CN105308219A - 涂布塑料功能组件的方法 - Google Patents

涂布塑料功能组件的方法 Download PDF

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CN105308219A
CN105308219A CN201380075917.1A CN201380075917A CN105308219A CN 105308219 A CN105308219 A CN 105308219A CN 201380075917 A CN201380075917 A CN 201380075917A CN 105308219 A CN105308219 A CN 105308219A
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injection moulding
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D.基斯利希
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Gerhardi Kunststofftechnik GmbH
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Abstract

本发明涉及通过电镀涂布具有图标（2）或类似物的塑料功能组件（1）的方法，其中组件（1）由可电镀的塑料以注塑方法制造，并且然后电镀或金属化，其中组件（1）的涂布区域保持没有电镀。在此，在组件（1）上施加再现图标（2）或类似物的印刷，图标（2）在薄膜上的印刷由与待后注塑的材料，优选后面待电镀的塑料材料不相容的材料形成，并且在载体薄膜上的印刷图像从薄膜到组件上的转移持续地在注塑工艺中进行。

Description

涂布塑料功能组件的方法
本发明涉及涂布塑料功能组件的方法，其中该功能组件具有带有能够通亮的图标或类似物的组件，该组件由可电镀的塑料以注塑方法制造，并且然后电镀或金属化，其中所述组件的涂布区域保持没有电镀。
本文提到类型的塑料功能组件，例如用于汽车工业，其基本上是指操控元件，利用该元件可以显示和操控汽车的各种功能。其中包括例如启动/停止按钮，用于车辆照明、气候调节、天窗、车篷或内室照明的操控元件。对于所提到的组件通用的，它们具有描述了各个功能的图标或词语或类似物。这些图标为了更好的可视性而以对比色，即不同于其它操控元件的其它颜色形成。对于这些图标的要求例如是相对于操控元件本身对比明显并且可以背后照明。
为了构造上述的具有金属涂层的塑料功能组件，已知各种方法。例如，PVD方法（物理气相沉积）基于由塑料制成的操控元件的金属化。为此在真空中沉积薄层。待沉积的材料以固体形式存在。蒸发的材料经过真空室并到达待涂布的组件，在此形成层。在这种情况下，后续用激光制造图标的处理是不利的。尽管该PVD方法适合于将所需图标施加在组件上。但是也存在如下问题：金属层在不存在额外保护层的情况下不具有对于磨损和腐蚀的足够耐受性。由此需要施加例如漆的保护层，以便例如在汽车工业中满足在涂层的粘附性和稳定性方面的高要求。然而，这些额外的工序增加了成本。
此外，已知电镀涂布组件的方法。在这种情况下，首先以注塑方法例如由ABS或ABS/PC制造部件。在注塑过程之后，电镀预处理所述组件，以便产生薄的金属层。然后从电镀过程中取出组件。在取出之后，例如借助激光除去电镀的金属层。这样处理过的组件然后再次输送到电镀过程中，并且进行电镀工艺，直至形成所需的铬层。激光处理过的区域这时形成图标。尽管可以使用所述方法制造技术上和光学上高质量的操控元件。然而，该方法具有缺点，一方面用于构造图标的额外激光处理工序提高了成本。此外，在所述的方法中需要两次电镀工艺。总之，由于给出的方法流程，上述的方法较不适合组件的大批量制造。
本发明希望在此提供帮助。本发明的目的在于，提供通过电镀涂布用于汽车工业中的具有图标或类似物的塑料功能构件的方法，其一方面成本有利并且也适用于大批量生产，另一方面在没有额外的处理的情况下也提供各个操控元件的金属层的所需耐磨损性。根据本发明，该目的如下实现：在组件上施加再现图标或类似物的印刷，该图标在薄膜上的印刷由与待后注塑的材料，优选后面待电镀的塑料材料不相容的材料形成，并且在载体薄膜上的印刷图像从薄膜到组件上的转移持续地在注塑工艺中进行。
本发明提供了通过电镀涂布优选用于汽车工业中的具有图标或类似物的塑料功能组件的方法，该方法相比于现有技术中已知的方法基本上成本更有利的。由此，仅仅需要一个电镀过程，并且因此相比于已知方法降低了生产线的构造复杂性。在电镀工艺中，仅仅电镀未涂布的区域，而转移的印刷的区域保持没有电镀。此外，不需要中断电镀工艺以进行现有技术中已知的组件的激光处理，从而可以在单一的连续过程中进行电镀。另外，使用本发明的方法可以制造出高质量的、满足例如针对磨损的要求的组件。
在本发明的扩展方案中，所述图标由不可电镀和电镀稳定的漆施加。使用漆的优点在于，已经存在具有不同性质的各种漆用于加工，另一方面可以使用漆形成各种形状的符号、词语或数字。
优选地，将图标通过薄膜载体印刷到组件上。尤其在使用不可电镀的漆构造图标时，印刷是简单的方法，并且另外可以很好地集成到其余的方法流程中。
特别优选地，在注塑过程中将薄膜的印刷施加到组件上。这种施加可以额外优化生产工艺，因为在这种情况下可以将注塑过程与施加印刷合并。由此在制造工艺中节省了一个生产站。
在本发明的有利的扩展方案中，所述薄膜在模内装饰方法中加工。其是指通过注塑制造的塑料注塑件在注塑过程中配有装饰层的方法，其中该薄膜优选地拉入注塑模具中，并且将再现图标的薄膜印刷完整地转移到塑料注塑件的表面上。形成图标的层可以与载体薄膜分开。此外，它具有可以热活化的蜡层，从而在注塑模具内部处于非常高的温度的注塑过程中将装饰层与载体薄膜分开，并且转移至待生产的组件上。将薄膜印刷转移到组件上的粘附机理通过底漆体系得到支持，该底漆体系通过注塑上的塑料材料活化并且提供持久的粘附。
本发明的其它扩展方案和实施方案在其它的从属权利要求中给出。本发明的具体实施例描述在附图中并且如下具体说明。
图1示出了启动/停止按钮的形式的塑料功能组件的示意图；
图2示出了本发明方法的流程图；
图3示出了本发明方法的另一个实施方案的流程图。
本发明的方法例如用于汽车工业通过电镀涂布塑料制成的功能组件1。在完成该方法之后，功能组件1具有图标2，其可以是象形图、数字、词语或类似物。在图1的具体实施例中，其是用于汽车的可以启动和停止汽车发动机的启动/停止按钮。在这种情况下，图标2由词语“符号”组成。如果其涉及其它操控元件，通常形成以象形图的形式的图标；例如，如果其是用于车辆照明的操控元件，其是汽车前大灯的描绘。但是，也可以是温度信息、操作信息等。所述组件在该具体实施例中具有金属多层结构。
在图3的具体实施例的方法中，首先以注塑方法制造由塑料制成的功能组件。该塑料是可电镀的塑料，优选ABS或ABS/PC。然后在组件1上施加具有图标2的薄膜。所述图标在此由不可电镀的材料形成。优选地，所述图标由不可电镀的漆施加。其可以是PET、PA、COC、PS、POM或聚烯烃。
在图2的具体实施例中，所述图标在组件1的注塑过程中施加。为此在本发明中采用模内装饰方法。其中，将具有位于其上的图标的薄膜通过注塑机拉动。所述薄膜是卷起的连续薄膜，其与注塑机同步地逐步地拉入到注塑模具中。将图标施加在连续薄膜上例如通过印刷，优选通过凹版印刷进行。如果具有图标的薄膜达到了其预定的位置，则闭合注塑模具。然后，在注塑模具中以已知的方式注射塑料。因为薄膜已经位于注塑模具中，其直接与注射的塑料接触。借助薄膜在注塑过程中施加图标在工艺技术上具有如下优点：可以省掉用于此操作步骤的单独处理站。在注塑过程中加工薄膜，例如在形成热冲压薄膜类型的薄膜的情况下，导致描绘图标的层由于高温还在注塑过程中就与薄膜分离，并且该图标附着在组件上。在所述组件冷却后，该图标在组件上突起，因为描绘该图标的层置于此处并且粘附于此。所施加的图标层的厚度为1微米至15微米。在该具体实施例中，将薄膜印刷转移到组件上的粘附机理通过底漆体系得到支持，该底漆体系通过注塑上的塑料材料活化并且提供持久的粘附。
在组件的冷却时间过去之后，将注塑装置打开，并将具有仿制图标的不可电镀的层的组件取出。当打开注塑装置时，薄膜与组件分离，而图标附着到组件。然后将薄膜在接下来的一个步骤中卷起，以使在注塑过程中不含图标的薄膜区域离开注塑模具。如此卷起薄膜，直至下一个图标已经占据了其预定的位置。
从注塑模具中取出的组件然后可以例如在待电镀的一侧通过酸洗而粗糙化，以便在电镀时实现更好的材料附着。然后电镀该组件。这可以通过可电镀一侧的表面的金属化进行。该电镀以已知的方式通过物理或电化学地沉积多个金属层直至铬装饰层而进行。这个铬层可以毫无问题地粘附在由可电镀塑料，特别是ABS或ABS/PC制成的组件上。只有带有图标的区域没有用铬涂布，从而由于组件的不同颜色的背衬而可以识别所述图标。此外，如图1所示，通过使用半透明的塑料用于组件也可以以这种方式制造背光的组件。在组件1的下方示出了光源3，其发射光束4。光束4照到组件4的背面，并在图标2的区域中穿过半透明的塑料，这在图1中通过箭头5示出。
此外，本发明的方法还提供在功能组件的设计方面的选项。例如，通过使用例如深色或黑色的半透明漆着色塑料材料（ABS或ABS/PC）和装饰可以采用所述方法描绘所谓的日夜设计。对于白天设计，通过例如黑色的选择性开放的铬区域在铬环境中形成对比度；对于夜间设计，通过彩色着色的基材可以照射穿过选择性开放的铬区域。
可替代地，通过使用透明漆着色塑料材料（ABS或ABS/PC）和装饰可以采用本发明的方法描绘日夜设计，其中通过开放的铬区域的颜色在铬环境中形成对比度，由此形成白天设计。对于夜间设计，通过照明彩色着色的基材的选择性开放的铬区域可以实现色彩的增强。

Claims (5)

1.涂布具有图标（2）或类似物的塑料功能组件（1）的方法，其中组件（1）由可电镀的塑料以注塑方法制造，并且然后电镀或金属化，其中组件（1）的涂布区域保持没有电镀，其特征在于，在组件（1）上施加再现图标（2）或类似物的印刷，图标（2）在薄膜上的印刷由与待后注塑的材料，优选后面待电镀的塑料材料不相容的材料形成，并且在载体薄膜上的印刷图像从薄膜到组件上的转移持续地在注塑工艺中进行。
2.权利要求1的方法，其特征在于，所述图标（2）由不可电镀和电镀稳定的漆施加。
3.权利要求1或2的方法，其特征在于，所述图标（2）通过薄膜载体印刷到所述组件（1）上。
4.前述权利要求一项或多项的方法，其特征在于，所述薄膜上的印刷在注塑过程中施加到组件（1）上。
5.前述权利要求一项或多项的方法，其特征在于，所述薄膜在模内装饰方法中加工。
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