Method for producing a foam-backed moulded component, and moulded component

Abstract

The invention relates to a method for producing a foam-backed molded component, the method comprising the following steps: a) introducing a cover material in a mold (100), the mold (100) having a negative-profiled surface (310); and b) generating and maintaining a vacuum and/or negative pressure on the side of the cover material facing the mold (100); and c) pouring a foam material in the mold (100); and d) closing the mold (100); and e) molding the foam material; and f) opening the mold (100) and removing a foam-backed molded component, the foam-backed molded component having a profiled surface.

Claims

1. A method for producing a foam-backed molded component, the method comprising the following steps: a) introducing a cover material in a mold, the mold having a negative-profiled surface, wherein the cover material is a real leather, a bonded leather, an imitation leather, a textile, a film, a composite material, or a mixture thereof; b) generating and maintaining a vacuum or negative pressure on the side of the cover material facing the mold; c) pouring a foam material in the mold, the foam material comprising a polyurethane foam; d) closing the mold; e) molding the foam material such that a size and prevalence of foam bubbles are essentially uniform over the foam material in all areas; f) opening the mold and removing the foam-backed molded component, the foam-backed molded component having a profiled surface corresponding to an inverted version of the negative-profiled surface of the mold; and wherein the cover material has the profiled surface comprising a plurality of indentations and protrusions with a height difference formed by at least one indentation and at least one protrusion, wherein the height difference is designed as a continuous and contiguous surface, and wherein the profiled surface further has at least one step with a step height of at least 5 mm.

2. The method according to claim 1, wherein the mold is made partially or entirely of a heat-resistant plastic, a metal, an alloy or a mixture thereof.

3. The method according to claim 1, wherein the mold comprises at least one first module and at least one second module and wherein the at least one first module is made partially or entirely of a first material and the at least one second module is made partially or entirely of a second material, the first and the second material being the same or different.

4. The method according to claim 1, wherein the mold has at least one lid.

5. The method according to claim 1, wherein the mold is produced partially or entirely by means of an additive manufacturing method or a chipping method.

6. A molded component comprising a cover material and a foam-backing, the cover material having an inner side and an outer side, wherein the outer side of the cover material has a profiled surface and the foam-backing being disposed on the inner side of the cover material; wherein the profiled surface comprises a plurality of indentations and protrusions with a height difference formed by at least one indentation and at least one protrusion, wherein the height difference is designed as a continuous and contiguous surface, the profiled surface further having at least one step with a step height of at least 5 mm; wherein the cover material is a real leather, a bonded leather, an imitation leather, a textile, a film, a composite material, or a mixture thereof; wherein the foam-backing is a polyurethane foam such that a size and prevalence of foam bubbles are essentially uniform over the foam-backing in all areas.

7. The molded component according to claim 6, wherein the molded component is inherently stable.

8. The molded component according to claim 6, wherein the cover material is wipeable, water-resistant, watertight, abrasion-resistant, tear-proof, heat-resistant, cold-resistant, UV-resistant, flame-retardant, air-permeable, sound-absorbing or sound-deadening.

9. The molded component according to claim 6 for use as a covering.

10. The molded component according to claim 6 for use as a seat or for use as part of a seat.

11. The molded component according to claim 6 for use as a clothing piece, an accessory, a suitcase or a bag or for use as part of a clothing piece, an accessory, a suitcase or a bag.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further details, features and advantages of the invention are derived from the following description of the preferred exemplary embodiments in connection with the dependent claims. In this context, the corresponding features can be realized each on their own or several in combination with each other. The invention is not limited to the exemplary embodiments. The exemplary embodiments are shown schematically in the figures. The same reference numerals in the individual figures refer to the same elements or elements having the same function and/or corresponding to each other regarding their function.

(2) FIG. 1 shows a perspective view of a first module of a mold:

(3) FIG. 2 shows a top view of a first and a second module of a mold;

(4) FIG. 3 shows a lateral cut view through a first and a second module of a mold:

(5) FIG. 4 shows another lateral cut view through a first and second module of a mold:

(6) FIG. 5 shows a detail of a cut through a first and a second module of a mold.

DETAILED DESCRIPTION

(7) FIG. 1 shows a perspective view of a first module 200 of a mold 100. First module 200 comprises a recess 210. Recess 210 is meant to receive a second module (not shown). Moreover, first module 200 comprises a negative-pressure channel 220. Negative-pressure channel 220 extends from the side of first module 200 to the center of recess 210. At its first end, in the center of recess 210, negative-pressure channel 220 comprises an outlet 221. At its other end, on the side of first module 200, negative-pressure channel 220 comprises a connection 222. Connection 222 allows a connection to a device (not shown), which is suitable for producing and maintaining a negative pressure and/or a vacuum. Via negative-pressure channel 220, the air is suctioned from recess 210 through negative-pressure channel 220 with the aid of the negative pressure and/or the vacuum. In this manner, a negative pressure and/or a vacuum is also generated in recess 210, provided it is sealed in an airtight manner. An airtight seal of this kind is realized by inserting a cover material (not shown), for example. Besides, first module 200 comprises two outlets 230, which facilitate handling the module. In this exemplary embodiment, first module 200 is made of steel.

(8) FIG. 2 shows a top view of first module 200 and a second module 300 of mold 100. In recess 210 of first module 200, second module 300 is inserted. Laterally to first module 200, connection 222 of negative-pressure channel 220 is identifiable. Second module 300 comprises a negative-profiled surface 310, which is formed by a negative profile 311. Negative profile 311 corresponds to the profile which is to be formed at the profiled surface of the foam-backed molded component, the protrusions and indentations having been inverted. In this embodiment, negative profile 311 is a repeating wave pattern. For forming negative profile 311, negative-profiled surface 310 has edges 314 and surfaces 315. For reasons of clarity, only three edges 314 and three surfaces 315 are exemplarily shown in FIG. 2. In this context, edges 314 are formed by the collision of surfaces 315. Some of surfaces 315 are curved, other surfaces 315 are flat. In this exemplary embodiment, all edges 314 are curved. However, it is also conceivable for a different negative-profiled surface (not shown), which has straight edges, to be produced for forming a different negative profile (not shown), which has straight edges. In this exemplary embodiment, second module 300 is made of a plastic.

(9) FIG. 3 shows a lateral cut through first module 200 and second module 300 of mold 100. The cut for the cut view extends along axis A-A in FIG. 2. Continuous negative-pressure 220 is easily recognizable. Outlet 222 ends below second module 300. Further, connection 222 is easily visible. Negative-profiled surface 310 of second module 300 has edges 314 and surfaces 315. Moreover, negative-profiled surface 310 has protrusions 312 and indentations 313. For reasons of clarity, two edges 314, two surfaces 315, two protrusions 312 and two indentations 313 are shown exemplarily in FIG. 3. First shown surface 315a is curved.

(10) FIG. 4 shows another lateral cut view of first module 200 and second module 300 of mold 100. The cut for the cut view extends along axis C-C in FIG. 2. The second module has negative-profiled surface 310. Likewise, one of surfaces 315 is shown exemplarily. Exemplarily shown surface 315 is flat.

(11) FIG. 5 shows the detail of the cut view in FIG. 4 designated in FIG. 4 with a B. Detail B has been enlarged in FIG. 5. First module 200 and second module 300 of mold 100 are recognizable. Owing to the enlargement, openings 320, which are disposed in indentations 313 of negative-profiled surface 310, are easily identifiable. Openings 320 are continuous so as to connect the upper side of module 300 with the lower side of module 300. In FIG. 5, openings 320 seem closed, which, however, can be led back to the nature of the engineering drawing. The lines at both ends of openings 320 represent the edges of openings 320. Openings 320 can be punctiform or oblong. In addition, second module 300 comprises feet 330. Owing to feet 330, second module 300 is spaced from first module 100, whereby a cavity 340 is created between second module 300 and first module 200. In this embodiment of the invention, feet 330 are round: however, any other functional embodiment is conceivable. In addition, only one cavity 340 is formed in this embodiment: individual cavity sections 340 are connected at other locations (not shown). For reasons of clarity, only two indentations 313, two openings 320 and two feet 330 as well as cavity 340 at two locations are shown exemplarily. As previously described above, a negative pressure and/or vacuum can be generated below second module 300 in recess 210. Via cavity 340, it becomes possible for the negative pressure and/or the vacuum to abut below second module 300 in the entire area. Via continuous openings 320, the negative pressure and/or the vacuum are transferred to the upper side of second module 300. If a cover material (not shown) is now laid over first module 200 and second module 300 and a negative pressure and/or vacuum is generated, the cover material (not shown) experiences a force directed toward second module 300, the force pulling the cover material into negative-profiled surface 310. Via the acting force, the cover material (not shown) is pre-deformed. The cover material (not shown) seals the space in recess 210 with respect to the environment in the process, meaning the negative pressure and/or the vacuum can be maintained.