# US 8,771,580 B2 · Method for making molded skins from multiple plastics

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 8,771,580 B2
- Document ID: US8771580B2
- Status: Granted
- Kind: B2
- Application number: 12/382,765
- Filed: 2009-03-24
- Published: 2010-04-15
- Granted: 2014-07-08
- Earliest claimed: 2006-09-30
- Assignees: Johnson Controls Interiors GmbH & Co. KG
- Applicants: André Walter; Harald Dalibor; Michael Heidkamp; Hans-Bernd Jacoby; Zbigniew Parzelski; Marco Sander
- Inventors: André Walter; Harald Dalibor; Michael Heidkamp; Hans-Bernd Jacoby; Zbigniew Parzelski; Marco Sander
- Web page: https://patentgrep.com/patent/US8771580B2

## CPC

- B29C 41/22: Making multilayered or multicoloured articles
- B29C 41/08: Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder {(spray-up of reinforcing fibres B29C70/305)}
- B29C 41/18: Slush casting, i.e. pouring moulding material into a hollow mould with excess material being poured off
- B29C 41/46: Heating or cooling
- B29C 41/36: Feeding the material on to the mould, core or other substrate
- B29K 2995/0021: Multi-coloured
- B29L 2031/3008: {Instrument panels}
- B29L 2031/3014: {Door linings}
- 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- 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
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

The invention relates to a method for the production of plastic molded skins which are built up by consecutively melting multiple plastics onto each other. The surface of the forming tool is partially covered with a covering or mask during the melting of a first plastic powder and the first plastic powder is applied to the forming tool by a powder spray method. Thereafter, the covering or mask is removed from the surface of the forming tool and the second plastic powder is applied to the surface of the forming tool and to the first plastic powder by rotation sintering.

## Claims

### Claim 1

A method for making a plastic molded skin for interior motor vehicle parts including dashboards and door trim, the method comprising the steps of:
(a) providing a forming tool having a surface and projecting webs on said surface for separating regions of said surface from each other for accommodating plastic powders of respectively different characteristics;
(b) applying a covering or mask to at least one of said regions with said covering or mask having a peripheral region whereat a seal is provided in seal tight engagement with said projecting webs;
(c) applying a first plastic powder to said forming tool utilizing a powder spray method while maintaining said forming tool at a first temperature during spraying of said first plastic powder;
(d) thereafter increasing the temperature of said forming tool so as to cause the first plastic powder applied in step (c) to adhere to the unmasked regions of said forming tool by melting on;
(e) removing said covering or mask from said at least one of said regions;
(f) thereafter placing said forming tool onto a powder box containing a second plastic powder and connecting said forming tool seal tight to said powder box with said surface of said forming tool facing toward an interior space of said powder box;
(g) imparting movement/rotation to said forming tool and said powder box so as to cause said second plastic powder to flow onto said surface of said forming tool and to cause, via rotation sintering, to adhere said second plastic powder to said surface and to said first plastic powder by melting on;
(h) increasing the temperature of said forming tool so that said first and second plastic powders completely react and fuse to a homogeneous plastic molded skin;
(i) removing said forming tool from said powder box; and,
(j) then cooling said forming tool so as to permit the homogeneous plastic molded skin to be removed therefrom,
wherein an expandable flexible tube is provided within a groove of said covering or mask at an underside of the seal;
wherein said seal is disposed entirely in the groove and is movable within said groove of said covering or mask prior to being transferred into a sealing position; and,
wherein said seal of said covering or mask lying against said projecting webs is switchably transferred into said sealing position.

### Claim 2 (depends on 1)

The method of claim 1, wherein said first and second plastic powders have different characteristics defined by respectively different colors.

### Claim 3 (depends on 1)

The method of claim 1, wherein said first and second plastic powders have different characteristics defined by different densities and/or different degrees of foaminess.

### Claim 4 (depends on 1)

The method of claim 1, wherein the temperature of the forming tool lies in a range of 190° C. to 210° C. during said method step (c).

### Claim 5 (depends on 4)

The method of claim 4, wherein said temperature of said forming tool in said method step (c) is 195° C.

### Claim 6 (depends on 1)

The method of claim 1, wherein the temperature of said forming tool lies in a range of 200° C. to 220° C. during the melting on of said first plastic powder in said method step (d).

### Claim 7 (depends on 6)

The method of claim 6, wherein said temperature of said forming tool in said method step (d) is 210° C.

### Claim 8 (depends on 1)

The method of claim 1, wherein the temperature of said forming tool lies in a range of 225° C. to 240° C. during said method step (h) so as to permit a complete reaction and fusion of said first and second plastic powders into said homogeneous plastic molded skin.

### Claim 9 (depends on 8)

The method of claim 8, wherein said temperature of said forming tool in method step (h) is 235° C.

### Claim 10 (depends on 1)

The method of claim 1, wherein the forming tool is positioned open downwardly during the powder spraying in said method step (c).