Method of 3D printing plastic molding compound on foil ply

Patent metadata

Field	Value
Publication number	US-9815241-B2
Application number	US-201514667098-A
Country	US
Kind code	B2
Filing date	Mar 24, 2015
Priority date	Mar 27, 2014
Publication date	Nov 14, 2017
Grant date	Nov 14, 2017

Abstract

A method for producing a molded body having the following steps: a) providing a foil ply; b) applying a plastic molding compound in a predefined three-dimensional shape onto the foil ply by means of a three-dimensional printing method.

First claim

The invention claimed is:

1. A method for producing a molded body comprising:
a) providing a foil ply, wherein the foil ply is a transfer foil comprising a transfer ply and a carrier layer detachably attached thereto;
b) applying a plastic molding compound in a predefined three-dimensional shape onto the transfer ply of the foil by means of a three-dimensional printing method; and
c) detaching the carrier layer from a transfer layer of the transfer ply whereby the transfer ply finally remains in the molded body.

2. A method according to claim 1 , wherein a foil ply is used, which has an adhesion-promoter layer, onto which the plastic molding compound is applied in step b).

3. A method according to claim 2 , wherein a foil ply is used, the adhesion-promoter layer of which consists of the same plastic material as the plastic molding compound applied in step b).

4. A method according to claim 2 , wherein a foil ply is used, the adhesion-promoter layer of which has a heat-activatable adhesive.

5. A method according to claim 2 , wherein a foil ply is used, the adhesion-promoter layer of which has a layer thickness of 0.01 μm to 50 μm.

6. A method according to claim 1 , wherein a foil ply is used, which has at least one decorative layer.

7. A method according to claim 6 , wherein a foil ply is used, the at least one decorative layer of which is or comprises one of the following layers or a combination thereof: a layer having at least one colorant, pigment, a pigment excitable in the visible, infrared, or ultraviolet spectral range to fluorescence and/or luminescence, an optically variable pigment, a liquid crystal layer, a cholesterol liquid crystal layer, a metal layer, a layer having a diffractive lattice structure, a hologram, a matte structure, a layer having a microlens and/or microprism arrangement, a layer made of a textile material, a leather, an artificial leather, or a wood veneer.

8. A method according to claim 1 , wherein a foil ply is used, which has at least one functional layer.

9. A method according to claim 8 , wherein the at least one functional layer is or comprises a layer comprising conductor track structures, antenna structures, electrical or electronic components, sensors, inductive or capacitive touch sensors, chips, OLED or LCD display elements.

10. A method according to claim 8 , wherein the plastic molding compound is applied so that it only partially covers the at least one functional layer.

11. A method according to claim 1 , wherein a foil ply is used, which comprises a tactilely perceptible surface relief having a predefined roughness and/or having a predefined item of tactilely perceptible information.

12. A method according to claim 1 , wherein the plastic molding compound is applied by means of a 3D print head, which is guided robotically.

13. A method according to claim 1 , wherein the plastic molding compound is applied in the form of drops and/or strands and/or threads.

14. A method according to claim 1 , wherein ABS, polycarbonate, or ABS-PC, is used as the plastic molding compound.

15. A method according to claim 1 , wherein, before the application of the plastic molding compound, the foil ply is fixed on a support element having a predefined surface geometry by means of mechanical clamping means and/or by vacuum fixation.

16. A method according to claim 1 , wherein, before the application of the plastic molding compound, the foil ply is heated to a temperature of approximately 30° C. to approximately 150° C.

17. A method according to claim 1 , wherein, during the application of the plastic molding compound, a plurality of plastics having different optical properties is applied, wherein the 3D print head is guided so that an item of visually perceptible information is represented by the plastics.

18. A method according to claim 1 , wherein the molded body is subjected to a surface treatment after the application of the plastic molding compound.

19. A method according to claim 18 , wherein the surface treatment comprises a solvent treatment and/or at least partial coating, wet lacquering and/or the application of a transfer foil, of the molded body.

20. A method for producing a molded body comprising:
a) providing a foil ply; and
b) applying a plastic molding compound in a predefined three-dimensional shape onto the foil ply by means of a three-dimensional printing method,
wherein, after the application of the plastic molding compound in step b), a further plastic molding compound is applied in a predefined three-dimensional shape to the side of the foil ply facing away from the plastic molding compound applied in step b) by means of a three-dimensional printing method.

21. A method according to claim 20 , wherein a hot stamping foil, which has a transfer ply and a carrier layer detachable therefrom, is used as the foil ply, wherein the plastic molding compound is applied in step b) to the transfer ply.

22. A method for producing a molded body comprising:
a) providing a foil ply having at least one decorative layer; and
b) applying a plastic molding compound in a predefined three-dimensional shape onto the foil ply by means of a three-dimensional printing method,
wherein the foil ply forms a decorative surface of the molded body.

23. A method for producing a molded body comprising:
a) providing a foil ply having at least one functional layer and a carrier layer detachably attached to the functional layer, the functional layer comprising an electrical or electronic layer;
b) applying a plastic molding compound in a predefined three-dimensional shape onto the foil ply by means of a three-dimensional printing method; and
c) detaching the carrier layer from the functional layer whereby the functional layer finally remains in the molded body.

24. A method for producing a molded body comprising:
a) providing a foil ply having an adhesion-promotion layer and a carrier layer, the adhesion-promotion layer comprising a plastic material;
b) applying a plastic molding compound in a predefined three-dimensional shape onto the adhesion-promotion layer of the foil ply by means of a three-dimensional printing method, wherein the plastic material of the adhesion-promotion layer is the same as the plastic molding compound; and
c) detaching the carrier layer from the adhesion-promotion layer whereby the adhesion-promotion layer finally remains in the molded body.

25. A method for producing a molded body comprising:
a) providing a foil ply;
b) applying a plastic molding compound in a predefined three-dimensional shape onto the foil ply by means of a three-dimensional printing method,
wherein the three-dimensional printing comprises:
melting a predefined quantity of a plastic molding compound in a print head;
bringing the melted predefined quantity of the plastic molding compound into contact in the molten state with at least one additive;
absorbing the at least one additive into the melted predefined quantity of the plastic molding compound; and
depositing the melted predefined quantity of the plastic molding compound with the absorbed additive at a predefined position on the foil ply with the print head.

Assignees

• Leonhard Kurz Stiftung & Co Kg

Inventors

• Pforte Klaus
• Hahn Martin

Classifications

• B05D2203/24

  Leather · CPC title

• Y10T442/20

  Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer · CPC title

• Y10T428/31696

  Including polyene monomers [e.g., butadiene, etc.] · CPC title

• B29C66/7487

  Wood · CPC title

• B32B15/082

  comprising vinyl resins; comprising acrylic resins · CPC title