CN113710498A

CN113710498A - Method for producing a decorative plastic part and decorative plastic part

Info

Publication number: CN113710498A
Application number: CN202080029222.XA
Authority: CN
Inventors: K·萨尔茨曼; S·海德尔
Original assignee: Boge Design Co ltd
Current assignee: Boge Design Co ltd; Burg Design GmbH
Priority date: 2019-04-16
Filing date: 2020-04-08
Publication date: 2021-11-26
Also published as: DE102019110030A1; WO2020212234A1; EP3956151A1

Abstract

The invention relates to a decorative plastic part (1) and a method for producing a decorative plastic part, comprising the following steps: providing a film (10) comprising, for example, a carrier layer (11) and a decorative layer (12); applying at least one plastic material (20) to the film at least regionally in a processing process; the alterations (61, 62) are introduced into the film in such a way that they are visually recognizable after the processing process, in particular by the plastic material (10), in particular by the depth effect and/or the 3D effect and/or the transparency effect.

Description

Method for producing a decorative plastic part and decorative plastic part

Technical Field

The invention relates to a method for producing a decorative plastic part and to a decorative plastic part.

Background

For decorating plastic parts, it is described, for example, in DE 4331167 a1, to apply one or more layers of colored pigments to the surface of the particles. The pellets are then supplied to a plastic processing machine, melted and subsequently processed by an extruder into plastic parts.

A disadvantage of this method of operation is that the control of the optical effect produced thereby and the optical design possibilities of the optical decoration of the plastic part are very limited.

Disclosure of Invention

The aim of the invention is to improve the decoration of plastic parts and to enable novel optical effects, in particular 3D effects and depth effects, to be produced in the decoration of plastic parts at low cost.

The object is achieved by a method for producing a decorative plastic part, comprising the following steps:

-providing a membrane, the membrane being provided,

applying at least one plastic material to the film at least in some regions in a production process,

the introduction of the alterations in the film is such that the alterations are visually recognizable after the processing process, in particular by a depth effect and/or a 3D effect and/or a transparency effect.

The object is also achieved by a decorative plastic part having at least one film and a plastic material which is applied to the film at least in regions during the production process, the irregularities being introduced into the film in such a way that they are recognizable after the production process, in particular visually recognizable by a depth effect and/or a 3D effect and/or a transparency effect.

The advantage achieved by the invention is that a large number of different decorative effects of plastic parts can be achieved at low cost by one and the same starting product, i.e. film and plastic material. Depending on the type of the introduced metamer, a large number of different optical decorations and optical effects can be achieved. It is therefore no longer necessary to provide different, specifically manufactured starting materials for different decorations, but different optical decorations can be realized in a very economical manner by corresponding pretreatment and/or change of the processing technology. Furthermore, it is advantageous that optical decoration, which otherwise could only be realized in a complicated and costly manner, can also be realized by correspondingly introducing the deformations and selecting the parameters of the machining process. For example, depth effects and/or 3D effects can also be achieved by films whose film layers and/or decorative layers do not produce such effects and, for example, impart only a two-dimensional, uniform color impression. This surprising effect can be explained by: when the plastic material is applied, the respective areas of the film layer and/or the decorative layer in the area of the alterations change in their spatial position and/or orientation compared to the areas without alterations and thus the reflection plane and/or the reflection angle of the incident light correspondingly change locally, which in turn produces a depth effect and/or a 3D effect and/or a transparency effect.

Advantageous embodiments of the invention are given in the dependent claims.

The film may be a single layer, such as a solid plastic film, or a single layer of a metal film, for example made of aluminum or copper. The film may also be paper or a paper-like material, e.g.

The film can also be multilayered and in particular have at least one carrier layer and at least one decorative layer.

Preferably the plastics material is melted before the film is applied. The molten plastic material is then brought into contact with the film while applying the plastic material. The advantage is thereby achieved that, on the one hand, the local orientation or position of the local regions of the membrane can be adjusted very well by means of the metamorphosis, since a "liquid" medium is applied. The advantage is furthermore achieved that this orientation or spatial position is "maintained" when the plastic material cools down. Studies have shown that particularly impressive depth effects and/or 3D effects can be achieved by these measures.

The term "position" is understood here to mean, in particular, a spatial position relative to a main surface of the plastic part and, in particular, a surface of the plastic material opposite the film after the processing operation.

By "orientation" is understood here, in particular, the local solid angle of the plane formed by the main surface of the decorative layer or film after the machining process has been carried out relative to the main surface of the plastic part and, in particular, the surface of the plastic material lying opposite the film.

The local change in orientation is formed here in particular by: the film layer and/or the decorative layer of the film are locally "tilted" relative to the main surface of the plastic part or the side of the plastic material facing away from the film and thus the reflection angle of the locally incident light is changed accordingly.

The local change in position includes, in addition to the change in orientation, a change in the vertical positioning and/or the horizontal local spacing of local regions of the decorative layer or film from the main surface of the plastic part or the side of the plastic material opposite the film. The travel length of the light impinging on the decorative layer or film is thereby also correspondingly changed

As plastic material, preferably a thermoplastic material is used, preferably containing Polycarbonate (PC), Acrylonitrile Butadiene Styrene (ABS), polymethyl methacrylate (PMMA), polypropylene (PP) and/or Polystyrene (PS).

The plastic material preferably has a glass transition temperature of between 60 ℃ and 300 ℃, in particular between 90 ℃ and 200 ℃, more preferably between 100 ℃ and 150 ℃.

It has proven to be particularly advantageous if the plastic material is pressed onto the membrane at a pressure of between 10 bar and 700 bar, preferably between 10 bar and 300 bar, in at least one stage of the processing process.

Studies have shown that a corresponding change, in particular a local change in position or a change in orientation, of the film layer and/or one or more decorative layers of the film is achieved by applying a corresponding mechanical force in the area of the irregularities, and thus the visual recognizability of the irregularities is increased and these irregularities contribute in particular to achieving a 3D effect and a depth effect.

The plastic material is preferably applied to the film at a temperature between 60 ℃ and 300 ℃, more preferably between 200 ℃ and 250 ℃. It has been found that the resulting temperature input facilitates a change in the position and/or orientation of the film and in particular of a local region of one or more decorative layers of the film and thus further improves the quality of the decorative effect.

Preferably, the anomaly is visually recognizable after the machining process by one or more of the following effects.

The heterovariates are preferably identifiable by local openings of areas and/or local crumples and/or folds and/or overlaps of areas in the film layer.

The irregularities can preferably be identified by local peeling of the one or more decorative layers from the carrier layer in the region of the irregularities, in particular in the region of the irregularities. In the peeled-off region of the decorative layer or layers, it is possible, on the one hand, for the peeled-off partial region of the decorative layer or layers to still be mechanically connected locally to the layer or layers of the film, but in the region of the peeling position the spatial position and/or orientation of the decorative layer or layers is changed accordingly.

Furthermore, it is also possible that in the region of the peeling location the decorative layer or layers are no longer mechanically coupled to the layer of the film, but are separated from the film, in particular dispersed as flake-like particles behind the plastic material.

The alteration is preferably visually recognizable after the machining process by: in the area of the alterations, the position of the local areas of the film layer and/or the one or more decorative layers is locally changed, in particular the orientation of the local areas of the film layer and/or the one or more decorative layers is locally changed. As described above, this causes a local change in the reflection angle and/or the run length of the incident light. Furthermore, local variations in the position of local areas of the film layer and/or the one or more decorative layers cause shadowing effects, in particular in the "volume" of the plastic material. These two effects also form the basis for the generation of depth effects and 3D effects.

Preferably, the irregularities are visually recognizable after the processing process by partial cutting and destruction of the film layer and/or one or more decorative layers of the film. By means of this effect the optical effect of the decorative layer or layers disappears or changes locally and accordingly locally, and thus a corresponding local optical change is achieved.

The molten plastic material is preferably applied to the film in such a way that the molten plastic material covers the film at least in regions on at least one main surface of the film.

The molten plastic material is preferably applied to the film in such a way that the molten plastic material covers the at least one main surface of the film and/or the covering film over the entire surface. The advantage achieved thereby is that the local "variations" in the decorative layer or layers of the film are particularly well "retained" and protected from the environment by the application of the plastic material.

Preferably the film is wrapped with plastic material on all sides during the manufacturing process. The advantage is thereby achieved that the film layer and/or the decorative layer or layers are reliably protected from environmental influences and mechanical and thermal loads of the subsequent processing.

The plastic material is preferably made of a transparent or translucent plastic material. Transparent plastic materials are understood to be plastic materials having a transmission in the visible wavelength range of more than 70%, preferably more than 80%, more preferably more than 90%. A translucent plastic material is understood to be a plastic material having a transmission in the visible wavelength range of between 70% and 10%, preferably between 70% and 30%, more preferably between 70% and 40%.

The advantage achieved in this embodiment of the plastic material is that the alterations are visually recognizable through the plastic material after the machining process, so that the decorative effect achieved in the production process can be visually recognized through the plastic material when viewed from the side of the plastic material.

Preferably the plastic material is an optically scattering plastic material. An optically scattering plastic material is understood to be a plastic material which scatters at least 10%, preferably more than 20%, more preferably 50% of the incident light in transmission and/or reflection.

Studies have surprisingly shown that more interesting optical effects can be achieved by this choice of plastic material. Thereby, especially the viewing angle range in which the depth effect and/or the 3D effect is visible is enlarged.

The plastic material can be adjusted accordingly to the desired scattering effect, in particular by adding corresponding inorganic pigments or additives as scattering centers for the incident light.

The above description of the transmission and scattering preferably relates to the layer thickness of the plastic material after the processing, i.e. after the processing.

Preferably, the plastic material is applied to the film in a processing process such that the visual appearance of the plastic part is changed in the area of the alterations.

The processing technology is therefore selected in particular such that the optical appearance of the film in the area of the metamorphic portion is visually discernible in the processing technology by thermal and/or chemical and/or mechanical influences. The optical effect is therefore caused primarily by the processing technology and in particular by the corresponding application and/or incorporation of the plastic material onto and/or into the film. Thus, the "irregularities" only partially define regions which, during the processing, in particular when applying the plastic material, cause a corresponding change in one or more decorative layers of the film, which changes ultimately lead to a visual identifiability of the irregularities after the processing.

This achieves the great advantage that the metamorphic portion can be introduced by a simple and inexpensive method and that no complicated processing steps are required and that optical effects which cannot be achieved even by complicated film pretreatments can be achieved thereby.

Preferably, one or more decorative layers in this relief and/or in the relief region are changed during the production process by the conditions present there, in particular the pressure and/or the temperature. The corresponding change is thereby caused in particular by warping and/or deformation of the film and/or one or more decorative layers of the film in the area of the relief.

Furthermore, it is preferred to modify the tear initiation by the film and/or one or more decorative layers of the film in the area of the metamerism.

Furthermore, it is preferable to change the peeling cause of the decorative layer or layers by the film in the varied portion region.

Furthermore, it is preferred to vary the increase in local cutting and/or plastic deformation of the decorative layer or layers through the film in the area of the metamerism, preferably by more than 100%, preferably more than 500%.

Furthermore, it is preferred to destroy, to a large extent destroy and/or modify the optical effect of one or more decorative layers of the film around the metamorphic section during the processing.

The above measures can be implemented in the processing technology alone or in any combination with one another.

Furthermore, the local optical change of the film occurring in the area in which the metamorphic portion is introduced is preferably maintained by curing of the plastic material at the end of the processing process. This can be achieved, for example, by corresponding cooling of the plastic material and/or by age hardening of the plastic material, in particular by thermal hardening, radiation hardening or electron beam hardening.

The metamorphic portion may be introduced into the film before and/or during the process. The metamorphic portion is preferably introduced into the film prior to application of the plastic material.

In particular, the following measures have proven effective for introducing the heterovariates:

one or more discontinuities may be formed by introducing a predetermined breaking point such that there is a first discontinuity in the film formed by the predetermined breaking point.

A predetermined breaking point is understood to mean, in particular, a local, in particular punctiform or linear region of the membrane in which the material structure of the membrane is mechanically weakened in comparison with the surrounding region, in particular by at least partially severing one or more layers of the membrane in this region or otherwise weakening its bonding strength with respect to the surrounding region (zusmammenhalt).

These predetermined breaking points are preferably introduced into the film by mechanically damaging one or more layers of the film, in particular by locally mechanically damaging the carrier layer and/or one or more decorative layers of the film.

In order to introduce the first alteration, the film is in particular cut at least partially through one or more layers, in particular the carrier layer and/or one or more decorative layers. This is preferably done mechanically, in particular by cutting, punching, scraping or engraving.

Furthermore, it is also possible to cut through one or more layers of the film and/or to weaken the material of the respective layer accordingly by means of radiation, in particular by means of a laser, electron beam or heat source, at least in part, for example by evaporating the material of the respective layer.

Furthermore, in order to introduce the first alteration, the at least one layer of the film may be partially cut or the material may be "weakened" accordingly, in particular by etching, in the region of the first alteration.

By introducing the first alteration, the composite of the film as a continuous structure can preferably be broken down and film sections separated from one another can be produced when the carrier layer and the decorative layer are cut open. These films may preferably have a local thickness of about 1mm²To 1,000,000mm²Preferably about 5mm²To 90,000mm²The area of (a).

It is further advantageous here if the first predetermined breaking point or points differ from one another, in particular with regard to the transverse plane extension or the shape of the layer to be cut, the cutting depth of the layer or the weakening strength of the film layer. In this way, even with the same film, correspondingly different optical effects and effects can be achieved in different partial regions of the plastic part.

Preferably, one or more of the varied portions (hereinafter, referred to as second varied portions) are formed of a bending point. To this end, when the second irregularities are introduced, one or more layers of the film, in particular the carrier layer and/or one or more decorative layers, are locally peeled off from at least one adjacent layer of the film in the region of the bending point by bending, in particular by plastic deformation and/or breaking, and/or by bending.

A bending point is to be understood to mean, in particular, a corresponding local region, such as a point-like or line-like region of the membrane, in which the above-mentioned corresponding local change of the membrane is effected by a bending load.

The second variant is preferably introduced here by locally bending the membrane, in particular by bending and/or creasing and/or folding and/or twisting the membrane.

It is particularly advantageous here if, for the introduction of the metamorphosis, the membrane is twisted one or more times by at least 180 °. This is especially true when a film is used having at least two decorative layers with different visual appearances that are visible in incident and/or transmitted light from different major surfaces of the film. By introducing such a metamer, a correspondingly large local tilt is induced in local regions of the film, which, in addition to the phase strain of the incident light reflection angle, also causes a corresponding change in the visual appearance on the basis of the special decorative layer structure.

It is also advantageous here for the second predetermined breaking point or points to be different from one another, in particular in terms of the transverse plane extension or the shape, the deformed and/or broken layer and/or in terms of the local bending radius of the film in the region of the discontinuity. The advantage is thereby achieved that different decorative effects can be achieved in the plastic part with the same film.

The metamorphic portions may be introduced regularly and/or randomly and/or pseudo-randomly in the form of a predetermined decoration according to a regular or irregular grid (Raster).

Different sets of varistors can also be introduced here, which are arranged in different patterns, respectively, for example a first set of varistors arranged according to a regular grid, a second set of varistors arranged according to a predetermined pattern, for example consisting of alphanumeric characters or a picture template, a third set of varistors arranged randomly or pseudo-randomly. By these measures, different decorative effects can be achieved in the plastic part with the same film.

The above measures are preferably combined with each other in order to achieve a complex, visually appealing decoration on the plastic part.

The film may be pre-treated prior to the processing process to improve adhesion and/or wetting between the film and the plastic material. As a pretreatment, one or more of the following processing methods are preferably carried out: in particular by aeration, flame treatment, plasma treatment, fluorination, irradiation, cleaning, coating.

In addition to the plastic material, one or more further plastic materials are preferably applied to the film in the processing process. In particular, the plastic material can be applied to one main surface of the film and another plastic material can be applied to the other main surface of the film.

According to a preferred embodiment variant, the film is fed to the machining process two or more times. Complex depth and 3D effects can be achieved by corresponding superimposed decorative effects.

According to a preferred embodiment variant, the processing process is an extrusion process and the plastic material is an extruded material of the extrusion process. The plastic material is preferably brought into contact with the film before the extrusion roll.

The extrusion process is here an extrusion process in which extrusion or coextrusion is carried out.

The processing technology can also be another processing technology, in particular a technology selected from the group consisting of a lamination technology, in particular using a roll laminator or a stroke press (hubpress), a gluing process/deep drawing process and an injection molding process.

In the injection molding process, the plastic material is applied to the film, in particular by back-injection molding, overmoulding and/or immersion. It is not necessary to manufacture the membrane insert for this purpose. Instead, the film is placed completely or partially superficially in the injection mold and is contacted on one or both sides with the injection material.

These processing techniques may also be further combined with each other. For example, the plastic part produced therefrom can be injection-molded on the back side and/or immersed and/or deep drawn and/or laminated after the extrusion process.

The plastic part can be treated after the machining process in order to improve, in particular, the adhesion and/or the wetting between the plastic part and a coating which may be subsequently applied to the plastic part. One or more of the following processing methods are preferably carried out as treatments: in particular by gas charging, flame treatment, plasma treatment, fluorination, irradiation, cleaning, coating.

Furthermore, particularly after the extrusion process, the plastic part which is particularly flat and undeformed there can be finished by further processing steps, in this case particularly by screen printing and/or digital printing and/or hot-stamping printing and/or cold-stamping printing and/or heat-transfer printing and/or laser marking and/or lamination.

In particular after the injection molding process or deep drawing, the now existing 3D molded parts can be finished by further processing steps, in particular by screen printing and/or digital printing and/or hot-stamping and/or cold-stamping and/or hot-transfer printing and/or laser marking and/or gluing.

These processing steps can be carried out individually or in combination after the extrusion process or after the 3D forming process on the visible side of the plastic part in order to apply special protective layers and/or haptic effects and/or other decorative layers, such as full-surface or partial-surface decorations, graduated surface decorations

And/or a matte effect and/or a glossy effect and/or a full-surface or partial opacity, in particular as defined transparent areas within an opaque layer, for example for generating a backlit lighting (hingerleuchtbar) area.

These processing steps can be carried out on the plastic part after the extrusion process or after the 3D forming process, either individually or in combination, alternatively or additionally also on the side facing away from the visible side of the plastic part, in order to achieve, for example, the full surface or partial opacity of the plastic part, or also in order to produce special light effects, for example in the form of backlit regions, in particular as defined transparent regions within an opaque layer, for example in order to produce backlit regions, or also in order to achieve, for example, technical advantages in terms of resistance and/or adhesion and/or wetting of the surface, in particular here for further subsequent processing steps, such as injection molding.

The layer thickness in screen printing is between 1 μm and 50 μm, preferably between 5 μm and 30 μm, particularly preferably between 5 μm and 15 μm. For example, for a layer thickness of between 5 μm and 30 μm, the layer thickness is 5g/m³To 20g/m³The coating amount of the liquid paint of (4). The screen printed layer may be transparent or translucent or opaque.

A transparent screen printed layer is understood to be a screen printed layer having a transmission in the visible wavelength range of more than 70%, preferably more than 80%, more preferably more than 90%. The translucent screen printed layer is understood as a screen printed layer having a transmittance of 70% to 10%, preferably 70% to 30%, more preferably 70% to 40% in the visible wavelength range. An opaque screen printed layer is understood as a screen printed layer having a transmission in the visible wavelength range of between 40% and 0%, preferably between 30% and 0%, more preferably between 10% and 0%.

The screen printed layer may comprise a plurality of partial layers which are superimposed and/or arranged side by side. Each partial layer may be transparent or translucent or opaque in the visible spectral range, so that the screen-printed layer may comprise a plurality of partial regions, which may each have a different transmittance in the visible spectral range.

Furthermore, it is possible to apply by screen printing a transparent protective lacquer with one or more components selected from the group consisting of uncrosslinked acrylates, polyurethanes, UV-crosslinkable acrylates, chemically crosslinkable acrylates (by means of isocyanates, melamine, carbodiimide, etc.), optionally in particular additionally provided with inorganic auxiliaries (for example SiO), in particular_xEtc.) and/or mold release agents. Such a protective lacquer can be applied over the entire surface or only in partial regions on the surface of the plastic part and/or on a layer present on the plastic part.

Furthermore, one or more additional layers may also be applied to the plastic material and/or film after the machining process is performed to form the plastic part. For this purpose, preference is given to using one or more of the abovementioned processing techniques, such as screen printing, digital printing, lamination, gluing, deep-drawing, injection molding or extrusion.

The film is preferably a laminate film or a transfer film.

The transfer film is formed here in a film in which the carrier layer can be peeled off from the one or more decorative layers and in particular also has one or more peeling layers. The use of such a film has the advantage that a local peeling of the decorative layer or layers is achieved here particularly simply by the introduction of the irregularities, in particular because of the provision of the peeling layer or layers in the layer structure.

The carrier layer is preferably made of polyethylene terephthalate (PET) or polymethyl methacrylate (PMMA).

The layer thickness of the support layer is preferably between 10 μm and 200 μm, more preferably between 25 μm and 75 μm.

The decorative layer or layers of the film are preferably each made of a lacquer layer coated with one or more dyes and/or pigments. Furthermore, the decorative layer or layers of the film are preferably each formed by one or more of the following layers:

the decorative layer can be formed by one metal layer and/or a plurality of, in particular different, metal layers, in particular metal layers of different colors. The different colours of the metal layer can be caused by the colouring of the metal by the glazing (lasierend) coating and/or by the inherent colour of the metal.

The decorative layer can be formed by a reflective layer, in particular by one or more HRI (high refractive index) or LRI (low refractive index) layers. Preference is given to using ZnS or SiO as the HRI layer_xAnd (3) a layer.

The decorative layer may be formed by a relief layer having an optically active surface relief.

The relief layer is preferably made of a thermoplastic or uv-curable lacquer, wherein the optically active surface relief is formed by means of a stamping die.

The optically active surface relief is preferably a diffractive structure, in particular a hologram, a matt structure, in particular an isotropic or anisotropic matt structure, a refractive structure, preferably a microlens structure, a zero-order diffraction grating.

The decorative layer can be formed from thin-film elements which produce a color-shifting effect by interference and/or layers which produce a color effect in transmitted light by plasmon resonance, such as a translucent metal layer in which relief structures with a period below the wavelength of visible light are formed or which are structured according to a grid with a period below the wavelength of visible light.

The decorative layers described above can be combined with one another in any combination in the film. The decorative layer can be present in the film over the entire surface, but can also be present locally or in a pattern.

The decorative layer preferably has a layer thickness of between 0.01 μm and 20 μm.

Plastic parts can be used in various applications: it is therefore advantageous for the plastic parts to be used in particular as exterior body parts or as exterior accessories or as part of the interior of motor vehicles in the automotive sector, in particular as base parts for electronic or electrical appliances in the consumer electronics sector or in the domestic appliance sector, for example as furniture parts in the furniture sector, for example as packaging films in the packaging sector.

Drawings

The invention is explained below by way of example with reference to the figures with the aid of various embodiments. The attached drawings are as follows:

FIG. 1 shows a cross-sectional view of a membrane;

FIG. 2 shows a cross-sectional view of a membrane;

FIG. 3 schematically illustrates a machining process;

fig. 4a to 4c each show a sectional view of a plastic part;

fig. 5 and 6 show schematic diagrams for illustrating the manufacture of plastic parts;

FIG. 7a shows a schematic diagram for illustrating the manufacture of a plastic part;

fig. 7b shows a cross-sectional view of the plastic part according to fig. 7 a;

FIG. 8a shows a schematic diagram for illustrating the manufacture of a plastic part;

fig. 8b shows a cross-sectional view of the plastic part according to fig. 8 a;

FIG. 9a shows a schematic diagram for illustrating the manufacture of a plastic part;

fig. 9b shows a cross-sectional view of the plastic part according to fig. 9 a.

Detailed Description

Fig. 1 and 2 show the structure of the membrane in an exemplary manner. The film is preferably formed of a transfer film or a laminate film. Furthermore, the film can also be constructed as a monolayer, as described above.

The membrane according to fig. 1 is a transfer membrane. The film 10 according to fig. 1 comprises a carrier layer 11, a release layer 13, one or more protective layers 14, one or more decorative layers 12 and one or more adhesive and/or adhesion promoter layers 15. The film has a front major surface 111 and a rear major surface 112.

A main surface is understood to mean the outer boundary surface of a body which does not have only a lower level of planar extension.

The carrier layer 11 is preferably made of plastic, which is well connected to the applied plastic material. The carrier layer 11 can be painted, vapor-sprayed and/or primed on one or both sides in order to improve inter-layer adhesion, in particular, to the plastic material applied thereto.

The carrier layer 11 is preferably made of PET. This is preferably a PET support material which is "optimized" for the subsequent processing. For better deep drawability, a flexible, deep drawable PET carrier material can be used. For better resistance to uv light, uv-stabilized PET carrier materials can be used.

Furthermore, the carrier layer 11 can also be made of other materials, in particular ABS or ABS-PC or PMMA or polyurethane or TPU or TPE. Furthermore, the carrier layer may also comprise one or more partial layers, which are preferably made of one of the materials mentioned above. Depending on the processing technology, it may be advantageous to select the carrier layer 11 from a material that is elastic or rigid, dissolves, peels and/or melts.

The layer thickness of the support layer 11 is preferably between 10 μm and 500 μm, more preferably between 25 μm and 150 μm.

The release layer 13 is preferably made of wax, optionally containing a solvent or being aqueous (e.g. PE, cellulose). It is also advantageous if the release layer 13 is made of a crosslinkable OH-functional acrylate, in particular isocyanate, melamine, carbodiimide. The release layer can also be made here from a combination of these materials. The layer thickness of the release layer 13 is preferably between 0.1 μm and 5 μm, more preferably between 0.5 μm and 3 μm.

The release layer 13 can also be omitted if the layers of the film 10 adjoining the carrier layer 11 are formed such that the interlayer adhesion between these layers is so low that these layers can be released from the carrier layer 11 without damaging these layers. Further, not only one release layer 13 but two or more release layers 13 may also be provided in the film 10.

The protective layer 14 is preferably formed by a protective lacquer layer. The protective lacquer is preferably made of uncrosslinked acrylates, polyurethanes and/or UV-or chemically crosslinkable acrylates, in particular isocyanates, melamines, carbodiimides. Inorganic auxiliaries, in particular SiOx and "mould release agents", can also be added to the protective lacquer layer.

Furthermore, the protective layer 14 may also comprise one or more protective lacquer layers, each of which preferably provides protection against specific environmental influences.

The layer thickness of the protective layer 14 is preferably between 1 μm and 10 μm, more preferably between 2 μm and 6 μm.

The protective layer 14 may also be omitted. This is because a plastic material is subsequently applied to the film 10 during the production of the plastic part, which plastic material can take over the protective function of the protective layer 14 for the next decorative layer or decorative layers 12.

The decorative layer or layers 12 are preferably formed from one or more layers of paint.

These lacquer layers preferably comprise one or more layers pigmented by means of dyes or pigments. These layers have, in particular, uncrosslinked acrylates, polyurethanes, crosslinkable OH-functional acrylates, in particular isocyanates, melamines, carbodiimides as binders, dyes and/or pigments, in particular organic or inorganic pigments, and/or additives such as dispersing additives.

As pigments, optically variable pigments, in particular liquid crystal pigments, interference layer pigments or diffractive pigments, can be used here. In addition to the use of dyes and/or pigments, dyes and/or pigments having luminescent and/or phosphorescent properties may also be used.

Furthermore, the decorative layer 12 can also comprise one or more of the above-mentioned layers, i.e. in particular also a true metal layer, such as a vapor-deposited layer of chromium, tin, aluminum, copper, indium, silver or gold.

The individual decorative layers 12 can be applied in a planar and local manner in the sense of a decorative design and/or in the sense of an optical and/or electrical function.

The layer thickness of the decorative layer 12 is preferably between 0.1 μm and 20 μm, more preferably between 0.5 μm and 10 μm.

The adhesive and/or adhesion promoter layer 15 preferably comprises at least one lacquer layer, and the respective lacquer structure may vary depending on the field of application, in particular "automotive", "consumer electronics", "packaging" and their technical requirements, in particular the light stability. The adhesive and/or adhesion promoter layer 15 is preferably made of a thermosol layer, which contains, in particular, polyvinyl chloride (PVC), low-melting acrylates, polyurethane.

The layer thickness of the adhesive and/or adhesion promoter layer 15 is preferably between 0.5 μm and 10 μm, preferably between 1 μm and 4 μm.

The adhesive and/or adhesion promoter layer 15 may also be omitted.

Fig. 2 shows the layer structure of the laminate film 10. The laminate film comprises a carrier layer 11, an adhesion promoter layer 16, one or more protective layers 14, one or more decorative layers 12 and one or more adhesive and/or adhesion promoter layers 15.

The laminated film shown in fig. 2 has basically the same structure as the transfer film shown in fig. 1, except that an adhesion promoter layer 16 is provided instead of the peeling layer 13.

The carrier layer 11, the protective layer 14, the decorative layer or layers 12 and the adhesive and/or adhesive layer 15 are here constructed analogously to the carrier layer 12, the protective layer 14, the decorative layer or layers 12 and the adhesive and/or adhesion promoter layer 15 according to fig. 1, so that reference is made in this respect to the previous description.

The adhesion promoter layer 16 improves the interlayer adhesion between the one or more decorative layers 12 and the carrier layer 11. The adhesion promoter layer 16 is preferably made of a highly crosslinkable acrylate system, in particular melamine or isocyanate.

The layer thickness of the adhesion promoter layer 16 is preferably between 0.5 μm and 10 μm, more preferably between 1 μm and 4 μm.

Fig. 3 now illustrates the basic sequence of a method for producing decorative plastic parts by means of an extrusion device 50:

first, a film 10, preferably a film 10 according to fig. 1 and/or 2, is provided, which has a carrier layer, in particular a carrier layer 11, and one or more decorative layers, in particular a decorative layer 12. In addition to these layers, the film 10 may also have one or more additional layers, as explained above with reference to fig. 1 and 2. However, the film can also consist of only the carrier layer 11 and one decorative layer 12 or the carrier layer 11 and a plurality of decorative layers 12, or the film can be present only as a single-layer film, for example as a single-layer opaque or translucent plastic material or as a single-layer metal film, for example made of aluminum or copper.

As shown in fig. 3, the film 10 is fed to a processing process. In the embodiment according to fig. 3, the processing process is an extrusion process. For this purpose, the plastic granules 21 are supplied from a storage container 51 to an extruder 52.

The plastic granules 21 are melted in the extruder 52 and the melted plastic material 20 is extruded at a pressure between 10 bar and 300 bar or 700 bar and at a temperature between 60 ℃ and 300 ℃.

The plastic material 20 is an extrudable plastic material, in particular comprising PC, ABS, PMMA, PP and/or PS.

The plastic material 20 is preferably transparent or translucent here. However, the plastic material 20 may also have opaque optical properties, i.e. in particular a transparency of the plastic material in the visible wavelength range of less than 80%, more preferably less than 90%, more preferably less than 99%. It is also advantageous if the plastic material 20 is coloured and/or the plastic material 20 has scattering properties.

The film 10 is now preferably provided with a predetermined breaking point before being fed to the processing and fed to the extrusion process as shown in fig. 3. As shown in fig. 3, the molten plastic material 20 is applied to the film 10, and the film 10 with the applied plastic material 20 still in a liquid state is then introduced into the roll gap between two extrusion rolls 53. The molten plastic material 20 is then pressed against the film 10 by means of an extrusion roller 53. As described above, by the high temperature and high pressure occurring here, the appearance of the film 10 in the area of the irregularities is preferably visibly discernible in comparison with the area without irregularities.

The roll gap between the extrusion rolls 53 is preferably between 0.5mm and 5mm, more preferably between 50 μm and 200 μm. As mentioned above, the temperature of the molten plastics material when pressed onto the film 10 is preferably between 60 ℃ and 300 ℃, more preferably between 210 and 240 ℃.

In this case, the process parameters are set accordingly as a function of the plastic material 20 and the film 10 selected in such a way that the above-described visually recognizable changes are preferably caused in the film as described above, in particular such that the alterations are visually recognizable by local warping and/or deformation of the film 10 in the area of the alterations, by tearing of the film 10 or the one or more decorative layers 12 of the film 10 in the area of the alterations, and/or by peeling off of the one or more decorative layers 12 of the film 10 in the area of the alterations and/or by an increase in local cutting and/or plastic deformation of the film 10 or the one or more decorative layers 12 of the film 10 in the area of the alterations and are visually recognizable, in particular by a depth effect and/or a 3D effect and/or a transparency effect.

Furthermore, the extrusion rollers 53 can also have one or more surface reliefs, such as matte and/or glossy and/or embossed and/or brushed (geb urtees), and the corresponding contours can also be pressed into the surface of the plastic part during the processing process by means of the corresponding contours of one or both extrusion rollers 53. The extrusion roll may have a uniform surface relief on its surface in contact with the plastic material or alternatively different surface areas adjacent to each other may have respectively different surface reliefs or substantially smooth areas. Thus, locally different surfaces, such as matte/glossy effects or only locally visually and/or tactilely perceptible surface reliefs or smooth areas without relief, can be formed on the plastic part.

Preferably, the machining process is followed by at least one further machining process in order to enhance, modify or optimize the optical effect of the plastic part, to protect the material to be introduced and to meet the requirements of a particular industry.

The irregularities are introduced into the film 10, in particular the carrier layer 11 and/or the decorative layer or layers 12, by different types of preprocessing during and/or before the extrusion process. This is preferably done before the film 10 and the plastic material 20 are bonded together in the extrusion process.

Different possibilities of introducing the metamorphic portion will now be illustrated with reference to fig. 4a to 4 c.

Introduction metamorphic part

The basic possibility of introducing a predetermined breaking point in one or more layers of the film 10. In this case, one or more layers of the film 10, in particular the carrier layer 11 and the carrier layer 11, are locally mechanically damaged or weakenedAnd/or one or more decorative layers 12 to introduce a predetermined breaking point. One possibility for this is, for example, to partially or completely cut through one or more layers of the film 10 in the region of the respective predetermined breaking point by means of a cutting or punching tool. The predetermined breaking point may have a punctiform transverse shape, in particular when using a punching tool, and/or a linear transverse extension, in particular when using a cutting tool.

Fig. 4a shows an embodiment of a plastic part 1, during the production of which such a variant 61 is introduced into the film 10:

the plastic part 1 according to fig. 4a comprises a film 10 with a carrier layer 11 and the decorative layer or layers 12, of which only one decorative layer 12 is shown by way of example in fig. 4 a. The plastic part 1 also has a plastic material 20.

In the region of the deformation 61 designed as the predetermined breaking point, holes are present in the processing process, which holes are produced by the film 10 already being cut open when the predetermined breaking point is introduced and/or by the predetermined breaking point being torn open in this region as a result of the "weakening" of the film 10 that is carried out there and the high pressure/temperature acting on it in the processing process. Through these "holes" the plastic material 20 can reach the side of the plastic part 1 opposite the side on which the plastic material 20 is applied during the machining process.

The plastic material 20 can thus spread at these locations on the opposing surfaces of the plastic part 1, as a result of which, in the edge region of the irregularities 61, as is also shown in fig. 4a, the film 10, in particular the decorative layer 12, is correspondingly warped and/or frayed (ausgefranst) and thus correspondingly a local change in the position and/or orientation of the surface region of the decorative layer 12 is caused in the region of the irregularities 61.

Instead of introducing the irregularities 61 by means of a cutting tool or a punching tool, as described above, it is also possible to "weaken" one or more layers of the film 10, for example by means of a scraping tool, such as a wire brush, or by radiation and/or chemical pre-processing.

The strength of the processing steps is selected such that the decorative layer 12 peels off at the processing location and/or predetermined breaking points are produced, which then lead to a corresponding tearing and/or breaking of the layer encapsulation of the film 10 in this region during the processing process and thus to a visual detectability of the anomalies caused thereby.

It is advantageous here if the membranes 10 have large penetrations (Durchgriff) (regular and/or irregular), so that the plastic material 20 can penetrate between the membranes 10 and no regions without adhesive connections are formed.

Furthermore, it is advantageous to introduce one or more bending points in the membrane 10 in order to introduce the discontinuities. This is explained below with reference to fig. 4b and 4 c:

in order to introduce the irregularities 62, the film 10 is bent once or several times in such a way that one or more bending points are introduced into the film, in the region of which bending points one or more layers of the film 10 are plastically deformed and/or broken by bending and/or the one or more decorative layers 12 are caused to peel off locally from at least one adjacent layer of the film by bending.

In fig. 4b, an exemplary embodiment is now shown, in which the irregularities 62 are introduced into the film 10 in the form of bending points, in the region of which one or more layers of the film 10 are plastically deformed by bending: fig. 4b shows a plastic part 10 with a plastic material 20 and a film 10 comprising a carrier layer 11 and one or more decorative layers 12, of which only one decorative layer 12 is shown in fig. 4b for the sake of simplicity. As shown in fig. 4, in the area of the irregularities 62, the carrier layer 11 of the film 10 and the decorative layers 12 are plastically deformed by bending, so that in the area of the bending point the position and/or orientation of one or more decorative layers 12 is locally changed, and in particular as shown in fig. 4b, correspondingly a local surface area of the decorative layer 12 is inclined relative to the main surface of the plastic part 1 opposite the film 10.

The bending point can be introduced here in particular by crimping the membrane 10, by bending the membrane 10, by folding the membrane 10 and/or twisting the membrane 10. The bending point preferably has a linear shape here and its lateral extent and the bending radius to be introduced can be determined accordingly by the choice of the bending tool. Furthermore, by targeted feeding of the membrane 10, bending points can also be introduced into the membrane 10 accordingly, for example by repeatedly changing the web tension (Bahnzug) or by causing a membrane torsion by a corresponding feed.

As shown in fig. 4b, the plastic deformation caused by the anomalies 62 is "held" and thus "stabilized" by the plastic material 20.

Furthermore, a corresponding "tearing" of the layer encapsulation of the film 10 can also be brought about in the region of the bending points, analogously to the exemplary embodiment according to fig. 4a, in the course of the production process by correspondingly breaking and/or weakening one or more layers of the film 10, and thus also partial predetermined breaking points can be brought about in one or more decorative layers 12, which predetermined breaking points bring about an optical effect analogous to the predetermined breaking points according to fig. 4 b.

Furthermore, as shown in the exemplary embodiment according to fig. 4c, a local peeling of one or more decorative layers can also be caused in the machining process in the region of the bending point: the embodiment according to fig. 4c shows a plastic part 1 with a plastic material 20 and a film 10 comprising a carrier layer 11 and one or more decorative layers 12, fig. 4c showing one of the decorative layers 12 for the sake of simplicity:

as shown in this figure, local peeling of the decorative layer 12 is brought about by the pressure load in the machining process in the areas of the irregularities 62 by correspondingly weakening the interlayer adhesion between the carrier layer 11 and the decorative layer 12 and by bending loads in these areas. In the area of the irregularities 62, therefore, local regions of the decorative layer 12 are provided which, on account of the peeling, have a significant change in the spatial position/orientation relative to the regions of the decorative layer 12 which are not subjected to a corresponding bending load. For example, in the area of the irregularities 62, the surface normal of the decorative layer 12 is correspondingly inclined with respect to the main surface of the plastic part 1 opposite the film, so that a corresponding optical change in the reflection properties of the plastic part occurs in this area.

The effect according to fig. 4b, the effect according to fig. 4c and/or the effect according to fig. 4a can thus be achieved by introducing a bending point and a corresponding visually recognizable change can thereby be caused in the area of the discontinuity and in particular a depth and/or 3D effect and/or a transparency effect in the plastic part.

In order to create the bending point, the membrane may be mechanically twisted one or more times about an axis, in particular a longitudinal axis, before being introduced into the plastic material. This can be done at different angles, which can achieve different appearances of the thus introduced irregularities in the subsequent material rolling process. The speed of the twist and the speed of passage of the extrudate have an effect on the visual appearance of the anomaly caused thereby.

It is particularly advantageous here that, with a twist of 180 ° and a corresponding decorative layer structure, the color of the decorative layer 12 changes as a function of the twist, so that a corresponding change in the visual appearance is achieved.

It is advantageous here to use a film 10 which produces a different visual appearance when viewed from the front and/or the back. For example, a colored metallized film can be used as the film 10, which is colored only on the front side by a further glossy decorative layer on the metal layer, so that the film, for example, gives the impression of a gold color when viewed from the front side in reflected light and the impression of a silver metal when viewed from the rear side in reflected light.

The film 10 can be introduced here in a planar manner and with a uniform tension or a laterally varying tension/pulling force. The laterally varying tension/pulling force can be used here to introduce the inhomogeneities randomly and/or regularly by corresponding adaptation to the thermal conditions and/or flow rate of the plastic material from the extruder 52 and the roll pressure and roll spacing of the extrusion rolls 53. The tension and/or pulling force of the film 10 can be varied manually and/or by a corresponding mechanical film supply. In particular, the tension and/or pulling force of the film 10 can be varied at will by manual intervention. Alternatively or additionally, the film feed speed and/or feed angle can also be varied by targeted control of the film feed device. For example, the actuators of the respective servomotors or other actuators and the film supply device can be controlled by means of a respective program. This effect may be further enhanced by local melting of the layers of the film 10 and/or by local swelling and/or pressure-separation of the layers of the film 10 by the plastic material 20. The position of the film in the plastic material 20 can also be varied, in particular, for example in the middle of the plastic part 1, in the edge region thereof or else over the entire surface.

In all the above embodiments, the film 10 can be supplied in various ways when it is introduced into the plastic material 20: tensioned/substantially smoothed, compressed/strongly deformed, untensioned/taut, twisted, etc. This may be done uniformly or non-uniformly depending on the desired effect. For example, the film is initially relaxed and shrunk and is tensioned in the next stage, which can be repeated repeatedly.

Furthermore, the film can also be joined to the plastic material 20 in such a way that the films 10 are located on the front and/or back of the plastic material 20 and/or are arranged next to one another in single or multiple passes. For this purpose, not only one film 10, but also two or more different films 10 can be combined with the plastic material 20 in the production process. It is particularly advantageous here for the films 10 to have different visual appearances.

Furthermore, the films 10 can also be supplied to the processing process in multiple superposed fashion and thus, for example, the plastic material 20 is in contact with two or more films 10 in the processing process. For example, one film 10 is arranged on each of the front and rear sides and thus forms a composite of a plastic material 20 and two or more films 10, which are preferably wrapped with the plastic material 20.

The following optical effects are achieved in particular by this method:

in principle, special optical effects, in particular depth effects, are produced in the finished extrudate by the additional introduction of material, i.e. one or more films 10, and by the introduction of the

deformations

61, 62.

The depth effect can be varied here by different introduction of the

alterations

61, 62 and by different introduction of the film 10 during the processing. If the film 10 is located (to be precise) on the underside in the plastic part, a much greater depth effect is thereby produced than if the film 10 was located (to be precise) on the front side in the plastic part.

Preferably, a depth effect in the form of "pleats" or relief images having a distinct height and depth is desired here.

By introducing the bending points accordingly, a further effect in the form of a series of undulations can be achieved, which appear in succession, can be designed to be small/large and convex/concave and whose size can also be varied in a targeted manner over the surface.

The appearance of the depth effect and/or the 3D effect and/or the transparency effect, which is caused by the change in the size and position of the local regions of the decorative layer or layers 12 in the area of the alterations, can be locally reinforced or reduced by correspondingly setting the strength of the bending, torsion and the strength and size of the introduction of the alterations.

A further depth influence is caused by the local change in position of the decorative layer or layers 12 in the volume of the plastic material 20 in the area of the irregularities. This visually appears as if the decorative layer or layers 12 were "floating" in the plastic material at different heights in regions.

Furthermore, the depth effect is also caused by the real shadow casting within the plastic part. If a transparent or translucent plastic material 20 is selected and a film is applied to the front side of the plastic material, the film will cast a shadow on the layer of the plastic part that is on the back side of the plastic material 20. If a lacquer layer is applied in a further processing step, for example by screen printing, in the background, i.e. on the rear side, this lacquer layer makes shadow casting show its effect well, which further emphasizes the depth effect.

The degree of glazing (Lasierungsgrad) of the plastic material 20 also influences the optical depth effect. The film 10 is clearly visible if it is located entirely on the surface of the plastic material 20. But if it is located in a deeper area, it appears here-depending on the degree of glazing of the plastic material-to be diffusely reflective, so that a corresponding depth effect results.

The depth effect and the shadow formation increase in principle with increasing layer thickness of the plastic material 20 in the plastic part 1.

Coextrusion is preferred. If the film 10 is located on the surface of the plastic material 20, it cannot protect the film from the outside. The coextrusion results in the film 10, in particular the decorative layer or layers 12, being completely enveloped and in this case has the following advantages, in particular:

thus, on the one hand, complete protection of the decorative layer or layers is achieved. Furthermore, the entire surface of the extrudate has the same material properties. Subsequent processing steps, such as screen printing, digital printing, hot stamping printing, cold stamping printing, thermal transfer printing, thermoforming and back injection are also made easier. In particular, a uniform lacquer connection (Lackanbindung) and a smooth, uniform surface are achieved, which for example ensures good suction in a screen printing machine.

The coextrusion can be carried out directly in the processing process. Different material combinations are also conceivable, depending on the requirements. This is shown for example in fig. 5:

fig. 5 shows an embodiment in which the film 10 comprising the carrier layer 11 and the at least one decorative layer 12 is in contact with the plastic material 20 on both sides during the processing. This is preferably achieved by modifying the extrusion process according to fig. 3 in such a way that the plastic material 20 is not only in contact with the molten plastic material 20 on one side, but the plastic material 20 is applied on both sides of the film 10 before the film 10 enters the roll gap of the extrusion roll 53.

Furthermore, such a coextrusion can also take place not directly in the processing process, but in a subsequent processing step.

In addition to using the same plastic material, different plastic materials can also be applied to both sides of the film 10. For example, a plastic material 20 made of ABS may be applied on one side and a plastic material 20 made of PC may be applied on the other side.

In parallel with and/or after co-extrusion, other subsequent processing steps may be performed. It is particularly advantageous here to carry out subsequent printing, for example by screen printing or digital printing, in order to reinforce the depth effect as described above and to produce further color effects and/or transparency effects and/or backlighting effects and/or haptic effects and surface textures, in particular matt, glossy. Drawing, back-injection molding, flow coating, painting, laser marking, trimming, polishing, cleaning, quality control are other possible subsequent processing steps, alone or in combination.

Various examples for implementing the method are described below:

example 1:

the film 10 has a resilient, in particular yellow, coating as an upper decorative layer 12 and an aluminum layer as an underlying second decorative layer 12. Thus, the film 10 gives a golden metallic impression when viewed from the front under reflected light, and a silver metallic impression when viewed from the back.

The film 10 is cut, for example by means of a cutting tool, to introduce predetermined breaking points and the film 10 is processed, for example by folding and/or crumpling, in such a way that a large number of bending points are introduced into the film. The machining is in this example performed in particular manually. After introducing a large number of aberrations into the film 10 in this way, it is supplied to the extrusion process according to fig. 3 and liquid transparent PC is used as the plastic material 20.

Therefore, a large number of new design effects and strong depth effects are exhibited based on the effects illustrated in fig. 4a to 4c, although the plastic part 1 has a smooth surface on the main surface of the plastic part 1 opposite to the film 10.

Example 2:

as film 10, a film is used which comprises a deep-drawable PET film as carrier layer 11, a gloss coat as first decorative layer 12 and a chromium layer as second decorative layer 12 thereunder.

The film is introduced into the process according to fig. 3 and twisted several times during the introduction and extrusion process in order to introduce a metamorphosis in the film 10. This preferably takes place alternately from left to right in a cycle of 3 seconds over a range of rotation angles from 0 ° to 180 °. Over a period of about 12 seconds, the film 10 is inverted once 360 ° (i.e., rotated twice 180 °), and the process is repeated repeatedly. Here, when the film 10 is fed into the roll gap of the extrusion roll 53, its tension is changed randomly or pseudo-randomly. Here, the roll gap is 0.5mm and the flow rate of the plastic material 20 is 4.8 meters per minute.

As plastic material 20, translucent ABS is used here, which material, as already explained above with reference to fig. 3, is in contact with film 10 in the molten and thus liquid state.

In a subsequent step, the plastic parts thus produced from the main extruder are co-extruded by means of a further compact extruder. A clear PC was placed in the mini-extruder and it was applied to the plastic part at a thickness of 0.5 mm. This results in a plastic plate comprising a plurality of layers and having a material thickness of 1 mm. The transparent PC forms the uppermost layer of the extrudate, while the film 10 is completely enveloped and protected from external influences by coextrusion. The plastic part thus produced is then produced as a plate-shaped article and is printed over the entire surface with a solvent-containing lacquer mixture, in particular a clear varnish, in a screen printing process on the front side, i.e. the front main surface formed from a transparent PC plastic material, and is thus protected. The thickness of the lacquer layer is preferably in the range between 1 μm and 20 μm, for example 10 μm.

This lacquer layer is subsequently printed again in a screen printing in the form of a pattern with a solvent-containing lacquer mixture, in particular a matt-touch lacquer. The layer thickness of this lacquer layer is preferably between 5 and 50 μm, more preferably between 20 μm and 25 μm. Visually recognizable matte/bright effects and tactilely perceptible matte/smooth effects are produced by a full-surface glossy protective varnish and a matte-touch paint present in the form of a pattern.

The plastic part produced after this machining process is carried out is shown in fig. 6:

the plastic part comprises a plastic film 10 with a carrier layer 11 and two decorative layers 12, a plastic material 20 made of translucent ABS applied thereto in the production process according to fig. 3, a substrate 30 made of a transparent PC plastic material co-extruded thereon, a transparent lacquer layer 32 printed on the substrate and a lacquer layer 33 printed on the lacquer layer. The upper decorative layer 12 is formed by a color lacquer layer structured in a decorative manner and the lower decorative layer 12 is formed by a chromium layer.

The layer of plastic material 20 has a layer thickness of, for example, 500 μm, the substrate 30 has a layer thickness of, for example, 500 μm, the lacquer layer 32 has a layer thickness of, for example, 20 μm and the lacquer layer 33 made of a matt touch lacquer has a layer thickness of, for example, between 20 μm and 25 μm.

The film 10 and its carrier layer 11 and the decorative layer 12 have a layer thickness in the range already mentioned above and are therefore constructed much thinner than the layer made of the plastic material 20. Due to the introduction of the alterations, the decorative layer 12, as shown in fig. 4a to 4c, is arranged in the volume of the layer made of plastic material 20 in a spatially different position and orientation, respectively, so that the above-described optical effects, in particular depth effects, transparency effects and color effects, are produced thereby.

For example, in some regions the decoration of the upper decorative layer 12 can be seen on the lower decorative layer 12, while in other regions only the optical effect of the lower decorative layer 12 can be seen. Depending on the angle and tension at the time of introduction, for example overlapping/smooth, tensioned/compressed, the decorative of the upper decorative layer 12 and the chrome surface of the lower decorative layer 12 can also visually influence one another, for example arranged side by side in a clearly separated manner from one another or in partial areas overlapping one another. The optical depth effect is further enhanced by the intermediate position of the membrane 10 in the overall structure of the plastic part. This is additionally reinforced by a screen-printed, in particular decorative, lacquer layer 33 on the front side of the plastic part.

The decorative layer 12 and the screen-printed lacquer layer 33 decoration thus cast a shadow on the substrate as a layer with a lower transparency. The film 10 is folded in a variety of different shapes and sizes depending on the tension of the film 10 at the time of introduction, and from a large, single fold to a plurality of concentrated small folds, producing a correspondingly varying optically variable effect based on the thus introduced metamers.

Example 3:

as shown with reference to fig. 7a, a plate 31, which is first of all made of preferably transparent polycarbonate, is printed with a color lacquer layer 32 on the front side, preferably in a pattern by screen printing. The plate 31 preferably has a layer thickness of 750 μm. The lacquer layer 32 is preferably printed in a layer thickness of 1 μm to 20 μm, preferably 5 μm to 15 μm, for example 10 μm. The lacquer is preferably a one-component acrylate system.

Subsequently, a full-surface lacquer layer 33, preferably a full-surface, matte and transparent protective lacquer layer, is applied to the surface. Solvent-based mixed lacquers are preferably used as lacquers. The lacquer is preferably printed in a layer thickness of 1 μm to 20 μm, preferably 5 μm to 15 μm, for example 10 μm.

The substrate 30 thus manufactured is then shaped by deep drawing a mold at a mold temperature of about 100 degrees celsius and a shaping temperature of about 140 degrees celsius. Optionally, processes such as milling and ultraviolet irradiation, trimming, cleaning, etc. are performed.

In a subsequent step, the irregularities are introduced into the film 10 with the carrier layer 11 and the decorative layer or layers 12, such as the decorative layer 12 formed from a chromium layer, as described above, for example by corresponding creasing, folding, cutting, stamping, etc.

Subsequently, an adhesive layer 40, for example a polyimide sticker with a layer thickness of 50 μm, is locally provided on the edge of the film 10 thus pretreated and is thus fixed to the back of the thermoformed substrate 30. Furthermore, the introduction of the metamers into the film 10 may also be done after the film 10 is secured to the substrate 30 and/or before and after the securing. It is particularly advantageous for the predetermined breaking point to be introduced by means of a cutting tool, for example, only after the film 10 has been fixed to the substrate 30.

After this pretreatment, the substrate 30 with the film 10 is placed in an injection mold and back-injection molded with a plastic material 20, such as a transparent polycarbonate, at a mold temperature of 65 degrees celsius.

In the injection molding process, the molten plastic material 20 is applied to the film 10 and the film 10 in the region of the predetermined breaking point is changed in appearance by the temperature and pressure in the injection molding process, as already explained above with reference to fig. 4a to 4 c.

The film 10 is therefore enclosed between the substrate 30 and the injection-molded back substrate formed from the plastic material 20 during the injection molding process and is positioned locally differently in its spatial position and orientation in the volume of the plastic material during the injection molding process as described above.

This effect is illustrated in fig. 7 b: fig. 7b shows the plastic part after the injection molding process has been performed: the plastic part comprises on the upper side a substrate 30 with a plate 31 and

lacquer layers

32 and 33. Followed by a composite formed of the plastic material 20 and the film 10. In this case, as shown in fig. 7b, the spatial position and orientation of the carrier layer 11 of the film 10 and the one or more decorative layers 12 in the volume of the plastic material 20 in the area of the irregularities changes, so that the optical effect, in particular the optical depth effect, already explained above, results.

The plastic parts thus produced have a strong optical depth effect and shadow effect. This is because the film 10 is distributed in the depth of the substrate made of the plastic material 20 and therefore the area of the film 10 located in the upper region of the substrate casts a shadow on the area of the film 10 located in the lower region of the substrate.

The plastic parts can be backlit in the areas where no covering, opaque screen-printing lacquer is applied, on the basis of the light-transmitting layer of the film 10, such as the carrier layer 11 and the upper decorative layer 12 made of a lustering coating. When backlit, interesting light effects are produced by localized areas of the decorative layer 12 and/or the film 10 distributed in the depth of the volume of the plastic material 20. These light effects may have optically different novel appearances. In particular, different light refraction and reflection occur locally at different locations in the plastic material by the film. Another special light effect is produced by the different transparency locally caused by the more or less often superimposed films, which results in a transparency of different intensity in the respective area. Finally, these light effects may occur individually or in combination.

Example 4:

the plastic part produced according to example 2 with the printed substrate 30 and the film 10 "flowing" in the plastic material 20 is personalized and/or personalized as a base material in a further processing step. Thereby for example making business cards or other personal items. For business cards, the respective card is punched and/or laser cut from a base material, for example, to the specifications of a credit card. And then personalized by hot stamping and/or digital printing and/or laser marking and/or stamping, etc.

Example 5:

as film 10, a film is used which comprises a deep-drawable PET film as carrier layer 11, a gloss coat as first decorative layer 12 and an aluminum layer as second decorative layer 12 lying thereunder. The film thus has an orange metallic or golden appearance.

The film 10 is fed manually to the extrusion process according to fig. 3, as plastic material 20 a liquid, transparent PC is used, which is in contact with the film 10 in the molten and thus liquid state as explained above with reference to fig. 3. When the film is introduced into the roll gap between the two extrusion rolls 35, the tension of the film varies randomly or pseudo-randomly or non-randomly. The plastic material 20 has, for example, a layer thickness of 750 μm. The roll gap is here 0.5mm and the flow rate of the plastic material 20 is 4.8 meters per minute.

The plastic part thus produced is produced as a plate-shaped article 31 after the cooling step and is printed in a screen printing pattern with a color lacquer 32, in particular a solvent-containing black lacquer, preferably twice, on the rear side, i.e. on the rear main surface of the plastic material made of a transparent PC plastic material and a metallic orange film. The lacquer is preferably printed in a layer thickness of 1 μm to 20 μm, preferably in a layer thickness of 5 μm to 15 μm, for example in a layer thickness of 10 μm.

The front side, i.e. the front main surface of the plastic material made of transparent PC plastic material and metal orange film, is then printed in a pattern in screen printing with a color lacquer, in particular a solvent-containing white lacquer 33. The lacquer is preferably printed in a layer thickness of 1 μm to 20 μm, preferably in a layer thickness of 5 μm to 15 μm, for example in a layer thickness of 10 μm.

The plastic part thus produced is subsequently shaped by deep-drawing a mold at a mold temperature of approximately 80 ℃ to 120 ℃, preferably 100 ℃, and a shaping temperature of approximately 100 ℃ to 180 ℃, preferably 140 ℃. The molded plastic part is then trimmed, in particular milled and cleaned.

In a next step, a further film 10 is provided, which comprises, in particular, a carrier layer 11 and a decorative layer 12 arranged thereon. As already mentioned above, the metamorphosis is subsequently introduced into the further film, for example, analogously to the already mentioned orange-colored metal film, for example by corresponding creasing, folding, cutting, stamping, etc. The further membrane may also be introduced without the metamorphosis.

Subsequently, an adhesive layer, for example a polyimide sticker with a layer thickness of approximately 50 μm, is provided on the edge of the further film thus pretreated and is thus fixed on the back of the thermoformed plastic part. Furthermore, it is also possible to introduce the irregularities into the film after the film has been fixed to the plastic part and/or before and after the film has been fixed to the plastic part. It is advantageous for the predetermined breaking point to be introduced by means of a cutting tool, for example, only after the film has been fixed to the plastic part.

After this pretreatment, the plastic part with the further film is placed in an injection mold and back-injection molded with a plastic material, such as transparent polycarbonate, at a mold temperature of about 40 ℃ to 90 ℃, preferably 65 ℃. In a next step, the front side of the plastic part with the further film is immersed with polyurethane.

In the injection molding process, the molten plastic material is applied to the further film and the plastic part and the appearance of the film in the region of the predetermined breaking point is changed accordingly by the temperature and pressure occurring in the injection molding process, as already explained above with reference to fig. 4a to 4 c.

In the injection molding process, the further film is therefore enclosed between the plastic part and the injected plastic material and is positioned in the volume of the plastic material locally differently in its spatial position and orientation as described above in the injection molding process.

This effect is illustrated in fig. 8 b: fig. 8b shows the plastic part after the injection molding process has been performed: the plastic part comprises on the upper side a substrate 30 with a plate 31 and

lacquer layers

32 and 33. Followed by a composite formed of the plastic material 20 and the film 10. As shown in fig. 8b, the spatial position and orientation of the carrier layer 11 of the film 10 and the one or more decorative layers 12 in the volume of the plastic material 20 in the area of the irregularities changes, so that the optical effect, in particular the optical depth effect, already explained above, results.

Example 6

The decorative layer 12 located on the carrier layer 11 of the film 10 is applied to the carrier layer 11 in sections by injection of an unstable adhesive 16 (e.g. hot melt adhesive), which is applied to the film, in particular on the side of the decorative layer facing the carrier layer 11, in a pattern or flat manner according to a desired design. That is to say, the adhesion promoter layer is arranged between the carrier layer 11 and the decorative layer 12. In this case, "injection-unstable" means that the adhesion promoter 16 is thermally and mechanically unstable, in particular at the pressures and temperatures occurring in the injection molding process, and is liquefied and washed away, in particular under the impact of liquefied injection-molding material. In the same injection molding process, the thermal and mechanical stability of the injected, in particular, unstable adhesion promoter is significantly lower than in the region of the decorative layer 12 without such an injected, unstable adhesion promoter 16.

The film can be applied to the rear, i.e. on the carrier material side, to a further carrier material 11, such as polycarbonate, PMMA or ABS.

In the injection molding process, the location where the unstable adhesion promoter 16 is injected (by the action of heat and/or injection pressure) is separated from the composite of the carrier material 20 and the decorative layer 12 and can thus flow into the injected plastic material 11. Instead, the remaining injection-stable regions 15 of the decorative layer 12 remain in place on the carrier material 20. This results in a decoration with a previously defined release decoration (where the unstable adhesion promoter 16 is injected) with an attractive depth and light effect by the floating, released decorative particles behind, as shown in fig. 9 b.

List of reference numerals

1 Plastic component

10 film

11 support layer

12 decorative layer

13 peeling layer

14 protective layer

15 adhesive and/or adhesion promoter layer

16 adhesion promoter layer

20 plastic material

21 Plastic granules

30 base

31 plate

32 paint layer

33 paint layer

40 adhesive layer

50 extrusion device

51 storage container

52 extruder

53 extrusion roller

61 different change part

62 part of variation

111 main surface

112 major surface.

Claims

1. Method for manufacturing a decorative plastic part (1), the method comprising the steps of:

-providing a membrane (10);

-applying at least one plastic material (20) to the film (10) at least in regions in one working process;

-introducing the alterations (61, 62) in the film (10) such that the alterations (61, 62) are visually recognizable, in particular visually recognizable by a depth effect and/or a 3D effect and/or a transparency effect, after said processing, in particular through the plastic material (10).

2. Method according to claim 1, characterized in that the film (10) has at least one carrier layer (11) and at least one decorative layer (12), or in that the film (10) is designed as a single layer, in particular made of a layer of plastic or metal or paper.

3. Method according to any of the preceding claims, characterized in that the plastic material (20) is melted before being applied onto the film (10), and that the melted plastic material (20) is brought into contact with the film (10) when the plastic material (20) is applied.

4. Method according to any one of the preceding claims, characterized in that the molten plastic material (20) is applied to the film (10) in such a way that the molten plastic material (20) covers, preferably covers and/or wraps at least one main surface (111, 112) of the film at least in partial regions, preferably over the entire surface.

5. Method according to any one of the preceding claims, characterized in that the film (10) is entirely wrapped with plastic material (20) during the processing.

6. Method according to any one of the preceding claims, characterized in that the plastic material is a thermoplastic plastic material, in particular containing PET, ABS, PMMA, PP, PS.

7. Method according to any one of the preceding claims, characterized in that the plastic material (20) is a transparent or translucent plastic material.

8. Method according to any one of the preceding claims, characterized in that the plastic material (20) is an optically scattering plastic material.

9. Method according to any one of the preceding claims, characterized in that the plastic material (20) has a glass transition temperature between 60 ℃ and 300 ℃, preferably between 90 ℃ and 150 ℃.

10. Method according to any one of the preceding claims, characterized in that the plastic material is pressed onto the membrane (10) at a pressure of 10 to 700 bar, preferably 10 to 300 bar and/or at a temperature of 60 to 300 ℃, in particular 210 to 240 ℃.

11. Method according to any of the preceding claims, characterized in that a metamorphic portion (61, 62) is introduced before and/or during the machining process.

12. Method according to any one of the preceding claims, characterized in that the metamers (61, 62) are introduced into the film (10) before the application of the plastic material (20).

13. Method according to one of the preceding claims, characterized in that the irregularities (61, 62) are visually recognizable by a local peeling of the decorative layer or layers (12) from the carrier layer (11) and/or a local change in the position of the local area of the decorative layer or layers, in particular a local inclination with respect to the main surface of the plastic part and/or a local cutting of the decorative layer or layers (12).

14. Method according to any one of the preceding claims, characterized in that the metamorphic portion (61, 62) is changed in the machining process by the conditions, in particular pressure and/or temperature, generated there, in particular in the following manner: warpage and/or deformation of the film in the region of the deformations (61, 62), tearing of the film (10) or tearing of the decorative layer(s) (12) of the film in the region of the deformations (61, 62), peeling of the decorative layer(s) (12) of the film in the region of the deformations (61, 62), and/or an increase in local cutting and/or plastic deformation of the film or of the decorative layer(s) (12) of the film in the region of the deformations (61, 62), preferably an increase of more than 15%, more preferably of more than 40%, more preferably of more than 60%.

15. Method according to any of the preceding claims, characterized in that the visual appearance of the plastic part in the area of the metamorphic section is changed by applying a plastic material.

16. Method according to any of the preceding claims, characterized in that one or more of the decorative layers (12) of the film around the alterations (61, 62) are destroyed or largely destroyed in the machining process.

17. Method according to any of the preceding claims, characterized in that the visual appearance of the film (10) in the area of the irregularities is visually recognisably altered in the processing process by a thermal and/or mechanical and/or chemical influence compared to the area without irregularities.

18. A method according to any of the preceding claims, characterized in that the local optical change of the film that occurs in the area where the metamorphic portion is introduced is maintained by the cured plastic material.

19. Method according to any one of the preceding claims, characterized in that one or more first of the irregularities (61) are formed by a predetermined breaking point, which is introduced in layers of the film, in particular in one or more of the decorative layers of the film, by mechanically damaging one or more layers of the film (10) when introducing the first irregularities.

20. Method according to claim 19, characterized in that for introducing the first variant (61) one or more layers of the membrane (10) are at least partially cut open, in particular mechanically, in particular by cutting, punching, scraping, engraving, and/or at least partially cut open and/or weakened by radiation, in particular by laser, electron beam or heat source, and/or chemically, in particular by etching.

21. Method according to one of claims 19 and 20, characterized in that the one or more first predetermined breaking points differ from each other, in particular in the transverse plane extension or shape, the cutting depth of the layers being cut and/or the layers of the film.

22. Method according to any one of the preceding claims, characterized in that one or more second varistors (62) of the varistors are formed by a bending point, the layer or layers of the film (10) being plastically deformed and/or broken by bending in the region of the bending point and/or causing local peeling of the decorative layer or layers of the film from at least one adjacent layer of the film by bending when the second varistors (62) are introduced.

23. Method according to claim 22, characterized in that the second anomaly (62) is introduced by locally bending the membrane (10), in particular by bending and/or folding and/or twisting said membrane.

24. Method according to claim 22 and/or 23, characterized in that, in order to introduce the metamorphosis, the film (10) is twisted one or more times by at least 180 ° and in that the film comprises at least two decorative layers (12) with different visual appearances, which are visible in reflected and/or transmitted light from different main surfaces (111, 112) of the film.

25. Method according to one of claims 22 and 24, characterized in that the one or more second irregularities differ from each other, in particular in terms of transverse plane extension or shape, plastically deformed and/or broken layer and/or in terms of local bending radius of one of the films and/or decorative layers of the films in the area of the irregularities.

26. Method according to any one of the preceding claims, characterized in that the introduction of the anomalies (61) is according to a regular or irregular grid or randomly or pseudo-randomly.

27. Method according to any one of the preceding claims, characterized in that two or more different plastic materials (20) are applied to the film (10), in particular to opposite main surfaces (111, 112) thereof, in the processing process.

28. The method according to any one of the preceding claims, characterized in that the film (10) is supplied to the process two or more times.

29. Method according to any of the preceding claims, wherein the processing process is an extrusion process and the plastic material is an extruded material of the extrusion process.

30. Method according to claim 29, characterized in that the plastic material (20) is brought into contact with the film (10) before the extrusion rollers.

31. Method according to any one of the preceding claims, characterized in that the processing process is a process selected from the group consisting of an injection molding process, a lamination process, a deep drawing process.

32. Method according to any of the preceding claims, characterized in that after the working process one or more further layers (31, 32, 33) are applied onto the plastic material (20) and/or the film (10) to form the plastic part.

33. The method according to any of the preceding claims, wherein the film is a transfer film or a laminate film.

34. A method according to any of the preceding claims, wherein the carrier layer of the film is selected from: PTT, PCM, PMM.

35. Method according to any of the preceding claims, characterized in that the carrier layer (11) of the film has a layer thickness between 10 μm and 200 μm.

36. Method according to any one of the preceding claims, characterized in that the decorative layer (12) of the film or one or more of the decorative layers (12) is selected from: in particular a lacquer layer comprising one or more colorants and/or pigments, in particular a metal layer made of a plurality of different metals, in particular a reflective layer made of one or more HRI or LRI layers, a relief layer with an optically active surface relief, in particular a diffractive structure, a hologram, a matt structure, a refractive structure, in particular a microlens structure, a zero-order diffraction grating, a thin-film element producing a colour-shifting effect by interference, a layer producing a colour effect in transmitted light by plasmon resonance.

37. Method according to one of the preceding claims, characterized in that the decorative layer or layers are structured in the form of a partial pattern or over the entire surface, in particular with a layer thickness of between 0.1 μm and 20 μm.

38. Decorative plastic part, in particular produced according to one of claims 1 to 37, characterized in that the plastic part (1) has a film (10) and a plastic material (20) which is applied to the film at least in regions during the processing, the alterations (61, 62) being introduced into the film in such a way that the alterations (61, 62) are visually recognizable after the processing, in particular through the plastic material (20), in particular by a depth effect and/or a 3D effect and/or a transparency effect.