Internal trim part, comprising a decorative skin having a decorative element that is arranged in a depression in the decorative skin and is connected to the decorative skin by means of ultrasonic welding, and method for producing said internal trim part with decorative element

Abstract

The present invention relates to an internal trim part for a vehicle, comprising at least two layers. A decorative skin (1) forms an upper layer and has a depression (3), in which a decorative element (8) is arranged. The decorative element (8) is connected to the decorative skin (1) by means of a bonded connection, such as a weld seam, in particular an ultrasonic weld seam (16). The invention further relates to a method for producing an internal trim part and to a device for performing said method.

Claims

1. An inner trim part for a vehicle, comprising at least two layers, wherein one of the layers is a decor skin, and further comprising a decor element arranged in a recess of the decor skin and being connected to the decor skin via a material-fit connection, wherein the material-fit connection comprises an ultrasonic weld seam.

2. An inner trim part according to claim 1, wherein the decor element is formed from a continuous, cavity-free material.

3. An inner trim part according to claim 1, wherein a layer arranged below the decor skin is an intermediate layer which comprises a foam layer, a textile layer and/or an adhesive layer, or is a carrier.

4. An inner trim part according to claim 1, wherein the decor skin and/or the decor element has a hardness degree of greater than 50 Shore-A and smaller that 95 Shore-A.

5. An inner trim part according to claim 1, wherein the decor skin and/or the decor element has a modulus of elasticity of greater than 1 MPa.

6. An inner trim part according to claim 1, wherein the decor skin and/or the decor element are of a thermoplastic material or comprise a thermoplastic material.

7. An inner trim part according to claim 1, wherein the decor skin is a slush skin.

8. An inner trim part according to claim 1, wherein the ultrasonic weld seam only runs on a base of the recess of the decor skin.

9. An inner trim part according to claim 1, wherein the decor element is a strip, a tape or a ledge.

10. An inner trim part according to claim 1, wherein a connection location of two parts of the decor skin lies in the recess and is covered by the decor element, wherein the two parts of the decor skin each have a different characteristic.

11. An inner trim part according to claim 1, wherein the recess in a longitudinal section is elongate and/or is step-like in cross section.

12. A method for manufacturing an inner trim part for a vehicle, said inner trim part comprising two layers, comprising the steps: a) incorporating a decor element into a recess of a decor skin, wherein the decor skin forms one of the two layers; b) fastening the decor element in the recess of the decor skin by way of a material-fit connection using ultrasonic welding; and c) fastening a lower one of the two layers on a side of the decor skin which is away from the decor element.

13. A method according to claim 12, wherein only a base of the recess of the decor skin is connected to the decor element.

14. A method according to claim 12, wherein the ultrasonic welding is effected from a rear side of the decor skin.

15. A device for carrying out the method according to claim 12, wherein the device comprises a mold which is provided with suction channels and a surface, wherein the decor skin is fixable on the surface by way of suctioning, and the surface comprises a hollow, in which the decor element can be attached during the suctioning.

16. A device according to claim 15, wherein a groove, in which at least one of the suction channels runs out, is incorporated in a base of the hollow.

17. A method according to claim 12, wherein, before the production of the material-fit connection, the decor element and the decor skin are arranged on a mold which is provided with suction channels and a surface, wherein the decor skin is fixable on the surface by way of suctioning, and the surface comprises a hollow, in which the decor element can be attached during the suctioning, and wherein the decor element and decor skin are fixed by way of producing a vacuum in the suction channels.

18. A method according to claim 17, wherein a groove, in which at least one of the suction channels runs out, is incorporated in a base of the hollow, and wherein the groove forms a vacuum space while a vacuum exists in the suction channels, said vacuum space being delimited by the decor element at a side of the vacuum space facing the decor skin.

19. A device for carrying out a method for manufacturing an inner trim part for a vehicle, said inner trim part comprising two layers, the method comprising the steps of: a) incorporating a decor element into a recess of a decor skin, wherein the decor skin forms one of the two layers; b) fastening the decor element in the recess of the decor skin by way of a material-fit connection; and c) fastening a lower one of the two layers on a side of the decor skin which is away from the decor element, wherein the device comprises a mold which is provided with suction channels and a surface, wherein the decor skin is fixable on the surface by way of suctioning, and the surface comprises a hollow, in which the decor element can be attached during the suctioning.

20. A device according to claim 19, wherein a groove, in which at least one of the suction channels runs out, is incorporated in a base of the hollow.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiment examples of the invention are represented in the drawings and are explained hereinafter by way of FIGS. 1 to 8.

(2) There are shown in:

(3) FIG. 1 a cross section of a decor skin and a recess, in which a decor element is arranged before welding by way of an ultrasonic sonotrode,

(4) FIG. 2 a view of the decor skin which corresponds to FIG. 1, after the ultrasonic welding,

(5) FIG. 3 the decor skin represented in FIG. 2, with a decor element fastened in the recess, said recess being a constituent of an inner trim part,

(6) FIG. 4 a view corresponding to FIG. 1, of a further embodiment example of a decor skin with a changed geometry of the recess and with a decor element which is circular in cross section,

(7) FIG. 5 a view of an embodiment example of the decor skin, with which the recess is asymmetrical, said view corresponding to FIG. 1,

(8) FIG. 6 a view of an embodiment example which is according to FIG. 1, with which the decor element is fastened on a step as a recess,

(9) FIG. 7 the decor skin which is represented in FIG. 4 and which is arranged in a mould for ultrasonic welding and

(10) FIG. 8a to f a further embodiment of a mould for ultrasonic welding the decor skin which is represented in FIG. 4, with the decor element likewise represented in FIG. 4, at different points in time of the method for fastening the decor element on the decor skin.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

(11) A decor skin 1 is shown in a sectioned representation in FIG. 1. The decor skin is a slush skin of polyvinyl chloride (PVC) as a thermoplastic material. The decor skin 1 is manufactured by way of a slush method, with which the powder-like plastic is brought into a slush mould, and the decor skin 1 is moulded amid the effect of heat and rotation of the slush mould. The decor skin 1 is flexible as well as extensible and pliable in a large range. A hardness degree of the decor skin 1 is 68 Shore A, and a modulus of elasticity 4 MPa. In further embodiment examples the decor skin 1 however can be formed in a stiffer manner, thus can have a hardness degree of greater than 68 Shore-A.

(12) The decor skin 1 consists of a first part 2 which in FIG. 1 is arranged on the left of a recess 3, as well as of a second part 4 which is arranged right of the recess 3 in FIG. 1. Alternatively, the decor skin 1 can also be designed in a single-part manner. The recess 3 was already incorporated during the manufacture of the decor skin 1 and has a linear course over a length of 20 cm as well as a base 5 which forms a lowest point of the recess 3. The recess 3 thus comprises the base 5 as well as a left side wall 6 and a right side wall 7, which are arranged at right angles to the base 5, wherein the left side wall 6 is connected to the first part 2 of the decor skin 1 and the right side wall 7 is connected to the second part 4 of the decor skin 1. A distance between the left side wall 6 and the right side wall 67 and thus a width of the base 5 is 2 mm, and the base 5 is distanced 3 mm from a viewed side 15 of the decor skin 1 which faces the vehicle occupants after the installation, and this distance corresponds to a depth of the recess 3. The recess 3 is thus groove-like. The first part 2 and the second part 4 in each case have different colours and pitting, but are otherwise identical.

(13) A decor strip 8 as a decor element of PVC as a thermoplastic material is incorporated in the recess 3, but however does not yet lie on the base 5. The decor strip 8 has a rectangular cross section and dimensions which permit the decor strip 8 to be integrated into the recess 3 in a flush manner. The decor strip 8 as soon as it lies on the base 5 terminates in a flush manner with the upper side of the decor skin 1. A length of the decor strip 8 is 20 cm and is greater than the dimensions of the decor strip 8 in cross section, thus greater than the width of the base 5 and a depth of the recess 3.

(14) An ultrasonic sonotrode 9 which emits ultrasonic waves with a frequency of 35 kHz and a power of 1 kW is led onto the recess 3 from a side of the decor skin 1 which is away from the decor strip 8 (also called rear side 14), over a time period of 1 second. The ultrasonic sonotrode 9 at its tip is 15 mm wide and merely effects a local ultrasonic input onto individual locations of the decor skin 1. The decor strip 8 is welded to the base 5 by way of the ultrasonic effect onto the base 5 of the recess 3, since the thermoplastic material heats up and becomes softer by way of this and finally the decor strip 8 melts with the base 5. Alternatively or additionally, the decor strip 8 can also be welded to the left side wall 6 and/or to the right side wall 7.

(15) FIG. 2 in a sectioned view corresponding to FIG. 1 shows the decor skin 1 after the ultrasonic welding has been effected. Recurring features in this figure as well as in the following figures are provided with identical reference numerals. The base 5 of the recess 3 is now fixedly connected to the decor strip 8. The base 5 as well as the decor strip 8 have changed their shape on account of the ultrasonic welding, so that the base 5 which at the same time forms a lower side of the decor strip 8 is round and comprises an ultrasonic weld seam 16. The ultrasonic weld seam 16 connects the base 5 of the recess 3, and thus the decor skin 1 to the decor strip 8. The left side wall 6 and the right side wall 7 have no ultrasonic weld seam 16.

(16) An inner trim part which comprises the decor skin 1 shown in FIG. 2 as an uppermost layer on the viewed side 15 is represented in FIG. 3 in a view corresponding to FIGS. 1 and 2. The inner trim part is an instrument panel for a motor vehicle, but in further embodiments the inner trim part can also be an arm rest or another component used in an interior. An intermediate layer 13 which is connected to the decor skin 1 is arranged below the decor skin 1 and is designed as a haptics layer, i.e. a layer which is compressible and gives the inner trim part flexible haptics. The intermediate layer 13 comprises a foam layer of polyurethane foam. In further embodiments, the intermediate layer 13 however can also include a textile ply which for example can be designed as a spacer fabric. Alternatively, the intermediate layer 13 can also be an adhesive layer. No sealing tapes against the exit of foam onto the viewed side 15 are necessary due to the fact that the decor skin 1 has no holes or openings, but a closed surface, also in the region of the ultrasonic weld seam 16.

(17) The intermediate layer 13 is arranged between the decor skin 1 and a carrier 10 such that no part of the carrier 10 contacts the decor skin. The carrier 10 is of polypropylene and has a hardness degree which is greater than the hardness degree of the decor skin 1 and also greater than a hardness degree of the intermediate layer 13. A modulus of elasticity of the carrier 10 is likewise greater than the modulus of elasticity of the decor skin 1. The intermediate layer 13 can be connected to the decor skin 1 and the carrier 10 via an additional adhesive layer.

(18) FIG. 4 in a sectioned view corresponding to FIG. 1 shows a further embodiment of the decor skin 1. The decor skin 1 in turn consists of the first part 2 and the second part 4, and these are connected to one another via a connection seam 12 as a connection location. The first part 2 and the second part 4 have been coloured differently during the manufacture. The recess 3 was likewise already incorporated into the decor skin 2 during manufacture. The recess 3 however is not rectangularly shaped as in the embodiment example represented in FIG. 1, but is arched, preferably in a semicircular manner. The recess 3 runs arcuately over a length of 15 m. The base 5 of the recess 3 is therefore a point of the arched recess 3 which has a maximal distance to the viewed side 15 of the decor skin 1. The connection seam 12 lies centrally in the recess 3 on the base 5. This connection seam 12 can be an ultrasonic weld seam. The connection of the first part 2 and of the second part 4 by the connection seam 12 can however also be effected by yarn or an adhesive.

(19) A decor strip 11 of PVC as a thermoplastic material is incorporated into the recess 3 and has a circular cross section and consists of a thermoplastic material. The cross section of the decor strip 11 can alternatively also have an elliptical surface or an asymmetrical surface. A diameter of the decor strip 11 is 8 mm and projects beyond the recess 3 and in further embodiments the diameter can however also be selected such that no part of the decor strip 11 projects beyond the recess 3. A length of the decor strip 11 corresponds to the length of the recess 3. The ultrasonic sonotrode 9 is led onto the recess 3 from the rear side 14 of the decor skin 1 which is away from the viewed side 15, and by way of ultrasonic input welds the decor strip 11 to the base 5 of the decor skin 1. The connection seam 12 is thus covered by the decor strip 11, is hidden beneath this and is not visible from the viewed side 15.

(20) FIG. 5 in a view corresponding to FIG. 1 shows a further embodiment example of the decor skin 1, with which the recess 3 is asymmetric. The decor skin 1 shown in FIG. 5 corresponds to the decor skin 1 shown in FIG. 4, but the left side wall 6 is longer than the right side wall 7. The recess 3 has an asymmetrical cross section on account of this. The ultrasonic weld seam 16 which connects the decor skin 1 to the decor strip 11 is arranged on the base 5 of the recess 3.

(21) In the embodiment likewise represented in cross section in FIG. 6, the recess 3 is a step of the decor skin 1. The first part 2 hereby has a height difference to the second part 4. Both parts 2, 4 are connected to one another via a step. The decor strip 11 is connected by way of the ultrasonic weld seam 16 to the base 5 as well as to the left side wall 6. The base 5 merges into the second part 4 without an angling. The second part 4 is angled by 90 with respect to the left side wall 6, said left side wall in turn forming a right angle with the first part 2.

(22) The decor skin 1 which is shown in FIG. 4 is arranged on a mould 17 having suction channels 18, in FIG. 7. The mould 17 for this has a surface 19, on which the decor skin 1 lies with the viewed side 15. The decor skin 1 is sucked onto the mould 17 and is positioned in a spatially fixed manner by way of the suction channels 18 which are uniformly distributed over the mould 17. The mould 17 moreover comprises a hollow 20, into which the decor strip 11 is inserted. One of the suction channels 18 which position the decor strip 11 in a spatially fixed manner is likewise located in this hollow 20. The recess 3 is located above the hollow 20. The decor strip 11 is thus enclosed by the hollow 20 and the recess 3. An ultrasonic welding can be effected from the rear side 14 due to the stationary fixed positioning of the decor skin 1 and the decor strip 11. Finally, a lower layer such as the intermediate layer 13 and/or the carrier 10 is fastened on the decor skin 1 for manufacturing the inner trim part.

(23) Features of the different embodiments which are merely disclosed in the embodiment examples can be combined with one another and claimed individually.

(24) One embodiment of the method for manufacturing a vehicle interior trim part is explained by way of FIGS. 8a to f.

(25) A mould 17 is represented in FIG. 8a, and this differs from the mould 17 of FIG. 7 in that a groove 21 is provided in a base of the hollow 20. The suction channels 18a which run out outside the groove 21 can be subjected to a vacuum independently of suction channels 18b which run out within the groove 21. For this, the suction channels 18b comprise a connection 22 for a vacuum supply, said connection being designed in a manner separate from connections for the vacuum supply of the suction channels 18a.

(26) FIG. 8b shows the method at a later a point in time. In the meanwhile, the decor strip 11 was arranged in the hollow 20 and fixed by way of a vacuum applied via the suction channels 18b (one can also envisage only a single suction channel 18b). A vacuum is not yet present at the suction channels 18a at this point in time. The groove 21 between the decor strip 11 and the mould 17 forms a vacuum space which is closed by the decor strip 11.

(27) Subsequently, the decors skin 1 is arranged on the mould 17, so that the decor skin 1 covers the decor strip 11. The decor skin 1 is now suctioned onto the mould 17 via the suction channels 18a by way of a vacuum 17. The mould in its condition after this method step is pictured in FIG. 8c.

(28) A weld seam is subsequently incorporated. This can be effected for example by way of ultrasonic welding. The trim part which is arranged on the mould 17 is shown in FIG. 8d after the incorporation of the weld seam 16. A bonding connection could also be provided instead of a weld seam 17. A decor strip which is provided with an adhesive already before laying onto the mould 17 could be used for this.

(29) In a further method step, the decor skin 1 is back-foamed with a foam layer 23. The mould with the trim part after producing the foam layer 23 is shown in FIG. 8a.

(30) The finished trim part represented in FIG. 8f is now removed from the mould 17.