Method for manufacturing a trim element

Abstract

A cost-effective and resource-saving method for manufacturing a trim element, in particular a trim element which is used as a vehicle interior lining element. The trim element has a rear side reinforcement layer and a decorative surface. In the method according to the invention, a first layer is bonded in a first lamination step under pressure and heat to a first lamination and a second layer is bonded in a second lamination step under pressure and heat to a second lamination. The heat introduced in the second lamination step also acts in the first lamination and increases its bonding strength to the first layer.

What is claimed is: 
     
         1 . A method for manufacturing a trim element, in particular a trim element for the automotive interior, with a rear side reinforcement layer and a face side decorative surface;
 in which a first layer is bonded under pressure and heat in a first lamination step to a first lamination for producing a substantially planar ply composite,   in which a second layer is bonded under pressure and heat in a second, subsequent lamination step to a second lamination,   where in the second lamination step, said second layer is abutted against said first lamination and heat introduced in said second lamination step also acts in said first lamination, so that said second layer is bonded to said ply composite via said first lamination to produce a substantially planar sandwich structure,   where said rear side reinforcement layer is formed by a fused arrangement of a plastic material against a rear side of said second layer and bonded to said second lamination.   
     
     
         2 . The method for manufacturing a trim element according to  claim 1 , wherein the heat introduced in said second laminating step takes said first lamination to a temperature not less than a maximum temperature in said first lamination in said first lamination step. 
     
     
         3 . The method for manufacturing a trim element according to  claim 1 , wherein a pressing pressure introduced in said second lamination step is not less than a pressing pressure in said first lamination step. 
     
     
         4 . The method for manufacturing a trim element according to  claim 1 , wherein a pressing time of said second lamination step is not less than a pressing time of said first lamination step. 
     
     
         5 . The method for manufacturing a trim element according to  claim 1 , wherein said second layer is abutted against said first layer with the interposition of said first lamination prior to said second lamination step. 
     
     
         6 . The method for manufacturing a trim element according to  claim 1 , wherein, in the context of manufacturing said trim element, a maximum temperature in each lamination, or with a multi-ply lamination in each ply, is not higher than a maximum temperature in the lamination or ply preceding on the face side. 
     
     
         7 . The method for manufacturing a trim element according to  claim 1 , wherein, in the context of manufacturing the trim element, a pressing pressure of a temporally subsequent lamination step is not less than a pressing force of a temporally immediately subsequent lamination step subsequent to this lamination step. 
     
     
         8 . The method for manufacturing a trim element according to  claim 1 , wherein, in the context of manufacturing said trim element, a pressing time of a temporally preceding lamination step is shorter than a pressing time of a temporally immediately subsequent lamination step preceding this lamination step. 
     
     
         9 . The method for manufacturing a trim element according to  claim 1 , wherein said first and said second layer form the face side decorative surface of said trim element. 
     
     
         10 . The method for manufacturing a trim element according to  claim 1 , wherein said first layer after application of said first lamination is provided with at least one through-hole penetrating said first layer and said first lamination and that a cavity pressure acting when forming said reinforcement layer on said rear side of said second layer presses a region of said second layer, which is located on a rear side of said first layer, into said through-hole. 
     
     
         11 . The method for manufacturing a trim element according to  claim 10 , wherein said through-hole is recessed in said sandwich structure. 
     
     
         12 . The method for manufacturing a trim element according to  claim 1 , wherein a two-ply first lamination is used in the first lamination step, that said first layer is bonded to a first lamination ply that is abutted against said first layer and that, in a second lamination step, said second layer on its side facing said first layer is bonded to a second lamination ply abutted against said second layer and on its side facing away from said first layer to said second lamination. 
     
     
         13 . The method for manufacturing a trim element according to  claim 10 , wherein a two-ply first lamination is used in the first lamination step, that said first layer is bonded to a first lamination ply that is abutted against said first layer and that, in said second lamination step, said second layer on its side facing said first layer is bonded to a second lamination ply abutted against said second layer and on its side facing away from said first layer to said second lamination. 
     
     
         14 . The method for manufacturing a trim element according to  claim 12 , wherein said first lamination ply that in the first lamination step is abutted against the first layer is fused or activated, but not said second lamination ply of said two-ply first lamination. 
     
     
         15 . The method for manufacturing a trim element according to  claim 1 , wherein the heat introduced in said second laminating step takes said first lamination to a temperature not less than the maximum temperature in said first lamination in said first lamination step and that the pressing pressure introduced in said second lamination step is not less than the pressing pressure in said first lamination step. 
     
     
         16 . The method for manufacturing a trim element according to  claim 1 , wherein the heat introduced in said second laminating step takes said first lamination to a temperature not less than a maximum temperature in said first lamination in said first lamination step and that a pressing time of said second lamination step is not less than a pressing time of said first lamination step. 
     
     
         17 . The method for manufacturing a trim element according to  claim 1 , wherein the pressing pressure introduced in said second lamination step is not less than the pressing pressure in said first lamination step and that a pressing time of said second lamination step is not less than a pressing time of said first lamination step. 
     
     
         18 . The method for manufacturing a trim element according to  claim 1 , wherein the heat introduced in said second laminating step takes said first lamination to a temperature not less than a maximum temperature in said first lamination in said first lamination step, that the pressing pressure introduced in said second lamination step is not less than the pressing pressure in said first lamination step and that the pressing time of said second lamination step is not less than the pressing time of said first lamination step. 
     
     
         19 . The method for manufacturing a trim element according to  claim 1 , wherein said second layer is abutted against said first layer with the interposition of said first lamination prior to said second lamination step and that, in the context of manufacturing said trim element, a maximum temperature in each lamination, or with a multi-ply lamination in each ply, is not higher than the maximum temperature in the lamination or ply preceding on the face side. 
     
     
         20 . The method for manufacturing a trim element according to  claim 1 , wherein said second layer is abutted against said first layer with the interposition of said first lamination prior to said second lamination step and that, in the context of manufacturing the trim element, the pressing pressure of a temporally subsequent lamination step is not less than the pressing force of a temporally immediately subsequent lamination step subsequent to this lamination step. 
     
     
         21 . The method for manufacturing a trim element according to  claim 1 , wherein, in the context of manufacturing said trim element, a maximum temperature in each lamination, or with a multi-ply lamination in each ply, is not higher than a maximum temperature in the lamination or ply preceding on the face side and the pressing pressure of a temporally subsequent lamination step is not less than the pressing force of a temporally immediately subsequent lamination step subsequent to this lamination step. 
     
     
         22 . The method for manufacturing a trim element according to  claim 1 , wherein said second layer is abutted against said first layer with the interposition of said first lamination prior to said second lamination step and that, in the context of manufacturing the trim element, a maximum temperature in each lamination, or with a multi-ply lamination in each ply, is not higher than a maximum temperature in the lamination or ply preceding on the face side and the pressing pressure of a temporally subsequent lamination step is not less than the pressing force of a temporally immediately subsequent lamination step subsequent to this lamination step. 
     
     
         23 . A method for manufacturing a trim element, in particular a trim element for the automotive interior, with a rear side reinforcement layer and a face side decorative surface;
 in which a first layer is bonded under pressure and heat in a first lamination step to a first lamination,   in which a second layer is bonded under pressure and heat in a second, subsequent lamination step to a second lamination,   wherein the heat introduced in said second lamination step also acts in said first lamination.   
     
     
         24 . A method for manufacturing a trim element with a decorative layer comprising the steps of:
 bonding a first layer to a first lamination partially with a first pressure and a first temperature forming a first ply composite;   placing a second layer adjacent the first lamination of the first ply composite; and   bonding a second lamination to the second layer with a second pressure and a second temperature sufficient to create additional bonding between the first layer and the first lamination,   whereby bonding between the first layer and the first lamination is increased during the step of bonding the second lamination to the second layer.