DE102021128990A1 - Process for manufacturing a component with different surfaces - Google Patents

Abstract

The invention relates to a method for producing a component (2) with different surfaces, the component (2) having embossing surfaces (8) and coating surfaces (9), with the following steps: producing the component (2) in an injection molding process; either providing the embossing surfaces (8) with a film in the hot embossing process; or IMD transfer of film in injection molding process; and demolding and attaching the component (2); Selective electroplating of the coating surfaces (9).

Description

The present invention relates to a method for producing a component with different surfaces.

In order to decorate components manufactured using the injection molding process with symbols, lettering or design structures, the components can be finished with a foil using a hot embossing process after production. Such methods are used, for example, in large numbers by manufacturers of radiator grilles in the automotive sector. Various materials such as polycarbonate (PC), acrylonitrile butadiene styrene (ABS), ABS/PC blends and polyamide (PA) are suitable for such processes. Apart from a visual inspection and, if necessary, cleaning, the components are already finished after the embossing process and are not processed any further.

Another known technology for producing decorative surfaces is the transfer of a decoration in injection molding through a film arranged in the injection mold, also referred to as in-mold decoration (IMD).

The pamphlets DE 10 2017 125 446 A1 , DE 10 2018 104 578 A1 and DE 10 2019 129 952 A1 , which go back to the applicant, describe methods for electroplating surfaces of plastic components. With the known methods it is not possible to build up areas on the same component as a combination of metal surfaces with different degrees of gloss, in particular as a combination of bright chrome and matt chrome side by side.

It is therefore the object of the present invention to specify a method for producing a component with different metallic, metallic-looking and/or colored surfaces, in which areas with different degrees of gloss can be built up on the same component, for example as a combination of matt and bright chrome side by side and/or or metallic color variants.

The problem described is solved by a method for producing a component with the features of claim 1 .

1. a) Herstellen des Bauteils im Spritzgießverfahren;
2. b) Versehen der Prägeflächen mit einer Folie im Heißprägeverfahren;
3. c) Selektives Galvanisieren der Beschichtungsflächen.

A method for producing a component with different surfaces, the component having embossing surfaces and coating surfaces, has the following steps in this order:

1. a) Manufacture of the component by injection molding;
2. b) providing the embossing surfaces with a film using the hot embossing process;
3. c) Selective electroplating of the coating surfaces.

This process can be used to produce a component that has surfaces with different degrees of gloss and/or colors. Areas on the component can preferably be built up as a combination of matt and bright chrome. The method can be carried out particularly effectively and very good results can be achieved. In particular, areas with different degrees of gloss can also be created directly adjacent to one another.

The electroplating in step c always produces a metallic surface.

In the method, in the second step b, the embossed surfaces are preferably provided with a foil in a glossy chrome look using the hot embossing method, and in the third step c, the coated surfaces are galvanized in matt chrome. This results in a component that has areas with a bright chrome look and areas with a matt chrome look next to each other.

It can also be provided that in the second step b of the method, the embossed surfaces are provided with a foil in a matt chrome look in the hot stamping process and in step c the coated surfaces are galvanized in a glossy chrome look or in a matt chrome look with a different degree of gloss . This also results in a component which has areas with a bright chrome look and areas with a matt chrome look or areas with different degrees of gloss in general next to one another.

If the material of the component in the area of the embossing surfaces consists of ABS or PC, the hot embossing process can be carried out particularly effectively.

In one embodiment, the component consists of only one plastic component. This has advantages in terms of manufacturing costs and subsequent recycling.

In a further embodiment, the component consists of several plastic components. For example, there are options for backlighting or transillumination of the embossing foil if the foil is embossed on PC components, or the foil is embossed on ABS components and the PC components can be used for welding processes. Such welding processes can be used to integrate the component into a more complex assembly.

• b1) IMD Übertragung der Folie im Spritzgießverfahren;
• b2) Entformen und Aufstecken des Bauteils,

ist das Herstellen des Bauteils bei gleichzeitiger Übertragung des Dekors von der Folie möglich. Dadurch kann das Verfahren besonders zeit- und kosteneffektiv durchgeführt werden.If, instead of step b, the method includes the following steps:

• b1) IMD transfer of the foil in the injection molding process;
• b2) demolding and attaching the component,

it is possible to manufacture the component with simultaneous transfer of the decoration from the film. As a result, the method can be carried out in a particularly time- and cost-effective manner.

The film can also have or transmit a colored surface with essentially any degree of gloss, in particular also have a colored surface with a metallic appearance.

The component produced in the method preferably has areas in which the material of the component consists of ABS. It is then particularly preferably provided that in step b1 a film is transferred in high-gloss chrome decoration or color decoration and in step c only the ABS areas are coated. The decorative foil or the transferred decoration is then not galvanically coated, but remains unchanged with its decorative surface.

• 1: einen schematischen Aufbau einer Heißprägefolie für Heißprägeverfahren im Querschnitt;
• 2: ein Schema eines Verfahrens zur Herstellung eines Bauteils mit verschiedenen Oberflächen;
• 3: ein Schema eines alternativen Verfahrens;
• 4: ein schematisch dargestelltes Ausführungsbeispiel eines nach einem der Verfahren gemäß den 2 und 3 hergestellten einkomponentigen Bauteils im Querschnitt; sowie
• 5: ein schematisch dargestelltes Ausführungsbeispiel eines nach einem der Verfahren gemäß den 2 und 3 hergestellten mehrkomponentigen Bauteils im Querschnitt.

Preferred embodiments of the invention are explained in more detail below with reference to the drawing. Components that are the same or have the same function are provided with the same reference symbols across the figures. Show it:

• 1 : a schematic structure of a hot embossing foil for hot embossing methods in cross section;
• 2 : a schematic of a method for producing a component with different surfaces;
• 3 : a scheme of an alternative method;
• 4 : a schematically illustrated embodiment of one of the methods according to the 2 and 3 manufactured one-component component in cross section; as well as
• 5 : a schematically illustrated embodiment of one of the methods according to the 2 and 3 manufactured multi-component part in cross section.

In 1 a structure of a hot stamping foil 1 is shown schematically in cross section as an example. The hot stamping foil 1 has a multilayer structure. A release layer 4 is applied to a carrier film 3 in the direction of a component 2 to be embossed. A protective layer 5 adjoins the release layer 4 in the direction of the component 2 . The protective layer 5 can be designed as a protective lacquer layer and can also be colored, or the protective layer 5 can consist of one or more colored layers. The protective layer 5 is provided, for example, for media and scratch resistance of the component surface. A metalized layer 6 , preferably a chromium layer, particularly preferably a high-gloss chromium layer, adjoins the protective layer 5 further in the direction of the component 2 , which adjoins an adhesive layer 7 . The carrier film 3, the detachment layer 4, the protective layer 5 and the metalized layer 6 can be bonded to the component 2 with the adhesive layer 7. After the embossing process, the release layer 4 enables the carrier film 3 to be separated from the other layers adjoining the release layer 4 in the direction of the component 2 , ie the protective layer 5 , the metalized layer 6 and the adhesive layer 7 . Alternatively, the metallized layer 6 of the hot stamping foil 1 can have a matt chrome look. The metallized layer 6 can in particular also have metallic colors.

2 shows schematically process steps a, b and c of a method for producing the component 2 with different surfaces. In a first step a, the component 2 is produced in an injection molding process. Subsequently, in a second step b, embossing surfaces 8 of the component 2, such as structures, symbols or lettering on the component 2, are provided with a film in a hot embossing process. Preferably, the film is as under 1 described hot stamping foil 1, preferably in glossy chrome look.

In a third step c, coating surfaces 9 of component 2 are selectively electroplated. The protective lacquer of the protective layer 5 of the hot stamping foil 1 is selective in the electroplating and is not attacked and/or coated. Correspondingly, however, the coating surfaces 9, the material of which is a plastic that can be electroplated, such as ABS, are electroplated. If the hot stamping foil 1 is set in a glossy chrome look and the electroplating is carried out as a matt chrome surface, matt and glossy chrome looks can be combined on the component 2 . In addition to the chrome surface, other variants of the hot stamping foil such as colors, gloss levels or similar are also possible. In particular, in the case of the matt gloss levels, dull matt, matt and satin-matt gloss levels are also conceivable, and in the case of the glossy gloss levels, satin-gloss, glossy and high-gloss gloss levels are also conceivable. If the hot stamping foil 1 is alternatively set as a matt look, different degrees of gloss can be combined with a matt chrome look by means of electroplating and the embossing surfaces 8 . It is therefore possible to produce metallic surfaces with different degrees of gloss on the same component and in particular directly next to one another.

3 shows schematically process steps a, b1, b2 and c of an alternative method for manufacturing position of component 2 with different surfaces. Steps b1 and b2 run out instead of step b 2 away. In first steps a and b1, when the component 2 is produced in an injection molding process, the film is transferred to the component 2 in the injection molding process by an IMD (in-mold decoration) process. Here, the film is preferably transferred directly to the component as a high-gloss chrome decoration or color decoration during the injection molding process. Preferably, the foil is an under 1 described hot stamping foil 1. In a second step b2, the component 2 is removed from the mold and placed on a carrier frame known per se for electroplating. In a third step c, the coating surfaces 9 of the component 2 are selectively electroplated. In this alternative method, too, the protective layer 5 acts selectively, for example as a final color/protective lacquer layer, in the subsequent electroplating, ie only the coating surfaces 9, the material of which is ABS, for example, are coated.

In 4 is a structure of an embodiment of a one-component in its base body 2, which according to one of the 2 and 3 described method is produced, shown schematically in cross section. An embossing surface 8, in the area of which the material of the component 2 is ABS, is embossed with a foil, preferably the hot embossing foil 1. The remaining areas are coating areas 9, in the area of which the material of the component 2 also consists of ABS, and are selectively galvanically coated. The embossing surfaces 8 on the component 2 can be made of both ABS and PC.

In 5 a structure of a further exemplary embodiment of a multi-component component 2 is shown schematically in cross section. This component which according to one of the 2 and 3 method described. An embossing surface 8 on a first component 10 of the component 2, the material of which is PC, is embossed with a foil, preferably the hot embossing foil 1. Because the embossing surface 8 is made of PC, there are other options, such as backlighting the film. Coating surfaces 9 on a second component 11, the body of which consists of ABS, are selectively electroplated. Multi-component parts with such a structure and an embossing of the film on ABS are also possible if, for example, the components made of polycarbonate are only used for welding processes. The design guidelines for hot stamping components must be observed in the 4 and 5 but not taken into account.

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited 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

• DE 102017125446 A1 [0004]
• DE 102018104578 A1 [0004]
• DE 102019129952 A1 [0004]

Claims (8)

Method for producing a component (2) with different surfaces, the component (2) having embossed surfaces (8) and coated surfaces (9), with the following steps: a) producing the component (2) by injection molding; b) either providing the embossing surfaces (8) with a film in the hot embossing process; or b1) IMD transfer of the foil in the injection molding process; and b2) demolding and attaching the component (2); c) selective electroplating of the coating surfaces (9) procedure after claim 1 , characterized in that in step b or b1 the embossed surfaces (8) are provided with a foil with a first degree of gloss in the hot stamping process and in step c the coated surfaces (9) are electroplated with a surface coating with a second degree of gloss. procedure after claim 1 or 2 , characterized in that in step b the embossed surfaces (8) are provided with a foil with a matt degree of gloss in the hot embossing process and in step c the coated surfaces (9) are galvanized with high-gloss chrome or semi-gloss chrome. Method according to one of the preceding claims, characterized in that the material of the component (2) in the area of the embossing surfaces (8) consists of ABS or PC. procedure after claim 4 , characterized in that the component (2) consists of only one plastic component. procedure after claim 4 , characterized in that the component (2) is made of several plastic components (10, 11). Method according to one of the preceding claims, characterized in that the foil is a colored foil. procedure after claim 6 or 7 , wherein the component (2) is partially made of ABS, characterized in that in step b1 a film is transferred in high-gloss chrome decor or color decor and in step c only the ABS areas are electroplated.

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