Method and tool for the tension-free positioning of a flat transfer segment on an elastic pressing means for bubble- and distortion-free, contour-accurate lamination of a workpiece

Abstract

Summary: In the method and tool for the tension-free positioning of a flat transfer segment (1) on an elastic pressing means (2) for the bubble- and distortion-free, contour-accurate lamination of a workpiece (3) without the use of supporting gas and without a clamping frame for the transfer segment, the lamination is carried out using gravity from a horizontal position from an elastic pressing means (2), on which the transfer segment (1) rests, onto a workpiece (3) arranged above. This method is used here, for example, in a closed system (4), in which the workpiece (3) is moved by means of a drive (5) either from top to bottom against the elastic pressing means (2) with the transfer segment (1) resting thereon, or the elastic pressing means is moved from bottom to top against the workpiece (3), or additionally by means of a stamp pad (6) with the aid of a further drive (7) the elastic pressing means is moved from bottom to top against the workpiece and pressed against it, or the transfer segment and workpiece are moved towards each other at the same time, whereby tilting movements of the workpiece and / or of any stamp pad (6) can support distortion-free contact. The pressing means chamber (8) and the workpiece chamber (10) can contain heating elements (9). Laminating in this horizontal process can only be carried out by means of pressure differences between the chambers (8, 10).The gas pressures in the chambers are controlled by gas channels (11 and 12) and external valves and pumps.

Description

State of the art: Contour-accurate lamination of a three-dimensional workpiece using a double-chamber vacuum process:

[0001] When laminating a three-dimensional workpiece with a true contour using the dual-chamber process, a flat substrate is either clamped in a clamping frame or applied to an elastic pressing agent clamped in a frame using an adhesive, thus indirectly clamping it into a frame. A clamping frame always influences the stress distribution within the flat substrate and can lead to distortions. This can be counteracted by using a removable, fixed or movable oval clamping frame with adjustable x, y, and z dimensions to position the flat substrate to be applied. Such a procedure is known, for example, from DE 10 2022 000 188 A1, but involves additional equipment complexity. IMD (Inmould Decoration) / deep drawing process for polymers

[0002] In a deep-drawing process, polymer films are clamped into a clamping frame, heated, and, if necessary, shaped into a curved shape using supporting air, into which the workpiece is inserted from below. The supporting air works against the effect of gravity on the film.

[0003] The present invention solves many of the current problems, simplifies the process, can contribute to material savings and thus represents a further development of the state of the art. DESCRIPTION

[0004] The present invention is suitable for the stress-free placement of flat substrates up to 3 mm thick for the contour-accurate lamination of three-dimensional workpieces with the aid of machines in an automated or semi-automated process sequence.

[0005] The initial placement of the flat substrate(s) is done manually or mechanically. Due to the horizontal or nearly horizontal position of the flat substrate on an elastic pressing means, fixation in a clamping frame is not necessary, as the adhesive contact between the flat substrate and the elastic pressing means, supported by gravity, is entirely sufficient to ensure a stable position of the flat substrate. However, the flat substrate can be bonded either fully or partially to the elastic pressing means using an adhesive. The preferred application is positioning the flat substrate without adhesive between the flat substrate and the elastic pressing means.

[0006] Unlike in a state-of-the-art deep-drawing process, the flat substrate can be positioned and laminated onto the workpiece entirely without the use of a clamping frame. The complete elimination of clamping of the flat substrate results in significant material savings compared to the full-surface clamping required, for example, in the conventional deep-drawing process. In particular, the complete elimination of any clamping of the flat substrate results in a significant reduction in material stresses in the flat substrate during the lamination process, while simultaneously maintaining high positioning accuracy.

[0007] The elimination of a clamping frame for the flat substrate allows the simultaneous use of several flat substrates that are not or only partially connected to laminate one or more workpieces in one operation.

[0008] Due to the horizontal or nearly horizontal position of the flat substrate, tilting and / or rolling movements of the workpiece are also possible during the lamination process in the main process without the need to clamp the flat substrate. Likewise, tilting and / or rolling movements of any stamp pad arranged below the pressing means are also possible to a lesser extent, as is a combination of movements of the workpiece and any stamp pad without the need to clamp the flat substrate. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2022 000 188 A1

[0001]

Claims

[1] Method and tool for the tension-free positioning of one or more flat transfer segments on an elastic pressing means for the bubble- and distortion-free, contour-accurate lamination of a flat, gas-tight substrate of less than or equal to 3 mm layer thickness onto the surface of a gas-tight workpiece, without the use of supporting gas and without a clamping frame for the transfer segment, in which a) by using gravity, the lamination is carried out from a horizontal or almost horizontal position of an elastic pressing means, on which the transfer segment or segments rest, onto a workpiece arranged above it, b) either the elastic pressing means with the transfer segment resting on it is moved from bottom to top against the workpiece by means of a pressure difference on both sides of the elastic pressing means or additionally by means of a stamp pad supporting it from below, or the workpiece is moved from above onto the transfer segment, or the transfer segment and workpiece are moved towards each other simultaneously, whereby tilting movements of the workpiece and / or any stamp pad can support the distortion-free contact, c) a clamping frame for the transfer segment or segments is no longer required, which increases the transfer precision and freedom from distortion, and d) additionally, the need to use a support gas is eliminated. [2] The method according to claim 1, wherein adhesive contact of the transfer segment with the membrane surface results in process-stable positioning of the transfer segment or segments, wherein the membrane is moved toward the workpiece with or without the aid of a punch, or the workpiece is moved toward the transfer segment, or the workpiece and membrane are moved toward each other with the transfer segment or segments, with or without a punch. The workpiece and / or punch can be moved in parallel or at variable angles. [3] Method according to claim 1, in which, instead of a single transfer segment, several non-connected or only partially connected transfer segments are laminated in one operation onto one or more workpieces in one operation. [4] Method according to claim 1, wherein one or more transmission segments have a 3D contour. [5] Method according to claim 1, in which a gas-tight support film is either completely dispensed with or is replaced by a non-gas-tight support or positioning material, for example a mesh structure. [6] Method according to claim 1, wherein the transfer segment or the transfer segments are fixed in position by means of adhesive, partially by means of adhesive or entirely without adhesive only by the gravitational adhesive contact with the elastic pressing means.

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