METHOD OF MAKING A FLAT BUILDING COMPONENT

1 . A method of making a thin component in lightweight sandwich construction with a high-quality surface, the method comprising the following steps of:

a) providing a film like substrate;

b) introducing the substrate into a lower mold part of a mold;

c) providing a granular starting material in the form of loose particles of an expandable particle foam;

d) completely expanding the particles;

h) baking the expanded particles into a curable particle foam that bonds to the substrate; and

i) curing the particle foam to form a molded body with the substrate.

2 . The method according to claim 1 , wherein the substrate is a thermoformed film.

3 . The method according to claim 1 , further comprising the step of:

k) applying a cover layer to a face of the particle foam directed away from the substrate.

4 . The method according to claim 1 , further comprising the step of:

g) processing of the molded body into a component.

5 . The method according to claim 2 , wherein the film has a wall thickness of between 0.2 mm and 13 mm.

6 . The method according to claim 1 , wherein the cured particle foam of step i) has a wall thickness of between 1 cm and 30 cm.

7 . The method according to claim 1 , further comprising the step of:

g) the mold forming the component into a vehicle part for a motor vehicle or for a commercial vehicle or for a trailer.

8 . The method according to claim 1 , wherein the starting material is expandable EPS, PP or PEEK.

9 . The method according to claim 1 , further comprising, before step h), the step of:

m) positioning of reinforcing elements in the lower mold part such that introduction of the expanded particles into the lower mold part encases the reinforcing elements with the expanded particles.

10 . A flat component with a high-quality surface made according to claim 1 , the component comprising a substrate to which the cured particle foam is bonded.

11 . The component according to claim 10 , wherein the film has a wall thickness of between 0.2 mm and 13 mm.

12 . The component according to claim 10 , wherein the cured particle foam has a wall thickness of between 1 cm and 30 cm.

13 . The component according to claim 10 , wherein the particle foam is expanded against the substrate.

14 . The method according to claim 1 , wherein in step b) the substrate is introduced into a cavity of the lower mold part, the method further comprising between steps d) and e) the steps of sequentially:

e) introducing the completely expanded particles into the cavity of the lower mold part on top of the substrate,

f) closing the mold,

g) heating the mold.

15 . The method according to claim 1 , wherein steps d), h) and i) are carried out in a cavity of the lower mold part.

16 . The method according to claim 7 , wherein the vehicle part is interior design part, cargo space cover, lining part, engine bonnet, roof element or roof segment, vehicle wall, or vehicle wall element.

17 . The method according to claim 1 , further comprising the step after step i) of:

j) opening the mold and removing the molded body therefrom.