US20050276874A1 - Decorative components for motor vehicle interiors - Google Patents
Decorative components for motor vehicle interiors Download PDFInfo
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- US20050276874A1 US20050276874A1 US11/142,861 US14286105A US2005276874A1 US 20050276874 A1 US20050276874 A1 US 20050276874A1 US 14286105 A US14286105 A US 14286105A US 2005276874 A1 US2005276874 A1 US 2005276874A1
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- Prior art keywords
- layer
- component
- mold
- vehicle interior
- veneer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/12—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels
- B29C33/14—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels against the mould wall
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/14—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets
- B29C51/145—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor using multilayered preforms or sheets having at least one layer of textile or fibrous material combined with at least one plastics layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
- B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D1/00—Steering controls, i.e. means for initiating a change of direction of the vehicle
- B62D1/02—Steering controls, i.e. means for initiating a change of direction of the vehicle vehicle-mounted
- B62D1/04—Hand wheels
- B62D1/06—Rims, e.g. with heating means; Rim covers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
- B29C2045/14237—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure the inserts being deformed or preformed outside the mould or mould cavity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2791/00—Shaping characteristics in general
- B29C2791/001—Shaping in several steps
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
- B29C45/14065—Positioning or centering articles in the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1679—Making multilayered or multicoloured articles applying surface layers onto injection-moulded substrates inside the mould cavity, e.g. in-mould coating [IMC]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/28—Component parts, details or accessories; Auxiliary operations for applying pressure through the wall of an inflated bag or diaphragm
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
- B29C69/02—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore of moulding techniques only
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
- B29K2027/06—PVC, i.e. polyvinylchloride
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2055/00—Use of specific polymers obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of main groups B29K2023/00 - B29K2049/00, e.g. having a vinyl group, as moulding material
- B29K2055/02—ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2711/00—Use of natural products or their composites, not provided for in groups B29K2601/00 - B29K2709/00, for preformed parts, e.g. for inserts
- B29K2711/14—Wood, e.g. woodboard or fibreboard
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3047—Steering wheels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2451/00—Decorative or ornamental articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/003—Interior finishings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/08—Cars
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Manufacturing & Machinery (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Transportation (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
- Steering Controls (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
Abstract
Description
- The present invention relates to decorative components for motor vehicle interiors, as well as to a method and devices for their production.
- 1. Background of the Invention
- In the automotive field the demand for decorative parts or components, in particular made of wood, continues to rise. It is known to cover an aluminum or plastic core with a layer of wood or other decorative layer that is glued and finished manually.
- To reduce the time required by such manual operations, techniques have been developed that produce a laminated shell in a one-step method with a wood veneer and a supporting layer of a thermosetting resin. A disadvantage of this technique is that pieces with hooks, locking rims and other mechanical attachment means cannot be produced. Another disadvantage is the long production times.
- 2. Discussion of the Prior Art
- U.S. Pat. No. 5,792,302 discloses a process for the production of steering wheels with a wood veneer as a surface layer. Two layers of wood are pre-formed in two half-shells that are placed in a mold with the metal armature of the steering wheel. An expansion resin is then injected into a space between the metal armature and the half-shells, according to the Reaction Injection Molding technique, in order to force the half-shells against the mold and bond them together. Alternatively, two half-shells already supplied with the expanded resin portion are produced separately and glued to the metal armature of the steering wheel. This technique has several drawbacks because pieces with means of attachment or locking rims or undercuts cannot be produced. During the foaming Reaction Injection Molding flash is formed that must be removed by hand. The pre-forming and Reaction Injection Molding molding times are particularly long, reaching 40 minutes each. Moreover, like in the thermosetting-resin molding technique, it also requires a manual finishing step.
- U.S. Pat. No. 5,264,062 discloses production methods for a composite molded article having a wood overlay surface material. This document teaches to laminate the wood overlay surface to a metal or resin sheet that is backed on the other side to a porous or fibrous material; the wood overlay veneer of the thus obtained laminate is then coated, possibly after polishing. According to one of the disclosed production methods, the coated laminated material is preliminary molded (formed) by press working before a thermoplastic supporting layer is injection molded to the back of the material.
- U.S. Pat. No. 5,863,479 discloses a method of producing a laminated or composite material having a wood overlay veneer wherein the wood veneer is backed with a thin aluminium sheet, treated with a primer-based colorant and coated with a resin layer before being pre-formed in a conventional mold using a press. The thus obtained piece is placed into a mold and a backing resin supporting layer and a front transparent coating layer are injected into the mold.
- The above methods are long and complex, involving several coupling and coating steps and are limited to pre-forming of very simple shapes, thus resulting in expensive production processes.
- It is an aim of the present invention to solve the aforementioned problems and provide a process and a device to produce decorative parts or components with a veneer layer of wood, fabrics or other decorative materials, in a reliable and economic way that gives very good aesthetic results and that reduces the manual finishing times.
- The present invention addresses the aforementioned problems. According to one aspect of the invention, the veneer layer sheet comprises one layer of wood veneer or other decorative material bonded to one layer of backing material selected from thermoplastic or thermosetting materials and is pre-formed prior to the final thermoplastic-material injection step that provides the required supporting and coupling layer. According to a further aspect, the layer of rigid material is transparent and is located on the external side of the decorative material layer.
- According to a still further aspect of the invention, the pre-forming step is carried out in a mold having a male and a female part, wherein the male part comprises a projecting element that is at least in part deformable to adapt its shape to the shape of the female part and to accordingly shape the decorative layer. The male part projecting element is made of rubber, e.g. silicone rubber, that can be full or provided with an internal cavity that can be expanded upon feeding of a pressurized fluid.
- According to another aspect of the invention, one of the layers of the decorative layer is provided with electrically resistant means, such as a layer of electrically resistant coating, to act as heating means for a steering wheel or similar component.
- During the closing of the mold or at the beginning of the injection step, the veneer layer sheet is held in position against the respective mold half. This holding in position action can be carried out with retaining means such as jacks, struts, needles or similar moving elements, or by the mentioned pre-forming of the veneer layer. Because the layer is pre-formed accurately, it already has a shape that is almost the final one and will therefore fit snugly in the mold half without requiring any mechanical means. If, because of the final shape a self-retaining effect cannot be achieved and mechanical means are required, such as those previously mentioned, they project from the mold half that does not house the veneer layer and are mobile between an extended position and a retracted position; the force applied by said projecting elements to the covering sheet is such as to maintain the sheet in position at least during the initial step of the molding process. Thus, for the present invention the wording “holding in position” refers to both the above ways only through the shape or with mechanical means.
- According to a further aspect of the invention, a varnish or a coating layer is injected on the side of the cavity that corresponds to the face of the decorative sheet, after the thermoplastic-material injection step.
- A further aspect of the invention is a mold for pre-forming the decorative components, comprising two mold halves, a cavity and a deformable forming means positioned in one of said mold halves.
- A further aspect of the invention is a decorative component as obtainable with the method of manufacturing described above, comprising a veneer layer, at least one layer of backing material selected from thermoplastic or thermosetting materials, at least one coupling layer of thermoplastic material having means of attachment and/or undercuts provided into said thermoplastic material.
- A still further aspect of the invention is steering wheel shells having a veneer layer as obtainable according to the invention method of manufacturing.
- Preferably, the decorative components obtained according to the invention comprise a first layer of thermoplastic glued to the decorative material layer and a second layer of thermoplastic injected onto the said first layer. A layer of fabric or non-woven fabric may be bonded externally to the layer of thermoplastic glued to the decorative material layer in order to improve flexibility and the adhesion of the injected material on the decorative portion.
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FIG. 1 is a perspective view in partial section of two half-shells according to the invention. -
FIGS. 2, 3 and 4 are schematic cross sectional views of the method of molding half-shells according to the invention. -
FIG. 5 is a schematic cross sectional view of a liner sheet to be used in the method of manufacturing according to the invention. -
FIG. 6 is a partially magnified cross sectional view of the bonded half-shells ofFIG. 1 . -
FIGS. 7 and 8 are schematic cross sectional views of a pre-forming mold during two steps of the pre-forming process. -
FIG. 9 is an enlarged exploded view of a veneer element after preforming ofFIGS. 7 and 8 and injection molding. -
FIG. 10 is a perspective view of the veneer element ofFIG. 9 . -
FIG. 11 is a cross sectional view of a rim of a steering wheel manufactured in accordance with the present invention. - As used herein and in the claims the term decorative components for motor vehicle interiors refers to steering wheel shells, handles, gear-change lever knobs, inserts for door interior panels, dashboards and similar articles.
- With reference to
FIGS. 2-4 , amold 1 according to the present invention comprisesmold halves cavity 4 having a shape corresponding to the design of a decorative component for a car interior, for example a knob for a gear-change lever; a shell for a steering wheel; an insert for a dashboard or for an interior panel for a door. In the embodiment shown and discussed herein, reference is made to a pair of half-shells for a steering wheel, but the same remarks are valid for other decorative components. Similarly, the decorative component disclosed hereinafter is provided with a wood veneer, but instead of wood, the veneer could be made of a fabric, e.g. carbon fiber fabric or aramid fibers, leather and other materials. - A
pre-shaped layer 5 comprising a layer of veneer material (wood, fabric or other) 12 (FIG. 5 ) and abacking layer 14 of thermoplastic or thermosetting material, is placed in the mold, held in position and an amount of athermoplastic material 6 is injected onto the back of thelayer 5. To maintain the layer ofwood 5 in position during the closing of the mold and to prevent it from moving from the desired position, in one embodiment of the invention the mold is provided with a means of retaining thelayer 5 in position. InFIGS. 2-4 such a means of retaining position is exemplified by retractable small rods orneedles 7, which move between an extended position with the mold open (FIG. 2 ), a partially retracted one at the beginning of the injection step, and a retracted one, in which they are positioned when the injection of thermoplastic support material is partially completed (FIG. 4 ). -
FIG. 3 shows the mold-closing step, in whichrods 7 hold in position the steering wheel half-shell 5 in themold half 2 before being retracted in the last step of the injection molding process. Alternatively, other known means such as for example needles, clips, suction pads, temporary adhesives can be used to hold in position theveneer layer sheet 5. - The injection molding conditions are e.g. those used in the technique known as “In Mold Labeling (IML)” or “In Mold Dekorieren (IMD)” and involve low injection pressures; in the inventive method injection pressures are related to the dimension of the decorative component. For example, injection molding of wood veneered steering wheel rim sectors, using a 30% glass reinforced polyamide, is carried out at a pressure within the range of 1.100 and 1.500 Kg/cm2, depending upon the shell length. In spite of the injection pressure being relatively low, the pressure is however sufficient to press the
pre-shaped sheet 5 against themold half 2 and to give the sheet orlayer 5 the desired shape and dimensions. Thermoplastic materials suitable for injection molding oflayer 6 are polyolefins and polypropylene in particular, polyamides, ABS and vinyl polymers. - The
mold half 3 is designed to moldhooks 8 or similar means of attachment of the half-shell to a steering wheel, dashboard or panel, as well as reinforcing ribs and other structural components as required. InFIG. 1 the two half-shells L and R are used for covering a steering wheel all the way around its circumference, i.e. for 360°. To enable an overlap without showing gaps, the half-shell L is provided with a lockingstep 9 and with aportion 10 of the thermoplastic layer of 6 protruding with respect to the layer ofwood 5. The corresponding half-shell R presents aportion 11 of thesheet 5 that projects beyond the injectedthermoplastic layer 6 in order to provide a complementary shape to the lockingstep 9. Once the half-shells L and R are joined, as shown inFIG. 6 , aportion 10 oflayer 6 of the half-shell L overlapslayer 6 of the half-shell R; the two half-shells can be welded using ultrasonic energy, vibration, “hot gas” and other known techniques of welding thermoplastic. In this way, the use of adhesives and the problems associated therewith are avoided. - The
mold half 3 is provided with at least onenozzle 16 for injecting the thermoplastic layer. In the simplest embodiment shown inFIGS. 1-5 , thesheet 5 is backed by alayer 6 comprising a thermoplastic material that provides the structural and coupling layer required. If the dimensions of the sheet are reduced one nozzle may be sufficient, but it is often preferred to inject through two or more nozzles in order to use low injection pressures. The nozzles can feed one or more thermoplastic materials according to the type of decorative component being produced. Different materials can be injected in various portions of the mold to give a portion of decorative component where the veneer is a wood sheet and a portion where the “veneer” is an imitation leather thermoplastic material, that was injection molded in that area. - The technique of using different injection molding materials is known and used in the production of car trim panels and will make possible e.g. car dashboards and door panels to be produced, in which the wood veneer is bonded to the panel as a single piece.
- It is also possible to use the invention's laminates to produce panels or other products having a “simple” shape by compression molding; with this method the decorative material, possibly or preferably pre-formed, is shaped and bonded to a supporting layer of thermoplastic material by compression in a mold.
- The wood or other
material veneer sheet 5, on the back of which thethermoplastic 6 is injected, is sufficiently formable to be initially pre-formed and to be later imparted the final shape, completely, as a result of the of injection molding step. Such asheet 5 is preferably made of a laminate of thermoplastic and a veneer material such as wood or fabric or leather or other material.FIG. 5 shows an example of such a laminate, with a wood veneer. - The
sheet 5 inFIG. 5 comprises a layer of wood 12 (but other materials may be used) bonded by means of a thin layer ofglue 13 to a layer of thermoplastic orthermosetting material 14 that ensures the necessary support and form (i.e. shape) retaining properties to the wood layer in order to retain the shape imparted to thelaminate sheet 5 with the pre-forming step. In other embodiments thesheet 5 is comprising a layer ofresistive material 15 such as e.g. an electrically resistive coating or varnish located externally to thefilm 14 or, alternatively, theresistive coating 15 is applied directly to the layer ofwood 12 andthermoplastic layer 14 is bonded to thevarnish 15. Electric contacts will be provided in a known way, e.g. by means of laminae provided in correspondence of hooks 8 (FIG. 1 ). -
FIG. 5 also depicts afurther layer 23 of transparent plastics such as a polycarbonate or polyester film that is bonded by means of anadhesive layer 24 to the external side oflayer 12. The use of this transparent film results in ready to use shells after injection molding has been carried out as above disclosed, i.e. there is no need of coating the wood or fabric layer after injection molding.Film layer 23 is either thin and used in addition tolayer 14, that is in this case the form-retaining means, orfilm layer 23 is thick enough to be used as an alternative to layer 14, i.e.film layer 23 acts both as a coating and as a form retaining element. - The product thus obtained is formable and resistant to stretching and can be easily pre-formed into the desired shape without the wood veneer surface cracking. The
layer 12 of wood (or fabric or other decorative material) that has to be laminated with the remaininglayers -
- U.S. Pat. No. 4,205,107 A and is commercially available.
- The thickness of the
wood veneer 12 is between 0.1 and 1.2 mm and preferably between 0.4 and 0.8 mm; the adhesive has a minimal thickness, for example around 0.01-0.05 mm, thetransparent layer 23 has thickness within the range of 0.1 to 0.3 mm and the sheet or film ofthermoplastic 14 has thickness of between 0.08 and 0.8 mm and preferably between 0.1 and 0.4 mm. Suitable adhesives are hot-melt adhesives, for example vinyl or polyester, and acrylic or neoprene adhesive. Materials for the thermoplastic film are selected from PVC, polyolefins, ABS and similar materials suitable to provide a formable support. The laminate is obtained as a flat sheet that is cut as necessary and is subsequently pre-formed into the required shape. - By using the formable, and pre-formed, laminates, in particular those having a wood veneer, above described, it is possible to produce by injection or compression molding decorative components for car interiors that range from gear lever knobs to steering wheels and from door panels to dashboards.
- An advantage of the invention is the use of formable laminates having a thickness of 1.8 mm or less, comprising one veneer layer and at least one layer of thermoplastic material, for the production of decorative components for car interiors.
-
FIGS. 7 and 8 show a mold for pre-forming the laminates according to the invention. Such a mold comprises twomold halves means 18 of regulating the temperature, such as e.g. a circuit for oil, to increase and to reduce the temperature in the shortest possible time. - A
mold half 31 is provided with a male portion comprising a projectingportion 19 that is at least partially deformable and that is housed in the cavity 26 of themold half 30 when the mold is closed. Thisdeformable projecting portion 19. In the shown embodiment the deformable means has acavity 25 and is formed by expandable means that can increase its volume, i.e. by an inflatable silicone rubber bladder that can be pressurized to increase its volume. To pressurize thebladder 19 it is connected to aduct 20, that is connected to a source of pressure, e.g. of compressed air (not shown).FIG. 7 also shows an insert 21 (i.e. an intermediate or additional mold portion) that is located between the twomold halves rim 32. Theinsert 21 has anopening 17 therein that generally corresponds to the shape of the cross-section of the cavity 26 of the mold halves 30, but with a smaller area. In other words, thedistance 27 between thesides 29 of theopening 17 forinflatable element 19 is greater than the distance between the corresponding edges of cavity 26 ofmold half 30. Thus, when theinsert 21 is positioned onmold half 30, a step is formed that will produce the required locking rim (FIG. 8 ); the pre-formed laminate layer L (FIG. 1 ) is thus produced. When the pre-formed laminate layer R ofFIG. 1 is to be produced, theinsert 21 is replaced by an insert wherein thedistance 27 and the distance 28 are the same, to avoid the forming of a step. - Instead of a bladder, the
deformable element 19 can be made of a solid, deformable material, such as silicone rubber or a foamed polymer having density sufficient to press thelaminate layer 5 against the mold cavity walls to impart the required, and exact, shape tolaminate 5. In other words, theelement 19 is deformed to follow the shape of the cavity 26 and of theinsert 21. Thedeformed element 19 compresses laminate 5 against the walls of cavity 26 and insert 21 to reproduce the required exact shape to be obtained. - The operation of the pre-forming mold will now be described. The
insert 21 is positioned on themold half 30 byguides 22 present on themold half 30. Then asheet 5, cut to the desired size and shape, is positioned in the cavity of themold half 30 from above i.e. through opening 17 ofinsert 21. As the mold is closed thedeformable protruding portion 19 is inserted into the cavity 26 of themold half 30, through theinsert 21. Then, the mold halves 30, 31 are heated and thebladder 19 is pressurized by feeding compressed air through a conduit. Thebladder 19 is inflated until it firmly presses thesheet 5 against the walls of themold half 30 and a part of theinsert 21. By the combined action of heat and pressure alaminate sheet 5 is formed into a shape that can be very close to the final one. In fact, it is possible to obtain parts pre-formed so well that in the following co-molding step there is no need for additional retaining means to retain thesheet 5 in the injection mold. - When the
sheet 5 is of the type laminated with a thermoplastic film, the temperature of the mold halves 30, 31 has to be lower than the melting point or degradation temperature of the glue present in the laminate, while trying to make pre-forming cycles as fast as possible. For the sheets used for the present invention the temperature used is between 50 and 200° C. and preferably between 55 and 100° C.; the pressure is between 4 and 6 bars, usually approximately 5 bars and the cycle time between 3 and 60 seconds. - The same mold and the same process can be used for the mold preparation of products in carbon fiber; in this case the times are of approximately 20 minutes and the pressure used is approximately 3-4 bar, with a temperature between 70° C. and 180° C., applied in different steps, depending upon the dimensions and the shape of the decorative component.
-
FIGS. 9 and 10 show a veneer element for steering wheels that is smaller than the half shell above disclosed, said element being an insert for a steering wheel having a main surface made e.g. of leather. The insert is to be housed in a seat provided in the leather coating. The net, exact shape of the insert obtained thanks to the process of the invention is clearly visible in these figures.Layer 5 has been pre-formed as above discussed to result in a shape comprising peripheral steps or rims 32. After injection molding of thermoplastic layer 6 (FIGS. 3-4 ) the resulting veneer element comprises adecorative layer 5 that ends withstep 32 and a supportinglayer 6 that comprises a peripheral “counter-step” 33 that matches step 32 to provide an evenperipheral edge 34. No further steps are required to bring the peripheral edges into the required shape. This is a great advantage when considering that inserts and half shells for steering wheels are in fact curved in two directions: transversally to the steering wheel and along its circumference. In other words, the pre-forming of the veneer layer into a form that is retained makes it possible to shape it to follow the shape of the steering wheel and to avoid further production steps for finishing the edges. -
FIG. 11 is a cross sectional view of the rim of a steering wheel manufactured according to the presentinvention showing insert 35 in place on asteering wheel armature 40, an expansion resin (PUR foam) 39, and a firstpartial coating 41 covering more or less half of the circumference of the steering wheel section and comprising aninner layer 38 of foam material glued or coupled to anouter layer 37 made of leather. On the steering wheel side opposite to that covered by theleather layer coating 41 thePUR foam 39 is shaped into at least oneseat 42 that acts as a retaining means forhook 8 of theinsert 35.Glue 43 is provided inseat 42 and aroundhook 8 to firmly retain it to thePUR foam 39. In the shown embodiment, aheating element 44 is located betweenPUR foam 39 and plastic supportinglayer 6 ofinsert 35; alternatively, a heating element such as a resistive layer can be located between theplastic layer 6 and thelaminate layer 5, as previously discussed. - The invention will now be further disclosed with reference to the following example.
- A formable laminate comprising a wood veneer layer 0.75 mm thick, a thermoplastic material layer 0.21 mm thick and a backing fabric layer, having a total thickness of 1.1 mm is cut to an arched shape of 130° C. The thus cut laminate is preformed in a pre-forming mold as above disclosed for 50 sec at 90° C. and 4.8 bar (pressure of the fluid fed to the inflatable bladder). The pre-formed laminate was then positioned in a mold and retained in position by suction means. A 30% fiberglass reinforced polyamide was injected on the back of the laminate to give a half shell with a perfect shape and without cracks of the wood layer. The injected supporting layer of thermoplastic material is provided with integral hooks for mounting on the steering wheel structure. After finishing and light sanding the shell is lacquered and polished to give an excellent decorative component that can be fit to a steering wheel.
- Returning to the “In Mold” molding step of the pre-formed sheet, it has been mentioned that this allows hooks, webbing and similar details to be obtained in a single piece. If no
transparent layer 23 is present, the invention makes it possible to directly paint the part in the mold for injection molding, according to the known “In-mold paint” techniques, such as by injection either of a transparent polyurethane varnish or of a coating layer. - The invention shows several advantages over the prior art. The invention solves the problem for open and closed shape parts in steering wheels shells lowering the cost of production. The invention enables the production in one-shot co-molding process of decorative components with a wood, leather or fabric finish, already provided with undercuts, rims and means of attachment such as hooks and similar, as necessary for their final use. The pre-forming and molding times are reduced and the temperature and pressure requirements are moderated.
- The method of manufacturing is simple and reliable and the parts produced are aesthetically very attractive. Moreover, by co-molding by injection molding the thermoplastic support a “net shape” part is obtained, i.e. no machining is required to achieve the final shape of the part.
- Although several preferred embodiments are illustrated and described above, there are possible combinations using other geometries, materials and different dimensions for the components that perform the same functions. This invention is not limited to the above embodiments and should be determined by the following claims.
Claims (17)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP04425423.3 | 2004-06-10 | ||
EP04425423A EP1604797A1 (en) | 2004-06-10 | 2004-06-10 | Decorative elements for motor vehicle interiors, process and molds for their production |
Publications (1)
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US20050276874A1 true US20050276874A1 (en) | 2005-12-15 |
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Application Number | Title | Priority Date | Filing Date |
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US11/142,861 Abandoned US20050276874A1 (en) | 2004-06-10 | 2005-06-01 | Decorative components for motor vehicle interiors |
Country Status (9)
Country | Link |
---|---|
US (1) | US20050276874A1 (en) |
EP (2) | EP1604797A1 (en) |
JP (1) | JP2007532364A (en) |
KR (1) | KR100859438B1 (en) |
CN (1) | CN1938140A (en) |
ES (1) | ES2442856T3 (en) |
MX (1) | MXPA06012029A (en) |
PL (1) | PL1755854T3 (en) |
WO (1) | WO2005123362A2 (en) |
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Also Published As
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WO2005123362A2 (en) | 2005-12-29 |
JP2007532364A (en) | 2007-11-15 |
MXPA06012029A (en) | 2007-01-25 |
CN1938140A (en) | 2007-03-28 |
EP1604797A1 (en) | 2005-12-14 |
WO2005123362A3 (en) | 2006-04-06 |
PL1755854T3 (en) | 2014-04-30 |
ES2442856T3 (en) | 2014-02-13 |
KR100859438B1 (en) | 2008-09-23 |
EP1755854A2 (en) | 2007-02-28 |
EP1755854B1 (en) | 2013-11-20 |
KR20070028409A (en) | 2007-03-12 |
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