DE102006024263A1 - Plastic moldings made by back-injection for use as interior lining parts for cars, comprise a thin thermoplastic film with an impressed pattern on the surface, an open-structured backing and a rigid plastic support - Google Patents

Abstract

A plastic moulding (1) formed by back-injection, back-stamping, back-pressing or back-injection stamping and comprising a thermoplastic film (2) with a thickness of 0.1-0.3 mm as decoration, an open-structured backing (3) and a rigid plastic support (4) bonded to (3), in which the plastic film (2) has an impressed structure on the surface. An independent claim is included for a method for the production of (1) by (a) laying a sheet material (5) comprising plastic film (2) and bonded backing (3) in a mold with the film (2) facing the side of the cavity which is itself at least partly structured, and (b) contacting the material (5) with molten plastic (4) so that the material (5) is deformed only by the pressure and temperature of the plastic (4) and without prior heating so as to form a shaped plastic part (1) with the surface structure of the mold transferred to the surface of the film (2).

Description

The The invention relates to a plastic molding with a decorative thermoplastic layer. Furthermore, the present invention relates a method for producing the plastic molding according to the invention.

Plastic moldings, which are covered on at least one side with a decorative surface, find a wide application as interior decor panels in Automobiles. So they are used as cladding for A, B, C and D pillars but also for dashboards, Interior door panels, center consoles and other panels of sides and ceiling areas in automobiles used. You need to meet the most diverse requirements.

Plastic moldings, which are covered on at least one side with a decor are, can different ways are produced. A procedure for their production is the laminating process. Here is a first Molded part by injection molding made of a thermoplastic material. Subsequently, will this molding with an embossed Foil or a decorative material coated and adhesively attached or laminated to the molding. The disadvantage here is the elaborate and expensive multi-step procedures, if necessary done manually Need to become.

Farther it is known to provide an already embossed film (e.g. PVC film) to inject. The disadvantage of this method is but that the already coined Foil in the back molding warps and thereby the imprinted pattern is distorted in the finished plastic moldings.

On the other hand, it is also known in the art but initially to first decorate the decor material especially in the case of film material and deep draw and inject the thus deformed film material in a second process step with a thermoplastic material. Such a method is used, for example, in EP 0 371 425 B1 described. In this case, a cold-stretchable film material at a working temperature below the softening temperature of the film material, preferably in the range of 80 to 130 ° C, applied directly and directly by means of a pressure medium such as compressed air or an inert gas and isostatically deformed. The process is further carried out at very high pressures, which are preferably between 50 and 300 bar. In a second process step, the deep-drawn film thus produced can then be placed in an injection mold and then back-injected with a thermoplastic material.

This However, prior art methods have significant disadvantages on. For the implementation of the method are basically two Tools necessary, namely a mold in which the film material is deformed or deep-drawn is and an injection mold, in which the subsequent Injection molding with a thermoplastic material takes place. Farther the deformation of the film material is not negligible temperature increase effected, which is preferably carried out in the range between 80 and 130 ° C. This means that in particular temperature-sensitive decorative materials such as temperature-sensitive plastics with this method is not can be processed. Namely, such decorative materials tend to be at high temperatures and according to the method provided high pressure to change their surface so much that possibly a wanted decorative embossed surface coating is no longer preserved, but it is only a flat press the decorative material comes into the respective mold. The procedure is therefore very expensive and expensive and can therefore for a inexpensive Use for the production of back-injected plastic moldings not always be used.

At the In-mold graining method of the prior art is the sheet material Deep-drawn by vacuum and deformed. This is a thermo plastic Foil brought to the softening temperature of the film material and by contacting with a heated mold containing a embossing has provided with an appropriate structure. Subsequently, will the deformed and embossed Foil material in a second step on a plastic molding laminated.

This However, prior art methods are essential Disadvantage to that for the execution of the procedure in principle several steps and special devices in the tool concerned are necessary, wherein the film material is first deformed or deep-drawn and then on the finished carrier is laminated on. Continue to have in these processes because of the handling of films with a thickness of 0.7 to 1 mm can be used.

In the further state of the art, it is also known to carry out the process for producing injection-molded plastic molded parts in one step, in which case the decorative material is inserted directly into the injection mold and this material is back-injected with a thermoplastic material. In the case of back molding, the decorative material is deep-drawn by the pressure of the thermoplastic material and pressed into the corresponding injection mold, thus producing a decorative embossed surface coating. For example, this describes wise the EP 0 320 925 A1 a process for the production of plastic moldings with embossed surface coating, in which the moldings are coated with a film having the surface embossing. For this purpose, an unembossable thermoformable film is placed in an injection mold, which has an embossed structure at least on portions of its inner surface and then introduced a flowable plastic in the molding tool. It is operated at a pressure of about 10 to 130 bar. In this case, the temperature of the thermoplastic material is preferably above the softening temperature of the thermoformable film. Preferably, at the same time or following the injection of the molten thermoplastic material, a gas is introduced into the plastic melt and the pressure in the molded part is maintained until the plastic is at least substantially solidified.

This Method has the advantage that a one-step process control in the production of the back-injected plastic moldings is possible. On the other hand, it has the disadvantage that in this case films with a strength of preferably 0.5 to 1 mm are used, so that it is complicated shaped moldings often to an insufficient filling of the cavities in the injection mold comes, and so the decorative character the surface coating is not even. Another disadvantage of using films with the mentioned Strengthen is the cost factor.

The DE 197 29 780.3 discloses the production of a plastic molded article with decorative embossed surface, wherein the decorative material is placed in an injection mold, is pressurized with a gas under pressure. As a result, the decorative material is pressed into the cavities of the injection molding tool and the surface embossing of the decorative material is produced by pressing into the embossed surface of the tool inner surface without any significant effect of temperature. Subsequently, the back of the decorative material with a plastic material. The disadvantage here is that the tool must be equipped with means for pressurizing.

The DE 10 2004 034 930 discloses a method of making a plastic molded article having a decorative embossed surface wherein the decorative material, such as a thermoplastic olefin (TPO), is heated and then placed in an injection mold. Subsequently, the decorative material is back-injected or back-pressed and the surface embossing of the decorative material produced by pressing into the embossed surface of the tool inner surface. The disadvantage here is the preparatory step of heating the film, which makes cumbersome and expensive measures on the tool required.

The technical object of the invention is therefore to provide a new plastic molding to provide, as well as a method for producing back-injected Plastic moldings with embossed surface to disposal to provide, which avoids the above disadvantages, in one Process step feasible is and in particular without prior heating, deep drawing or separate Shape the decorative material takes place.

This technical problem is solved by a plastic molding produced by shaping by means of injection molding, back embossing, backpressing or back injection stamping 1 comprising a thermoplastic film 2 with a thickness of 0.1 to 0.3 mm as a decoration, a lower fabric connected to the thermoplastic film 3 with an open structure, and a composite material connected to the lower fabric composite material 4 as a substantially rigid support, wherein the thermoplastic film 2 has an embossed structure on the surface.

According to one aspect of the present invention takes place during the molding of the plastic molded part 1 imaging a structure of the mullet side of the tool on the surface of the thermoplastic film. By the term "embossed structure" on the surface of the plastic molding 1 is a regular or irregular non-smooth surface, such as a grain pattern, a groove pattern, a dent pattern, a leather embossing pattern, a logo pattern of letters, numbers or geometric figures, a decorative embossing, etc. to understand.

In a preferred embodiment is the strenght the thermoplastic film 0.1 to 0.2, preferably 0.1 to smaller 0.2, more preferably 0.1 to 0.18 mm, and most preferably 0.1 up to 0.15 mm.

In the prior art plastic moldings with embossed surface are known, with a thickness of the thermoplastic film used as a decorative of about 0.7 to 1 mm. The disadvantage here are the higher costs, as well as the prob lematic handling in complicated geometries. Surprisingly, it was found according to the invention that plastic moldings with embossed (eg grained) surface can be produced with a very thin thermoplastic film as decorative surface in a one-step process, without, for example, injection marks of the introduced plastic material can be seen on the decorative side. Therefore, there is a cost savings because the film used can now be thinner. Furthermore, there is a better quality of the molded parts, because the thinner film allows better imaging accuracy with more complicated geometries. In addition, there is in the production of art fabric molding according to the invention, no special features in the mold temperature control.

In a preferred embodiment the thermoplastic film is a thermoplastic polyolefin (TPO), thermoplastic polyurethane (TPU), polyurethane, TPE or Vinyl, more preferably thermoplastic polyurethane (TPU). Thermoplastic polyurethane (TPU) is particularly preferred, i.a. because it is a soft material with good haptic properties; It is also scratch-resistant and available with good lightfastness.

Furthermore, it is preferred that the lower fabric is selected from the group fleece, fabric, fibers, felt, textile, wool, preferably non-woven, particularly preferably fleece made of polyester. This selection of the lower fabric, in particular nonwoven, allows a good connection between the decorative film with the plastic molded part, because the lower fabric due to the open structure enters into a close mechanical connection with the introduced plastic material, ie the plastic material 4 partially penetrates into the nonwoven layer.

In a further preferred embodiment, the plastic material 3 from thermoplastic polymers selected from the group polyolefin, polyethylene, polypropylene, highly crystalline polypropylene (HCPP), polycarbonate, polyamide, acrylic-butadiene-styrene copolymer, acrylic-butadiene-styrene-polycarbonate copolymer, polyvinylchloride, a polypropylene-polyester mixture or Mixtures thereof.

It is preferred that the thermoplastic film 2 composite with the lower fabric 3 connected is.

• – Einlegen eines Flächengebildes 5 umfassend eine thermoplastische Folie 2 mit einer Stärke von 0,1 bis 0,3 mm als Dekor und eine mit der thermoplastischen Folie 2 verbundene Unterware 3 mit offener Struktur in ein Werkzeug, wobei die thermoplastische Folie 2 zur Muldeseite des Werkzeuges gerichtet ist, die zumindest teilweise eine Struktur aufweist;
• – In-Kontakt-Bringen des Flächengebildes 5 mit einem schmelzflüssigen Kunststoffmaterial 4, wobei das Flächengebilde ohne wesentliche vorherige Temperatureinwirkung lediglich durch den Druck und die Temperatur des eingebrachten Kunststoffmaterials 4 verformt wird; und Ausformen des Kunststoffformteiles; wobei während der Formung des Kunststoffformteiles 1 die Struktur der Muldeseite des Werkzeuges auf die Oberfläche der thermoplastischen Folie 2 übertragen und in diese eingeprägt wird.

The technical problem is further solved by a method for producing a plastic molded part 1 comprising the following steps:

• - Inserting a fabric 5 comprising a thermoplastic film 2 with a thickness of 0.1 to 0.3 mm as decor and one with the thermoplastic film 2 connected subware 3 with an open structure in a tool, wherein the thermoplastic film 2 directed to Muldeseite of the tool, which has at least partially a structure;
• - Contacting the fabric 5 with a molten plastic material 4 wherein the sheet without substantial previous temperature influence only by the pressure and the temperature of the introduced plastic material 4 is deformed; and molding the plastic molding; wherein during the molding of the plastic molded part 1 the structure of the mullet side of the tool on the surface of the thermoplastic film 2 transferred and imprinted in this.

In A preferred method is the thermoplastic film in a Strength of film 0.1 to 0.2, preferably 0.1 to less than 0.2, especially preferably 0.1 to 0.18 mm, and most preferably 0.1 to 0.15 mm used.

Furthermore, it is particularly preferred that the fabric 5 prior to bringing into contact with the molten plastic material 4 essentially not deformed and substantially not heated.

In a further preferred method, the temperature of the introduced molten plastic material is 4 above the softening temperature of the thermoplastic film 2 ,

According to the invention, it is preferred that the applied pressure and the temperature of the liquid plastic material 4 the existing on the Muldeseite of the tool structure is transferred to the thermoplastic film and embossed.

The term "structure" on the cavity inner surface of the tool part 6 is a regular or irregular non-smooth surface, such as a grain pattern, a groove pattern, a dent pattern, a leather embossing pattern, a logo pattern of letters, numbers or geometric figures, a decorative embossing, etc. to understand.

Preferably, the molding of the plastic molding takes place 1 by means of injection molding, back embossing, back pressing or back injection stamping.

In a preferred embodiment is a thermoplastic polyolefin as a thermoplastic film (TPO), thermoplastic polyurethane (TPU), polyurethane, TPE or Vinyl, more preferably used thermoplastic polyurethane (TPU). Thermoplastic polyurethane (TPU) is particularly preferred, i.a. because it is a soft material with good haptic properties; It is also scratch-resistant and available with good lightfastness.

Furthermore, it is preferred that the lower fabric used 3 is selected from the group fleece, fabric, fibers, felt, textile, wool, particularly preferably nonwoven, particularly preferably nonwoven fabric made of polyester.

It is preferred as a plastic material 4 a material selected from the group consisting of polyolefin, polyethylene, polypropylene, highly crystalline polypropylene (HCPP), polycarbonate, polyamide, acrylic-butadiene-styrene copolymer, acrylic-butadiene-styrene-polycarbonate copolymer, polyvinylchloride, a polypropylene-polyester mixture or Mixtures thereof.

In a preferred embodiment is the pressure during the molding of the plastic molding in the tool is greater than 200 bar.

The Plastic molding according to the invention is preferably used as interior trim part for motor vehicles.

The present invention thus relates to a method for forming decorative surface structures on a molded plastic part in a tool. The method therefore includes providing a tooling assembly that includes a first tool part (trough) having a textured surface and a second tool part, wherein the first and second tool parts together create a cavity. In the method according to the invention, the sheet is 5 that is a thermoplastic film 2 and a lowerware 3 has, so inserted between the two tool parts, that the thermoplastic film 2 is directed to the Muldeseite. Subsequently, the hot molten plastic material 4 introduced into the tool on the one with the lower fabric 3 equipped side of the fabric 5 , Due to the applied pressure and the temperature of the introduced plastic material 4 the softened thermoplastic layer deforms 2 , which is pressed against the tool inner wall of the bowl side, and thereby transfer the embossing, which is present in the cavity surface of the tool part, on the thermoplastic resin film. After cooling and solidification in particular of the introduced plastic material 4 the plastic molding according to the invention is obtained with an embossed surface.

As already explained, the tool part forming the cavity (trough) has on its inside a (negative) embossing or structured surface, which corresponds to the later surface (decoration) of the plastic molded part. The later embossed decorative surface coating is achieved by a set of initially unembossed thermoplastic film. During the injection of the thermoplastic material 4 For the carrier material of the plastic molded part, the thermoplastic film inserted into the tool is pressed against the inner wall of the molded part tool. Due to the heat of fusion present in the injection molding compound for the carrier material, the thermoplastic film is heated to a temperature above the deformation temperature, so that the embossing pattern of the molding tool surface is transferred to the film.

Description of the figures

1 FIG. 12 is a schematic cross-sectional view of a tool assembly used in the method of the present invention with the tool assembly shown in the open position. FIG.

2 is a schematic cross-sectional view of the tool assembly of 1 in the closed position, showing the plastic molding according to the invention with a decorative surface.

3 shows the finished plastic molding.

In 1 becomes a tool assembly with tool core 7 and tool tray 6 shown in open position. The die side has an inner surface that forms the cavity. On the inside is a (negative) imprint 8th contained, which is transferred to the surface of the plastic molding to be produced. In the figure can be further seen that the sheet 5 with the thermoplastic film 2 and the lower fabric arranged thereon 3 between the two mold halves is introduced.

In the 2 is the closed tool after injecting the plastic material 4 to see. Here is the sheet material 5 to the inside of the tool part 6 pressed so that the thermoplastic film 2 directly on the inner wall of the tool part 6 is applied. By the temperature of the injected plastic material 4 as well as by the prevailing pressure, the thermoplastic film is deformed, which then a permanent embossing 9 receives.

In the 3 is the plastic molding according to the invention 1 with the plastic material 4 as a carrier, the thermoplastic film 2 as decor and the intermediate lower fabric 3 to see. The thermoplastic film 2 Here, in one subarea, there is a constant character 9 on the surface.

example

A blank of a polyester fleece coated with TPU, wherein the TPU layer thickness is only 0.1 mm, is hooked into the tool and then back-injected with HCPP. The HCPP melt has a temperature of about 220 ° C. During this injection molding process, the HCPP melt penetrates into the polyester fleece. The temperature of the HCPP melt also acts on the thermoplastic layer. The thermoplastic TPU layer has a softening temperature of about 150 ° C and is soft in this process. Due to the high cavity pressure during the back injection process of more than 200 bar, the softened TPU layer is pressed against the mold wall of the bowl side and one thus obtains an impression of the structure tur the tool inner wall on the decorative surface of the produced plastic molding.

1

Plastics molding

2

thermoplastic foil

3

under goods fleece layer

4

Plastic material

5

sheet

6

Tool-side trough

7

Tool core

8th

Embossing (negative) in the inside of the tool 6

9

Embossing (positive) on the surface of the plastic molded part 1

Claims (20)

A formed by shaping by means of injection molding, Hinterprägen, Hinterpressen or Hinterspritzprägen plastic molding ( 1 ) comprising a thermoplastic film ( 2 ) with a thickness of 0.1 to 0.3 mm as a decoration, a lower fabric connected to the thermoplastic film ( 3 ) having an open structure, and a plastic material bonded to the lower fabric in a composite manner ( 4 ) as a substantially rigid support, characterized in that the thermoplastic film ( 2 ) has an embossed structure on the surface. The plastic molding according to claim 1, characterized by during the molding of the plastic molded part ( 1 ), a pattern of the mullet side of the tool is imaged on the surface of the thermoplastic film. The plastic molding according to claim 1 or 2, characterized characterized in that the strength the thermoplastic film 0.1 to 0.2, preferably 0.1 to smaller 0.2, more preferably 0.1 to 0.18 mm, and most preferably 0.1 to 0.15 mm. The plastic molding according to one of claims 1 to 3, characterized in that the thermoplastic film 2 a thermoplastic polyolefin (TPO), thermoplastic polyurethane (TPU), polyurethane, TPE or vinyl, particularly preferably thermoplastic polyurethane (TPU). The plastic molding according to one of claims 1 to 4, characterized in that the lower fabric is selected from the group fleece, fabric, fibers, felt, textile, wool, preferred Nonwoven, particularly preferred nonwoven polyester. The plastic molding according to one of claims 1 to 5, characterized in that the plastic material ( 3 ) of thermoplastic polymers is selected from the group polyolefin, polyethylene, polypropylene, highly crystalline polypropylene (HCPP), polycarbonate, polyamide, acrylic-butadiene-styrene copolymer, acrylic-butadiene-styrene-polycarbonate copolymer, polyvinylchloride, a polypropylene-polyester Mixture or mixtures thereof. The plastic molding according to one of claims 1 to 6, characterized in that the thermoplastic film ( 2 ) composite with the lower fabric ( 3 ) connected is. The plastic molding according to one of claims 1 to 7, characterized in that the lower fabric ( 3 ) composite-like with the plastic material ( 4 ) connected is. Process for producing a plastic molded part ( 1 ), comprising the following steps: - inserting a fabric ( 5 ) comprising a thermoplastic film ( 2 ) with a thickness of 0.1 to 0.3 mm as decoration and one with the thermoplastic film ( 2 ) associated sub-commodity ( 3 ) with an open structure in a tool, wherein the thermoplastic film ( 2 ) is directed to the Muldeseite of the tool, which has at least partially a structure; - contacting the fabric ( 5 ) with a molten plastic material ( 4 ), wherein the sheet without substantial previous temperature influence only by the pressure and the temperature of the introduced plastic material ( 4 ) is deformed; and molding the plastic molding; wherein during the molding of the plastic molded part ( 1 ) the structure of the Muldeseite the tool on the surface of the thermoplastic film ( 2 ) is transferred and impressed in this. The method according to claim 9, characterized that the thermoplastic film in a thickness of 0.1 to 0.2, preferably 0.1 to less than 0.2, more preferably 0.1 to 0.18 mm, and more particularly preferably 0.1 to 0.15 mm is used. The method according to claim 9 or 10, characterized in that the sheet ( 5 ) is not substantially deformed and substantially not heated prior to injection molding. The method according to one of claims 9 to 11, characterized in that the temperature of the introduced molten plastic material ( 4 ) is above the softening temperature of the thermoplastic film ( 2 ). The method according to any one of claims 9 to 12, characterized in that by the applied pressure and by the temperature of the liquid plastic material ( 4 ) is transferred to the thermoplastic film on the Muldeseite of the tool existing structure and embossed. The method according to one of claims 9 to 13, characterized in that the molding of the plastic molded part ( 1 ) by means of injection molding, back embossing, back-pressing or injection-injection. The method according to one of claims 9 to 14, characterized in that as a thermoplastic film ( 2 ) a thermoplastic polyolefin (TPO), thermoplastic polyurethane (TPU), polyurethane, TPE or vinyl, particularly preferably thermoplastic polyurethane (TPU) is used. The method according to any one of claims 9 to 15, characterized in that selected as Unterware from of the group fleece, fabric, fibers, felt, textile, wool Nonwoven, particularly preferably nonwoven polyester is used. The method according to one of claims 9 to 16, characterized in that as plastic material ( 4 ) a material is used selected from the group polyolefin, polyethylene, polypropylene, highly crystalline polypropylene (HCPP, polycarbonate, polyamide, acrylic-butadiene-styrene copolymer, acrylic-butadiene-styrene-polycarbonate copolymer, polyvinyl chloride, a polypropylene-polyester mixture or mixtures thereof. The method according to any one of claims 9 to 17, characterized in that a plastic molding with the Features of the claims 1 to 8 is made. The method according to any one of claims 9 to 18, characterized in that the pressure during the forming greater than 200 bar. Use of the plastic molding according to claims 1 to 8, or use of the by the method according to claims 9 to 19 produced plastic molding as interior trim part for motor vehicles.