US 11,891,010 B2
Lining element, and process for manufacturing a lining element
Martin Schwabl, Hohenthann (DE)
Assigned to Bayerische Motoren Werke Aktiengesellschaft, Munich (DE)
Filed by Bayerische Motoren Werke Aktiengesellschaft, Munich (DE)
Filed on Sep. 20, 2019, as Appl. No. 16/577,217.
Application 16/577,217 is a continuation of application No. PCT/EP2018/056532, filed on Mar. 15, 2018.
Claims priority of application No. 10 2017 204 963.4 (DE), filed on Mar. 23, 2017.
Prior Publication US 2020/0010043 A1, Jan. 9, 2020
Int. Cl. B60R 21/2165 (2011.01); B29C 37/00 (2006.01); B29C 44/14 (2006.01); B29C 44/42 (2006.01); B32B 5/20 (2006.01); B32B 9/02 (2006.01); B29C 69/02 (2006.01); B60R 21/237 (2006.01); B29D 99/00 (2010.01); B29K 23/00 (2006.01); B29K 509/08 (2006.01); B29K 711/08 (2006.01); B29L 31/30 (2006.01)
CPC B60R 21/2165 (2013.01) [B29C 37/0057 (2013.01); B29C 44/146 (2013.01); B29C 44/428 (2013.01); B29C 69/02 (2013.01); B29D 99/005 (2013.01); B32B 5/20 (2013.01); B32B 9/025 (2013.01); B29K 2023/12 (2013.01); B29K 2509/08 (2013.01); B29K 2711/08 (2013.01); B29L 2031/3038 (2013.01); B32B 2262/101 (2013.01); B32B 2266/025 (2013.01); B32B 2605/003 (2013.01); B60R 21/237 (2013.01)] 7 Claims
OG exemplary drawing
 
1. A method for producing a lining element by an injection molding integral foam method, wherein the lining element comprises:
a dimensionally stable backing layer with a first predetermined breaking region which is delimited from a surrounding region and/or from a second predetermined breaking region by at least one predetermined breaking line, wherein a plurality of regularly spaced predetermined breaking points are disposed along the predetermined breaking line, wherein the breaking points are recesses in the backing layer, wherein the backing layer has a visible side and a rear side facing away from the visible side, and wherein the recesses are disposed only on the visible side of the backing layer such that the recesses have a respective depth in the backing layer that reduces a thickness of the backing layer in regions of the recesses to a residual thickness; and
a decorative layer disposed flat on the backing layer on the visible side of the backing layer, wherein a first surface of the decorative layer directly above one of the plurality of regularly spaced predetermined breaking points disposed on the visible side forms a plane together with a second surface of the decorative layer, wherein the second surface is directly adjacent to the first surface and completely surrounds the first surface such that the decorative layer on the visible side of the backing layer does not have any recesses in a region opposite the recesses of the backing layer;
and the method comprising:
injecting a fiber composite material into a cavity formed between a first die side and a second die side of a die to form the backing layer;
compressing the backing layer by bringing the first die side and the second die side of the die toward each other before the cavity formed between the first die side and the second die side has been enlarged in the injection molding integral foam method in order to foam the injected fiber composite material and, via the compressing, forming the recesses in the backing layer by impressing a plurality of projections which are disposed or formed on the first die side into the backing layer;
after the compressing, enlarging the cavity formed between the first die side and the second die side and foaming the injected fiber composite material of the backing layer such that the backing layer is expanded; and
removing the backing layer from the die and disposing the decorative layer flat on the visible side of the backing layer such that the first surface of the decorative layer directly above one of the plurality of regularly spaced predetermined breaking points disposed on the visible side forms the plane together with the second surface of the decorative layer and such that the decorative layer on the visible side of the backing layer does not have any recesses in a region opposite the recesses of the backing layer.