WO2023138964A1

WO2023138964A1 - Method and system for producing an at least two-layered composite

Info

Publication number: WO2023138964A1
Application number: PCT/EP2023/050517
Authority: WO
Inventors: Robert Thalhammer
Original assignee: Lisa Dräxlmaier GmbH
Priority date: 2022-01-20
Filing date: 2023-01-11
Publication date: 2023-07-27
Also published as: DE102022101280B4; DE102022101280A1

Abstract

The invention relates to a method and to a system for producing an at least two-layered composite for laminating a cladding component. The method provides for fixing a first material blank (140) that forms a first layer to a stencil (120) having a first contact surface (121) and at least one second contact surface (122) bevelled with respect to the first contact surface (121). The method also provides for rolling an adhesive onto the first material blank (140) in the region of the first contact surface (121) by means of a roll coater (110) which moves within a plane (E) common to the first contact surface (121). Furthermore, the method provides for applying a second material blank (150) that forms a second layer to the first material blank (140) roll-coated with the adhesive so as to form the composite.

Description

METHOD AND SYSTEM FOR MAKING AT LEAST TWO LAYERS TOGETHER

technical field

The present invention relates to a method for producing a composite with at least two layers for laminating a trim component. In addition, the present invention relates to a system, for example a tool system, for producing a composite with at least two layers for laminating a trim component. Such a composite can be used, for example, in vehicles, such as instrument panels, center consoles, door panels, pillar and headliner panels in the vehicle interior.

State of the art

Composites made from material cuts are used as decor for cladding components. Such a trim component can be used, for example, in a vehicle interior. In the production of such a composite, a material blank is provided with an adhesive and bonded to another material blank. It has been shown in practice that if the material blank or the composite formed from it is further processed in a subsequent process, the tool used for the subsequent process can become soiled. This contamination then requires increased cleaning and/or maintenance effort in order to ensure the production process of the assembly and its quality.

In order to reduce contamination of the tool, it would be conceivable to clean the material blank or composite provided with adhesive before further processing in the subsequent process, which would, however, make the entire manufacturing process more complex. Description of the invention

One object of the invention is therefore to reduce the cleaning and/or maintenance effort of a tool used to produce a composite of at least two layers while using means that are as simple as possible in terms of construction.

The object is solved by the subject matter of the independent claims. Advantageous developments of the invention are specified in the dependent claims, the description and the accompanying figures.

A method for producing a composite with at least two layers for laminating a trim component is proposed. In a method step, a first material blank forming a first layer is fixed to a template, the template having a first contact surface and at least one second contact surface which is beveled in relation to the first contact surface. In addition, the method includes rolling an adhesive onto the first material blank in the area of the first contact surface by means of a roller device that moves within a plane that is common to the first contact surface. In addition, the method comprises applying at least one second material cut, which forms a second layer, to the first material cut, which has been rolled with the adhesive, in order to form the composite.

In other words, in the method described above, a template is used which, thanks to its at least two contact surfaces that are aligned differently from one another, namely the first and second contact surface, makes it possible for no adhesive to be applied to that area or those areas of the first and/or second material blank that are to be processed further in a subsequent process. This is made possible by the fact that the rolling device moves (mainly or exclusively) within the plane common to the first contact surface of the template, but the second contact surface of the template is in a different plane due to the bevel provided between the first contact surface and the second contact surface, which consequently is not reached and processed by the rolling device.

In the proposed method, the first contact surface of the template can define a first area that is to be provided with the adhesive in order to target a To effect bonding with the second material blank. It should be noted that the area, ie the area of the first contact surface of the stencil, can very well be subjected to a subsequent process provided that the applied adhesive does not interfere with this. On the other hand, the second contact surface can define a second area in which a subsequent process, such as the introduction of a sewn seam, such as a connecting seam and/or decorative seam, or the like, is to be carried out, so that the application of the adhesive in this second area would interfere with the subsequent process. This means that the area of the first material cut fixed to the template that is assigned to the first contact surface can also be referred to as the adhesive area and the area of the first material cut that is fixed to the template that is assigned to the second contact surface can also be referred to as the non-adhesive area, i.e. the area that is to be kept as free of adhesive as possible.

The template used in the method makes it possible to keep the first and/or second material blank for a subsequent process as free as possible of adhesive in the areas and/or locations used for this purpose due to its first and second contact surface, which is beveled for this purpose. As a result, the first material cut is only rolled with the adhesive where it hardly or not at all interferes with the subsequent process or where the tool used for the subsequent process is soiled less or not at all. For example, the subsequent process can provide for the introduction of a sewn seam in one of the at least two layers or the composite, with the template used in the method using structurally simple means making it possible to keep the area or areas in which the sewn seam, such as a connecting seam or decorative seam, is to be introduced at least essentially free of adhesive. For example, the method with the template used in it can prevent the needle and/or a gripper of the sewing device from becoming soiled in the subsequent sewing process. As a result, the effort required for cleaning and maintenance of the sewing device can be kept as low as possible.

The template used for the method can have a plate shape, for example. In addition, the second contact surface, which is bevelled in relation to the first contact surface, can be understood to mean that there is a height difference between the first and second contact surface, as a result of which the roller or rolling device, which is held or moved at least essentially at the level of the first contact surface, is kept at a distance from the second contact surface and consequently not in the area thereof Applying glue to the first cut of material. In this way, the control of the rolling device can also be kept as simple as possible, but an application of adhesive can nevertheless be controlled or avoided in a targeted manner.

According to one embodiment of the method, the method can further provide that the rolling device is moved during the rolling on in the plane common to the first contact surface of the stencil and the second contact surface of the stencil is meanwhile outside of the common plane, whereby the adhesive on the first material blank in the area of the second contact surface is at least substantially spared. In other words, the rolling device or its roller is moved along the template with the first material blank fixed to it in such a way that the adhesive is applied in the area of the first contact surface, but left out in the area of the second contact surface, since this lies outside the plane spanned by the first contact surface due to the bevel. The template, which is of simple design, can thus reliably prevent the adhesive from being applied to the material blank fixed to the template in the area of the second contact surface.

In one embodiment of the proposed method, the size of the second contact surface of the template can be selected depending on the course of a sewn seam that is introduced into the composite in a subsequent process, whereby the adhesive in the region of the sewn seam is at least essentially left out. In other words, the second contact surface can be dimensioned in such a way that a transition area is provided between the first contact surface, i.e. the area of the first material blank fixed to the template to be rolled with the adhesive, and the area on the second contact surface that is to be kept as free of adhesive as possible. Since the bevel between the first and second contact surface of the template used does not necessarily have to be so strong that the roller or roller device completely omits the area on the second contact surface, a slightly larger second area, i.e. a larger second contact surface, allows the point arranged within the second area for further processing, e.g. the introduction of a sewn seam, to be kept free of adhesive. The second contact surface is therefore preferably selected to be at least slightly larger than the subsequent process would actually require. According to one embodiment of the proposed method, the composite can be provided with a sewn seam in an area assigned to the second contact surface after it has been detached from the template. As indicated above, the proposed method proves to be particularly advantageous if the second area, ie the area associated with the second contact surface of the template, is kept free of adhesive, since this would soil the tool used for sewing. As a result, the proposed method, in particular the use of the beveled stencil, can reliably reduce or prevent the effort required for cleaning and maintenance of the stencil used in the subsequent process.

In one embodiment of the proposed method, the visible side of the first material blank can be fixed to the template by means of a detachable connection method. For example, this connection can provide a clamp, such as a type of screw clamp. However, a double-sided adhesive tape can preferably be used, which is applied to the template and/or the first material blank. The double-sided adhesive tape can be provided only in the area of the first contact surface or both in both areas of the first and second contact surface. The first material blank can thus be fixed to the template in a particularly simple manner, in order to enable the adhesive to be rolled on.

According to one embodiment of the proposed method, the beveled second contact surface of the template used in the method can be formed by a chamfer. For example, the template may have a plate shape with one or more edges beveled or chamfered. It is also possible for several or all of the sides of the template to have a bevel. Accordingly, it is also possible for several or all of the edges of the template to be chamfered. The template can thus be manufactured and provided in a structurally particularly simple manner.

In one embodiment of the proposed method, the template can be provided in the same shape as the first and/or second material blank. The first and/or second section can thus be aligned on one or more outer sides, outer edges or the like of the template, as a result of which the production of the composite can be further simplified. According to one embodiment of the proposed method, the adhesive can be a hot-melt adhesive. While in conventional methods that do not use a template as proposed here, the melting material, which is also referred to or known as hotmelt, can melt due to the subsequent sewing process and thus soil the sewing device or needle and/or a gripper, the method proposed here has proven to be particularly effective, in particular due to the template used in it. In particular, contamination of the sewing device or the needle can be reduced or completely avoided.

In one embodiment of the proposed method, the first layer and/or the second layer can have a haptic layer, in particular a spacer fabric, and the other layer can have a decorative layer, in particular genuine and/or artificial leather. In this way, a composite or paneling part that appears to be particularly high-quality can be produced.

A system for producing a composite with at least two layers for laminating a trim component is also proposed. The system has a template which has a first contact surface and at least one second contact surface which is bevelled in relation to the first contact surface and which is set up so that the first material blank can be fixed to at least the first contact surface. In addition, the system has a rolling device that is set up to move within a plane that is common to the first contact surface and thus to roll an adhesive onto the first material blank in the region of the first contact surface.

With regard to the resulting advantages, reference is made to the method described above, since the proposed system enables essentially the same advantages. It should be noted that the system is designed in particular to carry out the method described above in one or more of the described embodiments. The proposed system can be further developed according to the method described above, i.e. for example set up for the use of a melting material, etc. Furthermore, the system can have a sewing device which can be set up to carry out the above-described subsequent process of sewing in the area of the first material cut assigned to the second contact surface.

The suturing device can also have a gripping device which is adapted to the to grip the first material cut or composite provided with adhesive and in particular to hold it during the introduction of the sewn seam.

Furthermore, it is conceivable that not only two layers are connected by means of the template according to the proposed method, but that several layers are joined together in this way.

In addition, a method for producing a trim component for a vehicle interior is proposed, the proposed method providing the steps of the above-described method for producing the composite according to one or more embodiments and also providing as a further step applying the composite to a carrier of the trim component.

Further features, advantages and application possibilities of the invention result from the following description of advantageous embodiments and the accompanying figures.

Brief character description

An advantageous exemplary embodiment of the invention is explained below with reference to the accompanying figures. Show it:

1 shows a system for producing a composite with at least two layers for laminating a trim component according to one embodiment in a highly schematic representation.

2 shows a perspective top view of a template that can be used in a method and/or a system for producing a composite with at least two layers for laminating a trim component according to one embodiment.

FIG. 3 shows a perspective top view of a template with a first material blank fixed thereto, as can be found in a method and/or a system for Manufacturing a composite can be used with at least two layers for laminating a trim component according to one embodiment.

4 shows a perspective top view of a template with a first material blank fixed thereto and an adhesive applied to it, as can be used in a method and/or a system for producing a composite with at least two layers for laminating a trim component according to one embodiment.

FIG. 5 shows a flow chart of a method for producing a composite with at least two layers for laminating a trim component according to one embodiment

The figures are only schematic representations and only serve to explain the invention. Elements that are the same or have the same effect are provided with the same reference symbols throughout.

Detailed description of preferred embodiments

1 shows a system 100, for example a tool system, which is suitable for producing a composite with at least two layers for laminating a trim component. Such a composite can be used, for example, in vehicles, such as instrument panels, center consoles, door panels, pillar and headliner panels in the vehicle interior.

The system 100 includes a rolling device 110 and a template 120 . As an optional feature, the system 100 includes a suturing device 130, which may be provided as part of the system 100 or separate therefrom. An arrow A in FIG. 1 indicates that the sewing device 130 is used in a subsequent process to the use of the rolling device 110 . In particular, the rolling device 110 will be used before the sewing device 130 to produce the above-mentioned composite with at least two layers by means of gluing, which in the subsequent process, i.e. at some point later, will be provided with one or more stitched seams, which may be composite and/or decorative seams. The rolling device 110 is set up to apply an adhesive by means of a rolling process to a surface of a first material cut 140 as the first layer of the composite to be produced, in order to attach a further, second material cut 150 to it as the second layer of the composite to be produced and to connect the two layers to one another by means of gluing. For example, the first layer can have a haptic layer, for example a spacer fabric, and/or the second layer can have a decorative layer, for example genuine and/or artificial leather. The decorative layer can be formed in particular on the basis of polyurethane, polyvinyl chloride, thermoplastic polyurethane or thermoplastic elastomers based on olefins. Textiles, carpets and all other common materials in vehicle interiors are also conceivable. The haptic layer can be located on a side of the composite facing away from the visible side and can be made of polyester, cut foam, fleece or wadding, for example.

As mentioned above, the sewing device 130 is set up to introduce at least one sewn seam 131 into at least one of the two layers or into the composite formed by gluing in the subsequent process in relation to the rolling on of the adhesive.

Template 120 has a first contact surface 121 and at least one second contact surface 122 that is beveled in relation to first contact surface 121 . The bevel causes the first bearing surface 121 and the second bearing surface 122 to be in different planes from one another. The first contact surface 121 and the second contact surface 122 of the template 120 are set up such that the first material blank 140 forming the first layer of the composite rests against them and is fixed at least on the first contact surface 121 by means of a detachable connection method, e.g. by means of a double-sided adhesive tape. For example, the template 120, as indicated in Fig. 1, is plate-shaped, with the rolling device 110 and the template 120 both being set up and/or aligned or arranged with respect to one another in such a way that the rolling device 110 is moved exclusively in a plane E common to the first contact surface 121 of the template 120. 1 clearly shows that the rolling device 110 thereby applies the adhesive only in the area of the first contact surface 121, while the adhesive is left out in the area of the second contact surface 122 by the contact surface 122 being arranged outside of the plane E. This is beneficial because the sewn seam 131 to be sewn in by the sewing device 130, which may be a connecting seam or a decorative seam, is to be arranged in the area of the second contact surface 122 and the sewing device 130 therefore has little or no contact with the adhesive.

2 shows the template 120 as a separate component in a perspective plan view. This is preferably designed with the same shape as the first and/or second material blank 140, 150, with FIG. 2 only showing an exemplary shape and the shape of the template 120 in contrast can be modified as desired. However, it can be seen in FIG. 2 that the second contact surface 122 is beveled in relation to the first contact surface 121 , which is achieved here by a chamfered edge of the template 120 . It should be noted that the second contact surface 122 can be designed to partially or completely encircle the first contact surface 121 . The template 120 can be made of virtually any material that is sufficiently dimensionally stable for rolling on the adhesive or at least can withstand the rolling pressure, such as a plastic, a material, etc.

FIG. 3 shows the template 120 with the first material blank 140 fixed thereto prior to being rolled with the adhesive. As mentioned above, the first material blank 140 is releasably fixed to the template 120, for example with a double-sided adhesive tape that is provided at least in the area of the first contact surface 121 of the template 120 (in Fig. 3 covered by the first material cut 140) or both in the area of the first contact surface and the second contact surface 122. It can be seen from Fig. 3 that the first material cut follows the shape, in particular the bevel from the first contact surface 121 to the second contact surface 122, so that the first material cut 140 in the region of the first contact surface, i.e. where the first material cut 140 bears against the second contact surface 122, lies outside of the plane E described above with reference to Fig. 1, which corresponds to the rolling plane of the rolling device 110. Therefore, when the adhesive is rolled onto the first material blank 140 by means of the rolling device 110, those areas of the first material blank 140 that are assigned to the second contact surface 122 are left open. It should be noted that the rolling device 110 applies the adhesive, depending on the shape, radius, etc. of the bevel between the first contact surface 121 and the second contact surface 122, also onto an edge or transition area between the first contact surface and the second contact surface 122 can be applied, but this can be taken into account by an oversize of the second contact surface 122, so that the sewn seam 131 introduced later in the region of the second contact surface 122 in the first material blank 140 can nevertheless be kept free of adhesive.

Fig. 4 shows the template 120 with the first material blank 140 fixed to it after the adhesive has been rolled onto the first material blank 140. As indicated in Fig. 4 by different hatchings, the adhesive is omitted in those areas of the first material blank 140 which are arranged in the area of the second contact surface 122 of the template 120.

FIG. 5 shows a flowchart of a method for producing a composite with at least two layers for laminating a trim component, it being possible for the method to be carried out using the system 100 described above. In a first step S1, the method provides that the first material blank 140 forming the first layer is fixed to the template 120 described above, which has the first contact surface 121 and the at least one second contact surface 122 that is beveled in relation to the first contact surface 121. In a step S2, the adhesive is rolled onto the first material blank 140 in the region of the first contact surface 121 by means of the rolling device 110, which moves within the plane E common to the first contact surface 121. In a step S3, the second material blank 150 forming the second layer is applied to the first material blank 140, which has been rolled with the adhesive, to form the composite.

REFERENCE LIST

100 system for creating a bond

110 rolling device 120 template

121 first contact surface

122 second bearing surface

130 sewing device

131 sewing seam 140 first material cut

150 second cut of material

E (rolling) plane

Claims

EXPECTATIONS

1. Method for producing a composite with at least two layers for laminating a trim component, with the steps:

Fixing a first material blank (140) forming a first layer on a template (120) which has a first contact surface (121) and at least one second contact surface (122) which is bevelled in relation to the first contact surface (121),

Rolling an adhesive onto the first material blank (140) in the area of the first bearing surface (121) by means of a rolling device (110) which moves within a plane (E) common to the first bearing surface (121), and

Application of a second material cut (150) forming a second layer to the first material cut (140) rolled with the adhesive to form the composite.

2. The method according to claim 1, wherein the rolling device (110) is moved during rolling on in the plane common to the first contact surface (121) of the stencil (120) and the second contact surface (122) of the stencil (120) is meanwhile outside the common plane, whereby the adhesive on the first material blank (140) in the region of the second contact surface (122) is at least substantially spared.

3. The method according to claim 1 or 2, wherein the size of the second contact surface (122) of the template (120) is selected depending on the course of a sewn seam (131), which is introduced into the composite in a subsequent process, whereby the adhesive in the region of the sewn seam (131) is at least substantially left out.

4. The method as claimed in one of the preceding claims, in which the composite is provided with a sewn seam (131) in an area associated with the second contact surface (122) after it has been released from the template (120).

5. The method according to any one of the preceding claims, wherein the visible side of the first material blank (140) is fixed to the template (120) by means of a detachable connection method.

6. The method according to any one of the preceding claims, wherein the beveled second contact surface (122) of the template (120) is formed by a chamfer.

7. The method according to any one of the preceding claims, wherein the template (120) is provided in the same shape as the first and/or second material blank (140, 150).

8. The method according to any one of the preceding claims, wherein the adhesive is a hot melt adhesive.

9. The method according to any one of the preceding claims, wherein the first layer and/or the second layer has a haptic layer, in particular a spacer fabric, and the other layer has a decorative layer, in particular genuine and/or artificial leather.

10. System for producing a composite with at least two layers for laminating a lining component, comprising: a template (120) which has a first contact surface (121) and at least one second contact surface (122) which is bevelled in relation to the first contact surface (121), and which is set up so that the first material blank (140) can be fixed on at least the first contact surface (121), and a rolling device (110) which is set up for this purpose, to move within a plane (E) common to the first contact surface (121) and thus to roll an adhesive onto the first material blank (140) in the region of the first contact surface (121).