Device and method for machining a plate-shaped workpiece for a motor vehicle

Abstract

A device for machining a plate-shaped workpiece for a motor vehicle comprises a lower tool with a holding region for the workpiece, and a folding element which has a holding region for the workpiece and which is movable relative to the lower tool. The folding element (40) can change from a first state into a second state and can thereby form a first cavity between the holding region of the folding element and the workpiece.

Claims

1. A device for machining a plate-shaped workpiece for a motor vehicle, comprising: a lower tool with a holding region for the workpiece, and a folding element which has a holding region for the workpiece and which is movable in a translatory manner relative to the lower tool in order to change from a first state into a second state by a translatory movement and to form a first cavity between the holding region of the folding element and the workpiece, wherein the translatory movement of the folding element predominantly takes place in a first direction which is parallel to a main plane of extent of the plate-shaped workpiece.

2. A device for machining a plate-shaped workpiece for a motor vehicle, comprising: a lower tool with a holding region for the workpiece, and a folding element which has a holding region for the workpiece and which is pivotable relative to the lower tool about a first axis in order to change from a first state into a second state by a device to fold over and to form a first cavity between the holding region of the folding element and the workpiece.

3. The device according to claim 1, in which the lower tool has a molding body with a holding region for the workpiece, and the first cavity can be formed between the holding region of the molding body, the holding region of the folding element and the workpiece.

4. The device according to claim 2, in which the folding element has a first component and a second component, wherein the first component is pivotable about the first axis and the second component is pivotable about a second axis in order, in a folded-over second state of the first component about the first axis, to form the first cavity, and, in a folded-over second state of the second component about the second axis, to form a second cavity, between the first component, the second component and the workpiece.

5. The device according claim 1, in which, in the region of the first cavity which can be formed, the lower tool and the folding element each comprise a predetermined first boundary surface which comprises silicone, aluminum, steel and/or plastic.

6. The device according to claim 4, in which, in the region of the second cavity which can be formed, the folding element comprises a predetermined second boundary surface which comprises silicone, aluminum, steel and/or plastic.

7. The device according to claim 1, comprising a first material dispenser which is movable relative to the lower tool and which is designed for introducing a predetermined material into the first and/or second cavity which can be formed, in order to form a first and/or second plastics molding.

8. The device according to claim 1, comprising a second material dispenser which is movable relative to the lower tool and which is designed for dispensing a predetermined material onto the workpiece in order to arrange an add-on element on the workpiece.

9. The device according to claim 1, in which the lower tool have/has a heating element for controlling the temperature of the lower tool and/or of the folding element.

10. The device according to claim 2, in which the folding element is movable in a translatory manner relative to the lower tool in order to change from the first state into the second state by a relative movement and to form the first cavity between the holding region of the folding element and the workpiece, wherein the relative movement of the folding element comprises a translatory movement and folding over about the first axis.

11. A method for machining a plate-shaped workpiece for a motor vehicle, comprising: providing the workpiece, providing a lower tool, providing a folding element which is movable relative to the lower tool positioning the workpiece and the lower tool with respect to each other, moving the folding element in a translatory manner from a first state into a second state predominantly along a first direction which is parallel to a main direction of extent of the plate-shaped workpiece and thereby arranging the folding element and the lower tool relative to each other such that the folding element makes contact with the workpiece and a first cavity is formed between the folding element and the workpiece, and introducing a predetermined material into the first cavity and thereby forming a first plastics molding.

12. A method for machining a plate-shaped workpiece for a motor vehicle, comprising: providing the workpiece, providing a lower tool, providing a folding element which is pivotable relative to the lower tool about a first axis, positioning the workpiece and the lower tool with respect to each other, folding over the folding element about the first axis from a first state into a second state and thereby arranging the folding element and the lower tool relative to each other such that the folding element makes contact with the workpiece and a first cavity is formed between the folding element and the workpiece, and introducing a predetermined material into the first cavity and thereby forming a first plastics molding.

13. The method according to claim 11, in which the lower tool has a molding body with a holding region for the workpiece, comprising: positioning the workpiece and the molding body with respect to each other, and forming the first cavity between the holding region of the molding body, the holding region of the folding element and the workpiece.

14. The method according to claim 11, in which the lower tool has a holding element, and the positioning of the workpiece and the lower tool with respect to each other comprises: placing the workpiece onto the holding element.

15. The method according to claim 11, in which the lower tool has a punch element, and the positioning of the workpiece and the lower tool with respect to each other comprises: displacing the workpiece relative to the lower tool by the punch element.

16. The method according to claim 11, in which the lower tool is movable relative to the folding element, and the positioning of the workpiece and the lower tool with respect to each other comprises: coupling the workpiece to the lower tool, and carrying along the workpiece by the lower tool along a normal direction with respect to a main plane of extent of the plate-shaped workpiece.

17. The method according to claim 11, comprising: controlling the temperature of the lower tool and/or of the folding element.

18. The method according to claim 12, in which the folding element has a first component and a second component, wherein the first component is pivotable about the first axis and the second component is pivotable about a second axis, and therefore the folding over of the folding element comprises: folding over the first component about the first axis and thereby forming the first cavity between the first component, the molding body and the workpiece, and folding over the second component about the second axis and thereby forming a second cavity between the first component, the second component and the workpiece.

19. The method according to claim 18, comprising: providing a frame element, arranging the frame element on the workpiece, and folding over the second component about the second axis and thereby forming the second cavity between the first component, the second component, the workpiece and the frame element.

20. The method according to claim 18, comprising: introducing a predetermined material into the second cavity and thereby forming a second plastics molding.

21. The method according to claim 11, in which the introducing of material into the first and/or second cavity comprises: forming the first and/or second plastics molding in the form of an encircling foam encapsulation.

22. The method according to claim 11, comprising: arranging an add-on element on the workpiece by an adhesive bonding process.

23. The method according to claim 12, comprising: opening up the folding element about the first axis or about the first axis and second axis such that the workpiece can be removed from the lower tool.

24. The method according to claim 12, in which the folding element is movable in a translatory manner relative to the lower tool, and the arranging of the folding element and the lower tool relative to each other comprises: moving the folding element relative to the plate-shaped workpiece from the first state into the second state such that the folding element makes contact with the workpiece and the first cavity is formed between the folding element and the workpiece, wherein the relative movement of the folding element comprises folding over about the first axis and a translatory movement along a first direction which is parallel to a main plane of extent of the workpiece.

Description

[0052] Exemplary embodiments of the invention are explained in more detail below with reference to the schematic drawings, in which:

[0053] FIG. 1 shows a vehicle roof in a perspective view,

[0054] FIGS. 2A-2F show various steps of a method for machining a plate-shaped workpiece for a motor vehicle,

[0055] FIGS. 3A-3B show an exemplary embodiment of a device for machining a plate-shaped workpiece for a motor vehicle,

[0056] FIGS. 4A-4B show a further exemplary embodiment of the device for machining a plate-shaped workpiece for a motor vehicle,

[0057] FIGS. 5A-5C show exemplary embodiments of a first and second plastics molding,

[0058] FIGS. 6A-6B show further exemplary embodiments of the first plastics molding.

[0059] Elements of identical design or function are identified by the same reference signs throughout the figures. For clarity reasons, not all of the illustrated elements in all of the figures may be identified with reference signs.

[0060] FIG. 1 shows schematically, in a perspective view, a motor vehicle 1 with a vehicle roof 3 which has a cover 5 and a foam encapsulation 7. The cover 5 is, for example, a fixed glass element which is immovable with respect to the vehicle roof 3. Alternatively, the cover 5 is movable relative to the vehicle roof 3 in order optionally to open up and to close an opening in the vehicle roof 3.

[0061] The foam encapsulation 7 realizes a first plastics molding 25 which can be produced by means of a special device with little outlay and in a time-saving and cost-effective manner within the scope of a method for machining the cover 5. As will be explained with reference to FIGS. 2 to 6 below, the device which is capable thereof realizes a special molding tool and permits advantageous machining of a plate-shaped workpiece 10 for a motor vehicle 1.

[0062] FIGS. 2A to 2F show various steps of a method for machining the plate-shaped workpiece 10 in a schematic sectional illustration by means of a configuration of the previously mentioned device. The plate-shaped workpiece 10 can represent, for example, the cover 5 from FIG. 1, which is designed as a glass or plastics cover. In other refinements, the plate-shaped workpiece 10 can be realized by a side window, windshield, rear window, tailgate window or else by a metallic cover, a panel or a plastics part.

[0063] FIG. 2A schematically illustrates a first step of a method for machining the plate-shaped workpiece 10. The device has a lower tool 30 and one or more folding elements 40. Four folding elements 40 are beneficially arranged with respect to a lateral edge of a substantially rectangular plate-shaped workpiece 10, in each case one on each side. Opposite folding elements are therefore arranged spaced apart from one another such that free access from above to the workpiece is provided between opposite folding elements. In this connection, it is pointed out that terms such as top or bottom and upper tool or lower tool relate to a vertical direction in accordance with the z direction illustrated.

[0064] However, the plate-shaped workpiece can also have other, for example round or oval, geometries which can be machined by means of the device. The term plate-shaped essentially refers here to a geometry of the workpiece 10, in which two dimensions predominate in relation to the third dimension. With respect to the illustration illustrated in FIG. 2A, the workpiece 10 has a significantly smaller thickness in the z direction than its substantial extent in the x-y plane (for example as in FIG. 1). In addition, the plate-shaped workpiece 10 can have a curvature, in particular with respect to the substantial plane of extent, as is customarily the case for windows for motor vehicles.

[0065] The lower tool 30 has a base plate on which a holding element 34 and a molding body 32 are arranged, the latter also acting as a movable carrier element within the scope of the method. The holding element 34 and the molding body 32 are configured, for example, as a continuous frame, and therefore the illustration shown in FIGS. 2A-2F illustrates, for example, a central section. In other refinements of the device, the holding element 34 and/or the molding body 32 can be of multi-part design.

[0066] Furthermore, a line of symmetry S which substantially defines a mirror axis is shown in FIG. 2A. The illustrated elements are present on opposite sides of the device with respect to the line of symmetry S. However, for clarity reasons, not all of the elements on both sides of the line of symmetry S are provided with reference signs. In other refinements of the device, a symmetrical construction is not necessarily provided, and therefore the device can be designed in accordance with its use, for example with respect to different geometries of the workpiece to be machined.

[0067] The lower tool 30 furthermore has one or more punch elements 36 which permit reliable positioning of the workpiece 10 on the holding element 34. The folding elements 40 each have a first component 41 and a second component 42, wherein the first component 41 is pivotable about a first axis A1 and the second component 42 about a second axis A2. The axes A1 and A2 are oriented substantially parallel to the plane of extent of the plate-shaped workpiece 10.

[0068] In the first step illustrated, the folding elements 40 and the respective first and second component 41 and 42 are provided in an open first state Z1 and for receiving the workpiece 10 to be machined. The workpiece 10 is positioned with a lower side 13 on the holding element 34.

[0069] FIG. 2B illustrates a further step within the scope of the machining method, in which the workpiece 10 to be machined is positioned in a predetermined manner on the holding element by means of the punch elements 36. For example, the workpiece 10 is centered relative to the molding body 32 and/or to the folding elements 40.

[0070] FIG. 2C shows a step of the method, in which the folding elements 40 and the respective first component 41 have changed into a second state Z2. The respective first component 41 is folded over about the associated first axis A1 and thereby permits forming of a first cavity 21. Also illustrated is a frame element or insert 50 which is placed onto an upper side 12 of the workpiece 10 in the inner region. In addition, the molding body 32 has been moved in the vertical direction and couples on the lower side 13 to the workpiece 10.

[0071] FIG. 2D illustrates a further step of the method, in which the movable molding element 32 has carried along the workpiece 10 in the vertical direction in accordance with the normal direction N shown and couples to the folding element 40. The first cavity 21 is thereby formed between the first component 41, the workpiece 10 and the molding body 32. Furthermore, the respective second components 42 have also changed into the second state Z2 by being folded over about the associated second axes A2. A respective second cavity 22 has therefore been formed between the respective first and second component 41 and 42 and the frame element 50 and the workpiece 10.

[0072] Alternatively or additionally, the first and/or second cavity 21, 22 can also be formed by means of a folding element 40 which is movable in a translatory manner. The folding element or the folding elements 40 is or are moved relative to the lower tool 30 from the first state Z1, in which they are, for example, spaced apart laterally from the workpiece 10, in the direction of the workpiece 10 and change into the second state Z2, in which they form the first and/or second cavity 21, 22. Such a translatory movement of the respective folding element 40 predominantly takes place in a first direction which is parallel to a main plane of extent of the plate-shaped workpiece 10. In the exemplary embodiments illustrated, the first direction corresponds to a direction in the x-y plane perpendicularly to the z direction and to the normal direction N, shown in FIG. 2D, of the workpiece 10.

[0073] For example, opposite folding elements 40 are thus moved in a translatory manner toward each other until a respective predetermined position relative to the workpiece 10 or to the lower tool 30 is reached in order, in contact with the workpiece 10 or other interacting elements, to form one or more designated cavities 21, 22 or to define predetermined positions for attaching add-on elements 54.

[0074] Reliable and secure contact of the folding elements 40 with the workpiece 10 or other interacting elements is formed, for example, by means of horizontal placing and/or vertical depositing of the respective folding element 40 at or on the corresponding element. A vertical movement relative to the workpiece 10 and the lower tool 30 is significantly less pronounced here than the previously described horizontal movement in the x-y plane.

[0075] Furthermore, the second component 42 can also be activatable independently of the first component 41 of the folding element 40 in such a manner that, for example, the first component 41 can be offset into the second state by means of folding over about the first axis A1, and the second component 42 changes into the second state by a translatory movement by means of horizontal and/or vertical movement, in order to permit controlled forming of the second cavity 22 and/or reliable and secure positioning of add-on elements 54 which are to be adhesively bonded on. For example, the second component is realized as a cylinder element or clamping element which can be moved or actuated in a predetermined manner.

[0076] FIG. 2E illustrates how the respective first and second cavities 21 and 22 are filled by means of a first and a second material dispenser 45 and 46, wherein the material dispenser 45 is illustrated with regard to the sectional illustration shown as an element which is placed on. The material dispensers 45, 46 are designed to be movable relative to the clamped workpiece 10 and can feed a material into the cavities 21 and 22 at predetermined positions. This makes it possible to form a first and a second plastics molding 25 and 26, the outer shape of which is predetermined by the delimiting geometry of the first and second cavity 21 and 22. In further refinements of the device, there can also be just one material dispenser which fills the respective cavities 21 and 22 with predetermined material successively or simultaneously, for example by means of various feed lines. Alternatively, there are further material dispensers in order to accelerate the feeding of material into the cavities 21 and 22 which are formed and in order to contribute to a prompt manufacturing process. The material dispensers 45 and 46 are, for example as mixing heads, provided with diverse feed lines.

[0077] Alternatively or additionally, the first and/or second material dispenser 45, 46 can also be capable of carrying out an adhesive bonding process in order, for example, in the inner region of the frame element 50, to arrange one or more add-on elements 52 on the upper side 12 of the workpiece 10. This makes it possible to carry out foam encapsulating and adhesive bonding by means of one and the same device without requiring time-consuming changes of the machine. Such an adhesive bonding of add-on elements 52 can be carried out as a further machining step simultaneously or promptly in order to form the first and/or second plastics molding 25 and 26.

[0078] In a further step of the method according to FIG. 2F, the folding elements 40 are opened again by the respective first and second component 41 and 42 folding over again about the respective axis A1 and A2 into the first state Z1. The machined workpiece 10 can then be safely removed from the device.

[0079] The described device and the corresponding method for machining the plate-shaped workpiece 10 realize an upwardly open tool concept without an upper tool, said tool concept having a movable substructure and one or more folding elements 40. Owing to such a special molding tool, the machining of workpieces 10 is substantially independent of the component size of the workpiece and is therefore not limited to maximum geometries of, for example, 1200 mm times 900 mm, as is customarily the case in the case of molding tools which have solid plates as the upper tool and lower tool and associated mold carriers and form closed cavities without further access to the workpiece.

[0080] Owing to the fact that a separate upper tool is not present, a neat and space-saving molding tool for machining plate-shaped workpieces 10 can be realized by means of the device described. The device described therefore includes a significant saving on material and weight in comparison to tools which have an upper tool. This additionally has an advantageous effect on the costs for the design of such a device and leads to further possible savings.

[0081] On account of the saved weight that an upper tool including mold carrier would entail, the lower tool 30 is relieved of load and has to be able to hold and move less weight during a machining operation. Such a saving on weight can comprise, for example, several thousand kilograms. The device described therefore permits additional simplifications with regard to activation and mobility of the substructure, and therefore the forces required for moving the lower tool 30 can be correspondingly reduced and a contribution is made to energy- and cost-efficient machining of the plate-shaped workpiece 10.

[0082] FIGS. 3A and 3B illustrate further exemplary embodiments of such a device for machining a plate-shaped workpiece 10 in a schematic side view. A folding element 40 is in each case illustrated in the second folded-over state Z2, and therefore the first cavity 21 is formed between the workpiece 10, the folding element 40 and the lower tool 30. In the exemplary embodiment shown, the first cavity 21 is formed between the workpiece 10, the folding element 40 and the mold carrier 32 of the lower tool 30. It is apparent with reference to FIGS. 3A and 3B that, by means of the device described and a corresponding machining method, forming of plastics moldings 25, 26 having steep contours, which, for example, can realize outer panels, is also possible.

[0083] FIGS. 4A and 4B show a further exemplary embodiment of the device for machining the plate-shaped workpiece 10. FIG. 4A illustrates the folding element 40 in the open first state Z1 (illustrated by dashed lines) and in the closed second state Z2 (illustrated by solid lines), in which said folding element is folded over about the first axis A1 and, in interaction with the workpiece 10 and the molding body 32, forms the first cavity 21.

[0084] FIG. 4B illustrates a detailed view of the exemplary embodiment illustrated according to FIG. 4A, in which a possible geometry of the first cavity 21 can be seen more clearly. Said cavity has a narrow lip or nose which extends away from the workpiece 10. The first cavity 21 is bounded by respective first boundary surfaces 37 and 47 of the molding body 32 and of the folding element 40, which comprise, for example, silicone, aluminum, steel and/or plastic, in order to permit careful, safe and reliable forming of the first plastics molding 25. In a corresponding manner, the outer shape of the first plastics molding 25 to be formed is determined by the contours of the boundary surfaces 37 and 47. The previously described second cavity 22 can be correspondingly bounded by second boundary surfaces which are formed on the folding element 40 or on the first and second component 41 and 42 and the frame element 50.

[0085] In this exemplary embodiment, the workpiece 10 is realized as a composite disk which has an outer layer, an inner layer and optionally one or more intermediate layers. In addition, heating elements 39 and 49 are illustrated, said heating elements being arranged within the molding body 32 or within the folding element 40 in order to control the temperature of the respective components in a predetermined manner. This makes it possible for the molding body and/or the folding element to be heated, for example, to a predetermined machining temperature, in particular in the region of the first and/or second cavity 21, 22 to be formed.

[0086] Furthermore, the molding body 32 and the folding element 40 respectively have a holding region 33 and 43 made of silicone, aluminum, steel and/or plastic for the workpiece 10, said holding regions permitting safe and reliable holding of the workpiece 10 to be machined. In addition, a vacuum region 55 is formed on the lower side 13 between the workpiece 10 and the molding body 32 and contributes further to reliable holding and stable positioning of the workpiece 10. Furthermore, the device can also comprise yet further holding elements, such as integrated magnets, which contribute to safe and stable holding of the workpiece 10 within the device.

[0087] FIGS. 5A to 5C illustrate possible refinements of the first and/or second plastics molding 25, 26. In FIG. 5A, the first plastics molding 25 is realized as a two-part foam encapsulation 7 which surrounds a front and a rear edge of the workpiece 10. In FIG. 5B, the workpiece 10 is machined in such a manner that, by means of the first cavity 21 and the second cavity 22, the first plastics molding 25 is designed as an outer peripheral frame and the second plastics molding 26 is designed spaced apart as an inner peripheral frame. The two plastics moldings 25 and 26 can be produced, for example, within the scope of a foam encapsulation process and can realize a foam encapsulation 7 which is formed from polyurethane in order to permit reliable connection to a body of the motor vehicle 1.

[0088] In FIG. 5C, the second plastics molding 26 is formed in multiple parts in the inner region of the workpiece 10. Furthermore, two add-on elements 52 are illustrated which have been attached to the upper side 12 of the workpiece 10 by means of an adhesive bonding process. Such add-on elements can realize, for example, fastening and/or reinforcing elements which contribute to improved stability and simple further processing of the workpiece 10. For example, by means of such elements, the stability of the cover 5 can be increased and simple and reliable connection of the cover 5 to a body of the motor vehicle 1 can be provided.

[0089] FIGS. 6A and 6B show two further possible refinements of the first plastics molding 25 which can be formed, for example within the first cavity 21, by means of the device described and a corresponding production method. Owing to the interaction of the folding element 40 and of the molding body 32, relatively steep and narrow outer contours of the plastics moldings 25, 26 can also be produced.

LIST OF REFERENCE SIGNS

[0090] 1 Motor vehicle [0091] 3 Vehicle roof [0092] 5 Cover [0093] 7 Foam encapsulation [0094] 10 Workpiece [0095] 12 Upper side of the workpiece [0096] 13 Lower side of the workpiece [0097] 21 First cavity [0098] 22 Second cavity [0099] 25 First plastics molding [0100] 26 Second plastics molding [0101] 30 Lower tool [0102] 32 Molding body [0103] 33 Holding region of the molding body [0104] 34 Holding element [0105] 36 Punch element [0106] 37 First boundary surface of the molding body [0107] 39 Heating element of the molding body [0108] 40 Folding element [0109] 41 First component of the folding element [0110] 42 Second component of the folding element [0111] 43 Holding region of the folding element [0112] 45 First material dispenser [0113] 46 Second material dispenser [0114] 47 First boundary surface of the folding element [0115] 49 Heating element of the folding element [0116] 50 Frame element [0117] 52 Add-on element [0118] 55 Vacuum [0119] A1 First axis [0120] A2 Second axis [0121] N Normal direction [0122] Z1 First open state of the folding element or of the respective component [0123] Z2 Second closed state of the folding element or of the respective component