DE102017223858A1 - Method for producing a decorative part - Google Patents

Abstract

The present invention relates to an economical method for producing a decorative part (4) provided with a decorative perforation, in which the decorative layer (2) is inserted into an injection mold (48), the injection mold (48) is closed and designed to form one against the Decor layer (2) adjacent sprayed layer (22) plastic is introduced into the injection mold (48), wherein the decorative layer (2) for forming the decorative perforations (14) is processed with a punching element (4), which forms during the formation of the sprayed layer ( 22) is located in the injection mold (48).

Description

The present invention relates to a method for producing a decorative part, in which a decorative layer is inserted into an injection mold, the injection molding tool is closed and introduced into the injection mold to form a sprayed against the decorative layer location sprayed plastic.

Such a generic method is for example from the DE 43 01 444 A1 known. In this prior art, the decorative layer is provided with a back reinforcing layer. Thereafter, the decorative layer is provided on the visible side with a transparent coating. Thus, a dimensionally stable, sealed on the visible side to the environment decorative part is formed.

The present invention is based on the problem to provide a method for producing a decorative part, which has a higher usability.

To achieve this object, a method with the features of claim 1 is provided by the present invention. This method differs from the prior art described above in that the decorative layer is processed to form a decorative perforation with a punching element, which is in the formation of the injection-molded layer in the injection mold. The punching element may have one or more punches which form a perforation on the decorative part. The decorative perforations can be formed before insertion into the injection mold. Also, first, the perforation can be made in the decorative layer and the decorative layer with the decorative holes and the punching element are introduced into the injection mold. As decorative layer in the context of the present invention, any decorative layer can be considered, for example, a metal layer, a textile material, a wood veneer or a layer of a plastic, such as a woven plastic, specially woven carbon fiber.

The punching element can be movable in the injection mold in order to form the decorative perforations in the decorative layer after the decorative layer has been inserted into the injection mold. Also, the already perforated decorative layer can be inserted into the injection mold together with the punch, which passes through the decorative holes.

In this case, the punching element is usually applied to the decorative layer opposite side of the injection mold against the injection mold, optionally placed in one or more receptacles provided therein, so that the punching element passes through the cavity within the injection mold, which is provided to form the sprayed layer. This cavity, which is also referred to below as the first cavity, usually extends between a main side surface of the decorative layer and a first mating surface of the injection molding tool. The first cavity usually covers the rear side of the decorative layer in the manner of a gap in order initially to form a back reinforcing layer on the decorative layer in an injection molding cycle. Since the punching element preferably passes through the cavity during the formation of the injection-molded layer, the injection-molded layer is also formed with a perforation which essentially corresponds to the decorative perforation. But it is also possible, as part of the injection mold, especially in those mold half, which is opposite to the punching element holding tool half, to provide a counter element whose profile corresponds to the profiling of the punching element. The counter element is usually the front side against the punching element. Although in the present description only one punching element and one corresponding counter-element are used, a particularly preferred further developing invention is formed in that the punching element is designed as a kind of grid or grid in order to provide a multiplicity of holes on the decorative layer. Thus, such a punching element on a plurality of punching projections, which form a plurality of decorative holes in the decorative layer. The punching projections are usually formed as a punching pin and thus cylindrical. The aforementioned counter-element lies against the end face of the punching bolt in such a way that it continues in the axial direction essentially free of shoulder. The counter-element may for example be fixed or movable on that mold half which covers the first cavity opposite to the decorative layer.

At relatively high injection pressures for the formation of the sprayed layer, it is preferable to machine the decorative layer during or after the formation of the sprayed layer. The punching can be done, for example, when the injected material forming the molded plastic material is substantially solidified and rests with little emphasis against the decorative layer. In this case, the punching element penetrates the decorative layer and displaces slightly solidified, possibly viscous melt, which forms the sprayed layer to form the decorative perforations and / or the corresponding perforation in the sprayed layer. In this case, the injection of the injected material forming the plastic material takes place against a still unpunched, still continuous surface of the decorative layer. Thus, relatively high injection pressures can be applied without the fear that the plastic melt passes through any decorative perforations provided and on which the sprayed layer opposite side on the decorative layer becomes visible.

Because this side is usually the visible side and must meet high aesthetic requirements.

On the other hand, the sprayed layer can also be produced with low injection pressure. Because the sprayed layer is usually a back reinforcing layer, which is not visible when using the decorative part and has no special aesthetic requirements to meet. Above all, it forms a reinforcement of the sometimes very thin decorative layer (thickness between 100 μm and 750 μm). It can form fasteners themselves or fasten them. For this it is not necessary that the sprayed layer has a special surface quality. Thus, the plastic for forming the sprayed layer can also be applied with low injection pressures against the surface of the decorative part.

The punching element may be formed on one or more parts of an injection mold, which forms a supine position, against which the decorative layer is supported during injection molding of the plastic.

A punching and back-up unit is usually removed from the mold after forming an intermediate product comprising the decorative sheet and the injection-molded sheet. For this purpose, the punching element and the supine position after the formation of the sprayed layer is moved away from the decorative layer. In the thus released decorative perforations and / or perforation of the sprayed layer is preferably then or at the same time introduced a counter element in the decorative perforations and / or the perforation of the sprayed layer. In this way, there is a certain connection between the counter element and the intermediate product. Thus, this intermediate product can be removed from and together with the counter element from the injection mold and fed to further processing.

However, the counter element preferably forms a core, which passes through the second cavity formed during the formation of a second injection-molded layer and accordingly forms a second perforation in a second injection-molded layer, which is usually formed opposite the first injection-molded layer. This second sprayed layer may be a transparent layer that covers the decorative layer on the visible side. Thus, a decorative part is obtained in which the decorative layer is received between a back reinforcing layer according to the present invention formed by the injection-molded layer and a face-side layer formed by the second injection-molded layer. With a view to a sealing of the punched edge surfaces of the decorative layer, the counter element may be slightly smaller than the punching element. In the case of a plurality of punching bolts, which pass through the decorative layer, for example, in the manner of a regular grid or a regular perforation, the counter element can have bolts with a slightly smaller diameter, so that the second plastic also through the decor holes and between the edge of the decorative layer within the decorative perforations and can pass the bolt of the counter and seal the decorative layer.

According to a further preferred method, the counter element is tracked when moving the punching element to the punching element adjacent the punching element. This procedure can be realized, for example, to remove by moving the counter element, the punching element and optionally the punching element associated with the supine position and at the same time introduce the counter element in the perforation of the intermediate product.

In this case, the introduction of the counter element in the decorative perforations and / or the perforation of the injection-molded layer takes place while the corresponding intermediate product is still in the injection mold, in which the injection-molded layer is formed. Of course, it is possible, however, to otherwise form the intermediate product and to subsequently introduce the counter element into the perforation of the intermediate product in order to transfer the intermediate product positioned on the counter element into a second cavity.

• 1 eine schematische Schnittansicht von Werkzeughälften zur Stanzbearbeitung einer Dekorlage;
• 2 eine schematische Schnittansicht von Werkzeughälften zur Ausbildung der ersten gespritzten Lage;
• 3 eine schematische Schnittansicht zu einem ersten Ausführungsbeispiel einer erfindungsgemäßen Verfahrensführung mit einer Dekorlage nach Anlegen gegen eine Werkzeughälfte vor der Stanzbearbeitung bei geöffnetem Stanzwerkzeug;
• 4 eine Dastellung gemäß 3 nach dem Schließen des Stanzwerkzeugs;
• 5 die Darstellung nach den 3 und 4 während der Stanzbearbeitung;
• 6 eine schematische Schnittansicht der gestanzten Dekorlage vor dem Ausbilden der gespritzten Lage bei geöffnetem Spitzgießwerkzeug;
• 7 die Darstellung nach 6 nach dem Schließen des Spitzgießwerkzeugs;
• 8 die Darstellung nach den 6 und 7 nach dem Ausbilden der gespritzten Lage;
• 9 die Darstellung nach den 6 bis 8 nach dem Ausbilden der gespritzten Lage und beim Ziehen eines Stanzelementes;
• 10 die Darstellung nach den 6 bis 9 beim Entformen des fertigen Dekorteils;
• 11 eine schematische Schnittansicht der gestanzten Dekorlage vor dem Ausbilden der gespritzten Lage bei geöffnetem Spitzgießwerkzeug für ein zweites Ausführungsbeispiel einer erfindungsgemäßen Verfahrensführung;
• 12 die Darstellung nach 11 nach dem Schließen des Spitzgießwerkzeugs;
• 13 die Darstellung nach den 11 und 12 beim Verschieben von Bolzen in dem Spitzgießwerkzeug;
• 14 die Darstellung nach den 11 bis 13 nach dem Ausbilden der gespritzten Lage;
• 15 die Darstellung nach den 11 bis 14 nach dem Öffnen des Spitzgießwerkzeugs;
• 16 eine schematische Schnittansicht eines geöffneten Spitzgießwerkzeugs zur Ausbildung einer sichtseitigen Überspritzung der Dekorlage;
• 17 die Darstellung nach 16 nach dem Schließen des Spitzgießwerkzeugs;
• 18 die Darstellung nach den 16 und 17 nach dem Ausbilden der sichtseitigen Überspritzung der Dekorlage und
• 19 die Darstellung nach den 16 bis 18 nach dem Entformen des fertigen Dekorteils.

Further details and advantages of the following invention will become apparent from the following description of an embodiment taken in conjunction with the drawings. In this show:

• 1 a schematic sectional view of tool halves for punching a decorative layer;
• 2 a schematic sectional view of mold halves to form the first injection-molded layer;
• 3 a schematic sectional view of a first embodiment of a process guide according to the invention with a decorative layer after applying against a mold half before punching with open die;
• 4 a Dastellung according to 3 after closing the punching tool;
• 5 the representation after the 3 and 4 during punching;
• 6 a schematic sectional view of the punched decorative layer before forming the sprayed layer with open injection mold;
• 7 the representation after 6 after closing the injection molding tool;
• 8th the representation after the 6 and 7 after forming the sprayed layer;
• 9 the representation after the 6 to 8th after forming the sprayed layer and drawing a punching element;
• 10 the representation after the 6 to 9 during removal of the finished decorative part;
• 11 a schematic sectional view of the punched decorative layer before forming the injection-molded layer with open Spitzgießwerkzeug for a second embodiment of a process guide according to the invention;
• 12 the representation after 11 after closing the injection molding tool;
• 13 the representation after the 11 and 12 when moving bolts in the injection molding tool;
• 14 the representation after the 11 to 13 after forming the sprayed layer;
• 15 the representation after the 11 to 14 after opening the injection molding tool;
• 16 a schematic sectional view of an open Spitzgießwerkzeugs to form a visible side over-molding of the decorative layer;
• 17 the representation after 16 after closing the injection molding tool;
• 18 the representation after the 16 and 17 after forming the visible over-molding of the decorative layer and
• 19 the representation after the 16 to 18 after demolding the finished decorative part.

The 1 shows a decorative layer 2 between a lower, a punching element 4 having tool half 6 and a suction hole 8th having tool half 10 , Between these two halves of the tool 6 . 10 is the decor layer 2 clamped for punching.

The punching element 4 consists of a variety of punching pins 12 which are mechanically coupled to each other, so that they can be simultaneously moved in the punching processing in the direction of the directional arrow S for the punching machining back and forth to the punching element 4 with a decorative perforation 14 to be provided in 2 already trained. For this purpose, the punching bolts 12 that is, the punching element 4 overall in the direction of the decorative layer 2 propelled and through the decorative layer 2 driven through. A wedge 13a is moved translationally to one of the punching pins 12 having counterwedge 13b towards the tool half 10 propel.

On the punching element 4 opposite side is the suction perforation 8th with that of the punching element 4 Apprentice hole pattern formed accordingly. So are by the punching process from the decorative layer 2 punched out areas of the decorative layer 2 through a suction guide 16 dissipated. The holes of the suction perforation 8th aligned with one through all punching pins 12 given hole pattern for the decorative layer 2 which the hole pattern of the decorative perforations 14 pretends. In the direction of advance of the punching pin 12 the suction perforation 8th downstream are enlarged chambers 18 the suction guide 16 intended. The recesses of the suction perforation 8th in the tool half 10 may be slightly larger in diameter than the outer diameter of the associated punching bolts 12 his. The hole pattern may be a regular or irregular hole pattern. The punched holes may be circular, oval, polygonal or star-shaped. They usually have a smallest diameter or a smallest dimension of not more than 0.5 mm. The largest dimension of the individual holes of the decorative perforations 14 is not larger than 10 mm. Between the individual recesses of the decorative perforations 14 remain at least webs of the decorative layer 2 so that it forms a continuum even after punching.

The previously described procedure corresponds to the illustrations of 3 and 4 , In 5 are punched surface elements of the decorative layer with reference numerals 20 characterized. Here is the decorative layer 4 in 3 at an initially planar surface bearing surface of the tool half 6 created, partially by a plate of the tool half 6 and partly through the end faces of the punching bolts 12 of the punching element 4 is formed, which are slidably held in the plate.

The tool half 10 and the tool half 6 After that, move the tool half 10 in the direction of the directional arrow Z according to 4 with interposition of the decorative layer 2 placed against each other. Thereafter, the punching element 4 pressed to the individual punching pins 12 in the direction of the arrows SB to move and form a Dekorlochung. In accordance with 2 are in 5 the punched-out surface portions, ie the punched slugs with reference numerals 20 characterized.

At the end of this punching process passes through the punching element 4 with his punching pins 12 the decorative sheet 2 according to the decorative perforations 14 (see. 5 ).

Thereafter, when the tool is open, for example, in a turning tool, the tool half 10 turned and a sprayed position 22 forming mold half 24 opposite to the tool half 6 arranged, which is provided stationary (see. 6 ). The tool half 24 has in the embodiment of the 3 ff. recordings 25 for the punching bolts 12 , that of a first cavity formed as a layer 26 are underlaid.

After closing the two tool halves 6 . 24 in the direction of the arrow S in 7 is through the first cavity 26 one of the punching pins 12 formed interspersed mold nest. The punching bolts 12 thus enforce the first cavity 26 for forming the sprayed layer 22 , where the first cavity 26 in 7 as a cavity and in 8th after filling with a plastic, the first sprayed layer 22 is shown containing. The tool half 24 forms a first mating surface 28 that the first cavity 26 opposite the decorative layer 2 limited. This first counter surface 28 usually extends parallel to the main extension of the decorative layer 2 (see. 7 ). The tool half 6 forms a supine position 29 against which the decor layer 2 in forming the sprayed layer 22 is applied and that of the punching element 4 interspersed and thus associated with this.

In the first cavity 26 becomes the formation of the sprayed layer 22 Injected plastic. The training of the sprayed situation 22 This is usually done together with fasteners as inserts into the first cavity 26 can be inserted to secure the decorative part to be produced, for example, in a vehicle interior. Likewise, from the plastic itself fasteners such as locking elements or male or female threaded elements are formed, including usually movable cores in the first cavity 26 be introduced. The sprayed situation 22 usually has a thickness of between 1 mm to 5 mm.

In the in the 3 to 10 shown embodiment after opening the tool (arrow OE in 9 ) one from the sprayed location 22 and the decorative layer 2 demoulded product. The surface of this decorative part 46 is through the surface of the decorative layer 2 educated. The decor layer 2 For example, it may be a film or a film-coated and accordingly protected against environmental influences open-pored decorative layer such as veneer or a fabric.

The embodiment of the 3 to 10 can be made for example in a turning tool, in which the tool half 6 stationary and thus axially immovable to the tool half 10 or the tool half 24 is arranged. Here are the tool halves 10 and 24 realized on a turntable, which by rotation either the tool half 10 or the tool half 24 opposite to the tool half 6 can arrange. The turntable does not necessarily have to be provided as a rotationally symmetrical disc. It can also be rotated alternately. The tool half 6 can also be provided several times on a turntable to each opposite to the mold halves 10 . 24 be arranged or expose at a sampling station, at which the product to 10 demolded and removed from the tool. The tool is opened and closed by moving the tool half 24 ,

An alternative procedure is in the 11 ff. clarified. The first phases of the process management correspond to the phases described above. 11 clarifies thereby a phase, which the before with reference to 6 phase described replaced.

In the process control according to the second embodiment according to the 11 ff. Has the sprayed situation 22 forming tool half 24 a movable counter element 32 with counter bolts 34 , The counter bolts 34 lie when closing (arrow S in 12 ) of the tool usually flush in the first mating surface 28 ( 12 ) and are then applied frontally against the punching bolts ( 13 ). The punching bolts can do this 12 and / or the mating bolts 34 in the first cavity 26 lie or limit this. The counter bolts 34 are in forming the sprayed layer 22 flush with the first mating surface 28 or beyond this counter surface 28 , When forming the sprayed layer 22 by injecting plastic into the first cavity 26 enforce the punching bolts 12 and / or the mating bolts 34 the first cavity 26 and prevent continuous training of the sprayed situation 22 (see. 12 ). Rather, this sprayed situation 22 with a perforation 36 formed, which correspond to the decorative perforations 14 is provided (cf. 14 ). In 13 become the counter bolts 34 advanced (arrow V ), against the punching bolts 12 created on the front side and moved further, so that the punching pin from the cavity 26 be pushed (arrow A ).

Depending on the position of the punching pins 12 or the counter bolt 34 can after molding the sprayed layer 22 and sufficient solidification of the present thermoplastic plastic counterbolt 34 towards the decor layer 2 to be moved. In this case, all mating bolts 34 be moved simultaneously. The counter bolts 34 can punch the punch 12 when pulling them out of the sprayed position 22 and the decorative layer 2 be tracked. In this case, the mating bolts 34 to about the front of the decorative layer 2 moved, the sprayed position 22 is provided opposite.

15 shows the intermediate product 30 after opening (arrow OE) of the tool by moving off the tool half 24 from the tool half 6 , By relative movement of the tool half 24 or one with reference numerals 38 marked another tool half, one with reference numerals 40 formed mold surface is formed, which is the decorative layer 2 and the sprayed situation 22 intermediate product formed 30 opposite to a second cavity 42 arranged after closing the tool (arrow S in 17 ) between the front surface of the decorative layer 2 and the molding surface 40 is trained (see. 17 ). Specifically, the tool half 24 rotated (arrow D) and so opposite to the other tool half 38 arranged. 17 already shows a state after advancing (arrow V ) of the counter bolt 34 against the mold surface 40 , The counter bolts 34 become sealing against the molding surface 40 created. This is the second cavity 42 is from the counterbolt 34 interspersed and formed with a hole pattern mold cavity.

In the second cavity 42 Now a second plastic, regularly transparent plastic injected to the decorative layer 2 to provide with a visible over-molding, which is the decorative layer 2 covers and protects against environmental influences or mechanical stress and a second sprayed layer 44 trains ( 18 ). The decor layer 2 may be formed for example by a thin film of plastic or metal, a textile material, a wood veneer or a woven carbon fiber material. After solidification of the second plastic material is in 18 with reference number 46 marked decorative part with a continuous hole pattern 47 completed. The decorative part 46 will now be demoulded. For this example, the counter element 32 along with a back holding layer, by the the sprayed layer 22 forming mold half 24 or by another tool half, the counter element in the second injection cycle 32 supported on the back, be removed from the mold. Alternatively, only the decorative part 46 together with the counter element 32 be removed from the mold. To equalize the injection molding of the process of demoulding, possibly also the cooling of the decorative part 46 until the complete dimensional stability of the injected plastics, the punching element 4 and / or the counter element 32 from the associated tool halves 6 . 24 be solvable and circulate on their own processing lines to be used if necessary in the respective injection mold, as for example for toothbrushes EP 1 614 519 A1 . EP 678 368 A1 or. EP 893 225 A is known.

According to 19 The mold is opened by removing the tool half to remove the mold 24 is moved away (arrow OE) and the decorative part 46 taken.

The injection mold in 7 or. 13 is through the the punching element 4 having tool half 6 and the sprayed location 22 forming mold half 24 formed and is in these figures with reference numerals 48 characterized. In 17 is a second injection mold with reference numerals 50 marked, which by the further tool half 38 and for example the sprayed layer 22 forming mold half 24 can be formed.

LIST OF REFERENCE NUMBERS

2

decorative sheet

4

punch

6

Tool half

8th

extraction perforation

10

Tool half

12

punching pins

13a

wedge

13b

counter wedge

14

Dekorlochung

16

Exhaust discharge

18

chamber

20

punched surface element

22

sprayed location

24

Tool half

25

Pick-up for punching pins

26

first cavity

28

first counter surface

29

supine position

30

intermediate product

32

counter-element

34

against bolt

36

perforation

38

another tool half

40

form surface

42

second cavity

44

second sprayed position

46

decorative part

47

hole pattern

48

first injection mold

50

second injection mold

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 4301444 A1 [0002]
• EP 1614519 A1 [0031]
• EP 678368 A1 [0031]
• EP 893225A [0031]

Claims (12)

Method for producing a decorative part (4), in which a decorative layer (2) is inserted into an injection mold (48), the injection mold (48) closed and plastic for forming a sprayed against the decorative layer (2) layer (22) in the plastic Injection mold (48) is introduced, characterized in that the decorative layer (2) for forming a decorative perforation (14) with a punching element (4) is processed, which is in the injection mold (48) when forming the sprayed layer (22). Method according to Claim 1 , characterized in that the punching element (4) when forming the sprayed layer (22) the decorative layer (2) enforced in whole or in part. Method according to Claim 1 , characterized in that the decorative layer (2) is stamped during or after the formation of the sprayed layer (22). Method according to one of Claims 1 to 3 , characterized in that the punching element (4) and / or a complementary to the punching element (4) formed counter element (32) in the injection mold (48) prevents formation of a continuous sprayed layer and in the sprayed layer (22) has a perforation ( 36) which at least substantially aligns with the decorative perforations (14). Method according to one of the preceding claims, characterized in that the punching element (4) and a in the formation of the sprayed layer (22) against the decorative layer (2) fitting, the punching element (4) associated with the supine position (29) after the formation of the sprayed layer (22) is moved away from the decorative layer (2). Method according to one of the preceding claims, characterized in that the counter element (32) in the decorative perforations (14) and / or the perforation (36) of the sprayed layer (22) is introduced. Method according to one of Claims 4 to 6 , characterized in that the counter-element (32) is applied against a forming surface (40) which forms a cavity (42) delimited by the decorative layer (2) into which a second plastic material is injected having a second injection-molded layer (44). ausformt. Method according to Claim 6 or 7 , characterized in that the counter element (32) during removal of a formed from the decorative layer (2) and the sprayed layer (22) intermediate product (30) on the punching element (4) fitting the punching element (4) is tracked. Method according to one of the preceding claims, characterized in that the counter element (32) in that injection mold (48) in the decorative layer (2) and / or the perforation (36) of the sprayed layer (22) is introduced, in which the sprayed layer (22) is formed. Method according to one of the preceding claims, characterized in that an intermediate product (30) formed by the decorative layer (2) and the sprayed layer (22) is transferred by the counter-element (32) from the injection-molding die (48) into a second injection-molding tool (50) in which a second sprayed layer (44) is produced. Method according to one of the preceding claims, characterized in that the decorative layer (2) between a punching element (4) having tool half (6) and a provided with a complementary to the punching element (4) suction perforation (8) provided punched tool half (10) is, the punched decorative layer (2) on the punching element (4) having tool half (6) to a sprayed layer (22) forming mold half (24) is transferred and plastic in the between the second mold half (24) and the decorative layer ( 2) formed first cavity (26) is injected, that by the decorative layer (2) and the injected layer (22) formed intermediate product (30) with the sprayed layer (22) forming the mold half (24) and interspersed by a in the Perforated (36) and the decorative holes (14) engaging counter element (32) transferred to a further injection mold (50) and in between the decorative layer (2) and the second tool half (38) is injected to produce a second injection-molded layer (44) penetrated by the counter element (32). Decorative part (46) having a decorative layer (2) which is connected between a first sprayed layer (22) and a second sprayed (44), wherein the two sprayed layers (22, 44) are respectively connected by encapsulation with the decorative layer (2) and each have a perforation (36) which is formed during encapsulation of the decorative layer (2).

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