Device and method for producing an interior part, and interior part

Abstract

The invention relates to an interior trim part, comprising a carrier element (11) and an upper layer (12), and a device and a method for producing an interior trim part, comprising an actuating device (101) and a part support (102) for receiving the carrier element and / or the upper layer; a welding head (103) and a sewing head (104) are arranged; the operating device is used for receiving and positioning the component supporting piece and / or the welding head and the sewing head; the component support has fastening means (105) for temporarily fastening the carrier element and / or the upper layer to the component support; a controller (106) for adjusting the operating device is provided, in which a data set for adjusting at least the operating device in relation to the material of the upper layer is stored; the handling device can be adjusted in relation to the upper layer material by means of a controller such that the upper layer and the carrier element are welded by means of a welding head or sewed by means of a sewing head in order to connect the upper layer to the carrier element. In this case, a process-reliable and repetitive precise production is achieved.

Description

Technical Field

[0001] The invention relates to a device for producing an interior component, a method for producing an interior component by means of the device, and an interior component. Background Art

[0002] One of the goals in the process of circular economy is that in the future, the plastic material of the interior parts of motor vehicles can be separated from the upper layer of the interior parts. Surface materials that are foamed on or firmly bonded on are counterproductive to this. Replaceable surface materials are also advantageous with regard to the individualization capabilities in the interior and the replaceability of damaged surfaces.

[0003] In the prior art, molded skins are produced on skin-foam carrier systems in an inseparable and also non-replaceable manner. Surfaces such as leather, artificial leather and fabrics are firmly and no longer reversibly bonded to the carrier part by means of adhesives.

[0004] Releasable surface coverings have not been used in the large-area cockpit sector so far. Therefore, later personalization or replacement in the event of damage is not possible or is only possible by replacing the entire component. Therefore, a simple separation of the various plastic quality types after the life cycle of the vehicle cannot be achieved. Due to shredding, low-value mixed plastics are produced or the components require thermal recovery.

[0005] Furthermore, in the known production apparatus, due to the different process steps for different upper layer materials and due to the resulting production errors, it is not possible to produce an interior component comprising a carrier element and an upper layer to be arranged on the carrier element in a repeatably precise and reproducible manner, in particular due to the fact that, for example, knitted fabrics are very stretchable and thermoplastic olefins and artificial leather are very rigid. Summary of the invention

[0006] The object of the present invention is therefore to overcome the aforementioned disadvantages and to provide a device for producing an interior component, a method for producing an interior component by means of the device, and an interior component, in which the connection of the carrier element to the upper layer is ensured in a process-reliable and reproducible manner depending on the material of the upper layer.

[0007] This object is achieved by the combination of features according to claim 1 .

[0008] The basic idea of ​​the invention is firstly to carry out the combination of a sewing process and a welding process in a common system for producing interior components by means of a manipulator or by means of a robot.

[0009] By means of a robotic process and an intelligent component receiving part or component support, which is specifically adapted to the corresponding material properties, different mechanical properties of the surface material to be processed can be formed process-reliable and reproducibly precisely. The required fixation can be implemented by a welding process and / or a sewing process in relation to the material properties of the upper layer. On the component support or on the multi-receiving part, the upper layer or the covering layer of different materials is connected to the carrier element in one process, for example, by a manipulator or a robot. Depending on the material of the upper layer, the manipulator can implement a suitable fixing method based on a welding head with a welding device, in particular an ultrasonic welding head, and a sewing head with a sewing device. In this way, a connection between the carrier element and the upper layer is formed, which can be separated, in particular completely separated, at the end of the life cycle of the interior component. In addition, manufacturing steps during the manufacturing method are saved.

[0010] Therefore, according to the invention, a device for producing an interior component, in particular an interior component of a motor vehicle, is proposed, the interior component comprising a carrier element and an upper layer to be arranged and / or fixed on the carrier element, the device comprising an operating device and a component carrier for receiving the carrier element and / or the upper layer. In addition, a welding head, in particular an ultrasonic welding head, is provided, and in particular the welding head has a corresponding welding device; and a sewing head, in particular the sewing head has a sewing device, is provided for connecting the upper layer to the carrier element. In addition, the operating device is designed for receiving and positioning the component carrier and / or the welding head and the sewing head. In addition, the component carrier has at least one fixing device for temporarily fixing the carrier element and / or the upper layer to the component carrier. In addition, a controller is provided for adjusting the operating device. A data set is stored in the controller for adjusting at least the operating device in dependence on the material of the upper layer. In addition, the operating device can be adjusted by means of the controller in dependence on the material of the upper layer, so that in order to connect the upper layer to the carrier element, the upper layer and the carrier element are welded by means of the welding head or sewn by means of the sewing head.

[0011] In an advantageous embodiment, it is provided that the component carrier has a receptacle for an auxiliary component, in particular a U-shaped receptacle, which is preferably made of plastic and / or the material of the carrier element for connecting the upper layer to the carrier element. In this way, during the production of the interior component by the device, auxiliary components can be additionally connected to the interior component, by means of which the preload of the upper layer can be adjusted.

[0012] Preferably, the device is designed such that the component carrier has a first receiving surface for sewing and a second receiving surface opposite the first receiving surface for welding. In addition, the component carrier is designed to be rotatable about the longitudinal axis of the component receptacle, in particular by means of an electric motor that can be adjusted by a control device according to the corresponding data stored in the data set.

[0013] In one embodiment of the invention, it is provided that the ultrasonic welding head and the sewing head are detachably arranged on the handling device. In addition, a tool holder is provided in particular for at least one of the ultrasonic welding heads and at least one of the sewing heads. However, it is also conceivable that a plurality of ultrasonic welding heads and / or a plurality of sewing heads are arranged on the tool holder, and the plurality of ultrasonic welding heads and / or a plurality of sewing heads can then be selected according to the material of the upper layer to be arranged on the carrier element.

[0014] In addition, an embodiment is advantageous in which a sensor device is provided for detecting the material of the upper layer and for positioning the upper layer and the carrier element, in particular the sensor device is provided on the handling device or in the region of the handling device. In addition, the handling device can be adjusted by means of a controller according to the data detected by the sensor device.

[0015] In a further advantageous embodiment, a further handling device is provided for receiving and positioning the carrier element and / or the upper layer. However, depending on the embodiment of the handling device, it is also conceivable to provide only one handling device, which is also designed for receiving and positioning the carrier element and / or the upper layer. In one embodiment, the corresponding handling device is a multi-axis robot. In addition, in one embodiment, the fixing means is a clamp.

[0016] In a preferred embodiment of the present invention, the welding head is an ultrasonic welding head having a sonotrode for ultrasonic welding.

[0017] Furthermore, the invention proposes a method for producing an interior component, in particular an interior component for a motor vehicle, by means of a device according to the disclosure hereinabove, the interior component comprising a carrier element and a top layer to be arranged on the carrier element, in which method the carrier element is arranged on a component carrier and subsequently the top layer is arranged on the carrier element, or in which method the carrier element is arranged together with the top layer already arranged on the carrier element, in particular by means of a further actuating device. Furthermore, the carrier element and the top layer are fixed to the component carrier by means of a fixing device, and the actuating device is adjusted by means of a control device depending on the material of the top layer, so that in order to connect the top layer to the carrier element, the top layer and the carrier element are welded by means of a welding head or sewn by means of a sewing head.

[0018] During adjustment, the handling device, in particular with the welding head and the sewing head, is moved to a rigidly or fixedly arranged component carrier. Alternatively, it is also conceivable that during adjustment, the component carrier is moved by means of the handling device to a rigidly or fixedly arranged welding head and / or sewing head. Furthermore, if further handling devices are provided, in particular during adjustment, the welding head and the sewing head can also be moved by means of the handling device and the component carrier can also be moved towards each other by means of the further handling device.

[0019] In an advantageous embodiment, it is provided that the material of the upper layer is detected by means of a sensor device before, during or after the application.

[0020] Preferably, the component carrier is positioned prior to the arrangement according to the material of the upper layer ascertained by means of the sensor device by means of a control device by rotating the component carrier.

[0021] In one embodiment of the method, it is provided that the welding of the upper layer takes place at an edge region of the carrier element, in particular at a wrapping edge.

[0022] In a preferred embodiment of the present invention, the carrier element has a protrusion made of plastic, which is welded to the upper layer during welding. Here, conical protrusions with pointed end sections are preferred, which enter into the upper layer when the upper layer is arranged on the carrier element.

[0023] In a further advantageous embodiment, it is provided according to the invention that during sewing the sewing takes place through the upper layer and the carrier element.

[0024] Furthermore, an embodiment is advantageous in which sewing is performed in the case of an upper layer made of artificial leather and / or TPO foam film (foam film made of thermoplastic polyolefin) and / or nylon with a polyurethane coating and / or polyurethane foam film, in particular PU-ISF (polyurethane integral skin foam). Furthermore, welding is performed in the case of a textile upper layer, in particular a knitted fabric.

[0025] In a further advantageous embodiment, it is provided according to the invention that before the arrangement, each auxiliary component is arranged in at least one receiving portion. In addition, the auxiliary component is welded or sewn to the upper layer and / or the carrier structure.

[0026] Furthermore, the invention proposes an interior component, in particular an interior component of a motor vehicle, which is produced by means of a method according to the above disclosure.

[0027] The features disclosed above can be combined in any desired manner, as long as this is technically possible and the features do not contradict one another. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Further advantageous developments of the invention are characterized in the dependent claims or are described in more detail below together with the description of preferred embodiments of the invention with reference to the accompanying drawings. The accompanying drawings are as follows:

[0029] Figure 1 A schematic diagram showing an apparatus for manufacturing an interior component and an interior component. DETAILED DESCRIPTION

[0030] The accompanying drawings are schematic and illustrative. The same reference numerals in the accompanying drawings indicate the same functional and / or structural features.

[0031] exist Figure 1 , a schematic diagram of a device 100 for producing an interior component 1 is depicted, and also shows an interior component 1 for a motor vehicle produced by means of the device 100 , which comprises a carrier element 11 and a top layer 12 fastened to the carrier element 11 .

[0032] The device 100 for manufacturing an interior component 1 comprises a handling device 101 and a component carrier 102 for receiving a carrier element 11 and / or an upper layer 12. In addition, a welding head 103 and a sewing head 104 are provided, wherein the welding head is configured as an ultrasonic welding head having an ultrasonic generator for ultrasonic welding, and the sewing head comprises a sewing device for connecting the upper layer 12 to the carrier element 11. In addition, the handling device 101 is configured for receiving and positioning the component carrier 102 and / or the welding head 103 and the sewing head 104. Here, the welding head 103 and the sewing head 104 are detachably arranged on the handling device 101. In addition, a tool holder 111 for at least one of the ultrasonic welding heads 103 and at least one of the sewing heads 104 is provided. In the figure shown in Figure 1 In the embodiment of FIG. 1 , a sewing head 104 and a welding head 103 are each arranged on a tool support 111 .

[0033] The component carrier 102 has a fixing device 105 for temporarily fixing the carrier element 11 and / or the upper layer 12 on the component carrier 102, which fixing device is a clamp. In addition, the component carrier 102 has a receptacle 107 for an auxiliary component 108, which in the described embodiment is a U-shaped support made of plastic for connecting the upper layer 12 to the carrier element 11. Prior to the arrangement, each auxiliary component 108 is arranged in the corresponding receptacle 107. In addition, the auxiliary component 108 is arranged in the corresponding Figure 1 The upper layer 12 and / or the carrier structure 11 are already welded thereto.

[0034] Furthermore, the component carrier 102 has a first receiving surface 109 for sewing and a second receiving surface 110 for welding, which is opposite the first receiving surface 109. Furthermore, the component carrier 102 is designed to be rotatable about the longitudinal axis of the component carrier 102 by means of an electric motor that can be adjusted by means of a control unit 106. Prior to placement, the component carrier 102 can be positioned by means of the control unit 106 according to the material of the upper layer 12 detected by means of the sensor device. Figure 1 After the upper layer 12 has been welded to the carrier element 11 , the interior component 1 is arranged on the second receiving surface 110 .

[0035] Furthermore, the control unit 106 is provided for adjusting the actuating device 101. A data set is stored in the control unit 106 for adjusting at least the actuating device 101 in dependence on the material of the upper layer 12. The actuating device 101 is adjustable in dependence on the material of the upper layer 12 by means of the control unit 106, so that in order to connect the upper layer 12 and the carrier element 11, the upper layer and the carrier element are welded by means of the ultrasonic welding head 103 or sewn by means of the sewing head 104.

[0036] exist Figure 1 The device 100 shown in FIG. 1 additionally has a sensor device 112 for detecting the material of the upper layer 12 and for positioning the upper layer 12 and the carrier element 11 in the area of ​​the handling device 101 . Furthermore, the handling device 101 can be regulated by means of a controller 106 based on the data detected by the sensor device 112 .

[0037] Furthermore, a further manipulator 113 is provided for receiving and positioning the carrier element 11 and / or the upper layer 12, which can also be adjusted by means of data stored in the control unit 106 for adjusting the further manipulator 113. The respective manipulators 101, 113 are multi-axis robots.

[0038] The interior component 1 is welded to an edge region, in particular to a wrapping edge, of the carrier element 11. The carrier element 11 has projections made of plastic, which are welded to the upper layer 12 during welding.

[0039] The upper layer 12 of the interior component 1 is a textile upper layer consisting of a knitted fabric. According to the data set stored in the controller 106, in the case of the upper layer 12 made of artificial leather and / or TPO foam film and / or nylon with a polyurethane coating and / or polyurethane foam film, especially PU-ISF, sewing is performed, and in the case of the textile upper layer 12, especially in the case of a knitted fabric, welding is performed; according to the data set, the upper layer 12 is welded to the carrier element 11.

[0040] The invention is not limited in its implementation to the preferred embodiments described above. Rather, a number of variants are conceivable, which are used by the described solution even in the case of fundamentally different types of implementation.

Claims

1. A device (100) for producing an interior component (1), the interior component comprising a carrier element (11) and an upper layer (12) to be arranged and / or to be fixed on the carrier element (11), the device comprising a handling device (101) and a component carrier (102) for receiving the carrier element (11) and / or the upper layer (12); A welding head (103) and a sewing head (104) are provided for connecting the upper layer (12) to the carrier element (11); The handling device (101) is designed to receive and position the component carrier (102) and / or the welding head (103) and the sewing head (104); The component carrier (102) has at least one fixing means (105) for temporarily fixing the carrier element (11) and / or the upper layer (12) on the component carrier (102); A controller (106) is provided for adjusting the operating device (101), in which a data set is stored for adjusting at least the operating device (101) in relation to the material of the upper layer (12), and the operating device (101) can be adjusted in relation to the material of the upper layer (12) by means of the controller (106), so that in order to connect the upper layer (12) to the carrier element (11), the upper layer and the carrier element are welded by means of a welding head (103) or sewn by means of a sewing head (104).

2. The device (100) according to claim 1, wherein The component carrier (102) has a receptacle (107) for an auxiliary component (108) which serves to connect the upper layer (12) to the carrier element (11).

3. The device (100) according to claim 1 or 2, wherein: The component carrier (102) has a first receiving surface (109) for sewing and a second receiving surface (110) opposite the first receiving surface (109) for welding, and the component carrier (102) is designed to be rotatable about a longitudinal axis of the component carrier (102).

4. The device (100) according to any one of claims 1 to 3, wherein: The welding head (103) and the sewing head (104) are arranged, in particular detachably arranged, on the operating device (101), wherein in particular a tool holder (111) is provided for at least one of the ultrasonic welding heads (103) and at least one of the sewing heads (104).

5. The device (100) according to any one of the preceding claims, wherein: A sensor device (112) is provided for detecting the material of the upper layer (12) and for positioning the upper layer (12) and the carrier element (11), and the operating device (101) can be adjusted by means of a controller (106) according to data detected by the sensor device (112).

6. A method for producing an interior component (1) by means of a device according to any one of the preceding claims, the interior component comprising a carrier element (11) and an upper layer (12) to be arranged on the carrier element (11), the method comprising the following steps: a. placing the carrier element (11) on the component carrier (102) and subsequently placing the upper layer (12) on the carrier element (11), or placing the carrier element (11) together with the upper layer (12) already placed on the carrier element (11); b. fixing the carrier element (11) and the upper layer (12) on the component support (102) by means of a fixing device (105); c. adjusting the operating device (101) by means of a controller (106) according to the material of the upper layer (12) so that in order to connect the upper layer (12) to the carrier element (11), the upper layer and the carrier element are welded by means of a welding head (103) or sewn by means of a sewing head (104).

7. The method according to claim 6, wherein: Before, during or after the setting, the material of the upper layer (12) is detected by means of a sensor device (112).

8. The method according to claim 6 or 7, wherein: The carrier element (11) has a projection made of plastic, which is welded to the upper layer (12) during welding.

9. The method according to any one of claims 6 to 8, wherein: In the case of an upper layer (12) made of artificial leather and / or TPO foam film and / or nylon with a polyurethane coating and / or polyurethane foam film, in particular polyurethane integral foam, sewing is performed; and in the case of a textile upper layer (12), in particular a knitted fabric, welding is performed.

10. The method according to any one of claims 6 to 9, wherein: Prior to the arrangement, an auxiliary component (108) is arranged in at least one receptacle (107), which auxiliary component is welded or sewn to the upper layer (12) and / or the carrier structure (11). 11 . An interior component ( 1 ), in particular an interior component of a motor vehicle, which is produced by means of a method according to claim 6 .

Images