US-12620327-B2 - Method for producing a component part, device for producing a component part, and component part

Abstract

A method as well as a device for producing a component part ( 1 ), wherein a label ( 2 ) with a flexible layer structure comprising a carrier layer ( 23 ) and a further layer ( 22 ) and/or one or more electrical and/or electronic and/or optical and/or optoelectronic components ( 261 ) is received by a label receiver ( 20 ), wherein a carrier ( 3 ) is received by a carrier receiver ( 30 ), wherein a flowable adhesive ( 4 ) is applied to the label ( 2 ) and/or the carrier ( 3 ) in one or more defined first shapes and a defined relative movement ( 45 ) of the label receiver ( 20 ) and the carrier receiver ( 30 ) is carried out, wherein the adhesive ( 4 ) is arranged between the label ( 2 ) and the carrier ( 3 ), with the result that one or more adhesive layers ( 41 ) are obtained, and wherein an at least partial curing and/or crosslinking of the one or more adhesive layers is then carried out.

Inventors

• Wolfgang Clemens
• Christoph Süss
• Matthias Popp
• Martin Hahn

Assignees

• POLYIC GMBH & CO. KG
• LEONHARD KURZ STIFTUNG & CO. KG

Dates

Publication Date

20260505

Application Date

20240329

Priority Date

20230406

Claims (20)

1. 1 . A method for producing a component part, wherein the method is carried out by means of a device with a label receiver, a carrier receiver as well as an adhesive dispensing unit and has at least the following steps: a1) providing a label with a flexible layer structure comprising at least one carrier layer and i) a further layer and/or ii) one or more electrical and/or electronic and/or optical and/or optoelectronic components; a2) receiving the label with the label receiver; b1) providing a carrier; b2) receiving the carrier by means of the carrier receiver; c) applying, by means of the adhesive dispensing unit, a flowable adhesive, in one or more first geometric shapes, to the label held by means of the label receiver and/or to the carrier held by means of the carrier receiver; d) laying the label and the carrier one on top of the other by means of a defined relative movement of the label receiver and the carrier receiver, such that the adhesive is arranged between the label and the carrier, and one or more adhesive layers are obtained between the label and the carrier; e) at least partially curing and/or at least partially crosslinking the one or more adhesive layers.
2. 2 . The method according to claim 1 , wherein the label, the adhesive, the one or more adhesive layers and/or the carrier are processed at a temperature which does not exceed a glass transition temperature of the carrier, of the label and/or of the adhesive and/or is less than 80° C.
3. 3 . The method according to claim 1 , wherein a pressure which does not exceed 10 N/cm 2 or exceeds 10 N/cm 2 for at most 10 s acts on the label, the adhesive, the one or more adhesive layers and/or the carrier.
4. 4 . The method according to claim 1 , wherein the label is curved by being received by means of the label receiver.
5. 5 . The method according to claim 1 , wherein the carrier has a curved carrier surface at least in a curvature area, wherein the curvature area of the label is applied to the curvature area of the carrier.
6. 6 . The method according to claim 1 , wherein the adhesive comprises or consists of a cold glue.
7. 7 . The method according to claim 1 , wherein the adhesive comprises or consists of an optical glue.
8. 8 . The method according to claim 1 , wherein the adhesive is crosslinkable or is crosslinked and/or the one or more adhesive layers have been or are crosslinked.
9. 9 . The method according to claim 1 , wherein the application of the adhesive is effected by dispensing or by printing.
10. 10 . The method according to claim 1 , wherein the adhesive has Newtonian or shear-thinning fluid properties and/or a viscosity in a range of from 0.5 mPa·s to 100,000 mPa·s.
11. 11 . The method according to claim 1 , wherein the one or more first geometric shapes have cross-section dimensions, in a range of from 50 μm to 5,000 μm.
12. 12 . The method according to claim 1 , wherein the laying of the label and the carrier one on top of the other is effected such that the one or more adhesive layers are arranged with a minimum thickness of 2 μm.
13. 13 . The method according to claim 1 , wherein a surface density of the one or more first geometric shapes relative to a surface area covered with the one or more adhesive layers after the label and the carrier have been laid one on top of the other, is less than 90%.
14. 14 . The method according to claim 1 , wherein the adhesive is deposited inside one or more first areas of the label and/or of the carrier for each area of the one or more first areas in an initial area and in a following area of the label and/or of the carrier, wherein during the laying of the label and the carrier one on top of the other a contact of the label, the adhesive and the carrier is produced in the initial area first and then in the following area.
15. 15 . The method according to claim 14 , wherein the adhesive with the one or more first geometric shapes has a higher surface density in the initial area than in the following area.
16. 16 . The method according to claim 1 , wherein the adhesive with the one or more first geometric shapes is applied with a distance of at least 1 mm, from an edge and/or a rim of a surface of the label and/or of the carrier to which the adhesive is applied and/or from an edge of an opening of the label and/or of the carrier.
17. 17 . The method according to claim 1 , wherein the adhesive is applied with a width in a range of from 100 μm to 10,000 μm.
18. 18 . The method according to claim 1 , wherein the adhesive is applied exclusively to the label.
19. 19 . The method according to claim 1 , wherein the adhesive is applied to the label over a first area and is applied to the carrier over a second area, wherein the first area is larger or smaller than the second area.
20. 20 . The method according to claim 1 , wherein the adhesive is applied to the label and a primer has been or is applied to the carrier or a primer has been or is applied to the label and the adhesive is applied to the carrier.

Description

BACKGROUND OF THE INVENTION The invention relates to a method for producing a component part, a device for producing a component part, and a component part. To integrate functional labels, such as touch sensors, in component parts, it is known to fasten labels with functional layers which provide such functions to or in a component part carrier by means of mechanical integration, for example clamping. A further method for integrating such functions is to laminate the label onto the component part carrier manually or in a partially automated manner using a PSA (pressure sensitive adhesive) or an OCA (optically clear adhesive). It is also known to integrate such labels on or in a plastic injection-molding compound forming the component part carrier by injection. A further method is to stamp the label onto a component part carrier with a heated stamp, wherein a thermoplastic glue is activated by the heat of the stamp to connect the label and the component part carrier. For flat and smooth glass sheets, so-called optical bonding is furthermore known, wherein an optical glue (usually called Optically Clear Resin (OCR) in these cases) is brought between two flat glass sheets or a flat glass sheet and a flat substrate in order to connect them. However, component parts produced by means of optical bonding are severely restricted in terms of the design freedom because of the condition that they are flat glass sheets or substrates. A mechanical integration, as described at the beginning, by means of clamping of the label likewise has reduced possibilities for complex constructions or compact constructions, and an automated manufacture is difficult to implement. In the case of mechanical connections, in addition, weak points often occur because of gaps between the parts not connected in a material-bonding manner and because of corresponding relative movements and positional tolerances. Also, in the case of a manual or partially automated lamination, high positional tolerances can occur and, in particular in the case of complex geometries, it is difficult to achieve a higher degree of automation. Component parts with labels which are provided by injection in or on a plastic compound or by stamping by means of heated stamps are restricted in terms of their design freedom because of the high pressures and high temperatures required here, which can strain the component parts and for example cause mechanical bending or thermal warping. In addition, functions integrated in the label, such as sensors, are often damaged in such production methods. In addition, decorative layers possibly additionally provided in the label are also restricted in terms of the design freedom and can be damaged by the high pressures and temperatures. Furthermore, at elevated temperatures, outgassing from the plastic materials can occur and result in a formation of bubbles at boundary surfaces. At the boundary surface between label and component part carrier, moreover, small nuisance particles can already result in relatively large cavities, which in particular impair the stability and the optical appearance of the component part, because of the high-viscosity or thermoplastic adhesive layers used. Labels integrated in such production methods therefore often have defects, such as creases, bubbles, crushing of conductive tracks or the like. The object of the present invention is thus to specify an improved method as well as an improved device for producing a component part which in particular make an automated method possible, preferably also for complex component part geometries or carrier geometries. A further object of the present invention is to specify an improved component part. The object is achieved by means of a method according to claim 1, by means of a device according to the present invention as well as by means of a component part according to the present invention. SUMMARY OF THE INVENTION The object is achieved by means of a method for producing a component part, in particular a casing component part and/or an operating element and/or a display element, preferably for a vehicle interior. It is also possible for the component part to be used in other areas of application. For example, it is possible for it to be a component part, in particular a casing component part or operating element or display element, preferably for a domestic appliance (white goods), consumer electronics device, or a component part which provides operating elements and/or decorative elements of one of the named or another device. The method is is carried out by means of a device with a label receiver, a carrier receiver as well as an adhesive dispensing unit. In the method at least the following steps are carried out, preferably in the specified order of the steps or preferably with two or more of the steps in the specified order: a1) providing a label with a flexible layer structure, wherein the label has at least one carrier layer and has a further layer and/o