EP2254744A1 - Dispositif et procédé de doublage d'une couche support avec une couche décorative - Google Patents

Dispositif et procédé de doublage d'une couche support avec une couche décorative

Info

Publication number
EP2254744A1
EP2254744A1 EP09713327A EP09713327A EP2254744A1 EP 2254744 A1 EP2254744 A1 EP 2254744A1 EP 09713327 A EP09713327 A EP 09713327A EP 09713327 A EP09713327 A EP 09713327A EP 2254744 A1 EP2254744 A1 EP 2254744A1
Authority
EP
European Patent Office
Prior art keywords
decorative layer
tool
laminating
contour piece
shaping contour
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP09713327A
Other languages
German (de)
English (en)
Inventor
Andreas Meyer
Marco Ganz
Dirk Hasse
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Faurecia Innenraum Systeme GmbH
Original Assignee
Faurecia Innenraum Systeme GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Faurecia Innenraum Systeme GmbH filed Critical Faurecia Innenraum Systeme GmbH
Publication of EP2254744A1 publication Critical patent/EP2254744A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/16—Lining or labelling
    • B29C51/165—Lining or labelling combined with the feeding or the shaping of the lining or the labels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26—Component parts, details or accessories; Auxiliary operations
    • B29C51/46—Measuring, controlling or regulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/007—Using fluid under pressure
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
    • Y10T156/1028—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina by bending, drawing or stretch forming sheet to assume shape of configured lamina while in contact therewith

Definitions

  • the invention relates to a tool and a method for laminating a decorative layer on a carrier part.
  • DE 10 2004 063 658 B4 shows a vacuum laminating tool with two tool parts for producing a decorative layer, wherein the tool parts each have a deformation contour defining the contour of the decorative layer in order to bring about the deformation of the decorative layer due to the collapse of the tool parts.
  • a laminating device for laminating a carrier molding with a cover fabric which has a lower tool and an upper tool.
  • the upper tool is provided with a membrane formed as an elastic pressing means to distribute the Kaschiertik even in steep flank areas and in the peripheral regions of the carrier molding homogeneous.
  • DE 94 08 396 U1 describes a device for HF laminating of trim parts with vacuum support, in which a Dekozuintroductory is clamped between the closing of the tool halves between a centering ring 4 and a pressure ring 6.
  • EP 0 734 841 A2 discloses a method of adhering a decorative layer to a carrier layer, in which the decorative layer is first pre-stretched by means of a contour piece and the abutment region, with which the decorative layer bears against the contour piece, is pressed into a concave deformation section of the carrier layer , By pressing the contour piece on the decorative layer and the impressions of said abutment area of the same arise gliding movements between the decorative layer and the contact side of the contour piece. This will reduce the quality of the Decorative layer impaired on its visible side.
  • the invention provides a laminating tool (1) for producing a component from at least one carrier part (10) and at least one foil-like decorative layer (16) with a first side (20) facing the carrier layer (10) and a second one opposite the first side Page (21), the laminating tool (1) comprising:
  • an upper tool frame (13) positioned above the first tool part (2) and a lower tool frame (6) located from a first position located below the holding position of the holding device (17) in a second position is, in which this is located on the upper tool frame (13) to hold in this position together with the upper tool frame (13), the decorative layer (16) at an edge region,
  • a shaping contour piece (15) which can be moved by means of an adjusting device with a shaping abutment surface (15a), wherein the adjusting device is designed such that in a first position the shaping abutment surface (15a) of the shaping contour piece (15) is located above the holding device in its holding position , and in a second position, the shaping contact surface (15a) of the shaping contour piece (15) is located below the holding device in its holding position, wherein the contoured piece (15) in its second position the decorative layer (16) on a region of the support surface (15). 8) lying support part (10) can press.
  • the flatly extending state of the decorative layer may be, in particular in an initial step, a state in which the decorative layer is kept taut, by heating the decorative layer before or in such a tensioned state, the decorative layer can be brought into a more or less sagging state the decorative layer seen in the plane cross-step forms a bending line due to its own weight.
  • a laminating tool for producing a component from at least one carrier layer or a carrier part and at least one particularly thermally deformable decorative layer comprising: a first or lower tool part with a shaping contour surface for placing the carrier layer or the carrier part and a holding device for holding the Decorative layer with a first, the carrier layer facing side and a opposite to the first page located second page.
  • the carrier arrow is placed as an injection molded part on a support surface of the lower tool part.
  • the lower tool part may be associated with a fastening or tensioning device, with which the carrier part can be fixed on the tool part.
  • the laminating tool has a shaping contour piece which can be moved by means of an adjusting device, wherein the adjusting device is designed in such a way that the shaping contour piece can press the decorative layer on its second side before it is placed on the carrier layer in the state held by the holding device.
  • the shaping contour piece is movable relative to the first tool part and can be brought into the vicinity and / or in abutment with the shaping contour or bearing surface of the first tool part or a decorative layer lying thereon.
  • the laminating tool according to the invention thus has a tool part with a contouring deformation surface for receiving or laying on the carrier layer or the carrier part.
  • at least one deformable decorative layer is applied to the latter, wherein a predetermined region of the first side of the decorative layer to be applied to the carrier layer is placed as completely as possible on the carrier layer.
  • the decorative layer is heated to a predetermined temperature for deformation in order to obtain an elasticity of the decorative layer required for proper laminating.
  • the decorative layer can either be pre-heated inserted or entered into the laminating, but it can also be heated only in the laminating to a temperature that allows reliable processing of the decorative layer.
  • the heating of the decorative layer can therefore take place before, during or after laying on or deformation.
  • the laminating tool according to the invention also has a shaping part which is movable relative to the tool part and which can be moved onto the second side of the decorative layer.
  • the shaping contour piece can thus be moved relative to the holding device, in particular if it holds the decorative layer in the laminating process, such that the shaping contour piece, the decorative layer before placing it on the carrier layer in the state held by the holding device on its second side can press.
  • the portion of the decorative layer, which is in contact with the contour piece can be fixed in such a way that a portion located between this portion of the decorative layer and a portion of the decorative layer with which it is held by the holding device extends freely over the carrier layer and can be manually or mechanically placed or mounted on the carrier layer.
  • the laminating tool can be configured in such a way that the contoured piece and / or the tool part on which the carrier layer is placed during the laminating process can be moved relative to one another such that the contoured piece is in contact with the shaping contour surface of the tool part or the visible side of a decorative layer can be brought, which rests on a lying on the tool part support part.
  • This movement of the shaping contour piece onto this section of the decorative layer, and this in turn onto the carrier layer located on the tool part causes the area of the decorative layer to be pressed onto a corresponding section of the carrier layer.
  • the sections pressed against one another by the contour piece of the decorative layer and of the carrier layer can be fixed or clamped to one another on the tool part.
  • the said portion exposed between this portion of the decorative layer and the portion of the decorative layer with which it is held by the holding device, over the carrier layer extending portion can thereby be manually or mechanically placed or mounted on the carrier layer.
  • the pressurization may be carried out by making negative pressure on the side of the decorative layer (16) facing away from the carrier part, or by blowing on that side of the decorative layer facing the carrier part.
  • the carrier part may in particular be an injection molded part formed from ABS.
  • the preheated decorative layer is thus held in a holding device, for example in a clamping device or a clamping frame on the tool part.
  • the holding device can hold the decorative layer in the direction of the tool part both before and / or during a movement of the clamping frame caused by a clamping frame adjusting device, and / or before and / or during a movement of the tool part in the direction of the holding device caused by a tool part adjusting device.
  • the shaping contour piece can be brought by means of a Kontur stained adjustment from the second side of the held decorative layer, can drive on this and can deform the decorative layer at least in the section of the startup of the shaping contour piece.
  • the shaping contour piece can be guided linearly in the process, wherein the shaping contour piece can be guided for emergence perpendicular to the portion of the second side of the decorative layer.
  • the shaping contour piece can also impinge on the decorative layer at an angle, for example at an angle between 80 ° and 90 °, and deform it in a section.
  • the adjusting devices may be driven adjusting devices, wherein the drive device may be, for example, an electric motor, a hydraulic or pneumatic drive or an elastic body, for example a spring.
  • the drive device may be, for example, an electric motor, a hydraulic or pneumatic drive or an elastic body, for example a spring.
  • the achievement of the correct position of the clamping frame can be detected by suitable means.
  • a light barrier can be attached to the tool part, which detects when the clamping frame with the clamped decorative layer reaches a predetermined desired position.
  • the detection can also be carried out by induction, mechanical switches or monitoring by means of a camera by comparing a stored desired position image with the current actual position image, each case when reaching the desired position, the movement of the frame stopped and the frame in this position can be fixed by appropriate means.
  • either only the shaping contour piece or the shaping contour piece together with the tensioning frame through the respective adjusting devices are moved in the direction of the tool part.
  • the shaping contour piece can be moved faster in the direction of the tool part, so that it can accumulate on the decorative layer held in the tensioning device before it comes to rest on the carrier layer.
  • the shaping contour piece and the tool part can also be moved toward the fixed clamping device by the respective adjusting devices, whereby the shaping contour piece can accumulate on the second side of the decorative layer as before, before the first side of the decorative layer comes to rest on the carrier layer.
  • the clamping device is movable in the direction of the shaping contour piece until it can deform the second side of the decorative layer by a predetermined amount in the direction of the tool part and can be fixed in this position.
  • the tool part can approach the decorative layer from the first side of the decorative layer and deform it, so that the decorative layer can be stretched over the carrier layer lying on the tool part and can come to lie on the carrier layer when the tool part moves on.
  • shaping contour piece, tool part and / or clamping device can take place simultaneously or in chronological succession, the latter can lead to higher production times, but can reduce the risk of defective products.
  • the shaping contour piece in the decorative layer held in the tensioning device Before or after emergence of the shaping contour piece in the decorative layer held in the tensioning device, it can be blown from the first side by means of a blowing device with compressed air to counteract premature cooling with hot or warmed compressed air, so that the Decorative layer bulges in the direction away from the tool part.
  • the curvature can also be achieved by terminating, near or just above the second side of the decorative layer, a suction device, for example a suction channel or suction tube, with which the decorative layer is sucked in without touching the suction device.
  • a suction device for example a suction channel or suction tube
  • wrinkles that may be present in the decorative layer can be smoothed or the wrinkling during lamination can be prevented.
  • the curvature can at least be maintained until the shaping contour piece deposits and presses the decorative layer on the carrier layer. That is, the curvature by the compressed air or the suction air can still be maintained until shortly before the end of the laminating process
  • the tool can have at least one sensor device, for example a light barrier, which controls the blowing air or the suction air Can regulate dependence on the size of the bubble formed.
  • the sensor device detects the vertical position of a portion of the decorative layer and thus the distance of the portion of the located below this portion of the first tool part or a resting thereon support member. That is, for example, when detecting too much blistering, the amount of supplied blowing or suction air can be reduced.
  • a too small formation of the bladder may not be desired, as with a too small bubble any existing in the decorative layer wrinkles can not be completely smoothed.
  • a light barrier non-contact distance meters, touch switches or other known and suitable sensor or detection devices can be used.
  • Monitoring the size of the bubble formed by the decorative layer by pressing or suction air can also help detect production-indicated defects in the decorative layer.
  • a material thickness of the decorative layer lying below the permissible product tolerances can be known per unit of time for a known air injection quantity lead to the formation of a bubble too large, lying over the tolerance material thickness can form a too small bubble at a known air supply.
  • the bubble size can be an indication that the decorative layer has the right temperature for further processing. If the decorative layer is already preheated entered into the tool, the bubble size can also be an indication of whether the decorative layer has the right temperature and thus the desired stretchability.
  • the shaping contour piece and the tensioning device and / or the tool part can be moved further until the shaping contour piece presses the decorative layer in the section onto the carrier layer. Due to the curvature, the decorative layer can be pressed onto the carrier layer only in the section which is deformed by the shaping contour piece or a contact surface of the shaping contour piece, while the remainder of the decorative layer does not yet have to have contact with the carrier layer. If the compressed air is reduced continuously, gradually or abruptly, and at the same time the clamping frame is lowered further over the tool part or the tool part retracted further into the clamping frame, the decorative layer not deformed by the shaping contour piece can be drawn onto the carrier layer, that is to say it can be stretched over the carrier layer.
  • the decorative layer can already be held in the section of the shaping contour piece at this time, tensile forces can only occur between the holding section of the shaping contour piece and the edge of the clamping device when the decorative layer is applied to the carrier layer.
  • the decorative layer can no longer be displaced relative to the carrier layer.
  • the degree of separation of the decorative layer can be reduced in all areas.
  • the contact pressure of the decorative layer on the support layer can be further increased without affecting the degree of extraction, for example by the carrier layer can be connected via small holes or material-related pores with a vacuum source, which can be activated when the clamping frame has reached its end position relative to the tool part ,
  • the shaping contour piece can accumulate on the decorative layer in a freely selectable area and deform it there, even in an area that can lie on the finished component in a built-in area, ie not visible to the user.
  • the movement of the shaping contour piece can be effected by means of a drive, for example by an electric motor, continuously in the direction of the decorative layer, but the shaping contour piece can also be biased by an elastic force, for example a spring in the direction of the tool part.
  • the speed of the lowering can be controlled when using an electric motor, so that the shaping contour piece at the beginning of its movement can have a different, for example, greater speed than when running on and deforming the decorative layer.
  • the movement of the shaping contour piece by means of a drive can be used, for example, when the shaping contour piece and the clamping device ascend to the non-moving tool part for laminating.
  • the shaping contour piece may initially move alone until it has deformed the decorative layer in the portion over a predetermined length in the direction of the tool part.
  • the shaping contour piece and the tensioning device can continue to drive together on the tool part until the contour piece forming the decorative layer can press the decorative layer in the section with a predeterminable force against the carrier layer lying on the tool part.
  • the shaping contour piece can now be in its end position for the laminating process, in which it can be held and / or fixed for the further laminating process.
  • the clamping device can continue in the Move movement direction, whereby the decorative layer is stretched over the tool part or the carrier layer lying thereon.
  • the biasing of the shaping contour piece in the direction of the tool part can be used, for example, when either the clamping device is not moved during lamination, or the clamping device is moved only so far in the direction of the shaping contour piece until it has accumulated on the second side of the decorative layer and continue to run the decorative layer has deformed by a certain amount in the direction of the tool part.
  • the deformation of the decorative layer should be completed by the shaping contour piece before the tool part rides on the first side of the decorative layer.
  • the movement of the shaping contour piece can be continued until the shaping contour piece touches the tool part or a section of the contour of the tool part.
  • the movement of the shaping contour piece can also be limited to an approach to the tool part. This means that upon reaching the end position of the shaping contour part, there may be a gap forming a gap between the shaping contour part and the tool part or the contour of the tool part.
  • the gap size that is to say the clear distance between the shaping contour part and the tool part, can then correspond to the thickness of the carrier layer plus the thickness of the decorative layer which the two parts have when compressed with a predetermined pressure.
  • the distance which the shaping contour piece and the tool part are to observe during the laminating process can also be presettable in order to be able to be adjusted accordingly, for example, when the thickness of the carrier layer and / or the decorative layer changes.
  • the setting of the gap size can also be effected automatically, for example by measuring the actual pressure on the shaping contours by means of a pressure measuring device. The determined actual pressure can then be transmitted to a control or regulating device of the tool or the machine and compared there with a stored desired pressure. Due to the measured pressure difference then the Pressure of the shaping contour piece to be adjusted by controlling the adjustment.
  • the tool part or the carrier layer lying thereon can first come into contact with the decorative layer in the section of the shaping contour piece.
  • the pressure of the shaping contour piece on the tool part may increase up to a predetermined target pressure with which the shaping contour piece is to press the decorative layer onto the carrier layer during the laminating process. If after reaching this setpoint pressure the tool continues to move to the first side of the decorative layer, then the shaping contour piece can be carried along by the tool part into a laminating position against the pretensioning force which corresponds to the force for generating the setpoint pressure.
  • moving the tool part into the laminating position may cause the decorative layer held in the clamping device to be stretched over the carrier layer.
  • the shaping contour piece can first be driven to run onto the first side of the decorative layer held on a stationary tensioning device and to deform or preform it in the section by the predetermined amount in the direction of the tool part. Subsequently, the tool part can accumulate on the first side of the decorative layer. If the setpoint pressure described above is reached, the shaping contour piece can either be driven synchronously with the tool part or be taken along by the tool part against a corresponding restoring force.
  • the shaping contour piece can have a shape at its decorative layer-side end, which corresponds at least in sections to the contour of the tool part in the region where the shaping contour piece presses the decorative layer onto the carrier layer.
  • the shaping contour piece can form a stamp with a mating contour matching the contour of the tool part in the section.
  • the shaping contour piece can also be used to additionally impress, for example, an article number, the manufacturer information, the date of manufacture or the batch number and / or other information into the decorative layer.
  • the shaping contour piece can also be of annular design, for example if the shaping contour piece is to hold the decorative layer on the carrier layer in a region in which the carrier layer has an opening or an opening. It is then not intended that the shaping contour piece presses the decorative layer through the opening directly onto the tool part. Therefore, in this area, the shaping contour piece can be shaped such that it rests only on the edges of the carrier layer formed by the carrier layer, but exerts no pressure on the decorative layer in the region of the opening.
  • the decorative layer can be a plastic film that is so flexible when heated to a predetermined temperature that it can follow more complicated contours.
  • the plastic film can be applied to the support layer lying on the tool part with a complex surface shape without wrinkles and bubbles.
  • the heating of the decorative layer can take place before the decorative layer in the holding frame is supplied to the tool part and / or during the feeding and / or after the completion of the feeding movement.
  • the decorative layer may have a smooth decorative surface, but it may also have a provided with a structure such as with aesthetically handsome Nabitch surface which then after the lamination impresses the visual and haptic impression of the surface of a laminated support member.
  • the device according to the invention and the method according to the invention achieve a lamination with which the surface structure and in particular hubs of the decorative layer with which or with which the decorative layer is moved to a position above the first tool part is not changed.
  • particularly elaborately produced surface structures and embossing of the decorative layer can be retained on the visible side thereof during the laminating process while carrying out a particularly economical laminating process.
  • the decorative layer can be single-layered or multi-layered, for example, with a closed surface and at least one soft, foam-like open-pored underlay formed thereunder.
  • This soft pad can be applied to the closed surface, for example, vulcanized, welded or glued.
  • the closed and the soft layer of the decorative layer may consist of a same material, for example of a plastic with both layers can be made in a process.
  • the subsequent disposal problem can be further prevented, even if the carrier layer is formed from a same or very similar plastic.
  • the laminated support parts can then be disposed of in one part and recycled without further separation effort. As a result, disposal costs and raw material costs, for example by admixing recycled material during the production of new parts, can be saved in the manufacturing process.
  • the application of the decorative layer on the carrier layer can also be carried out by a tool with a lower tool with a contour and an upper tool with a mating contour and a shaping contour part according to the invention associated with the upper tool and / or the lower tool, the decorative layer from the upper tool to the carrier layer lying in the lower tool is laminated on.
  • the upper tool can have a smooth surface or a surface with a structure, for example a graining, which permanently presses it into the surface of the decoration material during the laminating process.
  • the tool can also have a lower tool with a contour and an upper tool without a contour, for example a box adapted to the circumference of the lower tool, which together with the lower tool can form a hermetically sealed tool.
  • the decorative layer between the upper tool and lower tool can be clamped, so that the lower tool and the upper tool form two separated by the decorative layer spaces.
  • the decorative layer can separate the lower tool air-technically from the upper tool, that is, the decorative layer can be made of an airtight or largely airtight Material exist, so that an air exchange between the two tool parts is at least difficult.
  • the clamping device can release the decorative layer and be equipped, for example, with a next decorative layer for the next laminating process.
  • Air for example heated compressed air
  • Air can be blown between the lower tool or the carrier layer lying on the lower tool and the decorative layer held in the clamping frame or between the upper and lower tool parts, so that the decorative layer can bulge away from the carrier layer into the upper tool and any wrinkles in the decorative layer can be smoothed.
  • This blister or partial blister formed from the decorative layer can now accumulate the shaping contour piece and thereby already deform the decorative layer in this area before the actual laminating process.
  • the shaping contour piece can also extend into the decorative layer sitting in the tenter frame from the first side and preform it before the decorative layer is underblown by means of the compressed air. In this case, the underblowing in the latter case may begin before the shaping contour piece firmly presses the decorative layer onto the carrier layer or only after the shaping contour piece firmly presses the decorative layer onto the carrier layer.
  • the curvature can also be achieved by connecting the space formed by the second side of the decorative layer and the upper tool to a suction line or to a vacuum, whereby the decorative layer can bulge in the direction of the negative pressure hot away from the contour of the lower tool ,
  • the air forming the bubble can be sucked through the lower tool, or the air in the bladder via the lower tool are connected to a vacuum, so that the decorative layer presses firmly with its first side to the support layer and can be laminated to the carrier layer.
  • the suction force of the vacuum acting on the decorative layer can be assisted by an increase in the pressure on the second side of the decorative layer facing away from the carrier layer.
  • the attainment of the position for supplying the compressed air and for switching on the vacuum can be monitored by suitable well-known means and initiate the individual laminating steps via the machine control.
  • the decorative layer can be pressed by suction, a described combination of suction and pressing force of vacuum and pressure, or provided with a mating contour to the contour of the lower tool upper tool and in each case additionally with the shaping contour piece on the support layer. That is, when laminating always presses at least a portion of the shaping contour piece, the decorative layer directly on the support layer, regardless of how the upper tool is formed.
  • the invention also relates to the method for laminating a carrier part with a thermally deformable decorative layer in a tool, in which the decorative layer is held biased in a holding device or the tool for laminating and placed on a support layer lying on the tool, wherein prior to placing the decorative layer on the support part a relative to the decorative layer movable shaping contour piece is brought into abutment with the second side of the preheated decorative layer and deformed by a further relative movement of the decorative layer to the holding device, the decorative layer in a section.
  • the invention may also relate to the method for producing a laminated plastic part from a carrier layer and a thermally deformable decorative layer in a laminating tool according to the invention with a tool and the contour piece according to the invention. It is in a Holder device held, preheated to laminating temperature decorative layer placed and held in the holding device at a predetermined distance from the tool part.
  • the shaping contour piece is moved up to the second side of the decorative layer and pressed into the prestressed decorative layer in the direction of the tool part.
  • the shaping contour piece has a contact surface, which can correspond to a portion of a contour of the tool part.
  • the decorative layer can be blown with compressed air, for example, so that it bulges in the direction away from the tool part.
  • the shaping contour piece can be moved further in the direction of the tool part or the carrier layer lying thereon, until the shaping contour piece with its contact surface presses the decorative layer with a predetermined force in a section onto the carrier layer.
  • the decorative layer can be fixed on the carrier layer, so that during the further laminating process the decorative layer can no longer be displaced relative to the carrier layer, at least in this section.
  • the pressure of the compressed air can be reduced, the curvature can form back until the decorative layer rests completely on the carrier layer.
  • the shaping contour piece can be moved back, the clamping frame can be opened and the laminated component removed for further processing.
  • the carrier layer may, for example, have small bores which are connected via the tool part to a vacuum source which can be opened as soon as the decorative layer rests on the carrier layer.
  • the method according to the invention can comprise all movements of the contour part, holding device and tool part described for the device.
  • the curvature of the decorative layer can alternatively be produced by blowing with a gas or by suction for blowing with compressed air.
  • the tool for carrying out the method may be a one-part or a two-part tool.
  • FIG. 1 shows an open laminating tool with a decoration material in a clamping frame and a shaping contour piece according to the invention
  • FIG. 2 shows the laminating tool during the closing process with decorative material which is preformed in a section by the shaping contour piece according to the invention
  • Figure 3 shows the largely closed tool in which the shaping contour piece according to the invention presses the decorative material in the section on the support layer and finished molding;
  • FIG. 4 shows the closed tool with the decorative material laminated to the carrier layer, which is held in the section by the shaping contour piece according to the invention.
  • the laminating tool 1 used according to the invention is provided for producing a component from at least one carrier part 10 and at least one foil-like decorative layer 16.
  • the carrier part rests with its rear side on a supporting surface of a first tool part or lower tool part 2, so that the laminating side 10a, to which the decorative layer is to be applied in the process, faces upwards.
  • the carrier layer used for the device according to the invention and the method according to the invention is in particular a carrier part which is produced on the basis of an injection molding process.
  • provision may be made in particular for the carrier part to rest on the first tool part 2 in a dimensionally stable or cooled state in a first step following the injection molding process.
  • the plastic material used here is, for example, polypropylene PP, a mixture of PP and EPDM (PP / EPDM T20), ABS (acrylonitrile-butadiene-styrene copolymer plastic), ABS PC (ABS with polycarbonate portions) or PA (polyamides ) and generally thermoplastics into consideration.
  • Material used for the backing part is a natural fiber material with reinforcing parts such as plastic material or wood fiber material or a metal.
  • a laminating binder or laminating adhesive is applied to the laminating side of the carrier part 10.
  • the application of the laminating adhesive can take place before the carrier part 10 is placed on the first tool part 2, or after the carrier part 10 has been placed on the first tool part 2.
  • the laminating binder can in particular a
  • the decorative layer 16 may be formed from one or more layers and is preferably adhered to the support member.
  • the decorative layer can be provided, in particular, to provide haptic properties of the end product or of the interior trim part on its outside, which correspond to predetermined requirements.
  • the decorative layer is formed in two layers.
  • the decorative layer may have a cover layer and a foam layer seen from the visible side.
  • the cover layer is made of PVC or TPO or a combination of these materials and the foam layer is made of PVC, PP, PE, a soft polyester insert layer or a combination of these materials.
  • foam based on polyurethane (PU) can be used for the foam layer.
  • the decorative layer may be a composite of textile materials, a foam and a nonwoven material.
  • a textile fabric, a foam artificial leather, a plastic film or a leather can be used for the decorative layer. These materials may form a single layer of the decorative layer or a cover layer of a multilayer decorative layer.
  • the cover layer may have a thickness of 0.3 mm to 0.7 mm and the foam layer may have a thickness of 0.7 mm to 2.5 mm.
  • the laminating tool (1) has in particular: a first tool part (2) with a support surface (8) for placing the support part (10), a holding device (17) for holding the decorative layer (16), which is used to introduce the decorative layer in a tensioned manner from a region outside the laminating tool (1) into a holding position, in which a decorative layer (16) received by the latter is held above the first tool part (2), an upper tool frame (13) which is located above the first tool part (2) is positioned and a lower tool frame (6), which is located from a first position in which this is located below the holding position of the holding device (17), in a second position in which this is located on the upper tool frame (13), in order to hold in this place together with the upper tool frame (13) the decorative layer (16) at an edge region,
  • the device has a shaping contour piece (15) which can be moved by means of an adjusting device with a shaping contact surface (15a), wherein the adjusting device is designed such that in a first position the shaping abutment surface (15a) of the shaping contour piece (15) above the holding device is located in its holding position, and in a second position, the shaping abutment surface (15a) of the shaping contour piece (15) is located below the holding device in its holding position, wherein the contour piece (15) in its second position, the decorative layer (16) on a region of the on the support surface (8) lying support member (10) can press.
  • the tool frames or clamping frames may be movable relative to each other. It can also be provided that the upper clamping frame 13 is attached to an upper tool part and is not movable.
  • the lower clamping frame 6 can be brought from a position at which it is located on the first tool part 2 and in particular below the contact surface thereof into a position in which it is held with its holding section for holding the decorative cover (FIG ) is located on the upper clamping frame.
  • the laminating tool 1 shows a laminating tool 1 with a first tool part or upper tool 2 and a second tool part or lower tool 3 in a sectional view.
  • the laminating tool 1 can be installed in particular in a press, although the method according to the invention is not carried out according to an embodiment as a press-forming process.
  • the first tool part 1 is mounted on a base plate 4.
  • the second tool part 3 can be designed in particular as a housing part.
  • a vacuum-imparting device or vacuum pump is connected to the housing part 3 and a corresponding air passage is e.g. installed with a plurality of openings, so that in the space 18, which limits the second tool part 3, to apply negative pressure.
  • the second tool part 5 may be designed as an upper press plate 5.
  • the lower tool 3 consists of a lower tool frame 6 and a lower tool body 7, which has three straight sides and a fourth side with a tool contour 8.
  • the lower tool frame 6 rests on the base plate 4 and is prevented by position pins 9 from slipping or shifting the base plate 4 secured.
  • the tool body 7 can be firmly connected to the base plate 4 for Example bolted or clamped by a tensioning device, not shown.
  • the carrier layer 10 On the tool body 7 is a support layer 10, the contour 11 of the tool contour ⁇ is adjusted, so that the carrier layer 10 rests positively on the tool body 7.
  • the carrier layer 10 has a recess 12 or opening.
  • the upper tool 3 has an upper tool frame 13 which is fixedly connected to the upper press plate 5, for example by screws. Together with the upper press plate 5, the upper tool frame 13 forms a box which is open only on its underside 14, that is, the lower tool 2 side facing.
  • the upper tool 3 also has two detection devices in the form of light barriers 22.
  • a shaping contour piece 15 in a starting position, in which it protrudes downwards over the upper tool frame 13 in the direction of the lower tool 2.
  • the shaping contour piece 15 can, as indicated by the arrows, be moved perpendicularly in the direction of the lower tool 2 to and from the lower tool 2. This movement can be effected by an adjustment device, not shown, which is driven by a drive device.
  • a holding or clamping frame 17 is shown, with a held or clamped decorative layer 16 which is to be laminated to the carrier layer 10.
  • the decorative layer 16 has a first side 20 and a second side 21, wherein the first side 20 is the underside of the decorative layer 16, which is placed on the support part 10 and connected thereto, the second side 21 is the side of the decorative layer 16 , which forms the visible side of the finished laminated component.
  • the holding frame 17 is also connected to an adjusting device, not shown, which can enter and extend the holding frame 17 in the Kaschierposition.
  • FIG. 2 shows the next step of the laminating process.
  • the lower tool frame 6 was moved from the rest position shown in Figure 1 on the base plate 4 by means of a driven adjusting device, not shown, linearly upwards, so that the lower tool frame 6 and the upper tool frame 13 between them hold the decorative layer 16 by clamping.
  • the holding frame 17 has released the decorative layer 16 and is no longer visible in FIG.
  • the lower tool frame 6 has taken in the clamping frame 17 held decorative layer 16 with in the clamping position.
  • the shaping contour piece 15 has pressed into the decorative layer 16 by the length of the board and has this deformed in a section.
  • the decorative layer 16 is curved in a direction away from the lower tool 2.
  • This curvature can be achieved by blowing from below or one of the sides with a blowing device, for example a blower, compressed air or compressed gas into the body formed from the two tool frames 6, 13, so that the decorative layer 16 rises upward by the pressure bulges in the direction away from the lower tool body 7.
  • the curvature can also be achieved by creating a negative pressure in the space 19 between the decorative layer 16 and the upper tool 3, so that the decorative layer 16 bulges in the direction of the lower pressure.
  • the decorative layer 16 having a length and width greater than the length and width of the clamping connection between the tool frames 6, 13, and the decorative layer 16 thereby forming a first space 18 with the lower tool, and a second, from the first separated by the decorative layer 16 second space 19.
  • the air exchange between the first space 18 and the second space 19 is dependent on the air permeability of the decorative layer 16th
  • the upper tool has two sensor devices, for example two light barriers 22.
  • the sensor devices are connected to a control device, which differs from the Sensor device can detect and recover generated and received signals.
  • the two light barriers 22 it can be monitored, for example, whether the bubble formed by the blowing or the negative pressure from the decorative layer 16 is too large or too small. If the bubble is too large, then the decorative layer 16 may be too taut, which may adversely affect the quality of a possible graining of the second side 2 of the decorative layer 16, so that inferior or reject products are the result. If the blister is too small, wrinkles contained in the decorative layer 16 can not be completely smoothed out, or too little pre-stretching of the decorative layer 16 does not permit a clean laminating result.
  • the size of the bubble formation in relation to the amount of air supplied per unit time can also help to detect material defects in the decorative layer 16. For example, out-of-tolerance material thicknesses of the decorative layer 16 may result in the formation of too large or too small bubbles. Monitoring blistering prior to the lamination process can thus help reduce the production of inferior or defective parts.
  • the size of the bubble formation can also give conclusions about the temperature of the decorative layer 16. Since the extensibility of the decorative layer 16 increases with increasing temperature, excessive blistering may mean too high a temperature of the decorative layer, too small a blistering too low a temperature.
  • the tool frames 6, 13 which have moved together are moved together with the clamped decorative layer 16 in the direction of the lower tool body 7. Shown is the moment in which the shaping contour piece 15 with the deformed decorative layer 16 runs onto the lower tool body 7. That is, up to this point, the two tool frames 6, 13 moved together, together with the shaping contour piece 15, have been moved linearly in the direction of the base plate 4 from the uppermost end position. In this case, the curvature of the decorative layer 16 is maintained.
  • FIG. 4 shows the laminating tool 1 in the closed state.
  • the lower tool frame 6 is still connected to the upper tool frame 13, between the tool frame 6, 13 is still the decorative layer 16 is clamped.
  • the shaping contour piece 15 is pressed onto the carrier layer 10 with a predetermined pressure.
  • the decorative layer 16 is simultaneously stretched over the carrier layer 10.
  • the decorative layer 16 is held by the shaping contour piece 15 in the section, so that this section is no longer relative to the carrier layer 10 when the decorative layer 16 is stretched can be moved.
  • the degree of extraction of the decorative layer 16 is reduced at least on parts of the carrier layer 10, as a result of which a structure or grain present on the second side 21 of the decorative layer 16 is stretched less by the pulling forces than in known methods. This in turn means that the structure or graining on the second side 21 of the decorative layer 16 is better preserved in its original form.
  • the laminating tool can thus be the shaping contour piece 15 relative to the tool part 2; 3; 6; 13 and / or the holding device 17; 6, 13 be linearly movable.
  • the shaping contour piece 15 may have an adjusting device coupled to it, with which the contour piece 15 in the direction of the tool part 2; 3; 6, 13 is movable and in abutment with the second side of the decorative layer 16 in on the tool part 2; 3; 6; 13 launched state can be brought.
  • the laminating tool with the holding device 17; 6, 13 have coupled adjusting device, with which the holding device 17; 6, 13 from a holding position in the direction of the shaping contour piece and / or in the direction of the tool part 2; 3; 6; 13 is movable.
  • the laminating a with the tool part 2; 3; 6; 13 coupled adjusting device, with which the tool part 2; 3; 6; 13 in the direction of the holding device 17 and / or the shaping contour piece is movable.
  • the adjusting device of the holding device 17 may be designed such that the holding device 17 is seen from a first position from the tool part in the direction of the shaping contour piece 15 in an intermediate position relative to the position of the contour piece 15 is movable, wherein the contour piece 15 a predetermined amount over the cross-sectional profile of a held by the holding device 17 decorative layer in the direction to the tool part 2; 3; 6; 13 projects, and
  • the holding device 17 in the direction of the tool part 2; 3; 6; 13 to a desired position relative to the tool part 2; 3; 6; 13 can be moved.
  • the adjustment of the holding device 17 may have a drive device for actuating the same and the laminating device can be a functionally coupled to the adjustment of the holding device 17 control device for moving the holding device to a desired position relative to the tool part 2; 3; 6; 13 have.
  • the laminating device can have a sensor device for detecting the intermediate position of the holding device 17 and / or the desired position relative to the tool part 2; 3; 6; 13 have.
  • a display device can be functionally coupled, with the achievement of the intermediate position of the holding device 17 can be displayed. This display can serve in particular for the manual execution of the laminating method according to the invention.
  • the adjusting device of the holding device 17, the control device and the sensor device for detecting the intermediate position can be set up and functionally coupled in such a way that upon reaching the intermediate position of the holding device 17, the control device receives a signal from the sensor device and the control device receives this signal Signal sends a command signal to the adjusting device of the holding device 17, due to which this the holding device 17 to a desired position relative to the tool part 2; 3; 6; 13 moves.
  • the laminating tool can have an adjusting device for adjusting the position of the shaping contour piece 15, which is designed in such a way that
  • the adjusting device of the shaping contour piece 15 can move this from a position in the direction of the holding device 17 into an intermediate position in which the contoured piece has a predetermined extent over the cross-sectional profile of the decorative layer in its state held by the holding device 17 in the direction of the tool part 2; 3; 6; 13 survives, and
  • the adjusting device of the shaping contour piece (15) can move it in the direction of the tool part (2; 3; 6; 13) up to a desired position relative to the tool part (2; 3; 6; 13).
  • the adjusting device of the shaping contour piece 15 may have a drive device for actuating the same.
  • the laminating device can be a functionally coupled with the adjusting device of the shaping contour piece 15 control device for moving the shaping contour piece 15 up to a desired position relative to the tool part 2; 3; 6; 13 have.
  • the laminating device a sensor device for detecting the intermediate position of the shaping contour piece 15 and / or the desired position relative to the tool part 2; 3; 6; 13 have.
  • a display device can be functionally coupled, with the achievement of the intermediate position of the shaping contour piece 15 can be displayed.
  • the adjustment of the shaping contour piece 15, the control device and the sensor device for detecting the intermediate position are set up and functionally coupled such that upon reaching the intermediate position of the shaping contour piece 15, the control device receives a signal from the Sensor device receives and the control device sends a command signal to the adjustment of the shaping contour piece 15 due to this signal, on the basis of this the shaping contour piece 15 up to a desired position relative to the tool part 2; 3; 6; 13 moves.
  • the adjustment of the tool part 2; 3; 6; 13 be designed such that the tool part 2; 3; 6; 13 in the direction of the holding device 17 and / or the shaping contour piece 15 can move to a desired position relative to the holding device 17 and / or the shaping contour piece 15.
  • the adjusting device of the tool part 2; 3; 6; 13 have a drive device for actuating the same and the laminating device can be functionally connected to the adjusting device of the tool part 2; 3; 6; 13 coupled control device for moving the tool part 2; 3; 6; 13 have up to a desired position relative to the holding device 17 and / or the shaping contour piece 15.
  • the laminating device may have a sensor device for detecting the desired position relative to the holding device (17) and / or to the shaping contour piece (15).
  • a display device is functionally coupled to the sensor device, with which the reaching of the desired position of the tool part 2; 3; 6; 13 relative to the holding device 17 and / or the shaping contour piece 15 is displayed.
  • the adjusting device of the tool part 2; 3; 6; 13, the control device and the sensor devices for detecting an intermediate position are set up and functionally coupled such that upon reaching the intermediate position of the holding device 17 and / or the shaping contour piece 15, the control device receives a signal from the sensor device and the control device receives a command signal on the basis of this signal to the adjusting device of the tool part 2; 3; 6; 13 sends, due to which this the tool part 2; 3; 6; 13 to a target position of the tool part 2; 3; 6; 13 relative to the holding device 17 and / or the shaping contour piece 15 moves.
  • the method according to the invention for laminating a carrier layer with a thermally deformable decorative layer 16 can be carried out, in which for lamination, the decorative layer 16) held taut and on a on the tool part 2; 3; 6; 13 lying carrier layer 10 is placed, wherein the decorative layer 16 has a first side 20 which faces the carrier layer 10 and a second side 21 which faces away from the carrier layer 10, wherein prior to placing the decorative layer 16 on the carrier layer 10 is a relative to the decorative layer 16 movable shaping contour piece 15 is brought into abutment with the second side 21 of the preheated decorative layer 16 and deformed by a further movement of the shaping contour piece 15 relative to the holding device 17, the decorative layer 16 to the holding device 17, the decorative layer 16 in a section. It can be provided that the decorative layer 16 is held on the carrier layer 19 before and during lamination to a portion of the shaping contour piece 15 in order to reduce the degree of extraction of the decorative layer 16 on the carrier
  • the method according to the invention can have the steps:
  • the holding device releasing at least a portion of the decorative layer 16 and placing the portion which extends between the released area and the portion held by the shaping contour piece 15 onto the carrier part 19.
  • the decorative layer 16 is heated to a processing temperature.
  • the decorative layer 16 is blown onto the carrier layer 10 in the mold with hot compressed air before the application of the same and the decorative layer 16 is thereby heated to a processing temperature and / or the processing temperature is thereby kept within a predetermined temperature range. It can be partially blown by compressed air from the direction of the tool on the decorative layer 16th directed pressure force to form a partial bubble-shaped deformation of the decorative layer 16 of the tool part 2; 3; 6; 13 are generated, wherein the compressed air is generated by a blowing device or a suction device.
  • the method may include the steps of:
  • Moving the holding device 17 seen from a first position from the tool part in the direction of the shaping contour piece 15 in an intermediate position relative to the position of the contour piece T5 is movable, in which the contour piece 15 a predetermined amount over the cross-sectional profile of a held by the holding device 17 decorative layer in Direction to the tool part 2; 3; 6; 13 projects, and
  • the method may comprise the steps:
  • Moving the shaping contour piece 15 can move from a position in the direction of the holding device 17 in an intermediate position in which the contour piece a predetermined degree over the cross-sectional profile of the decorative layer in its state held by the holding device 17 in the direction of the tool part 2; 3; 6; 13 survives, and
  • the method can provide: movement of the tool part 2; 3; 6; 13 to a desired position relative to the holding device 17 and / or the shaping contour piece 15th LIST OF REFERENCES
  • Holding device clamping frame first room second room first side second side

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)

Abstract

L’invention concerne un procédé et un moule pour doubler un élément support d’une couche décorative thermodéformable (16) dans un moule (2; 3; 6; 13). Selon ce procédé de doublage, la couche décorative (16) est maintenue avec précontrainte dans un dispositif de maintien ou dans le moule (2; 3; 6; 13), et elle est appliquée sur une couche support (10) reposant sur le moule (2; 3; 6; 13). Selon l’invention, avant d’appliquer la couche décorative (16) sur l’élément support (10), on amène en application avec le deuxième côté (21) de la couche décorative préchauffée (16) une pièce profilée de façonnage (15), mobile par rapport à la couche décorative (16), et une partie de la couche décorative (16) est déformée par un mouvement relatif de la couche décorative (16) par rapport au dispositif de maintien (17).
EP09713327A 2008-02-19 2009-02-19 Dispositif et procédé de doublage d'une couche support avec une couche décorative Withdrawn EP2254744A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102008009762A DE102008009762A1 (de) 2008-02-19 2008-02-19 Vorrichtung und Verfahren zum Kaschieren einer Trägerschicht mit einer Dekorschicht
PCT/EP2009/001207 WO2009103541A1 (fr) 2008-02-19 2009-02-19 Dispositif et procédé de doublage d’une couche support avec une couche décorative

Publications (1)

Publication Number Publication Date
EP2254744A1 true EP2254744A1 (fr) 2010-12-01

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EP09713327A Withdrawn EP2254744A1 (fr) 2008-02-19 2009-02-19 Dispositif et procédé de doublage d'une couche support avec une couche décorative

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US (1) US9302422B2 (fr)
EP (1) EP2254744A1 (fr)
DE (1) DE102008009762A1 (fr)
WO (1) WO2009103541A1 (fr)

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JP6121643B2 (ja) * 2010-10-29 2017-04-26 スリーエム イノベイティブ プロパティズ カンパニー フィルム成型装置及びフィルム成型方法
DE102011086450B4 (de) 2011-11-16 2019-04-04 Lisa Dräxlmaier GmbH Verfahren zur Herstellung eines Interieurbauteils für Fahrzeuginnenräume
JP7053261B2 (ja) * 2014-10-15 2022-04-12 メディア ラリオ エス．アール．エル． 精密表面を有する物品を形成するプロセス
IT201700028817A1 (it) * 2017-03-15 2018-09-15 Comi S P A Macchina di formatura per lastre termoplastiche
JP6970557B2 (ja) * 2017-09-07 2021-11-24 株式会社イノアックコーポレーション 車両用内装材の成形装置及び車両用内装材の製造方法

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DE102008009762A1 (de) 2009-08-20
US9302422B2 (en) 2016-04-05
WO2009103541A1 (fr) 2009-08-27
US20110198021A1 (en) 2011-08-18

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