Method for producing a plastic composite element

1. A method for producing a plastic composite element ( 1 ) as an interior lining element for a motor vehicle, with an outer covering ( 2 ) being lined with a foamable plastic, characterized in that said outer covering ( 2 ) is lined at least partially with a flexible foam ( 3 ), that said flexible foam ( 3 ) is subsequently lined with a rigid foam ( 5 ), with a separating means being placed thereinbetween, and that a shaped part ( 4 ) which can be prefabricated is used as said separating means which by virtue of the mechanical properties of its material and/or its shape prevents said rigid foam ( 5 ) from penetrating said flexible foam ( 3 ) and/or prevents a deformation of said outer covering ( 2 ) and wherein a portion of said shaped part ( 4 ) contacts said outer covering ( 2 ) and is connected thereto.

2. The method according to claim 1 , characterized in that said shaped part ( 4 ) is produced by deep drawing.

3. The method according to claim 2 , characterized in that said shaped part ( 4 ) is made of acrylic butadiene styrene, polyvinyl chloride or polystyrene with an initial thickness of 0.1 to 0.7 mm.

4. The method according to claim 1 wherein during lining of said outer covering ( 2 ), a flexible foam material forming said flexible foam ( 3 ) is applied to a back side ( 2 a ) of said outer covering ( 2 ) which is laid into a lower mold ( 6 ) and subsequently, before or during foaming of said flexible foam material, said shaped part ( 4 ) which is mounted on an upper mold ( 7 ) is brought into contact with said flexible foam material.

5. The method according to claim 1 wherein said shaped part ( 4 ) includes an edge portion that is brought into a contact with said outer covering ( 2 ) and connected thereto.

6. The method according to claim 1 wherein said flexible foam ( 3 ) is a polyurethane foam having a specific weight from 0.11 to 0.18 g/cm 3 .

7. The method according to claim 2 wherein during lining of said outer covering ( 2 ), a flexible foam material forming said flexible foam ( 3 ) is applied to a back side ( 2 a ) of said outer covering ( 2 ) which is laid into a lower mold ( 6 ) and subsequently, before or during foaming of said flexible foam material, said shaped part ( 4 ) which is mounted on an upper mold ( 7 ) is brought into contact with said flexible foam material.

8. The method according to claim 3 wherein during lining of said outer covering ( 2 ), a flexible foam material forming said flexible foam ( 3 ) is applied to a back side ( 2 a ) of said outer covering ( 2 ) which is laid into a lower mold ( 6 ) and subsequently, before or during foaming of said flexible foam material, said shaped part ( 4 ) which is mounted on an upper mold ( 7 ) is brought into contact with said flexible foam material.

9. The method according to claim 2 wherein said shaped part ( 4 ) includes an edge portion that is brought to contact with said outer covering ( 2 ) and connected thereto.

10. The method according to claim 3 wherein said shaped part ( 4 ) includes an edge portion that is brought into contact with said outer covering ( 2 ) and connected thereto.

11. The method according to claim 4 wherein said shaped part ( 4 ) includes an edge portion that brought into contact with said outer covering ( 2 ) and connected thereto.

12. The method according to claim 2 wherein said flexible foam ( 3 ) is a polyurethane foam having a specific weight from 0.11 to 0.18 g/cm 3 .

13. The method according to claim 3 wherein said flexible foam ( 3 ) is a polyurethane foam having a specific weight from 0.11 to 0.18 g/cm 3 .

14. The method according to claim 4 wherein said flexible foam ( 3 ) is a polyurethane foam having a specific weight from 0.11 to 0.18 g/cm 3 .

15. The method according to claim 5 wherein said flexible foam ( 3 ) is a polyurethane foam having a specific weight from 0.11 to 0.18 g/cm 3 .