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US 10,005,207 B2Granted
Molded part and method for manufacturing the molded part
AssigneeFaurecia Innenraum Systeme GmbH
InventorsFriedhelm Kastell, Peter Günther, Jochen Reichhold
Life of this patent
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Abstract
The invention pertains to a molded part (10) with a visible surface and a rear surface (S1, S2), wherein the molded part (10) features: a substrate (20) of hot-pressed fibrous molding material (21); a coating (30) of at least one polymer material (34, 35); wherein the surface (33) of the coating (30) has at least sectionally a center line average height Ra in the range of 10 to 80 μm, as well as to a method for manufacturing the molded part.
Claims19
A molded part with a visible surface and a rear surface, with the molded part comprising:
- a substrate of hot-pressed fibrous molding material, wherein the hot-pressed fibrous molding material comprises fibers in a random arrangement;
- and
- a coating of at least one polymer material configured to adapt to a surface of the substrate of hot-pressed fibrous molding material;
- wherein a portion of the coating penetrates the substrate of hot-pressed fibrous molding material, wherein a surface of the coating is at least partially defined by the random arrangement and shape of the fibers of the fibrous molding material, and wherein, at least sectionally, a center line average height Ra of the surface of the coating is in the range of 10 to 80 μm.
1 more element
A method for manufacturing a molded part, with the method comprising the steps of:
- applying polymer materials onto at least one surface of a fibrous molding material in the form of dispersions, powders, granulates or a film that consists of at least one layer, wherein the polymer material is configured to adapt to the at least one surface of the fibrous molding material, wherein the fibrous molding material comprises fibers in a random arrangement;
- compressing the fibrous molding material and the polymer materials into a blank with a first temperature-controlled pressing tool at temperatures in the range of 160 to 230° C.;
- and
- compressing the obtained blank into a molded part with a second pressing tool at temperatures in the range of 20 to 140° C. to form a substrate of hot-pressed fibrous molding material with a coating comprising polymer materials, wherein a portion of the coating penetrates the substrate of hot-pressed fibrous molding material, wherein a surface of the coating is at least partially defined by the random arrangement and shape of the fibers of the fibrous molding material, and wherein, at least sectionally, a center line average height Ra of the surface of the coating is in the range of 10 to 80 μm.
1 more element
A method for manufacturing a molded part, with the method comprising the steps of:
- (a) providing a mat-shaped fibrous molding material, wherein the fibrous molding material comprises fibers in a random arrangement;
- (b) providing at least one polymer material in the form of dispersions, powders, granulates or a film that consists of at least one layer, wherein the polymer material is configured to adapt to at least one surface of the mat-shaped fibrous molding material;
- (c) providing a first temperature-controlled pressing tool;
- (d) providing a second pressing tool;
- (e) applying the polymer materials onto the at least one surface of the fibrous molding material;
- (f) compressing the fibrous molding material and the polymer materials into a blank with the first pressing tool;
- and
- (g) compressing the blank obtained in step (f) into a molded part having a substrate of hot-pressed fibrous molding material and a coating comprising the at least one polymer material with the second pressing tool;
- wherein:
- a first coating zone with a thickness D1 in the range of 10 to 200 μm is produced of at least one of the polymer materials in step (f);
- a second coating zone which extends into the substrate in a thickness direction is produced, the second coating zone having a thickness D2 in the range of 10 to 200 μm and being produced of at least one of the polymer materials and fibrous molding material in step (f);
- and
- a surface of the coating is at least partially defined by the random arrangement and shape of the fibers of the fibrous molding material, and wherein, at least sectionally, a center line average height Ra of the surface of the coating is in the range of 10 to 80 μm.
10 more elements
Dependencies are inferred from the claim text.