阅读说明：本技术 用于制造用作机动车辆内饰部件的覆层的至少两层的复合物的方法和系统 (Method and system for producing a composite of at least two layers for use as a coating for interior trim parts of motor vehicles ) 是由 罗伯特·塔尔哈默 于 2019-04-08 设计创作，主要内容包括：本发明涉及一种用于制造用作机动车辆内饰部件的覆层的复合物(38)的方法,包括以下步骤：为第一模板(10)提供用于所述复合物(38)的第一层(14)的凹缺(12)；将所述第一层(14)布置在所述第一模板(10)的凹缺(12)内；将设有粘合剂的托板(18)布置在所述被布置在所述凹缺(12)内的所述第一层(14)上,因此所述第一层(14)粘附在所述托板(18)上；将所述托板(18)与粘附在其上的所述第一层(14)一起从所述第一模板(10)的凹缺(12)取出,并且将粘合剂涂覆在所述第一层(14)的背对所述托板(18)的侧面上；为第二模板(28)提供用于所述复合物(38)的第二层(32)的凹缺(30)；将所述第二层(32)布置在所述第二模板(28)的凹缺(30)内；将所述托板(18)与粘附在其上的并且设有粘合剂的所述第一层(14)一起布置在所述被布置在所述第二模板(28)的凹缺(30)内的所述第二层(32)上；将所述托板(18)与由两层(14、32)制成的所述复合物(38)一起从所述第二模板(28)取出。本发明此外涉及用于制造用作机动车辆内饰部件的覆层的复合物(38)的系统。(The invention relates to a method for producing a composite (38) for use as a coating for interior trim parts of a motor vehicle, comprising the following steps: providing a first template (10) with a recess (12) for a first layer (14) of the composite (38); -arranging the first layer (14) within a recess (12) of the first template (10); -arranging a pallet (18) provided with an adhesive on the first layer (14) arranged in the recess (12), whereby the first layer (14) adheres to the pallet (18); removing the carrier (18) together with the first layer (14) adhered thereto from the recess (12) of the first template (10) and applying an adhesive to the side of the first layer (14) facing away from the carrier (18); providing a second template (28) with a recess (30) for a second layer (32) of the compound (38); disposing the second layer (32) within a recess (30) of the second template (28); -arranging the pallet (18) together with the first layer (14) adhered thereto and provided with adhesive on the second layer (32) arranged within the recess (30) of the second template (28); -removing the pallet (18) together with the composite (38) made of the two layers (14, 32) from the second template (28). The invention further relates to a system for producing a composite (38) for use as a coating for interior trim parts of a motor vehicle.)

1. A method for manufacturing an at least two-layer composite (38) for use as a coating of an interior trim part of a motor vehicle, comprising the steps of:

-providing the first template (10) with recesses (12) for a first layer (14) of the composite (38);

-arranging the first layer (14) within a recess (12) of the first template (10);

-arranging a pallet (18) provided with an adhesive on the first layer (14) within the recess (12) and within the recess (12) of the first template (10), whereby the first layer (14) adheres to the pallet (18);

-removing the pallet (18) together with the first layer (14) adhered thereto from the recess (12) of the first template (10) and applying an adhesive on the side of the first layer (14) facing away from the pallet (18);

-providing a second template (28) with a recess (30) for a second layer (32) of the compound (38);

-arranging the second layer (32) within a recess (30) of the second template (28);

-arranging the pallet (18) together with the first layer (14) adhered thereto and provided with adhesive on the second layer (32) arranged in the recess (30) of the second template (28) and in the recess (30) of the second template (28);

-removing the pallet (18) together with the composite (38) made of two layers (14, 32) from the second template (28).

2. The method of claim 1, wherein the first layer is a spacer fabric (14) or a foam.

3. Method according to claim 1 or 2, characterized in that said second layer (32) is made of leather.

4. Method according to any one of the preceding claims, characterized in that at least one of the formworks (10, 28) has a modular structure consisting of a plurality of segment variants (40) and, in adaptation to the layer (14, 32) concerned, consists according to the choice of the segment variants (40).

5. Method according to claim 4, characterized in that the segment variants (40) are screwed to one another.

6. Method according to any one of the preceding claims, characterized in that the formwork (10, 28) has respective positioning elements (16, 34), the carrier (18) being inserted with the respective corresponding positioning element (20) into the positioning element (16, 34) and thereby being centered with respect to the intended position of the formwork (10, 28).

7. Method according to any one of the preceding claims, characterized in that the carrier (18) is provided with a double-sided adhesive tape (36), the first layer (14) being adhered to the double-sided adhesive tape (36).

8. Method according to any one of the preceding claims, characterized in that at least one of the templates (10, 28) is made of polyoxymethylene.

9. Method according to any of the preceding claims, characterized in that the carrier (18) is made of glass fibre reinforced plastic.

10. Method according to any one of the preceding claims, characterized in that a hot-melt adhesive is applied as adhesive on the first layer (14).

11. Method according to any one of the preceding claims, characterized in that the second layer (32) is adsorbed onto the second template (28) by means of underpressure.

12. Method according to any one of the preceding claims, characterized in that the second layer (32) is cut slightly smaller than the indentations (30) of the second template (28).

13. Method according to any one of the preceding claims, characterized in that the compound (38) is removed from the pallet (18) after removal from the second formwork (28) and the layers (14, 32) are irreversibly connected to each other under the action of pressure and heat.

14. Method according to claim 13, characterized in that the layer (14, 32) is cooled after the action of heat.

15. A system for manufacturing a composite of at least two layers for use as a covering for an interior trim component of a motor vehicle, comprising:

-a first template (10) with recesses (12) for a first layer (14) of said compound (38);

-a pallet (18);

-a second template (28) with a recess (30) for a second layer (32) of the compound (38), wherein the templates (10, 28) and the pallets (18) are shaped such that the pallets (18) fit into the recesses (12, 30) only in a certain arrangement, respectively.

Technical Field

The invention relates to a method and a system for producing a composite of at least two layers for use as a coating for interior trim parts of motor vehicles.

Background

Such composites can be attached as a cladding in the interior of a motor vehicle to the inside of, for example, instrument panels, center consoles, doors, pillars, and roofs. The layer of such a composite, which usually forms the visible side, is often made of a decorative material that looks high in quality, for example leather, wherein the underlying second layer provides a pleasant tactile sensation, in particular a so-called soft tactile sensation. For example, the second layer may be a spacer fabric that provides the tactile sensation described above.

In particular in the case of expensive decorative layers, for example made of high-quality leather, it is desirable to produce such compounds with only a small amount of scrap. Furthermore, in the case of such composites of at least two layers, it is often difficult to arrange the two layers exactly on top of each other and to fix the two layers tightly against each other.

Such composites can be attached as a cladding in the interior of a motor vehicle, for example, on the inside of instrument panels, center consoles, doors, pillars, and roofs.

Disclosure of Invention

The object of the present invention is therefore to provide a solution by means of which a composite of at least two layers for use as a coating of an interior trim part of a motor vehicle can be produced particularly simply and efficiently.

The technical problem is solved by a method and a system for manufacturing a composite of at least two layers for use as a coating of an interior trim part of a motor vehicle with the features of the independent claims. Other possible configurations of the invention are specified in the dependent claims.

In a method according to the invention for producing a composite for at least two layers used as a coating for an interior trim part of a motor vehicle, a first template is provided with a recess for a first layer of the composite. The first layer is then disposed within the recess of the first template. Next, a pallet provided with an adhesive is arranged on said first layer arranged in the recess and in the recess of the first template, thereby adhering the first layer to the pallet.

The pallet is then removed from the recess of the first template together with the first layer adhered thereto, and adhesive is applied to the side of the first layer facing away from the pallet. In addition, a second template is provided with a recess for a second layer of the composite. The second layer is disposed within the recess of the second template. Then, the pallet is arranged with the first layer adhered thereto and provided with the adhesive on said second layer arranged in the recess of the second template and in the recess of the second template.

Thereby adhering the first layer to the second layer. The two layers are automatically positioned opposite or against each other, since the shape of the recesses in the two templates and the contour of the carrier plate are adapted to each other. The pallet is then removed from the second template together with the composite made of the two layers.

The carrier plate and the recesses are thus shaped such that the carrier plate fits into both recesses. The indentations can have similar profiles, but can also be shaped differently. It is important that the shape of the pallets and the templates is such that the pallets can always be repeatably arranged in the recesses of the templates in the same relative position with respect to the corresponding templates, but not otherwise. Thereby automatically ensuring that the two layers can only be positioned opposite each other and connected to each other in their intended arrangement.

The first layer may be, for example, a spacer fabric or a foam, wherein the second layer may be, for example, a decorative layer made of leather. Other decorative layers in the form of a second layer are also possible. The two layers are cut to the appropriate size to fit into corresponding recesses in the template. By using a template with recesses whose contour is adapted to the contour of the pallet, it is forced and in a simple manner to bring about an exact, superposed or superposed arrangement of the two layers of the composite. In other words, it is almost impossible for two layers to be arranged one above the other or one above the other in their unintended arrangement when carrying out the method according to the invention.

Complicated and possibly difficult alignment between the layers can be dispensed with. In particular in the method according to the invention, it is not required that one or both layers are cut afterwards after they have been connected to each other. Instead, the layers of the composite of the at least two layers can be cut and provided in advance-i.e. before being placed into the respective template-respectively so that they fit the shape of the indentations. Then, only the corresponding layers need to be arranged in the corresponding recesses in the template.

By means of the carrier plate, the first layer can be removed from the recess of the first template in a simple manner and, after application of the adhesive, can be arranged on the second layer previously arranged in the recess of the second template. The pallets may be operated, for example, by robots, so that the steps relating to the operation of the pallets may be automated particularly easily.

In particular, the first layer and the second layer can be arranged opposite one another by means of the method according to the invention such that, for example, the second layer (which can be made of leather, for example) protrudes circumferentially beyond the first layer or at least over some edge regions beyond the first layer, and thus forms a border region for fixing the second layer to the motor vehicle interior part concerned. For example, the projecting region of the second layer can also be used in part for sewing the second layer to the motor vehicle interior part concerned.

By means of the method according to the invention, by using the template and the carrier, it is thus possible in a particularly simple and efficient manner, on the one hand, to arrange two layers of the composite relatively precisely to one another and, on the other hand, also to manufacture and fix one layer with a certain amount of protrusion with respect to the other layer.

One possible embodiment of the invention provides that at least one formwork has a modular structure made of a plurality of segment variants and is composed, adapted to the shape of the layer in question, as a function of the choice of the segment variants. For example, if the cutting of one of the layers changes, this can take place completely in the course of the preliminary batch development up to the batch development, without the entire template having to be adapted in an expensive manner, but instead several section variants can simply be replaced. For example, during partial modification of the body of a motor vehicle, slight modifications of the cutting of the layers may also occur. In this case, it is also not necessary to replace all the templates. Instead, it is possible to simply replace several section variants with other section variants, so that the shape of the template and in particular the recesses of the template can be adapted to the new material cut. In particular, the segment variants can be screwed to one another, for example. The segment variants can thereby be fixed together in a very simple and detachable manner against one another.

According to a further possible embodiment of the invention, it is provided that the template has corresponding positioning elements, into which the carrier plate is inserted with the corresponding positioning elements and is thereby centered in the desired position relative to the template. The positioning elements of the template may be, for example, grooves, protrusions, ridges, etc., wherein the corresponding positioning elements are correspondingly shaped on the carrier. By means of the mutual cooperation between the positioning elements of the template and the positioning elements of the pallet, it is possible in a simple manner, for example, for a worker or a robot to position the pallet exactly in its intended arrangement position in the recess of the respective template. This also ensures a positionally accurate arrangement of the layers of the composite relative to one another. The positioning elements are arranged identically on both templates. That is, the positioning elements are equally arranged and aligned relative to each other in the first and second templates. Thereby, it can be ensured that the pallets are always arranged in the same way as the positioning elements of the respective formwork when they are inserted into the respective recesses in the formwork. Thus, when the pallet is inserted into the recess of the second template, with the first layer adhered thereto, into which the second layer was previously arranged, the first layer received by the pallet is always arranged in the same way as the second layer. For example, the recess can have a stop, so that the first layer or layers can also be arranged very simply always in the same position and alignment in the recess, which is achieved by a simple movement of the layers over the stop.

Another possible embodiment of the invention provides that the carrier plate is provided with a double-sided adhesive tape, to which the first layer adheres. In other words, the adhesive on the carrier may thus be a double-sided tape. The double-sided adhesive tape can be applied particularly simply to the carrier. Furthermore, the double-sided adhesive tape can be reused several times, wherein the first layer can be removed again from the double-sided adhesive tape without problems. For example, the double-sided adhesive tape may have the same profile as the pallet, and thus completely cover one side of the pallet. Here, the positioning element may be omitted.

According to a further possible embodiment of the invention, it is provided that at least one of the templates is made of polyoxymethylene. The advantage here is that the adhesive usually adheres poorly or not at all to this material.

According to a further possible embodiment of the invention, it is provided that the carrier is made of glass fiber reinforced plastic. The advantage of glass fiber reinforced plastics is in particular that they have no shrinkage behavior, in particular upon temperature changes. Thus, for example, the carrier can be prevented from expanding under the effect of heat during the manufacturing process and contracting when cooling down, whereby the first layer arranged on the carrier may be deformed correspondingly.

Another possible embodiment of the invention provides that the hot-melt adhesive is applied as an adhesive to the first layer. For example, the hot-melt adhesive can be applied by means of a corresponding apparatus by means of roller application. In contrast to, for example, spray application, the hot melt adhesive can therefore be applied only to the first layer in a particularly targeted manner, without the hot melt adhesive spreading out in another way. An advantage of hot melt adhesives is that they are relatively soft. This results in a particularly good feel in a composite made of at least two layers. After application of the hot melt adhesive, the first layer together with the pallet can be fed to a so-called flash station, by means of which the hot melt adhesive is slightly melted and made tacky, for example by means of infrared radiation.

A further possible embodiment of the invention provides that the second layer is sucked onto the second template by means of underpressure. For example, a plurality of openings can be provided in the recesses of the second template, to which openings a negative pressure can be applied. Thus, the second layer, once it has been accurately positioned, may remain fixed within the recess of the second template. It can thus be ensured in particular that the first layer can be arranged precisely on the second layer and fixed thereto.

According to a further possible embodiment of the invention, it is provided that the second layer is cut slightly smaller than the recesses of the second template. In particular, if the second layer is made of leather, it can thus be ensured that the second layer does not have any undulations or other irregularities, since in any case the second layer is slightly smaller than the indentations of the second template. In this way, the second layer can be arranged particularly smoothly in the recess of the second template. For example, the second template can be arranged slightly inclined, so that the second layer automatically slides downward in the recess of the second template due to gravity and in the device abuts against a corresponding abutment surface in the recess. Thereby, the worker is facilitated to precisely align and arrange the second layer within the recess of the second template.

According to a further possible embodiment of the invention, it is provided that the composite is removed from the carrier after removal from the second form and that the layers are irreversibly connected to one another under the action of pressure and heat. The composites can be permanently bonded to one another, for example, by means of a so-called flat-bed laminator, for example under the action of pressure and heat. The adhesive previously applied to the first layer is thereby reacted, in particular crosslinked, so that the two layers are then firmly bonded to one another.

Another possible embodiment of the invention provides that the layer is cooled after the thermal effect. The cooling is preferably carried out in the same apparatus or machine as the layers are joined to each other under the action of pressure and heat. Suitable cooling zones can be provided for this purpose in the apparatus or machine. By cooling, later sliding of the layers relative to each other is prevented.

The system according to the invention for manufacturing a composite for at least two layers used as a coating for an interior trim part of a motor vehicle comprises a first template with a recess for a first layer of the composite, a carrier plate and a second template with a recess for a second layer of the composite, wherein the template and the carrier plate are shaped such that the carrier plate fits into the recess only in one specific arrangement, respectively. Possible embodiments of the method according to the invention are considered to be possible embodiments of the system according to the invention, and vice versa, wherein the system has in particular means for performing the method steps.

Further possible advantages, features and configurations of the invention are given in the following description of the figures, wherein the features and feature combinations described above and those which are subsequently described in the figures and/or shown in the figures individually can be used not only in the respectively specified combination but also in other combinations or in isolation without departing from the scope of the invention.

Drawings

The figures show:

FIG. 1 is a perspective view of a first template with a recess for a spacer fabric;

FIG. 2 is another perspective view of the first template with the spacer fabric partially disposed within the recess of the first template;

FIG. 3 is another perspective view showing the first template with the pallet similarly placed in the recess after the spacer fabric has been placed;

FIG. 4 is a perspective view of an apparatus in which a pallet is disposed within the apparatus with a spacer fabric adhered therein to provide the spacer fabric with adhesive;

fig. 5 shows a further device by means of which the applied adhesive is activated by infrared radiation;

FIG. 6 is a perspective view of a second template with a recess for a decorative layer made of leather;

FIG. 7 is another perspective view of the second template after placing a decorative layer made of leather into the recess of the second panel;

FIG. 8 is another perspective view of a second form in which the pallet is positioned with the backing fabric adhered thereto on a decorative layer made of leather;

FIG. 9 is another perspective view of the second template as the pallet is removed with the composite made of the spacer fabric and the decorative layer;

FIG. 10 illustrates the separation of the composite from the pallet;

FIG. 11 is a perspective view of a flat bed laminator with which pressure and heat are applied to two composites; and

fig. 12 is a perspective view showing another possible embodiment of a first template, wherein the first template is comprised of a plurality of segments.

In the drawings, identical or functionally identical elements have the same reference numerals.

Detailed Description

Fig. 1 shows a perspective view of a first template 10 with a recess 12 for a spacer fabric 14. The spacer fabric 14 forms a first layer of the composite for use as a coating for an interior trim component of a motor vehicle. The shape or contour of the indentations 12 thus corresponds at least substantially to the shape or contour of the spacer fabric 14. The template 10 has a plurality of positioning elements 16, the function and purpose of which positioning elements 16 will be explained in more detail later.

The first formwork 10 is shown in fig. 2 in a further perspective view, i.e. when a spacer fabric 14 has just been inserted into the recess 12. From this figure it can be seen that the spacer fabric 14 can be inserted at least substantially fittingly and precisely into the recess 12.

The first template 10 is shown in a further perspective view in fig. 3. A carrier 18 with an adhesive is arranged on the first layer in the recess 12, i.e. on the spacer fabric 14, said adhesive having a similar contour as the recess 12 of the first template 10, whereby the side of said carrier 18 not visible in this figure adheres to the spacer fabric 14, said spacer fabric 14 having previously been arranged in the recess 12 of the first template 10.

The pallet 18 itself has corresponding positioning elements 20, said positioning elements 20 corresponding to the positioning elements 16 of the first template 10 described above. The positioning elements 20 of the carrier 18 are designed here in the form of tabs, wherein the positioning elements 16 are designed in the form of recesses. Other configurations of the positioning elements 20, 16 are also possible. It is essential that the positioning elements 16, 20 cooperate such that the carrier 18 can always only be inserted into the recess 12 exactly in the same relative position fit as the template 10.

After the pallet 18 is inserted into the recess 12 of the first template 10, the pallet 18, together with the spacer fabric 14 adhered thereto, is removed from the recess 12 of the first template 10 and fed to the apparatus 22 illustrated in fig. 4. By means of this apparatus 22, an adhesive, not shown in detail, in particular a hot-melt adhesive, is applied by means of roller application to the side 24 of the spacer fabric 14 facing away from the carrier plate 18. The roller application ensures that the hot melt adhesive is applied evenly and homogeneously to the side 24 of the spacer fabric 14 facing away from the carrier plate 18, i.e. without the hot melt adhesive (for example in the case of spray application) also spreading in a disadvantageous manner in the production facility.

After application of the adhesive, the backing fabric 14 is fed to another apparatus 26, such as a so-called flash station, for activating the adhesive, as can be seen in fig. 5. The adhesive is activated by means of infrared radiation by means of the device 26. At the same time, the spacer fabric 14 continues to adhere to the pallet 18.

Second template 28 is shown in perspective view in fig. 6. Second template 28 itself has a recess 30 for receiving a decorative layer 32 made of leather. As with the first template 10, the second template 28 itself includes a plurality of locating elements 34, the locating elements 34 being arranged in the same manner as the locating elements 16 in the first template 10. Notches 12 of first template 10 and notches 30 of second template 28 have the same contour or the same shape.

The decorative layer 32 is cut slightly smaller than the recess 30 of the second template 28. Furthermore, second template 28 is arranged slightly obliquely, so that when a respective decorative layer 32 is inserted or arranged, said decorative layer 32 automatically slides into its intended position under the influence of gravity.

Fig. 7 shows second template 28 in a further perspective view, i.e. after a decorative layer 32 made of leather has been positioned in recess 30 of second template 28. After decorative layer 32 is arranged as desired in second template 28, an underpressure can be generated in the region of recess 30 that is not visible here, so that decorative layer 32 is sucked onto second template 28.

Fig. 8 shows the second formwork 28 in a further perspective view, wherein the carrier 18 together with the backing fabric 14 adhered thereto and provided with the hotmelt adhesive is positioned on the decorative layer 32 in the recess 30 of the second formwork 28 and in the recess 30. The tab-shaped positioning elements 20 are used here again for aligning and arranging the carrier 18 in the recesses 30 of the second template 28 with precise position and as desired. By arranging locating elements 34 of second template 28 in the same manner as locating elements 16 of first template 10, as is the case with locating elements 16, pallets 18 are forcibly precisely aligned and arranged with respect to locating elements 34. By applying pressure to form 28, backing fabric 14 provided with hot melt adhesive is pressed onto the back side of decorative layer 32 and adhered thereto.

In fig. 9, it can be seen how the carrier 18 is removed from the second template 28 together with a composite made of two layers, namely the spacer fabric 14 and the decorative layer 32, and not shown in detail here.

The carrier 18 is visible in a perspective view in fig. 10, i.e. after the composite 38 made of the spacer fabric 14 and the decorative layer 32 has been removed from the carrier 18. Here, the double-sided adhesive tape 36 that has been applied to the carrier 18 is visible. The double-sided adhesive tape 36 serves as the aforementioned adhesive responsible for adhering the spacer fabric 14 to the backing fabric 18 when the backing fabric 18 is placed or pressed onto the spacer fabric 14 after the spacer fabric 14 is placed into the recess 12 of the first template 10. The composite 38, and in particular the spacer fabric 14, can be peeled off again from the double-sided adhesive tape 36 without damage and thus removed from the carrier 18. In the present illustration, a further composite 38 can also be seen, which composite 38 is separated on its decorative layer 32, which is not drawn in detail here.

Two composites 38 are visible in fig. 11, i.e. when the composites 38 are fed to a flat bed laminator 40. By means of the flat laminator 40, the respective backing fabric 14 and the decorative layer 32 made of leather are joined to one another under the action of pressure and the effect of heat, since the hot-melt adhesive crosslinks and thereby joins the two layers 14, 32 to one another. After the heat action, the composite 38 is cooled by means of the flat-bed laminator 40, so that a relative slipping of the respective backing fabric 14 and the respective decorative layer 32 is reliably prevented.

Another possible embodiment of the first template 10 is shown in fig. 12. The formwork 10 has a modular structure composed of a plurality of section variants 42, which section variants 42 can be configured in different ways and screwed to one another depending on the shaping or contour of the layers, i.e. depending on the respective spacer fabric 14 and decorative layer 32. By means of the segment-like structure, it is possible in a simple manner to react to a cutting change of the layers 14, 32, which may occur, for example, frequently in pre-development. In this way, for example, the entire template 10 can be adapted accordingly without having to be replaced when cutting changes during a change. Second template 28 can likewise consist of such segment variants 42.

Together, the forms 10, 28 and pallet 18 thus form a system for producing a two-layer composite 38 for use as a coating for automotive vehicle interior trim components. By adapting the recesses 12, 30 of the template and the carrier 18 to one another in terms of their shaping, the two layers of the composite 38, i.e. the spacer fabric 14 and the decorative layer 32 made of leather, can be easily aligned with one another with a precise fit and fixed to one another in a tight-fitting manner. Thus, the use of forms 10, 28 and pallet 18 is not limited to a backing fabric 14 and a decorative layer 32 made of leather. In principle, all types of layers can be used to manufacture such a composite 38 in the described manner by using the templates 10, 28 and the carrier 18.

List of reference numerals

10 first template

12 notches of a first template

14-pad fabric

16 positioning element of first template 10

18 pallet

20 positioning element of splint

22 device

24 side of the spacer fabric facing away from the pallet

26 device

28 second template

30 indentations of the second template

32 decorative layer

34 positioning element of second template 28

36 double-sided adhesive tape on supporting plate

38 composite made of a backing fabric and a decorative layer

40 section variation