METHOD FOR MANUFACTURING AN INTERIOR COMPONENT FOR VEHICLES

Description

Technical field

[0001] The present invention relates to a manufacturing process for an interior component for vehicles, wherein the interior component is particularly suitable for heating a vehicle interior. To manufacture the interior component, a heating element is placed in an injection mold. A molten plastic is then injected into the injection mold to produce a base body on whose surface the heating element is arranged. After the molten plastic has solidified, the base body with the heating element is removed from the injection mold. Subsequently, a cover is applied to the base body, the cover encompassing the heating element and at least a portion of the surface of the base body. State of the art

[0002] Heated interior components for vehicles are known from the prior art. These components are in direct contact with the driver or passenger during operation or use of the vehicle. Seat heaters are one example. In these known heated interior components, a heating mat is positioned between a flexible base body, such as a foam core, and a covering, such as a seat cover. Due to the flexibility of the base body, the heating mat can simply be placed on it during manufacturing without the risk of the heating mat or any wires connected to it being kinked and damaged during the covering process.

[0003] Other interior components, such as dashboards or interior trim panels, generally do not have a flexible base body. Instead, a rigid, non-deformable, i.e., non-flexible, base body is used. If such dimensionally stable interior components are manufactured using conventional methods, there is a risk that the heating mats will crease and be damaged at the edges of the base body during the trimming process. This leads to a high reject rate and, consequently, to increased manufacturing effort and costs.

[0004] Furthermore, such interior components are regularly covered with a tight-fitting material, such as leather. Consequently, the contour of the heating mat resting on the base would be visible through the covering. This results in an undesirable appearance for the user.

[0005] DE 10 2012 208 534 A1 discloses an interior component with a radiant heater. A surface heating element is integrated into a layered composite.

[0006] DE 10 2005 026 766 A1 describes a method for manufacturing a heatable molded body, in particular for external rear-view mirrors with a heating element. Description of the invention

[0007] Based on the prior art described above, it is an object of the present invention to provide a manufacturing process for interior components for vehicles which eliminates the aforementioned problems and disadvantages of the prior art. In particular, it is an object of the present invention to provide an improved manufacturing process for interior components with reduced manufacturing effort.

[0008] The problem is solved by a method for manufacturing an interior component according to claim 1. Advantageous embodiments of the invention are the subject of the dependent claims.

[0009] The solution according to the invention consists of a method for manufacturing the interior component for vehicles comprising the following process steps. First, a heating element is arranged in an injection mold. Then, a molten plastic is injected into the injection mold. The injected molten plastic then solidifies, preferably by cooling and / or by a chemical reaction. This produces a base body on whose surface the heating element is arranged. The heating element is preferably embedded in the base body. The base body with the heating element is then removed from the injection mold. In the subsequent process step, a cover is applied to enclose the heating element and at least part of the base body.The manufacturing process according to the invention advantageously results in the heating element being an integral part of the base body, in particular being embedded or encased in the base body, and not requiring subsequent adaptation to the shape of the base body. This has the advantage, firstly, of significantly minimizing the reject rate during the manufacturing process, since electrical components no longer need to be bent at the edges of the base body. Secondly, it prevents the contour of the heating element from protruding through the cladding after it has been installed.

[0010] The polymer melt can contain a heated rigid plastic, for example, a thermoplastic. For instance, the polymer melt can comprise polycarbonate and / or polystyrene with its copolymers, such as acrylonitrile butadiene styrene. In one exemplary further development, the polymer melt consists of a rigid plastic. The use of heated rigid plastic in or as the polymer melt has the advantage that the base body can be rigid, inflexible, and / or non-deformable, and the interior component can be used, for example, as a fitting and / or as a trim component in the interior of a vehicle.

[0011] Additionally, the polymer melt can contain gas inclusions, particularly inclusions of one or more inert gases. This has the advantage that the base body has a reduced weight and heat-insulating properties.

[0012] According to an exemplary further development of the manufacturing process, the injection is a single injection operation. This injection process can be carried out in a one-shot manner. This has the advantage of shortening the duration of the manufacturing process. Furthermore, partial solidification of the plastic melt does not occur during the injection process.

[0013] In another exemplary embodiment of the manufacturing process, the heating element is fixed in place before the molten plastic is injected into the injection mold. For example, the heating element can be fixed to or within the injection mold by means of plugs and / or fixing holes in the heating element. Alternatively or additionally, the injection mold can have plugs and / or fixing holes for securing the heating element.

[0014] Fixing the heating element in place prevents it from shifting during injection molding. This has the advantage that the interior component produced by the manufacturing process can have tighter manufacturing tolerances, or that the heating element can be positioned more precisely on the base body.

[0015] According to another exemplary embodiment, during the injection process, the first surface of the heating element is covered or sprayed with the plastic, in particular the molten plastic. The second surface of the heating element, opposite the first surface, remains essentially free of plastic, in particular free of the molten plastic, during the injection process. This means that wetting of the second surface with plastic is undesirable and is limited to the manufacturing tolerances inherent in the production process.

[0016] In a further development of the aforementioned embodiment, the second surface is covered by the covering, or in particular only by the covering, after the covering has been applied. For example, the covering is applied directly to the heating element. Preferably, the second surface of the heating element rests against the covering after the covering has been applied. This has the advantage that the heat emitted by the heating element can be transferred directly to the covering layer and dissipated into the vehicle interior. This increases the efficiency of the interior component with regard to heating the vehicle interior.

[0017] The heating element has a connector for control and / or power supply. During the injection molding process, the connector and the heating element are both overmolded by the molten plastic. This means that both the connector and the heating element are at least partially covered by the molten plastic during injection molding. This has the advantage that the connection between the connector and the heating element is reinforced by the base material after the molten plastic has solidified.

[0018] In a further development of the exemplary embodiment, in which the heating element has a connector, the connector and the heating element can be overmolded in such a way that the connector is only partially encased by the molten plastic. This has the advantage that the connector protrudes from the base body of the finished interior component and thus remains accessible from the outside.

[0019] The injection mold includes a hold-down device. Preferably, the heating element is held down by the hold-down device. If a connector is attached to the heating element, the hold-down device can hold the connector down during the injection process. This has the advantage that the interior component produced by the manufacturing process can have lower manufacturing tolerances, or that the heating element can be positioned more precisely on the base body. The hold-down device can, for example, include a spring that presses the heating element and / or the connector on the heating element against an outer wall of the injection mold.

[0020] In another exemplary embodiment, the heating element is connected via a conductor element to a connector for control and / or power supply. Preferably, the heating element and the conductor element are jointly overmolded or covered by the molten plastic during the injection molding process in such a way that at least part of the conductor element and the connector are not encased by the molten plastic. This results in at least part of the conductor element and the connector protruding from the finished interior component. This has the advantage that the connector is easily accessible from the outside and can be connected particularly easily to the vehicle's power and / or control system into which the interior component is installed. The connector can be moved relative to the finished interior component via the conductor element.

[0021] In an exemplary further development of the aforementioned embodiment, the heating element and at least part of the conductor element are arranged between the cover and the base body after the cover has been applied. Preferably, both the heating element and part of the conductor element are enclosed by the base body. This has the advantage, particularly with large interior components, that the heating element can be positioned at a distance from a connection point for the connector without requiring an additional, extending conductor element.

[0022] The heating element can be an electric surface heater. In particular, the heating element can have one or more electric heating loops. Preferably, the heating element is a non-woven stranded heating element, a heating film, and / or a heating fabric. This has the advantage that the heating element has the flattest possible design. In an exemplary embodiment, the heating element has a temperature sensor. The temperature sensor can be an electrical thermistor, in particular an NTC thermistor. A heating element with a temperature sensor has the advantage that the heating element can be controlled more precisely and / or overheating of the heating element can be prevented.

[0023] The interior component produced by the manufacturing process according to the invention can be an interior component of a vehicle, in particular a motor vehicle, an aircraft and / or a ship. Preferably, the interior component is a dashboard or an interior trim component of a vehicle. Brief description of the drawings

[0024] The various and exemplary features described above can be combined with one another according to the invention, insofar as this is technically sensible and suitable. Further features, advantages, and embodiments of the invention will become apparent from the following description of embodiments of the interior fitting according to the invention and with reference to the figures. These show: Fig. 1 a schematic representation of an exemplary heating element for a manufacturing process according to a first embodiment; Fig. 2 a schematic sectional view of a first process step of the manufacturing process according to the first embodiment; Fig. 3 a schematic sectional view of a second process step of the manufacturing process according to the first embodiment; Fig. 4 a schematic sectional view of a third process step of the manufacturing process according to the first embodiment; Fig. 5 a perspective view of an exemplary interior component after a fourth process step of the manufacturing process according to the first embodiment; Fig. 6 a schematic sectional view of a first process step of the manufacturing process according to a second embodiment; Fig.Fig. 7 a schematic sectional view of a second process step of the manufacturing process according to the second embodiment; and Fig. 8 a schematic representation of an exemplary interior component after a third and a fourth process step of the manufacturing process according to the second embodiment. Ways to implement the invention

[0025] Fig. 1 Figure 1 shows a schematic representation of an exemplary heating element 3, as it can be used for a manufacturing process according to a first embodiment. The heating element 3 comprises a film, a nonwoven fabric, or a similarly thin base material. The heating element 3, in particular the base material of the heating element 3, has a first surface 3a and a second surface 3b. The second surface 3b is arranged opposite and facing away from the first surface 3a.

[0026] Heating wires 3c are arranged in or on the heating element 3, in particular in or on the base material of the heating element 3. The heating wires 3c are electrically contacted by a connector 7. The connector 7 is suitable for being connected to a power supply and / or a control device.

[0027] The Figs. 2-4 The figures show various process steps of the manufacturing process according to the first embodiment in chronological order. Fig. 2 shows the first process step of the exemplary manufacturing process, in which the heating element 3 is manufactured according to Fig. 1 The second surface 3b of the heating element 3 is arranged in an injection mold 2. The second surface 3b of the heating element 3 is placed onto a first injection mold part 2a of the injection mold 2. Then, a second injection mold part 2b of the injection mold 2 is positioned opposite the first surface 3a of the heating element 3.

[0028] The second injection molded part 2b in the illustrated embodiment comprises a nozzle for a plastic melt 4 (see figure). Fig. 3 ) and a holding device 9. The holding device 9 is designed to hold the connector 7 in place during the process of Fig. 3 to fix the injection process shown, in particular to hold it down.

[0029] As in Fig. 3 As shown, the injection mold 2, in particular the first injection mold part 2a and the second injection mold part 2b of the injection mold 2, forms a cavity. The plastic melt 4 is injected into this cavity. The plastic melt 4 can be, for example, a heated rigid plastic 4, in particular a heated thermoplastic 4. The injection preferably comprises a single injection process, so that the plastic melt 4 does not cool down, or only cools down to an insignificant extent, during the injection process.

[0030] The heating element 3 is arranged in the cavity during injection molding, with its first surface 3a facing the cavity. The second surface 3b rests against the first injection-molded part 2a. As the molten plastic 4 is injected into the cavity, the heating element 3 is back-molded. In this process, the first surface 3a is covered by the molten plastic 4. The second surface 3b remains essentially free of the molten plastic 4.

[0031] In the illustrated embodiment, the connector 7 is also partially overmolded by the plastic melt 4. The connection between the connector 7 and the heating element 3 is encased by the plastic melt 4 during injection molding.

[0032] After injection of the polymer melt 4, the polymer melt 4 solidifies by cooling and / or a thermal reaction. The solidified polymer melt 4 forms a base body 5. The heating element 3 is arranged on the surface of the base body 5. The heating element 3 is enclosed by the base body 5.

[0033] Fig. 4 Figure 5 shows the base body 5, the heating element 3, and the connector 7 after they have been removed from the injection mold 2. The connection between the connector 7 and the heating element 3 is located in the base body 5. The heating element 3 is enclosed by the base body 5. The second surface 3b of the heating element 3 is flush with a surface of the base body 5. The second surface 3b and the adjacent surface of the base body 5 form a visible side.

[0034] Figure 5Figure 1 shows a finished interior component 1 in a perspective view. To complete the interior component 1, a cover 6 was applied to the visible side in a further process step. For better understanding, a portion of the cover 6 is shown in Fig. 5 not shown, so that at least part of the heating element 3, in particular the second surface 3b and the heating strands 3c, as well as part of the gold body 5 is visible.

[0035] The cladding 6 covers the heating element 3 and at least part of the surface of the base body 5. Preferably, the entire visible side is covered by the cladding. The second surface 3b of the heating element 3 rests against the inside of the cladding 6. In the finished interior component 1, the heating element 3 is no longer visible to a user.

[0036] The Figs. 6-8Figure 1 shows various process steps of a manufacturing process according to a second embodiment in chronological order. In the manufacturing process according to the second embodiment, the heating element 3 differs from the heating element 3 of the first embodiment in that the connector 7 is connected to the heating element 3 via a conductor element 8. The conductor element 8 is preferably one or more electrical conductors.

[0037] Analogous to the in Fig. 2In the illustrated process step, the heating element 3 is arranged in an injection mold 2. The heating element 3 is placed onto a first injection mold part 2a of the injection mold 2. A portion of the conductor element 8 is also placed onto the first injection mold part 2a along with the heating element 3. In areas where the conductor element 8 is bent due to curvature in the injection mold 2, the injection mold 2 may have support ribs. In the illustrated embodiment, the first injection mold part 2a may, in particular, have a support rib in the area of ​​the lower right corner, where the conductor element 8 is bent upwards by 90°.

[0038] After the heating element 3 is positioned in the injection mold 2, in particular in the first injection mold part 2a, a second injection mold part 2b of the injection mold 2 is positioned opposite the heating element 3. The second injection mold part 2b comprises a nozzle for the plastic melt 4. Unlike the first embodiment, the manufacturing process according to the second embodiment does not require a hold-down device 9 in the second injection mold part 2b.

[0039] As in Fig. 7As shown, the injection mold 2, in particular the first injection mold part 2a and the second injection mold part 2b, forms a cavity. The plastic melt 4 is injected into this cavity. The plastic melt 4 can, for example, be a heated rigid plastic 4, in particular a heated thermoplastic 4. The injection preferably comprises a single injection process, so that the plastic melt 4 does not cool down, or only cools down to an insignificant extent, during the injection process.

[0040] The heating element 3 and part of the conductor element 8 are positioned within the cavity, specifically within the mold cavity, during injection molding. As the molten plastic 4 is injected into the cavity, the heating element 3 and part of the conductor element 8 are back-molded. The connector 7 and the portion of the conductor element 8 not located within the cavity remain free of the molten plastic 4. The surface of the heating element 3 that contacts the first injection-molded part 2a remains substantially free of the molten plastic 4.

[0041] After injection of the polymer melt 4, the polymer melt 4 solidifies by cooling and / or a thermal reaction. The solidified polymer melt 4 forms a base body 5. The heating element 3 is arranged on the surface of the base body 5. The heating element 3 is enclosed by the base body 5.

[0042] Figure 8Figure 1 shows a sectional view of the finished interior component 1. To complete the interior component 6, a cover 6 was applied after the base body 5 with the heating element 3 was removed from the injection mold 2. In the finished interior component 1, the heating element 3 and part of the conductor element 8 are positioned between the cover 6 and the base body 5. The cover 6 conceals the heating element 3, part of the conductor element 8, and at least part of the surface of the base body 5.

[0043] The connector 7 remains accessible via the part of the conductor element 8 not enclosed in the base body 5 and is movable relative to the interior component 1. This has the advantage that the connector 7 can be moved flexibly and freely relative to the interior component 1 during assembly, for example in a vehicle, thus facilitating the assembly of the interior component 1. REFERENCE MARK LIST

[0044] 1 Interior component 2 Injection mold 2 First injection molded part 2 Second injection molded part 3 Heating element 3 First surface of the heating element 3 Second surface of the heating element 3 Heating wire 4 Molten plastic 5 Base body 6 Cover 7 Connector plug 8 Conductor element 9 Holding device

Claims

1. Method for producing an interior component (1) for vehicles, comprising the following method steps: a) arranging a heating element (3) in an injection mold (2), b) injecting a plastic melt (4) into the injection mold (2) in order to produce a base body (5) on the surface of which the heating element (3) is arranged, c) removing the base body (5) with the heating element (3) from the injection mold (2) after the plastic melt (4) has solidified, d) applying a covering (6) in order to cover the heating element (3) and at least a part of the surface of the base body (5), wherein a connector plug (7) for control and / or power supply is arranged on the heating element (3), wherein the connector plug (7) and the heating element (3) are back-injected together with the plastic melt (4) during the injection process, characterized in that the injection mold (2) comprises a holding-down device (9) and the holding-down device (9) holds down the connector plug (7) during the injection process.

2. Method according to claim 1, characterized in that the injecting of the plastic melt (4) is a single injection process.

3. Method according to any of the preceding claims, characterized in that the heating element (3) is fixed in the injection mold (2) before the plastic melt (4) is injected.

4. Method according to any of the preceding claims, characterized in that the heating element (3) has a first surface (3a) and a second surface (3b) opposite the first surface (3a), wherein the first surface (3a) is covered by the plastic melt (4) during the injection process and the second surface (3b) remains substantially free from the plastic melt (4).

5. Method according to claim 4, characterized in that the second surface (3b), after the application of the covering (6), faces the covering (6).

6. Method according to any of the preceding claims, characterized in that the connector plug (7) and the heating element (3) are back-injected with the plastic melt (4) in such a way that the connector plug (7) is only partially enclosed by the plastic melt (4).

7. Method according to any of claims 1-5, characterized in that the heating element (3) is connected via a conductor element (8) to a connector plug (7) for control and / or power supply, wherein the heating element (3) and the conductor element (8) are back-injected together with the plastic melt (4) during the injection process in such a way that at least a part of the conductor element (8) and the connector plug (7) are not enclosed by the plastic melt (4).

8. Method according to claim 7, characterized in that the heating element (3) and at least a part of the conductor element (8) are arranged between the covering (6) and the base body (5) after the application of the covering (6).