Patent Application
20240339051
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 claim 40 as well as by means of a component part according to claim 50.
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:
The object is further achieved by a device, in particular for carrying out the method according to the invention, for producing a component part. The device comprises:
The device has been has been configured such that a laying of the label and the carrier one on top of the other can be carried out and/or is carried out by means of a defined relative movement of the label receiver and the carrier receiver with an arrangement of the adhesive between the label and the carrier, and one or more adhesive layers, in particular in one or more second defined shapes, can be obtained between the label and the carrier.
The object is further achieved by a component part, in particular a casing component part and/or operating element and/or display element, preferably produced by means of the method according to the invention and/or the device according to the invention, comprising:
The object is further achieved by a system comprising the device according to the invention, in particular for carrying out the method according to the invention, wherein the method according to the invention is preferably carried out. The method is in particular implemented by computer and/or the device has been configured to carry out the computer-implemented method.
It is hereby achieved in particular that flexible labels can be applied to surfaces of in particular complex carriers, preferably of plastic or glass carriers, in a preferably automated or automatable process such that bending, warping and/or optical interference because of mechanical stresses, compressive loads and temperature loads are advantageously avoided. It is advantageously possible to carry out an automated method and/or to use a device for carrying out an automated method, wherein in particular at least the laying of the label and the carrier one on top of the other can be carried out in an automated manner or is carried out in an automated manner. By means of the high degree of automation possible or also a fully automated method, short cycle times for producing the component parts, a higher process reliability with few rejects, and resource savings can in particular be achieved. Here, in particular in the case of complex geometries of the carrier, the one or more first defined shapes of the adhesive and the defined relative movement of the label and the carrier can be matched to each other in a targeted manner, with the result that the one or more adhesive layers result from this. All steps of the method are thus preferably carried out in an automated manner and/or can be carried out in an automated manner by means of the device, wherein the one or more defined first shapes and the relative movement of the label and the carrier are matched to each other. Thus, by means of the flexible label, for example a complex shape, in particular a curved carrier with a so-called “2.5D” shape, can be coated. As the carrier here can additionally also have 3D shapes, for example because of frames or catches or other structures on the surface which would prevent a conventional integration, such as in the case of optical bonding, a particularly high degree of design freedom is achieved.
In addition, it has surprisingly been shown that, owing to the laying of the label and the carrier one on top of the other, in particular owing to a displacement of the flowable adhesive taking place in the process, unevennesses in the surface of the label and/or of the carrier are advantageously filled with adhesive, and air bubbles in the adhesive are sealed or pushed away. For this, the laying of the label and the carrier one on top of the other can comprise a pressure exerted on the label and the carrier and the flowable adhesive arranged in between and/or a relative movement between the label and the carrier and the flowable adhesive arranged in between. Thus, even narrow radii of curvature can be filled particularly deeply by means of the flowable adhesive and nuisance particles can be particularly tightly enclosed. At the same time, by means of the defined relative movement and the defined shape of the adhesive, a uniform distribution of the adhesive for shaping the one or more adhesive layers can be achieved, without air inclusions forming—for example when subareas of the adhesive merge or because of unevennesses on a surface of the label or of the carrier. A squeezing of the adhesive out at the sides of the label can advantageously also be reduced or avoided, in particular with the result that a curing can be effected with little to no additional cleaning effort. By means of the absent or reduced heating, the process where for example plastics used for the carrier release moisture and cause bubbles in an adhesive layer is moreover avoided or curtailed.
At the same time the formation of bubbles due to outgassing is further prevented, as the one or more adhesive layers, which can be processed at low temperatures, can act as a gas barrier because of the materials that can be used and the condition, such as in particular a crosslinked state. Optical and mechanical properties can thus be improved. Furthermore, stable materials can be used for the glue, with the result that for example the composite consisting of carrier, crosslinked glue and label has a higher mechanical stability than for example a thermoplastic glue or a “soft” glue, such as a self-adhesive OCA (optically clear adhesive).
By a label is meant in particular a substantially two-dimensional object. A label preferably serves to coat a carrier, and/or the circumference of the label, preferably when viewed perpendicular to a plane spanned by the label, has preferably already been formed, in particular cut out, completely or predominantly corresponding to the shape of this coating during the provision of the label. A label preferably has a flexible layer structure.
By a flexible layer structure is meant in particular that the label is bendable, preferably elastically bendable. The flexibility can be determined in particular by the elastic modulus (E modulus). The E modulus is in particular a material constant from materials engineering which describes the proportional relationship between stress and strain during the deformation of a solid body in the case of linearly elastic behavior. The E modulus is preferably determined according to the ISO standard 527-1:2019-12 (Plastics—Determination of tensile properties—Part 1: General principles, issue date 2019-12) and specified in particular in N/mm2 or MPa. In particular, the label has E moduli in a range of from 500 MPa to 5,000 MPa, preferably in a range of from 1,000 MPa to 4,500 MPa, particularly preferably in a range of from 1,500 MPa to 3,000 MPa. In particular, the label is rather called “tough material”.
The E moduli are preferably present at least in subareas of the label, in particular with the result that the label as a whole is flexible and/or bendable. It is possible for the label, in particular in addition to the flexible layer structure, not to be flexible in areas and/or to have, in areas, components, such as in particular the one or more electrical and/or electronic and/or optical and/or optoelectronic components, which are not flexible and/or are not layered, i.e. preferably have higher E moduli than the subareas of the label with the above-named E moduli.
Terms such as “first”, “second” or “third” are only used for differentiation. For example, a first layer and a second layer can be present, but the presence of a first layer is not a prerequisite for the presence of a second layer.
The component part is in particular a casing component part, preferably a motor vehicle casing component part, such as for example a vehicle interior casing part or a vehicle exterior casing part. The component part can also be for example an operating element and/or a decorative element and/or a display element, in particular in the field of white goods or other domestic appliances or also in devices of consumer goods or automation technology.
By carrier is meant for example a self-supporting and/or rigid body. The carrier comprises or preferably consists of glass and/or plastic. In particular, before or during its provision the carrier already has a shape which the carrier also has in the produced component part. The shape of the carrier can in particular be three-dimensional, preferably during step b1) and/or step d) and/or in the finished component part. The carrier comprises or is in particular rather a “brittle-hard material”. In particular, the carrier, preferably at least in areas or everywhere, has E moduli of 5,000 MPa or more. Preferably, the carrier is not or is substantially not deformed, in particular not plastically deformed, during the method or at least during the laying of the label and the carrier one on top of the other. For example, the carrier comprises an injection-molding compound. In particular, the carrier has been or is produced by means of injection molding. It is also possible for the carrier to have one or more decorative plies, which have been or are applied for example by means of in-mold decoration (IMD) or in-mold labeling (IML), thus in particular during an injection-molding process. The carrier is preferably a faceplate, for example of a vehicle interior part.
The carrier can also not be decorated or alternatively can have been or be decorated using any desired decoration method such as for example wet painting, vapor deposition, chemical vapor deposition (CVD), physical vapor deposition (PVD), film decoration, etc. In particular in a preferred embodiment wherein the further layer is or comprises an electrically conductive functional layer and/or the label preferably comprises a capacitive touch sensor, it is expedient that the carrier and possible coatings and/or decorative layers on the carrier are not electrically conductive. Alternatively or additionally, it is possible for the carrier to be transparent or translucent completely or in areas, in particular in areas which are provided for operation. This is advantageous in particular in the case of component parts in the form of operating elements.
The further layer is or comprises in particular an electrically conductive functional layer. The electrically conductive functional layer is preferably electrically contactable in the provided label and/or the produced component part. The electrically conductive functional layer preferably has an electrical and/or electronic and/or optical and/or optoelectronic function, for example a sensor function (for example for temperature, moisture, pressure, electrical capacitance, visible and/or invisible electromagnetic wavelengths (for example IR, visible light and/or UV), electrical resistance and/or chemicals), and/or a touch sensor function, a heating function, a cooling function and/or an actuator function. The carrier layer and the electrically conductive functional layer have preferably been comprised of or formed by a sensor film, in particular a touch sensor film.
The one or more first defined shapes have been or are determined in particular by a relative movement between the adhesive dispensing unit and the label and/or carrier and/or by the amount of adhesive dispensed by the adhesive dispensing unit and/or by the viscosity of the adhesive. The one or more second defined shapes have been or are determined in particular by the one or more first defined shapes and deformation brought about by the laying of the label and the carrier one on top of the other. A surface of the carrier, in particular at least one smooth surface and/or a 2.5D surface of the carrier, preferably has been or is coated by the one or more second defined shapes, preferably coated over the whole surface and/or over a large area, for example except for a defined distance from the edge of the surface. A 2.5D surface or 2.5D shape is characterized in particular by a cylindrical bending or curvature. It is also possible for the adhesive to be deformed because of a movement of the label receiver, for example toward the carrier receiver, in particular wherein this deformation has been or is taken into account for carrying out the defined relative movement of the label receiver and the carrier receiver. The one or more second defined shapes preferably have an edge which overlaps with an edge of the label or has a determined distance therefrom. This overlap can be present in areas or be present completely and/or be present in a subarea in which the label has an edge which overlaps with the carrier in the component part.
By displaced or displace is meant in particular that the adhesive has been or is displaced out of an area which has been or is formed by the one or more first defined shapes into further areas, preferably wherein adhesive likewise remains in the area which has been or is formed by the one or more first defined shapes.
By curing is meant in particular a crosslinking, preferably linking of chains. During crosslinking, preferably linking of chains, in particular a three-dimensional network of crosslinked polymer chains is formed. During linking of chains, in particular already existing and/or previously formed polymer chains are crosslinked. The adhesive is in particular cured, preferably completely cured, when the viscosity of the adhesive at room temperature, for example of 20° C., is greater than 50,000 mPa·s, preferably greater than 100,000 mPa·s. The adhesive with such viscosities is preferably no longer flowable. By completely cured is meant when more than 90% of the polymer constituents of the adhesive that are capable of crosslinking have a crosslinking. A completely cured adhesive is present when a complete (>90%) crosslinking of its polymer constituents has been effected.
By a layer or ply is preferably meant a substantially two-dimensional object. It is possible for a layer to be present over the whole surface or partially, in particular patterned. A layer can itself be single-layered or be multi-layered.
By pattern or patterned is meant for example individually or in combination patterns of dots and/or lines, in particular straight and/or curved lines, bone structure, T shape, Y shape, I shape, U shape, serpentines, nodes, branches, fractal shapes. A layer provided over part of the surface can in particular have been or be provided patterned. A pattern can also be a motif, preferably selected individually or in combination from: geometric shape, guilloche, endless pattern, image, symbol, logo, emblem, portrait, alphanumeric character, QR code, barcode. A motif can be present as a single image and/or as an endless pattern.
The provision of the label can be effected for example manually and/or on a receiving surface provided for it and/or by means of a first feed device, for example comprising one or more conveyor belts and/or one or more robot grippers. The provision of the carriers can be effected for example manually and/or on a receiving surface provided for them and/or by means of a second feed device, for example comprising one or more conveyor belts and/or one or more robot grippers.
The order of the steps of the method can be chosen as desired. Several steps can be effected one after another and/or several steps of the method can also be carried out at the same time. Step a1) is in particular carried out before step a2) and step b1) is in particular carried out before step b2). Step c) is preferably carried out after step a2). Step c) and step b2) can be carried out at least partially at the same time. It is also possible for step c) to be carried out before and/or after step b2). Step d) is preferably carried out after step c). Step e) is preferably carried out after step d).
Advantageous designs of the invention are described in the dependent claims.
It is possible for there to be pressures and/or temperatures resulting from the method, in particular from the defined relative movement and/or from curing and/or crosslinking mechanisms of the adhesive, in particular without the pressures and/or temperatures adopting preset and/or measured and/or controlled values. However, the resulting pressures and/or temperatures are advantageously comparatively low. It is possible for example that, to distribute the adhesive, no application of a pressure, in particular substantially no application of a pressure, or by a preferably low pressure, is exerted on the adhesive by the carrier and/or the label and/or a heating of the adhesive, and in particular of the carrier and/or of the label, takes place as a result of an irradiation of the adhesive and/or an exothermic reaction of the adhesive.
It is also possible for an exerting of a defined pressure and/or a defined heating of label, adhesive and carrier and/or a setting of a defined temperature range of label, adhesive and carrier to have been carried out and/or to be settable by means of the device, preferably during the laying of the label and the carrier one on top of the other.
Through corresponding resulting and/or defined pressures and/or temperatures, the flowability of the adhesive can in particular be utilized and/or optimized and damage or warping due to temperatures that are too high or pressure that is too high can be reduced.
During the method, in particular the laying of the label and the carrier one on top of the other, the carrier, the label and/or the adhesive preferably do not exceed a temperature which corresponds to a glass transition temperature of a material of the carrier, of the label and/or of the adhesive. A heating of the carrier and/or of the label or subareas thereof expediently takes place to temperatures which are lower than the glass transition temperatures of the materials used. In the case of PET-based films, which act in particular as a carrier layer of the label, the heating takes place for example to less than 80° C., or a temperature of 80° C. or more does not arise during the method. It is thus possible for the label, the adhesive, the one or more adhesive layers and/or the carrier to be processed at a temperature of less than 80° C., preferably of at most 60° C., during the method, in particular the laying of the label and the carrier one on top of the other. It is also conceivable that, in particular in step d), a cooling of carrier and/or label is carried out, for example if the adhesive is self-curing with an exothermic reaction. Low temperatures are advantageous in particular as a negative influencing of label and/or carrier, e.g. by a softening of the label that is too great or a bending of the carrier, can thus be avoided.
The label, the adhesive, the one or more adhesive layers and/or the carrier are preferably heated to a temperature of at most 100° C., preferably at most 80° C., for at most 30 s, preferably at most 15 s. During the method, in particular during the laying of the label and the carrier one on top of the other, the label, the adhesive, the one or more adhesive layers and/or the carrier preferably do not exceed a temperature of 80° C., preferably of 60° C., or in particular exceed it for at most 60 s, preferably at most 30 s, preferably at most 15 s.
The method is preferably carried out and/or the device has been designed such that, in particular after the defined relative movement has been carried out, holding of the label receiver and/or of the carrier receiver with a defined relative position of the label receiver and the carrier receiver is carried out or can be carried out. The holding is preferably a substep of step d), i.e. the laying of the label and the carrier one on top of the other. The defined relative movement is preferably carried out to distribute the adhesive, in particular wherein a pressure is exerted on the adhesive or acts on the adhesive, which is sufficient to distribute adhesive without it emerging between the label and the carrier at an edge. The holding is carried out in particular to at least partially cure and/or crosslink the distributed adhesive. The holding is carried out in particular until the label has been fixed to the carrier, for example by a sufficient curing and/or crosslinking by means of step e). The holding is effected in particular for at most 240 s, for example if the adhesive is self-curing, preferably for less than 60 s, preferably for less than 10 s, for example if the adhesive is radiation-curing, in particular UV-radiation-curing and/or cures by visible light.
In particular, the method is carried out and/or the device has been designed such that the defined relative movement and/or the holding is carried out, wherein a pressure which does not exceed 200 N/cm2 and/or lies in a range of from 0.1 N/cm2 to 200 N/cm2 is exerted or acts on the label, the adhesive, the one or more adhesive layers and/or the carrier, and/or without a pressure which is 200 N/cm2 or more being exerted on the label, the adhesive, the one or more adhesive layers and/or the carrier. It is alternatively or additionally possible for a pressure which does not exceed 10 N/cm2 or exceeds it for at most 10 s to be exerted or to act on the label, the adhesive, the one or more adhesive layers and/or the carrier, in particular during the laying of the label and the carrier one on top of the other.
The label receiver preferably has a receiving surface and/or a receiving mold for receiving the label. Preferably, the receiving mold is curved at least in areas and/or is a fitted shape adapted to the label, and in particular to a shape, preferably curved shape, of the label to be formed on the carrier. The shape of the receiving mold and/or of the receiving surface is preferably adapted to the shape of the label because the label receiver has at least one indentation with at least one edge which delimits the at least one indentation. The edge is used in particular for positioning the label on the label receiver.
The label is preferably flat but flexible, in particular in step a1) and/or before step a2). The receiving surface of the label receiver is preferably curved at least in areas and in step a2) the label is forced, in particular via vacuum or mechanical holders, to adopt the shape, curved at least in areas, of the receiving surface.
The label receiver and/or the carrier receiver preferably has means for holding the label and/or the carrier, in particular selected individually or in combination from: means for generating a vacuum, in particular for suctioning the label and/or the carrier, a clamping device, a spacer, an indentation, a screw joint, a magnetic holder, a vacuum holder.
It is possible for the label to be curved by being received by means of the label receiver. Expediently, at least one curvature area of the label receiver, which is in contact with the label after receiving the label, has a curved surface. The carrier preferably has a curved carrier surface at least in a curvature area, in particular wherein a curvature area of the label is preferably applied to the curvature area of the carrier during the laying of the label and the carrier one on top of the other. The curvature area of the label receiver preferably has a curved surface corresponding to the curvature area of the carrier, in particular such that the label has been or is curved when the label is received with the label receiver such that a curved label surface corresponding to the curved carrier surface, preferably a complementary curved label surface, has been or is formed in the curvature area of the label. It is also possible for the label to have for example a curved surface which has been or is adapted to an entirety of curvatures, indentations and/or elevations of the carrier. Thus, it is also possible for example for one or more elevations and/or indentations which are present in the carrier to have been or to be filled by through a variation in layer thickness of the one or more adhesive layers. It is possible in particular for the carrier in the component part to have a curved surface and/or elevations and/or indentations on a surface facing the label, in particular wherein the one or more adhesive layers have a variation in layer thickness following the curved surface and/or the elevations and/or the indentations.
A curved surface, in particular the label surface, the carrier surface and/or the curved surface of the label receiver, has in particular one or more of the following properties or is formed by them: a minimum radius of curvature of 10 mm, preferably of 20 mm, preferably of 50 mm, particularly preferably of 200 mm, one or more indentations, one or more elevations, a radius of curvature that varies over the curved surface.
It is also possible for the carrier, preferably inside and/or outside the curved surface of the carrier, preferably inside and/or outside the curvature area of the carrier, to have one or more catches, one or more frames and/or one or more elevations and/or indentations, preferably one or more additional elevations and/or indentations, which have in particular a height of at most 100 mm, preferably of at most 50 mm, further preferably of at most 20 mm, and/or to have one or more recesses.
In addition, it is possible for the carrier to have at least one smooth area, as an alternative or in addition to the curvature area of the carrier. As an alternative or in addition to the curvature area of the label, the label can in particular have at least one smooth area, with which the label is applied to the smooth area of the carrier, in particular during the laying of the label and the carrier one on top of the other. In particular, it is also possible for at least one smooth area of the label receiver to be in contact with the label after receiving the label, preferably wherein the at least one smooth area of the label receiver and/or of the label has been or is allocated to the at least one smooth area of the carrier. By “smooth area” is meant here in particular that a smooth surface, in particular without curvature, is present inside the smooth area. It is alternatively or additionally possible for the surface of the carrier to have a slightly curved surface, which has a radius in a plane which is larger than 100 mm. It is also possible for the carrier to have one or more areas which are raised and/or sunken compared with the smooth surface and/or the slightly curved surface.
By area is meant in particular in each case an area predefined by a defined surface area which is occupied when viewed in a top view onto the label, the carrier, the adhesive, the one or more adhesive layers, the label receiver and/or the carrier receiver, and/or when viewed perpendicular to a plane formed by the label, the carrier, the adhesive, the one or more adhesive layers, the label receiver and/or the carrier receiver.
The defined relative movement of the label receiver and the carrier receiver is matched in particular to the surface, preferably the curved surface of the label and/or of the carrier, as well as preferably the one or more defined shapes of the adhesive. In particular, the curved surface of the label is unrolled on the curved surface of the carrier. Preferably, the defined relative movement of the label receiver and the carrier receiver is implemented and/or the label receiver has been designed such that no bending and/or no curvature of the label takes place during the defined relative movement.
It is also possible for at most 0.5 s to 60 s, preferably 0.5 s to 20 s, to pass after the application of the adhesive by means of the adhesive dispensing unit and before the laying of the label and the carrier one on top of the other (s=seconds). The label receiver, the carrier receiver and the adhesive dispensing unit preferably have a maximum distance from each other of 2 m. An undesired flowing of the adhesive can advantageously hereby be avoided because there is a short period of time for undesired flowing of the adhesive, and sufficient time for an acceleration of the adhesive that is not too great is guaranteed during the positioning for the laying of the label and the carrier one on top of the other. The period of time can be reliably determined and complied with using an automated method.
It is preferred that the adhesive and/or the one or more adhesive layers comprise or consist of a cold glue. In particular, the adhesive is or comprises an optical glue and/or the one or more adhesive layers are or comprise one or more optical glues. By an optical glue is meant in particular that, in particular in the cured state, the transmittance is at least 50%, preferably at least 80%, and/or the optical glue is crystal clear transparent and/or the adhesive is colorless and/or the glue is free of one or more of the following materials: fillers, dyes, color pigments.
The application of the adhesive is effected to a surface, in particular at least in the curvature area, of the label and/or to a surface, in particular at least in the curvature area, of the carrier in particular over part of the surface, preferably patterned, or over the whole surface. The application of the adhesive is preferably effected by dispensing, in particular with a volumetric metering of the adhesive, or by printing, in particular by digital printing and/or screen printing. It is possible for the adhesive dispensing unit to have been comprised of or to have been formed by a printing device, in particular a digital printing device and/or a screen printing device and/or a dispenser. The adhesive dispensing unit preferably comprises one or more nozzles and/or channels and/or dispensers for dispensing the flowable adhesive. In particular, the adhesive dispensing unit comprises one or more printheads, preferably inkjet printheads. In particular, for example a depositing of the adhesive over the whole surface and/or over a large area can be carried out or is carried out by means of screen printing.
It is possible for the adhesive and/or the one or more adhesive layers to be curable, to have been cured or to be cured, selected individually or in combination from: by means of radiation, preferably UV radiation and/or visible light and/or IR radiation, by means of physical curing, by means of chemical curing, by means of dual curing. In particular, the method for producing the component part is designed and/or the device is configured such that the adhesive is crosslinkable or is crosslinked and/or the one or more adhesive layers are crosslinkable and/or have been or are crosslinked. It is possible in particular for the adhesive and/or the one or more adhesive layers to be crosslinkable, to have been crosslinked or to be crosslinked in particular by means of UV radiation and/or visible light.
It is possible for the adhesive to have a viscosity in a range of from 0.5 mPa·s to 100,000 mPa·s, in particular from 1 mPa·s to 100,000 mPa·s, preferably from 300 mPa·s to 50,000 mPa·s, preferably from 1,000 to 10,000 mPa·s and/or from 500 mPa·s to 2,000 mPa·s, preferably 1,000 mPa·s to 1,500 mPa·s, during the application of the adhesive. During the application of the adhesive and/or during the laying of the label and the carrier one on top of the other, the adhesive has Newtonian or shear-thinning fluid properties in particular. The fluid properties, in particular the viscosity, preferably has been or is designed such that during the laying of the label and the carrier one on top of the other a flowing of the adhesive is possible and/or the one or more first defined shapes of the adhesive are preserved or are deformed in a controlled manner until the label and the carrier have been laid one on top of the other. In particular, an automatable positioning of the adhesive and preferably a largely uniform distribution of the adhesive over the surface area of the label and/or of the carrier, in particular after the label and the carrier have been laid one on top of the other, can be obtained.
The viscosity, in particular the dynamic viscosity, here is preferably specified for a state of the adhesive which exists before the adhesive is delivered to the adhesive dispensing unit and/or while the adhesive is being applied to the label and/or the carrier. In the case of the viscosity, in particular dynamic viscosity, specified in the above range it can in particular also be an average value, around which tolerance values vary in particular. Such a viscosity guarantees in particular an optimum wetting of the label and/or of the carrier. A viscosity that is too low can for example result in an undesired running of the adhesive before the laying of the label and the carrier one on top of the other and a viscosity that is too high can for example result in a poor or insufficient flowing of the glue during the laying of the label and the carrier one on top of the other.
The viscosity of the adhesive is in particular measured, preferably by means of a viscometer, preferably according to the ISO standard 3219, further preferably according to DIN EN ISO 3219-1:2021-08 (Rheology—Part 1: Vocabulary and symbols for rotational and oscillatory rheometry, issue date 2021-08) or according to DIN EN ISO 3219-2:2021-08 (Rheology—Part 2: General principles of rotational and oscillatory rheometry, issue date 2021-08). The adhesive has preferably been formed such that it falls below its yield point at least after the application to the label and/or the carrier and/or before the laying of the label and the carrier one on top of the other and/or the adhesive remains in the one or more first defined shapes after the application by means of the adhesive dispensing unit and preferably does not or does not substantially change its shape, preferably until the yield point is exceeded again during the laying of the label and the carrier one on top of the other. A uniform distribution between the label and the carrier can thus be achieved, without adhesive running out of the label and/or the carrier at an edge.
It is possible for the one or more first defined shapes of the adhesive to have cross-section dimensions, in particular diameter, in a range of from 50 μm to 5,000 μm, preferably in a range of from 500 μm to 3,000 μm. It is also possible for the adhesive to be applied with a width in a range of from 100 μm to 10,000 μm, preferably in a range of from 1,000 μm to 6,000 μm. The width is preferably measured in a top view and/or when viewed perpendicular to a plane spanned by the label and/or the carrier. Thus, a sufficient flow during the laying of the label and the carrier one on top of the other can preferably be achieved.
The adhesive preferably has been or is applied over the whole surface and/or over part of the surface, preferably patterned. It is possible in particular for the first defined shapes of the adhesive to have one or more of the following shapes: straight and/or curved lines, bone structure, T shape, Y shape, I shape, U shape, serpentines, nodes, branches, fractal shapes.
It is possible for the one or more first defined shapes to be formed by one or more first layers of the adhesive which have been or are applied over the whole surface and/or over part of the surface. During the laying of the label and the carrier one on top of the other it is possible for a displacement of the adhesive to result in a greater surface coverage and/or a surface coverage over the whole surface of the label and/or of the carrier with adhesive. The one or more adhesive layers are in particular obtained therefrom. The laying of the label and the carrier one on top of the other is preferably effected such that the one or more adhesive layers are arranged with a minimum thickness of 2 μm, preferably 3 μm, between the label and the carrier. The component part preferably has a minimum thickness of the one or more adhesive layers of 2 μm, preferably 3 μm. Preferably, the one or more adhesive layers in the component part have a thickness in a range of from 2 μm to 150 μm, preferably from 3 μm to 50 μm. The defined relative movement preferably can be carried out and/or is carried out such that the one or more adhesive layers are arranged with a thickness of at least 2 μm, in particular in a range of from 2 μm to 200 μm, preferably from 3 μm to 50 μm, between the label and the carrier. It is also possible for the layer thickness of the one or more adhesive layers preferably to lie in a range of from 1 μm to 1 mm, preferably in the range of from 50 μm to 250 μm. The one or more adhesive layers preferably have a thickness which is at least 30% greater than the height or depth of structures to be compensated for in each case. Structures to be compensated for in each case can in particular be elevations and/or indentations of the carrier which are to be provided or are provided with the label and/or the adhesive and/or the one or more adhesive layers. By “at least 30% greater” is meant in particular that the thickness of the one or more adhesive layers is at least 1.3 times the height and/or depth of these elevations and/or indentations. Through a minimum thickness of the adhesive layer(s), it can advantageously be guaranteed that nuisance particles are enclosed by the one or more adhesive layers.
For example, the adhesive is deposited in the shape of “beads”. In particular, if the adhesive is deposited partially, preferably patterned. For example in the case of adhesive in the shape of a bead, a viscosity of the adhesive in a range of from 500 mPa·s to 2,000 mPa·s is advantageous. This makes it possible in particular for the adhesive to be able to be applied well and to remain stable until the label and the carrier have been laid one on top of the other. By bead is meant in particular a shape with a substantially circular or elliptical cross section.
The application of one or more layers of the one or more adhesive layers to the label is advantageously effected onto a surface of the label that is easy to coat as it is for example flat or has been uniformly bent. In particular, the label has a 2.5D shape. The carrier and/or the component part has in particular a 2.5D surface to be coated, but also a 3D shape, in particular because of elevations, indentations, catches and/or frames. An expediently particularly uncomplicated depositing of adhesive can thus be carried out. In particular a smaller mass of the label compared with the carrier as well as a better ability to be handled can also be advantageous here.
It is possible that in step c) one or more first layers of the adhesive are applied to the label partially, preferably patterned, and one or more second layers of the adhesive are applied to the carrier over the whole surface and/or over a large area or one or more first layers of the adhesive are applied to the carrier partially, preferably patterned, and one or more second layers of the adhesive are applied to the label over the whole surface and/or over a large area.
It is also possible for the layer thickness of the one or more first defined shapes to be greater, at least in areas, than the layer thickness of the one or more second defined shapes and/or for, in a top view, the area of the one or more first defined shapes to be greater than the area of the one or more second defined shapes. The surface density of the first defined shapes relative to the 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 in particular less than 90%, preferably less than 80%. It is expedient that the surface density of the one or more first shapes is at least 5%.
The method is preferably carried out and/or the device is configured such that 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 particular in an initial area and in a following area, 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 particular lastly, in the following area. The adhesive in the one or more first defined shapes advantageously has a higher surface density in the initial area than in the following area. It is also possible for an intermediate area to have been or to be arranged between the initial area and the following area. The surface density of the glue in the first defined shape is preferably greater in the initial area than in the intermediate area and/or in the following area. The surface density in the first defined shape is preferably greater in the intermediate area than in the following area. However, it is also possible for the surface density in the first defined shape to be greater in the following area than in the intermediate area. The surface density of the one or more first defined shapes preferably decreases from the initial area toward the following area at least in areas.
Depending on the geometry of the label and the carrier as well as for example the demands on the adhesive surfaces, the flowing of the glue while the label and the carrier are being brought together can thus be optimized. The one or more first defined shapes can be determined for example empirically and/or by simulation. The shape is in particular to be chosen such that, after the label and the carrier have been laid one on top of the other and in particular in the produced component part, a preferably uniformly distributed adhesive layer without bubbles is distributed over the complete surface area of the carrier provided with the label.
The surface density is preferably calculated when viewed perpendicular to a plane spanned by the label and/or the carrier. The surface density is preferably calculated from the area of a surface area covered by adhesive in the first defined shape in relation to the surface area of the label and/or of the carrier which is provided with the adhesive in the second defined shape or with the one or more adhesive layers after the label and the carrier have been laid one on top of the other.
The initial area can be formed for example by a proportion of at most 20%, preferably of at most 10%, of the total surface area of the label which has a connection of label, adhesive and carrier in the respective first area first. The following area can be formed for example by a proportion of at least 80%, preferably of at least 90%, of the total surface area of the label which has a connection of label, adhesive and carrier in the respective first area last. The one or more first defined shapes can in particular also not be provided in the following area and adhesive can first be distributed by being displaced thereto. It is conceivable that there is only one first area, as is illustrated by way of example by
It is also possible for the adhesive with the one or more first defined shapes to have been or to be applied with a distance of at least 1 mm, preferably at least 2 mm, from an outer edge and/or from an outer 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 inside the label and/or the carrier.
A “squeezing out” of a gap formed by the label and the carrier can thus preferably be avoided.
It is also conceivable that the adhesive is applied exclusively to the label or that the adhesive is applied to the label over a large area and is applied to the carrier over a small area or is applied to the label over a small area and is applied to the carrier over a large area. By “over a large area” and “over a small area” is preferably meant that the area of the surface area covered with adhesive over a large area is greater than the area of the surface area covered with adhesive over a large area. For example, a large-area application of the glue can have been or be carried out on the carrier or the label, wherein one or more contact regions, in particular contact points, have been or are applied to the respectively other part out of the carrier or the label. The contact points have in particular an area of at most 20 cm2, preferably at most 4 cm2, in particular when viewed perpendicular to a plane spanned by the carrier and/or the label.
An advantage of applying the adhesive to the label is in particular that the label typically has a less complex surface geometry and in particular has been designed relatively flat and light. An application to the carrier can be designed more difficult, in particular if the latter has a 3D shape, possibly with an edge. However, it can also be advantageous to provide the contact regions in particular areas of the carrier or of the label, in order to avoid accumulations of adhesive on the respectively other part, which can result for example in a stronger flowing during handling, and/or in order to optimize the relative movement of the label and the carrier together with the amount of adhesive with respect to a displacement of the adhesive.
It is also possible for the adhesive to be applied to the label and a primer to have been or to be applied to the carrier or for a primer to have been or to be applied to the label and the adhesive to be applied to the carrier. The primer is in particular applied to a side or surface area to be provided with adhesive. The primer preferably has been or is applied partially or over the whole surface. The primer has preferably been chemically matched to the adhesive. A primer is in particular also called an adhesion promoter or “tie coat”. The primer has been or is in particular deposited as a layer.
It is possible for one or more first layers of the one or more adhesive layers and/or for the adhesive deposited for these layers to have or to consist of a varnish that can be dispensed, preferably to have or to consist of a UV dispensing varnish. The adhesive dispensing unit preferably has one or more dispensers and/or one or more volumetric dosimeters, by means of which such a dispensing varnish preferably is printable or is printed. In particular, the method for producing the component part is designed and/or the device is configured such that one or more first layers of the one or more adhesive layers are applied with the one or more dispensers. It is further possible for one or more layers of the one or more adhesive layers to be crosslinkable or to have been or to be crosslinked, in particular by means of radiation, preferably with visible light and/or with UV radiation. The one or more dispensers expediently have been or are matched to the respective adhesive layer, in particular its viscosity, fillers, processing temperature and/or amount deposited.
It is possible for one or more first layers of the one or more adhesive layers and/or for the adhesive deposited for these layers to have or to consist of a digital printing ink, preferably to have or to consist of an inkjet printing ink, preferably a UV inkjet printing ink. The adhesive dispensing unit preferably has one or more inkjet printheads, by means of which such an inkjet printing ink preferably is printable or is printed. In particular, the method for producing the component part is designed and/or the device is configured such that one or more first layers of the one or more adhesive layers are applied with a digital printing method, preferably an inkjet printing method, preferably a UV inkjet printing method. It is further possible for one or more layers of the one or more adhesive layers to be crosslinkable or to have been or to be crosslinked, in particular by means of radiation, preferably with visible light and/or with UV radiation. Adhesive layers in the form of an inkjet printing ink have been or are applied preferably with a viscosity in a range of from 0.5 mPa·s to 100 mPa·s, advantageously 8 mPa·s to 30 mPa·s.
It is conceivable that alternatively or additionally one or more layers of the one or more adhesive layers have been or are applied by means of gravure printing and/or screen printing. It is thus also possible for one or more layers of the one or more adhesive layers of the total structure, in particular of the one or more defined shapes, to comprise a gravure printing ink and/or a screen printing ink. It is furthermore also conceivable that, in addition to radiation curing properties, in particular UV curing properties and/or curing properties brought about by visible light, one or more layers of the one or more adhesive layers also have properties of thermal curing, self-curing and/or curing by crosslinking due to a multi-component system. The one or more adhesive layers preferably have a sufficiently high viscosity during the depositing in order that the shape of the glue is largely preserved during the process, until the label is applied to the component part. For example, the adhesive and/or the adhesive deposited for one or more layers of the one or more adhesive layers has Newtonian and/or shear-thinning fluid properties.
The adhesive and/or the one or more adhesive layer(s) obtained therefrom or one or more layers thereof preferably have been or are formed from the class of polyacrylates and/or polymethacrylates, polyurethanes, in particular from the group of polyester polyols, polyether polyols, polycarbonate polyols, polyacrylate polyols and/or combinations of these polymers, polyesters, polyethers, polyolefins, epoxy resins and/or from derivatives of the abovenamed. These formulations can in particular be both uncrosslinked and further have been or be crosslinked, preferably by isocyanates, carbodiimides, melamines and/or aziridines and/or derivatives of the named compounds.
The adhesive and/or the one or more adhesive layer(s) obtained therefrom or one or more layers thereof can further in particular have been or be constructed from radiation-curing substances, in particular radiation-curing acrylates and/or methacrylates, comprising or consisting of polyacrylic acrylates, polyurethane acrylates, polyester acrylates, polycarbonate acrylates and/or polyether acrylates and/or copolymers of the abovenamed. The radiation-curing formulations, in particular the radiation-curing acrylates and/or methacrylates, are preferably oligomers here. An oligomer is in particular a molecule with a number of monomers in a range of from 2 to 100. A polymer is in particular a molecule with a number of monomers starting from 101.
The adhesive and/or the one or more adhesive layer(s) obtained therefrom or one or more layers thereof preferably contain, in particular in addition to the named polyacrylates, further UV-curable acrylate monomers and/or methacrylate monomers, and/or are produced therefrom. Depending on the embodiment, these monomers in particular contain one or more acrylate groups and/or preferably further side groups such as e.g. alkyl, aryl, cycloalkyl, cycloalkylaryl, alkoxyalkyl, alkoxyaryl, thionyl, thionylaryl, cyclothionyl, cyclothionylaryl, alkoxythionyl, cycloalkoxythionyl, alkoxycyclothionyl, cycloalkoxycyclothionyl, alkoxythionylaryl, cycloalkoxythionylaryl, alkoxycyclothionylaryl and/or cycloalkoxycyclothionylaryl groups. In particular, specific varnish properties can be set hereby, such as e.g. the viscosity and an optimized formation of the three-dimensional network during the radiation curing. Through the selection of the monomers or combinations of them further properties, such as e.g. the surface hardness or residual tack (usually referred to by the term “tackiness”), of the one or more adhesive layers can in particular be controlled in a targeted manner.
In the finished component part, the one or more adhesive layers preferably comprise or preferably consist of correspondingly radiation-cured, in particular UV-radiation-cured and/or visible-light-cured, substances.
The adhesive and/or the one or more adhesive layer(s) obtained therefrom or one or more layers thereof can, in particular in the sense of a combination of the abovenamed, consist of or have been or be produced from a radiation-curing dual cure varnish. Dual cure varnishes can consist of different polymers or oligomers, which have unsaturated acrylate groups and/or methacrylate groups. These functional groups can in turn be radically crosslinked with each other in the radiation-curing step. For the thermal pre-crosslinking in the first step, at least two or more alcohol groups are preferably also used in the case of these polymers or oligomers. These alcohol groups can in particular be crosslinked with multifunctional isocyanates or melamine formaldehyde resins. Various UV raw materials such as epoxy acrylates, polyether acrylates, polyester acrylates and in particular polyacrylic acrylates come into consideration for example as preferably unsaturated oligomers, polymers or dendrimers. In particular, blocked and/or unblocked representatives based on TDI (TDI=toluene-2,4-diisocyanate), HDI (HDI=hexamethylene diisocyanate) or IPDI (IPDI=isophorone diisocyanate) are used as isocyanate. The melamine crosslinkers can come from the group of the fully etherified, the imino types and/or the benzoguanamines.
The adhesive and/or the one or more adhesive layer(s) obtained therefrom or one or more layers thereof can in particular also have been or be equipped with fillers such as for example HDS (highly dispersed silica) for the optimization of rheological properties.
The one or more adhesive layers preferably contain so-called initiators, in particular UV initiators, in particular for the initiation of the radiation curing, if this is in particular a UV-radiation curing. The UV initiators are preferably selected from the class of the α-alkoxy, α-hydroxy or α-amino-aryl ketones and/or the class of the acyl phosphine oxides and/or polymer-bound variants of these above-named classes. Acyl phosphine oxides are preferably used in combination with dispensers, UV inkjet printing, flexographic printing, pad printing or screen printing of the one or more adhesive layers, in particular because of their particularly suitable absorption properties in the UV LED range.
In particular for the improvement of specific and typical varnish properties, such as e.g. the wetting, the flow, the foam formation etc., it is possible for the one or more adhesive layers to contain additives. For the integration of these additives into the three-dimensional network, they have for their part typically been provided with radiation-curing or thermally crosslinkable groups or combinations thereof.
It is possible that, in particular for the minimization of chain terminations during the radiation curing through reactions of the formed radicals with oxygen molecules from the air and/or for the reduction of the migration of radical chains to the layer surface, tertiary amines and/or acrylate amines, in particular so-called amine synergists, have been or are preferably added to the adhesive and/or the one or more adhesive layer(s) obtained therefrom or one or more layers thereof. In particular for the integration of these additives into the three-dimensional network, they have preferably for their part likewise been provided with radiation-curing or thermally crosslinkable groups or combinations thereof.
The method is preferably carried out and/or the device has preferably been configured such that through the defined relative movement of the label receiver and the carrier receiver the adhesive is displaced or can be displaced at least in areas from the one or more first defined shapes to the one or more second defined shapes of the one or more adhesive layers. The method is preferably carried out and/or the device has preferably been configured such that the laying of the label and the carrier one on top of the other, in particular the defined relative movement, can be carried out or is carried out through a translational and/or rotational movement of the label in relation to the carrier. The defined relative movement of the label receiver and the carrier receiver is or comprises in particular a seesawing and/or an unrolling. The defined relative movement of the label receiver and the carrier receiver is preferably carried out automatically and/or can be carried out automatically.
The method is preferably carried out and/or the device has preferably been configured such that, to carry out the defined relative movement of the label and the carrier, the label is rotated and/or is rotatable about a rotation point and/or at an angle in a range of from 0° to 45° and/or with an angular velocity of from 0.01 rad/s to 100 rad/s.
Alternatively or additionally, the method is particularly preferably carried out and/or the device has particularly preferably been configured such that, to carry out the defined relative movement of the label receiver and the carrier receiver and/or of the label and the carrier, a seesawing movement and/or an unrolling movement of the label or of the label receiver is carried out and/or can be carried out. By a seesawing movement is meant here in particular a rotational movement about a spatially fixed axis above the carrier and/or above the carrier receiver, in particular wherein there is a translational movement between the label receiver, in particular the label on the label receiver, and the carrier receiver, in particular the carrier on the carrier receiver. By an unrolling movement is meant here in particular a rotational movement with an axis of rotation above the carrier receiver, preferably above the carrier on the carrier receiver, in particular wherein the axis of rotation moves, preferably moves in the direction of an unrolling direction. Here, there is preferably no translational movement between the label receiver, in particular the label on the label receiver, and the carrier receiver, in particular the carrier on the carrier receiver. It is possible for the seesawing movement to be effected multiple times, wherein the direction of rotation alternates, i.e. in particular a seesawing back and forth is effected. It is possible for the unrolling movement to be effected multiple times, in particular wherein the direction of rotation and the translational direction of the axis of rotation alternates, i.e. wherein an unrolling back and forth is preferably effected.
It is, in particular in the case of labels with a surface area which is smaller than 100 cm2, preferably smaller than 20 cm2, preferably in a top view and/or when viewed perpendicular to a plane spanned by the label, conceivable to carry out the method and/or to design the device such that purely a lifting movement is carried out and/or can be carried out by the label receiver and/or the carrier receiver as the relative movement of the label and the carrier. The lifting movement is to be understood in particular as a purely translational movement. In particular, the simple structure of the device and the simple procedure are advantageous here. However, a rotational component of the movement is preferably advantageous in particular in the case of larger labels.
In particular, the device has means for carrying out the relative movement of the label receiver and the carrier receiver, which in particular comprise movable component parts, actuators for moving the component parts and means for actuating the actuators, preferably based on software commands, in particular by means of at least one storage medium and at least one processor. The defined relative movement of the label and the carrier can preferably be carried out or is carried out based on data regarding the position, attitude and/or movement of the label and/or of the carrier retrievable in particular from a storage medium. The label receiver preferably has been or is held and/or moved by means of a robot system, preferably a collaborating robot system. For this, the robot system preferably has one or more of the following components: one or more robot arms, one or more joints for the movable arrangement of the one or more robot arms, one or more actuators for moving the one or more robot arms, preferably one or more hydraulic actuators, one or more pneumatic actuators and/or one or more electric motors, preferably one or more servomotors, for moving the one or more robot arms, one or more sensors for detecting the position and/or attitude of the label receiver and/or of the one or more robot arms, a control device, in particular for storing and executing movement sequences, an interface for an operating device and/or an operating device, in particular for inputting, storing and/or retrieving the movement sequences. The one or more joints or at least one joint thereof preferably provide a rotational mobility. A translational movement can here preferably be able to be carried out or be carried out through the interaction of several rotational movements. The movement sequences can have been or be stored in the control device for example by a manual movement and/or manual positioning of the label receiver, in particular by storing data from the one or more sensors regarding the movement and/or position and/or attitude of the one or more robot arms.
It is preferred that the label receiver can be guided and/or is guided movably by a robot system, in particular a robot arm, and the carrier receiver is arranged in a fixed position of the device.
It is possible for the method to be executed and/or for the device to have been configured such that the adhesive depositing device and/or the label receiver are moved during the application of the adhesive. The method is preferably carried out and/or the device is configured such that the label receiver is preferably brought into a printing position and/or the adhesive is applied in the first defined shape by means of a relative movement of the adhesive dispensing unit and the label receiver. It is possible for the adhesive dispensing unit and/or the label receiver to be moved in one or more spatial directions, in particular selected from the x direction, the y direction and/or the z direction of a Cartesian coordinate system.
In particular, a movement of the label receiver relative to the glue dispensing unit and/or relative to the curing unit is in addition carried out by means of the means for carrying out the relative movement of the label receiver and the carrier receiver.
It is preferred that the label is held register-accurately in the label receiver and/or the label receiver is designed to hold the label in a register-accurate manner and/or the label and/or the label receiver has for example markings as registration marks, which preferably make a register-accurate holding position recognizable. For the register-accurate holding of the label, the label receiver can have for example a shape adapted to the shape of the label and/or adapted holding elements.
It is possible for the laying of the label and the carrier one on top of the other to be carried out register-accurately, in particular with a tolerance of less than ±1 mm, preferably ±0.5 mm, preferably ±0.2 mm. The tolerance is in particular a deviation of the actual position from a target position.
For this, the device can have one or more sensors for determining the relative position of the label and the label receiver and/or of the label and the carrier. It is also possible for the label receiver and/or the carrier receiver, the label and/or the carrier to have one or more registration marks or for one or more elements of the label and/or of the carrier to be used as registration marks, wherein the position of the registration marks is determined by the one or more sensors and compared with a target value, and an adaptation of the relative position of the label and the carrier is possibly derived therefrom.
The carrier receiver preferably comprises or consists of one or more of the following parts: a rigid surface, on which the carrier is placed, a table, indentation, spacer, clamping devices, screw joint, magnetic holder, vacuum holder. The provision of the carrier can for example be effected by means of a manual placement on the carrier receiver and/or by means of a placement on the carrier receiver preferably by a robot arm. In particular, the carrier, preferably by means of the one or more clamping devices and/or screw joint and/or indentation and/or magnetic holder and/or vacuum holder, is held in a defined position by the carrier receiver and/or the carrier receiver is provided in a defined and fixed position. The carrier receiver is in particular adapted to the geometry of the carrier. The carrier receiver can consist of steel or of plastic. The carrier receiver can be produced in particular by means of 3D printing.
The device preferably comprises a curing unit for at least partially curing and/or at least partially crosslinking the one or more adhesive layers. It is possible that, before the at least partial curing and/or at least partial crosslinking, in particular before a curing and/or complete crosslinking, of the one or more adhesive layers, the label receiver is moved away from the label. It is also possible for the at least partial curing and/or at least partial crosslinking to be effected by means of one or more of the following steps: irradiation, in particular in the visible range, i.e. in particular by means of irradiation with visible light, and/or by means of UV irradiation, preferably by means of UV-A radiation, UV-B radiation and/or UV-C radiation, electron beam curing, curing by heat, anaerobic curing, anionic curing, moisture-initiated crosslinking, multi-component curing, in particular two-component curing. It is thus possible for example for the curing to be carried out by waiting and/or a heat input in the case of self-curing adhesives.
UV radiation is formed in particular of wavelengths in a range of from 100 nm to 400 nm. UV-A radiation is formed in particular of wavelengths in a range of from 315 nm to 400 nm. UV-B radiation is formed in particular of wavelengths in a range of from 280 nm to 315 nm. UV-C radiation is formed in particular of wavelengths in a range of from 100 nm to 280 nm. Visible light is formed in particular of wavelengths in a range of from 400 nm to 780 nm. IR radiation is formed in particular of wavelengths in a range of from 780 nm to 1 mm. Near infrared (NIR) is formed in particular of wavelengths in a range of from 780 nm to 3 μm. Mid infrared (MIR) is formed in particular of wavelengths in a range of from 3 μm to 50 μm. Far infrared is formed in particular of wavelengths in a range of from 50 μm to 1 mm.
It is possible in particular for the curing unit to have or to have been formed by an irradiation unit, in particular for irradiation with visible light and/or with UV radiation, preferably UV-A, UV-B and/or UV-C radiation, for irradiation of the one or more adhesive layers and/or for the at least partial curing and/or at least partial crosslinking to be effected or to be able to be carried out by means of irradiation, in particular UV irradiation, preferably by means of UV-A radiation, UV-B radiation and/or UV-C radiation, and/or by means of visible light.
The irradiation unit has preferably been designed or the irradiation is preferably carried out such that an irradiation is carried out with wavelengths in a range of from 50 nm to 600 nm, preferably from 100 nm to 450 nm, further preferably from 100 nm to 405 nm, and/or an irradiation is carried out with a duration in a range of from 0.25 s to 20 s, preferably 1 s to 5 s, and/or that during the irradiation there is a temperature, in particular of the label, of the carrier and/or of the one or more adhesive layers, in a range of from 10° C. to 100° C., preferably 15° C. to 40° C. The irradiation is carried out for example by means of one or more lamps, in particular UV lamps, preferably UV LEDs, and/or LEDs for radiation in the visible range and/or mercury vapor lamps which have been doped with iron and/or gallium and/or indium and/or bismuth and/or lead and/or tin. The distance of the one or more lamps preferably lies in a range of from 10 mm to 1,000 mm, preferably from 50 mm to 200 mm. The power of the one or more lamps, in particular UV lamps, preferably UV LEDs, and/or LEDs for radiation in the visible range and/or mercury vapor lamps which have been doped with iron and/or gallium and/or indium and/or bismuth and/or lead and/or tin preferably lies in a range of from 10 mW/cm2 to 5,000 mW/cm2, preferably 50 mW/cm2 to 500 mW/cm2.
The irradiation is preferably effected over the whole surface, in particular after the label has been moved away from the label receiver. The one or more adhesive layers are thus to be cured and/or crosslinked in particular almost completely. A complete curing and/or complete crosslinking, thus in particular a crosslinking of 100% of the polymer constituents capable of crosslinking and/or an achievement of the final hardness of the one or more adhesive layers, can then be effected for example within a period of 12 hours.
The following step is preferably carried out in the method: precuring of the one or more adhesive layers over part of the surface or over the whole surface. A fixing of the label at one point or several points of the carrier can be achieved herewith, with the result that when the label receiver is taken off the label the label does not slip or lift off together with the label remover. It is possible for the device to have a precuring unit for precuring the one or more adhesive layers partially or over the whole surface, in particular while the label receiver is in contact with the label. The precuring unit is preferably an irradiation unit, in particular for irradiation with UV radiation, preferably UV-A, UV-B and/or UV-C radiation, and/or with visible light, and/or with IR radiation. The one or more adhesive layers here preferably have been or are not yet completely cured or not yet completely crosslinked at least in areas.
In particular, the label receiver has one or more transparent, preferably UV-transparent, areas and/or one or more holes, and/or the one or more adhesive layer are irradiated or can be irradiated through the one or more transparent areas and/or holes, in particular while the label receiver is still in contact with the label.
It is thus possible for the radiation of the precuring unit preferably to pass through the transparent areas and/or the holes before the radiation strikes the one or more adhesive layers. This makes it possible to increase the adhesion between the label and the carrier before the label is taken off the label receiver. Thus, the label receiver can in particular be taken off the label securely, reliably and in a manner that is gentle on the one or more adhesive layers.
A precuring of the adhesive after the application of the adhesive, in particular directly after the application of the adhesive, and before the laying of the label and the carrier one on top of the other is also conceivable. Undesired flowing of the adhesive can in particular be prevented hereby.
It is also possible for the one or more adhesive layers to be cured and/or completely crosslinked, in particular by means of the curing unit, in particular by means of irradiation, preferably UV irradiation, and/or irradiation with visible light and/or IR irradiation, preferably after the label receiver has been taken off. The device, in particular the curing unit, has preferably been designed such that the one or more adhesive layers are cured and/or completely crosslinked by means of the curing unit after the label receiver has been taken off, in particular by irradiation, preferably UV irradiation and/or irradiation with visible light.
“Not yet completely cured” preferably describes a layer, in particular the protective varnish layer, when its hardness and/or durability does not yet have a fixed minimum value. The fixed minimum value of the hardness and/or of the durability is preferably a function of the ultimate intended use of the layer, for example as a protective varnish layer. “Completely cured” within the meaning of the present invention therefore describes a layer when its hardness and/or durability has a fixed minimum value.
It is possible for the above-named minimum values to have been fixed such that a layer is described as not yet completely cured within the meaning of the present invention when not more than 95% of the polymer constituents of the layer that are capable of crosslinking have a crosslinking. A layer is therefore described as completely cured within the meaning of the present invention when more than 95% of the polymer constituents of the layer that are capable of crosslinking have a crosslinking. A completely cured or completely crosslinked layer is present when a complete (>95%) crosslinking of its polymer constituents has been effected.
It is also possible for the one or more adhesive layers to be only partially irradiated in an irradiation area, for example because the label and/or the carrier outside the irradiation area is opaque, at least in areas, for the radiation used for the irradiation. Here, the crosslinking initiated in the irradiation area is preferably continued outside the irradiation area in the form of a chain reaction, with the result that the one or more adhesive layers cure or can cure over the whole surface and completely. By opaque is preferably meant a transmittance in a range of from 0% to 15%. By semitransparent or partially transparent is preferably meant a transmittance in a range of from 15% to 50%. By transparent is preferably meant a transmittance in a range of from 50% to 100%. In particular if the label and/or the glue is opaque over the whole surface, it is possible for a self-curing and/or reactively curing adhesive advantageously to be used which does not require high-energy radiation such as for example UV radiation for the curing.
It is possible for the precuring unit and the curing unit to be formed by two separate devices or by the same device. In particular, it is thus possible for the precuring and the curing and/or complete crosslinking of the one or more adhesive layers to be carried out by means of a single irradiation unit or by means of separate irradiation units.
The precuring is effected in particular by means of a first irradiation unit, which has preferably been fastened to the label receiver or to the carrier receiver. In addition, it is possible for the curing and/or complete crosslinking to be effected by means of a second irradiation unit, which has been fastened in particular to the label receiver or to the carrier receiver. The first and the second irradiation units have preferably been fastened to the carrier receiver.
The label preferably comprises or is formed by a sensor film. The sensor film preferably forms a sensor function, preferably a touch sensor function. The sensor function, preferably touch sensor function, has been or is provided in particular by means of the electrically conductive functional layer of the label. For this, the electrically conductive functional layer preferably has one or more conductive tracks and/or one or more capacitive elements. It is possible for the sensor film and/or the electrically conductive functional layer, in particular the one or more conductive tracks and/or the one or more capacitive elements, and/or the carrier layer to be transparent and/or to be non-transparent, in particular opaque.
It is possible in particular for the label, preferably in addition to the sensor film, and/or the sensor film, to have been provided with a decoration and/or to have been provided with further films or layers, e.g. to have been provided with at least one optically active diffuser, at least one optically active mask layer, at least one light guide, at least one light-emitting layer, and/or to have been provided with a functional layer containing the one or more electrical and/or electronic and/or optical and/or optoelectronic components and/or with a functional layer containing one or more further electrical and/or electronic and/or optical and/or optoelectronic components and/or with a functional layer containing optical components.
As follows from the preceding statements, but is also conceivable independently thereof, it is possible for the label to have been designed such that it provides a touch function of the component part. Alternatively or additionally, it is possible for the label to have been designed such that it provides a decoration of the component part, in particular that it provides only a decoration of the component part. Alternatively or additionally, it is also possible for the label to have been designed such that it provides an electrical function, because the label forms for example a flexible printed circuit board with LEDs, with conductive tracks, and/or with heating tracks etc. Preferably, the flexible layer structure is provided by the at least one carrier layer and corresponding functions are provided by the further layer and/or the one or more electrical and/or electronic and/or optical and/or optoelectronic components.
The at least one further layer is preferably selected individually or in combination from: at least one electrically conductive functional layer, in particular the electrically conductive functional layer, at least one color layer, at least one electrically insulating functional layer, at least one optical diffuser layer, at least one optical mask layer, at least one light guide layer, at least one light-emitting layer, at least one protective layer, at least one barrier layer, at least one compensation layer, at least one adhesion-promoter layer, at least one adhesive layer, at least one barrier layer, at least one oxide layer, at least one metal layer.
The one or more electrical and/or electronic and/or optical and/or optoelectronic components and/or the one or more further electrical and/or electronic and/or optical and/or optoelectronic components can comprise active components and/or passive components. The one or more electrical and/or electronic and/or optical and/or optoelectronic components and/or the one or more further electrical and/or electronic and/or optical and/or optoelectronic components are preferably selected individually or in combination from: at least one LED; at least one OLED, at least one plug, at least one socket, at least one sensor, at least one electrical resistor, at least one capacitor, at least one controller, at least one processor. The one or more electrical and/or electronic and/or optical and/or optoelectronic components have preferably been electrically contacted by the at least one electrically conductive functional layer, in particular with the result that the electrically conductive functional layer in particular acts as a conductive track.
It is conceivable that the one or more electrical and/or electronic and/or optical and/or optoelectronic components are present in the label, preferably at least on the carrier layer, separately and/or exposed or that the further layer comprises or consists of a functional layer which comprises and/or encapsulates the one or more electrical and/or electronic and/or optical and/or optoelectronic components or parts thereof.
The label preferably has the following layers, in particular in the specified order, preferably starting with a side which forms a visible face of the component part, selected individually or in combination from:
However, further layers and any desired orders of the layers are also possible. The first protective layer has in particular been designed firmly integrated in the label or detachable from the label. The label preferably has at least the first protective layer and the primer, wherein the carrier layer and the further layer, in particular the electrically conductive functional layer, and/or the one or more electrical and/or electronic and/or optical and/or optoelectronic components, which are preferably comprised by the sensor film, have been arranged between the primer, in particular in any desired order. It is also conceivable that a second protective layer has been arranged on a side of the primer facing the carrier layer. It is also conceivable that a third protective layer has been arranged on a side of the primer facing away from the carrier layer, wherein the third protective layer is detachable and is preferably detached before the adhesive is applied.
It is possible for the carrier layer of the label to have or to consist of one or more of the following materials: PET (polyethylene terephthalate), PC (polycarbonate), PMMA (polymethyl methacrylate), ABS (acrylonitrile butadiene styrene), PC-ABS, PP (polypropylene), PA (polyamide), PE (polyethylene). In particular, the label has a thickness in a range of from 25 μm to 350 μm, preferably in a range of from 50 μm to 150 μm. It is also possible for the label to have a surface area, in particular in a top view and/or when viewed perpendicular to a plane spanned by the label and/or disregarding the thickness of the label, in a range of from 1 cm2 to 2,000 cm2, in particular in a range of from 1 cm2 to 1,000 cm2. In particular, it is possible for example for the label not to have a purely rectangular or purely circular contour. It is also possible for the label to have a surface area, in particular when viewed perpendicular to a plane spanned by the label and/or disregarding the thickness of the label, which comprises a contour of a part or a whole of one or more of the following shapes at least in areas: circle, ellipse, triangle, rectangle, alphanumeric character, fractal shape. The contour can also have been formed by openings at least in areas.
It is possible for the carrier to be transparent, opaque, partially transparent and/or non-transparent in areas or over the whole surface. In particular, the carrier can have one or more transparent windows, for example for a display, and/or one or more patterned transparent areas, for example symbol-shaped areas, in particular for buttons. It is therefore advantageous if the adhesive and/or the one or more adhesive layers expediently do not influence the transparency.
The carrier preferably has a maximum wall thickness in a range of from 0.1 mm to 10 mm, in particular in a range of from 0.1 mm to 5 mm, preferably in a range of from 1 mm to 5 mm, preferably in a range of from 1.5 mm to 3.5 mm, or in a range of from 0.15 mm to 10 mm, preferably in a range of from 0.2 mm to 10 mm. It is possible for the carrier to have such a maximum wall thickness only in subareas or in all areas. In particular in the case of small wall thicknesses, the advantage of a low thermal load carries particular weight.
In a preferred embodiment example, the carrier does not have a frame. However, it can have a frame with a height of at most 100 mm, preferably of at most 50 mm, particularly preferably of at most 20 mm. Here, in particular despite a comparatively poor handling, a rapid, safe and reproducible processing is guaranteed because of the automated method or the automated device.
It is possible for the carrier to have been decorated on the front and/or on the back, in particular before the application of the label. It is also possible for the component part to be decorated on the front and/or on the back after the application of the label to the carrier.
It is possible for the label to have a contacting tail for contacting, in particular electrically contacting, the further layer, in particular the electrically conductive functional layer, and/or the one or more electrical and/or electronic and/or optical and/or optoelectronic components. In the method the contacting tail preferably is and/or remains free of adhesive and/or free of material of the carrier, preferably free of adhesive and/or free of material of the carrier at least in a contact area. For this, in particular the one or more defined shapes of the adhesive are applied with an adapted shape and amount, for example to form beads in a bone structure, and in particular the contact area is left free of adhesive. Furthermore, the relative movement of the label and the carrier preferably has been or is adapted, in particular by means of a lifting movement and/or a seesawing movement, preferably with the result that the contact area remains free of adhesive and/or free of material of the carrier.
A defined pressure and/or a defined relative movement can in particular also be exerted on the label, the adhesive and the carrier. Furthermore, a defined temperature range of the label, the adhesive and the carrier can have been or be set during the laying of the label and the carrier one on top of the other. Thus, a squeezing of the glue out at the sides of the label, which would impair the contacting tail, can advantageously be avoided.
The contacting tail is held on the label receiver preferably in a defined position. For this, the label receiver can have for example means for suctioning the tail by means of vacuum, one or more clamping devices and/or one or more spacers. The contacting tail preferably has a smaller surface area than the rest of the label, in particular when viewed perpendicular to a plane spanned by the label.
It is possible for one or more of the following steps to be carried out, in particular after the label and the carrier have been laid one on top of the other, preferably after the complete curing and/or complete crosslinking of the one or more adhesive layers:
It is possible for one or more of the following steps to be carried out, in particular before the application of the adhesive and/or before the laying of the label and the carrier one on top of the other:
The device preferably has a pretreatment unit for pretreating the label and/or the carrier, for example by blowing ionized air against the carrier and/or by a plasma treatment and/or by a corona treatment and/or by a cleaning with chemicals, e.g. with alcohol. The pretreatment unit is or comprises for example individually or in combination: an ionizer and means for blowing ionized air against the carrier, a device for plasma treatment, a device for corona treatment, a device for cleaning with chemicals, e.g. with alcohol.
In particular, at least the surface of the label and/or of the carrier is pretreated by the pretreatment, and it is then brought into contact with the one or more adhesive layers. The pretreatment is thus preferably a cleaning or an activating of the corresponding surface. Thus, e.g. an improved wetting by the adhesive and/or improved flow properties of the adhesive in the process and/or an improved adhesive force in the process and/or in the final product can be achieved.
The label receiver is preferably detached and/or moved away from the label before the complete curing and/or complete crosslinking. Before the label receiver is moved away and/or detached from the label, the precuring of the adhesive or of the one or more adhesive layers is preferably carried out.
It is possible for one or more nuisance particles enclosed bubble-free to be present in the one or more adhesive layers and/or for a surface of the carrier which is provided with one or more adhesive layers bubble-free and which has unevennesses, steps, indentations and/or elevations to be present. It is also possible for the carrier to have a curved surface and/or elevations and/or indentations on a surface facing the label, in particular wherein the one or more adhesive layers have a variation in layer thickness following the curved surface and/or the elevations and/or the indentations. Furthermore, the carrier can have one or more elevations and/or indentations, in particular additional elevations and/or indentations, which are present in particular in the form of at least one frame and/or one or more catches. “Additional elevations and/or indentations” means here in particular that these are present in addition to the surface of the carrier provided with the one or more adhesive layers. In particular, the carrier thus has a three-dimensional shape. Despite correspondingly complex geometries of such carriers, they can still be reliably provided with a label in particular using the method according to the invention.
In the following, the invention is explained by way of example with reference to several embodiment examples with the aid of the accompanying drawings. There are shown in:
The carrier 3 preferably has a maximum wall thickness in a range of from 0.15 mm to 10 mm, in particular from 1 mm to 5 mm. It is possible for the carrier 3 to have such a maximum wall thickness only in subareas or in all areas. In particular in the case of small wall thicknesses, the advantage of a low thermal and mechanical load carries particular weight.
In a preferred embodiment example, the carrier 3 has a frame or other elevations (e.g. fastening elements) with a height of at most 100 mm, preferably of at most 50 mm, particularly preferably of at most 20 mm. Here, in particular despite a comparatively poor handling, a rapid, safe and reproducible processing is guaranteed because of an advantageously automated method or an advantageously automated device.
It is also possible for the carrier 3 to have been decorated on the front and/or on the back. It is also possible for the component part 1 to be decorated on the front and/or on the back after the application of the label 2 to the carrier 3.
As is moreover illustrated by
The carrier 3 preferably has at least one curved surface, which lies for example in the curvature area 53 in
As is illustrated in particular by
The steps a1) and a2) as well as b1 and b2) described below are illustrated by way of example by
Step a1) Providing a label 2. The label 2 has a flexible layer structure. The label 2 comprises at least one carrier layer, such as the carrier layer 23, and in addition comprises a further layer, such as for example the electrically conductive functional layer 22, wherein the carrier layer 23 and the functional layer 22 are illustrated for example with reference to one of
Step a2) Receiving the label 2 with the label receiver 20.
The label 2 shown in
It is also possible for the label receiver 20, as an alternative or in addition to the means for generating a vacuum, to have for example a mechanical holder and/or a clamp for receiving the label 2.
The label receiver 20 is preferably connected to a robot system, which makes it possible to move the label receiver 20 to different positions for carrying out the respective steps. With respect to the robot system, reference is made in particular to the above statements.
The provision of the label 2 is effected before the label 2 is received with the label receiver 20. The provision of the carrier 3 is effected before the carrier 3 is received with the carrier receiver 30, wherein it is possible for the receiving of the label 2 to be carried out first or for the receiving of the carrier 3 to be carried out first or for both to be carried out simultaneously.
Step c) Applying, by means of the adhesive dispensing unit 40, a flowable adhesive 4, in one or more first defined shapes, to the label 2 held by means of the label receiver 20. Example defined shapes of the adhesive 4 are described in relation to
Step b1) Providing a carrier 3. The carrier 3 has been constructed for example as is described in more detail in relation to one of
Step b2) Receiving the carrier 3 by means of the carrier receiver 30.
Step x1) Pretreating the carrier 3 by means of a pretreatment unit 80, for example by blowing ionized air against the carrier 3 and/or by a plasma treatment and/or a corona treatment and/or by a chemical cleaning, e.g. with alcohol. The pretreatment unit 80 is or comprises for example individually or in combination: an ionizer and means for blowing ionized air against the carrier 3, a device for plasma treatment, a device for corona treatment, a device for cleaning with chemicals, e.g. with alcohol.
Step d) Laying the label 2 and the carrier 3 one on top of the other by means of a defined relative movement of the label receiver 20 and the carrier receiver 30, such that the adhesive 4 is arranged between the label 2 and the carrier 3 and one or more adhesive layers, in particular the adhesive layer 41, preferably in one or more second defined shapes, are obtained between the label 2 and the carrier 3. Here, in particular in the case of complex geometries of the carrier 3, the one or more first defined shapes of the adhesive 4 and the relative movement of the label 2 and the carrier 3 can be matched to each other in a targeted manner, with the result that the one or more adhesive layers, in particular the adhesive view 41, results from this. The relative movement preferably comprises a rotational movement in the example shown by
As is illustrated by way of example with reference to a comparison of
The label receiver 20 is preferably guided to the carrier receiver 30 in particular by means of a robot system, in particular as a part of the defined relative movement of the label 2 and/or the carrier 3, or the defined relative movement is carried out and/or continued thereafter.
Step x2) Precuring the one or more adhesive layers over part of the surface.
It is possible for the device to have a precuring unit 60 as shown by way of example in
Step x3) Detaching the label 2 from the label receiver 20.
For this, the label receiver 20 is moved away from the label 2. It is possible for example for the vacuum to be ceased and/or a pressure to be increased on the label receiver 2.
Step e) At least partially curing and/or at least partially crosslinking the one or more adhesive layers, in particular the adhesive layer 41.
It is possible here for the curing to be carried out by means of irradiation, preferably UV radiation, preferably UV-A and/or UV-B and/or UV-C radiation, and/or with visible light and/or IR radiation, as is illustrated in particular by
After the curing, the component part 1 produced can be removed from the device.
The device according to the invention for producing the component part 1 preferably serves and/or has been configured to carry out the method. As is shown for example by
It is also possible for the device to have an optional curing unit 70 for at least partially curing the one or more adhesive layers, preferably the adhesive layer 41.
As is shown by
Step 1001: Providing the label 2, which has a flexible layer structure and preferably is or comprises a sensor film, manually and/or by means of a robot arm, in particular in or from a magazine, and the carrier 3 by means of a manual placement on the carrier receiver and/or by means of a placement on the carrier receiver by a robot arm.
Step 1002: Optionally pretreating the carrier, for example by means of treatment with ionized air, corona treatment and/or plasma treatment and/or cleaning with chemicals, e.g. with alcohol.
Step 1003: Receiving the label 2 by means of the label receiver 20, in particular by suction by means of a vacuum,
Step 1004: Applying the flowable adhesive 4 to the label 2
Step 1005: Laying the label 2 on top of the carrier 3, in particular by means of a movement of the label receiver 20.
Step 1006: Optionally precuring the adhesive 4 or the one or more adhesive layers obtained therefrom, in particular the adhesive layer 41, preferably wherein the precuring takes place only in a subarea and/or takes place by means of irradiation through the label receiver 20 and/or one or more holes of the label receiver 20.
Step 1007: Moving the label receiver 20 away from the label 2, in particular through a movement of the label receiver 20.
Step 1008: Curing and/or completely crosslinking the one or more adhesive layers, in particular the adhesive layer 41.
Step 1009: Optionally removing the component part 1 from the carrier receiver 30, for example manually, by means of a robot arm, by means of a removal means and/or by means of the label receiver. It is also possible here for a transfer of the component part 1 to be effected for example by means of an X/Y or X/Y/Z shift mechanism, for example to be effected onto a conveyor belt and/or onto and/or into a housing.
Step 1010: Optionally checking the component part 1 by means of optical inspection by means of cameras and/or optical sensors or visual inspection by a human and/or by means of one or more sensors. Here, in particular, measured values with respect to the geometry, transmittance, electrical capacitance, electrical resistance, are compared with a target value. The device preferably has means for comparing the values measured by means of the one or more sensors with a target value.
Step 1011: Optionally placing the component part 1, in particular manually and/or by means of a robot arm and/or by means of an X/Y or X/Y/Z shift mechanism or by means of conveyors, for example at a storage location and/or in a package.
The device has been configured in particular for carrying out one or more of the step 1001 to 1011, in particular step 1005, in an automated manner.
It is possible in particular for the one or more first defined shapes to have cross-section dimensions, in particular diameter, in a range of from 50 μm to 5,000 μm, preferably in a range of from 500 μm to 3,000 μm. For example, the adhesive is applied as a “bead”. A preferred range of the viscosity lies in a range of from 500 mPa·s to 2,000 mPa·s, further preferably in a range of from 1,000 mPa·s to 1,500 mPa·s. It is advantageously guaranteed that the adhesive remains stable in the one or more first defined shapes. The adhesive 4 preferably has been or is applied with a width in a range of from 100 μm to 10,000 μm, preferably in a range of from 1,000 μm to 6,000 μm. The width is preferably measured in a top view and/or when viewed perpendicular to a plane spanned by the label 2 or the carrier 3, thus in particular when viewed as shown in
A preferred adhesive has a temperature resistance of from −50° C. to 150° C. and/or a flash point of over 100° C. and/or a refractive index (nD20) in a range of from 1 to 2, preferably 1.2 to 1.8, preferably from 1.46 to 1.48.
As is illustrated by
In addition, it is conceivable that the adhesive 4 is applied to the label 2 and a primer has been or is applied to the carrier 3 or a primer has been or is applied to the label 2 and the adhesive 4 is applied to the carrier 3.
With respect to the composition of the adhesive 4, reference is made in particular to the above statements. It is preferably an adhesive crosslinkable by means of UV radiation and/or with visible light.
During the laying of the label 2 and the carrier 4 one on top of the other, the adhesive is in particular further distributed between the label 2 and the carrier 4, from which the one or more adhesive layers 41 with one or more second defined shapes result, with the result that preferably the layer thickness of the first defined shapes is greater at least in areas than the layer thickness of the second defined shapes and/or in a top view the area of the first defined shape is greater than the area of the second defined shapes. As is also illustrated by
An example defined relative movement of the label 2 and the carrier 3 is indicated here in particular by the arrow 45, wherein the arrow specifies the starting point of a contact of the label 2, the adhesive 4 and the carrier 3 and the direction of areas in which a contact of the label 2, the adhesive 4 and the carrier 3 is subsequently produced. The sequence shown can be achieved for example by a rotational movement of the label receiver 20, in particular a seesawing movement and/or an unrolling movement. By contact is meant here in particular that a line, preferably a vertical line, which extends through the label 2, the adhesive 4 and the carrier 3, can be formed in a cross section, for example a cross section as shown in relation to
As is illustrated in addition by
In the case of a depositing of the adhesive 4 onto the carrier, such areas can be defined analogously.
The initial area 401 can be formed for example by a proportion of at most 20% of the total surface area of the label which has a connection of label 2, adhesive 4 and carrier 3 in the respective first area first. The following area 403 can be formed for example by a proportion of at least 80% of the total surface area of the label which has a connection of label 2, adhesive 4 and carrier 3 in the respective first area last. The one or more first defined shapes can in particular also not be provided in the following area 403 and adhesive 4 can first be distributed by being displaced thereto. It is conceivable that there is only one first area 40, as is illustrated by way of example by
The surface density is preferably calculated when viewed perpendicular to a plane spanned by the label and/or the carrier. The surface density is preferably calculated from the area of a surface area covered by adhesive 4 in the first defined shapes in relation to the surface area of the label 2 and/or of the carrier 3 which is provided with the adhesive 4 in the second defined shape or with the one or more adhesive layers 41 after the label 2 and the carrier 3 have been laid one on top of the other.
The adhesive 4 with the one or more first defined shapes preferably has been or is with a distance of at least 1 mm, preferably at least 2 mm, from an outer edge and/or from an outer rim of a surface of the label 2 and/or of the carrier 3 and/or from an edge of an opening inside the label 2 and/or the carrier 3 to which the adhesive 4 is applied.
The contacting tail 21 preferably has a smaller surface area than the rest of the label 2, in particular when viewed perpendicular to a plane spanned by the label 2. In the method the contacting tail 21 preferably is and/or remains free of adhesive 4, preferably free of adhesive 4 and/or free of material of the carrier 3 at least in a contact area 211, and/or the device, in particular the carrier receiver and the label receiver, has been configured such that this is possible.
In particular, the one or more first defined shapes of the adhesive 4 are applied with an adapted shape and amount, for example to form beads in a bone structure, and in particular the contact area 211 is left free of adhesive 4, as is to be seen for example in
At least one subarea of the contact area 211 is suitable for the electrical contacting of the functional layer 22 and/or of the one or more electrical and/or electronic and/or optical and/or optoelectronic components. As is shown by way of example by
The protective layer 25 is for example a varnish layer or a film. It is possible for the protective layer to have been firmly integrated in the label 2 or for the protective layer 24 to have been designed detachable, in particular with the result that the protective layer 24 can be detached after the label 2 has been detached from the label receiver 20. The carrier layer 23 is for example a film substrate and/or comprises one or more of the following materials: PET, PC, PMMA, ABS, PC-ABS, PP, PA, PE. It is also conceivable that one or more color layers have been provided instead of the protective layer 24 or between the protective layer 24 and the functional layer 22. The further layer can here comprise one or more of the layers 22 and 24, wherein the remaining layer not comprised by the further layer is optional.
The intermediate layers 32, 33 and 34 can thus act in particular as an electrically insulating functional layer.
The one or more decorative layers 28 here preferably are or comprise a shadow mask.
The contacting layer 31 extends for example through the sensor area 201 as well as the optional contacting tail 21 or contact area 211. It is also possible for layers lying between the functional layer 22 and the contacting layer 31 and/or between the functional layer 33 and the contacting layer 31 to have through-connections, in particular such that the contacting layer 31 and the functional layer 22 are electrically conductively connected and/or galvanically connected.
A shadow mask is in particular a partially provided opaque layer.
The further protective layer 241 is in particular a protective film. The second protective layer 241 is preferably detachable from the label 2. In particular, the second protective layer 241 is detached before the glue 4 is deposited on the label 2 and/or before the label 2 and the carrier 3 are laid one on top of the other.
The further layer can in particular comprise one or more of the layers 24, 29, 27, 26, 31, 31, 33, 34, 22, 23, 35, 271, 28, 242, 25, 241, wherein the remaining layers not comprised by the further layer are optional.
The label 2 has in particular been designed such that the cross sections shown in
301 step
| Number | Date | Country | Kind |
|---|---|---|---|
| 102023108832.7 | Apr 2023 | DE | national |
