DE102021118659A1 - Production tool for producing a decorative semi-finished product for a molded part and method for producing a molded part - Google Patents

Abstract

The invention relates to a production tool (10) for producing a decorative semi-finished product (11) for a molded part (12), the molded part (12) being formed or capable of being formed at least from the decorative semi-finished product (11), the decorative semi-finished product ( 11) comprises at least one decorative layer (13) with a front side (14) designed as a visible side and a rear side (15) opposite the front side (14), and having a lacquer system (16) on its front side (14), the production tool (10 ) comprises at least a first upper mold (17) and a lower mold (18), which form a cavity (19) between them for producing the decorative semi-finished product (11), the cavity (19) having the intended shape of the decorative semi-finished product (11 ).The invention is characterized in that the production tool (10) is designed for forming the decorative semi-finished product (11) into the shape specified by the cavity (19) and for curing the paint system (16), the first upper mold ( 17) and/or the sub mold (18) is transparent or translucent, one or more first light sources (20) for curing the paint system (16) being arranged in or on the first upper mold (17) and/or in or on the lower mold (18). The invention also relates to a method for producing a molded part (12).

Description

The invention relates to a production tool, in particular a forming tool, for producing a decorative semi-finished product for a molded part and a method for producing a molded part, in particular a decorative and/or lining part designed as a molded part for a vehicle interior.

Numerous decorative and paneling parts are installed in the vehicle interior, for example door panels, console and instrument panels. The decorative and trim parts also include control buttons and their covers.

The production tool is provided and/or designed for the production of a decorative semi-finished product for a molded part. The molded part is formed at least from the decorative semi-finished product or can be formed from the decorative semi-finished product.

The decorative semi-finished product comprises at least one decorative layer with a front side designed as a visible side and a back side opposite the front side, and has a paint system on its front side.

The production tool comprises at least a first upper mold and a lower mold, which form a cavity between them for producing the decorative semi-finished product, with the cavity specifying the intended shape of the decorative semi-finished product.

Previously, two separate work steps were necessary for semi-finished products, in particular foil and/or aluminum semi-finished products, which were impregnated and/or printed with a paint system, in particular dual-cure paint system. A high pressure, high temperature pressing process and a UV tunnel curing process. These separate processes require a lot of energy, effort and time and are labor and cost intensive.

The present invention is based on the object of specifying a new production tool, in particular a production tool with which the production of decorative semi-finished products for molded parts is made possible, in which the aforementioned problems are at least largely avoided. In addition, the object of the invention is to specify a new method, in particular a method with which the production of molded parts is made possible, in which the aforementioned problems are also at least largely avoided.

The object is achieved with regard to the production tool by the features of claim 1 and with regard to the method by the features of claim 10. Advantageous refinements and developments are specified in the respective dependent claims.

The invention is characterized in that the production tool is designed to reshape the decorative semi-finished product into the shape specified by the cavity and to cure the paint system, with the first upper mold and/or the lower mold being transparent or translucent, with in or on the first upper mold and/or one or more first light sources for curing the paint system are arranged in or on the lower mold.

An essential advantage of the invention lies in the fact that the decorative semi-finished product can both be formed and the paint system of the decorative semi-finished product can be cured with a single production tool.

It is preferably provided that the molded part comprises a carrier, in particular a plastic carrier, the carrier being arranged on the rear side of the decorative layer, the carrier preferably being injection-molded onto the rear side of the decorative layer.

The decorative layer is or includes, in particular, a metal, for example aluminum, or a foil or a fabric, for example a carbon fabric and/or a glass fiber fabric and/or a polyester fabric. The paint system is preferably a dual-cure paint system.

A development of the invention provides that the first upper mold and/or the lower mold is made of, in particular, transparent and/or translucent glass and/or plastic.

It can be provided that the one or more first light sources are or include UV light sources, in particular UV tubes or UV LEDs.

According to one embodiment variant of the invention, one or more second light sources are arranged in or on the first upper mold and/or in or on the lower mold, the one or more second light sources being provided in particular for irradiating the decorative semi-finished product in order to increase the flexibility of the decorative layer increase. It can be provided that the one or more second light sources are or include IR light sources, in particular IR tubes or IR LEDs.

The one or more first light sources and/or the one or more second light sources are preferably in or on the first Are arranged upper form that the emission direction of the light sources is aligned towards the cavity.

According to one embodiment variant of the invention, the production tool has one or more first light sources and one or more second light sources and a control device for controlling the light sources, wherein the one or more first light sources and/or the one or more second light sources can be controlled individually, so that the one or more first light sources and/or the one or more second light sources can be activated independently of one another.

It can be provided that the production tool comprises at least one first upper mold and at least one second upper mold, in particular made of steel, with the first upper mold for processing the decorative semi-finished product with a first pressure at a first temperature and the second upper mold for processing the decoration -Semi-finished product is provided and/or formed with a second pressure at a second temperature, the second pressure being higher than the first pressure and/or the second temperature being higher than the first temperature.

Furthermore, it can be provided that the production tool has an exchange device, in particular a turning device, for exchanging the first upper mold and the second upper mold.

1. a) wobei das Formteil wenigstens aus einem Dekor-Halbzeug gebildet wird,
2. b) wobei das Dekor-Halbzeug wenigstens eine Dekorschicht mit einer als Sichtseite ausgebildeten Vorderseite und einer der Vorderseite gegenüberliegenden Rückseite umfasst, und an seiner Vorderseite ein Lacksystem aufweist,
3. c) wobei das Verfahren zumindest teilweise mit einem Herstellungswerkzeug durchgeführt wird, insbesondere einem erfindungsgemäßen Herstellungswerkzeug,
   • c1) wobei das Herstellungswerkzeug wenigstens eine erste Oberform und eine Unterform umfasst, die zwischen sich eine Kavität zur Herstellung des Dekor-Halbzeugs ausbilden, wobei die Kavität die vorgesehene Form des Dekor-Halbzeugs vorgibt,
   • c2) wobei das Herstellungswerkzeug zum Umformen des Dekor-Halbzeugs in die durch die Kavität vorgegebene Form und zum, insbesondere gleichzeitigem, Aushärten des Lacksystems ausgebildet ist,
   • c3) wobei die erste Oberform und/oder die Unterform transparent oder transluzent ausgebildet ist, wobei in oder an der ersten Oberform und/oder in oder an der Unterform eine oder mehrere erste Lichtquellen zum Aushärten des Lacksystems angeordnet sind.

The method according to the invention is intended and/or designed for producing a molded part, in particular a decorative and/or lining part for the vehicle interior,

1. a) the molded part being formed from at least one decorative semi-finished product,
2. b) the decorative semi-finished product comprising at least one decorative layer with a front side designed as a visible side and a rear side opposite the front side, and having a paint system on its front side,
3. c) the method being carried out at least partially with a production tool, in particular a production tool according to the invention,
   • c1) the production tool comprising at least a first upper mold and a lower mold, which form a cavity between them for producing the decorative semi-finished product, the cavity specifying the intended shape of the decorative semi-finished product,
   • c2) the production tool being designed for forming the decorative semi-finished product into the shape specified by the cavity and for curing the paint system, in particular simultaneously,
   • c3) the first upper mold and/or the lower mold being transparent or translucent, with one or more first light sources for curing the paint system being arranged in or on the first upper mold and/or in or on the lower mold.

• d) Bereitstellen eines zur Bildung der Dekorschicht vorgesehenen Dekormaterials,
• e) Beschichten oder Imprägnieren der Dekorschicht mit einem Lacksystem zur Bildung des Dekor-Halbzeugs,
• f) Öffnen des Herstellungswerkzeugs mittels Auseinanderfahren einer Oberform und der Unterform des Herstellungswerkzeugs,
• g) Einbringen, insbesondere Einlegen, des Dekor-Halbzeugs in das Herstellungswerkzeug, insbesondere die Kavität des Herstellungswerkzeugs,
• h) Umformen des Dekor-Halbzeugs mittels Zusammenfahren einer Oberform und der Unterform des Herstellungswerkzeugs, insbesondere unter Bereitstellung von Druck und Temperatur,
• i) Aktivieren der einen oder mehreren ersten Lichtquellen zum Aushärten des Lacksystems durch Bestrahlung mit der oder den ersten Lichtquellen,
• j) Öffnen des Herstellungswerkzeugs mittels Auseinanderfahren einer Oberform und der Unterform des Herstellungswerkzeugs,
• k) Entnehmen des Dekor-Halbzeugs aus dem Herstellungswerkzeug,
• l) Bilden eines Formteils mit dem Dekor-Halbzeug.

The method according to the invention comprises the steps:

• d) providing a decorative material intended to form the decorative layer,
• e) coating or impregnating the decorative layer with a paint system to form the decorative semi-finished product,
• f) opening the production tool by moving apart an upper mold and the lower mold of the production tool,
• g) introducing, in particular inserting, the decorative semi-finished product into the production tool, in particular the cavity of the production tool,
• h) forming of the decorative semi-finished product by moving an upper mold and the lower mold of the production tool together, in particular by providing pressure and temperature,
• i) activation of the one or more first light sources for curing the paint system by irradiation with the or the first light sources,
• j) opening the production tool by moving apart an upper mold and the lower mold of the production tool,
• k) removing the decorative semi-finished product from the production tool,
• l) Forming a molded part with the decorative semi-finished product.

The decorative layer is preferably coated and/or impregnated with a dual-cure paint system.

After the decorative layer has been coated with the lacquer system and in particular before the decorative semi-finished product is introduced into the production tool, the lacquer system can already partially cure via the isocyanate and/or OH groups.

The first upper mold and the lower mold are preferably brought together with an intended and/or defined pressure.

One or more second light sources are preferably arranged in or on the first upper mold and/or in or on the lower mold, the one or more second light sources being provided to increase the flexibility of the decorative layer by irradiating the decorative semi-finished product with the second light source or sources .

It can be provided that the one or more second light sources are activated after the decorative semi-finished product has been introduced into the production tool and before the upper mold and the lower mold are moved together for forming, and/or the one or more second light sources are deactivated after the upper mold and the lower mold were moved together for forming.

By activating the one or more second light sources, the decorative semi-finished product, for example with a decorative layer made of a foil or a fabric, is given greater flexibility and can be shaped better.

The one or more first light sources are preferably activated after the upper mold and the lower mold have been moved together for forming, and/or in particular after the one or more second light sources have been deactivated.

The paint system cures by means of the one or more first light sources, in particular by free-radical polymerization.

To form the molded part, the decorative semi-finished product can be subjected to further processing steps. For example, the decorative semi-finished product can be back-injected with a plastic on the rear side of the decorative layer in an injection molding tool to form a carrier.

According to one embodiment of the method, the production tool comprises at least one first upper mold and at least one second upper mold, in particular made of steel, with the decorative semi-finished product being formed using the second upper mold and the paint system being cured using the first upper mold.

The second upper mold is preferably used first and then the first upper mold. Provision can be made for the production tool to have an exchange device, in particular a turning device, for exchanging the first upper mold and the second upper mold.

Provision can furthermore be made for the decorative semi-finished product to be processed with a first pressure at a first temperature while the first upper mold is inserted, and for the decorative semi-finished product to be processed with a second pressure at a second temperature while the second upper mold is inserted, wherein the second pressure is higher than the first pressure and/or the second temperature is higher than the first temperature.

• 1 eine schematische Darstellung eines mit dem erfindungsgemäßen Verfahren und dem erfindungsgemäßen Herstellungswerkzeug herstellbaren Formteils in einer Schnittansicht;
• 2 eine schematische Darstellung eines Ausführungsbeispiels eines erfindungsgemäßen Herstellungswerkzeugs in einer Schnittansicht gemäß einem ersten Zustand;
• 3 eine schematische Darstellung eines Ausführungsbeispiels eines erfindungsgemäßen Herstellungswerkzeugs in einer Schnittansicht gemäß einem zweiten Zustand.

The invention is explained in more detail below, also with regard to further features and advantages, on the basis of the description of exemplary embodiments and with reference to the attached, schematic drawings. while showing

• 1 a schematic representation of a molded part that can be produced with the method according to the invention and the production tool according to the invention, in a sectional view;
• 2 a schematic representation of an embodiment of a production tool according to the invention in a sectional view according to a first state;
• 3 a schematic representation of an embodiment of a production tool according to the invention in a sectional view according to a second state.

Corresponding parts and components are also denoted by the same reference symbols throughout the various exemplary embodiments.

2 and 3 show a production tool 10 according to the invention for producing a decorative semi-finished product 11 for a molded part 12. In 2 the production tool is shown in a first, open state, whereas in 3 production tool 10 is shown in a second, closed condition. The molded part 12 is shown schematically in 1 shown, wherein the molded part 12 according to 1 is formed from the decorative semi-finished product 11 and a carrier 23 . The decorative semi-finished product 11 comprises a decorative layer 13 with a front side 14 designed as a visible side and a rear side 15 opposite the front side 14 and has a lacquer system 16 on its front side 14 . The decorative layer 13 can be aluminum or a foil or a fabric, for example a carbon fabric and/or a glass fiber fabric and/or a polyester fabric. The paint system 16 is a dual-cure paint system. The carrier 23 is a plastic carrier molded onto the rear side 15 of the decorative layer 13 by means of injection molding.

2 and 3 show that the production tool 10 comprises a first upper mold 17 and a lower mold 18 which form a cavity 19 for the production of the semi-finished decorative product 11 between them. The cavity 19 specifies the intended shape of the decorative semi-finished product 11 . The Crafting Tool 10 is designed both for forming the decorative semi-finished product 11 into the shape specified by the cavity 19 and for curing the paint system 16 . The first upper mold 17 is transparent, with a plurality of first light sources 20 for curing the paint system 16 being arranged in the first upper mold 17 . The first upper mold 17 is made of transparent and/or translucent glass or plastic. The first light sources 20 are UV light sources, in particular UV tubes or UV LEDs.

Furthermore, a plurality of second light sources 21 are arranged in the first upper mold 17 , the second light sources 21 being provided for irradiating the decorative semi-finished product 11 in order to increase the flexibility of the decorative layer 13 . The second light sources 21 are IR light sources, in particular IR tubes or IR LEDs.

The first and second light sources 20, 21 are arranged in the first upper mold 17 in such a way that the emission direction of the light sources 20, 21 is aligned towards the cavity 19.

The production tool 10 also has a control device 22 for controlling the light sources 20; 21, wherein the first light sources 20 and the second light sources 21 can be controlled individually, so that the first light sources 20 and the second light sources 21 can be activated independently of one another.

According to one embodiment variant of the invention (not shown in the figures), the production tool 10 can comprise a second upper mold made of steel in addition to the first upper mold 17, the first upper mold 17 for processing the decorative semi-finished product 11 with a first pressure at a first temperature and the second upper mold for processing the decorative semi-finished product 11 is provided and/or designed with a second pressure at a second temperature, the second pressure being higher than the first pressure and the second temperature being higher than the first temperature. In this case, the production tool 10 additionally has an exchange device, in particular a turning device, for exchanging the first upper mold 17 and the second upper mold. If high pressures and temperatures are required, such as for bonding or to shape rigid materials, two different upper molds can be used, a second upper mold made of steel which allows high pressures and temperatures and a first upper mold 17 made of transparent glass or plastic. After the rigid decorative semi-finished product 11 has been shaped with the second upper mold made of steel, UV curing can be carried out with the first, transparent upper mold.

An exemplary embodiment of a method according to the invention for producing, for example in 1 illustrated, designed as a molded part 12 decorative and / or trim part for the vehicle interior described.

The molded part 12 is formed from a decorative semi-finished product 11, the decorative semi-finished product 11 comprising a decorative layer 13 with a front side 14 designed as a visible side and a rear side 15 opposite the front side 14, and having a lacquer system 16 on its front side 14. The paint system 16 is a dual-cure paint system 16.

The procedure is partly carried out with the in 2 and 3 illustrated production tool 10 performed. The production tool 10 has a first upper mold 17 and a lower mold 18 which form a cavity 19 between them for producing the decorative semi-finished product 11 , the cavity 19 specifying the intended shape of the decorative semi-finished product 11 . The production tool 10 is designed both for forming the decorative semi-finished product 11 into the shape specified by the cavity 19 and for curing the paint system 16 . The first upper mold 17 is transparent, with a plurality of first light sources 20 for curing the paint system 16 being arranged in the first upper mold 17 . Furthermore, second light sources 21 are arranged in the first upper mold 17, the second light sources 21 being provided to increase the flexibility of the decorative layer 13 by irradiating the decorative semi-finished product 11 with the second light sources 21. The first light sources 20 are UV light sources, whereas the second light sources 21 are IR light sources.

• Zunächst wird gemäß einem ersten Schritt d) ein zur Bildung der Dekorschicht 13 vorgesehenes Dekormaterial bereitgestellt. Die Dekorschicht 13 wird anschließend gemäß einem Schritt e) mit einem Dual-Cure Lacksystem 16 zur Bildung des Dekor-Halbzeugs 11 beschichtet oder imprägniert. Nach dem Beschichten oder Imprägnieren der Dekorschicht 13 mit dem Lacksystem 16 kann das Lacksystem 16 bereits teilweise über die Isocyanat- und OH-Gruppen aushärten.

The procedure includes the following steps:

• According to a first step d), a decorative material provided for forming the decorative layer 13 is initially provided. According to a step e), the decorative layer 13 is then coated or impregnated with a dual-cure coating system 16 to form the decorative semi-finished product 11 . After the decorative layer 13 has been coated or impregnated with the paint system 16, the paint system 16 can already partially cure via the isocyanate and OH groups.

Subsequently, according to a step f), the production tool 10 is opened by moving the first upper mold 17 and the lower mold 18 apart. The decorative semi-finished product 11 is then placed in the cavity 19 of the production tool 10 according to a further step g), as shown in FIG 2 shown.

After the decorative semi-finished product 11 has been introduced into the production tool 10 , the second light sources 21 are activated, the flexibility of the decorative layer 13 being increased by irradiating the decorative semi-finished product 11 with the second light sources 21 .

Subsequently, according to a step h), the decorative semi-finished product 11 is formed by moving the first upper mold 17 and the lower mold 18 of the production tool 10 together while providing a specified pressure and a specified temperature, as in 3 shown. After the upper mold 17 and the lower mold 18 have been moved together for forming, the second light sources 21 are deactivated. According to a step i), the first light sources 20 are then activated in order to cure the paint system 16 by irradiation with the first light sources 20 . The paint system 16 then hardens by means of the first light source 20 by radical polymerization.

After the paint system 16 has cured, the production tool 10 is opened by moving apart the first upper mold 17 and the lower mold 18 of the production tool 10 according to a step j) and the decorative semi-finished product 11 is removed from the production tool 10 according to a further step k).

Then, according to a step I), the molded part 12 is formed with the decorative semi-finished product 11 . To form the molded part 12, the decorative semi-finished product 11 is fed to further processing steps. So will order that in 1 to form the molded part 12 shown, the decorative semi-finished product 11 back-injected in an injection mold (not shown in the figures) on the back 15 of the decorative layer 11 with a plastic to form a carrier 23 .

Reference List

10

crafting tool

11

Decor semi-finished product

12

molding

13

decorative layer

14

front

15

back

16

paint system

17

first upper form

18

subform

19

cavity

20

first light source

21

second light source

22

control device

23

carrier

Claims (15)

Production tool (10) for producing a decorative semi-finished product (11) for a molded part (12), the molded part (12) being formed or formable at least from the decorative semi-finished product (11), the decorative semi-finished product (11) having at least one comprises a decorative layer (13) with a front side (14) designed as a visible side and a rear side (15) opposite the front side (14), and having a lacquer system (16) on its front side (14), the production tool (10) having at least a first Upper mold (17) and a lower mold (18) which form between them a cavity (19) for producing the decorative semi-finished product (11), the cavity (19) specifying the intended shape of the decorative semi-finished product (11), characterized in that characterized in that the production tool (10) is designed for forming the decorative semi-finished product (11) into the shape specified by the cavity (19) and for curing the paint system (16), the first upper mold (17) and/or the lower mold (18) transparent or translucent excl is formed, one or more first light sources (20) for curing the paint system (16) being arranged in or on the first upper mold (17) and/or in or on the lower mold (18). manufacturing tool claim 1 , characterized in that the first upper mold (17) and/or the lower mold (18) is made of glass and/or plastic. manufacturing tool claim 1 or 2 , characterized in that the one or more first light sources (20) are or include UV light sources. Production tool according to one of Claims 1 until 3 , characterized in that one or more second light sources (21) are arranged in or on the first upper mold (17) and/or in or or on the lower mold (18). manufacturing tool claim 4 , characterized in that the one or more second light sources (21) are or include IR light sources. manufacturing tool claim 4 or 5 , characterized in that the production tool (10) has one or more first light sources (20) and one or more second light sources (21) and a control device (22) for controlling the light sources (20; 21), wherein the one or more first light sources (20) and/or the one or more second light sources (21) are individually controllable such that the one or more first light sources (20) and/or the one or more second light sources (21) are independent can be activated from each other. Production tool according to one of the preceding claims, characterized in that the one or more first light sources (20) are arranged in or on the first upper mold (17) in such a way that the emission direction of the light sources (20) is aligned towards the cavity (19). Production tool according to one of the preceding claims, characterized in that the production tool (10) comprises at least one first upper mold (17) and at least one second upper mold, the first upper mold (17) for processing the decorative semi-finished product (11) with a first pressure at a first temperature and the second upper mold is provided and/or designed for processing the decorative semi-finished product (11) with a second pressure at a second temperature, the second pressure being higher than the first pressure and/or the second temperature being higher than is the first temperature. manufacturing tool claim 8 , characterized in that the production tool (10) has an exchange device for exchanging the first upper mold (17) and the second upper mold. Method for producing a molded part (12), a) the molded part (12) being formed from at least one decorative semi-finished product (11), b) the decorative semi-finished product (11) comprising at least one decorative layer (13) with a front side (14) designed as a visible side and a rear side (15) opposite the front side (14), and on its front side (14) a paint system (16 ) having, c) the method being carried out at least partially with a production tool (10), c1) wherein the production tool (10) comprises at least a first upper mold (17) and a lower mold (18), which form a cavity (19) between them for producing the decorative semi-finished product (11), the cavity (19) being the intended one shape of the decorative semi-finished product (11), c2) the production tool (10) being designed for forming the decorative semi-finished product (11) into the shape specified by the cavity (19) and for curing the paint system (16), c3) the first upper mold (17) and/or the lower mold (18) being transparent or translucent, with one or more first light sources ( 20) are arranged for curing the paint system (16), the method comprising the steps: d) providing a decorative material intended to form the decorative layer (13), e) coating or impregnating the decorative layer (13) with a paint system (16) to form the decorative semi-finished product (11), f) opening the production tool (10) by moving apart an upper mold (17) and the lower mold (18) of the production tool (10), g) introducing the decorative semi-finished product (11) into the production tool (10), h) forming of the decorative semi-finished product (11) by moving an upper mold (17) and the lower mold (18) of the production tool (10) together, i) activating the one or more first light sources (20) for curing the paint system (16) by irradiation with the or the first light sources (20), j) opening the production tool (10) by moving apart an upper mold (17) and the lower mold (18) of the production tool (10), k) removing the decorative semi-finished product (11) from the production tool (10), I) Forming a molded part (12) with the decorative semi-finished product (11). procedure after claim 10 , characterized in that one or more second light sources (21) are arranged in or on the first upper mold (17) and/or in or on the lower mold (18), with the one or more second light sources (21) increasing the flexibility of the Decorative layer (13) is increased by irradiating the decorative semi-finished product (11) with the one or more light sources (21). procedure after claim 11 , characterized in that the one or more second light sources (21) are activated after the decorative semi-finished product (11) has been introduced into the production tool (10) and before the upper mold (17) and the lower mold (18) are moved together for forming, and/or that the one or more second light sources (21) are deactivated after the upper mold (17) and the lower mold (18) have been moved together for forming. Procedure according to one of Claims 10 until 12 , characterized in that the one or more first light sources (20) are activated after the upper mold (17) and the lower mold (18) have been moved together for forming. Procedure according to one of Claims 10 until 13 , characterized in that the production tool (10) has at least a first upper mold (17) and at least one second upper mold, the decorative semi-finished product (11) being formed by means of the second upper mold and the paint system (16) being cured by means of the first upper mold (17). procedure after Claim 14 , characterized in that the decorative semi-finished product (11) is processed with a first pressure at a first temperature while the first upper mold (17) is inserted, and the decorative semi-finished product (11) is processed with a second pressure while the second upper mold is inserted is processed at a second temperature, wherein the second pressure is higher than the first pressure and/or the second temperature is higher than the first temperature.

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