DE102020105024A1 - Method for manufacturing a vehicle surface component by means of multi-component injection molding - Google Patents

Abstract

The invention relates to a method for producing a vehicle surface component (1), in particular a vehicle trim component, by means of multi-component injection molding in a mold (8) with the steps of a) closing the mold (9) and a first mold plate (10) having a mold ( 8) with the formation of a first mold cavity (15), with at least one structural punch (11) being arranged on the tool plate (9) which has a punch shaft (12) and a punch head (14) and extends with the punch shaft (12) through the first mold cavity (15) extends to the first mold plate (10) and rests against the first mold plate (10) or engages in a recess (17) formed on the first mold plate (10) for the punch head (14), b) injection molding of a first component (2) into the first mold cavity (15), the stamp shaft (12) of the at least one structural stamp (11) being overmolded, c) opening the molding tool (8), d) relocating the first component (2) supporting tool plate (9) in a juxtaposition to a second mold plate (18), e) closing the mold (8) containing the tool plate (9) and the second mold plate (18) with the formation of a second mold cavity (19) between on the one hand the tool plate and the punch head (14) protruding beyond the first component (2) and, on the other hand, the second mold plate (18), f) injection molding of a second component (3) into the second mold cavity (19) as a coating of the first component (2), wherein the respective punch head (14) forms a structural recess (5) on the second component (3), andg) opening the molding tool (8) and ejecting or removing the formed component (1).

Description

The invention relates to a method for producing a vehicle surface component, in particular a vehicle trim component, by means of multi-component injection molding in a molding tool.

Such a procedure is basically from the EP 2 379 301 B1 known.

From the DE 10 2006 022 923 A1 a vehicle surface component made from an outer transparent component and an inner component using the 2K injection molding process has become known (see 3 ), in which the outer component has reflective prisms on the inside in areas that are not covered by the inner component.

For the creation of cladding components with 3D structures and the corresponding depth effect of color-contrasting patterns, it is known in the first step to produce transparent injection-molded parts with recessed 3D structures. The transparent back of the component is then printed with color, whereby the 3D structures are left out during printing. The remaining, unprinted, transparent 3D structures can then be painted with a separate color from the back and thus clearly contrasted with the surface color on the left.

This procedure requires separate processes that have to be coordinated with one another in a very complex manner. For the process of reverse printing and partial coloring of the structural pattern, a printing system with a high-performance printhead system and a high-precision printhead control is required to enable the required accuracy of the printing (precise recessing of the 3D structures, printing of the edge areas in the transition to the other component). To achieve a high level of reproducibility, it is necessary to measure each raw part before the printing process and to make this data available to the print head control in order to be able to compensate for an offset condition (deviating component shrinkage, warpage, etc.). The color of the printing must be carefully adapted to the black color of a frame area using "Color Match".

The invention is based on the object of creating a method as mentioned at the beginning which simplifies and improves the production of such a vehicle surface component.

1. a) Schließen des eine Werkzeugplatte und eine erste Formplatte aufweisenden Formwerkzeugs unter Bildung eines ersten Formhohlraums, wobei an der Werkzeugplatte zumindest ein Strukturstempel angeordnet ist, der einen Stempelschaft und einen Stempelkopf aufweist und sich mit dem Stempelschaft durch den ersten Formhohlraum zur ersten Formplatte erstreckt und an der ersten Formplatte anliegt oder in einer an der ersten Formplatte gebildeten Vertiefung für den Stempelkopf eingreift,
2. b) Spritzgießen einer ersten Komponente in den ersten Formhohlraum, wobei der Stempelschaft des zumindest einen Strukturstempels umspritzt wird,
3. c) Öffnen des Formwerkzeugs,
4. d) Umsetzen wie z. B. Drehen oder Wenden der die erste Komponente des Vorformlings tragenden Werkzeugplatte in eine Gegenüberstellung zu einer zweiten Formplatte,
5. e) Schließen des die Werkzeugplatte und die zweite Formplatte umfassenden Formwerkzeugs unter Bildung eines zweiten Formhohlraumes zwischen einerseits der Werkzeugplatte und dem über die erste Komponente hinausragenden Stempelkopf und andererseits der zweiten Formplatte,
6. f) Spritzgießen einer zweiten Komponente in den zweiten Formhohlraum als Beschichtung der ersten Komponente, wobei der jeweilige Stempelkopf eine Strukturvertiefung an der zweiten Komponente bildet, und
7. g) Öffnen des Formwerkzeugs und Ausstoßen und/oder Entnehmen des gebildeten Bauteils.

According to the invention, this object is achieved by a method mentioned at the beginning with the following steps:

1. a) Closing the mold having a mold plate and a first mold plate with the formation of a first mold cavity, with at least one structural stamp being arranged on the tool plate, which has a stamp shaft and a stamp head and extends with the stamp shaft through the first mold cavity to the first mold plate and on the first mold plate rests or engages in a recess formed on the first mold plate for the punch head,
2. b) Injection molding of a first component into the first mold cavity, the punch shaft of the at least one structural punch being overmolded,
3. c) opening the mold,
4. d) Implementation such as B. Rotating or turning the tool plate carrying the first component of the preform into opposition to a second mold plate,
5. e) closing the mold comprising the mold plate and the second mold plate with the formation of a second mold cavity between, on the one hand, the mold plate and the punch head protruding beyond the first component and, on the other hand, the second mold plate,
6. f) injection molding of a second component into the second mold cavity as a coating of the first component, the respective die head forming a structural recess on the second component, and
7. g) opening the mold and ejecting and / or removing the component formed.

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

With the method according to the invention, a complex printing process can thus be dispensed with. With the aid of the method according to the invention, the structural depressions or 3D structures including the surrounding black area are produced in the 2-component injection molding process. For example, one hundred or several hundred structural depressions or 3D structures can also be formed in the component. The method according to the invention thus expediently relates to the creation of the rear colored and in particular black area with recessed design patterns by means of a multi-component injection molding process with corresponding mapping of the 3D structures through the first component and, if further components are sprayed onto the first component, through such others Structural punches that act as components in the molding tool. First of all, the flat rear side of the component is covered with the corresponding design recesses generated from the first component using structure stamps. While the component is transferred for the injection molding of the second component, which represents a design front surface, the structure stamps remain in their position and, when the subsequent component or second component is applied, depict the desired 3D structure in the, in particular, transparent component front surface.

• - Die 3D-Strukturmuster werden reproduzierbar und präzise von der umgebenden Fläche abgeschirmt.
• - Die 3D-Muster können von der Bauteilrückseite aus problemlos lackiert oder anderweitig beschichtet werden, ohne dass weitere Kaschierungsmaßnahmen notwendig sind.
• - Die Flächenkomponente ist absolut blickdicht, so dass es durch Mehrschichtlackierung nicht zu einer Farbverfälschung kommt, ein „Color Match“ zum Rahmenbereich hin ist nicht notwendig.
• - Es wird keine aufwendige und teure Anlagentechnik für die rückseitige Flächenfärbung wie eine Bedruckung benötigt, was unmittelbar die Herstellkosten senkt.
• - Es gibt keine Enthaftungsprobleme hinsichtlich der Flächenfärbung bzw. der Bedruckung.
• - Es kommt zu weniger Verschmutzungsproblemen der Bauteilrückseite beim Rohteiletransport, wenn die Färbung der 3D-Strukturen extern stattfinden muss. Durch die flächige Anspritzung der ersten Komponente ist der Großteil der rückseitigen blickdichten Fläche bereits geschützt.

The following advantages arise:

• - The 3D structure patterns are reproducibly and precisely shielded from the surrounding area.
• - The 3D patterns can be painted or otherwise coated from the back of the component without any problems, without the need for further lamination measures.
• - The surface component is absolutely opaque, so that multi-layer painting does not lead to color falsification, a "color match" to the frame area is not necessary.
• - No complex and expensive system technology is required for the rear surface coloring such as printing, which directly lowers the manufacturing costs.
• - There are no delamination problems in terms of surface coloring or printing.
• - There are fewer soiling problems on the back of the component during the transport of the raw parts if the coloring of the 3D structures has to take place externally. The large area of the opaque area on the back is already protected by the two-dimensional injection of the first component.

In the method, it is expediently provided that the at least one structure stamp represents an ejector for the component and, in particular, is mounted movably or longitudinally displaceably on the tool plate. In the case of a large number of structural punches attached to the tool plate, only a few structural punches can be movably mounted as ejectors, whereas the remaining structural punches are fixedly attached to the tool plate and, if necessary, can be exchanged.

Appropriately, a number of structural stamps in a pattern arrangement on the tool plate can be used to produce a corresponding visual appearance on the second, transparently formed component.

A frame of the component is preferably formed on this first component during the injection molding of the first component. Other parts such as functional parts or insert parts can be molded or overmolded.

The first component is expediently made from a thermoplastic such as ABS / PC. In particular, it is colored or formed as a black component.

The second component is preferably made from a thermoplastic such as PC. In particular, it is formed as a transparent component so that the structural depressions or 3D structures are visible from the outside.

Further steps such as painting at least one of the two-sided surfaces or the structural depressions of the component can be carried out.

Furthermore, it can be provided that during the injection molding of the first component and / or the second component, the tool plate carries out an embossing step. The embossing step comprises an infeed movement of the tool plate against the respective mold plate, so that the respective injected material is embossed in the shrinking mold cavity.

Such a vehicle surface component is z. B. an outer surface component, an inner surface component such. B. a painted interior component, a roof surface part, a cladding part, a panel or a particularly transparent cover for closing a vehicle roof opening or an openable vehicle roof, sliding roof or panorama roof.

• 1.1 in einer Querschnittansicht in vereinfachter schematischer Darstellung einen Ausschnitt eines Formwerkzeugs zum Mehrkomponenten-Spritzgießen eines Fahrzeugflächenbauteils mit einer Werkzeugplatte und einer ersten Formplatte;
• 1.2 in einer Querschnittansicht das geschlossene Formwerkzeug der 1 mit einer in einem Formhohlraum spritzgegossenen ersten Komponente;
• 1.3 in einer Querschnittansicht das geöffnete Formwerkzeug vor dem Umsetzen einer Werkzeugplatte;
• 1.4 in einer Querschnittansicht das Formwerkzeug nach dem Umsetzen der Werkzeugplatte vor eine zweite Formplatte;
• 1.5 in einer Querschnittansicht das Formwerkzeug mit einer in einem zweiten Formhohlraum spritzgegossenen zweiten Komponente;
• 1.6 in einer Querschnittansicht das geöffnete Formwerkzeug beim Auswerfen des aus der ersten Komponente und der zweiten Komponente gebildeten Bauteils;
• 1.7 in einer Querschnittansicht das aus der ersten Komponente und der zweiten Komponente gebildete Bauteil;
• 2 in einer Querschnittansicht gemäß 1.5 das im Formwerkzeug aus der ersten Komponente und der zweiten Komponente gebildete Bauteil;
• 3 in einer Draufsicht eine Rückseite des Bauteils; und
• 4 in einer Querschnittansicht das in 3 dargestellte Bauteil.

The invention is explained in more detail below using an exemplary embodiment of a method according to the invention with reference to the drawing. It shows:

• 1 .1 in a cross-sectional view in a simplified schematic representation of a detail of a molding tool for multi-component injection molding of a vehicle surface component with a tool plate and a first mold plate;
• 1 .2 in a cross-sectional view of the closed mold of 1 a first component injection molded in a mold cavity;
• 1 .3 in a cross-sectional view the opened mold before the transfer of a tool plate;
• 1 .4 in a cross-sectional view the molding tool after the transfer of the tool plate in front of a second molding plate;
• 1 .5 in a cross-sectional view the molding tool with a second component injection-molded in a second mold cavity;
• 1 .6 in a cross-sectional view the opened mold when ejecting the component formed from the first component and the second component;
• 1 .7 the component formed from the first component and the second component in a cross-sectional view;
• 2 in a cross-sectional view according to 1 .5 the component formed in the mold from the first component and the second component;
• 3 in a plan view of a rear side of the component; and
• 4th in a cross-sectional view the in 3 component shown.

A vehicle surface component 1 , e.g. B. a trim component or a panel on the front of a car that is in the 3 and 4th is shown by way of example and schematically in a rectangular shape, has a first flat component 2 on, which is a base layer or a base body of the component 1 forms. The first component 2 is made of a thermoplastic such. B. injection molded from ABS / PC. A second external component 3 is as a flat coating on the first component 2 applied by injection molding. The second component 3 is z. B. injection molded from a thermoplastic such as PC.

The first component 2 has several openings through it 4th which are arranged in the form of a pattern, for example as shown in FIG 3 with 4 by 4 openings 4th in the form of a square grid. Every opening 4th has a square cross-section, but can also have a different cross-sectional shape such. B. a round cross-section. Every opening 4th in the first component 2 is a structural deepening 5 assigned that in the second component 3 as an extension of the opening 4th is formed. Any structural deepening 5 has the form z. B. a pyramid, a cone or another structure such as a star or the like and thus represents a 3D structure.

The first component 2 is preferably made of a colored plastic and in particular in black color or as a black component. The second component 3 is preferably made from a substantially transparent plastic or as a transparent component.

A frame 6th of the component 1 is as part of the first component 2 manufactured. Other parts such as functional elements 7th , e.g. B. locking hooks with which the component 1 Can be attached to a vehicle structure, or tabs or the like, can be used during injection molding of the first component 2 be integrated as inserted parts or from the plastic of the first component 2 are manufactured.

A method for producing such a vehicle surface component 1 is as multi-component injection molding using a mold 8th (please refer 1 .1 to 1.7 and 2 , with only a central section of the molding tool 8th is shown) carried out, which is a tool plate 9 and a first mold plate 10 having. On the tool plate 9 are several structure stamps 11 in the square grid according to 3 arranged. Any structural stamp 11 contains a stamp shaft with a square cross-section 12th that is in a corresponding recess 13th in the tool plate 9 is firmly inserted or is received therein in a longitudinally displaceable manner when the structural die 11 one relative to the tool plate 9 to represent movable ejector. Any structural stamp 11 has a stamp head 14th on, the one on the stamp shaft 12th is fixedly attached or is formed integrally with this or on the punch shaft 12th is attached interchangeably. The stamp head 14th has the form z. B. a pyramid or other shape structure to the structure recess 5 to build.

When closing the mold 8th become the tool plate 9 and the first mold plate 10 moved against each other and brought into a closed position in which the tool plate 9 and the first mold plate 10 a mold cavity 15th limit. Any structural stamp 11 extends with its stamp shaft 12th through the mold cavity 15th through to the mold plate 10 . The mold plate 10 contains in their the mold cavity 15th facing mold surface 16 one deepening each 17th assigned to each structure stamp 11 . The depression 17th is shaped in such a way that it either only has the punch head 14th takes up or even a small section of the stamp shaft 12th . In each case is located in the mold cavity 15th only the stamp shaft 12th that is attached to the mold plate 10 fits tightly. The depression 17th can e.g. B. as a negative form of the stamp head 14th be educated.

With the mold closed ( 1 .1) a thermoplastic material such. B. ABS / PC in the mold cavity 15th injected and flows around the punch shafts 12th which thus the continuous openings 4th in the flat first component 2 form ( 1 .2). Optionally it can be provided that the tool plate 9 an infeed movement against the mold plate 10 executes so that the mold cavity 16 is reduced. Injecting the thermoplastic material and filling the mold cavity 16 with thermoplastic material thus takes place in the enlarged mold cavity 16 . When shrinking the mold cavity 16 will the Injected thermoplastic material and embossed in the mold cavity 16 equally distributed. If such a coining step is provided, the stamp shafts 12th in the tool plate 9 mounted movably in the longitudinal direction, so that the tool plate 9 relative to the stationary punch shafts 12th can be relocated. The punch shafts 12th are z. B. by a spring device or a hydraulic device in their of the tool plate 9 protruding position biased.

Then the molding tool 8th opened ( 1 .3) and the first component 2 load-bearing tool plate 9 is in a juxtaposition to a second mold plate 18th of the molding tool 8th brought ( 1 .4). This is done in accordance with the basic design of the mold 8th the tool plate 9 z. B. turned or swiveled so that they the second mold plate 18th that the first mold plate 9 is opposite, facing or it is rotated when the second mold plate 18th laterally next to the first mold plate 10 is arranged.

Then the molding tool 8th closed, with a second mold cavity 19th between which the first component 2 load-bearing tool plate 9 and the second mold plate 18th is formed. Every structural stamp protrudes 11 with its about the first component 2 protruding punch head 14th into the second mold cavity 19th into it, but remains off the surface or mold surface 20th the second mold plate 18th spaced.

Then a thermoplastic is used as the second component 3 into the second mold cavity 19th injected ( 1 .5). The second component 3 forms a coating on the first component 2 , with each punch head 14th the structural deepening 5 on the second component 3 forms that of the first component 2 facing and towards the opening 4th in the first component 2 is arranged in alignment.

Finally the molding tool 8th opened ( 1 .6) and that by means of the first component 2 and the second component 3 Injection molded component is ejected, e.g. B. by means of the structure stamp serving as an ejector 11 . The removed component 1 ( 1 .7) z. B. passed on a handling device for further processing. In this way, at least one of the two-sided surfaces can be painted and the structural recesses 5 can be processed or refined, e.g. B. by painting or coating the surfaces of the structural depressions 5 .

List of reference symbols

1

Vehicle surface component

2

first component

3

second component

4th

opening

5

Structure deepening

6th

frame

7th

Functional element

8th

Forming tool

9

Tool plate

10

first mold plate

11

Structure stamp

12th

Stamp shaft

13th

Recess

14th

Stamp head

15th

first mold cavity

16

Molding surface

17th

deepening

18th

second mold plate

19th

second mold cavity

20th

Molding surface

QUOTES INCLUDED IN THE DESCRIPTION

This list of the documents listed by the applicant was 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.

Patent literature cited

• EP 2379301 B1 [0002]
• DE 102006022923 A1 [0003]

Claims (9)

A method for producing a vehicle surface component (1), in particular a vehicle trim component, by means of multi-component injection molding in a molding tool (8) with the steps a) including the molding tool (8) having a tool plate (9) and a first molding plate (10) Formation of a first mold cavity (15), with at least one structural punch (11) being arranged on the tool plate (9), which has a punch shaft (12) and a punch head (14) and extends with the punch shaft (12) through the first mold cavity ( 15) extends to the first mold plate (10) and rests against the first mold plate (10) or engages in a recess (17) formed on the first mold plate (10) for the punch head (14), b) injection molding of a first component (2) into the first mold cavity (15), the punch shaft (12) of the at least one structural punch (11) being overmolded, c) opening the mold (8), d) transferring the tool plate (9) carrying the first component (2) into a juxtaposition to a second mold plate (18), e) Closing the mold (8) containing the mold plate (9) and the second mold plate (18) with the formation of a second mold cavity (19) between the mold plate (9) on the one hand and the punch head (14) protruding beyond the first component (2) and on the other hand the second mold plate (18), f) injection molding of a second component (3) into the second mold cavity (19) as a coating of the first component (2), the respective punch head (14) forming a structural recess (5) on the second component (3), and g) opening the mold (8) and ejecting or removing the formed component (1). Procedure according to Claim 1 , characterized in that the at least one structure stamp (11) represents an ejector for the component (1) and is in particular mounted on the tool plate (9) so as to be movable or longitudinally displaceable. Procedure according to Claim 1 or 2 , characterized in that a corresponding optical appearance is produced on the second transparent component (3) by means of a plurality of structural stamps (11) in a pattern arrangement on the tool plate (9). Method according to one of the Claims 1 until 3 , characterized in that a frame (6) of the component (1) is formed during the injection molding of the first component (2). Method according to one of the Claims 1 until 4th , characterized in that the first component (2) is made of a thermoplastic such as ABS / PC and is in particular colored or formed as a black component. Method according to one of the Claims 1 until 5 , characterized in that the second component (3) is made from a thermoplastic such as PC and is in particular formed as a transparent component. Method according to one of the Claims 1 until 6th , characterized in that further steps such as painting at least one of the two-sided surfaces or the structural depressions (5) of the component (1) are carried out. Method according to one of the Claims 1 until 7th , characterized in that, during the injection molding of the first component (2), functional parts (7) or inserts are injected or overmolded. Method according to one of the Claims 1 until 8th , characterized in that during the injection molding of the first component (2) and / or the second component (3) the molding tool (8) or the tool plate (9) performs an embossing step.

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