Patent EP-2596950-A1 (EP)
Inventor: GRUNDWUERMER MANUELA
IPC: B42D25/45
Filed: 2012-11-20
Abstract: The method comprises: providing a carrier film (5), receiving films (1, 2, 3,4) comprising a recess, a cover film (6), and irregularly shaped components (20), where the recess is suitable in terms of shape and size to receive the component in an exact register; placing the receiving film on the carrier film; inserting the component in the recess of the receiving film to form a part-film stack; covering the component by placing the cover film to the formed part-film stack to form a film stack (10); and laminating the formed film stack by hot pressing to form a film composite material. The method comprises: providing a carrier film (5), receiving films (1, 2, 3,4) comprising a recess, a cover film (6), and irregularly shaped components (20), where the recess is suitable in terms of shape and size to receive the component in an exact register; placing the receiving film on the carrier film; inserting the component in the recess of the receiving film to form a part-film stack; covering the component by placing the cover film to the formed part-film stack to form a film stack (10); and laminating the formed film stack by hot pressing to form a film composite material using vacuum. A balancing material: is inserted into the recess before inserting the component into the recess of the receiving film; is applied on surface areas of the component inserted in the recess; and is thermally activated at a low temperature. The receiving films are stacked together with the recess for receiving a portion of the component, where all the recesses of the receiving film together form the recess for the component receiving the exact register. The component is embedded into a film composite material. The film stack is heated, during the lamination, by a heating device at its two outer films, where the step of heating is carried out by temperature profiles at one outer film and at other outer film, and the temperature profiles are temporally and/or spatially different from each other. A heat transfer is controlled from one of the heating devices to one of the outer films by inserting a thermal pressure pad between the heating device and the outer film, and optionally controlled from the other heating device to the other outer film by inserting a thermal pressure pad between the outer film and the heating device. The balancing material is completely lined to the recess of the receiving film, and optionally a portion of the carrier film, facing away from the surface the receiving film, is covered. The balancing material releases a portion of the recess and/or a surface of the receiving film, facing away from the carrier film, in which the component is connected to another component. The balancing material includes a thermally activatable adhesive, and a film made of thermoplastics or thermoplastic elastomer. An activation temperature of the adhesive is lower than a softening temperature of the film adjacent to the adhesive. A balancing material film has a softening temperature, which is lower than the softening temperature of the film adjacent to the balancing material film. An independent claim is included for a film composite material.