been cut, punched, etc., at least substantially to the exact required size. The electrical contact element typically includes a cable or conductor and can be routed out of the tool via a cable exit point. This is advantageous because a hole in a support structure is not required for the contact element to pass through. The foam layer preferably consists of or is made entirely of PUR (polyurethane) foam. The described process is an efficient method for manufacturing a heated interior component. A key advantage of using the precisely cut heating element is that it requires no further processing after the foaming process. Since it is already the correct size, trimming after foaming is unnecessary, thus eliminating a process step. The first sealing element creates a seal to the outside in the area where the electrical contact element is routed. This ensures that the foam mat is formed only within the cavity between the mold halves and does not leak outwards. In one embodiment, the foaming process can comprise the following steps. The foam material is applied to the second flat surface of the heating element, the first and second tool sides are closed, and the foam layer forms from the foam material between the second flat surface of the heating element and the second tool side. This represents a simple process for introducing the foam material. Alternatively, the two tool sides can be closed first, and then the foam material introduced. According to a further development, the first tool face can have at least one positioning element on its inner surface, and the heating element can have at least one counter-positioning element adapted to the positioning element. When the heating element is positioned on the first tool face, the at least one positioning element and the at least one counter-positioning element work together to precisely position the heating element. This ensures correct positioning of the heating element on the first tool face. The positioning element can be designed as a pin with a mushroom head. The counter-positioning element can be designed as a corresponding opening or through-hole. This creates an interference fit that can additionally hold the heating element in the correct position. In a further embodiment, the first sealing element can be attached to the first side of the tool. This allows the heating element to be positioned particularly easily on the first side of the tool in such a way that the electrical contact element is led outwards precisely in the area of ​​the first sealing element. According to a further development, the first tool side can have a substantially circumferential raised section at its edge, with the first sealing element located within this raised section. This means that the first tool side has a raised edge or a circumferential bead. The first sealing element is positioned there. This ensures that a cavity is created between the two tool halves and that the sealing element can effectively seal against the outside at the contact element. In a further development, the heating element can have heating strands and be arranged on the first side of the tool such that the heating strands point towards the first side of the tool. This means that, in the case of an interior component installed in a vehicle, the heating strands point towards the passenger compartment. This enables particularly efficient heating of the passenger compartment. Preferably, the planar heating element comprises a nonwoven fabric with heating strands. The heating strands are arranged on one side of the nonwoven fabric. A barrier film can also be bonded to the nonwoven fabric. The barrier film is preferably arranged on the side of the nonwoven fabric opposite the heating strands. The foam material can be arranged directly adjacent to the barrier film. The barrier film prevents the foam material from penetrating the nonwoven fabric. According to one embodiment, a functional test of the contact element and / or the heating element can be carried out during or after the foaming process. Preferably, the functional test is carried out during the foaming process. This allows it to be determined without loss of time whether the contact element and / or heating element have remained functional. According to further training, the process can additionally include the following steps before the foaming process. A carrier with a notch at its edge for guiding and / or expelling the contact element is provided. The carrier is positioned on the second side of the tool such that the notch is located in the area of ​​the first sealing element when both the first and second sides of the tool are closed. The second side of the tool has a second sealing element in the area of ​​the contact element. In this way, an interior component can be manufactured using a carrier. The carrier is located on the side of the foam layer opposite the heating element. The contact element can be guided outwards through the notch or recess. The first and second sealing elements ensure that the foam layer cannot penetrate outwards in the area of ​​the contact element.Typically, the support extends laterally beyond the first and second tool halves, creating pressure between the edges of the first and second tool halves and the support for outward sealing when the tool halves are closed. The two tool halves therefore do not touch directly. Furthermore, a method for manufacturing an interior component for a vehicle in at least two different versions is proposed. In the first version, the interior component is heated and has a flat heating element. In the second version, the interior component is unheated. The method comprises the following steps. First, it must be determined whether the interior component is to be provided in the first or second version. If the interior component is to be provided in the first embodiment, the procedure comprises the following steps. A foaming tool with a first tool side and a second tool side is provided, wherein the two tool sides form a cavity in a closed state and wherein one of the two tool sides has a first sealing element for sealing to the outside in a specific area. A flat heating element is provided as a precisely cut piece. The heating element is positioned on the first tool side, with one of its flat sides resting against an inner surface of the first tool side. An electrical contact element of the heating element is positioned in the foaming tool, with the electrical contact element extending laterally outwards in the area of ​​the first sealing element.A foaming process is carried out, whereby a layer of foam forms on a second flat surface of the heating element, opposite the first flat surface, and bonds to the heating element. The first sealing element prevents the foam layer from penetrating outwards in the area of ​​the contact element when the first and second tool sides are closed. If the interior component is to be provided in the second version, the procedure comprises the following steps. A foaming tool is provided, comprising a first tool side and a second tool side. In a closed state, the two tool sides form a cavity, and one of the two tool sides has a first sealing element for sealing to the outside. A foaming process is carried out, creating a layer of foam in the cavity. The first sealing element prevents the foam layer from escaping to the outside when the first and second tool sides are closed. This process allows interior components to be manufactured in both heated and non-heated versions using the same tool. This enables a wide variety of designs in a cost-effective manner, as multiple different tools are not required. Furthermore, an interior component for a vehicle is proposed, wherein the interior component is manufactured according to a process as described above. Furthermore, a vehicle with an interior component is proposed, wherein the interior component is manufactured using a process as described above. Further features, advantages and possible applications of the invention will become apparent from the following description of advantageous embodiments and the accompanying figures. Brief character description An advantageous embodiment of the invention is explained below with reference to the accompanying figures. These show: Fig. 1 in a schematic sectional view of a closed foaming tool with an interior component 100 without a support 130; Fig. 2 in a schematic sectional view of a closed foaming tool with an interior component 100 without a support 130 in the area of ​​the electrical contact element 116; Fig. 3 in a schematic sectional view of a closed foaming tool with an interior component 100 with a support 130; Fig. 4 in a schematic sectional view of a closed foaming tool with an interior component 100 with a support 130 in the area of ​​the electrical contact element 116; Fig. 5 in a schematic sectional view of an exemplary assembly of an interior component 100; Fig. 6 in a schematic sectional view of a further exemplary assembly of an interior component 100. The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are consistently identified by the same reference numerals. Detailed description of preferred embodiments Fig. 1 shows a schematic sectional view of a closed foaming tool with an interior component 100 without a support 130. The foaming process has already been carried out. The foaming tool has a first tool side 220 and a second tool side 230. The first tool side 220 has a substantially circumferential raised section 222 at its edge and is thus essentially U-shaped, so that in the closed state a cavity is formed between the first tool side 220 and the second tool side 230. A precisely cut, flat heating element 110 is arranged in the cavity on the first tool side 220. Its first flat side 111 rests against an inner surface of the first tool side 220. The heating element 110 comprises a nonwoven fabric 114 and heating strands 113. The heating strands 113 point towards the first tool side 220. The first tool side 220 has several positioning elements 223 on its inner surface. The positioning elements 223 are mushroom-shaped. Correspondingly, the heating element 110 has several counter-positioning elements 117 adapted to the positioning elements 223. The counter-positioning elements 117 are designed as through-openings in the nonwoven fabric 114 of the heating element 113 (not visible in the figure). When the heating element 110 is positioned on the first tool side 220 to position the precisely cut section of the heating element 110, the positioning elements 223 and counter-positioning elements 117 interact. A foam layer 120 made of a foam material is connected to the heating element 110. The foam layer 120 is arranged on a second flat side 112 of the heating element 110, which is opposite the first flat side 111 of the heating element 110. The foam layer 120 is formed between the second flat side 112 of the heating element 110 and the second tool side 230. Fig. 2 shows a schematic sectional view of a closed foaming tool with an interior component 100 without a support 130 in the area of ​​the electrical contact element 116. The descriptions of Fig. 1 also apply to Fig. 2. The only difference is that the section through the foaming tool and the interior component 100 is shown at a different location, namely in the area of ​​the electrical contact element 116. The first tool side 220 has a first sealing element 221 in certain areas for sealing to the outside. The first sealing element 221 is arranged in the raised section 222. The electrical contact element 116 of the heating element 110 is arranged in the foaming tool such that it is guided laterally outwards in the area of ​​the first sealing element 221. It forms a cable exit point. When the first tool side 220 and the second tool side 230 are closed, the first sealing element 221 prevents the foam layer 120 from penetrating outwards in the area of ​​the contact element 116. Fig. 3 shows a schematic sectional view of a closed foaming tool with an interior component 100 and a support 130. The descriptions of Fig. 1 also apply to Fig. 3. The only difference is that the interior component 100 in Fig. 3 has a support 130. The support 130 is arranged on the second tool side 230. The support 130 projects substantially around the entire circumference of the foaming tool. When the foaming tool is closed, the second tool side 230 presses on the support 130, and the support 130 presses on the raised section 222 of the first tool side 220. This creates a seal between the support 130 and the raised section 222, preventing the foam layer 120 from escaping. Fig. 4 shows a schematic sectional view of a closed foaming tool with an interior component 100 and a carrier 130 in the area of ​​the electrical contact element 116. The descriptions of Fig. 2 also apply to Fig. 4. The only difference is that the interior component 100 in Fig. 4 has a carrier 130, just as in Fig. 3. The carrier 130 has a cutout 131 at its edge for guiding and / or expelling the contact element 116. The contact element 116 is guided outwards through the cutout over an edge of the carrier. The cutout 131 can also be referred to as a recess or indentation. The carrier 130 is arranged on the second tool side 230 such that the notch 131 is located in the area of ​​the first sealing element 221 when the first tool side 220 and the second tool side 230 are closed. The second tool side 230 has a second sealing element 231 in the area of ​​the contact element 116.The contact element 116 is positioned between the first sealing element 221 and the second sealing element 231 to ensure a seal to the outside. This ensures that no foam material escapes to the outside in the area of ​​the contact element 116 during the foaming process. Fig. 5 shows a schematic sectional view of an exemplary structure of an interior component 100, which was manufactured using the described method and any subsequent methods. The layer structure is as follows: The foam layer 120 follows the carrier 130. This is followed by a barrier film 115. This film prevents the foam material of the foam layer 120 from penetrating the nonwoven fabric 114 of the heating element 110, which follows the barrier film 115. Heating strands 113 are arranged on the side of the nonwoven fabric 114 facing away from the barrier film 115. A decorative layer 150 is then arranged. The decorative layer 150 forms the visible side of the interior component 100 and, when installed in a vehicle, faces the passenger. The decorative layer can be, for example, leather, imitation leather, or textile.The interior component could be, for example, an armrest of a door panel or rear side panel, a center panel or center console of a vehicle, especially a car or truck. Fig. 6 shows a schematic sectional view of a further exemplary structure of an interior component 100. The descriptions of Fig. 5 also apply here. The only difference is that a further layer in the form of a cut foam 140 is arranged between the fleece 114 with the heating strands 113 and the decorative layer 150. REFERENCE MARK LIST 100 Interior component 110 Surface heating element 111 First surface side 112 Second surface side 113 Heating wires 114 Fleece 115 Barrier film 116 Electrical contact element 117 Counter-positioning element 120 Foam layer 130 Carrier 131 Notch 140 Cut foam 150 Decor 220 First tool side 221 First sealing element 222 Raise 223 Positioning element 230 Second tool side 231 Second sealing element QUOTES INCLUDED IN THE DESCRIPTION This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature DE 10 2022 103 362 A1

[0002]

Claims

A method for manufacturing an interior component (100) for a vehicle, comprising the steps of: - providing a foaming tool with a first tool side (220) and a second tool side (230), wherein the two tool sides (220, 230) form a cavity in a closed state, and wherein one of the two tool sides (220; 230) has a first sealing element (221) for sealing to the outside in a specific area; - providing a planar heating element (110) as a precise cut; - arranging the heating element (110) on the first tool side (220), wherein the heating element (110) bears against an inner surface of the first tool side (220) with a first planar side (111); - arranging an electrical contact element (116) of the heating element (110) in the foaming tool, wherein the electrical contact element (116) is guided laterally outwards in the area of ​​the first sealing element (221). becomes;- Performing a foaming process,◯ wherein a foam layer (120) is formed on a second flat side (112) of the heating element (110), which is opposite the first flat side (111), and which bonds with the heating element (110), ando wherein the first sealing element (221) prevents the foam layer (120) from penetrating outwards in the area of ​​the contact element (116) when the first tool side (220) and the second tool side (230) are closed.; Method according to claim 1, characterized in that the foaming process comprises the following steps: - Applying a foam material to the second flat side (112) of the heating element (110); - Closing the first tool side (220) and the second tool side (230); - Forming the foam layer (120) from the foam material between the second flat side (112) of the heating element (110) and the second tool side (230). Method according to one of the preceding claims, characterized in that the first tool side (220) has at least one positioning element (223) on its inner surface and the heating element (110) has at least one counter-positioning element (117) adapted to the positioning element (223), wherein when arranging the heating element (110) on the first tool side (220) to position the exact cut of the heating element (110), the at least one positioning element (223) and the at least one counter-positioning element (117) cooperate. Method according to one of the preceding claims, characterized in that the first sealing element (221) is attached to the first tool side (220). Method according to claim 4, characterized in that the first tool side (220) has a substantially circumferential elevation (222) at its edge, wherein the first sealing element (221) is arranged in the elevation (222). Method according to one of the preceding claims, characterized in that the heating element (110) has heating strands (113), and the heating element (110) is arranged on the first tool side (220) such that the heating strands (113) point towards the first tool side (220). Method according to one of the preceding claims, characterized in that a functional test of the contact element (116) and / or the heating element (110) is carried out during or after the foaming process. A method according to one of the preceding claims, characterized in that it additionally comprises the following steps prior to the foaming process: - providing a carrier (130) with a notch (131) arranged at its edge for guiding and / or diverting the contact element (116); - arranging the carrier (130) on the second tool side (230) such that the notch (131) is arranged in the area of ​​the first sealing element (221) when the first tool side (220) and the second tool side (230) are closed, wherein the second tool side (230) has a second sealing element (231) in the area of ​​the contact element (116). A method for manufacturing an interior component (100) for a vehicle in at least two different embodiments, wherein the interior component (100) in a first embodiment is heatable and has a planar heating element (110), and the interior component (100) in a second embodiment is unheatable, and wherein the method comprises the following steps: - Determining whether the interior component (100) is to be provided in the first or second embodiment; - wherein, when determining that the interior component (100) is to be provided in the first embodiment, the method comprises the following steps: o Providing a foaming tool with a first tool side (220) and a second tool side (230), wherein the two tool sides (220, 230) form a cavity in a closed state, and wherein one of the two tool sides (220;230) has a first sealing element (221) for sealing to the outside in certain areas;o providing a planar heating element (110) as a precise cut;o arranging the heating element (110) on the first tool side (220), wherein the heating element (110) bears against an inner surface of the first tool side (220) with a first planar side (111);o arranging an electrical contact element (116) of the heating element (110) in the foaming tool, wherein the electrical contact element (116) is guided laterally outwards in the area of ​​the first sealing element (221);• Performing a foaming process, • wherein a foam layer (120) is formed on a second flat side (112) of the heating element (110), which is opposite the first flat side (111), and which bonds with the heating element (110), and • wherein the first sealing element (221) prevents the foam layer (120) from penetrating outwards in the area of ​​the contact element (116) when the first tool side (220) and the second tool side (230) are closed; • wherein, if it is determined that the interior component (100) is to be provided in the second embodiment, the method comprises the following steps: • Providing a foaming tool with a first tool side (220) and a second tool side (230), wherein the two tool sides (220, 230) form a cavity in a closed state, and wherein one of the two tool sides (220; 230) is partially a first sealing element (221) for sealing to the outside;o Performing a foaming process, ▪ wherein a foam layer (120) is formed in the cavity, and ▪ wherein the first sealing element (221) prevents the foam layer (120) from escaping to the outside when the first tool side (220) and the second tool side (230) are closed.; Interior component (100) for a vehicle, wherein the interior component (100) is manufactured according to a method according to claims 1 - 9.

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