DE102023102209B3 - Method for producing a workpiece and tool device - Google Patents

Abstract

The invention relates to a method for producing a workpiece, in which a laminating element is press-laminated to a carrier (12) on a first side (22) by means of a single tool device (10) and at least one component (16) is joined to the carrier (12) on a second side (24) opposite the first side (22), whereby the workpiece is produced, wherein the laminating element (14) is inserted into a first tool part (26) and the at least one component (16) is inserted into a second tool part (28) of the tool device (10) and both the press-laminating and the joining are carried out by closing the tool device (10).

Description

Technical area

The invention relates to a method for machining and producing a workpiece and to a tool device.

If a workpiece is to be produced by press-laminating a laminating element onto a carrier and joining a component to the carrier, then the laminating element is usually laminated onto the carrier using a first tool. For press-laminating, the laminating element and/or the carrier can be provided with a heat-activated adhesive or contact adhesive. The adhesive is activated by heating. By closing this first tool, the laminating element is pressed onto the carrier, with the adhesive arranged between the laminating element and the carrier. By pressing the laminating element onto the carrier, the laminating element is press-laminated onto the carrier. Heat-activated adhesives are used as adhesives in press-laminating. After press-laminating the carrier, wait until the adhesive has reacted sufficiently for further processing. For this purpose, the press-laminated carrier can be temporarily stored in a buffer. After the adhesive has reacted sufficiently for further processing, the component can be joined to the carrier. By waiting until the adhesive has reacted sufficiently for further processing before the component is joined to the carrier, it is possible to avoid the hot melt melting into the carrier when welding heat is introduced, for example when welding the component as a joining process. Welding is usually carried out using a second tool that is different from the first tool.

It is known, for example, from the DE 39 30 603 A1 a method for producing trim parts or panels for motor vehicle doors in a single operation in one work station. EN 10 2009 012 956 A1 shows a method for producing a vehicle seat, EP 0 603 498 A1 and US 5 718 791 A describe a method for producing a trim part of a vehicle and a corresponding tool. In DE 103 11 231 A1 a method for producing a multi-layered trim part for the interior trim of a vehicle is disclosed and
US 2016 / 0 361 837 A1 also shows a method for producing a trim part for the interior of a vehicle.

Description of the invention

The object of the present invention is to provide a solution which enables a particularly rapid production of a workpiece from a carrier, a laminating element and at least one component.

This object is achieved by the subject matter of the independent claims. Further possible embodiments of the invention are disclosed in the subclaims, the description and the figures. Features, advantages and possible embodiments that are set out in the description for one of the subject matter of the independent claims are to be regarded at least analogously as features, advantages and possible embodiments of the respective subject matter of the other independent claims and of any possible combination of the subject matter of the independent claims, if appropriate in conjunction with one or more of the subclaims.

The invention relates to a method for producing a workpiece, in particular an instrument panel for a motor vehicle. In the method, it is provided that a laminating element is press-laminated to a carrier on a first side by means of a single tool device and at least one component is joined to the carrier on a second side opposite the first side, whereby the workpiece is produced. This means that in the method, the workpiece is both press-laminated and joined by means of the tool device. A tool change is not necessarily provided for in the method, but can be provided. In the method, the laminating element is inserted into a first tool part, in particular a lower tool, and the at least one component is inserted into a second tool part, in particular an upper tool, of the tool device and the press-lamination takes place by closing the tool device. To close the tool device, the first tool part, which is in particular the lower tool, and the second tool part, which is in particular the upper tool, are moved towards each other, in particular until they lie against each other and the tool device is thus closed. This means that in order to close the tool, at least one of the tool parts is moved towards the other tool part. The tool parts are in particular the respective tool halves of the tool device. The component can also be joined to the carrier by closing the tool device. It can be provided that the press-laminating and the joining take place simultaneously, in particular by closing the tool device. As a component, for example, a firing channel for an airbag or an air duct for a ventilation device can be joined to the carrier; in particular, both the firing channel for the airbag as the first component and the air duct for the ventilation device as the second component can be joined to the carrier. Because both the press lamination and the joining are carried out using the tool device, the workpiece can be manufactured using very few tools, in this case only the tool device. In the method, it is provided that the press lamination and the joining take place simultaneously or one after the other with a particularly short time interval. As a result, heat required for the press lamination and for the joining can be introduced simultaneously into the laminating element or the carrier or the at least one component. In the method, it is particularly provided that the at least one component is joined to the carrier while an adhesive applied to the carrier and/or the laminating element, in particular the hot melt, has not yet cooled down or has only cooled down insignificantly. This means that the adhesive cannot melt at all, as it has neither cooled down nor reacted. The process means that it is not necessary for the adhesive between the carrier and the laminating element to have reacted sufficiently for further processing before joining, in particular welding. This means that buffers for temporarily storing the press-laminated carrier while the adhesive hardens in a production plant are no longer required. This means that the production plant can be provided in a particularly space-efficient manner, as only the tool device is required for both joining and press-laminating, and no buffer areas are required for temporarily storing the press-laminated carrier before joining.

The covering element can in particular comprise a decoration and a spacer fabric, which is arranged in the finished workpiece on a side of the decoration facing the carrier. The spacer fabric is designed to maintain a predetermined distance between the decoration and the carrier in the workpiece. The spacer fabric is therefore a spacer. The spacer fabric can in particular comprise a textile and/or a foam.

In a possible development of the invention, it is provided that the at least one component is joined to the carrier by means of infrared welding and/or by means of heating element welding and/or by means of ultrasonic welding and/or by means of laser welding and/or by means of thermal riveting and/or by means of ultrasonic riveting and/or by means of mechanical riveting and/or by means of gluing. In infrared welding, the component and the carrier are welded together using infrared radiation. Part of the infrared radiation is absorbed by the carrier and/or the component and converted into heat. As a result, a surface layer of the component or the carrier is melted and the component and the carrier can be joined together by pressing them together. In heating element welding, the joining surfaces of the carrier and the component are heated using a heating element by contact or radiant heat and then joined under pressure. In ultrasonic welding, the heat required for plasticizing is generated by converting ultrasonic vibrations into mechanical vibrations and is fed to the carrier and/or the component with a certain contact pressure via a sonotrode. The mechanical vibrations that impact on the carrier or component are absorbed and reflected at an interface. The resulting interface and molecular friction generates heat, which causes the carrier or component to melt. Laser welding is a welding process in which energy is supplied via a laser beam. In laser welding, laser radiation is focused using optics and directed at the carrier and/or component. By absorbing the laser power of the laser radiation, the temperature on a surface of the carrier or component increases extremely quickly, so that a melt forms.

Riveting is a manufacturing process from the group of joining by forming, which involves the production of a riveted connection. During riveting, the rivet is plastically formed at a connection hole. A rivet usually has a prefabricated setting head at one end. At the other end, a closing head can be made using various riveting tools to close a riveted connection. Thermal riveting includes hot stamping riveting and hot air riveting. In hot stamping riveting, a heating stamp heats a rivet pin and forms a rivet head under pressure in the same process step. Hot air riveting works contactlessly in a warm-up phase. A continuously circulating hot air stream heats a rivet pin. Here, the rivet head is formed using a cold stamp. In ultrasonic riveting, the sonotrode serves as a forming tool and determines the shape of a rivet pin via its shape. During a holding time, in particular a cooling phase, the sonotrode also serves as a holding stamp, which causes the plasticized material to cool under pressure. The main The difference between ultrasonic welding and ultrasonic riveting is that with ultrasonic riveting, melting deformation takes place and only one of the two joining partners is plasticized. Mechanical riveting is a cold forming process.

Bonding is a material-locking joining process. During bonding, at least one component and the carrier are connected to one another using an adhesive. An adhesive is a non-metallic substance that is able to bond materials through surface adhesion and thus adhesion and its internal strength, which is cohesion. Adhesive is therefore a process material that is used in bonding to bond different materials.

A conventional press laminating process with warm tool parts can be implemented as press laminating. Alternatively, at least one of the tool parts can first be heated to melt the heat-activated adhesive and then cooled down for cold demolding of the press-laminated carrier. It is possible to arrange a heating field between the carrier and the laminating element to heat the adhesive, which can heat the gap between the carrier and the laminating element. In particular, this heats the adhesive that connects the carrier to the laminating element. A fine cut can be used as a laminating element for press laminating. An LCA press laminating process can also be implemented, where LCA stands for Low Cost Automation. The LCA press laminating process is a cost-optimized press laminating process without the use of slide technology. This means that the laminating element is not folded over around the respective edges of the carrier. A fully automatic press lamination process can be used, in which an automatic adhesive application and automatic press lamination takes place.

This process therefore allows for a particularly wide range of combinations of the respective press lamination processes with the respective joining processes.

In a possible development of the invention, it is provided that the carrier is positioned between the at least one component and the laminating element by means of a support frame. This means that the carrier is arranged between the first tool part and the second tool part by means of the support frame in order to bring the at least one component to be joined to the carrier, the carrier and the laminating element into overlap with one another in a closing direction in which the first tool part and the second tool part are moved towards one another when the tool device is closed. The support frame thus enables the carrier to be aligned particularly precisely relative to the laminating element and the at least one component, in particular before press laminating and before joining.

In this context, it can be provided in particular that the carrier is joined to the at least one component while the carrier is held on the support frame. The support frame is then removed from the carrier and the tool device is then closed in order to press-laminate the carrier to the laminating element. In other words, before the tool device is completely closed, the support frame is removed from a volume, which is also referred to below as the closing volume, which is passed over by the tool parts in the closing direction when the tool device is closed. This can prevent a collision of the support frame with the tool parts of the tool device when the tool device is closed. To join the carrier to the at least one component, the second tool part is moved towards the support frame until the at least one component rests on the carrier, in particular is pressed against the carrier in order to be joined to the carrier. The support frame thus holds the carrier firmly in a predetermined alignment with the at least one component during joining, whereby the at least one component can be joined to the carrier particularly precisely at a predetermined relative position. As soon as the carrier is joined to the at least one component, the carrier can also be held on the second tool part via the at least one component inserted into the second tool part of the tool device, so that the support frame for holding the carrier is no longer required. After the support frame has been moved out of the closing volume delimited by the tool parts upwards and downwards in the closing direction, the tool device is closed for press lamination by moving the first tool part, on which the lamination element is held, and the second tool part, on which the at least one component and the carrier are held, towards each other, in particular by placing them against each other. The support frame thus enables a particularly precise alignment of the carrier with the lamination element and the at least one component, whereby the workpiece can be manufactured particularly precisely.

It is provided that at least one heating field is arranged between the carrier and the laminating element and/or between the carrier and the at least one component. At least part of the heat required for press laminating or joining is provided by means of this heating field. In particular, the tool device can comprise two heating fields, one of the heating fields being arranged between the carrier and the at least one component and the other of the heating fields being arranged between the carrier and the laminating element. At least part of the heat required for joining can be provided by means of the heating field arranged between the carrier and the at least one component, while at least part of the heat required for press laminating is provided by means of the further heating field arranged between the carrier and the laminating element. The heating fields can be moved particularly close to respective surface areas of the laminating element or the carrier or the at least one component that are to be heated for press laminating or joining, whereby the heating of these components to be connected to the workpiece can be controlled particularly precisely. In particular, the respective heating field enables particularly uniform, flat heating of the respective component, in particular of the respective surface of the component of the workpiece to be heated. If only a single heating field is provided, this can be arranged one after the other between the carrier and the laminating element and between the carrier and the at least one component.

In this context, it is particularly provided that the at least one heating field is moved from a heating position to a stowage position before the tool device is closed. In the heating position, the heating field is arranged between the tool parts and provides at least part of the heat required for press-laminating or joining. This means that in the heating position, the at least one heating field is arranged in the closing volume through which the tool parts pass when the tool device is closed. In the stowage position, the heating field is arranged outside the closing volume, whereby a collision of the heating field with the tool parts can be avoided. This means that the at least one heating field is moved out of the closing volume before the tool device is closed by moving the tool parts towards one another. For example, the at least one heating field can be pivoted or moved between the heating position and the stowage position. The at least one heating field thus enables particularly precise heating of the respective components of the workpiece to be joined or press-laminated and, on the other hand, a particularly low risk of collision with the respective tool parts of the tool device when the tool device is closed.

In a further possible embodiment of the invention, it can be provided that a welding heating field is arranged between the carrier and the at least one component, by means of which the carrier and/or the at least one component are plasticized at least in some areas for welding. This means that sufficient heat is introduced into the carrier and the at least one component by means of the welding heating field in order to enable the at least one component to be welded to the carrier. Plasticizing refers to a transition of a material from a solid to a deformable or flowable state, which facilitates or enables further processing. The welding heating field thus enables particularly simple welding of the carrier to the at least one component.

In a further possible embodiment of the invention, a laminating heating field is arranged between the carrier and the laminating element, by means of which an adhesive applied to the carrier and/or an adhesive applied to the laminating element is heated for press laminating. This adhesive is a heat-activated adhesive or contact adhesive. In particular, the adhesive is a so-called hot melt. The hot melt can also be referred to as a hot melt adhesive. The hot melt is solvent-free or water-free and, when hot, is a viscous liquid that can be applied to an adhesive surface. The laminating heating field enables the adhesive applied to the laminating element and/or the carrier to be heated directly. This means that very little time is required to heat the adhesive. As a result, particularly short process times can be implemented for producing the workpiece. The rapid heating of the adhesive also means that very little energy is required to heat the adhesive. Alternatively or in addition to the laminating heating element, the adhesive can be heated using the lower tool. However, the heat provided by the lower tool must first penetrate the laminating element before it reaches the adhesive. As a result, heating the adhesive using the lower tool takes longer than using the laminating heating field.

In a further possible embodiment of the invention, it is provided that the laminating element is inserted into the first tool part, the at least one component is inserted into the second tool part and the carrier is positioned between the tool parts by means of the support frame. This means that before carrying out the press laminating process and before carrying out the joining process, both the laminating element and the carrier and the at least one component are placed in the tool device. The welding heating field is then arranged between the support frame and the second tool part and the laminating heating field is arranged between the first tool part and the support frame. It is provided that the carrier and/or the at least one component are plasticized for welding at least in some areas by means of the welding heating field and an adhesive applied to the carrier and/or an adhesive applied to the laminating element is heated for press laminating by means of the laminating heating field. The heat required for welding can thus be introduced into the carrier and the at least one component at least essentially simultaneously using the welding heating field, and the heat required for press lamination can be introduced into the lamination element and the carrier. Heating for joining and press lamination can thus be carried out in a particularly time-efficient and energy-efficient manner using the two heating fields, since the heating fields support each other in the heat input.

In this embodiment of the method, it is further provided that both heating fields are then arranged outside the closing volume through which the tool parts move when the tool device is closed. This means that the heating fields are moved out of the closing volume limited at the top and bottom by the tool parts. The carrier is then placed on the laminating element and the support frame is arranged outside the closing volume. This means that the support frame is moved out of the closing volume limited at the top and bottom by the tool parts. The tool device is then closed, whereby the carrier is simultaneously press-laminated to the laminating element and the carrier is welded to the at least one component. The method thus enables both the press-laminating and the welding to be carried out as a joining process using the tool device, and also that both the press-laminating and the welding are carried out at least essentially simultaneously by closing the tool device. The workpiece can thus be manufactured particularly quickly.

In an alternative possible embodiment of the invention, it is provided that the at least one component is placed in the second tool part and the carrier is positioned between the tool parts by means of the support frame. The welding heating field is then arranged between the support frame and the second tool part, the carrier and/or the at least one component is plasticized for welding at least in some areas by means of the welding heating field and the welding heating field is then arranged outside the closing volume through which the tool part moves when the tool device is closed. This means that in the method, the welding heating field is moved between the carrier and the at least one component in order to plasticize the carrier and/or the at least one component at least in some areas. After the heat required for welding has been introduced into the carrier and/or into the at least one component, the welding heating field is moved out of the closing volume, whereby no further component is arranged between the at least one component and the carrier in the closing direction of the tool device. Thereafter, the second tool part and the support frame are moved towards each other, whereby the carrier is welded to the at least one component.

Moving towards each other is to be understood as a relative movement in which the first tool part and/or the second tool part or the second tool part and/or the support frame can be moved and thus their position can be changed. In the method, it is particularly provided that the second tool part and the support frame are placed against each other, whereby the at least one component is pressed against the carrier and thereby welded to the carrier. The support frame is then arranged outside the closing volume. Since the carrier is now welded to the at least one component and the at least one component is held on the second tool part, the carrier is held at least indirectly via the at least one component on the second tool part. The support frame is therefore no longer required to hold the carrier. As a result, the support frame is moved out of the closing volume in order to avoid a collision of the support frame with the tool parts. The laminating element is then inserted into the first tool part. The laminating heating field is then arranged between the first tool part and the second tool part, with By means of the laminating heating field, an adhesive applied to the carrier and/or an adhesive applied to the laminating element, in particular the hot melt, is heated for press laminating. After the adhesive has been heated, the laminating heating field is arranged outside the closing volume. This means that when the adhesive applied to the carrier and/or the laminating element, in particular the hot melt, has been heated sufficiently for press laminating by means of the laminating heating field, the laminating heating field is moved out of the closing volume in order to prevent the laminating heating field from colliding with the tool parts. The tool device is then closed and the laminating element is pressed onto the carrier, whereby the carrier is press-laminated to the laminating element.

This method means that not all components of the workpiece have to be arranged in the tool device before both the joining process and the press-laminating process. Instead, the lamination element can be inserted into the first tool part during the welding process or after the welding process. By splitting the welding process and the press-laminating process, the second tool part can be pressed together with the support frame for as long as is particularly advantageous for the welding process. For press-laminating, the tool device can in turn be closed for as long as is particularly advantageous for the press-laminating process. The respective process parameters, in particular holding times, of the second tool part on the support frame or of the second tool part on the first tool part can thus be adapted particularly well to the welding process or the lamination process.

In a further alternative embodiment of the invention, it is provided that the laminating element is inserted into the first tool part, the at least one component is inserted into the second tool part and the carrier is positioned between the tool parts by means of the support frame. This means that all components that are needed for producing the workpiece are arranged in the tool device before the joining process, in particular a welding process, and before the press laminating process. In this method, it is also provided that the welding heating field is then arranged between the support frame and the second tool part, the carrier and/or the at least one component are at least partially plasticized for welding by means of the welding heating field and the welding heating field is then arranged outside the closing volume. This means that in order to weld the carrier to the at least one component, the welding heating field is moved into the closing volume, which is delimited by the tool parts upwards and downwards in the closing direction and through which at least one of the tool parts moves when the tool device is closed. After the at least partial plasticization of the carrier or of the at least one component, the welding heating field is moved out of the closing volume again. The second tool part and the support frame are then moved towards each other, whereby the carrier is welded to the at least one component. In particular, by moving the second tool part and the support frame towards each other, the carrier is pressed against the at least one component, whereby respective plasticized areas of the carrier or of the at least one component form a welded connection with each other. After the carrier has been welded to the at least one component, the support frame is arranged outside the closing volume.

After the support frame has been moved out of the closing volume, the laminating heating field is arranged between the first tool part and the second tool part, an adhesive applied to the carrier and/or an adhesive applied to the laminating element, in particular the hot melt, is heated for the press laminating by means of the laminating heating field and the laminating heating field is arranged outside the closing volume through which the tool parts move when the tool device is closed. This means that in order to heat the adhesive applied to the carrier and/or the laminating element, in particular the hot melt, the laminating heating field is arranged between the carrier and the laminating element and the adhesive is heated by means of the laminating heating element. After the adhesive has been heated to at least a temperature sufficient for the press laminating, the laminating heating field is moved out of the closing volume in order to avoid a collision of the laminating heating field with the tool parts when the tool device is closed. After the laminating heating field has been moved out of the closing volume, the tool device is closed, whereby the carrier is press-laminated with the laminating element. In this process, it is therefore intended that all components for the workpiece are placed in the tool device before the welding process and before the press-laminating process. The welding process takes place before the press-laminating process, which prevents the hot melt from remelting. because the welding process has already taken place before press lamination.

In a further possible embodiment of the invention, it is provided that the heat is provided by means of at least one infrared radiator of the heating field. This means that the respective heating field has at least one infrared radiator which is designed to provide infrared radiation and to heat at least one component of the workpiece using this infrared radiation. The respective areas of the respective component for the workpiece that are to be heated can be heated particularly precisely using the infrared radiation. Unnecessary large-scale heating of the respective component can thus be avoided, whereby the risk of damage to the respective component and the energy requirement for heating this component can be kept particularly low.

In a further possible embodiment of the invention, it is provided that an adhesive for gluing the at least one component is applied to the second side of the carrier as part of an adhesive process as a joining process using a robot device of the tool device. This means that the carrier is placed in the tool device, in particular placed on the laminating element, and then the adhesive is applied to the side of the carrier facing the at least one component to be glued to the carrier using the robot device. The robot device is a technical apparatus that serves to perform frequently recurring mechanical work. The robot device, which is in particular part of the tool device, is in particular a stationary machine that is controlled by a computer program. In particular, the robot device is an industrial robot. The robot device can be designed as a so-called gantry robot or as an articulated arm robot with at least one movable robot arm. If the robot device is designed as a gantry robot, the robot device can comprise a processing head and a linear gantry over which the processing head can be moved. The linear portal comprises in particular a portal carriage for horizontal movement on a main axis and a portal arm for vertical movement of the processing head. The processing head is designed to apply the adhesive to the carrier. The linear portal is a portal frame. As an alternative to the design of the robot device as a portal robot with up to three linear axes and possibly a rotation axis directly on the processing head, the robot device can be designed as an articulated arm robot. In this case, the processing head can be moved by a robot arm, which is in particular designed to be multi-axis. The robot device enables particularly precise and fast automated application of the adhesive to the carrier.

In this context, it can be provided in particular that for the application of the adhesive, a frame carrying the robot device, in particular the portal frame, is arranged between the tool parts and that the robot device with the frame is arranged outside the closing volume after the application of the adhesive, which is passed through by the tool parts when the tool device is closed, whereby a collision of the frame with the tool parts can be avoided. In other words, for the application of the adhesive to the carrier, the robot device is moved out of the closing volume together with the portal frame so that when the tool device is closed, no collision occurs between the robot device, in particular the frame, and the tool parts of the tool device. If the robot device is designed as a portal robot, the frame is part of the robot device. If the robot device is designed as an articulated arm robot, the frame can be designed separately from the robot device.

After the adhesive has been applied and both the robot device and the frame have been moved out of the closing volume, the tool device is closed, with the carrier being glued to the at least one component and the laminating element being press-laminated to the carrier at the same time. By closing the tool device, the at least one component held by the second tool part is pressed against the carrier and the carrier is in turn pressed against the laminating element held by the first tool part. In this method, the joining in the form of the gluing process and the press-laminating take place at least essentially simultaneously. The workpiece can therefore be produced particularly quickly using the tool device.

The invention further relates to a tool device with a first tool part, into which a laminating element to be fastened to a carrier can be inserted, and a second tool part, into which at least one component to be fastened to the carrier can be inserted. The tool device can be closed by moving the first tool part and the second tool part towards each other, whereby the laminating element is press-laminated to the carrier. The tool device is further designed to carry out a joining process in which the at least one component is joined to the carrier. The tool device is designed to carry out a method according to claim 13.

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 ein Verfahrensschema für ein Verfahren zum Herstellen eines Werkstücks in einer ersten Ausführungsform;
• 2 ein Verfahrensschema für das Verfahren in einer zweiten Ausführungsform; und
• 3 ein Verfahrensschema für das Verfahren in einer dritten Ausführungsform.

The drawing shows in:

• 1 a process diagram for a method for producing a workpiece in a first embodiment;
• 2 a process diagram for the process in a second embodiment; and
• 3 a process scheme for the process in a third embodiment.

In the figures, elements with the same functions are assigned the same reference symbols.

In the 1 to 3 Process diagrams of respective processes for producing a workpiece, in this case an instrument panel for a motor vehicle, are shown. Each of these processes has in common that a laminating element 14 is press-laminated to a carrier 12 for the instrument panel by means of a single tool device 10 and at least one component 16 is joined. In the processes shown in the 1 and 2 In the process diagrams shown, it is provided that the at least one component 16 is welded to the carrier 12, whereas in the process in 3 it is provided that at least one component 16 is glued to the carrier 12. In the present case, two components 16 are joined to the carrier 12. One of the components 16 is an airbag firing channel 18 and the other component 16 is an air channel 20 for a ventilation device of the motor vehicle.

The at least one component 16 can be joined to the carrier 12 by means of infrared welding and/or by means of heating element welding and/or by means of ultrasonic welding and/or by means of laser welding and/or by means of thermal riveting and/or by means of ultrasonic riveting and/or by means of mechanical riveting and/or by means of gluing. It is provided that the laminating element 14 is press-laminated to the carrier 12 by means of the tool device 10. Different press-laminating methods for press-laminating the laminating element 14 to the carrier 12 are possible here.

In the present case, the covering element 14 is designed as a decoration with a spacer fabric, wherein the spacer fabric is arranged on a side of the decoration facing the carrier 12. The decoration can be a leather, in which a haptic layer is arranged as a spacer fabric on the side facing the carrier 12. The covering element 14 is inserted into the first tool part 26 with a visible side facing the first tool part 26.

For press lamination, an adhesive, in particular a hot melt, is applied to the side of the laminating element 14 facing the carrier 12 and/or to the first side 22 of the carrier 12 facing the laminating element 14. For press lamination, this adhesive is heated and then the laminating element 14 and the carrier 12 are placed against each other and pressed against each other. After the adhesive has hardened sufficiently for further processing, in particular by reacting, the laminating element 14 press-laminated to the carrier 12 is held particularly securely to the carrier 12.

In the respective method, it is provided that the laminating element 14 is press-laminated to the carrier 12 on a first side 22 of the carrier 12 and the at least one component 16 is joined to the carrier 12 on a second side 24 opposite the first side 22. In each of the methods shown in the figures, it is provided that the laminating element 14 is inserted into a first tool part 26 of the tool device 10, in this case a lower tool, and the components 16 are inserted into a second tool part 28 of the tool device 10, in this case an upper tool. In an alternative embodiment not shown in the figures, the upper tool can be the first tool part and the lower tool can be the second tool part.

Press-laminating the lamination element 14 to the carrier 12 takes place by closing the tool device 10. To close the tool device 10, a distance between the first tool part 26 and the second tool part 28 is reduced, in particular until the first tool part 26 and the second tool part 28 abut one another. In this case, at least one of the tool parts 26, 28 has a closing volume 30, the closing volume 30 extending from the first tool part 26 to the second tool part 28 in an open state of the tool device 10. To close the tool device 10, at least one of the tool parts 26, 28 is moved in a closing direction 32 towards the other of the tool parts 28, 26. The closing volume 30 is delimited by the tool parts 26, 28 in the closing direction 32 upwards and downwards. The closing volume 30 is the entire space that is delimited by the tool parts 26, 28 in the closing direction 32 upwards and downwards in the open state of the tool device 10.

As in the 1 and 2 can be recognized, the tool device 10 can comprise respective heating fields 34, which are designed to introduce the heat required for the press lamination and/or the joining, in particular at least a part thereof, into the respective components to be connected to the workpiece. For heating the components, the respective heating fields 34 can have respective infrared radiators 36, which are designed to emit heat radiation. For reasons of clarity, only some of the infrared radiators 36 are provided with the associated reference numerals.

The following describes the procedure for the 1 shown process diagram. In this method, it is provided that the laminating element 14 is inserted into the first tool part 26, the carrier 12 is placed on the laminating element 14 and the components 16 are inserted into the second tool part 28. Alternatively, in this method, the laminating element 14 is pre-fixed to the carrier 12 and is inserted together with the carrier 12 into the first tool part 26, and the components 16 are inserted into the second tool part 28. The pre-fixing of the laminating element 14 to the carrier 12 takes place in an upstream process in which the laminating element 14 is positioned on the carrier 12 with spot-by-spot adhesion, i.e. with adhesive activation. The heating field 34 is then arranged in the closing volume 30 between the first tool part 26 and the second tool part 28. In other words, the heating field 34 is arranged between the components 16 and the carrier 12. The heating field 34 is used to heat the components 16 and the carrier 12 and, if necessary, also the laminating element 14 or the adhesive arranged between the laminating element 14 and the carrier 12 and intended for press laminating. In particular, the carrier 12 and/or the components 16 are plasticized at least in some areas by means of the heating field 34. After the heat has been introduced into at least one of the components for the workpiece by means of the heating field 34, the heating field 34 is moved out of the closing volume 30. This means that the heating field 34 is moved from a heating position, in which the heating field 34 is arranged between the tool parts 26, 28 and introduces the heat into the at least one component for the workpiece and thus provides at least part of the heat required for press-laminating and/or joining, to a stowed position in which the heating field 34 is arranged outside the closing volume 30. After the heating field 34 has been moved out of the closing volume 30, the tool device 10 is closed by moving the second tool part 28 in the closing direction 32 towards the first tool part 26, in particular until the second tool part 28 rests against the first tool part 26, whereby the components 16 are pressed against the carrier 12 and the carrier 12 is pressed against the laminating element 14. By closing the tool device 10, both the joining, in this case the welding, of the components 16 to the carrier 12 and the press-laminating of the carrier 12 to the laminating element 14 are carried out.

In the 1 In the method shown, it is therefore provided that the components for the workpiece are inserted into the tool device 10 in a first method step 1a. In this case, the carrier 12 can be pre-fixed to the laminating element 14 and/or to the first tool part 26. In a second method step 2a, the heating field 34 is moved into the closing volume 30. A welding area of the components 16 and/or the carrier 12 is plasticized by means of the heating field 34. In addition, supporting heat is introduced into a laminating joint between the laminating element 14 and the carrier 12 by means of the heating field 34. In a third method step 3a, the heating field 34 is moved out of the closing volume 30. In a fourth method step 4a, a joining process and a press-laminating process are carried out simultaneously by closing the tool device 10. It is provided that the laminating element 14 is press-laminated to the carrier 12 in a conventional press-laminating process with warm tool parts 26, 28. Alternatively, at least one of the tool parts 26, 28 can first be heated to melt the adhesive and then cooled for cold demolding of the press-laminated carrier 12. The adhesive arranged between the carrier 12 and the laminating element 14 can be heated by means of the first tool part 26.

In the 2 In the process diagram shown, it is intended that the components to be connected to the workpiece are inserted into the tool device 10. This means that the laminating element 14 is inserted into the first Tool part 26 is inserted, the components 16 are inserted into the second tool part 28 and the carrier 12 is positioned in the tool device 10 between the laminating element 14 and the components 16. For positioning the carrier 12 in the 2 In the method shown, a support frame 38 is provided. The support frame 38 is designed to position the carrier 12 between the tool parts 26, 28. To position the carrier 12 between the tool parts 26, 28, the support frame 38 is arranged in the closing volume 30. The method also provides for two heating fields 34, in this case a welding heating field 40 and a laminating heating field 42, to be arranged between the tool parts 26, 28 in the closing volume 30. The carrier 12 and the components 16 are plasticized at least in some areas for welding by means of the welding heating field 40. The adhesive applied to the carrier 12 and/or the laminating element 14 is heated for the press laminating by means of the laminating heating field 42. Both heating fields 34 are then removed from the closing volume 30. The carrier 12 is then placed on the laminating element 14 and the support frame 38 is moved out of the closing volume 30. The tool device 10 is then closed, whereby the carrier 12 is simultaneously press-laminated to the laminating element 14 and the carrier 12 is welded to the components 16.

In the 2 In the method shown, it is therefore provided that the components, in this case the laminating element 14, which is the decoration with the spacer fabric, the carrier 12, to which the adhesive for the press laminating is applied and which is a base body for the instrument panel, and the components 16 designed as welded parts to be joined to the carrier 12, are inserted into the tool device 10 in a first method step 1b. In a second method step 2b, the heating fields 34 are moved into the closing volume 30. As a result, the welding areas of the carrier 12 and/or the components 16 are plasticized and the adhesive, in particular the hot melt, or the carrier 12 is heated for the press laminating. In a third method step 3b, the heating fields 34 are moved out of the closing volume 30. In a fourth method step 4b, the carrier 12 is connected to the laminating element 14 and the support frame 38 is removed from the closing volume 30. In a fifth method step 5b, the tool device 10 is closed and the press laminating process and the welding process take place simultaneously. In this method, a so-called heating into the joint takes place by means of the laminating heating field 42.

In a first variant of this method, it can be provided that the components 16 are placed in the second tool part 28 and the carrier 12 is positioned between the tool parts 26, 28 by means of the support frame 38. The carrier 12 and the components 16 designed as welded parts are thus placed in the tool device 10. The welding heating field 40 is then arranged between the support frame 38 and the second tool part 28, the carrier 12 and/or the components 16 are plasticized for welding at least in some areas by means of the welding heating field 40 and the welding heating field 40 is then arranged outside the closing volume 30. In other words, the welding heating field 40 is moved into the closing volume 30 and the components 16 and/or the carrier 12 are plasticized in some areas.

The second tool part 28 and the support frame 38 are then moved towards each other, whereby the carrier 12 is welded to the components 16 as part of a welding process. The support frame 38 is then moved out of the closing volume 30. The laminating element 14 can be inserted into the first tool part 26 parallel to the welding process. The carrier 12 welded to the components 16 can move into a laminating position. For this purpose, the second tool part 28 can be moved towards the first tool part 26 in the closing direction 32. If the second tool part 28 is not arranged so as to overlap the first tool part 26 in the closing direction 32 and is therefore arranged laterally offset next to the first tool part 26 during the welding process, then the second tool part 28 is adjusted, in particular pivoted, in order to approach the laminating position in such a way that the second tool part 28 is brought into overlap with the first tool part 26 in the closing direction 32. In other words, it can be provided that at least one of the tool parts 26, 28 is arranged on a sliding table or on a rotary table. This enables the tool parts 26, 28 to be adjusted between the laminating position arranged one above the other and a pivoting position arranged next to one another, in particular offset in height. This enables the first tool part 26 to be arranged pivoted out to the side while the second tool part 28 is enclosed with a protective curtain during the welding process, whereby the first tool part 26 is arranged laterally next to the protective curtain. Thus, the laminating element 14 can be inserted into the first tool part 26 particularly easily and safely during the welding process. During the welding process, the tool parts are arranged in the pivoting position. After the welding process has been completed, the work tool parts 26, 28 are again arranged one above the other and thus in the laminating position so that the tool device 10 for press laminating can be closed in the closing direction 32.

The laminating heating field 42 is then arranged between the first tool part 26 and the second tool part 28, the adhesive applied to the carrier 12 and/or the laminating element 14 is heated for the press laminating by means of the laminating heating field 42 and the laminating heating field 42 is then moved out of the closing volume 30. The carrier 12 or the adhesive is thus heated by means of the laminating heating field 42. After the laminating heating field 42 has been moved out of the closing volume 30, the tool device 10 is closed, whereby the carrier 12 is press-laminated with the laminating element 14. Parallel to this laminating process, respective components 16 for another workpiece to be manufactured can be prepared for insertion into the tool device 10.

In a second variant of this method, it is provided that all components to be joined together to form the workpiece are initially inserted into the tool device 10. This means that the laminating element 14 is inserted into the first tool part 26, the components 16 are inserted into the second tool part 28 and the carrier 12 is positioned between the tool parts 26, 28 by means of the support frame 38. The welding heating field 40 is then arranged between the support frame 38 and the second tool part 28, the carrier 12 and/or the components 16 are plasticized for welding at least in some areas by means of the welding heating field 40 and the welding heating field 40 is then moved out of the closing volume 30. This means that the welding heating field 40 is moved into the closing volume 30 and the components 16 and/or the carrier 12 are plasticized at least in some areas by means of the welding heating field 40. The welding process then takes place in that the second tool part 28 and the support frame 38 are moved towards one another, whereby the carrier 12 is welded to the components 16. After the welding process, the support frame 38 is moved out of the closing volume 30. The carrier 12 with the welded components 16 can then be moved into a heating position. The carrier 12 can be moved by the second tool part 28 together with the components 16 into the heating position. The laminating heating field 42 is then arranged between the first tool part 26 and the second tool part 28, the adhesive applied to the carrier 12 and/or the laminating element 14 is heated for the press laminating by means of the laminating heating field 42 and the laminating heating field 42 is then moved out of the closing volume 30. The carrier 12 or the adhesive is thus heated. The laminating process then takes place in which the tool device 10 is closed, whereby the carrier 12 is press-laminated to the laminating element 14.

In 3 The process diagram shows a process in which the components 16 are glued to the carrier 12. In order to be able to glue the components 16 to the carrier 12, it is provided that an adhesive is applied to the second side 24 of the carrier 12 by means of a robot device 44. In the present case, the robot device 44 is designed as a gantry robot, in which a processing head 46 of the robot device 44 can be moved along a portal 48. The adhesive is applied to the second side 24 of the carrier 12 by means of the processing head 46. The portal 48 is a frame of the robot device 44, by means of which the processing head 46 is guided. In this process, it is therefore provided that in a first process step 1c the components to be connected to one another to form the workpiece are inserted into the tool device 10. This means that the components 16 are inserted into the second tool part 28, wherein the laminating element 14 is inserted into the first tool part 26 and is pre-fixed to the carrier 12. Alternatively, it is possible for the laminating element 14 to be arranged on the first tool part 26 and then the carrier 12 to be placed on the laminating element 14. If necessary, the laminating element 14 can be held in its position relative to the first tool part 26, in particular the lower tool, via pins and thus positioned on the first tool part 26. The robot device 44 is then moved into the closing volume 30 and the adhesive, in particular a structural adhesive, is applied to the second side 24 of the carrier 12 by means of the processing head 46 in a second method step V2c.

In a third step 3c of the method, it is provided that the robot device 44 is moved out of the closing volume 30. The tool device 10 is then closed, whereby the components 16 are simultaneously glued to the carrier 12 as part of the joining process and the carrier 12 is press-laminated to the laminating element 14. As variants of this method, the carrier 12 can be inserted into the upper tool and/or a spacer can be provided for an adhesive joint to be maintained between the carrier 12 and the components 16. As a further variant, the adhesive can be applied by means of a bending device. The workpiece can be applied to the carrier 12 by a robot device 44 designed as a articulated arm robot or comprising the articulated arm robot.

In the respective processes, it is intended that the press lamination process and the joining process are carried out at least essentially simultaneously or that the joining process is carried out shortly before the press lamination process.

The described method, in its various embodiments, makes it possible to dispense with the provision of buffer areas and thus intermediate storage areas for intermediate storage of semi-finished products between press lamination and welding. Furthermore, particularly short processing times can be achieved, since it is not necessary to wait after press lamination until the laminating adhesive has reacted sufficiently for further processing before the other components 16 can be joined to the carrier 12. Instead, respective buffer times for the hot melt to react sufficiently for further processing before the welding process are dispensed with and no independent or separate process is necessary for press lamination and for joining. In the method, two processes, in this case joining and press lamination, are combined in one. These processes are carried out in the tool device 10 and thus in a single system. Reduced parts handling can thus be achieved.

The method enables existing inventories in a production plant to be kept particularly low, since the workpiece can be manufactured particularly quickly. The method enables particularly simple and quick product tests with regard to weld strength and laminate adhesion on the same component, since there is no longer a long wait between press laminating and joining. The method also enables systems and tools to be saved, since half of the systems and tools currently required per project are eliminated, since the joining process and the press laminating process can be carried out together using the tool device 10. The method also enables an area to be saved, in particular a buffer area and a production area. The method also enables energy to be saved for heating and cooling, since only half as many systems need to be operated. In addition, production minutes and machine minutes can be saved, particularly since heating and cooling processes run in parallel and only half as many systems need to be operated. Furthermore, particularly few employees are required for logistics and production. Synergy effects can be used during cooling by running the cooling process of the press lamination process and the joining process in parallel, which allows a particularly fast and good cooling result to be achieved. If the welding process were to be carried out separately from the press lamination process and after the press lamination process, a release problem could arise if the welding process were to be carried out when the hot melt has not yet reacted sufficiently for further processing. The processes described in connection with the figures enable a particularly good elimination of this release problem.

Overall, the invention shows how combined press lamination and joining can be carried out.

LIST OF REFERENCE SYMBOLS

10

Tool device

12

carrier

14

Laminating element

16

Component

18

Airbag firing channel

20

Air duct

22

first page

24

second page

26

first tool part

28

second tool part

30

Closing volume

32

Closing direction

34

Heating field

36

Infrared heaters

38

Support frame

40

Welding heating field

42

Laminating heating field

44

Robot facility

46

Processing head

48

portal

Claims (14)

Method for producing a workpiece, in which a laminating element is press-laminated to a carrier (12) on a first side (22) by means of a single tool device (10) and at least one component (16) is joined to the carrier (12) on a second side (24) opposite the first side (22), whereby the work piece is produced, wherein the laminating element (14) is inserted into a first tool part (26) and the at least one component (16) is inserted into a second tool part (28) of the tool device (10) and the press laminating is carried out by closing the tool device (10), wherein at least one heating field (34) is arranged between the carrier (12) and the laminating element (14) and/or between the carrier (12) and the at least one component (16), and by means of this heating field (34) at least part of the heat required for the press laminating or the joining is provided. Procedure according to Claim 1 , characterized in that the at least one component (16) is joined to the carrier (12) by means of at least one of the following methods: - infrared welding - heated element welding - ultrasonic welding - laser welding - thermal riveting - ultrasonic riveting - mechanical riveting - gluing. Method according to one of the preceding claims, characterized in that the carrier (12) is positioned between the at least one component (16) and the laminating element (14) by means of a support frame (38). Procedure according to Claim 3 , characterized in that the carrier (12) is joined to the at least one component (16) while the carrier (12) is held on the support frame (38), then the support frame (38) is removed from the carrier (12) and then the tool device (10) is closed in order to press-laminate the carrier (12) to the laminating element (14). Method according to one of the preceding claims, characterized in that the at least one heating field (34) is adjusted before closing the tool device (10) from a heating position in which the heating field (34) is arranged between the tool parts (26, 28) and provides at least part of the heat required for press-laminating or joining, into a stowage position in which the heating field (34) is arranged outside a volume through which the tool parts (26, 28) move when closing the tool device (10), whereby a collision of the heating field (34) with the tool parts (26, 28) can be avoided. Method according to one of the preceding claims, characterized in that a welding heating field (40) is arranged between the carrier (12) and the at least one component (16) as a heating field (34), by means of which the carrier (12) and/or the at least one component (16) is plasticized at least in regions for welding. Method according to one of the preceding claims, characterized in that a laminating heating field (42) is arranged between the carrier (12) and the laminating element (14) as a heating field (34), by means of which an adhesive applied to the carrier (12) and/or an adhesive applied to the laminating element (14) is heated for the press laminating. Procedure according to Claim 4 , 6 and 7 , characterized in that - the laminating element (14) is inserted into the first tool part (26), the at least one component (16) is inserted into the second tool part (28), and the carrier (12) is positioned between the tool parts (26, 28) by means of the support frame (38), - then the welding heating field (40) is arranged between the support frame (38) and the second tool part (28) and the laminating heating field (42) is arranged between the first tool part (26) and the support frame (38), by means of the welding heating field (40) the carrier (12) and/or the at least one component (16) are plasticized at least in some areas for welding and by means of the laminating heating field (42) an adhesive applied to the carrier (12) and/or an adhesive applied to the laminating element (14) is heated for the press laminating, - then both heating fields (34) are arranged outside the volume through which the tool parts (26, 28) pass when the tool device (10) is closed, - the carrier (12) is then placed on the laminating element (14) and the support frame (38) is arranged outside the volume through which the tool parts (26, 28) pass when the tool device (10) is closed, and - the tool device (10) is then closed, whereby the carrier (12) is simultaneously press-laminated to the laminating element (14) and the carrier (12) is welded to the at least one component (16). Procedure according to Claim 4 , 6 and 7 , characterized in that - the at least one component (16) is inserted into the second tool part (28) and the carrier (12) is positioned between the tool parts (26, 28) by means of the support frame (38), - then the welding heating field (40) is positioned between the support frame (38) and the second Tool part (28) is arranged, by means of the welding heating field (40) the carrier (12) and/or the at least one component (16) are plasticized at least in some areas for welding and then the welding heating field (40) is arranged outside the volume through which the tool parts (26, 28) pass when the tool device (10) is closed, - then the second tool part (28) and the support frame (38) are moved towards one another, whereby the carrier (12) is welded to the at least one component (16), - then the support frame (38) is arranged outside the volume through which the tool parts (26, 28) pass when the tool device (10) is closed, - the laminating element (14) is inserted into the first tool part (26), - then the laminating heating field (42) is arranged between the first tool part (26) and the second tool part (28), by means of the Laminating heating field (42) an adhesive applied to the carrier (12) and/or an adhesive applied to the laminating element (14) is heated for the press laminating and the laminating heating field (42) is arranged outside the volume through which the tool parts (26, 28) pass when the tool device (10) is closed, and - the tool device (10) is then closed, whereby the carrier (12) is press-laminated to the laminating element (14). Procedure according to Claim 4 , 6 and 7 , characterized in that - the laminating element (14) is inserted into the first tool part (26), the at least one component (16) is inserted into the second tool part (28) and the carrier (12) is positioned between the tool parts (26, 28) by means of the support frame (38), - the welding heating field (40) is then arranged between the support frame (38) and the second tool part (28), the carrier (12) and/or the at least one component (16) are plasticized for welding at least in some areas by means of the welding heating field (40) and the welding heating field (40) is then arranged outside the volume through which the tool parts (26, 28) move when the tool device (10) is closed, - the second tool part (28) and the support frame (38) are then moved towards one another, whereby the carrier (12) is welded to the at least one component (16), - then the support frame (38) is arranged outside the volume through which the tool parts (26, 28) pass when the tool device (10) is closed, - the laminating heating field (42) is then arranged between the first tool part (26) and the second tool part (28), an adhesive applied to the carrier (12) and/or an adhesive applied to the laminating element (14) is heated for the press laminating by means of the laminating heating field (42) and the laminating heating field (42) is arranged outside the volume through which the tool parts (26, 28) pass when the tool device (10) is closed, and - the tool device (10) is then closed, whereby the carrier (12) is press-laminated to the laminating element (14). Method according to one of the preceding claims, characterized in that the heat is provided by means of at least one infrared radiator (36) of the heating field (34). Method according to one of the preceding claims, characterized in that an adhesive for bonding the at least one component (16) is applied to the second side (24) of the carrier (12) by means of a robot device (44) of the tool device (10). Procedure according to Claim 12 , characterized in that for the application of the adhesive, a frame (48) carrying the robot device (44) is arranged between the tool parts (26, 28) and the robot device (44) with the frame (48) is arranged after the application of the adhesive outside a volume through which the tool parts (26, 28) move when the tool device (10) is closed, whereby a collision of the frame (48) with the tool parts (26, 28) can be avoided. Tool device (10), with a first tool part (26) into which a concealing element (14) to be fastened to a carrier (12) can be inserted, and with a second tool part (28) into which at least one component (16) to be fastened to the carrier (12) can be inserted, wherein the tool device (10) can be closed by moving the first tool part (26) and the second tool part (28) towards each other, wherein the tool device (10) is designed to carry out a method according to Claim 13 to carry out.

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