EP3233307A1

EP3233307A1 - Method for producing a decorative part of a motor vehicle

Info

Publication number: EP3233307A1
Application number: EP15823688.5A
Authority: EP
Inventors: Sophie Vidal; Jérôme Brizin; Frédéric Viot
Original assignee: Plastic Omnium SE
Current assignee: Plastic Omnium SE
Priority date: 2014-12-19
Filing date: 2015-12-18
Publication date: 2017-10-25
Also published as: RU2703209C2; KR20170097706A; MA41199A; MX2017008073A; JP6908527B2; RU2017121036A; FR3030314B1; JP2018504275A; CN107107106A; US20180036766A1; BR112017012997A2; WO2016097654A1; FR3030314A1; RU2017121036A3

Abstract

The invention relates to a method for producing a motor vehicle part (10) made of a plastic material, said method comprising a step of spraying a product, and the part comprising an area to be protected during the spraying. The method comprises the following steps: applying a fluid material forming a temporary masking layer on the area to be protected, said step being carried out automatically; spraying the product onto the part (10); and removing the temporary masking layer.

Description

Process for producing a motor vehicle part

The present invention relates to a method for producing a motor vehicle part made of plastic. More specifically, the method is preferably directed at producing a part of appearance, undergoing a step of spraying a product such as a decorative coating, for example paint. This part is called part of appearance because it has a visible part from outside or inside the vehicle once mounted on the vehicle. The appearance part can be for example an outer skin of tailgate assembled on an inner lining, a spoiler, a side door, a hood, etc.

It may happen that the part of appearance has an area to protect, which must remain as clean as possible and devoid of sprayed product. According to a first example, the zone to be protected is a fastening zone making it possible to fix the appearance part with another piece of vehicle, possibly by gluing. This fixing area must be as clean as possible before the glue is placed on it, ie it must not be polluted or soiled before fixing. However, the product spraying step on the appearance part, usually performed by spraying the part prior to its attachment with the part to be fixed, can generate the deposition of fine droplets of paint on the fastening area. In fact, the paint particles are dispersed in fog and can pass on the other side of the room, depositing in the form of a sail. This may affect the quality of the attachment that takes place later, especially the adhesion of the glue or other material used in particular for the connection. In another example, the area to be protected is a part of the surface of appearance intended to be devoid of paint, usually for a decorative purpose. In this case also, we do not want paint to be deposited on the area to be protected.

One solution to solve this problem is to deposit on the area to be protected, before the passage in paint, an adhesive film for masking the area to be protected. This film has the advantage of not leaving a deposit harmful to the bonding or the appearance once it is removed. The film is placed manually and removed at the end of the painting step, also manually. These manual steps are long, expensive and may lack repeatability. The present invention is intended in particular to facilitate the method of producing a motor vehicle part. For this purpose, the subject of the present invention is a method for producing a piece of a motor vehicle made of plastic material, the method comprising a product spraying step and the part having an area to be protected during the spraying, characterized in that it comprises the following steps:

a fluid material forming a temporary masking layer is applied to the zone to be protected, this step being carried out automatically,

- the product is sprinkled on the piece, and

the temporary masking layer is removed.

Thanks to the temporary masking layer, we protect the area to be protected, avoiding that it is covered with residues from the painting step. As the layer is deposited by application of fluid material, an automatic method can be used to deposit it by a robot. The process can therefore be faster, more accurate and repeatable easily.

It should be noted that the use of a temporary masking layer deposited automatically on the zone to be protected is particularly advantageous, unlike adhesive masking films. Indeed, such adhesive films can not be automatically applied to a 3D part, because the film generates folds as soon as it must follow turns.

Note also that one could use a swing masking (or masking) to hide the area to protect. Such a swing is a wall disposed in front of the area to be protected during product spraying on the part, forming a protective screen. However, the difficulty of such a swing lies in the fact that it must match exactly the shape of the room to ensure the sealing function of the sprayed product, which is difficult because the rooms and swing seats do not always have the same dimensions due to manufacturing tolerances.

Note that the product spray on the part may be for example a sprinkling step of paint, varnish, chrome plating and / or salts in solution. This product spraying step can take place with or without prior surface treatment. Furthermore, by plastic part is meant a part comprising predominantly plastic. It can of course integrate other particles and composite materials. The method may further comprise one or more of the following features, taken alone or in combination. The part has a surface of appearance coated with the sprayed product, and the zone to be protected is a local area of the surface of appearance, devoid of sprayed product. In particular, the area to be protected is a zone devoid of paint, so as to keep on a piece of appearance a visible part unpainted, for a style effect.

- The part is a part of appearance, the area to be protected is a fixing area of another piece of motor vehicle, said piece to fix, and the step of removing the temporary masking layer is followed by a step of fixing the workpiece to be fixed on the attachment area of the workpiece. By "piece to fix" any piece likely to be assembled with the part of appearance, including any type of functional element. The attachment zone is generally disposed on the face opposite to the face which is painted. This is for example a bonding area. It will be understood that the method proposed here is particularly advantageous in the case of attachment of the part by a surface connection at the level of the fastening zone. Indeed in this case, it is advantageous to be able to present an extremely clean surface. For example, the piece is fixed by gluing, by applying a layer of glue on the fastening zone. According to another example, the part is fixed by means of an additive printing or 3D printing, by applying a bonding layer produced by printing. Note also that the fixing step of the workpiece to be fixed on the attachment area of the appearance part can take place with or without prior surface treatment.

- Fix the piece to be fixed by applying an adhesive on the fixing area of the appearance part.

The part is fixed by means of an additive printing or 3D printing, by applying a bonding layer deposited by printing. In this case, the fixing can be done by mechanical anchoring or adhesion of materials.

- The temporary masking layer comprises a hot melt glue. Note that a hot melt glue ("hot melt" in English) is an adhesive that becomes fluid under the action of heat and can be easily applied to the liquid state. Once applied, the glue re-solidifies while cooling, adhering to the surface without leaving a gap, and can thus provide a seal to paint and resistance to clashes during handling, to fulfill the protection function of the area to be protected during the product spraying step such as paint. In addition, this cooled adhesive can be removed quickly and easily from the room due to its residual flexibility and its good cohesion at room temperature, allowing the layer to be removed, preferably in one piece, without breaking down into many pieces. This hot-melt adhesive is preferably non-crosslinkable, that is to say that by heating it again, it becomes fluid again and can easily be reused. Hot melt adhesives generally comprise, as basic constituents, thermoplastic polymers such as polyethylene, polypropylene, polyamide or copolymers of the EVA type, to which tackifying resins and additives are added. In general, hot melt glues are liquid from 110 ° C and are cured below 90 ° C. An example of a fusible seal is marketed by Henkel under the name "TEROSON CF 438". An old name for this type of glue is "MACROPLAST CF 438". A particularly interesting example of hot melt glue that can be used is a polyamide-type glue, such as that marketed by Henkel under the name "TECHNOMELT PA 2420", or the glue marketed by Henkel under the reference "HENKEL 6208".

The temporary masking layer comprises a peelable varnish such as that marketed by Zuelch under the reference 826-W1272-00 or by the company

EFTEC under the reference EFCOAT PO 380. Generally, such a peelable varnish is composed of a polymer based on PVC (polyvinyl chloride). Another type of peelable varnish may be similar to solderable masks ("soldermask" in English), known under the name of "blue welding mask", such as that marketed by Atotech under the reference "SD 2954 ". Such masks can be applied by screen printing.

- The temporary masking layer comprises a hot melt glue. The piece is hooked to a hanging swing during the product spraying step and the temporary masking layer is pressed against the swing so as to be held by gluing on the swing. This results in a temporary bonding of the piece against the swing. This ensures a good maintenance of the appearance part during the painting step. Advantageously, with a same temporary layer, a masking layer of the zone to be protected and a bonding layer on the swing are advantageously combined. Preferably, the pressure of the appearance part against the swing is performed automatically. The temporary masking layer comprises a hot melt glue. The temporary masking layer is applied at a temperature above 110 ° C, preferably between 140 ° C and 220 ° C, more preferably between 150 and 200 ° C and the temporary masking layer is removed at a lower temperature. at 90 ° C, preferably between 10 ° C and 40 ° C.

The step of removing the temporary masking layer is followed by a step of reuse of the material having formed this temporary masking layer. For example, it is possible to reuse a temporary masking layer comprising a non-crosslinked hot melt glue. Reuse may include a remelting step at a temperature above 140 ° C in a melter. Cleaning of the material to be reused can be provided, for example by filtration of the material according to observed physical properties, such as density, mechanical effect, particle size, etc.

The temporary masking layer comprises a hot-melt adhesive having a melting temperature Te which is different from, preferably relatively low, with respect to a melting temperature Tp of the sprayed product. This is particularly advantageous for facilitating the recycling or even reuse of hot melt glue. Indeed, with a different melting temperature, it is possible to separate the glue from the product, for example by melting the glue while maintaining the product in the non-liquid state. A filter can therefore be used to remove the product. For example, the melting temperature Te of the adhesive is less than 150 ° C, preferably less than 130 ° C, more preferably close to 100 ° C; and / or the melting temperature Tp of the sprayed product is greater than 150.degree. C., preferably greater than 180.degree. C., more preferably close to 200.degree. According to one example, the hot-melt glue is made of polyamide (PA) having a melting temperature Te close to 100 ° C., and the sprayed product is a polyurethane-type polymer paint having a melting point Tp close to 200 ° C.

The step of reuse of the temporary masking layer comprises the following steps: the temporary masking layer is recovered after it has been removed, it is ground, it is dried, it is introduced into an extruder at a higher temperature T at the melting temperature of the masking layer and below the melting temperature of the sprayed product, the product is removed by filtration and / or the material is recovered to form a new masking layer. Advantageously, during the extrusion, an additive, for example one or more stabilizers, can be added to the masking layer so that it can be recycled several times. It should be noted that the steps can be fully implemented and in the advertised order, or some may be omitted or replaced by other steps, or the order of implementation may change. The solution proposed here allows an operational recycling of the masking layer, while guaranteeing a certain purity, without product residues such as paint residues. - The step of removing the temporary masking layer is followed by a step of degreasing and / or surface treatment of the area to be protected. The surface treatment may be flaming, plasma and / or corona treatment. Degreasing takes place for example using a wipe.

The deposition of the temporary masking layer is provided by an automatism, such as a six-axis robot, which can be parameterized so as to predefine the width and the thickness of the temporary masking layer. For example, the width is between 10 and 30 mm (millimeters), close to 20 mm, and the thickness is between 1 and 3 mm.

- A step of firing the layer of sprayed product occurs after the step of applying the temporary masking layer on the area to be protected, preferably at a temperature above 80 ° C. This is for example a paint baking step.

The invention furthermore relates to the use of a method as described above for manufacturing an outer part of a motor vehicle, such as a hatchback skin, a front or rear bumper skin; a front or rear wing; a bay amount; a rocker; a side door; a cap ; a convergent such as a roof spoiler or roof spoiler.

The invention also relates to an installation for producing a motor vehicle part comprising plastic, comprising the following devices arranged one after the other on a production line of the part:

a device for automatic application of fluid material forming a temporary masking layer on the part,

a product spraying device on the part,

a device for removing the temporary masking layer,

- And possibly a repackaging station of the temporary masking layer for reuse.

Advantageously, the repacking station of the masking layer temporary comprises an extruder at a temperature T, T being greater than the melting temperature of the masking layer and lower than the melting temperature of the sprayed product, and provided with a filter, for example rotary, to separate the layer of product masking.

The invention will be better understood on reading the appended figures, which are provided by way of examples and are in no way limiting, in which:

FIG. 1 is a diagrammatic exploded perspective view of a tailgate outer skin made according to an embodiment of the method and assembled on an interior lining of a tailgate,

FIG. 2 is an internal view of the outer skin of FIG. 1, and

FIG. 3 is a diagram illustrating a method for producing the outer skin of FIG. 1. Referring to FIG. A motor vehicle part 10 made according to the method presented above may be an outer hatch skin. This outer skin 10 is intended to be attached to a hatch liner 12, so as to form a tailgate 14. The appearance part 10 has in this example two parts 10a, 10b: a lower outer skin 10a, intended to cover the lower part of the liner 12, and an upper outer skin 10b, intended to cover the upper part of the liner 12. The part of appearance 10 is generally made of thermoplastic material injected, for example polypropylene. It has an appearance surface which is painted, visible from the outside of the vehicle, corresponding to the outer surfaces of the skins 10a and 10b, schematically illustrated in FIG. 1. It also has an inner surface, corresponding to the inner surfaces of the skins. 10a and 10b, schematically illustrated in Figure 2. The inner surface of the skin 10a, 10b is not intended to be visible once the tailgate assembled and mounted on the motor vehicle. This is a surface which can be described as "technical", in the sense that it is not intended for decoration and can therefore have technical functionalities, in particular means for fixing the appearance part 10 on the hatch liner 12. The tailgate liner 12 has the general shape of a frame, having an opening 16 for receiving a rear window. This hatch liner 12 is for example made of reinforced thermosetting material. In this example, the appearance part 10 is fixed on the hatch liner 12 by gluing. For this purpose, the part of appearance 10 has two areas to be protected 18a and 18b, namely fixing areas 18a and 18b, respectively disposed on the inner surface of the skins 10a, 10b. The fastening zones 18a and 18b are shown in dashed lines in FIG. 2. At the end of the process for producing the aspect part 10, these fixing zones 18a and 18b will be covered with glue tracks, then glued on the liner hatch 12 to ensure permanent attachment of the appearance part 10 on the hatch liner 12.

The method of producing the part of appearance 10 will now be described, with reference to FIG. 3. It will be understood that when simplifying steps for producing "part of aspect 10", so general, but that these steps are implemented on the one hand on the lower skin 10a, on the other hand on the upper skin 10b, generally independently.

The process begins with an injection of material into a mold, so as to mold the body of the part of appearance 10, more precisely to form on the one hand the lower skin 10a, on the other hand the upper skin 10b . Before proceeding to the painting of the appearance part 10, there is proceeded to a step 22 during which a temporary masking layer 22a, 22b is applied to the zone to be protected 18a, 18b. Step 22 is done automatically, thanks to a robot. The layer 22a, 22b is made at the same place as the zone to be protected 18a, 18b. Also, it is shown fictitiously in FIG. 2, although it is not present on the final appearance part 10 shown in FIG.

The temporary masking layer 22a, 22b comprises, in this example, a hot-melt adhesive as presented above. The step 22 for applying the temporary marking layer 22a, 22b is carried out at a temperature greater than 110 ° C., preferably between 140 ° C. and 220 ° C., more precisely between 150 and 200 ° C. Furthermore, step 22 is provided by a configurable robot so as to predefine the width and the thickness of the temporary masking layer 22a, 22b. For example, the width of the layer 22a, 22b is close to 20 mm and the thickness is between 1 and 3 mm. The speed of movement of the robot is here between 50 and 200 mm per second, with an adhesive flow rate of between 20 and 80 rpm (revolutions per minute). Furthermore, the application of the layer is implemented by means of an extended nozzle disposed closer to the workpiece, according to a distance of between 2 and 8 mm between the piece and the end of the nozzle. Thus, it allows to gain in precision to deposit the glue. In addition, so that the layer can spread over a glue track of a certain length, for example 25 mm, it is possible to vary the viscosity of the glue, depending on the temperature, the type and the reference glue.

The step 22 of applying the temporary masking layer 22a, 22b to the zone to be protected 18a, 18b is followed by a step 24 during which a product, namely paint, is sprayed onto the blank. 'aspect. This step 24 is done by spraying paint on the surface of appearance, corresponding to the outer surfaces of the skins 10a and 10b. In this example of paint spraying, step 24 has a step of baking in an oven lasting between 20 and 30 minutes per piece and is carried out at a temperature in the region of 80 ° C. The inner surfaces of the skins 10a and 10b are not directly painted, but indirectly receive paint residues in the form of a veil, because of the paint mist generated by the spray. Thus, the temporary masking layer 22a, 22b, which is sealed at this temperature, probably receives paint droplets instead of the area to be protected 18a, 18b that it covers.

According to a particularly advantageous improvement, during the step 24 of applying the paint, the appearance part 10a, 10b is attached to a hanging swing and the layer 22a, 22b of temporary masking is pressed against the swing so as to be held by gluing on the swing.

The product spraying step 24 is followed by a step 26 during which the temporary masking layer 22a, 22b is removed. For example, lift one end of the layer and pull on it. This step of removing the layer 22a, 22b is carried out at a temperature below 90 ° C, preferably between 10 ° C and 40 ° C. At this temperature, the hot-melt adhesive forming the layer 22a, 22b is cooled and flexible and can be removed quickly and easily without fragmenting.

The step 26 of removing the temporary masking layer is followed by a degreasing step, and possibly a surface treatment of the fixing zone. According to a particularly advantageous embodiment, the step 26 of removing the temporary masking layer is also followed by a step 28 of reuse of the material having formed this temporary masking layer. According to one for example, the temporary masking layer comprises a hot melt glue having a melting temperature Te relatively low compared to a melting temperature Tp of the sprayed product. According to one example, the hot-melt glue is polyamide (PA) having a melting temperature Te close to 100 ° C, and the sprayed product is a polyurethane-type polymer paint having a melting temperature Tp close to 200 ° C. Step 28 of reuse of the temporary masking layer comprises the following steps: the temporary masking layer is recovered after being removed, ground, dried, introduced into an extruder at a neighboring temperature T 120-130 ° C, therefore higher than the melting temperature Te of the masking layer and lower than the melting temperature of the sprayed product. Thus, the masking layer melts but not the sprayed product. The extrusion end product is then removed by filtration using a coarse rotary filter which separates the masking layer from the product. Then, the material is recovered to form a new masking layer. Advantageously, during the extrusion, an additive, for example stabilizers and / or other additives, can be added to the masking layer so that it can be recycled several times.

Step 30 is then followed by a step 32 during which the part to be fixed is fixed on the fastening zone of the appearance part, namely in this example a step during which the lining of tailgate 12 on the fastening area 18a, 18b of the appearance part 10. The fastening zones 12a, 12b have been shown schematically in FIG. 1.

At the end of this step 32, the tailgate 14 is obtained, ready to be assembled on the vehicle. To implement such an embodiment method, an installation is used comprising the following devices arranged one after the other on a production line of part 10:

a device for automatic application of fluid material forming a layer 22a, 22b of temporary masking on the part,

a product spraying device on the part 10,

- A device for removing the layer 22a, 22b of temporary masking.

In addition, the installation preferably includes a station for repackaging the temporary masking layer for reuse. Advantageously, this station comprises an extruder at a temperature T, T being greater than the melting temperature of the masking layer and lower than the melting temperature of the sprayed product, and provided with a filter, possibly rotating, to separate the masking layer of the product. The filter is preferably coarse, that is to say with filter mesh between 150 and 600 μηη (micrometers).

According to another embodiment, the part to be produced has a surface of appearance coated with the sprayed product, and the area to be protected is a local area of the surface of appearance, devoid of sprayed product. For example the outer surfaces of the skins 10a and 10b of the appearance part 10 have a local area unpainted, devoid of paint and which is to be protected similarly to the areas to be protected 18a, 18b. It is understood that the method described above applies similarly to such areas to be protected and that the entire description can be read with such an application.

The invention is not limited to the embodiments presented and other embodiments will become apparent to those skilled in the art. In particular, the method is used to fabricate a hatch skin 10 but many other parts can be made by means of this method, especially a front or rear bumper skin; a front or rear wing; a bay amount; a rocker; a side door; a cap ; a convergent such as a roof spoiler or roof spoiler.

In addition, according to another example, the temporary masking layer 22a, 22b comprises a peelable varnish in place of the hot melt glue. For example, a peelable varnish such as that sold by Zuelch under the reference 826-W1272-00 is used. This varnish is deposited automatically, with a drying time of about two hours at room temperature. The drying time can be reduced by raising the temperature, for example 15 minutes of drying at a temperature of about 140 ° C.

Furthermore, the fixing of the part of appearance 10 and the part to be fixed 12 is, in the example presented above, by gluing, but other types of attachment are possible, in particular other types of fixing by surface bonding requiring a very clean surface to fix, without residues. In particular, it is possible to envisage fastening by mechanical fastening over a relatively large surface, during which a bonding layer made by additive printing or 3D printing is applied to the fastening zone, making it possible to hang the part to be fixed on the part. of appearance 10.

Claims

1. Method for producing a plastic vehicle part (10), the method comprising a product spraying step and the part having a zone (18a, 18b) to be protected during the spraying, characterized in that that it includes the following steps:

a fluid material forming a temporary masking layer (22a, 22b) is applied to the zone to be protected (18a, 18b), this step being carried out automatically,

- the product is sprinkled on the piece (10), and

- removing (26) the layer (22a, 22b) of temporary masking.

2. Method according to the preceding claim, wherein the layer (22a, 22b) of temporary masking comprises a hot melt adhesive or peelable varnish.

3. Method according to any one of the preceding claims, the temporary masking layer comprising a hot-melt glue, in which process the piece (10) is hooked to a hook-and-loop during step (24) of spraying the product and the temporary masking layer is pressed against the swing so as to be held by gluing on the swing.

4. A method according to any one of the preceding claims, the temporary masking layer comprising a hot-melt glue, in which process (22) the layer (22a, 22b) of temporary marking is applied at a temperature greater than 110 ° C, preferably between 140 ° C and 220 ° C, and the temporary masking layer is removed at a temperature below 90 ° C, preferably between 10 ° C and 40 ° C.

A method according to any one of the preceding claims, wherein the step (26) of removing the temporary masking layer is followed by a step (28) of reuse of the material having formed this masking layer. temporary (22a, 22b).

6. Method according to the preceding claim, the temporary masking layer comprising a hot melt glue having a melting temperature Te relatively low compared to a melting temperature Tp of the sprayed product, for example the melting temperature Te of the glue is lower. at 150 ° C, preferably below 130 ° C, more preferably close to 100 ° C; and / or the melting temperature Tp of sprayed product is greater than 150 ° C, preferably greater than 180 ° C, more preferably close to 200 ° C.

7. Method according to the preceding claim, wherein the step (28) of reuse of the temporary masking layer comprises the following steps: the temporary masking layer is recovered after being removed, crushed, dried, it is introduced into an extruder at a temperature T greater than the melting temperature of the masking layer and lower than the melting temperature of the sprayed product, an additive, for example one or more stabilizers in the masking layer, is optionally added. the product is removed by filtration and / or the material is recovered to form a new masking layer.

8. Method according to any one of the preceding claims, wherein the hot melt glue is polyamide and the sprayed product is a polyurethane-type polymer paint.

9. A method according to any one of the preceding claims, wherein the step (26) of removing the temporary masking layer is followed by a step (30) of degreasing and / or surface treatment of the zone. to protect.

10. Method according to any one of the preceding claims, the deposition (22) of the layer (22a, 22b) of temporary masking is provided by a configurable robot so as to predefine the width and thickness of the temporary masking layer .

11. A method as claimed in any one of the preceding claims, wherein the part has an appearance surface coated with the sprayed product, and the area to be protected (18a, 18b) is a local area of the appearance surface, devoid of sprayed product .

12. Method according to any one of the preceding claims, wherein the part (10) is a part of appearance, the area to be protected (18a, 18b) is an attachment zone of another piece of motor vehicle, called piece to be fixed (12), and the step of removing (26) the temporary masking layer (22a, 22b) is followed by a step (32) for fixing the part to be fixed on the fastening zone of the aspect piece (10).

13. Method according to the preceding claim, in which one fixes (32) the piece to be fixed by applying an adhesive on the fastening area of the appearance part.

14. A method according to any one of claims 11 or 12, during which we fix (32) the piece to be fixed by means of an additive printing or 3D printing, applying a bonding layer made by printing.

15. Use of the method according to any one of the preceding claims for manufacturing an outer part (10) of a motor vehicle, such as a hatchback skin; front or rear bumper skin; a front or rear wing; a bay amount; a rocker; a side door; a cap ; a convergent such as a roof spoiler or roof spoiler.

16. Installation for producing a plastic vehicle part (10) comprising the following devices arranged one after the other on a production line of the part (10):

a device for automatic application of fluid material forming a temporary masking layer (22a, 22b) on the part (10),

a product spraying device on the part (10),

a device for removing the temporary masking layer (22a, 22b),

and possibly a station for repackaging the temporary masking layer (22a, 22b) with a view to its reuse.

17. Installation according to the preceding claim, wherein the repacking station of the temporary masking layer comprises an extruder at a temperature T, T being greater than the melting temperature of the masking layer and less than the melting temperature of the product. sprayed, and provided with a filter for separating the masking layer of the product.