U.S. patent application number 13/311879 was filed with the patent office on 2012-03-29 for molded skins produced from a plurality of plastic materials having improved properties during airbag deployment at low temperatures.
This patent application is currently assigned to JOHNSON CONTROLS INTERIORS GMBH & CO. KG. Invention is credited to Walter ANDRE, Heribert DECHER, Michael HEIDKAMP, Zbigniew PARZELSKI, Marko SANDER, Christian SEIDEL.
Application Number | 20120076998 13/311879 |
Document ID | / |
Family ID | 39711069 |
Filed Date | 2012-03-29 |
United States Patent
Application |
20120076998 |
Kind Code |
A1 |
DECHER; Heribert ; et
al. |
March 29, 2012 |
MOLDED SKINS PRODUCED FROM A PLURALITY OF PLASTIC MATERIALS HAVING
IMPROVED PROPERTIES DURING AIRBAG DEPLOYMENT AT LOW
TEMPERATURES
Abstract
The invention relates to a method and a device for the
production of plastic molded skins, which are formed by
consecutively performing a plurality of partial melting processes
of a plurality of plastic materials, wherein the first plastic
material is applied to the mold as a plastic powder in a
centrifugal molding method and the second plastic material by a
spraying method.
Inventors: |
DECHER; Heribert;
(Barsinghausen, DE) ; ANDRE; Walter; (Bomlitz,
DE) ; PARZELSKI; Zbigniew; (Braunschweig, DE)
; SANDER; Marko; (Leipzig, DE) ; SEIDEL;
Christian; (Hannover, DE) ; HEIDKAMP; Michael;
(Dedelstorf, DE) |
Assignee: |
JOHNSON CONTROLS INTERIORS GMBH
& CO. KG
Grefrath
DE
|
Family ID: |
39711069 |
Appl. No.: |
13/311879 |
Filed: |
December 6, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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12450240 |
Nov 13, 2009 |
8101111 |
|
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PCT/EP2008/053284 |
Mar 19, 2008 |
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13311879 |
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Current U.S.
Class: |
428/201 ;
264/241; 428/195.1 |
Current CPC
Class: |
B29C 41/08 20130101;
Y10T 428/3158 20150401; B29C 41/46 20130101; B29L 2031/3008
20130101; B60R 21/215 20130101; B29K 2995/0021 20130101; Y10T
428/24851 20150115; B29C 41/22 20130101; B29C 41/18 20130101; B29L
2031/3014 20130101; B29L 2031/3038 20130101; Y10T 428/24802
20150115 |
Class at
Publication: |
428/201 ;
264/241; 428/195.1 |
International
Class: |
B32B 27/08 20060101
B32B027/08; B32B 27/30 20060101 B32B027/30; B32B 27/40 20060101
B32B027/40; B29C 41/04 20060101 B29C041/04 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 21, 2007 |
DE |
10 2007 013 449.7 |
Jan 16, 2008 |
EP |
PCT/EP2008/050413 |
Claims
1. A molded plastics skin for motor-vehicle-interior parts, e.g.
dashboards and door cladding, produced by a process where the
molded plastics skins are constructed by successive repeated
continuous fusion of a plurality of plastics materials of different
properties at surface regions of a heated mold, wherein a) first,
the first plastics material in the form of plastics powder is
applied by a rotational sintering process (rotation of a powder
box) to the mold, and the mold is heated to, and kept at, a first
temperature of from 180 to 240 degrees C. during the fusion and
gelling of the plastics powder, and so the first plastics powder
applied adheres by fusion to the mold, b) then a second plastics
material is applied by a spray process, and the second plastics
material here adheres by fusion to the first plastics powder, and
then the mold is adjusted to a second temperature in such a way
that the plastics material applied by spraying is heated to, and
kept at, a temperature of 60 to 250 degrees C., and the first
plastics powder and the second plastics material here react to
completion and fuse to give a homogeneous molded plastics skin, and
c) the resultant molded plastics skin is cooled, and so it can be
removed from the mold, and the layer thickness applied of the first
plastics powder applied to the mold is from 200 to 15 000 .mu.m,
and the layer thickness applied of the second plastics material
applied is from 50 to 1700 .mu.m; and wherein the second plastics
material is applied to the reverse side of the first layer in
regions which have been isolated with the aid of fillets from the
remaining regions of the reverse side; and wherein an outer layer
which is external within the plastics skin and has been applied by
rotational sintering processes to the mold is composed of polyvinyl
chloride, and a backing layer situated thereunder within the
plastics skin, and applied by spraying to the mold is composed of a
polyurethane.
2. The molded plastics skin as claimed in claim 1, wherein a lower
layer is composed of material having low-temperature
flexibility.
3. The molded plastics skin as claimed in claim 2, wherein the
lower layer is composed of acrylates.
4. The molded plastics skin as claimed in claim 2, wherein the
lower layer is composed of unsaturated polyolefins.
5. The molded plastics skin as claimed in claim 2, wherein the
lower layer is composed of polyurethane.
6. A molded plastics skin for motor-vehicle-interior parts, e.g.
dashboards and door cladding, produced by a process where the
molded plastics skins are constructed by successive repeated
continuous fusion of a plurality of plastics materials of different
properties at surface regions of a heated mold, wherein a) first,
the first plastics material in the form of plastics powder is
applied by a rotational sintering process (rotation of a powder
box) to the mold, and the mold is heated to, and kept at, a first
temperature of from 180 to 240 degrees C. during the fusion and
gelling of the plastics powder, and so the first plastics powder
applied adheres by fusion to the mold, b) then a second plastics
material is applied by a spray process, and the second plastics
material here adheres by fusion to the first plastics powder, and
then the mold is adjusted to a second temperature in such a way
that the plastics material applied by spraying is heated to, and
kept at, a temperature of 60 to 250 degrees C., and the first
plastics powder and the second plastics material here react to
completion and fuse to give a homogeneous molded plastics skin, and
c) the resultant molded plastics skin is cooled, and so it can be
removed from the mold, and the layer thickness applied of the first
plastics powder applied to the mold is from 200 to 15 000 .mu.m,
and the layer thickness applied of the second plastics material
applied is from 50 to 1700 .mu.m; and wherein during the
application of the second plastics material to the reverse side of
the first layer, the regions not to be coated with the second
plastics material have been covered with the aid of masks or
covering elements; and wherein an outer layer which is external
within the plastics skin and has been applied by rotational
sintering processes to the mold is composed of polyvinyl chloride,
and a backing layer situated thereunder within the plastics skin,
and applied by spraying to the mold is composed of a polyurethane.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of and Applicant claims
priority under 35 U.S.C. .sctn..sctn.120 and 121 of parent U.S.
patent application Ser. No. 12/450,240 filed Nov. 13, 2009, which
application is a national stage application under 35 U.S.C.
.sctn.371 of PCT/EP2008/053284 filed on Mar. 19, 2008, which claims
priority under 35 U.S.C. .sctn.119 of International Application No.
PCT/EP2008/050413 filed on Jan. 16, 2008 and German Application No.
10 2007 013 449.7 filed Mar. 21, 2007, the disclosures of each of
which are hereby incorporated by reference. The international
application under PCT article 21(2) was not published in
English.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a process and an apparatus for the
production of molded plastics skins, in particular for
motor-vehicle-interior parts e.g. dashboards and door cladding,
where the molded plastics skins are constructed by successive
repeated continuous fusion of a plurality of plastics materials of
different properties at surface regions of a heated mold.
[0004] 2. The Prior Art
[0005] There are known processes of this type for the production of
molded plastics skins by successive fusion of a plurality of
plastics powders in the production of dual-color molded plastics
skins, very generally using masks for the covering of individual
regions.
[0006] EP 0 972 625 A1 describes in this connection a device,
namely a mold for the production of dual-color molded plastics
skins for motor-vehicle parts, i.e. in essence dashboards, door
cladding, etc. The production process applied here for the
production of sinter foils/slush skins is rotational sintering in
which there is a plastics powder in the rotating mold and this
fuses onto appropriately heated parts of the wall of the mold.
[0007] The device revealed here has two different lower parts of
the molding boxes. The lower parts of the molding boxes, which also
respectively comprise the powder bed, have been releaseably
arranged with respect to the single upper molding box, onto which
the plastics powder fuses. For the production of dual-color molded
plastics skins, the first lower molding box then has a hollow
rounded protruding element, protruding into the interior, and
covering parts of the upper mold box--in the manner of a mask.
[0008] In a first operation, rotation sintering is used to fuse a
powder of a first color, and those regions of the upper molding box
which are situated under the hollow rounded covering element are
not impacted here and therefore remain free from powder.
[0009] Prior to a second operation, the first lower molding box is
replaced by a second lower molding box, which comprises a powder of
another color and has no covering elements. During the rotational
sintering process subsequently repeated, the powder with the new
color fuses on the previously uncovered region of the upper molding
box and on the reverse side of the existing molded skin. After
cooling and removal of the molded skin from the mold, a dual-color
molded plastics skin is obtained on the future external side facing
toward the mold.
[0010] To this end, during the first operating step, the hollow
rounded covering element protruding into the interior and
associated with the lower molding box has to be carefully sealed
with respect to the upper molding box, in order that no sinter
powder of the first color passes into the covered region. For this
purpose, the edges of the hollow rounded protruding element have
sealing elements which have been designed to be elastic and/or
hollow; pressure or elastic media can, if appropriate, be applied
to the interior of these.
[0011] Disadvantageous here are the high operating cost which is
required for the changeover of the lower molding boxes and which
arises through the need to use covering elements/masks, and also
the difficulty in achieving sealing of the mask, i.e. sealing
between the edges of the hollow rounded covering element protruding
into the interior and associated with the lower molding box and the
inner side of the upper molding box. Leaks and uneven seating,
which can blur boundaries between the colors here, are caused by
thermal expansion, and by varying pressure conditions which affect
the seals and which result from complicated internal shapes of the
upper molding box.
[0012] A similar situation applies with the powder sintering
process disclosed by WO 2004/082917, with a plurality of
powder-application steps. Essential to the invention in the case of
this process is the use of a mask and, located on the mask, an
inflatable seal which is laterally in contact with and between
delimiting fillets, with inflation automatically providing firm
clamping of the mask. A first powder-application step is thus first
carried out, while the mask is in a clamped position, and then the
mask is removed, and powder sintering is again carried out. Even if
the powder boxes required for this purpose can per se be of simpler
structure, the handling of a plurality of heavy boxes with
different types of powder has to be considered rather
disadvantageous for mass production.
[0013] U.S. Pat. No. 5,234,653 describes a process for the
production of multicolor molded plastics skins by sintering, using
a plastics powder in a mold divided by separating walls and fusing
the powder on appropriately heated parts of the wall of the mold.
The separating walls are fixed here by way of pressure systems
within the separating walls. By virtue of the pressure system, the
separating walls are braced between a lower and upper mold with the
aid of sealing profiles, thus providing reliable sealing during the
respective sintering procedures using different color powders.
[0014] Here again, a disadvantage is that relatively complicated
fixing of the separating walls has to be undertaken, and a high
pressure force is also required for the pressure systems.
[0015] DE 694 28 377 T2 discloses a process and an apparatus for
the conduct of a spray molding process for a dual-color process in
which, in the upper region, a mask is placed onto a fillet which
delimits certain regions of a spray mold and isolates them from the
remaining regions of the surface. The edges of the mask here
project toward the spray side to some extent. The elastomeric spray
material is then sprayed onto one side of the upstanding edge. The
mask is then removed, and spraying is used to apply another
elastomeric material, for example one of another color. On the
basis of the materials described in the examples of the invention,
the disclosure comprises a process for the spraying of liquid
components. However, spray processes using a plurality of different
liquid materials are difficult to operate in industrial mass
production processes, simply because of the amounts of solvent
required.
[0016] "Patent Abstracts of Japan" discloses, with publication
number 1 134 8057, a Japanese publication which discloses a
combined spray and sintering process, which likewise uses masks to
cover individual regions of a mold and applies a first plastics
powder in a first sub-region of the mold by spraying, and then
removes the mask. The second plastics powder is then applied by
sintering in a further operating step onto those regions of the
mold that have not yet been coated, and onto those regions
previously coated with the first powder. Here again, a disadvantage
is that the handling of the masks is relatively complicated.
SUMMARY OF THE INVENTION
[0017] The invention was therefore based on the object of providing
a process and an apparatus for the production of molded plastics
skins, composed of regions of different plastics, reliably
providing a molded plastics skin of high quality and capable of
reliably adjusting the properties and the perceived quality/feel of
the molded plastics skin to the intended application over a wide
range via the selection of the materials and steps of the
process.
[0018] A further object consisted in providing a material for
molded plastics skins which is particularly suitable for reliable
non-splintering fracture during operation of an airbag.
[0019] Said object is achieved via the features of the main claim.
Advantageous embodiments are given in the dependent claims. An
apparatus of the invention is also disclosed, for conducting the
process.
[0020] In the process, [0021] a) first, the first plastics material
in the form of plastics powder is applied by a rotational sintering
process (rotation of a powder box) to the mold, and the mold is
heated to, and kept at, a first temperature of from 180 to
240.degree. C. during the fusion and gelling of the plastics
powder, and so the first plastics powder applied adheres by fusion
to the mold, [0022] b) then a second plastics material is applied
by a spray process, and the second plastics material here adheres
by fusion to the first plastics powder, and then the mold is
adjusted to a second temperature in such a way that the plastics
material applied by spraying is heated to, and kept at, a
temperature of 60 to 250.degree. C., and the first plastics powder
and the second plastics material here react to completion and fuse
to give a homogeneous molded plastics skin, and [0023] c) the
resultant molded plastics skin is cooled, and so it can be removed
from the mold, and the layer thickness applied of the first
plastics powder applied to the mold is from 200 to 15 000 .mu.m,
and the layer thickness applied of the second plastics material
applied is from 50 to 1700 .mu.m.
[0024] Surprisingly, it has been found that the essential
properties of a molded plastics skin in relation to perceived
surface quality, shape, color, and surface tension, and feel can be
adjusted in a precise and targeted manner by using an outer layer
which is only very thin, produced according to the invention, in
combination with a backing or supportive layer situated thereunder.
Furthermore, use of the differently formulated materials, combined
with one another in the manner of the invention, reliably avoids
splintering or escape of particles when the molded plastics skin is
fractured by deployment of an airbag.
[0025] In one advantageous embodiment of the process, the second
plastics material applied is a plastics powder, or is a liquid
plastic, or is a plastisol, which is applied by a spray process.
This provides advantages in handling and facilitates application
and the adjustment of the properties.
[0026] In another advantageous embodiment of the process, the
second plastics material applied is applied in the form of a single
web to the reverse side of the first layer. This permits precise
definition of the area active during fracture of the airbag. The
same advantages are achieved via alternative process embodiments,
for example where the second plastics material applied is applied
in a plurality of webs to the reverse side of the first layer, the
second plastics material applied is applied in sheet form, in a
particular region, to the reverse side of the first layer, the
second plastics material is applied to the reverse side of the
first layer in regions which have been isolated with the aid of
fillets from the remaining regions of the reverse side, or, during
the application of the second plastics material to the reverse side
of the first layer, the regions not to be coated with the second
plastics material have been covered with the aid of masks or
covering elements.
[0027] In another advantageous embodiment of the process, the
second plastics material applied is applied to the entire reverse
surface of the first layer. It is then possible to select any
desired location for the airbag at a subsequent stage.
[0028] In another advantageous embodiment of the process, the layer
thickness applied of the first plastics powder, applied by means of
rotational sintering to the mold, is from 500 to 1500 .mu.m, and
the layer thickness applied of the second plastics material,
applied by spraying to the first layer, is from 150 to 750
.mu.m.
[0029] An advantage of this type of embodiment of the process of
the invention, in the conduct of the process, is that the layer
thicknesses of the individual plastics materials can be designed
with high precision. The spray process with this layer thickness
moreover requires no great machinery cost beyond that for a
correspondingly equipped and, if appropriate, robot-controlled
spray equipment/spray gun, and this process can, given the absence
of heavy moving machinery parts, achieve high cycle times in mass
production.
[0030] The second plastics powder applied to the mold is
advantageously composed of a thermoplastic material to which a
filler has been admixed. This likewise serves for
precision-targeted adaptation of perceived surface quality, shape,
color, and surface tension, and feel. The same applies to another
advantageous embodiment, in which the second plastics powder
applied to the mold is composed of a thermoplastic material with a
grain size of from 30 to 300 .mu.m, to which glass fibers or
natural fibers have been admixed.
[0031] In another advantageous embodiment, the Shore hardness of
the finished molded plastics skin is from 60 (Shore A) to 45 (Shore
D). This gives a particularly attractive feel to the molded
plastics skin, and also an opportunity to influence the mechanical
properties/strength properties of the molded skin.
[0032] In another advantageous embodiment, the second plastics
powder applied to the mold is composed of recycling material. This
permits reuse of excess plastics offcuts from preceding
manufacturing operations, or of returns of used plastics
material.
[0033] In another advantageous embodiment, there are fillets
protruding on the surface of the mold, and these separate the
surface regions provided with plastics powders of different
properties, and at least one of the surface regions delimited by
the fillets here is provided, during fusion of a first plastics
powder, with a covering element or mask which has a seal in its
edge areas and is in contact with the fillets; the covering element
or mask here is removed from the surface of the mold prior to
application of the second plastics powder. By using this type of
process it is possible to achieve targeted control of individual
regions of the molded plastics skin.
[0034] In another advantageous embodiment, the plastics powders
have, as different property, a different color. This then permits,
in a simple manner and with the advantages described, the
production of dashboards, for example, whose upper part facing
toward the windshield is designed with a color and pigment density
that eliminate problematic reflected sunlight.
[0035] In another advantageous embodiment, the plastics powders
have, as different property, a different density and/or degree of
foaming. This provides a simple method of producing surfaces which,
for example, have a different perceived quality or feel in
different regions.
[0036] In another advantageous embodiment, during the powder
spraying in step a) of the process, the temperature of the mold is
from 190 to 210.degree. C. preferably 195.degree. C. The result of
this, in conjunction with the kinetic energy of the spray process
and with the other features of the process, specifically that,
during the fusion of the first plastics powder, in the subsequent
step b) of the process the temperature of the mold is from 200 to
220.degree. C. preferably 210.degree. C., is an initial slight
degree of "attachment", and just an incipient slight degree of
coagulation of the spray powder, which, although it is sufficient
to fix the powder particles in position, does not yet permit
"melting of the entire material".
[0037] In another advantageous embodiment of the process, for
complete reaction and fusion of the first and second plastics
powder, to give a homogeneous molded plastics skin, in an
additional step d) of the process, the temperature of the mold is
from 225 to 240.degree. C., preferably 235.degree. C. The result of
this is then, together with the second plastics powder,
introduction of sufficient heat for complete melting and
coagulation, and therefore for formation of a homogeneous molded
plastics skin composed of a plurality of layers/colors.
[0038] In another advantageous embodiment of the process, a
plurality of plastics powders are successively applied by
rotational sintering or by powder spraying to the mold. This too,
permits precise selection, as desired, of surface character and
feel.
[0039] One particularly suitable molded plastics skin, produced by
the process of the invention, for motor-vehicle-interior parts,
e.g. dashboards and door cladding, is characterized in that the
outer layer which is external within the plastics skin and has been
applied by means of powder-spraying processes to the mold is
composed of polyvinyl chloride (PVC), and the backing layer
situated thereunder within the plastics skin, and applied by
rotational sintering to the mold is composed of a plastics mixture
of in essence from 60 to 90% of polyvinyl chloride (PVC) and from
10 to 40% of polyurethane (PU). In an embodiment using material of
these types it is possible to influence and adjust the fracture
properties and tensile strain properties of the molded plastics
skin, the result being particular suitability for an advantageous
use as covering element for regions provided with airbag-trigger
devices, in the interior cladding of motor vehicles.
[0040] The lower layer of the molded plastics skin is
advantageously composed of material having low-temperature
flexibility, and in particular here of acrylates, of unsaturated
polyolefins or of polyurethane. The result is reliable elimination
of splintering or escape of particles during fracture of the molded
plastics skin by airbag deployment, even at temperatures extending
to -40.degree. C. When the molded plastics skin is fractured in an
airbag deployment test, the good adhesion of the layers to one
another reduces the tendency for particles to escape from the upper
layer, which is generally below the glass transition temperature,
because the particles adhere to the material having low-temperature
flexibility.
[0041] The second layer can also advantageously have points of
weakness, which can be introduced by various devices, for example
by knives or by laser cutting.
* * * * *