WO2001098060A1

WO2001098060A1 - Method and apparatus for attaching a covering to a substrate

Info

Publication number: WO2001098060A1
Application number: PCT/GB2001/002725
Authority: WO
Inventors: Victor Charles Sumner; Mark Brian Davis
Original assignee: Intier Automotive Interiors Limited
Priority date: 2000-06-21
Filing date: 2001-06-21
Publication date: 2001-12-27
Also published as: GB2363755A; GB0015145D0; AU2001266146A1

Abstract

A method of and apparatus for attaching a covering (12) to a substrate (11) comprising the steps of disposing said substrate (11) and said covering (12) on a support (31) and acting on said substrate (11) and said covering (12) with a membrane (27) to urge said covering (12) in the direction of said support (31).

Description

Title: Method and Apparatus for Attaching a Covering to a Substrate

Description of Invention

This invention relates to a method and apparatus for covering a substrate, particularly but not exclusively for manufacturing components for the interior of vehicle compartments.

Conventionally, to manufacture interior components for cars, a substrate comprising, for example, fibre board, is covered with a covering, particularly textile or leather. A heat actuated adhesive is disposed between the substrate and the covering material, and then a heated aluminium polished tool of an appropriate shape is applied to the substrate and the covering material, to urge the substrate and covering material into engagement and to activate the adhesive.

Such a technique requires a skilled operator to smooth the covering material-onto the substrate, and does not effectively permit undercuts or edge wrapping to take place. To apply the covering material to undercuts or edges of the substrate requires a tool with sliding components which are appropriately shaped, and which again require a skilled operator. The direct application of the heated aluminium tool to the covering material can lead to a change in the condition of the covering material, for example, a change in colour or change in pile.

An aim of the invention is to provide a new or improved method of attaching a covering to a substrate.

According to first aspect of the invention we provide a method of attaching a covering to a substrate comprising the steps of disposing said substrate on a support and acting on said covering with a membrane to urge the covering towards the substrate.

The method may comprise disposing adhesive on a surface of at least one of said substrate and said covering, disposing said covering on said substrate such that the adhesive is disposed therebetween and warming said adhesive.

The method may comprise the step of directing warm air on at least one of the covering and the substrate to warm said adhesive prior to said step of acting on said covering.

The method may comprise the steps of disposing said substrate and said covering on said support and acting on said substrate and said covering to urge the covering in the direction of said support.

When the support comprises a lower mould and an upper mould the method may comprise the step of creating a low pressure adjacent the lower mould to draw the membrane towards the lower mould.

Where the support comprises a lower mould and an upper mould provided with said membrane mould the method may comprise the step of holding the membrane adjacent the upper mould by creating a low pressure adjacent the said upper mould.

The method may comprise the step of holding the membrane adjacent the upper mould and spacing the upper mould from said lower mould to define a space into which said warm air is directed.

The method may comprise the step of cooling said support by passing water through cooling ducts in said support.

The method may comprise the initial step of attaching said covering to said substrate at least one part thereof.

The covering may be attached to said substrate at a stitch line thereof.

According to a second aspect of the invention we provide an apparatus for attaching a covering to a substrate comprising a support to receive said substrate and a membrane the apparatus being operable to cause said membrane to act on said covering to urge the covering towards the substrate.

The apparatus may comprise heating means to warm said substrate and covering. Said heating means may comprise means to direct hot air on at least one of said substrate and covering.

The support may be adapted to receive said substrate and said covering and said apparatus may be operable to cause said membrane to act on said covering and said substrate to urge the covering and the substrate in the direction of said support.

The apparatus may comprise pressure means to create a low pressure adjacent to the support to draw the membrane towards the support.

The support means may comprise a lower mould and an upper mould.

The lower mould may have an upper surface shaped to the desired shape of the substrate.

The upper mould may have a lower surface of a complementary shape to the upper surface of the lower mould.

The upper mould and the lower mould may comprise aluminium.

The lower mould may comprise pressure means to create a low pressure adjacent said lower surface to draw the membrane towards said lower surface.

The upper mould may comprise pressure means to create a low pressure adjacent said lower surface to draw the membrane towards said lower surface.

The pressure means may comprise at least one duct disposed within at least one of said upper mould and said lower mould and means to create a low pressure within said at least one duct, and wherein said at least one duct is connected to said lower surface or said upper surface by at least one conduit.

The apparatus may further comprise air supply means to supply air to said at least one duct to direct cooling air over said covering and said substrate.

The support means may be provided with cooling means comprising cooling ducts through water may be passed.

According to a third aspect of the invention we provide a component comprising a substrate and a covering where made by a method according to the first aspect of the invention or by an apparatus according to the second aspect of the invention.

The component may be in or for an interior of a vehicle compartment.

The invention will now be described by way of example only with reference to the accompanying drawings, wherein

Figure 1 is a section through a covering and substrate,

Figure 2a is a section through an apparatus according to the second aspect of the invention in a first stage of operation,

Figure 2b shows the apparatus of Figure 2a in a second stage of operation,

Figure 2c shows a part of the apparatus of Figure 2a in a third stage of operation,

Figure 2d shows a part of the apparatus of Figure 2a in a fourth stage of operation,

Figure 2e shows a part of the apparatus of Figure 2a on a larger scale in a fifth stage of operation,

Figure 2f shows a part of the apparatus of Figure 2a on a larger scale in a sixth stage of operation,

Figure 2g shows the apparatus of Figure 2a on a larger scale in a seventh stage of operation,

Figure 2h shows the apparatus of Figure 2a on a larger scale in a eighth stage of operation,

Figure 2i shows the apparatus of Figure 1 in a ninth stage of operation,

Figure 2j shows the apparatus of Figure 2a in a tenth stage of operation,

Figure 3 is a diagrammatic sectional view of an alternative apparatus according to the first aspect of the invention, and

Figure 4 is a section on line 4-4 of Figure 3.

Referring to Figure 1, a component to be formed is generally indicated at 10, and provided with a substrate 11 to be covered by a covering 12. In the present example, disposed between the substrate 11 and the covering 12 is a pad 13, in the present example comprising a foam pad to form an arm rest. The covering 12 is provided with a stitch line 12a, which may be a stitched line between two pieces of material forming the covering 12, or may be a stimulated stitch line for aesthetic purposes. The substrate 11 has an edge part 1 la about which is desired to wrap the covering 12.

Referring to Figures 2a to 2j, an apparatus according to the first aspect of the invention is shown generally at 20 comprising an upper part 21 and a lower part 22. The upper part 21 is movable relative to the lower part 22, for example by hinged movement or by vertical movement, and may be manually moved or moved by suitable drive means (not shown). The upper part 21 comprises an upper mould 23 comprising a shaped aluminium tool having a lower surface 23 a. The upper mould 23 comprises a plurality of ducts 24a, 24b, 24c, which are in flow communication with respective conduits 25a, 25b, 25c each extending between a corresponding one of the ducts and the lower surface 23 a of the upper mould 23. At either side of the upper mould 23 is an upper mechanical stop 26. The upper part 21, below the lower surface 23a of the upper mould 23, is provided with a flexible membrane 27. The membrane 27 may comprise a latex membrane, for example in the form of a latex bag which is attached by suitable means to the upper part 21. In the present example, the membrane 27 has a thickness of approximately 2mm, although any other suitable thickness, for example in the range 0.5mm to 2mm, or material may be used as desired. Disposed at either side of the mould 23 is a closure element 28, each closure element 28 being provided with an opening 29. The closure elements 28 are disposed at such a separation that they pass either side of the lower part 22 when the upper part 21 is lowered. Cooling ducts 30 are provided in the upper part 21 in flow connection with a water source (not shown).

In similar fashion, the lower part 22 comprises a lower mould 31 comprising a shaped aluminium tool having an upper surface 3 la including at least one indent 37. The lower mould 31 is supported on a base 32. The lower mould 31 is provided with ducts 33a, _. 33b, 33c which are in flow communication via respective conduits 34a, 34b, 34c with the upper surface 31a of the lower mould 31. Disposed either side of the lower mould 31 are lower mechanical stops 35. The lower part 22 is further provided with cooling ducts 36 to receive cooling water from a cooling water supply means (not shown).

The upper mould 23 and lower mould 31 are shaped such that when said upper mould and lower mould are disposed in an operating relationship to one another, the spacing in between the lower surface of the membrane 27 and the upper surface of the covering 12 is preferably about 1.5mm. In the present example, the membrane 27, covering 12 and substrate 11 each have a thickness of 2mm. To provide the desired spacing between the membrane 27 and the covering 12, in the present example the lower surface 23 a of the upper mould 23 and the upper surface 31a of the lower mould 31 are separated by about 7.5mm. Experiments have shown that an air gap of about 1.5mm between the lower surface of the membrane 27 and the upper surface of the covering 12 is most effective. Obviously, where the thickness of the membrane 27, covering 12 or substrate 13 is different, the spacing of the upper mould 23 and lower mould 31 will need to be varied to provide the desired spacing between the membrane 27 and covering 12.

The ducts 24a, 24b, 24c, 33a, 33b, 33c, are connected to pressure means (not shown) operable either to lower the pressure within one or more of said ducts 24a, 24b, 24c, 33 a, 33b, 33 c, relative to ambient pressure, or to supply air to one or more of said ducts 24a, 24b, 24c, 33a, 33b, 33c.

The method of operation is as follows. The substrate 11 is sprayed with a solution of a suitable heat actuated adhesive, and the covering 12 is laid on the substrate. To hold the covering 12 in generally the correct position relative to the substrate 11, an adhesive line is applied to the underside of the covering 12, ideally below the stitch line 12a, and fixed to the substrate 11. In Figure 1, the stitch line 12a is preferably glued such that it is located in an angle lib defined by the substrate 11 and the foam pad 13.

As seen in Figure 2a, the apparatus 20 is initially opened such that the upper part 21 is spaced from the lower part 22. The component 10 is introduced into the apparatus 20, and as seen in Figure 2b is located on the upper surface 31a of the lower mould 31. The pressure in the ducts 24a, 24b, 24c is reduced to produce a low pressure at the lower surface 23a of the upper mould 23 and so to hold the membrane 27 in place adjacent to the lower surface 23 a of the upper mould 23. If desired, the pressure may be reduced in the duct 33b to maintain the component 10 in position adjacent to the lower part 22. The upper part 21 is then lowered towards the lower part 22 as seen in Figure 2b, until the upper part 21 and the lower part 22 are spaced as shown in Figure 2c such that the apertures 29 are still in flow communication between the upper part 20 and the lower part 21.

As seen in Figure 2d, heated air is introduced into the apparatus 20 such that it flows in the direction indicated at A from a heating means (not shown). The air is preferably heated to 90°C by suitable heated means (not shown) and thus actuates the heat actuated adhesive. In the present example, the heat actuated adhesive actuates at a temperature of approximately 60 to 65°C. The heated air is introduced for a sufficient period of time for the adhesive to reach its actuation temperature in conventional manner.

As seen in Figure 2e, the upper part 21 is then lowered towards the lower part 22 until the mechanical stops 26, 35 engage. The pressure in the ducts 24a, 24b, 24c is permitted return to ambient such that the membrane 27 drops away from the lower surface 23a of the upper mould 23 and rests on the component 10.

The pressure in the ducts 33a, 33b, 33c is then reduced, drawing the membrane 27 against the lower mould 31 and the component 10 as seen in Figure 2f. The membrane 27 thus applies an even pressure over the entire surface of the component 10, pressing the covering 12 and substrate 11 firmly into engagement with the heat actuated adhesive therebetween. In particular, the membrane 27 is drawn into an indent 37 provided in the lower mould 31, thus wrapping the covering 12 around the edge parts of the substrate 11, for example, in Figure 1 around the end part 1 la.

Once the covering 12 has been held against the substrate 11 for a desired period of time, preferably in the range of 30 to 40 seconds, cooling air is then supplied to duct 24b as shown in Figure 2g, such that it passes between the upper part 21 and the lower part 22 and is extracted through conduits 25a, 25c and ducts 24a and 24c, to reduce the adhesive below this actuating temperature.

The pressure in the ducts 33a, 33b, 33c is then permitted to return towards ambient whilst the pressure in ducts 24a, 24b, 24c is reduced, lifting the membrane 27 away from the component 10 and bringing it back into engagement with the lower surface 23 a of the upper mould 23, as seen in Figure 2h. The upper part 21 is lifted away from the lower part 22 as seen in Figure 2i, and the formed component 10 removed from the lower part 22 as seen in Figure 2j.

The apparatus 20 thus permits a component 10 having edge parts to be formed by a simple process, with relatively little operator skill requirement in a apparatus with no moving apart other than the relatively movable upper and lower parts 21, 22. The apparatus 20 may thus be made free standing as appropriate. The reduced pressure may be supplied from a factory supply as desired. To maintain the temperature of the upper mould 23 and lower mould 31 below a desired threshold, cooling water may be passed through cooling ducts 30, 36 from a suitable supply as desired. In the second, third, fourth and fifth stages of the operation as seen in Figures 2b to 2e, lower pressure need not be applied to the duct 33b. In the sixth stage of the operation, as shown in Figure 2f, the pressure in ducts 24a, 24b, 24c may be increased to press the membrane 27 downwards onto the component 10 as desired, in addition to or instead of the reduced pressure applied in ducts 33a, 33b, 33 c.

The lower surface 23 a of the upper mould 23 and the upper surface 31a of the lower mould 31 are shaped to be separated by approximately 7.5mm in the present example as discussed above, when the upper part 21 and the lower part 22 are in the position as shown in Figure 2e. In this fashion, the membrane 27 is moved to within 1.5 mm of the surface of the component 10, and then is drawn down onto the component by the reduced pressure in the conduits 34a, 34b, 34c thus providing a relatively short distance of travel for the membrane 27 and maximising the force supplied by the membrane 27 to the component 10. In the drawings, the thicknesses of the membrane 27, covering 12 and substrate 11 have been exaggerated for clarity.

Because a heated surface is not applied directly to the component 10, there is no colour change or change in pile of the cover 11 and the flexibility of the membrane 27 enables it to press the covering 12 around edges of the substrate 11 in a manner not assumable by conventional apparatus. The membrane 27 may comprise a simple stretch membrane, or it may be formed to match the lower surface 23a of the upper mould 23.

In the position shown in Figure 2f, the upper part 21 and the lower part 22 are in sealing relationship with one another such that the pressure in the gap between the upper part 21 and the lower part 22 is affected only by the pressure in the ducts 24a, 24b, 24c, 33a, 33b, 33c.

In an alternative embodiment as shown in Figures 3 and 4, the heat actuated adhesive is actuated not by blowing hot air through the apparatus but by sliding the lower mould into a heating unit. Referring to Figures 3 and 4 an apparatus 120 is shown having an upper part 121 and a lower part 122. The upper part 121 and the lower part 122 are provided with suitable ducts, water cooling passages etc as shown in the embodiment of Figures 2a to 2j. In this embodiment, the lower part 122 is slidably mounted on slide rods 123 by slide bearings 124. A fluid operated ram means 125 is operable to move the lower part 122 along the slide 123. In a first position, as shown in Figures 3 and 4, the lower part 122 is disposed to receive the upper part 121, which is mounted in hinged fashion on hinges 126 to move the upper part 121 into and out of engagement of the lower part 122. Extending in a rightwards direction from this position as seen in the Figures, the slide rods 123 extend into a heater 127 comprising a plurality of heater units 128 and a fan 129. The apparatus 120 is operated in like manner to the apparatus of Figures 2a to 2j, with the exception that instead of actuating the adhesive by blown air as shown in Figure 2d, the lower part 122 is slid into the heater unit 127 on the slider rods 123 under the heaters 128 to actuate the adhesive. After a sufficient period in the heater unit 127, the lower part 122 is returned to the left-hand position as shown in the Figures, and the upper part 121 lowered into engagement therewith.

In the present specification "comprise" means "includes or consists of and "comprising" means "including or consisting of.

The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

Claims

1. A method of attaching a covering to a substrate comprising the steps of disposing said substrate on a support and acting on said covering with a membrane to urge the covering towards the substrate.

2. A method according to Claim 1 comprising disposing adhesive on a surface of at least one of said substrate and said covering, disposing said covering on said substrate such that the adhesive is disposed therebetween and warming said adhesive.

3. A method according to Claim 2 comprising the step of directing warm air on at least one of the covering and the substrate to warm said adhesive prior to said step of acting on said covering.

4. A method according to any one of the preceding claims comprising the steps of disposing said substrate and said covering on said support and acting on said substrate and said covering to urge the covering in the direction of said support.

5. A method according to Claim 4 comprising the step of creating a low pressure adjacent to the support to draw the membrane towards the support.

6. A method according to Claim 4 or Claim 5 wherein the support comprises a lower mould and an upper mould comprising the step of creating a low pressure adjacent the lower mould to draw the membrane towards the lower mould.

7. A method according to any one of Claims 4 to 6 wherein the support comprises a lower mould and an upper mould provided with said membrane comprising the step of holding the membrane adjacent the upper mould by creating a low pressure adjacent the said upper mould.

8. A method according to Claim 7 when dependent on Claim 3 comprising the step of holding the membrane adjacent the upper mould and spacing the upper mould from said lower mould to define a space into which said warm air is directed.

9. A method according to any one of Claims 4 to 8 comprising the step of cooling said support by passing water through cooling ducts in said support.

10. A method according to any one of the preceding claims comprising the initial step of attaching said covering to said substrate at least at one part thereof.

11. A method according to Claim 10 wherein the covering is attached to said substrate at a stitch line thereof.

12. A method as described herein and/or with reference to the accompanying drawings.

13. An apparatus for attaching a covering to a substrate comprising a support to receive said substrate and a membrane the apparatus being operable to cause said membrane to act on said covering to urge the covering towards the substrate.

14. An apparatus according to Claim 12. or Claim 13 comprising heating means to warm said substrate and covering.

15. An apparatus according to Claim 14 wherein said heating means comprises means to direct hot air on at least one of said substrate and covering.

16. An apparatus according any one of the preceding claims wherein said support is adapted to receive said substrate and said covering and wherein said apparatus is operable to cause said membrane to act on said covering and said substrate to urge the covering and the substrate in the direction of said support.

17. An apparatus according to Claim 16 comprising pressure means to create a low pressure adjacent to the support to draw the membrane towards the support.

18. An apparatus according to Claims 16 or 17 wherein the support means comprises a lower mould and an upper mould.

19. An apparatus according to Claim 18 wherein the lower mould has an upper surface shaped to the desired shape of the components.

20. An apparatus according to Claim 19 wherein the upper mould has a lower surface of a complementary shape to the upper surface of the lower mould.

21 An apparatus according to any one of Claims 18 to 20 wherein the upper mould and the lower mould comprise aluminium.

22. An apparatus according to any one of Claims 18 to 21 where dependent directly or indirectly on Claim 17 wherein the lower mould comprises pressure means to create a low pressure adjacent said lower surface to draw the membrane towards said lower surface.

23. An apparatus according to any one of Claims 18 to 22 wherein the upper mould comprises pressure means to create a low pressure adjacent said lower surface to draw the membrane towards said lower surface.

24. An apparatus according to Claim 22 or Claim 23 wherein the pressure means comprises at least one duct disposed within at least one of said upper mould and said lower mould and means to create a low pressure within said at least one duct, and wherein said at least one duct is connected to said lower surface or said upper surface by at least one conduit.

25. An apparatus according to Claim 24 further comprising air supply means to supply air to said at least one duct to direct cooling air over said covering and said substrate.

26. An apparatus according to any one of Claims 13 to 25 wherein the support means is provided with cooling means comprising cooling ducts through which water may be passed.

27. An apparatus as described herein and/or with reference to the accompanying drawings.

28. A component comprising a substrate and a covering where made by a method according to any one of Claims 1 to .12 or a by an apparatus according to any one of claims 12 to 21. _Λ

29. A component according to Claim 28 wherein said component is in or for an interior of a vehicle compartment.

30. Any novel feature or novel combination of features described herein and/or in the accompanying drawings.