DE102017007963A1 - Foil forming tool, method of making a foil forming tool, and using a foil forming tool - Google Patents

Foil forming tool, method of making a foil forming tool, and using a foil forming tool

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Publication number
DE102017007963A1
DE102017007963A1 DE102017007963.3A DE102017007963A DE102017007963A1 DE 102017007963 A1 DE102017007963 A1 DE 102017007963A1 DE 102017007963 A DE102017007963 A DE 102017007963A DE 102017007963 A1 DE102017007963 A1 DE 102017007963A1
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Germany
Prior art keywords
characterized
forming tool
film forming
tool according
producing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
DE102017007963.3A
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German (de)
Inventor
Edgar P. Nimmergut
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kiefel GmbH
Original Assignee
Kiefel GmbH
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Filing date
Publication date
Priority to US201762460374P priority Critical
Priority to US62/460,374 priority
Application filed by Kiefel GmbH filed Critical Kiefel GmbH
Publication of DE102017007963A1 publication Critical patent/DE102017007963A1/en
Application status is Withdrawn legal-status Critical

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/38Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3828Moulds made of at least two different materials having different thermal conductivities
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/38Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/42Moulds or cores; Details thereof or accessories therefor characterised by the shape of the moulding surface, e.g. ribs or grooves
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08Deep drawing or matched-mould forming, i.e. using mechanical means only
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26Component parts, details or accessories; Auxiliary operations
    • B29C51/30Moulds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C53/00Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
    • B29C53/02Bending or folding
    • B29C53/04Bending or folding of plates or sheets

Abstract

The invention relates to a film forming tool for laminating a component with a laminating element or for molding a thermoplastic film of a grained geometry, an alternative method for Narbschalenfertigung and the use of a corresponding film forming tool.
In particular, the invention relates to a production method for a grain pan, which saves both manufacturing time and manufacturing costs, has a long service life and also allows a high impression quality.
For this purpose, a thin shell mold of a film forming tool is made by means of electrochemical deposition of nickel and stiffened by means of metal spraying, wherein the metal spray layer includes a honeycomb-shaped fabric.

Description

  • The invention relates to a film forming tool, a method for producing a film forming tool and a use of a film forming tool.
  • Automotive surfaces are often made with film that is applied to backing parts in a laminating process or other process. An alternative to the lamination process is in particular a foaming process.
  • The film usually has a surface graining, which is either already produced during the film production or transferred to the film during an impression process or is formed during the laminating process with a grained film molding tool.
  • If the surface graining is transferred to the film by means of an impression process, a molding shell is used in the molding machine, which has a surface texture, which is also referred to as a negative grain structure and causes an impression of the film during the impression taking. The force required for embossing the film force between the film and the shell mold can be achieved by suction of the surface by means of vacuum, by applying compressed air, by mechanical contact pressure or by a combination of the aforementioned methods.
  • If the surface graining is produced during the laminating process, a molding shell with a surface texture is used in the laminating plant, which causes an embossing of the film during the laminating process. The force required for embossing the film force between the film and the shell mold can be achieved by suction of the surface by means of vacuum, by applying compressed air, by mechanical contact pressure or by a combination of the aforementioned methods.
  • Advantage of the embossing during the lamination process or the Abformprozesses is that the grain structure is produced in the three-dimensional state of the film and thus no so-called grain loss can occur by expansion, as is often the case with alternative methods. A scar loss is understood to mean a negative impairment of the optical or haptic grain quality on the carrier part of the foil.
  • A shell mold with a negative grain structure is often also called Narbschale and often galvanically produced. For this purpose, nickel is deposited on a positive model of the outer contour of the finished component with a positive grain structure until a layer thickness of approximately 4 mm has formed.
  • As a variant of a nickel shell with a negative grain structure, a milled steel shell is used, which has obtained a negative grain structure by means of etching. The production of a steel shell is faster compared to a galvanized nickel shell.
  • In addition to producing a surface texture in a steel shell by means of etching, this can also be made with a laser.
  • Another variant offers a plastic shell with a negative grain structure, which is produced in the casting process and for the lamination of components or the molding of films in small series is well suited.
  • The known shell molds with a negative grain structure (Narbschalen) have in common that they are often permeable to air, so that the necessary force between the film and the shell mold can be achieved. The air permeability can be generated by perforation, for example by discrete openings created by means of lasing or etching, or by a material-specific microporosity of the shell mold.
  • For lamination or molding in the production operation of large series, a grain pan with a tempering system and a substructure, often in the form of a support structure, is added to a complete tool.
  • A method for laminating a component by a laminating tool is in DE 10 2013 203 408 A1 disclosed.
  • The invention has for its object to provide the prior art an improvement or an alternative.
  • According to a first aspect of the invention, the object is achieved by a film forming tool for laminating a component with a laminating element or for molding a film, wherein the film forming tool has a mold shell, wherein the mold shell comprises two material layers of different materials, wherein a first material layer consists of nickel and a second material layer has a sprayed layer of metal.
  • Conceptually, the following is explained:
  • First of all, it should be expressly pointed out that, in the context of the present patent application, indefinite articles and numerical data such as "a", "two", etc. are generally referred to as "at least" Should be understood as "at least one ...", "at least two ..." and so on, unless expressly stated in the respective context or it is obvious or technically imperative for the skilled person that only " exactly one ... "," exactly two ... "and so on.
  • Furthermore, it should be expressly noted that in the context of the present patent application, a "part" of something should be understood that it may also be the whole part of something.
  • Under "film shapes" is here optionally "laminating" or "molding" understood.
  • By "laminating" is meant the joining of multiple layers of the same or different materials. In particular, a layer may be a film. This film is also called a "laminating element". In general, the laminating of components is understood to mean the laminating of a laminating element with the component to be laminated, which serves as a carrier part, wherein the laminating element can achieve surface graining during laminating.
  • "Molding" is understood to mean the shaping of a shaped element, in particular a foil, with a foil forming tool, it being possible for the forming element to acquire a surface grain during the casting. In particular, the molded part may be the designated surface of an interior trim part of a motor vehicle, wherein the molded part, in particular a film, is connected to a carrier element in a subsequent process.
  • A "foil forming tool" is understood to mean either a tool for laminating a component with a laminating element or a tool for molding a shaped element. Often one and the same film forming tool can be used both for laminating a component with a laminating element and for molding a molded element, wherein the respective laminating and molding processes have differences.
  • A film forming tool has at least one mold shell, which is usually supplemented by a support structure and a tempering system.
  • A "foil" refers to a thin metal, ceramic or plastic sheet.
  • A "grain" is the structuring of a surface, so that it is also referred to as a "grain structure". A grain is characterized by the haptic and visual properties of a surface.
  • As a "shell mold" is referred to a cup-shaped construction with a specific shape. Form shells can consist of different materials and material combinations. They find application in the shaping of other components and transfer the shape of their surface on the component to be molded. The relief of a shell mold in particular runs in reverse to the object or model to be molded, which is why a shell mold is often referred to as a "negative mold shell". The object to be formed or the "model" of this object is often referred to as a "positive model".
  • A "material layer" is understood as meaning a layer of a material, wherein the material layer may have a layer thickness in the region of one or more atomic layers. Likewise, a material layer may have gaps in which the material of the material layer can not be found. In other words, a material layer is a coherent layer of atoms of a material.
  • By "metal spraying" is meant a process of spraying metal which belongs to the surface coating processes. In particular, metal spraying includes thermal spraying as well as cold gas spraying. In metal spraying, metal is deposited, melted or fused as filler material inside or outside a spray burner, accelerated in a gas flow in the form of spray particles and thrown onto the surface of the component to be coated. The component surface is usually not melted and only a small thermal load.
  • A "sprayed coating" is a sprayed layer of material having a perceivable thickness. It is built up during thermal spraying, in particular during metal spraying, since the spray particles flatten more or less depending on process and material when hitting the surface of the component, primarily sticking by mechanical clamping and build up the sprayed layer in layers. Quality features of sprayed coatings are - depending on the selected process design - low porosity, good connection to the component, freedom from cracks and a homogeneous microstructure.
  • The state of the art has hitherto provided that the mold shell was galvanically produced by a film forming tool, with nickel being deposited on a positive model of the finished component, that is to say with a positive grain structure, until a layer thickness of approximately 4 mm had been formed. During the electroplating process, mechanical corrections of the component had to be made manually from time to time, so this procedure was expensive and time consuming. An essential feature here was the comparatively high thickness of the nickel layer with a thickness of approx. 4 mm, which required high process times for depositing the nickel and was necessary for the rigidity of the shell mold.
  • Alternatively, the prior art has heretofore provided that the shell mold of a foil forming tool was milled from a steel block.
  • Another alternative known in the prior art has heretofore been that the mold shell of a plastic sheet molding tool has been produced in a casting process or by a lamination process.
  • By way of derogation, it is proposed here that the surface of the molding shell facing the laminating element or the molding element in the laminating process or in the molding process is made of nickel, which is deposited galvanically on a positive model and a rear layer of the molding shell is produced by metal spraying.
  • Thus, it is conceivable that a layer of nickel is electrodeposited on a positive model and this nickel layer is supplemented and / or reinforced by metal spraying, wherein the nickel layer is in particular stiffened by the metal spraying.
  • The stiffening of the electrodeposited nickel layer by metal spraying makes it possible to advantageously allow comparatively thin nickel layers for the surface of the shell mold, whereby the process of galvanic deposition of the nickel layer can be significantly shortened and the costs for the nickel layer can be drastically reduced.
  • Advantageously, it can be achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality. Furthermore, the film forming tool can have a high impression quality of the positive model even without the need for post-processing.
  • In particular, it can be achieved that the production time for a galvanically produced nickel shell can be drastically reduced. In experiments of the inventor has been shown that the production time can be halved.
  • The sprayed layer of metal preferably has a honeycomb-shaped structure.
  • Conceptually, the following is explained:
  • By "honeycomb" is meant a cellular material pattern constructed of individual cavities. A honeycomb cell structure may consist of closed and open cavities.
  • Advantageously, it can thus be achieved that a particularly lightweight and rigid support structure for the shell mold of a film forming tool can be achieved.
  • Optionally, the surface of the shell mold has a negative grain structure.
  • Conceptually, the following is explained:
  • A "negative fringe structure" comprises a surface of a component, in particular the surface of a mold shell constructed as a negative mold shell, whereby the relief of the mold shell is inverted to the object or model to be molded and the model has a fringe structure. The negative mold shell thus has a negative grain structure.
  • Thus, a film forming tool is made possible, which has a mold shell with a negative grain structure and thus carries the scar information for the component to be laminated or formed, so that embossing of the laminating element during the laminating process or embossing of the molding element during the molding process can take place.
  • It is conceivable, for example, a shell mold with an outer layer of nickel, which carries the Narbinformation and is stiffened by a layer of metal, which was applied by spraying, so that the shell mold has the necessary dimensional stability.
  • Advantageously, it can thus be achieved that a mold shell with high abrasion resistance and high dimensional stability can be produced, with which the embossing of the laminating element can take place during the laminating process or the molding element during the molding process.
  • With the embossing during the lamination process or the molding process can also be advantageously achieved that the grain structure is generated in the three-dimensional state of Kaschierelementes or the mold element and thus no grain loss can occur.
  • In particular, it can be achieved that a mold shell for a film forming tool which has a long service life and for the Large-scale production is suitable, inexpensive, comparatively fast and can be produced with high impression quality. Furthermore, the film forming tool can have a high impression quality of the positive model even without the need for post-processing.
  • Preferably, the surface of the mold shell is permeable to air.
  • Conceptually, the following is explained:
  • By "air permeable" is meant that the surface of the shell mold is permeable to air. Air can thus penetrate the surface of the shell mold.
  • Specifically, among other things, it is conceivable that the laminating element or the mold element is sucked into the mold shell by a vacuum applied to the rear side of the mold shell, so that the force necessary to emboss the laminating element or the mold element can take place between the laminating element and the shell mold.
  • In a particularly suitable embodiment, the material of the mold shell is permeable to air. Thus, it is conceivable that the sprayed layer produced by metal spraying has a porosity which makes the sprayed layer of the mold shell and thus suitable design of the nickel layer the entire mold permeable to air, so that the laminating element or the mold element by a vacuum applied to the back of the mold shell vacuum in the mold shell can be sucked.
  • Alternatively, in one embodiment, it is conceivable that a mold shell consisting of a plurality of material layers is permeable to air as a result of the properties of the material layers; in particular, the mold shell can have material layers of different materials. Specifically, among other things, it is conceivable that a mold shell consisting of a galvanically deposited nickel layer and a metal spray layer has a cross-material porosity that makes the mold shell permeable to air, so that the laminating element or the mold element is sucked into the mold shell by a vacuum applied to the back of the mold shell can. In particular, it is conceivable that both the electrodeposited nickel layer and the metal sprayed layer are made microporous.
  • Advantageously, it can thus be achieved that the laminating process or the molding process can be carried out inexpensively and with comparatively short throughput times despite high qualitative standards.
  • In addition, if desired, it can be achieved that the embossing of the laminating element can take place during laminating.
  • If the air permeability of the molding shell is based on the use of porous materials, it can be achieved in particular advantageously that the molding shell does not have to be perforated separately in a separate process step.
  • Optionally, the shell mold on a back on a support structure.
  • Conceptually, the following is explained:
  • A "support structure" is understood to be a type of skeleton which stiffens the shell mold behind the material layer forming the surface of the shell mold.
  • Advantageously, it can be achieved that the overall shape of the shell can be made very stiff, whereby the quality of the laminated components or the molded form elements increases, especially with respect to the reproducibility of components with different only within tolerances component geometries.
  • In particular, can be achieved so advantageous that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality. Furthermore, the film forming tool can have a high impression quality of the positive model even without the need for post-processing.
  • Preferably, the support structure and the shell mold are connected to a releasable connection element, wherein the connection element is adapted to be able to combine different form shells with the support structure.
  • Conceptually, the following is explained:
  • A "connector" is a component for indirectly or directly connecting several other components. In particular, a connecting element allows a detachable connection between two components or between a component and an assembly or between two assemblies. Examples of a connecting element are in particular a screw, a rivet or an adhesive.
  • Specifically, it is conceivable, inter alia, that a support structure is adapted to be alternately combined with different shell molds by a connecting element. So it is conceivable that a change in the Surface geometry for the laminating element or the mold element can be made possible by an exchange of a mold shell.
  • Advantageously, it can be achieved that a station for laminating and / or molding of components can be used more flexibly by interchangeable shell molds and can be quickly and inexpensively adapted to changing requirements, whereby the cost of laminating and / or molding, especially for small batches, can sink.
  • Optionally, the support structure is honeycomb.
  • Advantageously, it can thus be achieved that a particularly light and stiff support structure for the shell mold of a film forming tool can be manufactured.
  • The support structure preferably has webs.
  • Conceptually, the following is explained:
  • A "bridge" is a part of a framework, which is constructed of webs.
  • Advantageously, it can thus be achieved that a particularly lightweight and rigid support structure for the shell mold of a film forming tool can be achieved, which also enables cost-effective production.
  • Optionally, part of the support structure is made of aluminum.
  • Advantageously, it can be achieved that the material-specific characteristics of aluminum can be targeted according to the specific requirements of the support structure to advantage. Concretely, the use of aluminum can improve the heat conduction in the support structure and / or make the support structure lighter.
  • The film molding tool preferably has a temperature control.
  • Conceptually, the following is explained:
  • A "tempering" is a device with which the temperature in a component can be specifically influenced. In this case, a temperature control can be provided with a temperature control, which is set up to maintain the temperature of a component in a predefined range.
  • "Cooling" can also be understood here as "heating". In particular, a cooling device can also cool at one area and simultaneously heat at another area.
  • Advantageously, it can thus be achieved that the film forming tool can be adjusted by the temperature control to an optimum operating temperature.
  • Optionally, the temperature control on a cooling channel.
  • Conceptually, the following is explained:
  • A "cooling channel" is a channel through which a fluid can flow, wherein the fluid absorbs a heat flow from the environment of the cooling channel or delivers a heat flow to the surroundings of the cooling channel.
  • Advantageously, it can thus be achieved that the film forming tool can have liquid cooling, whereby all the advantages of liquid cooling can be transferred to the film forming tool. In particular, a liquid cooling allows a very fast reaction and efficient cooling of components.
  • Preferably, the temperature control is completely integrated into the support structure, wherein the temperature is adapted to be used for different shell molds can.
  • Concretely, among other things, it is conceivable that the tempering system is completely integrated in the support structure, whereby an exchange of shell molds requires no adjustments or modifications to the temperature, whereby a change in the surface geometry of a mold with a tempering for the laminating element or the mold element by a Replacement of a mold shell can be made possible.
  • Advantageously, it can thus be achieved that a temperature-controlled station for laminating and / or molding of components can be used more flexibly by means of an exchangeable shell independently of the temperature and can be quickly and inexpensively adapted to changing requirements, whereby the cost of laminating and / or Abformen, especially in small series, can decline.
  • Optionally, the film forming tool has a cooling plate.
  • Conceptually, the following is explained:
  • A "cooling plate" is a component which, in addition to other functionalities, also has special properties that enable efficient cooling of surrounding components.
  • Advantageously, it can thus be achieved that the film forming tool can be cooled efficiently. Heat flows can be distributed particularly well in a cooling plate, whereby a homogenization of the temperatures is supported in the film forming tool.
  • Preferably, the cooling plate is flat.
  • Advantageously, it can be achieved that the cooling plate has a flat surface and thus is particularly well suited for positive connection with another component or another assembly. In particular, as a standardized interface for mounting and changing of molds within a station or plant for laminating and / or molding of components can be achieved, whereby the design of molds in the area of a mounting interface is standardized and assembly or changing of molds are accelerated can. The cooling plate serves in a functional unit of the homogenization of the temperatures in the mold and the simplifications of assembly and Auswechselprozessen.
  • According to a second aspect of the invention, the object solves a method for producing a film forming tool, in particular for producing a film forming tool according to a first aspect of the invention, wherein a metal layer is sprayed onto an electrochemically deposited nickel layer.
  • Conceptually, the following is explained:
  • A "metal layer" is understood as meaning a material layer which consists predominantly of a metallic material.
  • An "electrochemically deposited nickel layer" is understood as meaning a material layer of nickel which has been electrochemically (galvanically) deposited.
  • The state of the art has hitherto provided that the surface of the film forming tool, which comes into operative connection with the laminating element or during the molding process with a molding element during the laminating process, was either molded by electroplating, molded with plastic in a casting process or from a steel block was worked out. Especially with a negative skin structure having shell molds, the grain structure was directly molded, worked out with a cutting tool or chemically etched out of the material.
  • In this case, molding tools are known in the prior art, which in particular have an electrochemically deposited nickel layer. In the prior art, this electrochemically deposited nickel layer has a comparatively high thickness of approximately 4 mm. During the electroplating process, mechanical corrections to the component had to be made manually from time to time, so that this process was expensive and time-consuming. The comparatively high thickness of the nickel layer of about 4 mm essentially had the effect that the nickel layer considered individually was sufficiently rigid and dimensionally stable.
  • By way of derogation, it is proposed here for the surface of the film forming tool, which during the laminating process with the laminating element or during the molding process with the molding element in an operative context, to use a nickel layer. This electrochemically deposited nickel layer is stiffened by combining the reverse side with a metal layer applied by metal spraying to form a shell mold. This shell mold is then supplemented in subsequent steps with a support structure and optionally with a temperature control and thus completed to form a film forming tool.
  • Advantageously, this can be achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality.
  • In particular, it can be advantageously achieved that the production time for a galvanically produced nickel shell can be seriously reduced; in particular, the production time can be halved.
  • In other words, it can be advantageously achieved that the production times for a film molding tool can be shortened and that the rigidity and dimensional stability of a molded shell produced in this way can be increased, whereby a high molding quality and a long service life of the film molding tool can be achieved.
  • Preferably, the sprayed layer of metal is reinforced.
  • Conceptually, the following is explained:
  • A "reinforcement" is understood to mean reinforcement of one object by another, which has a higher compressive or tensile strength or a greater durability against further environmental influences. If an object is so strengthened, it will be "armored".
  • Advantageously, this can be achieved by the fact that the mold is additionally stiffened by the reinforcement connected to the metal spray layer, whereby a more dimensionally stable shell mold can be achieved with a longer service life.
  • It can also be advantageously achieved that the shell mold can have a lower weight with comparable rigidity.
  • Optionally, the sprayed layer of metal is reinforced with a honeycomb structure.
  • Advantageously, it can thus be achieved that a particularly lightweight and rigid support structure for the shell mold of a film forming tool can be achieved.
  • It should be expressly understood that the subject matter of the second aspect may be advantageously combined with the subject matter of the first aspect of the invention.
  • According to a third aspect of the invention, the object is achieved by a method for producing a film molding tool, in particular for producing a film molding tool according to the first aspect of the invention, in particular method according to the second aspect of the invention, wherein a honeycomb structure is soldered to an electrochemically deposited nickel layer.
  • Conceptually, the following is explained:
  • "Soldering" is understood to mean a thermal process for materially joining materials, wherein a liquid phase is formed by melting a solder or by diffusion at the interfaces. After the solidification of the liquid phase, a cohesive connection is made. A connection made by "soldering" is also called "soldered".
  • The prior art has heretofore provided that the surface of the film forming tool, which comes into operative connection with the laminating element during the laminating process, was either molded by electroplating, molded in a casting process with plastic or worked out from a steel block. Especially with a negative skin structure having shell molds, the grain structure was directly molded, worked out with a cutting tool or chemically etched out of the material.
  • In this case, molding tools are known in the prior art, which in particular have an electrochemically deposited nickel layer. In the prior art, this electrochemically deposited nickel layer has a comparatively high thickness of approximately 4 mm. During the electroplating process, mechanical corrections to the component had to be made manually from time to time, so that this process was expensive and time-consuming. The comparatively high thickness of the nickel layer of about 4 mm essentially had the effect that the nickel layer considered individually was sufficiently rigid and dimensionally stable.
  • By way of derogation, it is proposed here for the surface of the film forming tool, which during the laminating process with the laminating element or during the molding process with the molding element in an operative context, to use a nickel layer. This electroplated nickel layer is stiffened by soldering the back surface of the electrodeposited nickel layer to a honeycomb structure, whereby the flexural rigidity and the dimensional stability of the nickel shell can be drastically increased.
  • Such a mold shell with a soldered honeycomb structure is supplemented in subsequent steps with a support structure and optionally with a temperature control and thus completed to form a film forming tool.
  • Advantageously, this can be achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality.
  • In particular, it can be advantageously achieved that the production time for a galvanically produced nickel shell can be seriously reduced; in particular, the production time can be halved.
  • In other words, it can be advantageously achieved that the production times for a film molding tool can be shortened and that the rigidity and dimensional stability of a molded shell produced in this way can be increased, whereby a high molding quality and a long service life of the film molding tool can be achieved.
  • Preferably, a metal layer is sprayed onto the honeycomb structure and / or the nickel layer.
  • Specifically, it is conceivable, inter alia, that the honeycomb structure soldered on the rear side of the electrochemically deposited nickel layer is combined with a metal layer applied by metal spraying.
  • Such a mold shell with a soldered honeycomb structure and a metal spray layer is then supplemented in subsequent steps with a support structure and optionally with a temperature control and thus completed to form a film forming tool.
  • Advantageously, this can be achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality.
  • In other words, it can be advantageously achieved that the production times for a film molding tool can be shortened and that the rigidity and dimensional stability of a molded shell produced in this way can be increased, whereby a high molding quality and a long service life of the film molding tool can be achieved.
  • Optionally, the sprayed layer of metal is mechanically reworked.
  • Conceptually, the following is explained:
  • "Mechanical post-processing" is understood to mean a group of production processes which give a workpiece a specific geometric shape by removing excess material from blanks in the form of chips by mechanical means. The most important mechanical finishing methods are turning, drilling, milling and grinding in particular.
  • Specifically, it is conceivable inter alia that a shell mold is mechanically reworked, which has no sprayed layer of metal. Thus, inter alia, it is conceivable that only the galvanically produced nickel layer or the combination of a galvanically produced nickel layer with a soldered honeycomb structure or the combination of a galvanically produced nickel layer with a soldered honeycomb structure and a sprayed layer of metal is mechanically reworked.
  • Specifically, it is also conceivable, inter alia, that the mechanical post-processing relates only to the material of the sprayed layer and / or the material of the soldered honeycomb structure and / or the material of the galvanically produced nickel layer.
  • It is concretely conceivable, among other things, that the mechanical reworking prepares connecting elements for the connection of the shell mold with cooling plates.
  • Advantageously, this can be achieved that the shell mold receives a defined geometric shape at the mechanically reworked points. Advantageously, the mold shell can be connected at these locations with another component, wherein the joint has defined geometric surfaces, so that the geometry of the shell mold defined with the geometry of the connected component can be continued.
  • Preferably, the mold shell consisting of the ceramic layer and the metal layer is perforated.
  • Conceptually, the following is explained:
  • By "perforating" is meant a perforation of hollow bodies or flat objects. The arrangement, amount, shape and size of the holes can be homogeneous and / or inhomogeneous.
  • Specifically, it is conceivable, among other things, that the perforation is produced with a cutting tool. The distances between the perforation can be chosen homogeneous and uniformly distributed or inhomogeneous executed.
  • Advantageously, it can thereby be achieved that the laminating tool is suitable for allowing a perforation on the rear side of the mold shell to act on the laminating element so that the force necessary to emboss the laminating element can take place between the laminating element and the shell mold.
  • Optionally, the mold shell is perforated with a laser.
  • Advantageously, this can be achieved that the perforation can be performed very fine-pored and with thin perforation channels.
  • Preferably, the mold shell is connected to a cooling plate.
  • Advantageously, it can thus be achieved that the film forming tool can be cooled efficiently. Heat flows can be distributed particularly well in a cooling plate, whereby a homogenization of the temperatures is supported in the film forming tool.
  • Optionally, the mold shell is connected to a support structure.
  • Advantageously, it can be achieved that the overall shape of the shell can be made very stiff, whereby the quality of the laminated components or the molded form elements increases, especially with respect to the reproducibility of components with different only within tolerances component geometries.
  • In particular, can be achieved so advantageous that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality. Furthermore, the film forming tool can have a high impression quality of the positive model even without the need for post-processing.
  • Preferably, a cooling channel is embedded in the support structure.
  • Advantageously, it can thus be achieved that the support structure can be cooled efficiently and responsively.
  • Optionally, the electrochemically deposited nickel layer is deposited on a silicone blank.
  • Conceptually, the following is explained:
  • A "blank" is a workpiece which is intended for further processing. In particular, a blank is a positive model for producing a foil forming tool. A "silicone blank" is a blank, which consists of the material silicone.
  • Specifically, among other things, it is conceivable, among other things, that a silicone blank is used as a positive model for the nickel layer to be deposited electrochemically, which comes into operative connection with the laminating element during the laminating process or during the molding process.
  • Silicones have unique properties. They can be produced very well by casting and, as a casting, offer a high degree of accuracy in molding, especially with complex model geometries.
  • In addition, silicones have optimal surface properties, making them suitable as an optimal blank for an electrochemical process. Thus, silicones are self-releasing, so that with a silicone mold can be dispensed with a release agent during casting, so again the surface fidelity of the casting or the electrochemically produced nickel layer can be improved.
  • In addition, silicones are very elastic, so that they can be removed from the electrochemically produced nickel layer easily and non-destructively. Due to the non-destructive removal of the silicone blank, it can be reused as a positive model.
  • Advantageously, this can be achieved that with a silicone blank a detailed surface texture can be achieved even with complex grained surfaces.
  • In addition, it can be advantageously achieved that the silicone blank can be produced easily and inexpensively.
  • In addition, the silicone blank can be removed from the electrochemically produced nickel layer easily and non-destructively, whereby it can also be reused.
  • The silicone blank preferably has a grain structure.
  • Thus, it is concretely conceivable, inter alia, that the silicone blank already has a grain structure, as a result of which it does not have to be transferred to the laminating element or the forming element in a subsequent step after the laminating of a laminating element or the molding of a shaped element.
  • In concrete terms, this allows the negative scar structure to be transferred directly from the grain structure of the silicone blank to the shell mold, so that the relief of the shell mold, in particular, runs inversely to the relief of the positive model.
  • Advantageously, this can be achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality. Furthermore, the laminating tool can have a high degree of quality with regard to the negative grain structure even without the need for post-processing. The negative scar structure can be extremely robust.
  • Optionally, the silicone blank has a cold-cured silicone rubber.
  • Cold-crosslinked silicone rubber types have the advantage that the surfaces of cold-crosslinked silicones can be hydrophilized. On the other hand, hot-crosslinked silicones have a superhydrophobic surface. A hydrophilic surface is particularly advantageous for use in an electrochemical process.
  • Advantageously, this can be achieved by the use of cold-crosslinked silicones, a hydrophilic silicone surface can be achieved, which increases the quality of the nickel shell produced electrochemically on the silicone blank.
  • The silicone blank is preferably cast in a mold which has a support for the silicone blank, a silicone casting of a model template and a support for the negative shell.
  • Concretely, it is conceivable, inter alia, that the use of a support for the silicone blank allows the silicone blank not to be designed as a full-volume positive model, but merely represents a thin-walled surface for the positive model.
  • Thus, it can be advantageously achieved that the silicone blank can be cast better during its production and demolded without destruction after the electrochemical production of the nickel shell.
  • Advantageously, it can be achieved by this aspect that the silicone blank is directly conforming to its exact shape also used for the electrochemical process, so that overall a dimensionally accurate silicone blank can be achieved, which can also be demoulded non-destructive.
  • In addition, it can be advantageously achieved by the use that can be dispensed by the use of the silicone casting on a release agent between the mold and silicone casting in the casting of the silicone blank, whereby the detail and the dimensional accuracy of the surface to be reached is not deteriorated by a release agent.
  • Furthermore, the use of a support for the silicone negative shell allows this not to be performed as a full volume model, but that the silicone casting of the model template can only represent a thin walled surface for the model and thus allows the silicone casting of the model template in its use as Molded part can be demoulded non-destructive.
  • Optionally, the silicone blank and / or the support for the silicone blank can be demoulded without destruction after the electrochemical deposition of the nickel layer and / or after spraying the metal layer on the nickel layer.
  • Advantageously, it can thereby be achieved that the silicone blank and / or the support for the silicone blank can be reused.
  • The silicone casting of the model template is preferably cast in a mold which has the support for the silicone blank, the model template and the support for the negative shell.
  • Advantageously, this can be achieved that the silicone casting of the model template does not have to be executed as a full volume model, but that the silicone casting of the model template can only represent a thin-walled surface for the model and thus allows the silicone casting of the model template in its use as a molding for the Casting of the silicone blank after casting can be demoulded non-destructive.
  • Optionally, the model template is made of epoxy resin.
  • Thus, it is concretely conceivable, among other things, that a model template made of epoxy resin is cast by a softer negative impression. Epoxy resin is a very durable, long-lasting and hard material, so that a model of epoxy resin can be stored well over years and reused several times.
  • Advantageously, this can be achieved that a long storable, dimensionally stable model template is achieved, which can be reused many times.
  • Preferably, the model template is reusable.
  • Advantageously, this can be achieved by the fact that the model template can be used over and over again to produce an electrochemically produced nickel shell thereof after the above-described process steps. Thus, a mold shell of a film forming tool after damage easily, quickly and even after many years in which the model template was stored, be replaced inexpensively.
  • Optionally, the epoxy model mold is cast in a mold having the support for the silicone blank, a silicone casting of a model and the support for the negative shell.
  • Advantageously, this can be achieved that the model template is made directly so that it fits to the support for the silicone blank so that it can also be poured later in a subsequent process step on this edition. Thus, it is also advantageously possible that the model template only has to be cast as a thin surface and consequently does not need so much material and is not so heavy, which makes storage advantageous over years.
  • In addition, by using a silicone casting of the model, it can be achieved that a release agent is not needed for the cast of the model artwork, so that the surface fidelity and the surface details of the silicone casting can be used by the model.
  • Preferably, the surface of the model template of epoxy resin is post-processed after casting.
  • Advantageously, it can thereby be achieved that a final model contouring of the model template with the desired surface can be achieved.
  • Optionally, the silicone casting of a model is cast in a mold having the negative shell support and a model.
  • Advantageously, it can thereby be achieved that the silicone casting of the model fits directly to the negative shell and so the negative shell can be used unchanged during the subsequent process steps, whereby costs can be saved.
  • Preferably, the model has wood.
  • Advantageously, can be achieved by the fact that the model can be processed by the low hardness of wood comparatively easy and fast with high level of detail.
  • Optionally, the model is coated before the silicone casting.
  • It is conceivable, among other things, that the model made of wood is sealed with a coating and the surface texture of the wood is simultaneously smoothed.
  • In addition, it is specifically conceivable, among other things, that the coating of the model is used as a release agent for the silicone casting.
  • Advantageously, this can be achieved by the fact that the surface quality of the model can be increased by the coating and that the silicone casting can be easily removed and destroyed without destruction.
  • Preferably, the coating of the model has a grain structure.
  • Specifically, it is conceivable, inter alia, that the model already has a grain structure, whereby it can be transferred from process step to process step to all subsequently required casts, models and shapes, so that the relief of the shell mold, in particular, runs inversely to the relief of the model.
  • Advantageously, this can be achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality. Furthermore, the laminating tool can have a high degree of quality with regard to the negative grain structure even without the need for post-processing. The negative scar structure can be extremely robust.
  • It is to be expressly understood that the subject matter of the third aspect may be advantageously combined with the subject matter of the foregoing aspects of the invention, cumulatively either alone or in any combination.
  • According to a fourth aspect of the invention, the object solves a use of a film forming tool according to a first aspect of the invention for producing and laminating a component, wherein the laminated component has a grain or for molding a film of a grained film molding tool.
  • It is understood that the advantages of a film forming tool according to the first aspect of the invention for laminating a component with a laminating element or for molding a film, wherein the film forming tool has a mold shell, wherein the mold shell has a sprayed metal layer produced by metal spraying, as above describe directly the use of a film forming tool according to the first aspect of the invention for producing and laminating a component, wherein the laminated component has a grain and for molding a film from a grained film molding tool.
  • It is to be expressly understood that the subject matter of the fourth aspect may be advantageously combined with the subject matter of the foregoing aspects of the invention, cumulatively, either singly or in any combination.
  • The invention will be explained in more detail below with reference to a production process sequence for producing a mold shell and also to an embodiment of a foil mold with reference to the drawing. Show there
    • 1 schematically a flowchart for the manufacturing process of a film forming tool,
    • 2 schematically a film forming tool in a section.
  • The manufacturing process 1 in 1 for producing a film forming tool 2 consists essentially of the first phase 3 for the production of electrochemically deposited nickel layer 4 in Figure 1a and the second phase 5 for further processing of the electrochemically deposited nickel layer 4 to the film forming tool 2 in 1b ,
  • The first phase 3 in Figure la for the preparation of the electrochemically deposited nickel layer 4 is subdivided chronologically into the production of a wooden model 6 , the application of a release agent 7 on the wooden model 6 , the manufacture of a silicone casting 8th from the wooden model 6 , the casting of a model template 9 from the silicone casting 8th , the manufacture of a silicone casting 10 from the model template 9 , the manufacture of a silicone blank 11 from the silicone casting 10 and the production of a nickel layer 4 by electrochemical deposition 12 ,
  • The wooden model 6 offers the advantage that the material wood can be processed comparatively easily and quickly with simultaneously high detail depth. Concretely, the model would not be made of wood concrete.
  • In the production of the wooden model 6 this is already provided with a grain structure. This grain structure is retained during the subsequent process steps and can thus be found on the model template 9 and the silicone blank 11 again.
  • From the wooden model 6 becomes a silicone casting 8th made and the model template 9 is a silicone casting 10 made, so the silicone casting 8th and the silicone casting 10 have a negative grain structure whose relief is inversely to the relief of the wood model 6 runs and the negative grain structure precisely on the grain structure of the wood model 6 , the model template 9 and the silicone blank 11 Fits, so the grain of the wood model 6 about the corresponding process steps step by step on the silicone blank 11 is transmitted. This can be achieved by the grain structure of the wood model 6 on the electrochemical on the silicone blank 11 deposited nickel layer 4 can be transferred, which has a negative grain structure, the relief inversely to the relief of the wood model 6 runs.
  • Before the silicone casting 8th from the wooden model 6 is poured off, the wooden model 6 with a release agent 7 coated. Concretely, it is also conceivable that the wooden model 6 is not prior to producing a silicone casting 8th with a release agent 7 but the release agent seals the surface texture of the wood model 6 and increases the likelihood that the silicone casting 8th light and non-destructive of the wooden model 6 can be removed from the mold.
  • For the production of the silicone casting 8th will continue to be a print run 13 used for the negative dish. The silicone casting 8th can also be done without the pad 13 for the negative shell, however, allows the edition 13 for the negative shell a thin-walled silicone casting 8th from the wooden model 6 , which can be demolded easily and non-destructively.
  • The edition 13 for the negative shell can also in the subsequent process steps for casting a model template 9 from the silicone casting 8th , for the production of a silicone casting 10 from the model template 9 and for producing a silicone blank 11 from the silicone casting 10 continue to be used.
  • After the production of a silicone casting 8th from the wooden model 6 becomes a model template 9 cast.
  • Specifically, it is conceivable, among other things, that the model template 9 made of epoxy resin. Epoxy resin is a very durable, durable and hard material, so the model template 9 can be stored very well over years and can be reused several times, so that a possibly damaged nickel layer 4 can be made faster again.
  • For making the model template 9 will continue to be a print run 14 used for a blank. The model template 9 can also be done without the pad 14 for a blank manufacture, however, allows the edition 14 for a blank a thin-walled and lightweight model template 9 , which can be stored well.
  • The edition 14 for a blank can also in the subsequent process steps for the production of a silicone casting 10 from the model template 9 and for producing a silicone blank 11 from the silicone casting 10 continue to be used.
  • Specifically, it is also conceivable that the model template 9 also made of a material other than epoxy resin is poured.
  • In particular, it is conceivable that instead of the model template 9 directly the silicone blank 11 is poured and then the nickel layer 4 produced by electrochemical deposition.
  • Following the production of the model template 9 becomes the silicone casting 10 from the model template 9 produced. The silicone casting 10 offers the advantage of being easy to demould and non-destructive and also offers each of the silicone moldings 8th . 10 . 11 the advantage without the need of use of release agent 7 to be used as a mold.
  • The next step is the silicone blank 11 as a casting of the silicone casting 10 produced.
  • The silicone blank 11 then becomes electrochemical deposition 12 for the production of the nickel layer 4 used. The silicone blank can be easily and non-destructively removed from the nickel layer 4 be demolded and just like the other silicone moldings 8th . 10 be reused.
  • After the nickel layer 4 Electrochemically deposited, the second phase begins 5 for further processing of the electrochemically deposited nickel layer 4 to the film forming tool 2 ,
  • The second phase 5 in 1b for further processing of the electrochemically deposited nickel layer 4 to the film forming tool 2 is broken down chronologically into the brazing of a previously manufactured honeycomb structure 15 on the back of the nickel layer 4 , the spraying of a metal layer 16 on the back of the nickel layer 4 and the honeycomb structure 15 , the mechanical reworking 17 the shape shell 18 , the demoulding 19 of mechanically reworked shell mold 18 , the drilling 20 of vacuum channels, the cooling plate mounting 21 for connecting previously manufactured cooling plates 22 with the mold shell 18 and the support structure attachment 23 a previously prepared support structure 24 ,
  • The honeycomb structure 15 is on the nickel layer 4 soldered. Alternatively, the honeycomb structure 15 also on the nickel layer 4 be applied or glued.
  • Subsequently, the back of the nickel layer 4 and the honeycomb structure 15 by metal spraying 16 stiffened with a metal layer.
  • After that, the mold shell 18 mechanically reworked, whereby by metal spraying 16 applied metal layer and / or the honeycomb structure 15 and / or the nickel layer 4 is machined so that the already prepared cooling plates 22 after demolding 19 with the mold shell 18 can be connected.
  • Subsequently, the mold shell 18 by drilling 20 perforated. This can be done by means of a mechanical processing or with a laser.
  • After drilling 20 the shape shell 18 become the cooling plates 22 connected to the mold shell 18.
  • Following this, the mold shell 18 by means of the already produced support structure 24 to form a film forming tool 2 completed.
  • The foil mold 30 in 2 essentially has a shell mold 31 with a nickel layer 32 , a honeycomb-shaped structure 33 , a cooling plate 34 and a support structure 35 on.
  • The shape shell 31 consists essentially of a honeycomb structure 33 that with the nickel layer 32 has been soldered.
  • The shape shell 31 was with the support structure 35 and the cooling plate 34 to the film forming tool 30 added.
  • The film forming tool may have cooling channels (not labeled) that provide active cooling of the film forming tool 30 enable.
  • The cooling plate 34 serves for a homogeneous temperature distribution in the film forming tool 30 to reach. In this case, the cooling plate 34 be both active and passive tempered.
  • Overall, the film forming tool 30 by its construction with the nickel layer 32 , the honeycomb structure 33 and the support structure 35 very robust and dimensionally stable. It can be used in particular for the lamination of a laminating element or the molding of a molded element, wherein high quantities can be achieved.
  • The rigid design of the foil forming tool 30 allows a high impression quality due to the homogeneous temperature control through the cooling channels and the cooling plate 34 can be maintained during all conditions of use.
  • LIST OF REFERENCE NUMBERS
  • 1
    manufacturing
    2
    Sheet mold
    3
    First phase
    4
    nickel layer
    5
    Second phase
    6
    wooden model
    7
    release agent
    8th
    silicone casting
    9
    model template
    10
    silicone casting
    11
    silicone blank
    12
    Electrochemical deposition
    13
    edition
    14
    edition
    15
    Honeycomb structure
    16
    metal spraying
    17
    Mechanical post-processing
    18
    shell mold
    19
    unmolding
    20
    Drill
    21
    Cold plate mounting
    22
    cooling plates
    23
    Support structure mounting
    24
    support structure
    30
    Sheet mold
    31
    shell mold
    32
    nickel layer
    33
    honeycomb structure
    34
    cooling plate
    35
    support structure
  • 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
    • DE 102013203408 A1 [0013]

Claims (40)

  1. A film forming tool for laminating a component with a laminating element or for molding a film, wherein the film mold has a mold shell, characterized in that the mold shell comprises two material layers of different materials, wherein a first material layer consists of nickel and a second material layer has a sprayed layer of metal ,
  2. Foil molding tool after Claim 1 , characterized in that the sprayed layer of metal has a honeycomb-shaped structure.
  3. Foil molding tool according to one of Claims 1 or 2 , characterized in that the surface of the shell mold has a negative grain structure.
  4. Foil mold according to one of the preceding claims, characterized in that the surface of the mold shell is permeable to air.
  5. Foil mold according to one of the preceding claims, characterized in that the mold shell has a support structure on a rear side.
  6. Foil molding tool after Claim 5 , characterized in that the support structure and the mold shell are connected to a detachable connection element, wherein the connection element is adapted to be able to combine different form shells with the support structure.
  7. Foil molding tool according to one of Claims 5 or 6 , characterized in that the support structure is honeycomb-shaped.
  8. Foil molding tool according to one of Claims 5 to 7 , characterized in that the support structure has webs.
  9. Foil molding tool according to one of Claims 5 to 8th , characterized in that a part of the support structure consists of aluminum.
  10. Film forming tool according to one of the preceding claims, characterized in that the film forming tool has a temperature.
  11. Foil mold according to one of the preceding claims, characterized in that the temperature has a cooling channel.
  12. Foil molding tool according to one of the preceding claims, characterized in that the temperature control is completely integrated into the support structure, wherein the temperature control is adapted to be used for different shell molds can.
  13. Film forming tool according to one of the preceding claims, characterized in that the film forming tool has a cooling plate.
  14. Foil molding tool after Claim 13 , characterized in that the cooling plate is flat.
  15. Method for producing a film molding tool, in particular for producing a film molding tool according to one of the preceding claims, characterized in that a metal layer is sprayed onto an electrochemically deposited nickel layer.
  16. A method for producing a film forming tool according to Claim 15 , characterized in that the sprayed layer of metal is reinforced.
  17. A method for producing a film forming tool according to Claim 15 , characterized in that the sprayed layer of metal is reinforced with a honeycomb-shaped structure.
  18. Method for producing a film molding tool, in particular for producing a film molding tool according to one of the Claims 1 to 14 , in particular method according to Claim 15 to 17 , characterized in that a honeycomb structure is soldered to an electrochemically deposited nickel layer.
  19. A method for producing a film forming tool according to Claim 18 , characterized in that a metal layer is sprayed onto the honeycomb structure and / or the nickel layer.
  20. Method for producing a film forming tool according to one of Claims 15 to 19 , characterized in that the sprayed layer of metal is mechanically reworked.
  21. Method for producing a film forming tool according to one of Claims 15 to 20 , characterized in that the ceramic shell and metal layer existing mold shell is perforated.
  22. Method for producing a film forming tool according to one of Claims 15 to 21 , characterized in that the mold shell is perforated with a laser.
  23. Method for producing a film forming tool according to one of Claims 15 to 22 , characterized in that the mold shell is connected to a cooling plate.
  24. Method for producing a film forming tool according to one of Claims 15 to 23 , characterized in that the mold shell is connected to a support structure.
  25. Method for producing a film forming tool according to one of Claims 15 to 24 , characterized in that a cooling channel is embedded in the support structure.
  26. Method for producing a film forming tool according to one of Claims 15 to 25 , characterized in that the electrochemically deposited nickel layer is deposited on a silicone blank.
  27. Method for producing a film forming tool according to one of Claims 15 to 26 , characterized in that the silicone blank has a grain structure.
  28. Method for producing a film forming tool according to one of Claims 15 to 27 , characterized in that the silicone blank has a cold-crosslinked silicone rubber.
  29. Method for producing a film forming tool according to one of Claims 15 to 28 , characterized in that the silicone blank is cast in a mold having a support for the silicone blank, a silicone casting of a model template and a support for the negative shell.
  30. Method for producing a film forming tool according to one of Claims 15 to 29 , characterized in that the silicone blank and / or the support for the silicone blank after the electrochemical deposition of the nickel layer and / or after the spraying of the metal layer on the nickel layer can be demoulded non-destructive.
  31. Method for producing a film forming tool according to one of Claims 15 to 30 , characterized in that the silicone casting of the model template is cast in a mold having the support for the silicone blank, the model template and the support for the negative shell.
  32. Method for producing a film forming tool according to one of Claims 15 to 31 , characterized in that the model template is made of epoxy resin.
  33. Method for producing a film forming tool according to one of Claims 15 to 31 , characterized in that the model is template reusable.
  34. Method for producing a film forming tool according to one of Claims 15 to 33 , characterized in that the model template is molded of epoxy resin in a mold having the support for the silicone blank, a silicone casting of a model and the support for the negative shell.
  35. Method for producing a film forming tool according to one of Claims 15 to 34 , characterized in that the surface of the model template of epoxy resin is post-processed after casting.
  36. Method for producing a film forming tool according to one of Claims 15 to 35 , characterized in that the silicone casting of a model is cast in a mold having the negative shell support and a model.
  37. Method for producing a film forming tool according to one of Claims 15 to 36 , characterized in that the model comprises wood.
  38. Method for producing a film forming tool according to one of Claims 15 to 37 , characterized in that the model is coated before the silicone casting.
  39. Method for producing a film forming tool according to one of Claims 15 to 38 , characterized in that the coating of the model has a grain structure.
  40. Using a foil forming tool according to one of Claims 1 to 14 for producing and laminating a component, wherein the laminated component has a grain, or for molding a film from a grained foil molding tool.
DE102017007963.3A 2017-02-17 2017-08-24 Foil forming tool, method of making a foil forming tool, and using a foil forming tool Withdrawn DE102017007963A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US201762460374P true 2017-02-17 2017-02-17
US62/460,374 2017-02-17

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/DE2017/000418 WO2018149428A1 (en) 2017-02-17 2017-12-12 Film molding tool, method for producing a film molding tool and use of a film molding tool

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Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3315246C2 (en) * 1983-04-27 1986-05-07 Messerschmitt-Boelkow-Blohm Gmbh, 8000 Muenchen, De
US5609922A (en) * 1994-12-05 1997-03-11 Mcdonald; Robert R. Method of manufacturing molds, dies or forming tools having a cavity formed by thermal spraying
US20020025270A1 (en) * 1998-04-07 2002-02-28 Mcdonald Robert R. Heat-exchanging forming tool and method of making
US7028744B2 (en) * 2004-03-17 2006-04-18 National Research Council Of Canada Surface modification of castings
WO2011040181A1 (en) * 2009-09-30 2011-04-07 コニカミノルタオプト株式会社 Molding die and method for producing molding die
DE102013203408B4 (en) 2013-02-28 2016-02-11 Faurecia Innenraum Systeme Gmbh Method for laminating a component by a laminating tool with a laminating element
CN103600040A (en) * 2013-11-13 2014-02-26 宁波市鄞州科启动漫工业技术有限公司 Method for casting mold

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