DE102013222535A1 - A method of making a plastic part provided with at least one colored print - Google Patents

Abstract

The invention relates to a process for producing a part made of plastic, which comprises at least one colored impression on its visible surface. A method, characterized in that it consists of providing a mold in two complementary parts (5 and 5 '), one of which (5) on its active surface (6') facing the other part (5 ') with at least an added part (7) constituting an ink pad / modeler, and consisting of performing the following operations for each new part to be manufactured: applying at least one coloring substance to each ink pad (7); Inserting a sheet (4) of thermoplastic polymer material between the two parts (5 and 5 ') of the mold in the open state; Closing the mold by using the controlled application of heat and pressure at least in the area determined thereby in order to come into contact with the ink pad (7); and removing the workpiece provided with at least one colored impression.

Description

This invention relates to the sector of plastic parts, in particular cowl panels for motor vehicle passenger compartments, and to a method of manufacturing these components provided with at least one imprint having a colored background, an installation for carrying out this method and a plastic part produced by this method is obtained.

In many sectors, notably the equipment and consumer goods sectors, in particular the automotive sector, users are increasingly and consistently expressing their desire for a unique visual, preferably almost customized, look.

The answer to this demand includes - for example in the field of motor vehicles - above all the proposal of colored and even multi-colored interiors, which are associated with decorative contents or reliefs.

Manufacturers are therefore seeking improved technology solutions for cladding parts for passenger compartments of automobiles, which are usually molded and / or thermoformed plastic compatible with current manufacturing processes.

These technical solutions designed to meet the aforementioned demand must also be flexible and easily adaptable to various aesthetic needs, so that they can easily be incorporated into the existing manufacturing process without significant changes or additional costs.

In this context, a particularly inconvenient problem has arisen in connection with the production of impressions of negative or recessed molding processes or similar decorative surface relief where the specific coloring of the interior of these elements is desired.

• – Farbgebung des Grundes des Abdrucks unter Verwendung einer Maske oder von Tampondruck nach dem Formen oder Thermoformen des Kunststoffteils mit seinem Abdruck;
• – Einführung eines Teils oder eines zusätzlichen dekorativen Elements auf die Oberfläche des Kunststoffteils, zum Beispiel durch Einfügen, Kleben oder einen ähnlichen Prozess.

There are already several suggestions known which try to address this problem:

• Coloring the reason of the impression using a mask or pad printing after molding or thermoforming the plastic part with its impression;
• - Introduce a part or an additional decorative element on the surface of the plastic part, for example by insertion, gluing or a similar process.

However, these known solutions are expensive and require additional elements and / or operations after the manufacture of the plastic part.

Other proposals have been made for coloring the visible layer of the part before it is molded, or for making the part by overmolding a colored skin (see e.g. WO 2011/079961 and EP 0855952 ) made. However, these known processes are not designed to color specific areas and in any case do not guarantee a specific color of an impression which is subsequently shaped.

The invention aims to provide a solution to the above problem and to provide an answer to at least some of the implied implementation requirements.

To this end, the invention relates to a method for producing a plastic part, comprising on its visible surface at least one impression or analogue entry which is at least partially colored, the part being formed by or comprising at least one layer forming the visible surface the method being characterized in that it consists in providing a mold of two paired parts, one of which is provided on its active surface facing the other part with at least one insert mold modeller and ink pad, and that for each new part to be produced essentially performs at least the following operations: application of at least one coloring matter on the or each ink pad, possibly in certain patterns; Introducing a sheet of thermoplastic polymer material between the two mold parts in the opened state; Closing the mold using the controlled application of heat and pressure to the surface of the sheet opposite the ink pad in at least the area or areas thereof designed to contact the ink pad (s) and removing it with at least a colored impression provided part, after opening the mold.

The invention will be better understood from the following description with reference to a preferred embodiment given by way of non-limiting example, which will be explained with reference to the attached diagrammatic drawings, in which:

a simplified schematic sectional view of an apparatus for carrying out the manufacturing method according to an embodiment of the present invention is;

- by schematic sectional views four successive operating phases of the manufacturing method of the invention with reference to a skin-overcasting technique that is similar to that of a skin as in be performed device shown;

is a schematic sectional view of the part, by the in the - shown method is generated, and

an alternative embodiment of the means for applying a coloring substance as part of in shown device.

- illustrate an embodiment of a manufacturing method for producing a plastic part 1 , on its visible surface 1' at least one analogue impression or an admission 2 comprising at least partially colored, wherein the part 1 from at least one layer 4 It consists of or includes the visible surface 1' forms.

This method according to the invention involves first providing a mold in two complementary parts 5 and 5 of which a part 5 on his the other part 5 ' facing active surface 6 with at least one insertion 7 which forms a color pad and a modeler ( ). This method then consists of routinely performing substantially at least the following operations for each new part to be manufactured 1 : Applying at least one coloring substance 3 on the or each color pad 7 , possibly in a specific pattern ( ); Introduction of a sheet 4 ' a thermoplastic polymer material between the two moldings 5 and 5 ' in the open state ( ); Closing the mold using controlled application of heat and pressure to the surface 8th of the leaf 4 ' opposite the color pad (s) 7 , at least in the area or areas 9 of the same designed with the color pad (s) 7 ( and ) to come into contact; and removing the with at least one colored imprint 2 provided workpiece 1 after opening the mold 5 . 5 ' ( ).

The operations of application of the substance 3 on the color pad 7 and the introduction of the sheet 4 ' can at least partially overlap or even occur simultaneously.

Thanks to the invention it is therefore possible, both the final shape and the color of at least one impression 2 perform in a single operation step, the from the form 1 removed part does not require a supplementary treatment process (at least as far as the finishing of the impression / impressions 2 relates).

Carrying out the simultaneous coloring of the impression (s) 2 Moreover, they do not disrupt the manufacturing process (just a supplementary step to deposit the substance 3 on the impression (s) 7 is added), and there is no essential change in the shape itself required (it is only the ink pad 7 to the form and association of an agent 10 for applying the coloring matter 3 added to the mold).

The number, characteristics and arrangement of the impressions 2 as well as their coloring can also easily without involving any modification in the parts 5 . 5 ' be changed in the form, in addition to a return to the generation of the part 1 without an impression 2 is easily possible.

The method advantageously includes providing pressure and temperature conditions during the closing phase of the mold so that the material containing the sheet 4 ' forms, on the one hand, at least on the or each opposite the ink pad 7 located area 9 however, below its glass transition temperature it is carried below its melting temperature and, on the other hand, tight against the ink pad 7 associated with obtaining a transfer of the colorant (s) 3 and the relief pattern of the color pad in question 7 is concerned.

In order to achieve an extremely durable color, which resists the attack of the elements from the outside (UV, solvents, cleaning products, ...) can the material of the sheet 4 ' at the area or at each of the opposite the color pad 7 located areas 9 is expected to be heated to a temperature suitable for passing at least on the surface layer of the material through the coloring matter (s) 3 , preferably by forming a chemical bond, to achieve an impression on the mass.

The coloring matter (s) 3 However, even without phase mixing with the material of sheet 4 ' form a surface layer, with their final bond to the bottom of the impression 2 optionally by the energy absorption during the formation of the corresponding impression 2 provided.

The bond between the coloring substances 3 and the leaf 4 ' can be further reinforced by performing (ink jet applied) adhesion promoters or adhesives.

According to a variant of a practical, compatible with an automated and flexible manufacturing process embodiment, in particular As can be seen, the invention 1 in the previous construction of one or more ink pads / modeller / s 7 consist of a deposit (s) that are on one part 5 Of the parts 5 . 5 ' The mold can be located by removable mounting and with a predetermined position a number of similar parts 1 to create. It may also be the deposition of the coloring substance (s) on the or each color pad 7 before each closing of the mold by at least one application agent 10 , preferably on a robot arm or similar object 10 ' , include.

According to a preferred technical embodiment of the invention, the great flexibility in the production and a good transfer of the coloring substances 3 is possible, is every color pad 7 in a removable manner via a contact or pressure sensitive adhesive bond 7 on an indexed side on the surface 6 attached to the relevant part 5 the form 5 . 5 ' matches, with the color pad 7 is advantageously made of silicone or covered with a layer of silicone (which is based on a support structure of suitable shape) and preferably side edges 7 which is at least light from its base to its upper surface 7 ' converge. The shape, the adaptation and the size and the extent of the color cushions 7 as well as the complexity of the patterns and reliefs that they carry can of course vary greatly.

part 1 according to a first variant, which is not particularly shown in the accompanying drawings, only by the sheet 4 ' be, ie only a single shift 4 have (which may optionally have a laminated or layered structure), and the method of preparation according to the invention can then only from the thermoforming with an integrated generation of one or more impressions 2 consist of the above-mentioned modalities. In this case, the second part 5 ' the shape optionally a slight admission to the color pad 7 exhibit.

According to a second preferred embodiment and from the to and Following the accompanying drawings, the method consists of generating a part 1 with at least two layers 4 and 11 comprising a first layer 4 forming a visible skin, shaped by the leaf 4 ' of the thermoplastic material and at least one second layer 11 that forms the support and / or root structure that may or may not be through the skin 4 is covered, the second layer 11 by injecting into the mold 5 . 5 ' which is used to produce the color impression (s) 2 ( and ) was used.

In the context of this second variant, the method can continue, in particular after the introduction of a sheet 4 ' that to the skin 4 and closing the mold 5 . 5 ' is designed from the injection of the formation of the layer 11 designed material between the second part 5 ' the shape and the surface 8th of the leaf 4 ' opposite the color pad (s) 7 under pressure and heat to the material of the sheet ( 4 ' ) and soften it at the affected areas 9 of the leaf 4 ' ( ) in close contact with the color pad (s) 7 to press.

According to a possible technical embodiment of the method, the latter can during the closing of the mold 5 . 5 ' and before injecting the second layer to form 11 material may also consist in providing at least a first rough shape by bending the plastic under pressure and optionally by calorically receiving the thermoplastic polymer material ( ) existing sheet 4 ' , the two parts 5 and 5 ' The shape can be easily pulled apart before the second layer 11 forming material injected under pressure and the configuration of the skin 4 is completed.

As a non-limiting material example, the first layer 4 thermoplastic polyolefin-type material (optionally with an outer layer of polyurethane) and the second layer 11 consist of a polymer of the polypropylene or polyamide type or the like (example of the thickness: layer 4 : 0.5 mm / layer 11 : 2.5 mm).

In the case of complex and complicated decorations, it is possible to deposit at least two coloring substances 3 different colors on the or at least one of the color cushions 7 where appropriate, on surfaces which are at different distances from the base of the ink pad in question 7 be considered and / or considered according to predefined patterns.

The coloring substances 3 may consist of mixing the inks, diluents and thickeners using a known method.

The surface of the formation of the visible surface 1' of the part 1 designed leaf 4 ' can be advantageously pretreated by flame (plasma or corona treatment).

The invention also relates to a manufacturing apparatus for carrying out the above-described manufacturing method.

This device includes, as in to shown in the drawings, essentially a shape in two parts 5 and 5 ' (male / female, core / cavity) related to each other movable and suitable for defining an open and a closed condition for the mold, the mold optionally having a molten thermoplastic meterial injection system 12 can be combined.

This device is characterized in that a part 5 the two parts 5 . 5 ' the form on its the other part 5 ' facing surface 6 at least one color pad / modeler 7 that covers on the surface 6 is releasably secured at a predetermined location, for example by a contact or pressure sensitive adhesive bond, and that the device further comprises a means 10 for applying the coloring substance (s) 3 on the or each color pad 7 by contact, projection, spraying, transfer or a similar deposition method, where the means 10 preferably on a robotic arm 10 ' or an analog automatic device with controlled movement.

The application means 10 may consist of an ink jet head using 3D color-beam technology, pad printing or film transfer.

This ink jet head can be activated either in several parts or even for the deposition of different colors. The movement of the head is planned so that it lies completely outside the mold when the mold has to close and that the direction of deposition of the coloring substances 3 perpendicular to the upper printing surface on the ink pad 7 runs. The movement of the arm 10 ' will be synchronous with the movement of the parts 5 . 5 ' the (already known) movement and the operation process 12 controlled.

Alternatively and as in shown, the application means 10 also consist of a paint roller, which is able to different coloring substances 3 optionally in different patterns on one or more color cushions 7 apply.

The invention ultimately also relates to a plastic part 1 that on its visible surface 1' at least one impression or analogue inlet area 2 of which, if necessary, at least the reason is at least partially colored in a specific pattern, and the part 1 optionally of at least two layers 4 and 11 exists, ie a first layer 4 which forms a visible skin, and at least a second layer 11 which forms the support and / or documentation structure.

this part 1 , Especially a part for a passenger compartment of a motor vehicle and more particularly the dashboard, is procured by means of the aforementioned device and by performing the above-described manufacturing process.

Of course, the invention is not limited to the embodiments described and shown in the attached drawings. Modifications remain possible, particularly from the point of view of the structure of the various elements or by replacing technical equivalents, without departing from the scope of the invention.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• WO 2011/079961 [0009]
• EP 0855952 [0009]

Claims (11)

A method of manufacturing a plastic part comprising on its visible surface at least one impression or analogous depression which is at least partially colored, the part being constituted by or comprising at least one layer forming the visible surface, the process being characterized characterized in that it consists of providing a mold in two complementary parts ( 5 and 5 ' ), in which a part ( 5 ) on its active, the other part ( 5 ' ) facing surface ( 6 ), with at least one added part ( 7 ) constituting a color pad / modeler and performing at least the following operations for each new part to be manufactured ( 1 ): Application of at least one coloring substance ( 3 ) on the or each color pad ( 7 ), possibly in a specific pattern; Introduction of a sheet ( 4 ' ) of a thermoplastic polymer material between the two parts ( 5 and 5 ' ) of the mold in the opened state; Closing the mold using the controlled application of heat and pressure to the surface ( 8th ) of the leaf ( 4 ' ) opposite the color pad (s) ( 7 ), at least in the areas ( 9 ) of which are designed with the color pad (s) ( 7 ) to get in touch; and removing the with at least one colored impression 2 provided workpiece ( 1 ) after opening the mold ( 5 . 5 ' ). Manufacturing method according to claim 1, characterized in that it comprises providing pressure and temperature conditions during the closing phase of the mold so that the material containing the sheet ( 4 ' ), on one side at least on the or each opposite the ink pad ( 7 ) ( 9 ) is carried below its glass transition temperature but below its melting temperature and on the other side closely against the ink pad ( 7 ), which involves obtaining a transfer of the coloring substance (s) ( 3 ) and the relief pattern of the relevant ink pad ( 7 ) is concerned. Manufacturing method according to claim 2, characterized in that the material of the sheet ( 4 ' ) on the or each opposite the ink pad ( 7 ) ( 9 ) is heated to a temperature sufficient to achieve impregnation on the mass at least on the surface layer of the material by the coloring matter (s) ( 3 ), preferably by the formation of a chemical compound. Manufacturing method according to any one of Claims 1 to 3, characterized in that it is used to produce a series of similar parts ( 1 ) by removable mounting and at a predefined position from the previous installation of one or more ink pads ( 7 ) and modelers exist as insertions that are on a part ( 5 ) Of the parts ( 5 . 5 ' ) and that it is due to the deposition of the coloring substance (s) on the or each color pad ( 7 ) by at least one application agent ( 10 ), preferably on a robot arm or similar object ( 10 ' ) is attached before each closing of the mold. Manufacturing method according to any one of Claims 1 to 4, characterized in that the or each color pad ( 7 ) in a removable manner by a contact or pressure sensitive adhesive bond on an indexed side on the surface ( 6 ) attached to the mold ( 5 . 5 ' ) ( 5 ), wherein the ink pad ( 7 ) is advantageously made of silicone or covered with a layer of silicone and preferably side flanks ( 7 ' ) at least from its base to its upper surface ( 7 ' ) converge slightly. Production process according to any one of Claims 1 to 5, characterized in that it consists in the production of a part ( 1 ) with at least two layers ( 4 and 11 ) comprising a first layer ( 4 ), one by sheet ( 4 ' ) forms visible skin of a thermoplastic material, and at least one second layer ( 11 ), which forms a support and / or a continuous or non-continuous rooting structure through the skin ( 4 ), the second layer ( 11 ) by injection into the mold ( 5 . 5 ' ) used to produce the colored impression (s) ( 2 ) is used. Manufacturing method according to claim 6, characterized in that after insertion of a sheet ( 4 ' ), which contribute to the formation of the skin ( 4 ) and closing the mold ( 5 . 5 ' ) consists of injecting the material under pressure and heat, the second layer ( 11 ) between the second part ( 5 ' ) of the form and the surface ( 8th ) of the leaf ( 4 ' ) opposite the color pad (s) ( 7 ) forms the material of the sheet ( 4 ' ) and to keep it in close contact with the color pad (s) ( 7 ) in which the sheet ( 4 ' ) area 9. Manufacturing method according to any one of Claims 6 and 7, characterized in that during the closing of the mold ( 5 . 5 ' ) and before injecting the material containing the second layer ( 11 ), by providing at least a first rough shaping by bending the plastic under pressure and optionally by caloric uptake by the sheet of thermoplastic polymer material ( 4 ' ), where the two parts ( 5 and 5 ' ) of the mold then before injecting the second layer ( 11 ) can be easily pulled apart under pressure as well as terminate the configuration of the skin ( 4 ). Manufacturing method according to any one of Claims 1 to 8, characterized in that it consists of the deposition of at least two coloring substances ( 3 ) of different colors on the or at least one of the ink pads ( 7 ), where appropriate, on surfaces which are at different distances from the base of the respective ink pad ( 7 ) and / or predefined patterns. Manufacturing apparatus for carrying out the method according to any one of claims 1 to 9, comprising a mold in two parts ( 5 and 5 ' ) which are movable with respect to each other and adapted to define an open and a closed condition for the mold, the mold optionally being equipped with a molten thermoplastic material injection system (US Pat. 12 ), the device is characterized in that a part ( 5 ) of the two parts ( 5 . 5 ' ) of the form at its the other part ( 5 ' ) facing surface ( 6 ) at least one color pad / modeler ( 7 ) in a removable manner on a particular side of the surface ( 6 ), for example, by a contact or pressure-sensitive adhesive bond, and that the device further comprises an application means ( 10 ) of coloring substance (s) ( 3 ) on the or each color pad ( 7 ) by contact, projection, spraying, transfer or an analogous deposition method, the means ( 10 ) preferably on a robot arm ( 10 ' ) or an analog automatic device with controlled movement. Part made of plastic, in particular a part for a passenger compartment of a motor vehicle, and more particularly the instrument panel, obtained by means of manufacturing the device according to claim 10 and by carrying out the manufacturing method according to any one of claims 1 to 9, wherein the part ( 1 ) on its visible surface ( 1' ) at least one imprint or analogous submission ( 2 ) in which the ground is at least partially colored, possibly in a specific pattern, and the part ( 1 ) optionally of at least two layers ( 4 and 11 ), ie a first layer ( 4 ), which forms a visible skin, and at least one second layer ( 11 ), which forms the support and / or documentation structure.

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