LAMINATING DEVICE AND A METHOD FOR LAMINATING A DECOR LAYER ONTO A CARRIER PART

Abstract

A laminating device and method for laminating a decor layer onto a carrier part includes a lower tool with a support region for receiving the carrier part, an upper tool including a pressing surface for exerting a pressing pressure onto the decor layer which is arranged between an upper side of the carrier part and the pressing surface, and at least one movable slider for edge-folding an overhang of the decor layer around an edge of the carrier part by way of pressing the slider against the overhang of the decor layer. A distance between the lower tool and the pressing surface can be enlarged or reduced. The lower tool includes a first membrane, wherein the arrangement of the first membrane and the slider to one another is such that the first membrane is movable onto the slider, for pressing the slider against the overhang of the decor layer.

Claims

1. A laminating device for laminating a decor layer onto a carrier part, comprising: a lower tool with a support region for receiving the carrier part; an upper tool comprising a pressing surface for exerting a pressing pressure onto the decor layer which is arranged between an upper side of the carrier part and the pressing surface; and at least one movable slider for edge-folding an overhang of the decor layer around an edge of the carrier part by way of pressing the slider against the overhang of the decor layer, so that the overhang is pressed around the edge of the carrier part onto a lower side of the carrier part, wherein the upper tool and lower tool are configured such that a distance between the lower tool and the pressing surface can be enlarged or reduced, and wherein the lower tool comprises a first membrane, wherein the arrangement of the first membrane and the slider to one another is such that the first membrane is movable onto the slider, for pressing the slider against the overhang of the decor layer.

2. A laminating device according to claim 1, wherein the first membrane is movable against the slider by way of producing an underpressure.

3. A laminating device according to claim 1, wherein the pressing surface is a second membrane.

4. A laminating device according to claim 3, wherein a space between the first membrane and the second membrane can be sealed off in a fluid-tight manner, so that the second membrane can be pressed against the decor layer which is arranged on the upper side of the carrier part and the first membrane against the slider, by way of subjecting the space to an underpressure.

5. A laminating device according to claim 1, wherein at least one of the upper tool and the lower tool is at least one of actively coolable and heatable.

6. A laminating device according to claim 1, wherein the slider is translatorily and rotationally movable.

7. A laminating device according to claim 1, including at least one of a pneumatic, hydraulic, and motoric device for moving the slider.

8. A method for laminating a decor layer onto a carrier part comprising the following steps: providing a laminating device with a lower tool, a slider and an upper tool which has a pressing surface , wherein the lower tool comprises a first membrane and the arrangement of the first membrane and the slider to one another is such that the first membrane is movable against the slider; arranging the carrier part on a support region of the lower tool; arranging a decor layer on an upper side of the carrier part in a manner such that a region of the decor layer projects beyond an edge of the carrier part and forms an overhang; pressing the pressing surface onto the decor layer such that the decor layer is pressed onto the carrier part; and pressing the first membrane against the slider such that the first membrane presses the slider against the overhang of the decor layer and edge-folds this at least partly around the edge of the carrier part.

9. A method according to claim 8, compromising the step: moving the slider into a pre-edge-folding position, so that the overhang of the decor layer is laid at least partly around the edge of the carrier part.

10. A method according to claim 8, wherein the decor layer comprises at least one of leather and artificial leather and/or wherein the carrier part comprises at least one of wood, fibre material, plastic and a natural fibre composite material.

11. A method according to claim 8, compromising the step: depositing an adhesive onto at least one of a lower side of the decor layer, the upper side, and the edge of the carrier part so that the adhesive is arranged between the decor layer and the carrier part.

12. A method according to claim 8, compromising the step: providing at least one of heating and cooling to at least one of the upper tool and the lower tool.

13. A method according to claim 8, wherein the steps of the pressing-on of the pressing surface and pressing-on of the first membrane are carried out simultaneously.

14. A method according to claim 8, wherein a pressing pressure for at least one of the pressing-on of the pressing surface and pressing-on of the first membrane are applied by an under pressure.

15. A method according to claim 8, wherein the pressing surface is a second membrane and an under pressure is applied between the first membrane and the second membrane, so that the first membrane presses the slider against the decor layer and thus against at least one of the carrier part and the second membrane presses the decor layer on the upper side of the carrier part.

16. A vehicle interior trim part, manufactured by a method according to claim 8.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The disclosure is hereinafter described by way of embodiment examples which are explained in more detail by way of the figures. There are shown in:

[0033] FIG. 1 a sectioned view through a schematically represented laminating device at a first point in time of a laminating and edge-folding method, according to embodiments of the disclosure;

[0034] FIG. 2 a sectioned view through the schematically represented laminating device at a second point in time of the laminating and edge-folding method, according to embodiments of the disclosure;

[0035] FIG. 3 a sectioned view through the schematically represented laminating device at a third point in time of the laminating and edge-folding method, according to embodiments of the disclosure;

[0036] FIG. 4 a sectioned view of a further schematically represented laminating device in an opened position, according to embodiments of the disclosure;

[0037] FIG. 5 a sectioned view of a further schematically represented laminating device in the folded open position, according to embodiments of the disclosure;

[0038] FIG. 6 a sectioned view of the further schematically represented laminating device in the closed position, according to embodiments of the disclosure; and

[0039] FIG. 7 a sectioned view of the further schematically represented laminating device in the closed position with an extended slider, according to embodiments of the disclosure.

DETAILED DESCRIPTION

[0040] FIG. 1 shows a laminating device in a schematic representation, according to embodiments of the disclosure. The laminating device comprises a lower tool 1 which comprises a rigid component 2 and a first membrane 3. The rigid component 2 has a support region 4 at its upper side. The rigid component 2 can be movable relative to other parts of the lower tool 1, for example relative to a frame 2. The laminating device moreover comprises an upper tool 5 with a pressing surface 6. Of the upper tool 5, only the pressing surface 6 and the fastening points 7 of the upper tool 5 on the lower tool 1 are shown. The laminating device moreover comprises a movable slider which is translatorily movable in the x- and y-direction as well as rotationally movable about the z-axis. A carrier part 9 is arranged on the support region 4 in a manner such that the carrier part 9 projects beyond the support region 4. A lower side 10 of the carrier part 9 is therefore accessible to the slider 8. The carrier part 9 moreover comprises an edge 11 which is arranged on the lower side 10 of the carrier part 9. A decor layer 13 is moreover arranged on an upper side 12 of the carrier part 9 in a manner such that an overhang 14 of the decor layer 13 projects beyond the edge 11 of the carrier part 9. The upper tool 5 and the lower tool 1 are represented in a connected manner, thus the laminating device is represented in the closed condition. In the represented embodiment example, the pressing surface 6 is a second membrane. The first membrane 3 as well as the second membrane is extensible and airtight and of a natural or artificial material, for example of latex. The first membrane 3 is connected to the rigid component 2 in an airtight manner and the second membrane is also connected in an airtight manner to the lower tool 1 by way of fastening points 7. In embodiments, at least one of the fastening points is releasable, so that an arresting between the upper tool 5 and the lower tool 1 can be released and the laminating device opened. Each membrane is preferably fastened to a frame 2. In some embodiments, the frames 2 are rigid and do not move with the support region 4 given a subjection to a vacuum. Hereon, the lower tool, the upper tool and the slider are enclosed by the membranes which are fastened in the frames. A space 15 between the upper tool 5 and the lower tool 1 is therefore sealed in an airtight manner and can be subjected to compressed air when the device is closed. The first membrane 3 and the second membrane can be stretched in a manner such that a distance between the pressing surface 6 and the lower tool 1, for example a distance between the first membrane 3 and the second membrane can be reduced compared to a condition, in which the space 15 is under normal pressure. This is particularly evident when comparing FIGS. 1 and 3, wherein in FIG. 1 the space 15 is under normal pressure whilst in FIG. 3 a reduced pressure in the form of a vacuum prevails in the space 15.

[0041] The decor layer 13 can be laminated onto the carrier part 9, and thus be connected to this, by way of the laminating device. A component 16, preferably a vehicle interior trim part is thus manufactured. An adhesive, for example a hot-melt adhesive or a polyurethane adhesive is arranged between the carrier part 9 and the decor layer 13, for connecting the decor layer 13 to the carrier part 9. The adhesive can be deposited onto an upper side and edge, in particular onto the inner side 18 of the edge, before the insertion of the carrier part 9 into the laminating device or not until the carrier part 9 is already arranged on the support region 4. Of course, the adhesive can also be deposited onto a lower side of the decor layer 13. The decor layer 13 with or without adhesive can be arranged on the carrier part 9 before or after laying the carrier part 9 onto the support region 4, in the manner described above. The adhesive for example can be sprayed on or rolled on.

[0042] The decor layer 13 is a real leather skin. The decor layer 13 can of course also be an artificial leather skin, a textile layer, a foil or a different type of edge-foldable layer, for example a thin metal foil. One also envisages the decor layer 13 consisting of different parts which are connected to one another, for example sewn to one another. Here, the decor layer 13 can comprise materials which are connected to one another, said materials being the same or different. In embodiments, an upper side of the decor layer 13 is a viewed side of the finished manufactured component, here of the vehicle interior trim part. In the shown example, a thickness of the decor layer 13 is 1 mm. The carrier part 9 comprises wood, fibre material or plastic and in the shown example is an NFPP composite material of natural fibres and polypropylene. In further embodiments, the carrier part 9 can of course comprise other materials.

[0043] In FIG. 1, the slider 8 is shown at the beginning of a pre-edge-folding movement. The slider is moved in the x-direction against the overhang 14 and herein folds the overhang 14 partly around the edge 11 of the carrier part 9. The slider 9 is shown at a later point in time during the pre-edge-folding movement in FIG. 2 and is displaced further in the x-direction compared to the representation in FIG. 1. The overhang 14 is folded around the edge 11 by an angle of 90 by way of this slider movement and bears on the lower side 17 of the edge 11. The pre-edge-folding movement of the slider 8 is completed with this.

[0044] The space 15 of the laminating device is subjected to a reduced pressure in FIG. 3. The first membrane 3 pushes the slider 8 against the pre-edge-folded overhang 14 of the decor layer 13 upon subjecting the space 15 to a vacuum. Herein, the overhang 14 of the decor layer 13 is edge-folded around the edge 11, which is to say is folded about the edge 11 and is pressed onto the carrier part. In FIG. 3, the slider is shown at a point in time, at which the edge-folding process is not yet fully completed, which can be recognised by the fact that the overhang 14 of the decor layer 13 does not yet bear on the inner side 18 of the edge 11. The edge-folding process is therefore not completed until the slider 8 has pressed the overhang 14 completely against the inner side 18 of the edge 11 of the carrier part 11 by way of the pressing pressure exerted by the first membrane 3. Herein, the slider 8 can be moved rotationally about the axis z or translatorily in the x- and y-direction from the first membrane 3.

[0045] FIG. 3 further shows the second membrane which likewise presses against the decor layer 13 by way of subjecting the space 15 to the vacuum. However, the second membrane pushes the decor layer 13 onto the upper side 12 of the carrier part 9 and in the shown example additionally partly onto a side 19 of the carrier part 9. The decor layer 13 is laminated onto the carrier part 9 by way of the second membrane.

[0046] The surface of the upper tool or lower tool 5,1 is heated to a temperature for example of 80 C., in order to activate or melt the adhesive between the decor layer and the carrier part. This can be realised for example by way of fluid conduits (not shown in FIGS. 1 to 3), for example pipes. These are connected onto a hot water connection and a cold water connection. On heating, for example water or oil with a temperature of 90 C. or above 100 C. is led through the pipes. The heat of the water or oil is transmitted through the upper tool and lower tool in the direction of the decor layer 13, so that the adhesive can be activated or melted. After the heating, cold water, for example at a temperature of 5 C. can be led through the pipes instead of hot water, by way of reversing the way valve, so that the surfaces of the upper tool 5 and/or of the lower tool 1 can be cooled and the adhesive be cure.

[0047] FIGS. 4 to 7 show further embodiments of a laminating device. Recurring features are provided with the same reference numerals.

[0048] All four FIGS. 4 to 7 shows the upper tool 5 and the lower tool 1 with the rigid component 2. Moreover, the slider 8 which serves for edge-folding the overhang 14 of the decor layer 13 around the edge of the carrier part 9 is represented in all three figures. As already described, the slider 8 herein edge-folds the overhang 14 by way of it pressing against the overhang 14 of the decor layer 13, so that the overhang 14 is pressed around the edge of the carrier part 9 onto a lower side of the carrier part 9. As is shown in FIG. 4, the laminating device can comprise a translatory opening mechanism, concerning which the upper tool 5 is movable in the y-direction. As is shown in FIG. 5, the laminating device can additionally or alternatively have a rotatory opening mechanism, concerning which the upper tool 5 can be tilted about a z-axis, in order to open the laminating device. The laminating device is represented in FIGS. 4 and 5 in an opened manner, wherein FIGS. 6 and 7 show the laminating device in a closed condition. In the opened condition, the component 16 is laid into the laminating device. The component 16 comprises the decor layer 13, the adhesive and the carrier part 9, wherein the adhesive is not yet activated and the decor layer 13 and the carrier part 9 are therefore not yet fixedly connected to one another. The lower tool 1 comprises the first membrane 3 and the upper tool 5 the second membrane as a pressing surface 6. The membranes are of latex and are connected to the upper tool 5 and lower tool 1, respectively, in a fluid-tight manner. The space 15 between the upper tool 5 and the lower tool 1 is sealed in a fluid-tight manner in the closed condition of the laminating device.

[0049] The upper tool 5 moreover comprises an insert 20. The insert 20 in turn comprises three pipes 21 which are connected to a warm water connection and cold water connection and is heatable or coolable by way of this. The outer shape of the insert 20 is moreover formed by an aluminium frame which is adapted to a concave shape of the carrier part 9. The aluminium frame thus leads heat or cold onto the component 16 via a surface of the insert. The pressing surface 6, here the second membrane, presses the insert 20 against the decor layer 13 and therefore against the carrier part 9. Even a complex concave region can therefore be laminated given an adequately uniform surface pressing. As already explained above in more detail, the adhesive can be activated by way of heating the insert and the adhesive can be cured by way of it being cooled.

[0050] A momentary picture during an edge-folding process and laminating process is represented in FIG. 7. The space 15 is subjected to a vacuum, so that the second membrane to some extent presses upon the insert 20 and this upon the decor layer 13 at the upper side of the carrier part 9 and to a further extent directly upon the decor layer 13 and therefore presses the decor layer 13 onto the carrier part. The slider 8 is moreover pressed against the overhang 14 so that the slider 8 edge-folds the overhang 14 around the edge of the carrier. The slider 8 is of metal and is mounted in a guide rail.