Device and method for laminating a laminating foil element onto a component, device and method for applying adhesive, system for laminating, component to be laminated with a laminating foil element, and use of a deposit part for keeping ready a laminating foil element

Abstract

The invention relates to a device for laminating a laminating foil element onto a component having a profiled lamination plane using a lamination tool, by means of which tool the laminating foil element is laminated onto the component, the lamination tool comprising a first tool half and a second tool half, and the device comprising a deflection arrangement for deflecting portions of the laminating foil element out of the profiled lamination plane.

Claims

1. Method for laminating a laminating foil element onto carrier part for obtaining a component with a predetermined area free from foil, the method comprising: during lamination of the laminating foil element onto the carrier part, deflecting a portion of the laminating foil element out of a profiled lamination plane of the carrier part and into a deflection cavity of a deflection arrangement arranged into at least one tool half of two tool halves of a lamination tool, wherein the portion is deflected with respect to other surrounding portions of the laminating foil element such that said portion of the laminating foil element does not come in contact with the carrier part, wherein the deflection cavity is spatially separated from laminating portions of the laminating tool by means of sealing elements, cooling, by a cooling unit, said at least one tool half in a region of the deflection cavity, such that an adhesive applied on said portion of the laminating foil element loses its adhesive power, or such that its adhesive power is at least substantially reduced; after lamination of the laminating foil element, removing said portion of the laminating foil element from the other surrounding portions of the laminating foil element for obtaining the component with the predetermined area free from foil.

2. Method according to claim 1, wherein said portion of the laminating foil element is deflected into the deflection cavity by means of a vacuum.

3. Method according to claim 1, comprising, with the lamination tool closed, flushing with air interspaces between the carrier part and said portion of the laminating foil element.

4. Method according to claim 1, wherein the deflection cavity of the deflection arrangement has walls at least partially corrugated or waffle-shaped.

5. Method according to claim 1, wherein the sealing elements form sealing edges on the deflection cavity.

6. Method according to claim 5, comprising cutting out the portion of the laminating foil element for obtaining the component with the predetermined area free from foil, wherein the sealing edges define a pattern to be cut.

7. Method according to claim 1, comprising transporting the laminating foil element to the laminating tool by means of a transport unit.

Description

(1) In the drawings:

(2) FIG. 1 schematically shows a perspective view of a device for applying adhesive on a surface of a laminating element, having a deflection arrangement for deflecting portions of the laminating foil element out of an application plane on which adhesive is transferred to the surface of the laminating element by an application device;

(3) FIG. 2 schematically shows a lateral view of the device in FIG. 1;

(4) FIG. 3 schematically shows a top view of the device in FIGS. 1 and 2;

(5) FIG. 4 schematically shows a detailed view of the application device in FIGS. 1 to 3; and

(6) FIG. 5 schematically shows a perspective view of a component to be laminated with a laminating foil element, i. e. of the laminating foil with the component arranged below it, respectively;

(7) FIG. 6 schematically shows a partially cut view of a device for applying a laminating foil element with an open lamination tool, comprising a deflection arrangement for deflecting the laminating foil element out of a profiled lamination plane;

(8) FIG. 7 schematically shows another partially cut view of the device in FIG. 6 with a closing lamination tool;

(9) FIG. 8 schematically shows another partially cut view of the device in FIGS. 6 and 7 with a closed lamination tool;

(10) FIG. 9 schematically shows a view of the laminating foil element shown in FIGS. 6 through 8, formed with the lamination tool and applied, positioned in the upper tool half of the lamination tool; and

(11) FIG. 10 schematically shows a view of the component laminated with the device in FIGS. 6 through 9, with differently structured areas already separated.

(12) In this example of embodiment, the device 1, shown in FIGS. 1 through 4, for applying adhesive 2 on a surface 3 of a laminating foil element 4 (indicated here only by way of example) for laminating a component 5 is merely one of several processing stations 6 (not shown) of an only schematically indicated system 7 for laminating a component 5 with a respective laminating foil element 4. In total, according to FIG. 1, four laminating foil elements 4 of this type are shown.

(13) Component 5, which is shown only exemplarily in the context of the present invention, can be any component 5 which can be used in many different ways. Preferably, the present component 5 is an automotive lining component, in particular an automotive inner lining component, which is to be upgraded by the laminating foil element 4.

(14) Thus, the laminating foil element 4 can be a decorative layer (not referenced again) for giving an impression of higher value, in optical, but generally also in haptic terms.

(15) Seen in the machine direction 7, that is, in the transport direction of the laminating foil element 4, the device 1 for applying adhesive 2 is arranged before a device (not shown) for laminating the laminating foil element 4 onto the component 5 of the system 7.

(16) The device 1 comprises an application device 10 for applying adhesive 2 onto the surface 3 of the laminating foil element 4, wherein for applying the adhesive 2, application means 11 are provided, embodied in this specific example of embodiment by an application roller element 12.

(17) The application device 10 also comprises an adhesive reservoir 13 containing adhesive 2.

(18) The adhesive reservoir 13 is positioned above the application means 11 and the application roller element 12 thereof, such that the application roller element 12 can be charged with adhesive 2 by the force of gravity.

(19) The application roller element 12 forms the lower end of the adhesive reservoir 13.

(20) The device 1 is further characterized by an application plane 15 (see especially FIG. 2) opposite to the application device 10. More precisely, the application plane 15 is located beneath the application device 10.

(21) On this application plane 15, the adhesive 2 is transferred from the application roller element 12 to the surface 3 of the laminating foil element 4 which faces the application device 10.

(22) In this example of embodiment, the application plane 15 is substantially built by a transport unit 18 by means of which individual laminating foil elements 4 are transported through the device 1 and in particular through the system 7.

(23) The transport unit 18 allows, specifically in the device 1, a relative movement between the laminating foil element 4 and the application device 10 located above it.

(24) For this purpose, the transport unit 18 has an endless circulating transport belt 19; in this example of embodiment, advantageously, the transport belt 19 of a DMY conveyor (not separately referenced) of the system 7. This helps to keep the construction of the present device 1 simpler.

(25) In particular, the device 1 according to the invention is further characterized by a deflection arrangement 20 by means of which the respective laminating foil element 4 can be partially deflected with respect to the application device 10 with a deflection direction 21, the deflection direction 21 leading away from the application device 10.

(26) In particular, a deflection movement 22 of the areas 25, 26, 27 etc. of the laminating foil element 4 in the deflection direction 21 transverse to the machine direction 7 or the application plane 15 is envisaged for implementing these areas 25, 26, 27 etc. without adhesive.

(27) In FIGS. 1 through 4, the areas 25, 26, 27 etc. are marked, i.e. surrounded by border edge lines, for better visibility.

(28) Thus, the areas 25, 26, 27 etc. very precisely indicate the contours 28 (indicated only by way of example) of areas 29 (indicated only by way of example) on the laminating foil element 4 which are left free from adhesive.

(29) With the device 1 described here, the surface 3 of the laminating foil element 4 is deflected in such a way out of the application plane 15 that adhesive 2 is only applied on portions of the surface 3 of the laminating foil element 4.

(30) In this manner, the application device 10 applies, i. e. produces, an adhesive layer 31 on the laminating foil element 4 only in those portions 30 which are or were not deflected out of the application plane 15 according to the invention.

(31) The application plane 15 is arranged between the application device 10 and the deflection arrangement 20.

(32) Thus, the deflection arrangement 20 and the application device 10 are located on different sides 33 and 34 of the application plane 15 or the laminating foil element 4, respectively; the application device 10 being positioned above the application plane 15 on the first side 33 and the deflection arrangement 20 on the second side 34 of the application plane 15 which is opposite the first side 33.

(33) Substantially on the side 34 of the application plane 15 which is opposite to the application device 10, a pressure difference pump 35 is located by means of which a vacuum or a partial vacuum can be created on the surface 36 of the laminating foil element 4 which is opposite the application device 10, so that the surface 3 of the laminating foil element 4 can be deflected in portions from the application means 11 or from the application roller element 12 of the application device 10, respectively.

(34) For allowing the vacuum to act on the laminating foil element 4 in an even more targeted manner, the deflection arrangement 20 also comprises deposit parts 40 (here only referenced by way of example) for depositing the laminating foil elements 4, the deposit parts 40 each having at least one concave cavity 41 which is only suggested in the drawing and which is substantially congruent with the areas 25, 26, 27 etc. which will subsequently be free from adhesive; so that these areas 25, 26, 27 etc. are drawn into the cavities 41 at least to a certain extent by means of the partial vacuum.

(35) In this manner, the laminating foil element 4 is deflected out of the application plane 15 at least above the provided cavities 41.

(36) For this purpose, a depth 42 (see FIG. 4) of approximately 2 mm is already sufficient for a vacuum or partial vacuum space, such as, for instance, the cavity 41 or a through opening (not shown) in the deposit part 40 which has some other form.

(37) This depth 42 is preferably measured in the direction 21 of deflection from a deposit surface 43 for depositing the laminating foil element 4 on the deposit part 40.

(38) For as precise an alignment as possible of the laminating foil parts 4, with their designated areas 25, 26, 27 etc. free from adhesive, with the cavities 41 of the deposit parts 40, the device 1 also has a positioning unit not shown here in detail, which is implemented in this example of embodiment by a print-to-part system which is already known and operates with sufficient reliability.

(39) In FIG. 5, the abovementioned component 5 with the laminating foil element 4, which has partially been laminated onto the component, is shown by way of example, with this example of embodiment showing an automotive inner lining component (not referenced separately).

(40) The laminating foil element 4, which has been partially applied, has portions 50 (only referenced by way of example) laminated permanently onto the component 5, which are substantially smooth, as well as other portions 51 not laminated onto the component 5 which are structured differently.

(41) In this example of embodiment, it is easy to recognize portions (only referenced by way of example) of the component 5 onto which portions 50 of the laminating foil element 4 which are covered by adhesive are to be laminated permanently.

(42) It is also easy to recognize other portions 51 with different structures (only referenced by way of example) of the component 5, or of the laminating foil element 4 laminated onto it, respectively, which are to be embodied as areas 52 free from foil. In other words, the areas 52 of the component 5 which are free from foil will subsequently be located in the positions corresponding to the differently structured portions 51 when the latter have been removed.

(43) The differently structured portions 51 have been produced by deflecting or sucking, respectively, these differently structured portions 51 into a tool half of a lamination tool which is provided with a deflection cavity so as to avoid or minimize effective adhesive contact between the component surface and the adhesive surface of the laminating foil element 4.

(44) Cumulatively or alternatively, according to one of the present aspects, the portions 25, 26, 27 etc. of the laminating foil element 4 which are free from adhesive can be made congruent with the differently structured portions 51 of the component 5 during lamination.

(45) The component 5 defines a profiled lamination plane 53 onto which the laminating foil element 4 is to be permanent laminated in the end while leaving the areas 52 free from foil.

(46) In another embodiment or method, which is also particularly advantageous, it can be envisaged that the entire component 5, that is, both (text missing)

(47) Advantageously, the component 5 which is only shown by way of example in FIG. 5 can be substantially produced according to any of the aspects on which the invention is based.

(48) At this point, it should also be mentioned that in the positions of the differently structured portions 51 represented here, a so called hand rail field 55, a door means field 56, a loudspeaker field 57 or the like can be located later on.

(49) In FIGS. 6 through 8, a device 60 for applying a laminating foil element 4 and a component 5 laminated with the same (see FIG. 8) are shown.

(50) FIG. 6 shows the device 60 with an open laminating tool 61 comprising a first tool half 62 (upper tool half) and a second tool half 63 (lower tool half).

(51) The tool halves 62 and 63 are arranged in the device 60 in such a way that they can move towards and away from each other in the closing and opening direction 66 by means of hydraulic cylinders 64 and 65.

(52) On the second tool half 63, a carrier part 5A is supported which forms the final laminated component 5 together with the laminating foil element 4.

(53) The laminating foil element 4 is fed to the lamination tool 61 in the machine direction 8 as a flat foil element (not referenced separately), the machine direction 8 in this example of embodiment going from left to right.

(54) The device 60 has a deflection arrangement 70 for deflecting portions of the laminating foil element 4 out of the profiled lamination plane 53.

(55) In this example of embodiment, the profiled lamination plane 53 extends together with the surface of the carrier part 5A, with the tool halves 62 and 63 comprising respective mold elements 71 (referenced only on the first tool half 62), which also correspond to the profiled lamination plane 53.

(56) In this example of embodiment, the deflection arrangement 70 comprises several deflection cavities 72, 73 and 74 whose openings (not shown here) preferably extend in or in parallel to the profiled lamination plane 53, in particular with their opening diameter contours.

(57) The deflection cavities 72, 73 and 74 (shown only schematically) are limited by at least partially corrugated or waffle-shaped walls 75 (only referenced by way of example).

(58) These at least partially corrugated or waffle-shaped walls 75 are created by the first tool half 62 and its mold element 71, respectively.

(59) In addition, the laminating tool 61 has sealing elements 77, 78, 79 (only shown by way of example) in the form of sealing struts or the like in order to seal the deflection cavities 72, 73 and 74 with respect to laminating portions 80, 81 and 82 by differential pressure, at least in a closed or nearly closed state of the lamination tool 61.

(60) The sealing elements 77, 78, 79 are wall-shaped in the form of sealing struts or the like but are shown in cross-sectional view and therefore only shown as lines.

(61) The sealing elements form sealing edges 83 (see FIG. 9 by way of example) on the deflection cavities 72, 73 and 74 and at the laminating foil element 4, respectively, the edges having a thickness of more than 1.5 mm, in particular approximately 3.5 mm. The edges can later be used as pattern edges for cutting out the laminating foil element 4. The thickness of the sealing edges 83 is preferably lower than 10 mm.

(62) In any case, by means of the deflection cavities 72, 73 and 74 which are spatially separated in this manner, portions which cannot be laminated, preferably in the form of differently structured portions 51, are produced in particular on the laminating foil element 4.

(63) For producing the additional pressure difference specifically within the deflection cavities 72, 73 and 74, the device also has a suitable pressure difference unit 85 which is with reference to its individual components only schematically indicated in FIG. 6.

(64) In FIG. 7, the lamination tool 61 has already been largely closed by means of differential pressure, the laminating foil element 4 has already been pre-blown into the first tool half 62; in particular, it has been sucked into the upper mold element 71 and, with a view to the portions which are not to be laminated, it has subsequently also been sucked into the deflection cavities 72, 73 and 74.

(65) In this manner, the differently structured portions 51 are produced which cannot permanently come in effective contact with the carrier part 5A by adhesion.

(66) This effect is reinforced by a cooling unit 86 for cooling these differently structured portions 51 and any adhesive applied thereon, so that this adhesive cools off very rapidly, losing its adhesive effect.

(67) Advantageously, the device 60 also comprises a fluid flushing unit 90 (air flushing unit; see only FIG. 6) for flushing an interspace 91 (see FIG. 9) between the carrier part 5A or the component 5, respectively, to be laminated, and the laminating foil element 4, preferably with the lamination tool 61 closed and at least portions of the laminating foil element 4 pressed on the carrier part 5A, as is the case shown in FIG. 8.

(68) FIG. 9 shows a bottom view of the first tool half with the laminating foil element 4 shown therein, but without the carrier part 5A.

(69) It is easy to see the differently structured portions 51 (only referenced by way of example) with their corrugated structure, which form the non-laminated areas 93.

(70) FIG. 10 shows the component 5 with the laminating foil element 4 laminated onto it, the differently structured portions 51 all having been removed, for which reason non-laminated areas 93 with the visible carrier part 5A of the component 5 can be clearly recognized.

(71) At this point, it is explicitly pointed out that the features of the solutions described above, in the Claims and/or in the Figures, can also be combined, as desired, for cumulative implementation of the features and achievement of the effects and advantages explained.

(72) It is understood that the example explained above is only one first embodiment of the device 1 according to the invention. The implementation of the invention is not limited to this example.

(73) All features disclosed in the application documents are claimed as essential to the invention, provided that they are novel individually or in combination with respect to the state of the art.

LIST OF REFERENCE NUMBERS

(74) 1 device 2 adhesive 3 surface 4 laminating foil element 5 component 5A carrier part 6 processing station 7 system 8 machine direction 10 application device 11 application means 12 application roller element 13 adhesive reservoir 15 application plane 18 transport unit 19 transport belt 20 deflection arrangement 21 deflection direction 22 deflection movement 25 first portion without adhesive 26 second portion without adhesive 27 third portion without adhesive 28 contour 29 areas 30 portions with adhesive 31 adhesive layer 33 first face of application plane 34 second face of application plane 35 pressure difference pump 36 opposite surface 40 deposit parts 41 cavities 42 depth 43 deposit surface 50 portions 51 differently structured portions 52 areas with no foil 53 profiled lamination plane 55 hand rail field 56 door means field 57 loudspeaker field 60 lamination device 61 lamination tool 62 first or upper tool half, respectively 63 second or lower tool half, respectively 64 upper hydraulic cylinder 65 lower hydraulic cylinder 66 closing and opening direction 70 deflection direction 71 mold elements 72 first deflection cavity 73 second deflection cavity 74 third deflection cavity 75 walls 77 first sealing element 78 second sealing element 79 third sealing element 80 first laminating portion 81 second laminating portion 82 third laminating portion 83 sealing edges 85 pressure difference unit 86 cooling unit 90 fluid flushing unit or air flushing unit, respectively 91 interspace 93 non-laminated portions