Plastic moulded part and method for the production thereof

Patent metadata

Field	Value
Publication number	US-10377067-B2
Application number	US-201415104624-A
Country	US
Kind code	B2
Filing date	Dec 15, 2014
Priority date	Dec 18, 2013
Publication date	Aug 13, 2019
Grant date	Aug 13, 2019

Abstract

The invention relates to a method for producing a plastic molded part ( 1 ), comprising the steps of:
a) providing a first decorative film ( 11 ), which at least partially has an opaque coating ( 112 ); b) introducing at least one decorative element of a decoration into the first decorative film ( 11 ) by machining using a machining tool; c) providing a second decorative film ( 12 ); d) placing the decorative films ( 11, 12 ) into an injection mold ( 2 ) having a first ( 21 ) and second mold half ( 22 ), which together form a cavity ( 23 ) for molding the plastic molded part ( 1 ), the first decorative film ( 11 ) being placed on a first wall ( 22 f ) of the cavity ( 23 ) and the second decorative film ( 12 ) on a second wall ( 21 f ) of the cavity ( 23 ) lying opposite the first wall ( 22 f ); e) back-injecting the decorative films ( 11, 12 ) with a polymer melt, so that the first decorative film ( 11 ) forms a first surface and the second decorative film ( 12 ) forms a second surface of the plastic molded part ( 1 ) opposite the first surface.

First claim

The invention claimed is:

1. A method for producing a plastic molded part comprising the steps of:
a) providing a first decorative film, which at least partially has an opaque coating;
b) introducing at least one decorative element of a decoration into the first decorative film by machining using a machining tool wherein, when the at least one decorative element of a decoration is introduced into the first decorative film using the machining tool, the opaque coating is at least partially removed in the area machined using the machining tool and/or the opacity of the opaque coating is reduced in the area machined using the machining tool, and wherein, before the at least one decorative element of a decoration is introduced by machining using the machining tool, the opaque coating has a transparency in the wavelength range visible to humans of less than 50%, and wherein, after the at least one decorative element of a decoration has been introduced into the first decorative film, the area machined using the machining tool and the area not machined using the machining tool have a difference in transparency of at least 5%, and wherein the at least one decorative element of a decoration introduced using the machining tool comprises at least one line having a line thickness of at least 50 μm;
c) providing a second decorative film, wherein the second decorative film is transparent or translucent at least in some areas and has a transparency of 5% to 100%;
d) placing the decorative films into an injection mold having a first and second mold half, which together form a cavity for molding the plastic molded part, the first decorative film being placed on a first wall of the cavity and the second decorative film on a second wall of the cavity lying opposite the first wall;
e) back-injecting the decorative films with a polymer melt, so that the first decorative film forms a first, back surface and the second decorative film forms a second, front surface of the plastic molded part opposite the first surface; and
f) applying at least one backlighting device and/or a touch sensor on the side of the plastic molded part formed by the first decorative film after the back injection.

2. The method according to claim 1 , wherein the introduction of at least one decorative element of a decoration into the first decorative film in step b) takes place by laser irradiation, milling or stamping.

3. The method according to claim 1 , wherein the at least one decorative element is introduced into the first decorative film before the back injection, and before the first decorative film is placed into the injection mold.

4. The method according to claim 1 , wherein the at least one decorative element is introduced into the first decorative film after the back injection.

5. The method according to claim 1 , wherein the opaque coating is applied by screen printing or intaglio printing.

6. The method according to claim 1 , wherein the opaque coating is applied using a transfer film.

7. The method according to claim 1 , wherein, after the at least one decorative element has been introduced by machining using the machining tool, in the area machined using the machining tool the opaque coating has a transparency in the wavelength range visible to humans of more than 75%.

8. The method according to claim 1 , wherein the opaque coating has a layer thickness of between 5 μm and 50 μm.

9. The method according to claim 1 , wherein the first decorative film has at least one transparent or translucent colored coating, a protective lacquer coating and/or an adhesive coating.

10. The method according to claim 1 , wherein the at least one decorative element is or comprises a logo, a symbol and/or at least one alphanumeric character.

11. The method according to claim 1 , wherein at least one further decorative element of the decoration is introduced into the first decorative film by stamping.

12. The method according to claim 1 , wherein the first and/or second decorative film is deep-drawn before being placed into the injection mold.

13. The method according to claim 1 , wherein the first decorative film is provided in a thickness of 50 to 2000 μm.

14. The method according to claim 1 , wherein the first decorative film has at least one ply composed of a colorless or colored transparent or translucent thermoplastic material.

15. The method according to claim 1 , wherein the second decorative film has a carrier layer, an optional release layer and at least one decorative ply, wherein the decorative ply comprises at least one protective lacquer coat which is high-gloss or matt and/or has been provided with a tactile structure, and wherein the carrier layer is removed from the decorative ply after the back injection.

16. The method according to claim 1 , wherein, during the back injection, a tactile surface relief is molded into the surface of the second decorative film facing away from the polymer melt, based on a pattern layer which is disposed between the wall of the cavity and a carrier film of the second decorative film or the second decorative film.

17. The method according to claim 1 , wherein the decorative films are placed into the injection mold with a spacing of 0.5 mm to 10 mm.

18. The method according to claim 1 , wherein, between the decorative films, at least one core is introduced into the injection mold.

19. The method according to claim 1 , wherein the first and/or second decorative film comprises one or more electrical functional layers, comprising a backlighting device or one or more capacitive touch sensors.

20. The method according to claim 1 , wherein the injection-molding compound has a transparency of 5% to 98% in the wavelength range visible to humans, and is formed from one of the following materials: ABS (acrylonitrile-butadiene-styrene copolymer), PC (polycarbonate), ABS/PC, PC/ABS, PMMA (polymethyl methacrylate), PP (polypropylene), PA (polyamide), TPU (thermoplastic polyurethane).

Assignees

• Leonhard Kurz Stiftung & Co Kg

Inventors

• Deckert Klaus
• Hahn Martin

Classifications

• B29C45/14508 Primary

  Joining juxtaposed sheet-like articles, e.g. for making trim panels · CPC title

• B29C2045/14532

  injecting between two sheets · CPC title

• B29C45/14467 Primary

  Joining articles or parts of a single article (B29C45/14377, B29C45/14385, B29C45/14581, B29C45/14614 and B29C45/006 take precedence) · CPC title

• B29L2031/3475

  Displays, monitors, TV-sets, computer screens · CPC title

• B29C45/14811

  Multilayered articles (B29C45/14827 takes precedence) · CPC title