Method for producing interconnected components of an interior-trim part, and interconnected components of an interior-trim part

Abstract

The invention relates to a method for producing interconnected components of an interior-trim part which comprise at least one at least partially translucent decorative layer (11), at least one at least to some extent transparent body (10) and at least one opaque structural part (12), wherein the at least to some extent transparent body (10) and the opaque structural part (12) are produced as a multi-component structural part by the plastics injection-moulding process, characterized by at least the following method steps: producing the opaque structural part (12) by the plastics injection-moulding process in a first cavity of a mould (100), transferring the opaque structural part (12) into at least part of a second cavity of the mould (100), wherein a carrier film (T), carrying the translucent decorative layer (11), is positioned in another part of the second cavity in such a way that an intermediate space (Z) remains between the decorative layer (11) and the opaque structural part (12), producing the at least to some extent transparent body (10) in the intermediate space (Z) by a plastics injection-moulding process, removing from the mould (100) a composite part (V) comprising the at least partially translucent decorative layer (11), the at least to some extent transparent body (10) and the opaque structural part (12).

Description

[0001] Description

[0002] Method for producing interconnected components of an interior trim part and interconnected components of an interior trim part

[0003] The invention relates to a method for producing interconnected components of an interior trim part. The invention also relates to interconnected components of an interior trim part.

[0004] From WO 2021 / 219552 A1, both a method having the features of the preamble of patent claim 1 and an interior trim part having the features of the preamble of patent claim 7 have become known.

[0005] In this process, a decorative layer located on a carrier film is first back-injected with a translucent material in a plastic injection mold. After the translucent material has cured, a translucent body is created, which is firmly bonded to the decorative layer. After the plastic injection mold is opened, one half of the mold, on which the translucent body with the decorative layer is located, is turned 180 degrees. Another half of an injection mold is then fed to the turned half of the plastic injection mold, forming a second cavity above the translucent body. The second cavity is then filled with an opaque material using the plastic injection molding process. After curing, interconnected components of an interior trim part are created, having the features of the preamble of patent claim 7.

[0006] Against this background, the present invention is based on the object of creating an alternative to the known methods.

[0007] A further object of the invention is the alternative provision of interconnected components of an interior trim part.

[0008] The present objects are achieved by a method having the features of patent claim 1, and by interconnected components of an interior trim part having the features of patent claim 7. The invention is initially based on a method for producing interconnected components of an interior trim part. The interconnected components comprise at least one decorative layer that is translucent at least in some areas, at least one body that is translucent at least in some sections, and at least one opaque component. The body that is translucent at least in some sections and the opaque component are manufactured as a multi-component component using a plastic injection molding process.A multi-component component within the meaning of the invention is to be understood as a component which has at least two different material components, each material component being manufactured using the plastic injection molding process.

[0009] The process according to the invention is characterized by the following process steps:

[0010] • The opaque component is first manufactured using a plastic injection molding process in a first cavity of a tool.

[0011] • The opaque component is then transferred into at least part of a second cavity of a mold. A carrier film carrying the translucent decorative layer is positioned in another part of the second cavity such that, when the mold is closed, a gap remains between the decorative layer and the opaque component.

[0012] • This is followed by the production of the at least partially translucent body in the said space by a plastic injection molding process.

[0013] • Finally, a composite part comprising the decorative layer which is at least partially translucent, the body which is at least partially translucent and the opaque component is removed from the tool.

[0014] These process steps provide the basic prerequisite for the process being suitable for series or even mass production. The process according to the invention can be carried out cost-effectively and is well suited for manufacturing the interconnected components in series production with large quantities. The composite part that can be removed or removed from the tool preferably consists of the decorative layer that is at least partially translucent, the body that is at least partially translucent, and the opaque component. Such a process makes it possible for the part of the tool on which the carrier film with the decorative layer is located not to have to be moved during the process. This ensures reliable positioning or repositioning of the decorative layer for each subsequent work step.

[0015] A very fast positioning of the decorative layer, which thus significantly accelerates the process, can be achieved by passing the carrier film carrying the decorative layer through the tool as part of an unrollable endless film.

[0016] In such a further development, it is also expedient for the carrier film to be unrolled on one side of the tool and rolled up on an opposite side of the tool. The unrolling side can preferably be arranged above the tool, and the rolling side can preferably be arranged below the tool.

[0017] To further accelerate and ensure process reliability, the process can be carried out if the opaque component is transferred from the first cavity into at least a portion of the second cavity in one and the same tool. In other words, a tool having multiple, in particular two, stations is advantageously used. Deviating from the exemplary embodiment, a transfer to a second, separate tool in a separate production machine is also possible (not shown).

[0018] In the first station, which forms the first cavity in the mold, the opaque component is first produced by injecting opaque plastic material. The second station of the mold then forms the second cavity, into which the finished, opaque component is then placed. In the second cavity, translucent plastic material is then injected into the space formed by the decorative layer and the opaque component.

[0019] It contributes to process reliability and to material-friendly treatment of the opaque component if the transfer of the opaque component from the first cavity into at least a part of the second cavity is carried out by means of a transfer gripper acting mechanically and / or by means of negative pressure on the opaque component.

[0020] The speed of the method can be further increased if the opaque component is first pulled out of the first cavity during the transfer from the first cavity into at least one part of the second cavity, then moved transversely, preferably exclusively transversely, aligned with the second cavity and finally guided into at least one part of the second cavity.

[0021] As already stated, the present invention also aims to provide components of an interior trim part that are connected to one another (to form a composite part). Such components of an interior trim part comprise at least one decorative layer that is at least partially translucent, at least one body that is at least partially translucent, and at least one opaque component. The at least partially translucent body and the at least one opaque component are designed as a multi-component component produced using a plastic injection molding process. According to the invention, the components of the interior trim part are produced using the described method according to the invention. As described, the components can thus be produced cost-effectively using a series or even mass-production process.

[0022] A preferred embodiment of the invention is illustrated in the figures and is explained in more detail in the following description with reference to the figures. This also makes further features and advantages of the invention clear. Identical reference symbols, even in different figures, refer to identical, comparable or functionally identical components. Corresponding or comparable properties and advantages are achieved even if a repeated description or reference to them is not made. The figures are not, or at least not always, to scale. In some figures, proportions or distances may be exaggerated in order to emphasize features of an embodiment more clearly. If the term “and / or” is used in a list of two or more terms or objects, this can mean that any one of the listed terms or objects can be used on its own.It can also mean that any combination of two or more of the listed terms or objects can be used.

[0023] They show, schematically

[0024] Fig. 1a to 1i show the essential process steps of an embodiment of the process according to the invention, Fig. 2 shows a tool together with the two cavities used for the process,

[0025] Fig. 3 a sectional view of an interior trim part, which is made with the help of the

[0026] Process components, according to section III of Fig. 4,

[0027] Fig. 4 a view of the interior trim part according to view IV of Fig. 3 and

[0028] Fig. 5 the interior of a motor vehicle with interior trim parts, the

[0029] Components which are produced by the process according to the invention.

[0030] Reference is first made to Figures 1a to 1i.

[0031] The figures depict a tool 100 for performing a plastic injection molding process. Tool 100 comprises a tool part 101 and a tool part 102. Only feed channels 103 and 104 for supplying molten plastic granulate to a respective cavity to be filled are indicated in the figures. Other components that are not necessary for understanding the invention are not depicted.

[0032] In Fig. 1a, the mold 100 is shown in the closed state. The mold parts 101 and 102 are thus brought together. This creates a first cavity K1 in the mold 100.

[0033] Fig. 1b shows the state in which the first cavity K1 is filled with plastic material via the feed channels 103 and the plastic material has already cooled to an opaque component 12.

[0034] Fig. 1c shows how the tool 100 was subsequently opened by a movement B1 of the tool part 101. It also shows how the opaque component 12 is pulled out of the tool part 102 with the aid of a transfer gripper 150 in a movement B3. The transfer gripper 150 was previously placed on the opaque component 12 in a movement B2 with the tool 100 open. The transfer gripper 150 acts on the opaque component 12 by means of vacuum and / or mechanical means such that the opaque component 12 can be moved by the transfer gripper 150 in any desired manner and with minimal damage to the component.

[0035] The movement B3 of the transfer gripper 150 continues until the opaque component 12 is completely removed from the tool part 102. This is shown in Fig. 1d, whereby the tool part 101 is no longer shown for the sake of simplicity.

[0036] Subsequently, the opaque component 12 is moved transversely (in this case, perpendicular to the plane of the drawing) over the tool part 102 with the aid of the transfer gripper 150 until it aligns with parts K2a and K2b of a second cavity. Once this is the case, the opaque component 12 is inserted into part K2a of the second cavity, which is formed by the tool part 102, by means of a movement B5. The other part K2b of the second cavity is in turn formed in the tool part 101 (see Figs. 1e and 1f).

[0037] Additionally, it can be seen that a decorative layer 11 located on a carrier film T is positioned in part K2b of the second cavity. For the sake of simplicity, the carrier film T and the decorative layer 11 (although they form two layers) are shown as a single line. The decorative layer 11 is translucent, at least in some areas.

[0038] Furthermore, it can be seen that the carrier film T carrying the decorative layer 11 is guided through the tool 100 as a component of an unrollable continuous film. In particular, the carrier film T is unrolled from a roll 160 on one side of the tool 100, preferably above the tool 100, and rolled onto a roll 161 on an opposite side of the tool 100, preferably below the tool 100.

[0039] Fig. 1f shows that the carrier film T together with the decorative layer 11 is positioned in a preferably vertical movement B7 before each subsequent operation, and then the tool 100 is closed again in a movement B6. Fig. 1g shows the closed state of the tool 100. A gap Z is formed between the decorative layer 11 located on the carrier film T and the opaque component 12.

[0040] Subsequently, molten plastic granules (not shown) are fed into the intermediate space Z in an injection molding process via feed channels 104. The supplied plastic granules are translucent and, after curing, form a translucent body 10 (see Fig. 1h).

[0041] Fig. 1h shows how the tool 100 is moved apart to form the translucent body 10 after the translucent plastic material has hardened, and how a composite part V consisting of the decorative layer 11, the translucent body 10 and the opaque component 12 is then moved out of the tool part 102.

[0042] It should be noted that by filling the intermediate space Z with molten plastic material (see Fig. 1g), the decorative layer 11 has bonded so firmly to the translucent body 10 that upon opening the tool 100, the decorative layer 11 bonded to the translucent body 10 is completely detached from the carrier film T. For the sake of clarity, a handling tool for moving the composite part V is not shown in Fig. 1h.

[0043] Finally, Fig. 1i shows the state in which the composite part V has been completely removed from the tool 100. It can also be seen that the opaque component 12 has welding ribs 12a for further fastening the composite part V to other components, as will be explained later.

[0044] To better understand the method, another perspective of the tool 100 is shown in Fig. 2, extremely schematically. This figure is intended only to clarify that the first cavity K1 and the second cavity formed from the parts K2a and K2b are located in one and the same tool 100. The feed channels 103 and 104 are only indicated schematically. Furthermore, the opaque component 12 located in the first cavity K1 is indicated. After the tool 100 is opened and removed from the tool part 102, this is moved by the transfer gripper 150, also indicated, in a transverse movement B4 to the parts K2a and K2b of the second cavity and aligned with them (see also Figs. 1d to 1g). This figure also shows that the carrier film T is guided through the tool 100 from one side to the opposite side of the tool 100.

[0045] In the present embodiment, the carrier film T is guided through the tool 100 from top to bottom in the movement B7.

[0046] Due to the procedure adopted, namely to first inject the opaque component 12 in the first cavity K1 and only after the opaque component 12 has been transferred into the second cavity of the tool 100 to back-inject the translucent decorative layer 11 with translucent plastic material, the carrier film T together with the rollers 160, 161 (see Fig. 1f to 1h) does not need to be pivoted or rotated.

[0047] Rather, the carrier film T can remain aligned over the parts K2a, K2b of the second cavity and, for positioning before a subsequent work step, only needs to be moved through the tool 100 until the carrier film T with the decorative layer 11 thereon is again positioned exactly at the level of the parts K2a, K2b of the second cavity.

[0048] The general structure of an interior trim part 1 is now described in more detail with reference to Fig. 3, which has interconnected components that were produced by means of the method according to the invention (see also Fig. 1i).

[0049] The figure shows that the interior trim part 1 has the translucent body 10. The translucent body 10 is preferably transparent, i.e., crystal-clear. It is also conceivable for the translucent body 10 to be colored and / or merely translucent.

[0050] The translucent body 10 is also flat. Its surface area is thus several times greater than its thickness.

[0051] One side of the translucent body 10 is covered by the decorative layer 11, which is translucent at least in some areas. The decorative layer 11 thus forms a visible side S for a vehicle occupant located in the interior of a motor vehicle K (see also Fig. 5). The decorative layer 11 is preferably a decorative layer produced using the so-called IMD process (IMD = In-Mold Decoration). It can consist of one or more layers of paint or varnish. The decorative layer 11 is translucent in some areas and can thus contain a translucent pattern, translucent characters and / or symbols, or the like.

[0052] As already explained in the process, the translucent body 10 is injection-molded onto the decorative layer 11, i.e. firmly connected to the decorative layer 11.

[0053] Furthermore, the translucent body 10 is covered on its rear side in the edge area with the opaque component 12. As already explained, the opaque component 12 is also injection-molded onto the translucent body 10, thus also firmly connected to the translucent body 10.

[0054] The translucent body 10 and the opaque component 12 thus form a multi-component component MK consisting of several permanently connected components. In particular, the multi-component component MK is a two-component component consisting of a translucent material component and an opaque material component. A peripheral edge of the multi-component component MK is designated R.

[0055] The opaque component 12 has a frame-like outline. This creates a transillumination area LB through which light rays L can pass. The light rays L can be generated by one or more light sources 15 (preferably light-emitting diodes) located in the interior trim part 1.

[0056] The multi-component component MK, or its opaque body 12, is firmly connected, preferably welded, to an equally opaque holder 13. The holder 13 can preferably be provided with a reflective inner coating and thus act as a reflector.

[0057] For this purpose, the opaque component 12 has welding ribs 12a, which are inserted through through-openings 13c of the holder 13 and are converted into welding projections 12a' by the welding process, thus creating a positive connection between these components. In this way, a substantially closed receiving space 13a is formed between the multi-component component MK and the holder 13, in which a light guide 14 is accommodated.

[0058] The holder 13 therefore serves to hold the light guide 14 in a manner not shown in detail here. The light guide 14 is also flat and rests on a base 13b of the holder 13.

[0059] The receiving space 13a is preferably dimensioned such that a clear distance a remains between the light guide 14 and the light-permeable body 10.

[0060] The light guide 14 is also preferably designed as a transparent body. It may have light extraction structures (not shown in detail) on its rear side facing away from the translucent body 10, via which light coupled laterally into the light guide 14 by the illuminants 15 is extracted again in the direction of the translucent body 10. The holder 13, designed as a reflector, can also contribute to this.

[0061] The figure shows that the translucent body 10 is completely covered by the decorative layer 11 on the visible side S. In particular, the decorative layer 11 extends up to the opaque component 12. The decorative layer 11 rests against the opaque component 12 with one edge or end face.

[0062] Preferably, the translucent body 10, the opaque component 12 and the decorative layer 11 are designed such that in the region of the said circumferential edge R, a surface 11o of the decorative layer 11 and a surface 12o of the opaque component 12 abut one another flush.

[0063] Deviating from the exemplary embodiment, however, it is also conceivable for the translucent body 10 to be somewhat smaller, such that the aforementioned surfaces 11o and 12o do not abut flush with one another, but rather result in a so-called shingling. However, the shingling is only achieved in such a way that the opaque component 12 protrudes beyond the translucent body 10 at the edges.

[0064] In any case, it should be emphasized that the decorative layer 11 is brought up to the opaque component 12. Thus, when the decorative layer 11 is brought up to the opaque component 12, no gap remains between the decorative layer 11 and the opaque component 12 through which unwanted scattered light could escape.

[0065] Such a construction results in a photometric encapsulation of the translucent body 10 in the region of the edge R of the interior trim part 1 by the decorative layer 11 on one side and by the opaque component 12 on the other side.

[0066] This creates the basic prerequisite for a very efficient avoidance of unwanted stray light.

[0067] As is further clear from Fig. 3, the multi-component component MK creates a circumferential overlapping area ÜB in which the material components of the translucent body 10 and the opaque component 12 lie against one another, forming a material interface G.

[0068] It is evident from the illustration that the material interface G, starting from the circumferential edge R of the multi-component component MK, extends inwards at least in sections in such a way that the material of the translucent body 10 continuously increases, whereas the material of the opaque component 12 continuously decreases.

[0069] Such a material flow has a very positive effect on the flow properties of the materials during the manufacturing process, whereby material defects, such as discoloration in the translucent body 10, can be avoided as far as possible.

[0070] Furthermore, several rear fastening projections 13d should be mentioned, at the ends of which the interior trim part 1 can be fastened in the interior of a motor vehicle by means of fastening means 13e (e.g. screw connections).

[0071] In Fig. 4, the interior trim part 1 is shown in a plan view of its outline seen from the visible side S.

[0072] The frame-like, opaque component 12 is indicated by dashed lines, forming the window-like transillumination area LB and the peripheral overlap area ÜB. Also indicated is the elongated, flat light guide 14, on whose opposite ends the lamps 15 are arranged, whose light can be coupled into the light guide 14.

[0073] Finally, reference is made to Fig. 5. This figure shows the interior of a motor vehicle K in the area of ​​a cockpit 2. An instrument panel 3, a steering wheel 4, side door panels 5, and a center console 6 can be seen in the interior of the motor vehicle K. Furthermore, several elongated, strip-like interior trim parts 1 are shown, which extend horizontally across the instrument panel 3 and along the door panels 5. Each of the interior trim parts 1, as explained, has interconnected components that were manufactured with the aid of the method according to the invention.

[0074] List of reference symbols

[0075] 1 interior trim part cockpit instrument panel steering wheel door trim center console

[0076] 10 translucent body

[0077] 11 decorative layer

[0078] 11o surface

[0079] 12 opaque component

[0080] 12a Welding ribs

[0081] 12a' Schweißbuckel

[0082] 12o surface

[0083] 13 opaque holder

[0084] 13a Recording room

[0085] 13b Floor

[0086] 13c Passage opening

[0087] 13d mounting projection

[0088] 13e Fasteners

[0089] 14 light guides

[0090] 15 light sources, LEDs

[0091] 100 tools

[0092] 101 tool part

[0093] 102 tool part

[0094] 103 feed channels

[0095] 104 feed channels

[0096] 150 transfer grippers

[0097] 160 roll

[0098] 161 roll a clear distance

[0099] B1-B7 Movements of the tool parts

[0100] G Material interface

[0101] K Motor vehicle K1 first cavity

[0102] K2a Part of a second cavity

[0103] K2b Part of a second cavity

[0104] L light beam

[0105] LB fluoroscopy area

[0106] MK multi-component component

[0107] R surrounding edge

[0108] S visible side

[0109] T carrier film

[0110] ÜB coverage area

[0111] V Composite part

[0112] Z space

Claims

Claims: Method for manufacturing interconnected components of an interior trim part (1), comprising at least one at least partially translucent decorative layer (11), at least one at least partially translucent body (10) and at least one opaque component (12), wherein the at least partially translucent body (10) and the opaque component (12) are manufactured as a multi-component component (MC) using plastic injection molding, characterized by at least the following process steps: • Production of the opaque component (12) using the plastic injection molding process in a first cavity (K1) of a tool (100), • Transferring the opaque component (12) into at least one part (K2a) of a second cavity of a tool (100), wherein in another part (K2b) of the second cavity a carrier film (T) carrying the translucent decorative layer (11) is positioned such that a space (Z) remains between the decorative layer (11) and the opaque component (12), • Production of the at least partially translucent body (10) in the space (Z) by a plastic injection molding process • Removal of a composite part (V) comprising the at least partially translucent decorative layer (11), the at least partially translucent body (10), and the opaque component (12) from the tool (100). Method according to the preceding claim, characterized in that the carrier film (T) carrying the translucent decorative layer (11) is guided through the tool (100) as part of a continuous rollable film. Method according to claim 2, characterized in that the carrier film (T) is unwound on one side of the tool (100) and wound up on the opposite side of the tool (100). A method according to any of the preceding claims, characterized in that the transfer of the opaque component (12) from the first cavity (K1) to at least one part (K2a) of the second cavity takes place in one and the same tool (100). A method according to any of the preceding claims, characterized in that the transfer of the opaque component (12) from the first cavity (K1) to at least one part (K2a) of the second cavity takes place by means of a transfer gripper (150) that acts mechanically and / or by suction on the opaque component (12).Method according to one of the preceding claims, characterized in that the opaque component (12) is first withdrawn from the first cavity (K1) during the transfer from the first cavity (K1) to at least one part (K2a) of the second cavity, then moved transversely, aligned with the second cavity and finally introduced into at least one part (K2a) of the second cavity.Interconnected components of an interior trim part (1), comprising at least one at least partially translucent decorative layer (11), at least one at least partially translucent body (10) and at least one opaque component (12), wherein the at least partially translucent body (10) and the at least one opaque component (12) are designed as a multi-component component (MC) manufactured by plastic injection molding, characterized in that the said components (10, 11, 12) of the interior trim part (1) are manufactured by the method according to one of the preceding claims.

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