TRIM COMPONENT FOR COVERING AN INTERIOR SPACE OF A MEANS FOR TRANSPORTING PASSENGERS AS WELL AS METHOD FOR PRODUCING SUCH A TRIM COMPONENT

Abstract

The present invention relates to trim component for covering an interior space of a means for transporting passengers, in particular of a vehicle, comprising a support element which has at least one separation surface and at least one edge-folded section abutting the separation surface, wherein the support element has at least one folded edge which includes at least one edge-folded section. Moreover, the present invention relates to a method for producing such a trim component.

Claims

1. A trim component for covering an interior space of a passenger transport vehicle, comprising a support element comprising a separation surface and an edge-folded section attached to the separation surface, wherein the edge-folded section is folded over to form a folded edge.

2. The trim component of claim 1, further comprising a decorative layer applied on the support element with the decorative layer being bent over at the folded edge.

3. The trim component of claim 1, wherein the support element comprises a predefined buckling point which delimits the edge-folded section with respect to a remaining section of the support element.

4. The trim component of claim 1, wherein the edge-folded section encloses a bending angle of 90 or 180 with respect to a surface of the support element.

5. The trim component of claim 1, wherein the edge-folded section encloses a bending angle of 180 relative to a surface of the support element and the edge-folded section at least partially contacts the surface of the support element.

6. The trim component of claim 1, wherein the folded edge encloses a cavity.

7. The trim component of claim 1, further comprising functional elements.

8. A method for manufacturing a trim component covering an interior space of a passenger transport vehicle, wherein the trim component comprises a support element having an edge-folded section, the method comprising the steps of: Heating and placing a calibrated mat in a mold having an upper tool and a lower tool, Closing the mold by moving at least one of the upper tool and the lower tool and reshaping the calibrated mat to form the support element, and Heating the support element and bending the edge-folded section to form a folded edge.

9. The method of claim 8, further comprising the following steps: Providing the support element with a predefined buckling point when closing the mold, and Bending the edge-folded section at the predefined buckling point.

10. The method of claim 8, wherein the support element comprises a decorative layer.

11. The method of claim 10, wherein decorative layer rests on a first side of the support element, whereas an opposite second side of the support element lacks a decorative layer, further comprising, after the support element has been removed from the mold, the following steps: Locally heating the support element on the first side to a first temperature, and Locally heating the support element on the second side to a second temperature which is higher than the first temperature.

12. The method of claim 8, further comprising the following step: Over-molding functional elements on the support element while the mold is closed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Exemplary embodiments of the invention will be explained in more detail below with reference to the accompanying drawings, which show in:

[0053] FIGS. 1A to 1H the main steps of a first method for producing a first trim component known from the prior art,

[0054] FIGS. 2A and 2B selected steps of a second method for producing a second trim component known from the prior art,

[0055] FIGS. 3A to 3H the main steps of a proposed first method for producing a first trim component according to the invention, and

[0056] FIGS. 4A to 4C selected steps of a proposed second method for producing a second and third inventive trim component, each shown in schematic diagrams.

[0057] FIGS. 1A to 1H show in form of schematic diagrams the main steps of a first method for producing a first trim component 10P known from the prior art.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0058] The trim component 10P (see FIG. 1G) includes a support element 12, which is present in the initial state as a mat 12A, for example, as a natural fiber mat. The mat 12A is first calibrated in a manner not here shown in detail, heated and, as shown in FIG. 1A, inserted into an open mold 14, which has an upper tool 16 and a lower tool 18. The upper tool 16 and lower tool 18 can be moved towards one another and away from one another. In the open state, the upper tool 16 and the lower tool 18 open a gap 20, which is sized such that the heated, calibrated mat 12A can be inserted into the mold 14.

[0059] The upper tool 16 and the lower tool 18 each have trimming edges 21. The calibrated mat 12A is sized in the initial state such that it extends outwardly beyond the trimming edges 21, but not beyond the mold 14 when inserted into the mold 14.

[0060] After the calibrated mat 12A has been inserted into the open mold 14, the mold is closed 14, as shown in FIG. 1B. For this purpose, the upper tool 16 and lower tool 18 are moved towards one another. Closing the mold 14 has the effect that the calibrated mat 12A is first shaped into a reformed mat 12B. The trimming edges 21 cooperate such that they separate, when closing, edge pieces 22 from the calibrated mat 12A. The regions formed as a result of the separation of the calibrated mat 12A and of the reformed mat 12B are in the following referred to as separation surfaces 24 (see for example FIG. 1D).

[0061] The upper tool 16 and lower tool 18 have recesses 26 and bumps 28. Furthermore, the mold 14 has cores or sliders 30. The calibrated mat 12A conforms to the shape of the recesses 26 and bumps 28, to the extent that the recesses 26 are designed to come into contact with the calibrated mat 12A when the mold 14 closes. Several of the recesses 26 of the lower tool 18 are designed to form a cavity 32 when the mold 14 is closed. The slider 30 can be introduced into this cavity 32. In the step illustrated in FIG. 1C, the cavities 32 are filled with an injection-molding material, whereby the functional elements 34, such as positioning and/or attachment sections or ribs, are overmolded or back-molded on the bottom side of the deformed mat 12B in relation to FIGS. 1A to 1H. After the functional elements 34 are completed, a trim component 10P is produced, wherein the deformed mat 12B represents the support element 12 of the trim component 10P. A clear distinction between the deformed mat 12B and the support element 12 is possible, but not necessary. As soon as the deformed mat 12B has permanently assumed the desired shape, it forms the support element 12.

[0062] As shown in FIG. 1D, the mold 14 is subsequently opened and the slider 30 is retracted. The support element 12 can now be removed from the mold 14. The edge pieces 22 are discarded or recycled. FIG. 1E shows the support element 12 with a molded functional element 34. The respective functional element 34 has a hollow region 36 where the slider 30 was arranged.

[0063] Subsequently, a decorative layer 38 is applied to the side of the support element 12, which does not have any of the functional elements 34, with reference to the top side in FIGS. 1A to 1H. The decorative layer 38 can, for example, be glued to the support element 12. As seen from FIG. 1F, the decorative layer 38 projects laterally beyond the support element 12. In this way, the decorative layer 38 can be applied not only on the upper side of the support element 12, but also on the separation surfaces 24 and on an edge region of the bottom side. This is shown in FIGS. 1G and 1H, with FIG. 1H showing an enlarged view of the section A defined in FIG. 1G of the now finished trim component 10P. In this way, the following advantages can be achieved: Firstly, the separation surfaces 24 are covered by the decorative layer 38, so that the trim component 10P has the same appearance from the side as from the top side. This allows the trim component 10P to be installed also in an interior space of a means for transporting passengers and to be visible from the side, without impairing the visual appearance of the interior space. On the other hand, the decorative layer 38 may have a different coefficient of shrinkage, which may cause the decorative layer 38 to contract more strongly than the support element 12, so that the decorative layer 38 uncovers again surface portions of the support element 12 that were originally covered. Since in this case the uncovered surface portions are located on the bottom side of the support element 12, they are not visible from the interior space, so that the appearance is not adversely affected.

[0064] FIGS. 2A and 2B show in form of schematic diagrams selected steps of a second method for manufacturing a second trim component 10P known from the prior art. FIG. 2B shows an enlarged detail of the second trim component 10P corresponding to FIG. 1H. The mold 14 corresponds to the mold shown in FIGS. 1A to 1D.

[0065] In contrast to the first method, with the second method the decorative layer 38 is inserted into the opened mold 14 together with the previously heated calibrated mat 12A. The subsequent steps correspond largely to those illustrated in FIGS. 1B to 1D. The decorative layer 38 may be coated with a hot melt adhesive or may even have such properties itself, so that the decorative layer 38 is attached to the support element 12 during the reshaping steps. The pressure generated when the mold 14 is closing and the residual heat can be sufficient to attach the decorative layer 38 to the support element 12. It must be ensured that, on the one hand, enough heat is available for attaching the decorative layer 38 to the support element 12 and, on the other hand, not too much heat is introduced into the support element 12 and the decorative layer 38 so as not to damage the decorative layer 38. It is not necessary to carry out further steps for applying the decorative layer 38 to the support element 12 after the mold 14 has been opened.

[0066] As explained for the first method, the upper tool 16 and lower tool 18 are designed so that they separate, during closing, the edge pieces 22 from the calibrated mat 12A by forming separation surfaces 24. However, since the decorative layer 38 has already been inserted into the open mold 14 together with the calibrated mat 12A, it is not possible, unlike with the first method, to cover the separation surfaces 24 and the edge portions of the bottom side with the decorative layer 38 (see FIG. 2B in comparison to FIG. 1H). The advantages achievable by covering the separation surface 24 and the edge areas cannot be realized with the second method or not without further steps.

[0067] The trim component 10P produced in this way is an off-tool part, meaning that it has its desired shape after removal from the mold 14 and does not require further processing. Such manufacturing method is also called a one-shot method.

[0068] FIGS. 3A to 3F illustrate the main steps of a first embodiment of a method according to the invention for producing a proposed trim component 10D.sub.1 according to a first exemplary embodiment (see FIG. 3G) and a proposed trim component 10D.sub.2 according to a second exemplary embodiment (see FIG. 3H).

[0069] The upper tool 16 corresponds to the upper tool depicted in the FIGS. 1A and 2A. However, the lower tool 18 has projections 44, which serve to provide the support element 12 with predetermined buckling points 48, as will be discussed in more detail later.

[0070] Also in this embodiment according to the invention, the decorative layer 38 is inserted in the open mold 14 together with the calibrated mat 12A, so that the proposed trim component 10C.sub.1 upon removal from the mold 14 corresponds to the trim component which is removed from the mold 14 according to the second method known from the prior art. Accordingly, the steps shown in FIGS. 3A through 3D correspond substantially to those steps shown in FIGS. 1A to 1D. FIG. 3E shows the support element 12 with the decorative layer 38 applied thereon after removal from the mold 14. As can be seen, the support element 12 has two predetermined buckling points 48, which are produced because the lower tool 18 has correspondingly shaped projections 44.

[0071] However, the trim component 10C, can also be used in situations where no decorative layer 38 is necessary. In this case, the calibrated mat 12A can also be inserted into the mold 14 without the decorative layer 38. As mentioned above, when the mold 14 closes, the edge pieces 22 are separated from the calibrated mat 12A (see in particular FIG. 3D), forming the separation surfaces 24. As seen from FIG. 3F, the separation surfaces 24, on the one hand, and the predetermined buckling points 48, on the other hand, delimit an edge-folded section 40. FIG. 3F shows schematically the detail B defined in FIG. 3E on an enlarged scale.

[0072] After removal from the mold 14, the edge-folded section 40, which in the illustrated example includes the support element 12 and the decorative layer 38 attached thereto, is bent by using the predetermined buckling points 48 by a certain fold angle in the direction R indicated in FIG. 3F, so that a folded edge 42 is formed in the region of at least one end of the support element 12 (see FIGS. 3G and 3H). The trim component with the folded edge 42 is designated as 10D.sub.1. Consequently, the edge-folded section 40 is the section of the support element 12 abutting the separation surface 24, which is moved relative to the rest of the support element 12 during bending. As seen in FIGS. 3D and 3E, the support element 12 includes at least one of the above-mentioned predetermined buckling points 48. Providing the predetermined buckling point 48 simplifies bending of the support element 12 and provision of the folded edge 42. In addition, the precision of the folded edge 42 can be increased since the region in which the support element 12 is to be bent can be specified more accurately. In the illustrated exemplary embodiment, the predetermined buckling points 48 delimit the edge-folded section 40 towards the inside of the support element 12.

[0073] In the first exemplary embodiment of the trim component 10D.sub.1 according the invention illustrated in FIG. 3G, the fold angle is 180, so that the trim component 10D.sub.1 is folded much like a hem. In the region of the respective end, the support element 12 is then constructed at the folded edge 42 in two layers, since the edge-folded section 40 rests on the bottom side of the support element 12.

[0074] In the second exemplary embodiment of the trim component 10D.sub.2 according to the invention illustrated in FIG. 3H, the fold angle is 90. In this case, the edge-folded section 40 does not rest on the bottom side of the support element 12.

[0075] In both cases, provision of the folded edges 42 causes that the trim components 10D.sub.1 and 10D.sub.2, when seen from the side, to be provided with the decorative layer 38. The separation surface 24, which is also not covered by the decorative layer 38 in the proposed first trim component 10C.sub.1, is aligned by bending in such a way that it is no longer visible from the side. Furthermore, in both cases, the support element 12 is reinforced in the region of the respective folded edge 42.

[0076] As can be seen in FIG. 3F, the trim component 10C.sub.1 can be heated after removal from the mold 12 and before bending the edge-folded section 40. For this purpose, a first heat source 50.sub.1 and a second heat source 50.sub.2 are provided, between which the trim component 10C.sub.1 can be positioned after removal from the mold 14. The top side of the support element 12 on which the decorative layer 38 rests and which faces the first heat source 50.sub.1, will hereinafter be referred to as the first side 52, whereas the opposite bottom side, which does not have a decorative layer 38, will be referred to as the second side 54. The second side 54 faces the second heat source 50.sub.2. The heat sources 50.sub.1, 50.sub.2 can for example be implemented as infrared radiators or as a source of hot air. Due to the heat-up of the trim component 10C, and in particular of the support element 12, the support element 12 is softened, facilitating bending. In addition, the risk of breakage of the support element 12 is eliminated.

[0077] By providing two heat sources 50.sub.1, 50.sub.2, the trim component 10C.sub.1 can be heated to a first temperature T on the first side 52, and to a second temperature T.sub.2 on the second side 54. In the illustrated exemplary embodiment, the heat sources 50.sub.1, 50.sub.2 are adjusted so that the first temperature T.sub.1 is lower than the second temperature T.sub.2. In particular, this protects the frequently temperature-sensitive decorative layer 38 from thermal damage, while at same time rendering the support element 12 so soft that it can be bent without breaking.

[0078] Moreover, by heating the edge-folded sections 40 before bending, the edge-folded section 40 abuts at a folded edge angle of 180 not only the second side 54 of the support element 12, but also fuses with the second side 54 when the support element 12 consists of a material with corresponding properties. The trim component 10D.sub.1 is hereby further reinforced in the region of its ends.

[0079] FIG. 4A illustrates a second embodiment of the proposed method wherein the support element 12 may have more than one predetermined buckling point 48 in the region of an edge. In the illustrated exemplary embodiment, the support element 12 has three predetermined buckling points 48. As already mentioned above, the edge-folded section 40 is delimited by the separation surface 24 and the adjacently arranged predetermined buckling point 48. However, since the support element 12 shown in FIG. 4A has three predetermined buckling points 48, these also delimit two additional edge-folded sections 43 in relation to the rest of the support element 12. In this way, the bending process can be specifically influenced and folded edges 42 with special geometries can be produced. 10C.sub.2

[0080] FIG. 4B illustrates a third exemplary embodiment of a trim component 10D.sub.3 according to the invention with a support element 12 having three predetermined buckling points 48. Accordingly, one edge-folded section 40 and two more folded edge sections 43 are present. In particular, by providing more than one predetermined bending points 48, the thereby formed folded edge 42 may include additional bending edges 46. The unmarked fold angle is 180, as in the first exemplary embodiment.

[0081] FIG. 4C illustrates a fourth embodiment of a trim component 10D.sub.4 according to the invention. By providing a corresponding number of predetermined buckling points 48 and a corresponding process control when bending the edge-folded sections 40 and the two other edge-folded sections 43, the folded edge 42 can be designed so that it encloses a cavity 56, thereby additionally stiffening the trim component 10D.sub.4 at the folded edge 42. The unmarked fold angle is 180, as in the first exemplary embodiment.

[0082] Both in the third embodiment of the trim component 10D.sub.3 and in the fourth embodiment of the trim component 10D.sub.4, the edge-folded section 40 of the folded edge 42 rests on the support element 12, so that the trim components 10D.sub.3 and 10D.sub.4 are constructed at that location in two layers, thereby additionally increased the stiffness.

[0083] While the invention has been illustrated and described in connection with currently preferred embodiments shown and described in detail, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.

[0084] What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims and includes equivalents of the elements recited therein: