DE102022107643A1 - Film, film-coated article and process for producing a film-coated article - Google Patents

Abstract

The invention relates to a film, a film-coated article and a method for producing a film-coated article. The film comprises at least one adhesion promoter layer. In addition, the film comprises a protective layer (14) and/or a carrier layer (11). The adhesion promoter layer (16) is designed for the addition of polyurethane. The film-coated article additionally comprises a polyurethane layer (P) cast onto the adhesion promoter layer (16).

Description

The invention relates to a film, a film-coated article and a method for producing a film-coated article.

Film-coated articles are known in the art as injection molded articles.

This is how it reveals DE 10221482 C1 a device for producing a molded part from a hardening injection molding material, which is decorated during injection molding by the IMD process (IMD = Inmold Decoration) with an embossing film having a carrier film and a decorative layer that can be removed from the carrier layer. The embossing foil is inserted into an open injection mold, with the decorative layer of the embossing foil facing an upper part of the mold. The injection mold is closed and liquid injection molding material is injected through an injection channel into the cavity of the injection mold, with the embossing foil nestling against the visible side of the injected molded part. The embossing foil combines its decorative layer with the injection molding material, which is removed from the injection mold after hardening. After removing the carrier film from the decorative layer, the decorated molded part is finished. Injection molded articles decorated in this way are used in particular in automotive interior parts such as door trims, strips in instrument panels, gear lever covers and center console covers, in automotive exterior parts such as door bumper strips and covers on A, B and C pillars, and in the audio and video sector in decorative strips on housings of radio and television sets, as well as in the telecommunications sector for housing shells of mobile devices such as cell phones or navigation devices.

Insert molding (Insert Molding = IM) is a combined process of hot stamping, vacuum forming and casting, especially injection molding. Compared to the IMD process, insert molding offers the possibility of deforming the film more. This is an advantage if, for example: B. highly profiled and shaped parts are required. First, a vacuum-formable, thin hot stamping foil is hot stamped on a carrier, for example an ABS foil (thickness between 200 µm and 750 µm) (ABS = acrylonitrile butadiene styrene). This hot-stamped carrier is vacuum formed under heat. The vacuum-formed layers of hot stamping foil and carrier form the so-called “insert” and are cut or punched with precise contours. The “insert” is positioned in an injection mold, the mold is filled with plastic (the “insert” is back-injected), then the decorated injection molded article is removed from the injection mold.

The flooding of objects, for example injection molded articles, using polyurethane (PU) is also known from the prior art. For this purpose, for example, an object to be coated is positioned in a tool that has two tool halves. A first tool half holds the object to be coated and a second tool half forms a slightly larger cavity than the object to be coated. PU is introduced into this gap and the object to be coated is flooded with PU. Two-component PU systems (2K-PU) are also known, which harden within seconds of mixing the components before and/or immediately during flooding. When the tool opens, the PU is already sufficiently hard.

The international patent application WO 2019/034361 A2 discloses a film-coated article manufactured by injection molding with a thermoplastic material, in which additional surface protection is applied to the film coating by flooding with polyurethane.

When producing the known film-coated article, two separate production units are required. This makes production relatively complex, time-consuming and expensive.

The invention is based on the task of eliminating the disadvantages of the prior art. In particular, a simple and inexpensive process for producing a film-coated article as well as a film suitable for this process and a corresponding film-coated article are to be provided. The film-coated article should in particular have a high quality or surface quality.

According to the invention, this object is achieved by a film according to the subject matter of claim 1, by a film-coated article according to the subject matter of claim 14 and by a method according to the subject matter of claim 26. Advantageous embodiments of the invention are specified in the dependent claims.

According to the invention, a film is claimed for coating with polyurethane, in particular for flooding with polyurethane. The film comprises at least one adhesion promoter layer. In addition, the film comprises a protective layer and/or a carrier layer. The adhesion promoter layer is designed for the addition of polyurethane.

The film preferably comprises several adhesion promoter layers, particularly preferably two or three adhesion promoter layers. The several adhesion promoter layers preferably follow one another directly.

In other words, the adhesion promoter layer is preferably made up of several layers.

The adhesion promoter layer can be designed in one or more layers. The adhesion promoter layer is particularly preferably designed in two or three layers.

To simplify language, the term “adhesion promoter layer” is used in particular in the singular in the present application. The term “adhesion promoter layer” can also be read to mean that there are actually several adhesion promoter layers or that the adhesion promoter layer is designed in multiple layers.

In the present application, the term “protective layer” is understood to mean, in particular, a layer that protects against chemical and/or mechanical influences, in particular external influences. A protective layer preferably forms an outer layer of the film and/or the transfer layer.

According to an advantageous embodiment of the invention, the film comprises at least one decorative layer. The adhesion promoter layer is arranged on the side of the at least one decorative layer facing away from the protective layer and/or the carrier layer.

According to a further advantageous embodiment of the invention, the film is a transfer film. The transfer film comprises a carrier layer and a transfer layer arranged on the carrier layer. The transfer layer includes the at least one decorative layer, the protective layer and the adhesion promoter layer. The carrier layer is arranged on the side of the at least one decorative layer facing away from the adhesion promoter layer. The carrier layer includes the carrier layer.

The carrier layer preferably has a layer thickness of between 10 μm to 100 μm, preferably from 23 μm to 75 μm.

Preferably, the carrier layer can be designed as an endless film or as a single sheet of film or as a sheet of film. Such a film sheet or such a film sheet can be obtained from a previously existing endless film by separating it.

If the film is designed as a transfer film, the carrier layer is preferably removed again during the production of the film-coated article.

The protective layer can be formed from a protective varnish. The protective layer preferably has a layer thickness of between 0.1 μm to 20 μm, preferably from 1 μm to 3 μm.

According to a further advantageous embodiment of the invention, the carrier layer additionally comprises a release layer. The release layer preferably has a layer thickness of 0.1 nm to 50 nm. The release layer is arranged on the side of the carrier layer facing the transfer layer. The release layer preferably comprises or consists of at least one wax. The release layer may additionally or alternatively comprise or consist of one or more polymers. After the carrier layer has been removed from the film, the release layer can be arranged completely or partially on the transfer layer and/or completely or partially arranged on the carrier layer.

According to the invention, the film-coated article comprises a film according to the invention, or the transfer layer of the film according to the invention designed as a transfer film, and a polyurethane layer cast onto the adhesion promoter layer. Preferably, the polyurethane layer is cast or flooded by flooding the film with polyurethane.

The polyurethane layer can be a solvent-containing and polyurethane-containing composition and in particular has several components, selected individually or in combination from polyol, isocyanate, catalyst, release agent, additive.

The film-coated article is preferably dimensionally stable.

1. a) Bereitstellen einer erfindungsgemäßen Folie,
2. b) Bereitstellen einer Formkavität,
3. c) Einbringen der Folie in die Formkavität,
4. d) Bereitstellen eines Polyurethan bildenden Gemischs an einem Mischkopf,
5. e) Injizieren des Gemischs in die Formkavität, so dass die Folie an ihrer durch die Haftvermittlerschicht begrenzten Seite vom Gemisch zumindest bereichsweise überflutet und/oder übergossen wird,
6. f) Erhalt des folienbeschichteten Artikels.

According to the invention, the method for producing a film-coated article, preferably for producing the film-coated article according to the invention, comprises the following steps, in particular in the following order:

1. a) providing a film according to the invention,
2. b) providing a mold cavity,
3. c) introducing the film into the mold cavity,
4. d) providing a polyurethane-forming mixture at a mixing head,
5. e) injecting the mixture into the mold cavity so that the film is at least partially flooded and/or covered by the mixture on its side delimited by the adhesion promoter layer,
6. f) Receipt of the foil coated item.

In the present application, the term “area” is understood to mean, in particular, a defined area of a layer or film or layer in the plane formed by the respective layer and/or film and/or layer. For example, the polyurethane layer has at least a first region and at least a second region, with each of the two or more regions each occupying a defined area in the plane formed by the polyurethane layer. Accordingly, the adhesion promoter layer can have at least a first region and at least a second region, with each of the two or more regions each occupying a defined area in the plane formed by the adhesion promoter layer. Accordingly, the at least one decorative layer can have at least a first region and at least a second region, with each of the two or more regions each occupying a defined area in the plane formed by the at least one decorative layer. The respective layers, films or layers preferably extend parallel to one another. In particular, the adhesion promoter layer preferably extends parallel to the at least one decorative layer. The adhesion promoter layer preferably extends parallel to the polyurethane layer.

The term “area-wise” is preferably understood in the present application in the manner mentioned above for the term “area”.

In the present application, the areal extent of a layer or film or layer is preferably understood to mean the extent of the plane formed by the respective layer and/or film and/or layer. The areal extent of the respective layer and/or film and/or layer includes in particular a longitudinal and/or transverse extent of the respective layer, film and/or layer.

The term “mold cavity” can be understood in two different ways in the present application. A mold cavity may be formed as a tool or formed in a tool to form a cavity or cavity corresponding to a desired shape of the film-coated article. This cavity is filled by flooding or flooding with the polyurethane-forming mixture. After crosslinking the polyurethane, the desired shape of the film-coated article is formed in a mechanically stable manner and the film-coated article can be removed from the cavity. If the term “mold cavity” is to be understood specifically in one of the two ways, the term “tool forming the mold cavity” or “cavity formed by the mold cavity” is used, for example.

The term “hardening” or “hardening” is preferably understood to mean the transition from a liquid or plastically deformable state to a solid state of a substance or mixture of substances under standard conditions (temperature: 25 ° C, pressure: 1013 mbar).

The process of hardening or hardening can preferably be carried out by cooling, ie by reducing the temperature below the freezing point and/or below the glass transition temperature of a substance or mixture of substances and/or by physical drying, ie by removing at least one liquid Component, for example solvent, and / or by chemical reaction, for example by chain polymerization, polyaddition and / or polycondensation.

The term “polymeric component and/or precursor thereof” is preferably understood to mean a substance or mixture of substances which has at least one, preferably organic, polymer and/or at least one precursor thereof.

The term “polymer” is preferably understood to mean a substance that is made up of preferably at least 10 structural units, so-called constitutional repeating units, which can be the same or different from one another and, by chemical reaction, preferably chain polymerization, polyaddition and/or polycondensation, the at least one form organic polymer. Preferably, a constitutional repeating unit (KRE) is the smallest repeating group of atoms within a polymer.

A polymer within the meaning of the invention can be unbranched or branched.

The term “precursor of a polymeric component” is preferably understood to mean monomers or monomer mixtures as well as oligomers and mixtures thereof, which can each combine to form the corresponding unbranched or branched polymer, preferably by chemical reaction, more preferably chain polymerization, polyaddition and/or polycondensation.

The term “reactive functional group” is preferably understood to mean a functional group that can participate in the formation of the corresponding unbranched or branched polymer through chemical reaction, more preferably chain polymerization, polyaddition and/or polycondensation.

Monomers or monomer mixtures in the sense of the invention are preferably low molecular weight, reactive molecules or mixtures of reactive molecules, which can each combine to form the corresponding unbranched or branched polymer by chemical reaction, more preferably chain polymerization, polyaddition and / or polycondensation, and thereby form a constitutional repeating unit of the Form polymer. Preferably, a reactive molecule, for example monomer, oligomer and optionally polymer, has at least one reactive functional group.

The term “oligomer” is preferably understood to mean a substance that is made up of preferably 2 to 9 constitutional repeating units, which can be the same or different from one another and preferably form into an unbranched one by chemical reaction, more preferably chain polymerization, polyaddition and/or polycondensation or branched polymer.

The term “cured polymeric component” is preferably understood to mean a polymeric substance or a mixture of polymeric substances which has a solid state under standard conditions (temperature: 25°C, pressure: 1013 mbar) and is preferably not plastically deformable.

In step c), the film is preferably introduced into the mold cavity in such a way that the adhesion promoter layer faces the cavity formed by the mold cavity, in particular that the adhesion promoter layer directly adjoins the cavity formed by the mold cavity.

In step d), components of the polyurethane-forming mixture are preferably mixed with one another at the mixing head. The mixture provided in step d) is preferably flowable. The mixture can be a solvent-containing and polyurethane-containing composition. The components preferably include at least one polyol and one isocyanate.

The mixture provided in step d) is formed in particular from a polyol and an isocyanate and preferably contains further chemical additives.

In other words, the polyurethane-forming mixture can be a solvent-containing and polyurethane-containing composition and in particular have several components, selected individually or in combination from polyol, isocyanate, catalyst, release agent, additive.

Preferably, a chemical reaction starts when the mixture is provided in step d). The chemical reaction is preferably an exothermic reaction. Furthermore, the chemical reaction takes place preferably a crosslinking reaction in which molecular polymer chains are preferably formed. Cross-links preferably form between the polymer chains. Polyurethane is preferably formed in the crosslinking reaction. Preferably, step d) takes place immediately before step e), that is, the components forming the mixture are mixed with one another immediately before injection into the mold cavity.

In particular, the chemical reaction starts by mixing the two polyurethane-forming components, polyol and isocyanate. A crosslinking reaction preferably takes place to form the molecular polymer chains. The crosslinking reaction is preferably exothermic. Preferably, the polyol and isocyanate components remain separated before the mixing process and are only brought together immediately before injection into the mold cavity according to step e). This allows a premature chemical reaction to be avoided. This advantageously allows the rheological flow properties of the mixture to be maintained for injection into the mold cavity in step e).

Preferably, the mixture is thin when injected into the mold cavity in step e). Preferably, the viscosity at the start of injection into the mold cavity according to step e) is in a range between 100 mPas to 300 mPas, preferably 120 mPas to 200 mPas, at a temperature of the mixture of 40 ° C to 100 ° C, preferably at a temperature of the mixture from 50°C to 75°C, particularly preferably at a temperature of the mixture from 60°C to 70°C.

Preferably, the viscosity of the mixture and/or the polyurethane layer that forms increases as the chemical crosslinking reaction progresses until the end of the chemical reaction. Preferably, the mixture and/or the polyurethane layer that forms hardens as the chemical crosslinking reaction progresses. Preferably, a fully cured polyurethane layer is formed at the end of the chemical reaction.

The mixture provided in step d) preferably has reactive groups. Particularly preferably, the mixture provided in step d) has at least two reactive groups, preferably three or more reactive groups.

Preferably, the respective components of the mixture each have at least two reactive groups, preferably three or more reactive groups. In particular, the polyol preferably has at least two reactive groups, preferably three or more reactive groups. Furthermore, the isocyanate preferably has at least two reactive groups, preferably three or more reactive groups.

The reactive groups can preferably be free reactive groups and/or capped reactive groups which release the corresponding reactive group again at a temperature in the range from 30 ° C to 180 ° C.

The presence of three or more reactive groups preferably enables the formation of crosslinks to form the polyurethane layer.

Preferably, the adhesion promoter layer is immediately flooded and/or poured over by the mixture in step e). The adhesion promoter layer can only be flooded and/or poured over in certain areas.

In step e), the film is preferably flooded and/or poured over the entire surface of the film on its side delimited by the adhesion promoter layer.

The term “flooding” in the sense of the present application can mean flooding, underflooding, flooding and/or flooding. Different orientations of the film in the mold cavity are therefore possible. The film is at least partially covered by the mixture on its side delimited by the adhesion promoter layer. To simplify language, the term “flooding” will be used in particular below. The meanings mentioned above can be read along.

The polyurethane layer is preferably applied to the adhesion promoter layer in step e) by at least partially flooding and/or pouring over the film on its side delimited by the adhesion promoter layer with at least one solvent-containing, preferably flowable, polyurethane-containing composition and subsequent curing.

The term “flowable polyurethane-containing composition” is preferably understood to mean a polyurethane-containing composition which preferably has a dynamic viscosity in the range from 2 mPas to 1500 mPas, preferably from 10 mPas to 1000 mPas, more preferably from 10 mPas, at a temperature of 25 ° C to 500 mPas, preferably determined according to in DIN EN ISO 3219:1994-10 described method, for example using a HAAKE Viscotester® VT550, more preferably using a cylinder measuring device NV and a measuring cup NV.

As described above, the at least one solvent-containing, preferably flowable, polyurethane-containing composition preferably also has free, reactive groups, preferably free isocyanate groups or free groups reactive towards isocyanate groups, and/or corresponding capped, reactive groups which are at a temperature release the corresponding reactive group again in a range from 30 ° C to 180 ° C.

During the curing, preferably complete curing, of the adhesion promoter layer, which has not yet been completely cured at least in some areas, and/or the polyurethane layer applied thereto, free isocyanate groups contained in the adhesion promoter layer can therefore, for example, be mixed with free groups which are reactive towards isocyanate groups and are used for production react with the solvent-containing, preferably flowable, polyurethane-containing composition used in the polyurethane layer.

This preferably significantly improves the adhesion of the polyurethane layer to the adhesion promoter layer after curing according to the method according to the invention, preferably according to step h).

Further preferably, the at least one solvent-containing, preferably flowable, polyurethane-containing composition is selected from the group consisting of polyurethane-containing dispersions, polyurethane-containing resins, polyurethane solutions, compositions of polyurethane precursors (2K-PUR systems) and mixtures thereof , which preferably also contain free, reactive groups, preferably isocyanate groups or groups reactive towards isocyanate groups and/or corresponding capped, reactive groups, which at a temperature from a range of 30 ° C to 180 ° C the corresponding reactive group again release, have.

For example, the at least one solvent-containing, preferably flowable, polyurethane-containing composition as described above, as compositions of polyurethane precursors (2K-PUR systems), in particular as a mixture of at least one of the aforementioned compounds with two or more isocyanate groups and at least one of The aforementioned compounds, which have two or more groups reactive towards isocyanate groups, are applied to the adhesion promoter layer, preferably either the at least one compound having two or more isocyanate groups or the at least one compound which has two or more groups reactive towards isocyanate groups Groups are used in molar excess.

For example, polyurethane-containing dispersions, polyurethane-containing resins and/or polyurethane solutions, the aforementioned prepolymers with free, isocyanate-reactive groups, which can be crosslinked or uncrosslinked, the aforementioned prepolymers with capped, isocyanate-reactive groups, which may be crosslinked or uncrosslinked, or mixtures thereof and/or aforementioned isocyanate prepolymers, which may be crosslinked or uncrosslinked, aforementioned blocked isocyanate prepolymers, which may be crosslinked or uncrosslinked, or mixtures thereof.

More preferably, the at least one solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer has at least one organic solvent, for example ethyl acetate, 2-butanone, acetone, toluene, xylenes or mixtures thereof.

Further preferably, at least one solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer, which comprises the aforementioned isocyanate prepolymers, is anhydrous. On the other hand, the aforementioned blocked isocyanate prepolymers can be present as an aqueous dispersion.

Further preferably, a polyurethane layer used to produce a polyurethane layer has at least one solvent-containing, preferably flowable, polyurethane-containing composition, which contains the aforementioned prepolymers with free groups that are reactive towards isocyanate groups and which can be crosslinked or uncrosslinked nen, aforementioned prepolymers with capped, isocyanate-reactive groups, which can be crosslinked or uncrosslinked, or mixtures thereof, water and / or at least one organic solvent, for example ethyl acetate, 2-butanone, acetone, toluene, xylenes or mixtures thereof , on.

When using 2K PUR systems, the polyurethane precursors, for example polyol-containing and isocyanate-containing components, are preferably stored separately and are only brought together in the mixing head when required. The heat of reaction generated during the reaction of the polyurethane precursors preferably results in heating to a temperature of 60°C to 180°C, preferably 80°C to 120°C.

The surfaces or walls of the mold cavity can also preferably have a temperature in a range from 40 ° C to 160 ° C, preferably in a range from 80 ° C to 120 ° C.

Preferably, in one embodiment, the polyurethane layer can be applied to the at least one adhesion promoter layer in step e) by open flooding or flooding in a casting tool.

During open flooding, the surface tension of the at least one solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer is preferably used in the outer edge area of the component to be flooded, the polyurethane layer being flooded onto the component without a shape that gives the tool contour. Hardening is preferably carried out by appropriate storage, preferably for a period of 2 s to 60 s, of the flooded component at a temperature in the range from 20 ° C to 100 ° C.

When flooding in a casting tool, the entire process takes place in a closed tool, which defines the area to be flooded as a cavity.

The filling of the at least one solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer is preferably carried out via a mixing head, preferably at a pressure of less than 10 bar.

A first curing phase can be initiated by applying heat to the mold, for example at a temperature of 60 ° C to 160 ° C, preferably for a period of 60 s to 600 s.

After removing the casting tool, the component is preferably stored for residual curing for approximately 24 hours before further use.

During the curing, preferably complete curing, of the adhesion promoter layer, which has not yet been completely cured at least in some areas, and the polyurethane layer applied thereon, free isocyanate groups contained in the adhesion promoter layer can, for example, be mixed with free groups which are reactive towards isocyanate groups and which are used to produce the polyurethane layer react with a solvent-containing, preferably flowable, polyurethane-containing composition.

A layer is preferably referred to as “cured” in the sense of the present invention if the polymer components capable of crosslinking, preferably binders, for example free isocyanate groups and/or free groups reactive towards isocyanate groups, of the respective layer are more than 95% % have networking.

Preferably, before and/or during and/or after the application of the polyurethane layer in step e), the polyurethane layer can be modified and/or structured, preferably by inserting/placing particles on the adhesion promoter layer after step c) and/or by using tool structures during the application in step e) and/or by subsequent processing of the polyurethane layer using process steps individually or in combination selected from laser processing, overprinting, hot stamping, cold stamping, blind stamping, mechanical processing.

In particular by means of laser processing and/or by mechanical processing and/or by using tool structures, it is possible to produce exposed relief structures in the polyurethane layer with a minimum line thickness and/or a minimum laserable spot diameter of 5 µm to 150 µm, preferably 10 µm up to 100 µm. This means the finest details, especially for motifs and/or alphanumeric information can be produced. It is also possible to combine such fine structures with coarser, macroscopic structures, either in a laterally adjacent combination or as a superposition of a coarse structure on a fine structure. This can be achieved in particular by combining several of the above-mentioned process steps, for example to produce rough structures with dimensions of the individual structural elements of 0.5 mm to 50 mm in combination with laser processing and/or mechanical processing adjacent thereto and/or superimposed with a minimum line thickness and/or a minimum laserable spot diameter of 5 µm to 150 µm, preferably from 10 µm to 100 µm. However, it is also possible that coarse structures and fine structures exist together as a tool structure and are thus molded in the polyurethane layer. The depth of the relief structures can be between 1 µm and the maximum wall thickness of the polyurethane layer, in particular between 1 µm and 30 mm, preferably between 1 µm and 15 mm.

Preferably, a modification of the polyurethane layer and/or the adhesion promoter layer can take place in register with design features and/or motifs already present in the transfer layer and/or in the decorative layer. For example, a surface structure can be arranged in register with a wood grain, in particular of the decorative layer, and/or a tactile and/or optically perceptible structure can be arranged in register with a motif, in particular in the decorative layer. The structures mentioned can, for example, be produced by process steps selected individually or multiple times or in combination from the use of tool structures during application in step e), laser processing, overprinting, overembossing, mechanical processing.

Registered accuracy means a positional accuracy of two or more layers, elements, areas and/or layers relative to one another. The register accuracy should be within a specified tolerance and be as low as possible. At the same time, the register accuracy of several layers, elements, areas and/or layers relative to one another is an important feature in order to increase process reliability and/or product quality, but also security against counterfeiting. The precise positioning can be carried out in particular by means of register marks that can be detected by sensors, preferably optically. These register marks can either represent special separate layers, elements, areas and/or layers or can themselves be part of the layers, elements, areas and/or layers to be positioned.

A polyurethane layer produced by the method according to the invention preferably has transparent or reduced translucent properties.

• g) Entnehmen des folienbeschichteten Artikels aus der Formkavität.

The method preferably has the further following step or does step f) comprise the further following sub-step:

• g) Removing the film-coated article from the mold cavity.

The method according to the invention can advantageously produce components without the use of thermoplastic materials and without the use of an injection molding process with the manufacturing unit required for this. This means that both investment costs and operating costs can be reduced. Furthermore, there is no need to switch between the separate production units for the injection molding process and flooding with polyurethane. This makes the method according to the invention simple and quick compared to the prior art. This means that foil-coated items can be manufactured particularly cost-effectively.

Furthermore, thermoplastic materials shrink when they cool. This means that special geometries cannot be implemented with thermoplastic materials. In particular, with thermoplastic materials there is a risk that shrinkage will cause geometric distortions and/or sink marks and/or voids. The term “blowhole” refers to gas-free cavities inside a molded part. Thermoplastic materials also have a high viscosity. Therefore, thermoplastic materials cannot precisely follow complicated geometries when injected. In contrast, polyurethane is not thermoplastic, but a reaction product with an initially very low viscosity. Polyurethane can therefore mold complicated geometries. The method according to the invention can therefore advantageously be used particularly flexibly with regard to special geometry specifications. Film-coated items with complicated geometries can be produced. These geometries can include, for example, abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, tips and/or arches. In particular, the film-coated articles can have particularly thick wall thicknesses and/or abrupt changes in wall thickness. Compared to the injection molding process with thermoplastic materials, very small and/or very few geometric distortions occur Sink marks and/or voids. The film-coated articles according to the invention therefore advantageously have a high optical quality.

In addition, when using both thermoplastic materials and polyurethane in the production of a specific component, the different shrinkage properties of the different materials lead to difficulties in terms of tool technology and/or process technology. Such difficulties can be avoided by using only polyurethane.

Advantageously, lower temperatures are required to form the polyurethane layer than when using thermoplastic materials in the injection molding process. Furthermore, the mixture introduced into the mold cavity in step e) advantageously heats up through an exothermic reaction. Depending on the current phase of the exothermic reaction, it is advantageous to temper the mixture, in particular to heat it up or cool it down, so that the exothermic reaction takes place at a process temperature that remains approximately the same. At the beginning of the exothermic reaction, the mixture is therefore heated up or warmed up by the then prevailing tool temperature, which is higher than the mixture temperature, and as the exothermic reaction progresses over time with increasing thermal energy being released, the tool temperature, which is kept largely constant, then leads to a cooling of the tool by the reaction of the heating mixture, because the tool temperature is then temporarily below the mixture temperature, which is influenced by the exothermic reaction. The tool temperature is largely constant during the exothermic reaction.

Advantageously, lower mold cavity pressures are also required than in the injection molding process of thermoplastic materials.

The decoration process using a transfer film, i.e. using paint transfer technology, enables a significantly greater variety of designs compared to other decoration processes such as wet painting, so that individual images, technical designs, haptic surfaces and many other design variants can be created. By decorating using transfer film, it is possible to forego one or more subsequent process steps following the decoration, such as separate overprinting or lasering of lettering, symbols, etc. This means that costs for decoration can advantageously be saved. A transfer film could already have all of these decorative elements such as decorative prints, negative decorations such as lettering or symbols, etc. in the layer structure of the transfer layer.

Further advantageous embodiments of the invention are described in the subclaims.

According to a further advantageous embodiment of the invention, the film is a label or a print mold design sheet (PMD sheet) or an insert.

The embodiments of the invention as a label, as a PMD sheet and insert are usually products made of or with a carrier layer. The carrier layer can also be called backing material. The carrier layer can, for example, consist of materials selected individually or in combination from ABS, PC, PC-ABS, PMMA, TPE (TPE = thermoplastic elastomer). A decoration and/or information can then be applied to the front and/or back of the carrier layer in one or more layers using processes such as printing processes, casting processes, spraying processes, laser processes.

The carrier layer for a label is usually in the form of sheet material. The decoration and/or information can be applied to the carrier layer on a label, for example via direct printing using screen printing, flexographic printing, gravure printing, digital printing, as well as via a lamination process and/or via the application of a transfer film. A label is usually a two-dimensional printed sheet that is connected to the plastic material during injection molding, for example. The layer thickness of the label is preferably between 20 µm and 1000 µm, preferably from 100 µm to 750 µm.

With PMD technology, the carrier layer is usually in the form of a sheet material. The decoration and/or information is applied to the carrier layer in particular via direct printing using screen printing, flexographic printing, gravure printing, digital printing. Transparent “backing materials” (support layers) are preferably used in the PMD process. Due to this fact, it is also possible, among other things, to coat the sheet on the front and back. The coated carrier layer is preferably preformed in a forming process, then trimmed and/or lasered on the outer contours in order to obtain a clean contour and then, for example, in an injection molding tool connected to a plastic material, in particular back-injected. The layer thickness of the PMD sheet is preferably between 20 µm and 1000 µm, preferably from 100 µm to 750 µm.

In insert molding technology, the carrier layer is preferably in the form of a roll material. The decoration and/or information is applied to the “backing material” (support layer) in particular via the application of a transfer film and/or via direct printing using screen printing, flexographic printing, gravure printing, digital printing. The coated carrier layer is fed to a deep-drawing tool as a roll product and preformed in a forming process, then separated into individual panels, then trimmed and/or lasered on the outer contours in order to obtain a clean contour and then z. B. connected in an injection molding tool with a plastic material, in particular back-injected. The layer thickness of the label is preferably between 20 µm and 1000 µm, preferably from 100 µm to 750 µm.

The carrier layer is preferably formed from a material selected from the group consisting of polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), polycarbonate (PC), acrylonitrile butadiene styrene polycarbonate (ABS-PC), polypropylene (PP). and mixtures thereof.

If the film is designed as a label, PMD sheet or insert, the carrier layer can also fulfill the role of a protective layer. The carrier layer can form a protective layer on the back of the film-coated article, that is, a protective layer on the side of the film-coated article facing away from the polyurethane layer.

According to a further advantageous embodiment of the invention, the adhesion promoter layer is preferably applied directly or indirectly to the decorative layer over the entire surface and/or in certain areas by means of a type of printing, individually or in combination, selected from screen printing, flexographic printing, gravure printing, inkjet printing.

Particularly preferably, the adhesion promoter layer is applied directly or indirectly to the decorative layer over the entire surface and/or in certain areas using gravure printing.

According to a further advantageous embodiment of the invention, the adhesion promoter layer has at least one binder which is selected from the group consisting of polyurethane resins, polyurethane dispersions, acrylic resins, methacrylic resins, phenolic resins, epoxy resins, polyureas, melamine resins, aminoplasts, polyester resins, alkyd resins, polyamide resins, vinyl ester resins and Mixtures thereof, preferably polyurethane resins, polyurethane dispersions, phenolic resins, epoxy resins, polyureas, melamine resins, aminoplasts, polyester resins, alkyd resins, polyamide resins and mixtures thereof.

More preferably, the adhesion promoter layer is not yet completely hardened, at least in some areas, and the adhesion promoter layer comprises the at least one binder which contains free isocyanate groups and/or free groups reactive towards isocyanate groups, preferably amino groups and/or hydroxy groups, and/or each has correspondingly masked analogues thereof, in a proportion of at least 15% by weight (% by weight = percent by weight), preferably from a range of 20% by weight to 90% by weight, in each case based on the total weight of the layer.

The following concrete example can be given in this regard: The adhesion promoter layer is, for example, a mixture of acrylate resin with free OH and/or acid groups and at least one suitable crosslinking agent with a reactive group, for example a polyfunctional aziridine (PFA), or polyisocyanate. This adhesion promoter layer can be in a not completely hardened state and can enter into a chemical reaction under the reactive conditions during flooding with, for example, polyol or polyisocyanates.

According to a further advantageous embodiment of the invention, the adhesion promoter layer is designed such that a chemical bond can be formed with the polyurethane to be deposited through the adhesion promoter layer.

The adhesion promoter layer preferably has free, reactive groups and/or capped, reactive groups which release the corresponding reactive group again at a temperature in the range from 30 ° C to 180 ° C. The term “free, reactive group” is preferably understood to mean a functional group that can form a covalent bond during a polymerization reaction.

Suitable reactive groups are preferably isocyanate groups (-NCO) and/or groups reactive toward isocyanate groups, preferably amino groups (-NH ₂ ) and/or hydroxy groups (-OH). Preferably, capped, reactive groups, which can also be referred to as blocked, reactive groups, are addition compounds of blocking agents and the aforementioned reactive groups, which are present at a temperature in the range from 30 ° C to 180 ° C, preferably at a temperature in the range of 40 ° C to 160 ° C, more preferably at a temperature in a range from 60 ° C to 140 ° C, release the corresponding reactive group again.

Capped, reactive groups are preferably capped isocyanate groups which release the corresponding reactive group, preferably isocyanate group, again at a temperature in the range from 30 ° C to 180 ° C.

For example, the adhesion promoter layer can contain free, reactive isocyanate groups. Free, reactive isocyanate groups can react in the presence of water, for example atmospheric moisture, to form a carbamic acid, which can undergo further polymerization reactions.

According to a further advantageous embodiment of the invention, the adhesion promoter layer is not yet completely hardened, at least in some areas.

A layer is referred to as “not yet fully cured” in the sense of the present invention if at most 90%, preferably at most 95%, of the functional groups capable of crosslinking of polymers or polymer mixtures contained in the at least partially not yet fully cured layer, preferably Binders or binder mixtures that have crosslinking.

The adhesion promoter layer, which has not yet been completely cured at least in some areas, is preferably cured together with the polyurethane layer applied thereon, preferably completely cured. The polyurethane layer is preferably bonded to the adhesion promoter layer. The composite of the film and the polyurethane layer is preferably dimensionally stable.

More preferably, the adhesion promoter layer does not have any free, ethylenically unsaturated groups.

During the curing, preferably complete curing, of the adhesion promoter layer, which has not yet been completely cured at least in some areas, and/or the polyurethane layer applied thereto, free isocyanate groups contained in the adhesion promoter layer can therefore, for example, be mixed with free groups which are reactive towards isocyanate groups and are used for production react with the solvent-containing, preferably flowable, polyurethane-containing composition used in the polyurethane layer.

If the adhesion promoter layer, which has not yet been completely cured at least in some areas, has, for example, free groups that are reactive towards isocyanate groups, these can react accordingly with free isocyanate groups of the solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer.

This preferably significantly improves the adhesion of the polyurethane layer to the adhesion promoter layer after curing in step h) described below for the method according to the invention.

If the adhesion promoter layer, which has not yet completely hardened at least in some areas, has, for example, masked, reactive groups, these release the corresponding reactive groups again in the process according to the invention, preferably in step e), preferably at a temperature in the range from 30 ° C to 180 ° C. Subsequently, for example, released isocyanate groups contained in the adhesion promoter layer can also react with free, isocyanate-reactive groups of the solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer.

This preferably significantly improves the adhesion of the polyurethane layer to the adhesion promoter layer, with the storage stability of a film or transfer film according to the invention preferably also being increased by the presence of capped, reactive groups, for example capped isocyanate groups, in the at least partially not yet completely cured adhesion promoter layer can.

Preferably, the polyurethane layer adheres to the adhesion promoter layer after curing with an adhesive force determined according to in DIN EN ISO 4624: 2016-08 described method, preferably with a PosiTest® AT series adhesive tensile testing device from DeFelsko Corporation (Ogdensburg, NY, USA) using a 20 mm test stamp, from a range of 2.5 MPa to 5 MPa, in particular from 2.5 MPa to 10 MPa, liable.

Therefore, after curing, the polyurethane layer cannot be removed from a film-coated object according to the invention without damaging the film or the transfer layer of the transfer film.

Furthermore, in particular by applying the polyurethane layer in step e) of the method according to the invention by flooding and/or pouring over the film at least in some areas, the mixture with a solvent-containing, preferably flowable, polyurethane-containing composition is formed on its side delimited by the adhesion promoter layer, which has not yet been completely hardened at least in some areas simple process for producing the polyurethane layer is provided.

Flooding and/or pouring preferably allows the use of a large number of different solvent-containing, preferably flowable, polyurethane-containing compositions, which, for example, are specific to the composition of the adhesion promoter layer, which has not yet been fully cured at least in some areas, and/or to the properties to be fulfilled by the polyurethane layer, for example in terms of optical properties, mechanical properties and/or chemical resistance.

As explained above, the adhesion promoter layer, which has not yet completely hardened at least in some areas, preferably has free, reactive groups and/or capped, reactive groups which release the corresponding reactive group again at a temperature in the range from 30 ° C to 180 ° C.

Methods for determining the content of free amino groups, hydroxy groups and/or isocyanate groups in raw materials for the production of plastics are known in the prior art.

Suitable methods for determining the content of free hydroxy groups are, for example, in ASTM E1899-16 (“Standard Test Method for Hydroxyl Groups Using Reaction with p-Toluenesulfonyl Isocyanate (TSI) and Potentiometric Titration with Tetrabutylammonium Hydroxide”, 2016, ASTM International, West Conshohocken, PA, USA), ASTM D4273-11 (“Standard Test Method for Polyurethane Raw Materials: Determination of Primary Hydroxyl Content of Polyether Polyols”, 2011, ASTM International, West Conshohocken, PA, USA), DIN 53240-3:2016-03 (“Binders for coating materials - Determination of hydroxyl number - Part 3: Rapid procedure”, issue date: 2016-03), ISO 14900:2017-03 (“Plastics - Polyols for use in the production of polyurethane - Determination of hydroxyl number”, issue date: 2017-03) or ASTM D4274-16 (“Standard Test Methods for Testing Polyurethane Raw Materials: Determination of Hydroxyl Numbers of Polyols”, 2016, ASTM International, West Conshohocken, PA, USA).

Suitable methods for determining the content of free isocyanate groups are described, for example, in DIN EN ISO 14896:2009-07 (“Plastics - Polyurethane raw materials - Determination of the isocyanate content”, edition date 2009-07) or ASTM D2572-97(2010) (“Standard Test Method for Isocyanate Groups in Urethane Materials or Prepolymers”, 2010, ASTM International, West Conshohocken, PA, USA ).

A suitable method for determining the content of free amino groups is, for example, in ASTM D2074-07 (2013) (“Standard Test Methods for Total, Primary, Secondary, and Tertiary Amine Values of Fatty Amines by Alternative Indicator Method”, 2013, ASTM International, West Conshohocken, PA, USA).

Free, reactive groups, preferably free isocyanate groups and/or free groups reactive towards isocyanate groups, preferably amino groups and/or hydroxy groups, or correspondingly masked analogues of the adhesion promoter layer which has not yet been completely cured at least in some areas are preferably present in the layer contained monomers, prepolymers and / or mixtures thereof bound.

Further preferred are free, reactive groups, preferably free isocyanate groups and/or free groups reactive towards isocyanate groups, preferably amino groups and/or hydroxy groups, and/or correspondingly masked analogues thereof of the adhesion promoter layer which has not yet been completely cured at least in some areas bound to binders, crosslinking agents and/or mixtures thereof contained in the adhesion promoter layer.

The adhesion promoter layer, which has not yet completely hardened at least in some areas, preferably comprises at least one binder which has free isocyanate groups and/or free groups reactive towards isocyanate groups, preferably amino groups and/or hydroxy groups, and/or correspondingly masked analogues thereof .

Suitable binders are preferably from the group consisting of polyurethane resins, polyurethane dispersions, phenolic resins, epoxy resins, polyureas, melamine resins, aminoplasts, polyester resins, alkyd resins, polyamide resins and mixtures thereof, more preferably polyurethane resins, polyurethane dispersions, phenolic resins, polyureas, melamine resins, aminoplasts, polyester resins, alkyd resins , polyamide resins and mixtures thereof.

More preferably, the at least one binder that is contained in the adhesion promoter layer, which has not yet been completely cured at least in some areas, does not have any free, ethylenically unsaturated groups.

In a preferred embodiment, the adhesion promoter layer, which has not yet been fully cured at least in some areas, comprises at least one aqueous, uncrosslinked or crosslinked polyurethane dispersion, which preferably has free groups that are reactive towards isocyanate groups, more preferably amino groups and/or hydroxy groups, or at least one uncrosslinked or crosslinked polyurethane resin, which preferably has isocyanate groups and/or capped analogues thereof or groups reactive towards isocyanate groups, more preferably amino groups and/or hydroxyl groups, and/or correspondingly capped analogues thereof , or consists of it.

Capped, reactive groups can also be referred to as capped analogues of the aforementioned free groups that are reactive towards isocyanate groups or capped analogues of the aforementioned isocyanate groups.

Suitable compounds with capped, reactive groups are known in the art and include, for example, isocyanate groups that have been blocked (capped) by the addition of organic compounds with acidic H atoms, so-called blocking agents.

Suitable blocking agents with acidic H atoms are, for example, dialkyl malonate with alkyl groups, which can each be the same or different from one another and have 1 to 4 carbon atoms, alkyl acetoacetate with an alkyl group that has 1 to 4 carbon atoms, phenol derivatives, secondary amines, lactams, pyrazoles , oximes or mixtures thereof.

Examples of suitable dialkyl malonate are dimethyl malonate, diethyl malonate, diisopropyl malonate, di-tert-butyl malonate and mixtures thereof.

Examples of suitable alkyl acetoacetates are methyl acetoacetate, ethyl acetoacetate, isopropyl acetoacetate, tert-butyl acetoacetate and mixtures thereof.

Examples of suitable phenol derivatives are phenol, cresols, nonylphenols and mixtures thereof.

Examples of suitable secondary amines are N-isopropyl-N-methylamine, N-isopropyl-N-ethylamine, N-tert-butyl-N-methylamine, N-tert-butyl-N-isopropylamine, N,N-diisopropylamine, N-tert -Butyl-N-benzylamine (BEBA), N,N-dicyclohexylamine and mixtures thereof.

An example of suitable lactams is ε-caprolactam. An example of suitable pyrazole is 3,5-dimethylpyrazole (DMP).

Examples of suitable oximes are aromatic aldoximes, aliphatic, cycloaliphatic or aromatic ketoximes and mixtures thereof. Examples of suitable aromatic aldoximes are benzaldoxime, tolylaldoxime, terephthaldialdoxime, isophthaldialdoxime and mixtures thereof. Suitable ketoximes are included for example acetone oxime, methyl ethyl ketoxime, methyl propyl ketoxime, 2-butanone oxime, methyl isobutyl ketoxime, 3-methyl-2-butanone oxime, diisobutyl ketoxime, 2-pentanone oxime, 3-pentanone oxime, 4-methyl-2-pentanone oxime, 2-heptanone oxime, 3-heptanone oxime, ethylhexyl ketoxime, cyclohexanone oxime , acetophenone oxime, benzophenone oxime and mixtures thereof.

Preferably, the aforementioned compounds with capped, reactive groups can be used together with at least one catalyst. All known compounds that can catalyze isocyanate reactions can be used as catalysts. Examples of these are titanates such as tetrabutyl titanate and tetrapropyl titanate, tin carboxylates such as dibutyltin dilaulate (DBTL), dibutyltin diacetate, tin octoate; tin oxides such as dibutyltin oxide and dioctyltin oxide; Organoaluminum compounds such as aluminum trisacetylacetonate, aluminum trisethyl acetoacetate; chelate compounds such as titanium tetraacetylacetonate; Amine compounds such as triethylenediamine, guanidine, diphenylguanidine, 2,4,6-tris(dimethylaminomethyl)phenol, morpholine, N-methylmorpholine, 2-ethyl-4-methylimidazole, and 1,8-diazabicyclo-(5,4,0)undecene 7 (DBU), 1,4-diazabicyclo[2,2,2]octane, N,N-dimethylpiperazine, 1,8-diazabicyclo[5.4.0]undec-7-ene, dimorpholinodimethyl ether, dimorpholinodiethyl ether (DMDEE) or mixtures thereof . The presence of one of the aforementioned catalysts preferably leads to a reduction in the temperature necessary to release the corresponding reactive group from the corresponding capped analog.

The term “prepolymer” preferably refers to reactive oligomers, which are preferably used to produce binders contained in the adhesion promoter layer, preferably polyurethane polymers. Prepolymers can, for example, have at least two identical groups, preferably at least two free isocyanate groups and/or at least two free groups reactive towards isocyanate groups, for example amino and/or hydroxy groups, and/or correspondingly capped analogues thereof.

The adhesion promoter layer, which has not yet completely hardened at least in some areas, can be produced, for example, by reacting at least one compound with two or more isocyanate groups with at least one compound that has two or more groups that are reactive toward isocyanate groups, for example hydroxy groups and/or amino groups are preferably used in excess either the at least one compound with two or more isocyanate groups or the at least one compound which has two or more groups reactive towards isocyanate groups.

Suitable compounds with two or more isocyanate groups are known and include, for example, monomeric isocyanates with two or more isocyanate groups, isocyanate adducts, isocyanate prepolymers with two or more isocyanate groups or mixtures thereof.

Monomeric isocyanates with two or more isocyanate groups are, for example, aliphatic isocyanates with two or more isocyanate groups, cycloaliphatic isocyanates with two or more isocyanate groups, aromatic isocyanates with two or more isocyanate groups, adducts thereof, or mixtures thereof, for example 1,6-hexamethylendiisocyanate (HDI), isophorondiisocyanate (ipdi), 2,4-toluylendiisocyanate, 2,6-toluylendiisocyanate, 2,4'-diphenylmethandiisocyanate, 2,2'-diphenylmethandiisocyanate ethandiisocyanate, naphthylendiisocyanate (ndi ), 4,4'-diisocyanatodicyclohexylmethane (H12MDI), xylylene diisocyanate (XDI), tetramethylxylylene diisocyanate (TMXDI), pentamethylene diisocyanate (PDI), 1,3-phenylene diisocyanate, 1,4-phenylene diisocyanate, adducts thereof or mixtures thereof.

Isocyanate adducts are commercially available and are preferably formed by dimerization or trimerization of one of the aforementioned aliphatic diisocyanates, cycloaliphatic diisocyanates or aromatic diisocyanates.

For example, the trimer of 1,6-hexamethylene diisocyanate (HDI), also known as HDI-biuret, can be purchased commercially from Covestro AG (Leverkusen, DE) under the trade name Desmodur® N.

Suitable compounds with two or more isocyanate groups are, for example, isocyanate prepolymers which have two or more isocyanate groups.

Isocyanate prepolymers are commercially available and can preferably be obtained by reacting at least one of the aforementioned aliphatic diisocyanates, cycloaliphatic diisocyanates, aromatic diisocyanates, adducts thereof or mixtures thereof with at least one di- or polyol, the diisocyanate used is preferably used in a molar excess, based on the number of free OH groups of the di- or polyol used.

Isocyanate prepolymers therefore preferably have urethane groups in the polymer chain as well as free, reactive isocyanate groups, which can preferably be at least partially capped.

Isocyanate prepolymers can also be partially converted into allophanates and/or biurets by increasing the temperature.

Suitable compounds with two or more hydroxide groups are polyhydric alcohols, which are selected, for example, from the group consisting of alkanediols, alkanetriols, alkanetraols, polyester polyols, polyether polyols, and mixtures thereof.

Suitable polyester polyols are preferably reaction products of polyfunctional, preferably difunctional alcohols, optionally together with small amounts of trifunctional alcohols, and polyfunctional, preferably difunctional and/or trifunctional carboxylic acids. Instead of free polycarboxylic acids, the corresponding polycarboxylic anhydrides or corresponding polycarboxylic esters with alcohols with preferably 1 to 3 carbon atoms can also be used. The polyols and carboxylic acids known per se for the production of polyesters can be selected. Examples of diols suitable for producing such polyester polyols are ethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,2-butanediol, 1,4-butanediol, pentanediol, the isomeric hexanediols, octanediol, 1,4-hydroxymethylcyclohexane, 2-Methyl-1,3-propanediol, butanetriol-1,2,4, triethylene glycol, tetraethylene glycol, polyethylene glycol, dipropylene glycol, polypropylene glycol, dibutylene glycol or polybutylene glycol. Aromatic diols can also be used.

The polycarboxylic acids used can be aliphatic, cycloaliphatic, aromatic or heterocyclic or both. They can optionally be substituted, for example by alkyl groups, alkenyl groups, ether groups or halogens. Examples of suitable polycarboxylic acids are succinic acid, adipic acid, suberic acid, azelaic acid, sebacic acid, phthalic acid, isophthalic acid, terephthalic acid, trimellitic acid, phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, glutaric anhydride, maleic acid, maleic anhydride, fumaric acid or mixtures of two or more of these. Suitable tricarboxylic acids, which may optionally be included in proportion, are, for example, citric acid or trimellitic acid. All of the acids mentioned can be used individually or as mixtures of two or more of them.

However, polyester polyols of oleochemical origin can also be used. Such polyester polyols can be produced, for example, by complete ring opening of epoxidized triglycerides of an at least partially olefinically unsaturated fatty acid-containing fat mixture with one or more alcohols with 1 to 12 carbon atoms and subsequent partial transesterification of the triglyceride derivatives to alkyl ester polyols with 1 to 12 carbon atoms in the alkyl radical getting produced.

Other suitable polyester poles are polycarbonate polyols. Polycarbonates can be obtained, for example, by the reaction of diols such as propylene glycol, 1,4-butanediol or 1,6-hexanediol, diethylene glycol, triethylene glycol or tetraethylene glycol or mixtures of two or more of these with diaryl carbonates, for example diphenyl carbonate, or with phosgene. Another group of suitable polyols are polylactones, for example polyesters based on ε-caprolactone. Polyester polyols that contain one or more urethane groups in the molecular chain are also suitable.

Suitable polyether polyols are, for example, reaction products of low molecular weight polyfunctional alcohols with alkylene oxides. The alkylene oxides preferably have 2 to 4 carbon atoms. Suitable, for example, are the reaction products of ethylene oxide, propylene oxide, butylene oxide or mixtures thereof with aliphatic diols, such as ethylene glycol, 1,2-propanediol, 1,3-propanediol, the isomeric butanediols, hexanediols, 2,2-dimethyl-1,3-propanediol , 2-methylpropanediol, 1,6-hexanediol, 2,4,4-trimethylhexanediol-1,6, 2,2,4-trimethylhexanediol-1,6, 1,4-cyclohexanedimethanol, or aromatic diols such as 4,4' -Dihydroxydiphenylpropane, bisphenol A, bisphenol F, catechol, resorcinol, hydroquinone or mixtures of two or more of these. Furthermore, the reaction products of polyfunctional alcohols, such as glycerol, trimethylolethane or trimethylolpropane, pentaerythritol or sugar alcohols with the alkylene oxides, can also be suitable.

Other suitable polyols are created by polymerizing tetrahydrofuran.

Furthermore, the aforementioned polyether polyols or polyester polyols, preferably polyether polyols, can be amino-functionalized, one or more hydroxide groups preferably being replaced by one or more amino groups, primary amino groups and/or secondary amino groups.

For example, amino-functionalized polyether polyols, which can also be referred to as amino-terminated polyethers, are known to those skilled in the art and can be obtained commercially, for example, under the name JEFFAMINE® from Huntsman Corporation (The Woodlands, TX, USA).

Preferably, the at least partially not yet fully cured adhesion promoter layer can comprise or consist of isocyanate prepolymers, which can be crosslinked or uncrosslinked, blocked isocyanate prepolymers, which can be crosslinked or uncrosslinked, or mixtures thereof, the aforementioned isocyanate prepolymers or blocked isocyanate prepolymers containing traces of monomeric diisocyanates and/or Adducts thereof may contain, preferably in a proportion of less than 5% by weight, preferably less than 1% by weight, in each case based on the total weight of the prepolymer used.

Prepolymers with free groups that are reactive toward isocyanate groups, more preferably amino groups and/or hydroxy groups, can preferably be prepared by reacting at least one of the aforementioned aliphatic diisocyanates, cycloaliphatic diisocyanates, aromatic diisocyanates, adducts thereof or mixtures thereof with at least one diol, Polyol and/or amino-functionalized polyether polyol are obtained, the diols, polyols and/or amino-functionalized polyether polyols used preferably being used in a molar excess, based on the number of free isocyanate groups of the diisocyanate used.

Prepolymers with free groups that are reactive towards isocyanate groups therefore preferably have urethane groups in the polymer chain as well as free, reactive hydroxy groups and/or amino groups, which can preferably be at least partially capped, for example by thermally reversible addition of isocyanate.

Alternatively, the adhesion promoter layer, which has not yet been completely cured at least in some areas, can comprise prepolymers with free groups that are reactive towards isocyanate groups and which can be crosslinked or uncrosslinked, prepolymers with capped groups which are reactive toward isocyanate groups and which can be crosslinked or uncrosslinked, or mixtures thereof or consist thereof, whereby the aforementioned prepolymers can contain traces of diols, polyols and/or amino-functionalized polyether polyols used, preferably in a proportion of less than 5% by weight, preferably of less than 1% by weight, in each case based on the total weight of the prepolymer used.

More preferably, the aforementioned isocyanate prepolymers, capped isocyanate prepolymers, prepolymers with free groups that are reactive toward isocyanate groups, and/or prepolymers with capped groups that are reactive toward isocyanate groups of the adhesion promoter layer, which has not yet been fully cured at least in some areas, can be used by using suitable crosslinking agents, for example polyfunctional aziridines ( PFA), can be networked.

Furthermore, the adhesion promoter layer, which has not yet been fully cured at least in some areas, can have at least one co-binder, which is preferably selected from the group consisting of acrylic resins, methacrylic resins, vinyl ester resins and mixtures thereof and more preferably does not have any free, ethylenically unsaturated groups.

More preferably, the adhesion promoter layer, which has not yet completely hardened at least in some areas, has the at least one co-binder in a proportion of at most 30% by weight, more preferably at most 25% by weight, preferably in a range of 5% by weight. % to 20% by weight, based on the total weight of the layer.

Furthermore, the adhesion promoter layer, which has not yet been completely hardened at least in some areas, can contain at least one crosslinking agent, which preferably has at least two free isocyanate groups and/or at least two free groups that are reactive towards isocyanate groups, for example amino and/or hydroxy groups.

Suitable crosslinking agents are known and include organic compounds with two or more free, reactive groups, for example aliphatic or alicyclic compounds with two or more free isocyanate groups, aliphatic or alicyclic compound with two or more free hydroxide groups, aliphatic or alicyclic compound with two or more free amine groups, correspondingly capped analogues thereof or mixtures thereof.

More preferably, the adhesion promoter layer, which has not yet completely hardened at least in some areas, has the at least one crosslinking agent in a proportion of at most 15% by weight, more preferably at most 12% by weight, preferably in a range of 1% by weight to 10% by weight, based on the total weight of the layer.

The adhesion promoter layer, which has not yet been completely cured at least in some areas, preferably contains at least one, preferably inorganic, filler in a proportion of at most 15% by weight, preferably in a range of 0.1% by weight to 12% by weight, more preferably a range from 1% by weight to 10% by weight, based in each case on the total weight of the layer.

The adhesion promoter layer, which has not yet been completely hardened at least in some areas, preferably contains at least one, preferably organic, additive, for example at least one wetting agent, at least one leveling agent, at least one defoamer, at least one thixotropic agent or a mixture thereof, preferably in a proportion of at most 12% by weight. , preferably from a range of 0.1% by weight to 10% by weight, in each case based on the total weight of the layer.

More preferably, the adhesion promoter layer, which has not yet completely hardened at least in some areas, has a thickness in the range of 0.5 μm to 15 μm, more preferably in the range of 1 μm to 12 μm.

Preferably, the adhesion promoter layer, which has not yet been fully cured at least in some areas, does not contain any photoinitiators.

Photoinitiators are chemical compounds that, after absorbing light, decay in a photolysis reaction, forming reactive species that can start a reaction, such as polymerization. The reactive species can be radicals, anions or cations.

More preferably, the adhesion promoter layer, which has not yet been fully cured at least in some areas, does not contain any photoinitiators and no binders with free, ethylenically unsaturated groups.

According to a further advantageous embodiment of the invention, the adhesion promoter layer has a layer thickness selected from a range of 0.1 μm to 15 μm, preferably from 0.5 μm to 10 μm, particularly preferably from 1 μm to 4 μm.

According to a further advantageous embodiment of the invention, the at least one decorative layer has at least one decorative element.

The at least one decorative layer can contain one or more lacquer layers with a layer thickness selected from a range of 0.1 μm to 15 μm, preferably from 0.3 μm to 8 μm. This lacquer layer or these lacquer layers can be colored, i.e. pigmented and/or colored with dyes. These additional layers of lacquer can be printed as a full surface or partially or partially in the decor. The lacquer layers can preferably be applied using gravure printing, screen printing, flexographic printing and/or inkjet printing.

Alternatively or additionally, one or more lacquer layers of the decorative layer can be transparent.

The at least one decorative layer can contain at least one metal layer. The metal layer is preferably applied by metallization using a PVD process or using a CVD process, such as vapor deposition and/or sputtering. The metal layer preferably has a layer thickness selected from a range of 1 nm to 200 nm, preferably 5 nm to 40 nm. Possible metals include Cr, In, Al, Sn, Ag, Si. Furthermore, a combination of one or more lacquer layers with at least one metallization is also possible.

The at least one decorative layer and/or the at least one decorative element can be arranged in certain areas or over the entire surface. At least a first region of the decorative layer and/or at least one first decorative element can have different configurations. In particular, the design or shape of the at least one first region of the decorative layer and/or the at least one first decorative element is each selected from one or more of the following group: motif, lettering, letter, number, symbol, geometric figure, visually recognizable design element, pattern, Logo, codes and conductor track.

• Ist eine Schicht nur bereichsweise aufgebracht, kann dies als fortlaufendes Endlosmuster oder als Einzelbild-Dekor oder als eine Kombination davon ausgeführt sein. Mehrere partiell aufgebrachte Schichten können (müssen aber nicht) dabei im Register, d. h. lagegenau relativ zueinander angeordnet sein.
• Beispielsweise kann sich ein Einzelbild-Dekor einer Schicht mit einem Endlosmuster einer anderen partiell aufgebrachten Schicht überlagern.
• Beispielsweise kann sich ein Einzelbild-Dekor einer Schicht mit einem Einzelbild-Dekor einer anderen partiell aufgebrachten Schicht überlagern.
• Beispielsweise kann sich ein Endlosmuster einer Schicht mit einem Endlosmuster einer anderen partiell aufgebrachten Schicht überlagern.

In the following paragraph, the term “layer” is understood to mean a layer of paint, a decorative layer or a decorative element:

• If a layer is only applied in certain areas, this can be carried out as a continuous, endless pattern or as a single-image decoration or as a combination thereof. Several partially applied layers can (but do not have to) be arranged in register, ie in precise positions relative to one another.
• For example, a single image decoration of one layer can be superimposed on an endless pattern of another partially applied layer.
• For example, a single image decoration of one layer can be superimposed on a single image decoration of another partially applied layer.
• For example, an endless pattern of one layer can be superimposed on an endless pattern of another partially applied layer.

According to a further advantageous embodiment of the invention, several decorative layers comprise at least one varnish, individually or in combination or as a mixture selected from a UV-crosslinked varnish, a thermally crosslinked varnish, a thermoplastic varnish. The decorative layers are each independently unpigmented or pigmented or colored or not colored.

According to a further advantageous embodiment of the invention, the at least one decorative layer containing at least one decorative element is selected from the group consisting of transparent and/or colored lacquer layers, in particular comprising one or more dyes and/or pigments, replication layers with a molded optically active surface structure, reflection layers , in particular opaque reflection layers, transparent reflection layers, metallic reflection layers or dielectric reflection layers, optically variable layers, optically active layers, interference multilayer systems, volume hologram layers, liquid crystal layers, in particular cholesteric liquid crystal layers, electrically conductive layers, antenna layers, electrode layers, magnetic layers, magnetic storage layers, barrier layers and combinations of which consists.

In the present application, a film, layer or layer with a transmission greater than 70% is preferably referred to as transparent. If the transmission is between 50% and 70%, the film, layer or layer is preferably referred to as translucent. If the transmission is less than 50%, the film, layer or layer is preferably referred to as opaque. The % values mentioned refer in particular to transmission in the wavelength range that can be perceived by the human eye. The wavelength range perceivable by the human eye is preferably assumed to be the wavelength range from 380 nm to 780 nm.

According to a further advantageous embodiment of the invention, the polyurethane layer has a wall thickness selected from a range of 0.2 mm to 30 mm, preferably from 0.3 mm to 20 mm, particularly preferably from 0.5 mm to 15 mm. The film-coated article is preferably dimensionally stable.

The wall thickness of the polyurethane layer can also be referred to with the term “layer thickness” of the polyurethane layer or with the term “layer thickness” or “thickness” of the polyurethane layer.

Advantageously, film-coated articles according to the invention can have a wide range of wall thicknesses. In particular, film-coated articles according to the invention can have particularly thin and/or particularly thick wall thicknesses. Advantageously, film-coated articles according to the invention can have particularly thin and particularly thick wall thicknesses at the same time. Such wall thicknesses are very difficult or impossible to achieve using an injection molding process with thermoplastic materials.

According to a further advantageous embodiment of the invention, the polyurethane layer has a wall thickness that remains constant along the areal extent of the polyurethane layer and/or along the areal extent of the decorative layer.

Preferably, the areal extent of the polyurethane layer is parallel to the areal extent of the decorative layer. Furthermore, the extension of the plane formed by the polyurethane layer (or decorative layer) is preferably parallel to the extension of the plane formed by the decorative layer. The longitudinal extent of the polyurethane layer is preferably parallel to the longitudinal extent of the decorative layer. The transverse extent of the polyurethane layer is also preferably parallel to the transverse extent of the decorative layer.

According to a further advantageous embodiment of the invention, the polyurethane layer has a wall thickness that does not remain constant along the areal extent of the polyurethane layer and/or along the areal extent of the decorative layer. The wall thickness preferably has a first wall thickness at least in a first region and preferably a second wall thickness at least in a second region. The wall thickness can change continuously or in one or more stages. The first wall thickness can differ from the second wall thickness in particular by 5% to 75%, preferably by 10% to 50%.

With regard to the first and second areas, reference is made to the explanation of the term “area” above.

Advantageously, film-coated articles according to the invention can have particularly complicated geometries. These geometries can include, for example, abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, tips and/or arches.

According to a further advantageous embodiment of the invention, the polyurethane layer has at least one continuous change in wall thickness along the areal extent of the polyurethane layer and/or along the areal extent of the decorative layer.

According to a further advantageous embodiment of the invention, the polyurethane layer has at least one jump in wall thickness along the areal extent of the polyurethane layer and/or along the areal extent of the decorative layer. A jump in wall thickness is understood to mean, in particular, a gradual change in wall thickness. The jump in wall thickness preferably runs perpendicular to the decorative layer. A jump in wall thickness is therefore preferably understood to mean an abrupt and/or discrete jump in wall thickness.

Advantageously, film-coated articles according to the invention can have abrupt changes in wall thickness.

According to a further advantageous embodiment of the invention, the film-coated article is delimited on a first side by the polyurethane layer and on an opposite second side by the protective layer and / or the carrier layer.

The film-coated article is therefore preferably protected on its first side by the polyurethane layer.

If the film is designed as a transfer film, the protective layer of the transfer layer preferably forms the boundary of the film-coated article on the second side of the film-coated article, that is, on the side of the film-coated article facing away from the polyurethane layer. In this case, the film-coated article is preferably protected by the protective layer of the transfer layer on its second side. If the film is designed as a label, PMD sheet or insert, the carrier layer can also fulfill the role of a protective layer.

Preferably, the carrier layer in the film-coated article forms the protective layer on the back. More specifically, the backing layer in the film-coated article forms the protective layer on the second side of the film-coated article, that is, on the side of the film-coated article facing away from the polyurethane layer. In this case, the film-coated article is preferably protected on its second side by the carrier layer of the film.

According to a further advantageous embodiment of the invention, the carrier layer has at least one anchoring area for anchoring or fastening, in particular adhesive bonds and/or functional elements, such as conductor tracks, sensors, lights and/or electronic components. The carrier layer preferably has functional elements, such as conductor tracks, sensors, lights and/or electronic components.

According to a further advantageous embodiment of the invention, the polyurethane layer has a transmission greater than 50%, preferably greater than 70% for the wavelength range perceivable by the human eye.

If the transmission is greater than 70%, the polyurethane layer is preferably referred to as transparent. With a transmission between 50% and 70%, the polyurethane layer is preferably referred to as translucent.

The wavelength range perceivable by the human eye is preferably assumed to be the wavelength range from 380 nm to 780 nm.

The polyurethane layer can advantageously be easily transilluminated optically. The high optical translucency enables a good design representation of decorative layers, mask layers and/or other optical functional layers arranged under or behind the polyurethane layer in the viewing direction.

According to a further advantageous embodiment of the invention, the decorative layer embedded in the film-coated article is visible or perceptible to the human eye from both sides of the layer structure, at least partially or completely, and/or measurable by an optical sensor unit.

The decorative layer embedded in the article is therefore visible to a human observer, in particular from both sides of the layer structure. More precisely, the decorative layer embedded in the film-coated article is preferably at least partially or completely visible both from the first side of the film-coated article through the polyurethane layer and from the opposite second side of the article through the protective layer and / or the carrier layer. Preferably, both the polyurethane layer and the protective layer and/or the carrier layer are transparent. In addition, the article is preferably protected on the outside by both the polyurethane layer and the protective layer and/or the carrier layer.

According to a further advantageous embodiment of the invention, the polyurethane layer adheres to the adhesion promoter layer with an adhesive force selected from a range of 2.5 MPa to 5 MPa, preferably from 2.5 MPa to 10 MPa.

Preferably, the adhesive force is determined in accordance with in DIN EN ISO 4624: 2016-08 The method described is determined, particularly preferably with a PosiTest® AT series adhesive tensile testing device from DeFelsko Corporation (Ogdensburg, NY, USA) using a 20 mm test stamp.

Therefore, after curing, the polyurethane layer preferably cannot be removed from a film-coated object according to the invention without damaging the film or the transfer layer of the transfer film.

According to a further advantageous embodiment of the invention, the film-coated article does not comprise any injection-molded thermoplastic, that is, no injection-molded thermoplastic material.

According to a further advantageous embodiment of the invention, the mixture in step e) is injected into the mold cavity with a filling pressure selected from a range of 70 bar to 140 bar, preferably from 80 bar to 100 bar.

According to a further advantageous embodiment of the invention, the mold cavity forms a negative for the polyurethane layer to be formed. The mold cavity preferably has cavity areas of different thicknesses to form different wall thicknesses of the polyurethane layer.

The mold cavity preferably has at least a first cavity region for producing the first wall thickness of the polyurethane layer and at least a second cavity region for producing the second wall thickness of the polyurethane layer. The first wall thickness can differ from the second wall thickness in particular by 5% to 75%, preferably by 10% to 50%.

According to a further advantageous embodiment of the invention, the polyurethane layer forms in the mold cavity as a result of injecting the mixture after step e) at a temperature selected from a range of 40 ° C to 160 ° C, preferably from 60 ° C to 140 ° C, in particular preferably from 80 ° C to 120 ° C, and / or at a pressure selected from a range from 3 bar to 100 bar, preferably from 5 bar to 50 bar, particularly preferably from 8 bar to 30 bar.

Advantageously, lower temperatures are required to form the polyurethane layer than when using thermoplastic materials in the injection molding process.

Preferably, when the polyurethane-forming mixture is provided at the mixing head in step d), an exothermic reaction in the mixture begins.

This exothermic reaction preferably heats up the mixture introduced into the mold cavity in step e). Depending on the current phase of the exothermic reaction, it is advantageous to temper the mixture, in particular to heat it up or cool it down, so that the exothermic reaction takes place at a process temperature that remains approximately the same. At the beginning of the exothermic reaction, the mixture is therefore heated up or warmed up by the then prevailing tool temperature, which is higher than the mixture temperature, and as the exothermic reaction progresses over time with increasing thermal energy being released, the tool temperature, which is kept largely constant, then leads to a cooling of the tool by the reaction of the heating mixture, because the tool temperature is then temporarily below the mixture temperature, which is influenced by the exothermic reaction. The tool temperature is largely constant during the exothermic reaction.

The mold cavity is preferably pre-tempered before injecting the mixture according to step e) to a temperature selected from a range of 40 ° C to 160 ° C, preferably from 60 ° C to 140 ° C, particularly preferably from 80 ° C to 120 ° . Preferably, the temperature of the mixture at the start of the chemical reaction and/or immediately after mixing the mixture according to step d) and/or immediately upon injection into the mold cavity is lower than the temperature of the mold cavity (mold temperature). Preferably, due to the low thermal conductivity of the polyurethane of approximately 0.020 W/Km to 0.040 W/Km, the mixture and/or the polyurethane layer that forms assumes the preset temperature of the mold cavity (mold temperature) as time progresses and/or as the reaction progresses.

Preferably, a temperature difference for cooling the film-coated article formed in the mold cavity is 0K to 100K, preferably 0K to 50K, particularly preferably 0K to 30K. The temperature difference for cooling the film-coated article formed in the mold cavity is therefore advantageously much lower than when injection molding thermoplastic materials.

Advantageously, lower pressures are required to form the polyurethane layer than when using thermoplastic materials in the injection molding process.

• h) Härten des Gemischs innerhalb und/oder außerhalb der Formkavität unter Ausbildung der Polyurethanschicht.

According to a further advantageous embodiment of the invention, the method additionally comprises the following step, which is preferably carried out after step e):

• h) curing the mixture inside and/or outside the mold cavity to form the polyurethane layer.

The duration of the hardening process within the mold cavity is preferably 10 seconds to 120 seconds, particularly preferably 20 seconds to 90 seconds. This is in particular 2 times to 10 times the pot life of the mixture, preferably 3 times to 7 times the pot life of the mixture. The pot life is the processability or service life of the reactive mixture.

The duration of the hardening process outside the mold cavity, in particular on a holding device with the shape of the film-coated article, is preferably 5 minutes to 90 minutes, particularly preferably 5 minutes to 45 minutes.

Preferably, the viscosity of the mixture and/or the polyurethane layer that forms increases as the chemical crosslinking reaction progresses. Preferably the mixture and/or the resulting mixture hardens forming polyurethane layer as the chemical crosslinking reaction progresses. Preferably, a fully cured polyurethane layer is formed at the end of the chemical crosslinking reaction.

Preferably, the mixture is completely cured in step h) to form the polyurethane layer.

The hardening according to step h) preferably takes place at a temperature selected from a range of 20 ° C to 160 ° C, preferably from 20 ° C to 120 ° C.

In the case of the design of the adhesion promoter layer which has not yet been completely cured at least in some areas, the adhesion promoter layer which has not yet been completely cured at least in some areas is preferably cured together with the mixture applied thereto and/or with the polyurethane layer applied thereon, preferably completely cured. Cross-links preferably form between the polyurethane layer and the adhesion promoter layer. The polyurethane layer is preferably bonded to the adhesion promoter layer. The composite of the film and the polyurethane layer is preferably dimensionally stable.

Preferably, the polyurethane layer cannot be removed from the adhesion promoter layer without being destroyed.

• i) Entfernen der Trägerlage der Folie.

According to a further advantageous embodiment of the invention, the method additionally comprises the following step, which is preferably carried out after step e), g) and/or step h):

• i) Removing the carrier layer of the film.

This advantageous embodiment therefore preferably relates to the design of the film as a transfer film.

After carrying out step i), only the transfer layer of the transfer film remains present on the film-coated article.

After the carrier layer has been removed from the film, the release layer can be arranged completely or partially on the transfer layer and/or completely or partially arranged on the carrier layer.

According to a further advantageous embodiment of the invention, the film is provided in step c) as roll goods and/or as a continuous film and/or as a sheet and/or introduced into the mold cavity using film feed device technology.

The process is preferably carried out as an IMD process (IMD = In-Mold Decoration). The film comprising the decorative layer is conveyed as a transfer film with a carrier layer and a transfer layer having the decorative layer, in particular as roll goods, and is introduced into the mold cavity in particular according to step c).

The decoration process using paint transfer technology advantageously enables a significantly greater variety of designs compared to other decoration processes such as painting. This advantageously allows individual images, technical designs, haptic surfaces and many other design variants to be created.

• j) Reinigen der Folie und/oder des folienbeschichteten Artikels, vorzugsweise der Haftvermittlerschicht und/oder der Polyurethanschicht, insbesondere durch zumindest eine Bürste, ein Gebläse und/oder eine Absaugeinrichtung.

According to a further advantageous embodiment of the invention, the method has the further following step or does step a), c) and/or step f) comprise the further following sub-step:

• j) Cleaning the film and/or the film-coated article, preferably the adhesion promoter layer and/or the polyurethane layer, in particular by at least one brush, a blower and/or a suction device.

• k) Bedrucken des folienbeschichteten Artikels, vorzugsweise der Polyurethanschicht, insbesondere in zumindest einem ersten und/oder zweiten Bereich, vorzugsweise allein oder in Kombination ausgewählt aus Inkjetdruck, Tiefdruck, Siebdruck, Flachdruck, Hochdruck und Flexodruck.

According to a further advantageous embodiment of the invention, the method has the further following step or does step f) comprise the further following sub-step:

• k) printing the film-coated article, preferably the polyurethane layer, in particular in at least a first and/or second area, preferably alone or in combination selected from inkjet printing, gravure printing, screen printing, planographic printing, letterpress printing and flexographic printing.

• l) Vorbehandlung der Folie, vorzugsweise der Haftvermittlerschicht, insbesondere mittels eines Verfahrens allein oder in Kombination ausgewählt aus Coronabehandlung, Flammbehandlung, Plasmabehandlung.

According to a further advantageous embodiment of the invention, the method has the further following step or does step c) comprise the further following sub-step:

• l) Pretreatment of the film, preferably the adhesion promoter layer, in particular by means of a process alone or in combination selected from corona treatment, flame treatment, plasma treatment.

• m) Zuschneiden des folienbeschichteten Artikels mittels Stanzen oder Wasserstrahlschneiden oder Laserschneiden.

According to a further advantageous embodiment of the invention, the method has the further following step or does step f) comprise the further following sub-step:

• m) Cutting the film-coated article using punching or water jet cutting or laser cutting.

The cutting preferably refers to external cutting.

• n) Zerteilen des folienbeschichteten Artikels in einzelne Nutzen, insbesondere bei Vorliegen von mehrere Nutzen aufweisender Rollenware oder bei Vorliegen eines mehrere Nutzen aufweisenden Bogens.

Preferably, the method can have the further following step or step f) can comprise the further following sub-step:

• n) dividing the film-coated article into individual benefits, in particular when there are roll goods with multiple benefits or when there is a sheet with multiple benefits.

According to a further advantageous embodiment of the invention, the film-coated article obtained in step f) is selected from the group display, touch field, panel, cover, functional element, in particular from the following areas: white goods, motor vehicles, aviation, ships, household appliances, telecommunications devices, consumer goods , documents, security elements, labels and/or electronic items.

According to a further advantageous embodiment of the invention, the method does not include thermoplastic injection molding.

It is also possible for the process steps and sub-steps to be carried out once or several times. In particular, process steps and sub-steps can be repeated. The preferred sequence of the method steps has at least the order of step a) - step b) - step c) - step d) - step e) - step f), in which further steps or sub-steps can be inserted in particular between these steps.

Of course, the material characteristics listed above can also be used equivalently in a process or the process characteristics listed can be used in the product.

• 1 zeigt eine Auftragung der Höhe der Viskosität verschiedener Polyurethan bildender Gemische in Abhängigkeit der Temperatur.
• 2 zeigt einen schematischen Aufbau einer Transferfolie zur Durchführung des Verfahrens.
• 3 zeigt einen schematischen Aufbau eines ersten folienbeschichteten Artikels.
• 4 zeigt einen schematischen Aufbau eines zweiten folienbeschichteten Artikels.
• 5 zeigt ein Flussdiagramm zu einem beispielhaften erfindungsgemäßen Verfahren.

The invention is explained below by way of example using several exemplary embodiments with the aid of the accompanying drawings. The exemplary embodiments shown are therefore not to be understood as restrictive.

• 1 shows a plot of the viscosity of various polyurethane-forming mixtures as a function of temperature.
• 2 shows a schematic structure of a transfer film for carrying out the process.
• 3 shows a schematic structure of a first film-coated article.
• 4 shows a schematic structure of a second film-coated article.
• 5 shows a flowchart for an exemplary method according to the invention.

In 1 a plot of the viscosity of various polyurethane-forming mixtures is shown as a function of temperature. The plot refers to the time before the start of the crosslinking reaction. The application only refers to the viscosity of the polyurethane-forming mixture before the reaction. The influence of the temperature of the mold cavity (mold temperature) is not taken into account.

The numerical values for 1 are shown in Table 1 below. The data comes from Ruehl Puromer GmbH. Table 1: Dependence of the viscosity of various polyurethane-forming mixtures on the temperature system Temperature [°C] 25 30 40 50 60 70 75 Puronate 960/1 1748 1270 702 398 240 155 128 Puroclear 3351 IT 929 699 362 218 132 85 70 A+B Puroclear 3351 IT 1117 898 494 275 171 115 97

2 shows a schematic structure of a transfer film 1 for carrying out the method. The transfer film 1 comprises a carrier layer 10 and a transfer layer 13. The carrier layer 10 comprises a carrier layer 11 and a release layer 12. The transfer layer 13 comprises a protective layer 14, at least one decorative layer 15 and an adhesion promoter layer 16.

The carrier layer 11 preferably has a layer thickness of between 10 μm to 100 μm, preferably from 23 μm to 75 μm. In the exemplary transfer film 1, the carrier layer 11 has a layer thickness of 75 μm. The one release layer 12 preferably has a layer thickness of 0.1 nm to 50 nm. The release layer is arranged on the side of the carrier layer 10 facing the transfer layer 13 and consists of a thin wax layer.

The protective layer 14 preferably has a layer thickness of between 0.1 μm to 20 μm, preferably from 1 μm to 3 μm. In the exemplary transfer film 1, the protective layer 14 is formed from a protective lacquer and preferably has a layer thickness of 2 μm.

The at least one decorative layer 15 preferably comprises one or more lacquer layers and/or one or more metal layers. The lacquer layers preferably have a layer thickness between 0.1 µm to 15 µm, preferably between 0.3 µm to 8 µm. The metal layers preferably have a layer thickness between 1 nm and 200 nm, preferably from 5 nm to 40 nm. In the exemplary transfer film 1, the decorative layer comprises a lacquer layer with a layer thickness of 4 μm and a metal layer with a layer thickness of 30 nm.

The adhesion promoter layer 16 preferably has a layer thickness selected from a range of 0.1 μm to 15 μm, preferably from 0.5 μm to 10 μm, particularly preferably from 1 μm to 4 μm. In the exemplary transfer film 1, the adhesion promoter layer 16 has a layer thickness of 2 μm.

The adhesion promoter layer is, for example, a mixture of acrylate resin with free OH and/or acid groups and at least one suitable crosslinking agent with a reactive group, for example a polyfunctional aziridine (PFA), or polyisocyanate. This adhesion promoter layer can be in a not completely hardened state and can enter into a chemical reaction under the reactive conditions during flooding with, for example, polyol or polyisocyanates.

3 shows a schematic structure of a first film-coated article. The film-coated article 2 includes the transfer layer 13 in 1 transfer film 1 shown. In addition, the film-coated article 2 comprises a polyurethane layer P applied directly to the adhesion promoter layer 16.

The polyurethane layer P preferably has a wall thickness selected from a range of 0.2 mm to 30 mm, preferably from 0.3 mm to 13 mm, particularly preferably from 1 mm to 8 mm.

In the in 3 In the embodiment shown, the film-coated article 2 has a flat polyurethane layer P. The polyurethane layer P therefore has a constant wall thickness. The wall thickness of the polyurethane layer P is, for example, 12 mm. The film-coated article 2 shown is dimensionally stable.

The mixture preferably contains a polyol, an isocyanate and other chemical additives as components. For example, “Puroclear 3351 IT” from Ruehl Puromer GmbH is used as a mixture.
The polyol “Puroclear 3351 IT” as an individual component has a density of 1.09 g/cm ³ at a temperature of 20°C and a viscosity of 1000 mPas at a temperature of 25°C.
The isocyanate “Puronate 960/1” as an individual component has a density of 1.13 g/cm ³ at a temperature of 20°C and a viscosity of 2500 mPas at a temperature of 25°C.

4 shows a schematic structure of a second film-coated article. The structure of the second film-coated article corresponds to the structure of the first film-coated article. In contrast to the first film-coated article, the polyurethane layer P of the second film-coated article forms different wall thicknesses. The wall thickness of the polyurethane layer P varies between 1 mm and 10 mm.

Advantageously, a film-coated article 2 according to the invention can form complicated geometries. The film-coated article 2 can form a concrete three-dimensional body. The film-coated article 2 is dimensionally stable.

5 shows a flowchart for an exemplary method according to the invention. The following steps are preferably carried out one after the other.

In a step S01, a film according to the invention is provided. The film is, for example, as in 1 Transfer film 1 shown is designed with the carrier layer 10 and the transfer layer 13. The carrier layer 10 includes the carrier layer 11 and the release layer 12. The transfer layer 13 includes the protective layer 14, the decorative layer 15 and the adhesion promoter layer 16.

The adhesion promoter layer 16, for example, has not yet completely hardened.

The transfer film 1 is provided, for example, as roll goods and/or continuous film.

In a step S02, a mold cavity is provided. The tool forming the mold cavity is pre-heated, for example, to a temperature of preferably in the range between 80 ° C and 120 ° C, particularly preferably in the range between 90 ° C and 110 ° C. This is referred to as the tool temperature.

In a step S03, the transfer film 1 is introduced into the mold cavity. The transfer film 1 is preferably introduced into the mold cavity using film feed device technology.

In a step S04, a mixture forming polyurethane is provided at a mixing head. The mixture preferably contains a polyol, an isocyanate and other chemical additives as components. For example, “Puroclear 3351 IT” from Ruehl Puromer GmbH is used as a mixture. The components are mixed at the mixing head. When the components are mixed at the mixing head, an exothermic chemical crosslinking reaction starts.

The polyol “Puroclear 3351 IT” as an individual component has a density of 1.09 g/cm ³ at a temperature of 20°C and a viscosity of 1000 mPas at a temperature of 25°C.

The isocyanate “Puronate 960/1” as an individual component has a density of 1.13 g/cm ³ at a temperature of 20°C and a viscosity of 2500 mPas at a temperature of 25°C.

The Puroclear 3351 IT and the isocyanate and possibly other chemical additives as individual components or already premixed with one of the two main components are combined in the mixing head, preferably at a raw material temperature of 60°C to 70°C.

The recommended tool temperature for this PUR mixture should preferably be in the range between 80°C and 90°C.

The mixture is injected into the mold cavity in step S05 immediately following step S04. The mixture is injected into the mold cavity, for example, with a filling pressure of 70 bar to 140 bar. In this exemplary embodiment, the transfer film 1 is completely flooded by the mixture on its side delimited by the adhesion promoter layer 16.

When the mixture is injected into the mold cavity, the temperature of the mixture is, for example, 60°C to 70°C. The filling pressure of the mixture is when the mixture is injected into the mold cavity for example at 70 bar to 140 bar. The viscosity of the mixture is, for example, up to 100 mPas when the mixture is injected into the mold cavity.

The temperature of the mixture when injected into the mold cavity in this example is lower than the temperature of the mold cavity (mold temperature).

The duration of the injection, i.e. the filling phase, is approx. 5 seconds to 20 seconds, depending on the current tool temperature.

In a step S06, the mixture hardens in the mold cavity as a result of the exothermic chemical crosslinking reaction. The polyurethane layer P is formed. In particular, an exothermic chemical cross-linking reaction also occurs between the mixture forming the polyurethane layer and the not yet fully cured adhesion promoter layer 16. Cross-links preferably form between the mixture forming the polyurethane layer and the adhesion promoter layer 16. The resulting polyurethane layer P is preferably bonded to the adhesion promoter layer 16. Hardening forms a composite of the film and the polyurethane layer, which forms a precursor to the film-coated article. The composite of the film and the polyurethane layer is dimensionally stable.

The temperature of the mixture is, for example, approximately 100 ° C immediately after the mixture has been completely injected into the mold cavity. This temperature corresponds to the tool temperature or is slightly higher than the tool temperature. The cavity pressure immediately after the mixture has been completely injected into the mold cavity is, for example, approximately 50 bar to 150 bar. The viscosity of the mixture is, for example, up to 100 mPas immediately after the mixture has been completely injected into the mold cavity. The viscosity of the mixture is unchanged from the viscosity of the mixture as at the start of the injection.

After the mixture has been completely injected into the mold cavity, the so-called holding time is approximately 60 seconds. That's about 5 times the pot life. In this example, the hardening time after removing the component is approx. 30 minutes. This time can be accelerated, for example, using cooling, so that reduced practical hardening times of approximately 10 minutes are obtained.

Due to the low thermal conductivity of the polyurethane of approximately 0.020 W/Km to 0.040 W/Km, the mixture and/or the polyurethane layer P that forms assumes the preset temperature of the mold cavity (mold temperature) as time progresses, which in this example is 100°C amounts.

Due to the exothermic chemical crosslinking reaction, no additional heat is required during curing in this example. After the mixture has been completely injected into the mold cavity, the cavity pressure is approximately 50 bar to 150 bar. The cavity pressure decreases over the holding time in the tool due to the increase in viscosity of the PUR mixture.

As the chemical crosslinking reaction progresses, the viscosity of the mixture and/or the polyurethane layer P that forms increases. The mixture and/or the polyurethane layer P that forms hardens.

At the end of the chemical crosslinking reaction, the temperature of the mixture in the mold cavity is, for example, around 100°C (corresponds to the mold temperature). The cavity pressure in the mold cavity is, for example, around 50 bar at the end of the chemical crosslinking reaction.

In a step S07, the composite of the film and the polyurethane layer is removed from the mold cavity.

In a step S08, the carrier layer 10 of the transfer film 1 is removed. In this example, both the carrier layer 11 and the release layer 12 of the carrier layer 10 are completely removed. As a result, only the transfer layer 13 of the transfer film 1 remains on the film-coated article 2. Preferably, the film-coated article 2 is detached from the carrier layer 10 immediately during removal.

In a step S09, the film-coated article 2 is placed on a holding device outside the tool (that is, outside the mold cavity). The holding device preferably has the shape of the film-coated article.

In a step S10, the film-coated article 2 is cooled to a temperature of, for example, 20 ° C to 25 ° C (room temperature). The temperature difference for cooling the film-coated article 2 based on the temperature of the mixture in the mold cavity is only approx. 80 K. The temperature difference for cooling the film-coated article 2 is therefore advantageously much lower than when injection molding thermoplastic materials. While the film-coated article 2 is cooling, the curing process preferably continues and is preferably completed when room temperature is reached.

In a step S11, the finished film-coated article 2 is obtained. The finished film-coated article 2 is dimensionally stable.

• - Fräsen der überschüssigen Konturen der Polyurethanschicht P zur Erzeugung einer „sauberen“ Außenkontur.
• - Polieren des folienbeschichteten Artikels 2, insbesondere der der Polyurethanschicht P.
• - Lasern der Polyurethanschicht P und/oder der der Polyurethanschicht P gegenüber gelegenen Schutzschicht 14.

After dimensional stability has been achieved, the following further work steps can be carried out:

• - Milling the excess contours of the polyurethane layer P to create a “clean” outer contour.
• - Polishing the film-coated article 2, in particular the polyurethane layer P.
• - Lasering the polyurethane layer P and/or the protective layer 14 located opposite the polyurethane layer P.

The same sequence of steps S01 to S11 with the exception of step S08 (removing the carrier layer of the transfer film 1) also results for designs of the film as a label, PMD sheet (print-mold design sheet) or insert. The composite of the film and the polyurethane layer in steps S06 and S07 can already be referred to as film-coated article 2.

Advantageously, the method according to the invention eliminates the need to switch between the separate production units for the injection molding process and flooding with polyurethane. This makes the method according to the invention simple and quick compared to the prior art. This means that foil-coated items can be manufactured particularly cost-effectively.

It is clear to the person skilled in the art that the embodiment variants of the devices, devices, methods or method steps listed above can be combined with one another in any way and do not represent any limitation, particularly in their shape and combination.

Reference symbol list

1

Transfer film

2

Foil coated item

P

Polyurethane layer

10

Carrier layer

11

Backing layer

12

release layer

13

Transmission situation

14

protective layer

15

decorative layer

16

Adhesion promoter layer

QUOTES INCLUDED IN THE DESCRIPTION

This list of 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.

Cited patent literature

• DE 10221482 C1 [0003]
• WO 2019/034361 A2 [0006]

Non-patent literature cited

• DIN EN ISO 3219:1994-10 [0057]
• DIN EN ISO 4624: 2016-08 [0116, 0209]
• DIN 53240-3:2016-03 [0122]
• DIN EN ISO 14896:2009-07 [0123]

Claims (38)

Film for coating with polyurethane, in particular for flooding with polyurethane, the film comprising at least one adhesion promoter layer (16), the film additionally comprising a protective layer (14) and/or a carrier layer (11), characterized in that the adhesion promoter layer (16 ) is designed for the addition of polyurethane. Slide after Claim 1 , characterized in that the film comprises at least one decorative layer (15), and that the adhesion promoter layer (16) is arranged on the side of the at least one decorative layer (15) facing away from the protective layer (14) and / or the carrier layer (11). Slide after Claim 1 or 2 , characterized in that the film is a transfer film (1), the transfer film (1) comprising a carrier layer (10) and a transfer layer (13) arranged on the carrier layer (10), the transfer layer (13) comprising the at least one decorative layer (15), which comprises the protective layer (14) and the adhesion promoter layer (16), and wherein the carrier layer (10) is arranged on the side of the at least one decorative layer (15) facing away from the adhesion promoter layer (16), and wherein the carrier layer (10) the carrier layer (11). Slide after Claim 3 , characterized in that the carrier layer (10) additionally comprises a release layer (12), preferably with a layer thickness of 0.1 nm to 50 nm, the release layer (12) being on the side of the carrier layer (10) facing the transfer layer (13). is arranged, and wherein the release layer (12) preferably comprises or consists of at least one wax. Slide after Claim 1 or 2 , characterized in that the film is a label or a print mold design sheet (PMD sheet) or an insert, and wherein the carrier layer (11) is preferably formed from a material selected from the group that consists of polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), polycarbonate (PC), acrylonitrile butadiene styrene polycarbonate (ABS-PC), polypropylene (PP) and mixtures thereof. Film according to one of the preceding claims, characterized in that the adhesion promoter layer (16) is preferably applied directly or indirectly to the decorative layer (15) over the entire surface and/or in certain areas by means of a type of printing, individually or in combination, selected from screen printing, flexographic printing, gravure printing, inkjet printing is. Film according to one of the preceding claims, characterized in that the adhesion promoter layer (16) has at least one binder which is selected from the group consisting of polyurethane resins, polyurethane dispersions, acrylic resins, methacrylic resins, phenolic resins, epoxy resins, polyureas, melamine resins, aminoplasts, polyester resins, Alkyd resins, polyamide resins, vinyl ester resins and mixtures thereof, preferably polyurethane resins, polyurethane dispersions, phenolic resins, epoxy resins, polyureas, melamine resins, aminoplasts, polyester resins, alkyd resins, polyamide resins and mixtures thereof. Film according to one of the preceding claims, characterized in that the adhesion promoter layer (16) is designed such that a chemical bond can be formed with the polyurethane to be deposited through the adhesion promoter layer (16). Film according to one of the preceding claims, characterized in that the adhesion promoter layer (16) has not yet completely hardened, at least in some areas. Film according to one of the preceding claims, characterized in that the adhesion promoter layer (16) has a layer thickness selected from a range of 0.1 µm to 15 µm, preferably from 0.5 µm to 10 µm, particularly preferably from 1 µm to 4 µm, having. Film according to one of the preceding claims, characterized in that the at least one decorative layer (15) has at least one decorative element. Film according to one of the preceding claims, characterized in that a plurality of decorative layers (15) comprise at least one varnish, individually or in combination or as a mixture selected from a UV-crosslinked varnish, a thermally crosslinked varnish, a thermoplastic varnish, and that the decorative layers (15) are each independently unpigmented or pigmented or colored or not colored. Film according to one of the preceding claims, characterized in that the at least one decorative layer (15) containing at least one decorative element is selected from the group consisting of transparent and/or colored lacquer layers, in particular comprising one or more dyes and/or pigments, replication layers with molded optically active surface structure, reflection layers, in particular opaque reflection layers, transparent reflection layers, metallic reflection layers or dielectric reflection layers, optically variable layers, optically active layers, interference multilayer systems, volume hologram layers, liquid crystal layers, in particular cholesteric liquid crystal layers, electrically conductive layers, antenna layers, electrode layers, magnetic Layers, magnetic storage layers, barrier layers and combinations thereof. Foil-coated article comprising a foil Claim 1 , 2 , 5 until 13 or the transfer layer (13) of the film designed as a transfer film (1). Claim 3 or 4 , and a polyurethane layer (P) cast onto the adhesion promoter layer (16). Foil-coated article Claim 14 , characterized in that the polyurethane layer (P) has a wall thickness selected from a range of 0.2 mm to 30 mm, preferably from 0.3 mm to 20 mm, particularly preferably from 0.5 mm to 15 mm. Foil-coated article Claim 14 or 15 , characterized in that the polyurethane layer (P) has a wall thickness that remains constant along the areal extent of the polyurethane layer (P) and/or along the areal extent of the decorative layer (15). Foil-coated article Claim 14 or 15 , characterized in that the polyurethane layer (P) has a wall thickness that does not remain constant along the areal extent of the polyurethane layer (P) and/or along the areal extent of the decorative layer (15), the wall thickness preferably having a first wall thickness at least in a first region and preferably has a second wall thickness at least in a second region, the first wall thickness differing from the second wall thickness in particular by 5% to 75%, preferably by 10% to 50%. Foil-coated article according to one of the Claims 14 until 17 , characterized in that the polyurethane layer (P) has at least one continuous change in wall thickness along the areal extent of the polyurethane layer (P) and/or along the areal extent of the decorative layer (15). Foil-coated article according to one of the Claims 14 until 18 , characterized in that the polyurethane layer (P) has at least one jump in wall thickness along the areal extent of the polyurethane layer (P) and / or along the areal extent of the decorative layer (15), the jump in wall thickness preferably running perpendicularly with respect to the decorative layer (15). . Foil-coated article according to one of the Claims 14 until 19 , characterized in that the film-coated article (2) is delimited on a first side by the polyurethane layer (P) and on an opposite second side by the protective layer (14) and / or the carrier layer (11). Foil-coated article according to one of the Claims 14 until 20 , characterized in that the carrier layer (11) has at least one anchoring area for anchoring or fastening, in particular adhesive bonds and / or functional elements, such as conductor tracks, sensors, lights and / or electronic components. Foil-coated article according to one of the Claims 14 until 21 , characterized in that the polyurethane layer (P) has a transmission greater than 50%, preferably greater than 70% for the wavelength range perceivable by the human eye. Foil-coated article Claim 22 , characterized in that the decorative layer (15) embedded in the film-coated article (2) from both sides of the layer structure, at least partially or completely, can be perceived by the human eye and/or can be measured by an optical sensor unit. Foil-coated article according to one of the Claims 14 until 23 , characterized in that the polyurethane layer (P) adheres to the adhesion promoter layer (16) with an adhesive force selected from a range of 2.5 MPa to 5 MPa, preferably from 2.5 MPa to 10 MPa. Foil-coated article according to one of the Claims 14 until 24 , characterized in that the film-coated article (2) does not comprise any injection-molded thermoplastic. Method for producing a film-coated article (2), preferably for producing the film-coated article (2) according to one of Claims 14 until 25 , wherein the method comprises the following steps, in particular in the following order: a) providing a film according to one of Claims 1 until 13 , b) providing a mold cavity, c) introducing the film into the mold cavity, d) providing a polyurethane-forming mixture at a mixing head, e) injecting the mixture into the mold cavity so that the film is on its side delimited by the adhesion promoter layer (16). is at least partially flooded and/or poured over by the mixture, f) receipt of the film-coated article (2). Procedure according to Claim 26 , characterized in that the mixture in step e) is injected into the mold cavity with a filling pressure selected from a range of 70 bar to 140 bar, preferably from 80 bar to 100 bar. Procedure according to Claim 26 or 27 , characterized in that the mold cavity forms a negative for the polyurethane layer (P) to be formed, the mold cavity preferably having cavity regions of different thicknesses to form different wall thicknesses of the polyurethane layer (P). Procedure according to one of the Claims 26 until 28 , characterized in that the polyurethane layer (P) in the mold cavity as a result of injecting the mixture after step e) at a temperature selected from a range of 40 ° C to 160 ° C, preferably from 60 ° C to 140 ° C, especially preferably from 80 ° C to 120 ° C, and / or at a pressure selected from a range of 3 bar to 100 bar, preferably from 5 bar to 50 bar, particularly preferably from 8 bar to 30 bar. Procedure according to one of the Claims 26 until 29 , characterized in that the method additionally comprises the following step, which is preferably carried out after step e): h) curing the mixture inside and / or outside the mold cavity to form the polyurethane layer (P). Procedure according to one of the Claims 26 until 30 , characterized in that the method additionally comprises the following step, which is preferably carried out after step e) and/or after step h): i) removing the carrier layer (10) of the film. Procedure according to one of the Claims 26 until 31 , characterized in that the film is provided in step c) as roll goods and/or as a continuous film and/or as a sheet and/or is introduced into the mold cavity using film feed device technology. Procedure according to one of the Claims 26 until 32 , characterized in that the method has the further following step or that step a), c) and / or step f) comprises the further following sub-step: j) cleaning the film and / or the film-coated article (2), preferably the adhesion promoter layer (16) and/or the polyurethane layer (P), in particular by at least one brush, a blower and/or a suction device. Procedure according to one of the Claims 26 until 33 , characterized in that the method has the further following step or that step f) comprises the further following sub-step: k) printing the film-coated article (2), preferably the polyurethane layer (P), in particular in at least a first and/or second area, preferably selected alone or in combination from inkjet printing, gravure printing, screen printing, planographic printing, letterpress printing and flexographic printing. Procedure according to one of the Claims 26 until 34 , characterized in that the method has the further following step or that step c) comprises the further following sub-step: l) pretreatment of the film, preferably the adhesion promoter layer, in particular by means of a process alone or in combination selected from corona treatment, flame treatment and plasma treatment. Procedure according to one of the Claims 26 until 35 , characterized in that the method has the further following step or that step f) comprises the further following sub-step: m) cutting the film-coated article (2) by means of punching or water jet cutting or laser cutting. Procedure according to one of the Claims 26 until 36 , characterized in that the film-coated article (2) obtained in step f) is selected from the group of display, touch field, panel, cover, functional element, in particular from the following areas: white goods, motor vehicles, aviation, ships, household appliances, telecommunications devices, Consumer goods, documents, security elements, labels and/or electronic items. Procedure according to one of the Claims 26 until 37 , characterized in that the method does not include thermoplastic injection molding.

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