DE102020113705B4 - Method for producing a component - Google Patents

Abstract

Method for producing a component (10), comprising the steps
- providing a decorative layer (12) having a plurality of through-openings (14) which extend from a rear side (18) of the decorative layer (12) to a visible side (20) of the decorative layer (12);
- providing a reactive filling compound (22) which is designed to cure irreversibly;
- Providing a cover (24) which has a carrier layer (26) and at least one transfer layer (28) which is designed to reversibly adhere to the visible side (20) of the decorative layer (12) and to impart at least one property to the reactive (22) filling compound, wherein respective material properties and/or process parameters are selected such that at least components (32) of the transfer layer (28) are transferred to the filling compound (22) in the region of the through-openings (14) and thereby impart at least one mechanical and/or optical property of these components (32) to the filling compound;
- Attaching the cover (24) with its transfer layer (28) to the visible side (20) of the decorative layer (12) while covering the through openings (14);
- filling the through-openings (14) of the decorative layer (12) by applying the filling compound (22) in the flowable state to the back (18) of the decorative layer (12) provided with the cover (24) while exerting pressure, wherein the transfer layer (28) imprints the at least one property on the filling compound (22) in the region of the through-openings (14) and wherein the transfer layer (28) is produced with a defined surface structure (30) which is imprinted on the filling compound (22) in the region of the through-openings (14);
- removing the cover (24) from the visible side (20) of the decorative layer (12) after the applied filling compound (22) has hardened at least in its areas facing the cover (24).

Description

Technical area

The present invention relates to a method for producing a component.

State of the art

Perforated decorative layers are often used in a wide variety of applications, whereby their through holes can be filled with a filling compound to prevent the through holes, i.e. the perforation, from becoming clogged with dust, dirt or other particles. When filling such decorative layers, it may be desirable to influence or process a visible surface of the filling compound used to fill the through hole in such a way that a certain optical appearance can be achieved. Setting the desired optical properties or other properties for such filling compounds, with which said through holes of a decorative layer are filled, can sometimes be difficult and time-consuming.

It is known from EN 10 2019 107 019 A1 a method for producing a translucent interior surface for a vehicle. A decorative layer with a large number of openings is provided and an irreversibly hardening filling compound is applied to the back of the decorative layer.

EN 10 2017 101 981 A1 discloses a method for producing a decoration for an equipment part of a motor vehicle with a filling with the aid of a masking layer.

US 2010 / 0 047 543 A1 shows a transfer film for producing a decorative laminate, which can be used, among other things, for automotive parts.

Description of the invention

It is therefore the object of the present invention to provide a solution with which the properties of a filling compound, by means of which through holes in a perforated decorative layer are filled, can be adjusted particularly easily.

This object is achieved by a method for producing a component and by a component having the features of the independent claims. Further possible embodiments of the invention are specified in the dependent claims.

In the method according to the invention for producing a component, a decorative layer is provided which has a large number of through-openings which extend from a rear side of the decorative layer to a visible side of the decorative layer. The through-openings, i.e. holes, can have any shape. They can be, for example, ellipses, polygons, text characters and/or symbols. In addition, the through-openings can be positioned in any regular or irregular arrangement relative to one another. The decorative layer can consist of, for example, leather, polyvinyl chloride, polyurethane, a thermoelastic elastomer or the like and can be completely or only poorly translucent. The decorative layer can also be made of less flexible or virtually inflexible materials, such as wood, stone or the like.

In addition, a reactive filling compound is provided which is designed to harden irreversibly. Furthermore, a cover is provided which has a carrier layer and at least one transfer layer which is designed to reversibly adhere to the visible side of the decorative layer and to impart at least one property to the reactive filling quantity. The transfer layer can in particular be an adhesive layer.

The cover provided is attached with its transfer layer to the visible side of the decorative layer, covering the through-openings. As a result, the transfer layer adheres to the visible side of the decorative layer and covers said through-openings. The through-openings of the decorative layer are then filled by applying the filling compound in a flowable state to the back of the decorative layer provided with the cover by exerting pressure, the transfer layer imparting at least one property to the filling compound in the area of the through-openings. Finally, the cover is removed from the visible side of the decorative layer again, namely after the applied filling compound has hardened at least in the areas facing the cover.

By means of the method according to the invention, the component is produced in the form of a component composite, which has at least the decorative layer provided with the through-openings and the reactive filling compound by means of which the through-openings have been filled. By using the cover, which has said transfer layer, it is possible in a simple manner to impart at least one property to the reactive filling compound, namely in the areas where the reactive filling compound is in the area of the through-openings. openings and can, for example, be more or less flush with the visible side of the decorative layer.

Embossing in the sense of the invention can, but does not have to, be understood as purely mechanical. For example, using the method according to the invention it is possible to mattify the filling material in the area of the through-openings or to adjust other optical properties, which can be done chemically and/or mechanically. It is also possible to produce raised structures on the filling material, namely in the areas in which the filling material runs more or less flush with the visible side of the decorative layer and fills the through-openings. It is also possible, for example, that embossing can be understood as coloring the filling material.

The transfer layer comprises in particular an adhesive layer, which can be structured and/or functionally equipped in another way, for example. In the sense of a hot stamping process, the structuring of the transfer layer and/or at least one functional property of the transfer layer is transferred exclusively to the filling compound, namely in the areas where the filling compound fills the through-openings more or less flush with the visible side of the decorative layer. This makes it easy to imprint a structure transfer, a function transfer or, for example, a geometric shape, for example in the form of a nub formation or the like, on the filling compound in the area of the through-opening.

Using the method according to the invention, it is possible, for example, to produce an interior component for a motor vehicle which has a perforated decorative layer, wherein the through-openings of the perforated decorative layer are filled with the said reactive filling compound. Optical and/or other properties of the reactive filling compound in the area of the through-openings can be easily adjusted using the method according to the invention. The component produced using the method according to the invention can also be used in any other areas, i.e. not only in the interior areas of motor vehicles.

By using the said cover with the transfer layer, it is possible to use a wide variety of decorative layers made of a wide variety of materials when producing the component, in particular also poorly adhering materials, such as fibrous, rough or heavily grained decorative materials, for example textiles in the form of Alcantara, fabrics or the like. The shape and hole diameter of the through-openings can be designed to be particularly variable, since the method according to the invention makes it easy to fill a wide variety of through-openings with the reactive filling compound and to impart a wide variety of properties to the filling compound using the transfer layer. Because the filling compound is pressed into the through-openings in a flowable state, in particular in a low-viscosity state, under pressure, the reactive filling compound clings to the transfer layer in the area of the through-openings even before it hardens. This ensures a particularly reliable transfer of structure and/or function from the transfer layer to the reactive filling compound. After the reactive filling compound has hardened, it retains at least one of the properties imprinted by the transfer layer.

One possible embodiment of the invention provides that the carrier layer of the cover is made of a flexible material. This ensures that the entire cover, and thus also the transfer layer, reliably conforms to the reactive filling compound and the visible side of the decorative layer during the filling process. As a result, a transfer of structure and/or a transfer of function from the transfer layer to the filling compound in the area of the through-openings can be ensured particularly reliably. The fact that the carrier layer is made of a flexible material also ensures that the cover conforms particularly well to any unevenness on the visible side of the decorative layer. This ensures that the reactive filling compound does not ooze out of the through-openings in an undesirable manner in the direction of the visible side of the decorative layer during the filling of the through-openings. The flexibility of the carrier layer also ensures that any thickness fluctuations in the decorative layer can be compensated for.

The invention provides that the transfer layer is produced with a defined surface structure, which is embossed in the area of the through-openings of the filling compound. During the filling process of the through-openings, the reactive filling compound is pressed through the through-openings from the back until the reactive filling compound comes into contact with the transfer layer. The reactive filling compound is pressed against the structured transfer layer with a certain pressure, as a result of which a structure is transferred from the transfer layer to the filling compound in the area of the through-openings. This makes it possible, for example, to mat the filling compound. in the area of the through-openings. In addition to the optical appearance of the filling compound in the area of the through-openings, the feel can also be adjusted.

According to a further possible embodiment of the invention, it is provided that the respective material properties are selected such that the transfer layer adheres more strongly to the carrier layer than to the filling compound. This ensures that the cover together with its transfer layer can be easily removed from the reactive filling compound after it has hardened. During the filling process, it is therefore possible to implement the said structure transfer using the transfer layer, whereby after the filling compound has hardened, the cover together with its transfer layer can be reliably removed from the then structured filling compound in the area of the through-openings. This can be done in particular in such a way that no particles or components are torn out of the hardened filling compound using the transfer layer.

According to the invention, it is provided that respective material properties and/or process parameters are selected such that at least components of the transfer layer in the area of the through-openings are transferred to the filling compound, thereby imparting at least one mechanical and/or optical property of these components. In this case, a function is transferred from the transfer layer to said areas of the filling compound. Respective material properties and/or process parameters are selected such that certain components, such as particles or the like, are transferred from the transfer layer in the area of the through-openings to the filling compound, thereby imparting certain properties to the filling compound. For example, a color, softness, adhesive properties or the like of the filling compound can be imparted to the filling compound by said components of the transfer layer. In this way, a wide variety of properties of the filling compound in the area of the through-openings can be changed by means of the transfer layer.

Another possible embodiment of the invention provides that the respective material properties and/or process parameters are selected such that the adhesion between the transfer layer and the filling compound is sufficient to transfer at least some components of the transfer layer to the filling compound. If the filling compound is therefore conveyed into the through-openings under pressure during the filling process and then reaches the transfer layer at some point, at least certain components of the transfer layer reach the filling compound in the area of the through-openings and are transferred to it. Said components of the transfer layer therefore adhere so strongly to the filling compound that they remain on the hardened filling compound after the filling compound has hardened and the cover has been removed, thereby continuing to determine or shape its properties.

In a further possible embodiment of the invention, it is provided that a process temperature is set such that a diffusion of at least some components of the transfer layer onto the filling compound takes place and/or a chemical reaction takes place between at least some components of the transfer layers of the filling compound. It is therefore possible to cause a diffusion of some components of the transfer layer onto the filling compound in a temperature-controlled manner and/or to cause a chemical reaction between at least some components of the transfer layer and the filling compound. In each case taken individually or in combination, it is thus possible to achieve a transfer of function from the transfer layer to the filling compound in the area of the through-openings. The optical properties, colors, mechanical properties and the like can be reliably adjusted on the filling compound in this way.

Another possible embodiment of the invention provides that a flexible layer is arranged on a side of the carrier layer facing away from the transfer layer, through which the transfer layer is pressed against the visible side of the decorative layer. The flexible layer can be part of the cover itself or form a separate layer. A silicone mat, for example, can be used as a flexible layer. By providing the flexible layer, it is possible to ensure that the transfer layer is reliably pressed against the visible side of the decorative layer. This ensures that the through-openings are filled reliably using the reactive filling compound, without the reactive filling compound undesirably overflowing from the through-openings and, for example, partially contaminating the visible side of the decorative layer in an undesirable manner.

In a further possible embodiment of the invention, it is provided that a translucent filling compound is used as the filling compound. In this context, it can be provided that the decorative layer is made of a material that is little to not at all translucent. By using the translucent filling compound, it is possible to backlight the manufactured component in order to, for example, easily create ambient lighting. By said transfer of structure and/or function at the reac By using a special filling compound in the area of the through openings, it is also possible to specifically adjust the optical appearance of such ambient lighting.

According to a further possible embodiment of the invention, it is provided that a reactive hot melt adhesive is used as the filler. The filler can therefore be a cross-linking hot melt adhesive. Such adhesives are synthetic adhesives that get their adhesive strength from chemical reactions of the polymers, which react with air humidity, for example, through heat, UV radiation and/or pressure. After polymerization, the adhesive can no longer be melted or dissolved, so the process is irreversible. For example, the filler can also be a reactive urethane. Polyurethane adhesives or reactive urethanes can be used for high temperatures and high flexibility. They have very good resistance to solvents and chemicals and a low processing temperature, making them particularly suitable for heat-sensitive decorative materials. In addition, they offer good heat resistance after curing. In principle, any reactive hot melt adhesive can be used, as long as they are compatible with the decorative layer used. All fluid media suitable for the described filling based on one-component systems, two-component systems and the like can be used as the filling compound, in particular provided that they are sufficiently UV-stable, reactive, viscoelastic, flexible, quickly block-free, emission-free, adhere well and are compatible with the decorative layer in question. In addition, the filling compound used preferably has no or hardly any stringing and little or no gas formation.

Another possible embodiment of the invention provides that at least one adhesive tape is used as the cover. The cover can be produced, for example, as a continuous material in the form of the adhesive tape mentioned. Using the adhesive tape, it is easy to attach it with its transfer layer, i.e. the adhesive layer, to the visible side of the decorative layer, covering the through openings.

Further advantages, features and details of the invention can be found in the following description of possible embodiments and from the drawing. The features and combinations of features mentioned above in the description as well as the features and combinations of features shown below in the description of the figures and/or in the figures alone can be used not only in the combination specified in each case, but also in other combinations or on their own, without departing from the scope of the invention.

Short character description

• 1 eine schematische Darstellung eines Verfahrens zum Herstellen eines Bauteils, welches aus einer perforierten Dekorschicht hergestellt wird, wobei die Perforierung bildende Durchgangsöffnungen mittels einer reaktiven Füllmasse befüllt werden;
• 2 eine schematische Darstellung eines weiteren Verfahrens zum Herstellen des Bauteils aus der perforierten Dekorschicht und der reaktiven Füllmasse.

The drawing shows in:

• 1 a schematic representation of a method for producing a component which is made from a perforated decorative layer, wherein through openings forming the perforation are filled by means of a reactive filling compound;
• 2 a schematic representation of another process for producing the component from the perforated decorative layer and the reactive filling material.

In the figures, identical or functionally identical elements are provided with the same reference symbols.

A method for producing a component 10 is shown in a schematic representation in 1 shown. To produce the component 10, a decorative layer 12 is provided which has a plurality of through openings 14 between different areas 16. The decorative layer 12 can in principle be made of any material, such as leather, a textile, wood, stone or the like. The through openings 14 between the areas 16 can be arranged regularly, but do not have to be. The shape of the through openings 14 can essentially be arbitrary, for example circular, square, in the form of a wide variety of symbols or the like. The through openings 14 extend from a rear side 18 of the decorative layer 12 to a visible side 20 of the decorative layer 12. The visible side 20 is to be understood as the side of the decorative layer 12 which a user sees when the component 10 is installed, for example a vehicle occupant if the component 10 is an interior component.

During the manufacture of the component 10, a reactive filling compound 22 is also provided, which is designed to cure irreversibly. The reactive filling compound 22 can be, for example, a reactive hot melt adhesive. It is also possible for the filling compound 22 to be translucent. In addition, a cover 24 is provided, which has a carrier layer 26 and at least one transfer layer 28, which is designed to reversibly adhere to the visible side 20 of the decorative layer 12 and to impart at least one property to the reactive filling compound 22. The transfer layer 28 can be This could be an adhesive tape, for example. This can have a thickness of around 90 µm, but can also have other thicknesses. The transfer layer can have a low elongation at break, eg around 4 percent. Acrylate can be used as an adhesive. The adhesive force on steel can be greater than 0.5 N/cm.

The carrier layer 26 can in particular be made of a soft material and have a thickness of more than 500 µm. For example, the carrier layer 26 can have a foam core, e.g. a flexible PE foam. The carrier layer 26 can be provided on both sides with an adhesive, e.g. with an acrylate, and have an adhesive force that is greater than 1 N/cm, whereby the adhesive force is less than a tear force. In particular, the carrier layer 26 can also be temperature-resistant, e.g. up to 80 °C.

For example, a carrier plate can be arranged beneath the carrier layer 26. The carrier plate can in particular be distortion-free and can also be made of a glass fiber reinforced epoxy resin and have a thickness in the range of 2 mm.

Before the through-openings 14 are filled with the reactive filling compound 22, the cover 24 with its transfer layer 28 is first attached to the visible side 20 of the decorative layer 12, covering the through-openings 14. As a result, the transfer layer 28 adheres to the visible side 20 of the decorative layer 12. The through-openings 14 of the decorative layer 12 are then filled by applying the filling compound 22 in a flowable state, in particular in a low-viscosity state, to the back 18 of the decorative layer 12 provided with the cover 24 while applying pressure. The reactive filling compound 22 is therefore pressed through the through-openings 14 from the back by applying pressure. This can be done, for example, by means of a roller application or, for example, in a suitable tool.

In the case shown here, the transfer layer 28 was produced with a defined surface structure 30. This surface structure 30 is embossed in the area of the through-opening 14 of the reactive filling compound 22. This can be done particularly easily because the reactive filling compound 22 is applied while still in a flowable state, in particular in a low-viscosity state. The filling compound 22 therefore conforms to the surface structure 30 of the transfer layer 28. After the through-opening 14 has been filled, the reactive filling compound 22 hardens. In the area of the through-opening 14, the filling compound 22 retains its embossed surface structure or surface shape, which results from the defined surface structure 30 of the transfer layer 28.

After the applied filling compound 22 has hardened at least in its areas facing the cover 24 and thus the transfer layer 28, the cover 24 is removed again from the visible side 20 of the decorative layer 12. The respective material properties are selected such that the transfer layer 28 adheres more strongly to the carrier layer 26 than to the filling compound 22. The cover 24 together with its transfer layer 28 can thus be easily peeled off or removed from the visible side 20 and from the hardened filling compound 22, without the structured surface of the hardened reactive filling compound 22 in the area of the through-opening 14 being changed or affected.

In 2 another possible method for producing the component 10 is shown schematically. In the case shown here, instead of a structure transfer, a function transfer takes place from the transfer layer 28 to the filling compound 22 in the area of the through-openings 14. The respective material properties and/or process parameters are selected such that at least certain components 32 of the transfer layer 28 are transferred to the filling compound 22 in the area of the through-openings 14 and thereby impart at least one mechanical and/or optical property of these components 32 to the filling compound.

The components 32 can be, for example, color pigments which are detached from the transfer layer 28 during the manufacturing process and adhere to the filling compound 22 in the area of the through-opening 14. They can also be other types of components 32 which can, for example, influence the softness, adhesive properties or other properties of the filling compound 22 in the area of the through-openings 14. The respective material properties and/or process parameters are selected such that the adhesion between the transfer layer 28 and the filling compound 22 is sufficient to transfer at least some of the components 32 from the transfer layer 28 to the filling compound 22 in the area of the through-opening 14.

For example, a process temperature can be set such that a diffusion of at least some of the components 32 from the transfer layer 28 to the filling compound 22 takes place in the region of the through-openings 14. For example, the process temperature can also be set such that a chemical reaction between at least some of the components 32 of the transfer layer 28 and the filling compound 22. In both cases, taken individually or in combination, it is possible to realize a function transfer from the transfer layer 28 to the filling compound 22 in the area of the through-openings 14. One or more functions are thus transferred from the transfer layer 28, for example by chemical reaction between the components 32 and the filling compound 22 and/or by detaching and transferring the components 32 to the filling compound 22, which retains this function or property after curing.

Based on the 1 and 2 Different procedures for producing the component 10 were explained in order to produce the said structure transfer and function transfer. The structure transfer and the function transfer can also be implemented in combination by appropriate process controls in order to produce a component 10 which can have the said structure transfer and function transfer at least partially at different through-openings 14.

Using the procedure explained, it is possible in a simple manner to structure, mattify and/or create raised geometries on the respective surfaces of the filling compound 22 in the area of the through-openings 14. It is also possible, for example, to color the filling compound 22 close to the surface in the area of the through-openings 14.

LIST OF REFERENCE SYMBOLS

10

Component

12

Decorative layer

14

Passage openings

16

Areas between the passage openings

18

Back of the decorative layer

20

Visible side of the decorative layer

22

reactive filling compound

24

cover

26

Carrier layer

28

Transfer layer

30

Surface structure

32

Components

34

flexible layer

Claims (10)

Method for producing a component (10), comprising the steps - providing a decorative layer (12) which has a plurality of through-openings (14) which extend from a rear side (18) of the decorative layer (12) to a visible side (20) of the decorative layer (12); - providing a reactive filling compound (22) which is designed to harden irreversibly; - Providing a cover (24) which has a carrier layer (26) and at least one transfer layer (28) which is designed to reversibly adhere to the visible side (20) of the decorative layer (12) and to impart at least one property to the reactive (22) filling compound, wherein respective material properties and/or process parameters are selected such that at least components (32) of the transfer layer (28) are transferred to the filling compound (22) in the region of the through-openings (14) and thereby impart at least one mechanical and/or optical property of these components (32) to the filling compound; - Attaching the cover (24) with its transfer layer (28) to the visible side (20) of the decorative layer (12) while covering the through-openings (14); - Filling the through openings (14) of the decorative layer (12) by applying the filling compound (22) in the flowable state to the back side (18) of the decorative layer (12) provided with the cover (24) while exerting pressure, wherein the transfer layer (28) imparts the at least one property to the filling compound (22) in the region of the through openings (14) and wherein the transfer layer (28) is produced with a defined surface structure (30) which is imparted to the filling compound (22) in the region of the through openings (14); - Removing the cover (24) from the visible side (20) of the decorative layer (12) after the applied filling compound (22) has hardened at least in its regions facing the cover (24). Procedure according to Claim 1 , characterized in that the carrier layer (26) is made of a flexible material. Method according to one of the preceding claims, characterized in that respective material properties are selected such that the transfer layer (28) adheres more strongly to the carrier layer (26) than to the filling compound (22). Method according to one of the preceding claims, characterized in that respective material properties and/or process parameters are selected such that the adhesion between the transfer layer (28) and the filling material (22) is sufficient to transfer at least some components (32) of the transfer layer (28) to the filling material (22). Method according to one of the preceding claims, characterized in that a process temperature is set such that a diffusion of at least some components (32) of the transfer layer (28) onto the filling compound (22) takes place and/or a chemical reaction takes place between at least some components (32) of the transfer layer (28) and the filling compound (22). Method according to one of the preceding claims, characterized in that a flexible layer (34) is arranged on a side of the carrier layer (26) facing away from the transfer layer (28), by means of which the transfer layer (28) is snuggled up to the visible side (20) of the decorative layer (12). Procedure according to Claim 6 , characterized in that a silicone mat is used as the flexible layer (34). Method according to one of the preceding claims, characterized in that a translucent filling compound is used as the filling compound (22). Method according to one of the preceding claims, characterized in that a reactive hot melt adhesive is used as the filling compound (22). Method according to one of the preceding claims, characterized in that at least one adhesive tape is used as the cover (24).

Images