DE102022127334A1 - Component having a layer structure, method for producing the component and injection molding tool for producing the component - Google Patents

Abstract

The invention relates to a component, in particular a component with a polyurethane layer, a method for producing the component and an injection molding tool for producing the component and/or for carrying out the method. In order to be able to manufacture the component in a simple manner and to ensure that the component can be used widely, it is proposed that the component has a layer structure, in particular a layer structure with at least three layers. The layer structure comprises a decorative layer (1) comprising at least one decorative layer. A first layer (3) made of a first material, in particular thermoplastic, is arranged on the decorative layer (1). A second layer (4) made of a second material, in particular polyurethane, is arranged on the first layer (3). The first layer (3) has a peripheral edge. The first layer (3) comprises at least one holding element or is connected to at least one holding element, wherein the holding element extends along the edge of the first layer (3).

Description

The invention relates to a component having a layer structure, a method for producing the component and an injection molding tool for producing the component and/or an injection molding tool for carrying out the method for producing the component.

Components having a layered structure are known in the state of the art as injection-molded articles.

The DE 10221482 C1 a device for producing a molded part from a hardening injection molding material, which is decorated during injection molding using the IMD process (IMD = Inmold Decoration) with an embossed foil having a carrier film and a decorative layer that can be detached from the carrier layer. The embossed foil is placed in an open injection mold, with the decorative layer of the embossed foil facing an upper mold part. 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 embossed foil clinging to the visible side of the injected molded part. The embossed foil and its decorative layer bond to the injection molding material, which is removed from the injection mold after hardening. After the carrier film has been removed from the decorative layer, the decorated molded part is finished. Injection-molded articles decorated in this way are used in particular for automotive interior parts such as door strips, strips in instrument panels, gear lever covers and center console covers, for automotive exterior parts such as door sill protection strips and covers on A, B and C pillars, in the audio and video sector for decorative strips on the housings of radio and television sets, and in the telecommunications sector for housing shells of mobile devices such as cell phones or navigation devices.

Insert molding (IM) is a combined process of hot stamping, vacuum forming or deep drawing and casting, particularly injection molding. Compared to the IMD process, insert molding offers the possibility of deforming the film more strongly. This is an advantage if, for example, highly profiled and shaped parts are required. First, a vacuum-formable, thin stamping film is hot-stamped or cold-stamped on a carrier, e.g. an ABS film (thickness between approximately 200 µm and 750 µm, ABS = acrylonitrile butadiene styrene). This carrier, coated with the decorative layer of the stamping film, is vacuum-formed under heat. The layers of stamping film and carrier vacuum-formed in this way form the so-called "insert" and are cut or punched out 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, 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 a short time, in particular a few seconds, after the components have been mixed and/or immediately during and/or after flooding (with the tool halves still closed). When the tool opens, the PU is already sufficiently hard.

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

The production of the known component requires two separate production units. This makes production relatively complex, time-consuming and expensive.

Furthermore, according to the state of the art, the film and thus also the decorative layer and/or the decorative layer are encapsulated between the injection molding material and the flooding material, i.e. between the thermoplastic and polyurethane. Such an arrangement severely limits the possibilities of X-raying and subsequent processing of the decorative layer.

The invention is based on the task of eliminating the disadvantages of the prior art. In particular, a versatile and adaptable component, a simple and inexpensive method for producing a component and a device for producing the component or a device for carrying out the method for producing the component are to be provided. The component should preferably be manufactured with at least one polyurethane layer. The component should preferably be easy to manufacture using an injection molding process. In particular, an injection molding tool should be provided for this purpose. In particular, series production of the component in large quantities should be made possible.

According to the invention, this object is achieved by a component according to the subject matter of claim 1, by a method according to the subject matter of claim 13 and by an injection molding tool according to the subject matter of claim 23. Advantageous embodiments of the invention are specified in the dependent claims.

According to the invention, a component is created which has a layer structure, in particular a layer structure with at least three layers. The layer structure or the component comprises at least one decorative layer, wherein the decorative layer comprises at least one decorative layer. A first layer made of a first material is arranged on the decorative layer. The first layer is preferably arranged directly on the decorative layer.

The decorative layer or the decorative layer can preferably have several layers, individually, multiple times or in combination selected from: primer layer, adhesive layer, adhesion promoter layer, color layer, color lacquer layer, masking layer, spacer layer, light guide layer, functional layer, in particular optical functional layer, metal layer, reflection layer, HRI layer (HRI = High Refractive Index), replication layer with optically active and/or optically variable structures, in particular optically active relief structures, preferably diffractive structures and/or holograms and/or refractive structures and/or matt structures. The one or more layers of the decorative layer are or are preferably applied in the process for producing the decorative layer. The one or more layers of the decorative layer can each be present over the entire surface or partially. The one or more layers of the decorative layer can each overlap in areas and/or be adjacent to one another in areas. The adjacent arrangement can be spaced apart relative to one another or directly adjacent to one another without spaced apart relative to one another.

In particular, the decorative layer can have a primer layer and/or an adhesive layer. The primer layer and/or adhesive layer is preferably arranged directly on one of the at least one decorative layer. The primer layer and/or the adhesive layer is preferably connected to the first layer. In this case, the first layer is arranged directly on the primer layer and/or adhesive layer. The first layer is preferably made of at least one thermoplastic.

A second layer made of a second material is arranged on the first layer. The second layer can be arranged directly on the first layer. Alternatively, at least one further layer, in particular a further decorative layer and/or a further decorative layer having a further decorative layer, can be arranged between the first layer and the second layer. The second layer is preferably made of polyurethane. The second layer can also be referred to as a protective layer.

The further decorative layer or the further decorative layer can preferably have several layers, individually, multiple times or in combination selected from: primer layer, adhesive layer, adhesion promoter layer, color layer, color lacquer layer, functional layer, in particular optical functional layer, metal layer, reflection layer, HRI layer (HRI = High Refractive Index), replication layer with optically active and/or optically variable structures, in particular optically active relief structures, preferably diffractive structures and/or holograms and/or refractive structures and/or matt structures. The one or more layers of the further decorative layer are or are preferably applied in the process for producing the further decorative layer. The one or more layers of the further decorative layer can each be present over the entire surface or partially. The one or more layers of the further decorative layer can each overlap in areas and/or be adjacent to one another in areas. The adjacent arrangement can be spaced apart relative to one another or directly adjacent to one another without spaced apart relative to one another.

The first layer has a peripheral edge, preferably a closed peripheral edge. The first layer comprises at least one holding element or is connected to at least one holding element, in particular connected in one piece. The holding element is preferably made of the first material. The holding element extends along the edge of the first layer. The holding element can extend partially along the edge of the first layer. Alternatively, the holding element can extend completely extend continuously along the edge of the first layer. Due to the formation of the holding element, the first layer can also be referred to as a carrier layer. The first layer can be dimensioned in its wall thickness or thickness and/or the first material can be selected so that the component achieves a predetermined mechanical stability. The mechanical stability can have a bending stiffness or torsional strength.

The holding element preferably extends at least in a direction perpendicular to the layer structure. The holding element therefore preferably extends essentially in a plane in which the areal extension of the first layer also lies. The holding element particularly preferably extends essentially in a direction perpendicular to the layer structure. The holding element particularly preferably extends exclusively in planes in which the areal extension of the first layer also lies. Alternatively, the holding element can also extend partially in the direction of the layer structure. It is therefore also possible for the holding element to partially leave the plane in which the areal extension of the first layer also lies.

The holding element is preferably designed such that the component is held firmly and/or fixed by an interaction of the holding element with at least one holding arm of a holding device. The holding element is in particular designed such that the component is held firmly and/or fixed by an engagement of at least one holding arm of a holding device in the holding element. The engagement of the holding arm can take place directly on the peripheral edge of the first layer. In this case, it is particularly possible for the holding arm to engage in an area of the first layer that is on the inside with respect to the peripheral edge. Such an area can in particular be formed by an indentation. This will be discussed in more detail below.

Alternatively, the holding element can comprise a molding starting from the peripheral edge of the first layer and/or a projection on the peripheral edge of the first layer. In this case, the interaction with the holding arm takes place in an area of the first layer that is located on the outside with respect to the peripheral edge. The interaction can be achieved by the holding arm engaging in the holding element and/or by the holding element engaging in the holding arm. The molding and/or the projection can also have an indentation. Such a molding or such a projection can in particular be formed by a tab. This will be discussed in more detail below.

The component is advantageously held or fixed in two opposite directions by the holding element, in particular by tension and pressure. In one embodiment, the holding element can fix the component in an injection molding tool. In particular, to enable simple production even when changing cavity halves or tool parts. Due to the advantageous fixation of the component by pressure and tension by the holding element, cavity halves or tool parts can be changed on both sides of the component without this having a negative impact on production.

The holding element can be used to fix the finished component to another part, for example by locking or gluing it. Alternatively, the holding element can also be removed after the component has been manufactured. For example, by separating it, preferably by cutting it off and/or breaking it off. The holding element can preferably have corresponding predetermined breaking points. Alternatively or additionally, the holding element can be removed by milling.

Even if these terms are used in the singular in the explanations of the holding element and/or holding arm, the person skilled in the art will understand that the features mentioned can also apply to all holding elements and/or holding arms if there are several holding elements and/or several holding arms. Similarly, when explanations of the holding element and/or holding arm are used in the plural, the person skilled in the art will understand that the features mentioned can also apply if there is only one holding element and/or only one holding arm.

One advantage of the invention is that the decorative layer comprising at least one decorative layer, the first layer and possibly further decorative layers and/or further application layers are protected by the second and/or third layer lying above it, which is preferably made of polyurethane, as a protective layer. This enables additional effects, such as the creation of an increased optical depth effect.

Advantageously, the decorative layer comprising at least one decorative layer is only coated on one side with the further layer structure. In particular, the decorative layer comprising at least one decorative layer is not encapsulated on both sides. Therefore, the decorative layer comprising at least one decorative layer is advantageously accessible for further processing. In particular, the layer structure according to the invention enables direct laser processing of the decorative layer or decorative layer without having to laser through an injection molding material. By means of the laser processing, in particular one or more layers of the decorative layer can be specifically removed, in particular ablated, and/or one or more layers of the decorative layer can be specifically modified. Such a modification is, for example, bleaching and/or a color change of one or more layers of the decorative layer.

Furthermore, there are many possibilities for integrating structures. Structures, in particular relief structures, can be provided in one cavity half of the injection molding tool, for example. Such a structure can be imaged or molded onto the second and/or third layer, i.e. in particular onto the protective layer made of polyurethane, in particular as a relief structure corresponding to the relief structure of the injection molding tool, so that the structure is visible on the front side of the finished component. Furthermore, such a structure can be imaged or molded onto the first layer so that the structure is visible on the back side of the finished component. It should be emphasized that when the structure is introduced on the back side, the decorative layer also images or molds the structure very well. In particular, one or more microstructures and/or nanostructures can be provided as relief structures, for example, preferably one or more diffractive structures and/or holograms and/or refractive structures and/or matt structures.

Furthermore, rear structures, which are reflected by the decorative layer or an IMD film covering it, are clearly visible as a design element. Rear structures can also be provided using a laser. Laser processing can be used to specifically remove one or more layers of the decorative layer, in particular to ablate them, and in particular to create a visually visible flat structure and/or a surface relief. Furthermore, further application can be carried out using hot stamping and/or cold stamping and/or digital printing and/or functional foil bonding (FFB).

The component can advantageously be used in automobile construction as a body part on the exterior, or as a functional part and/or decorative part in the interior. In particular, it can be used for interior automobile parts such as door strips, strips in instrument panels, gear lever covers and center console covers, for exterior automobile parts such as door ram protection strips and covers on A, B and C pillars, in the audio and video sector for decorative strips on the housings of radio and television sets, and in the telecommunications sector for housing shells of mobile devices such as cell phones or navigation devices.

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

According to an advantageous embodiment of the invention, the first material is formed by an injection molding material, in particular by at least one thermoplastic, or by polyurethane.

According to a further advantageous embodiment of the invention, the second material is a flooding material, in particular polyurethane.

Polyurethane is not thermoplastic, but a reaction product with an initially very low viscosity. Polyurethane can therefore mold geometries and/or structures, in particular complicated geometries and/or structures. The component according to the invention, in particular the second layer of the component according to the invention, can therefore have geometries and/or structures, in particular complicated geometries and/or structures. These geometries and/or structures can, for example, comprise abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, tips and/or arches. The component, in particular the second layer of the component, can preferably have particularly thick walls and/or abrupt jumps in wall thickness. In comparison to the injection molding process with thermoplastic materials, very little and/or very few geometric distortions and/or sink marks and/or cavities occur when flooding with polyurethane. The components according to the invention therefore advantageously have a high optical quality.

The first material is preferably transparent, in particular a transparent thermoplastic or transparent polyurethane.

The second material is preferably transparent, in particular transparent polyurethane.

It is also conceivable that the first material and/or the second material is translucent or opaque and/or colored. The first material and the second material can have different degrees of transmission.

In the present application, a film, layer or ply or a material with a transmission greater than 70% is preferably referred to as transparent. With a transmission between 50% and 70%, the film, layer or ply or the material is preferably referred to as translucent. With a transmission of less than 50%, the film, layer or ply or the material is preferably referred to as opaque. The percentage values (% values) mentioned relate in particular to a transmission in the wavelength range perceptible to the human eye. The wavelength range perceptible to 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, a third layer made of a third material is arranged on the second layer. The third layer is preferably arranged directly on the second layer. The third material is preferably a flooding material, in particular polyurethane. The third material is preferably transparent, in particular transparent polyurethane.

According to a further advantageous embodiment of the invention, the second layer and the third layer are each made of a flooding material, in particular polyurethane. In this embodiment, the second and the third material are each a flooding material, in particular polyurethane. The second material is preferably translucent or opaque and/or colored. The third material is preferably transparent. The second layer preferably forms geometries and/or structures, in particular complicated geometries and/or structures. These geometries and/or structures can, for example, include abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, tips and/or arches. In particular, the second layer can have particularly thick walls and/or abrupt jumps in wall thickness. The third layer is preferably arranged directly on the second layer. The third layer preferably covers the geometries and/or structures formed by the second layer. The third layer preferably has a smooth free surface or a free surface structured in a different way than the second layer. The third layer therefore preferably forms a protective layer on the second layer. Advantageously, the geometries and/or structures formed by the second layer are protected from contamination and/or damage by the third layer and remain visible through it. It can be provided that several layers of the third layer are provided to smooth the structures of the second layer.

According to a further advantageous embodiment of the invention, the holding element is designed to hold the component in an injection molding tool. The component can thus be fixed in the injection molding tool.

According to a further advantageous embodiment of the invention, the holding element is designed as a tab that protrudes outwards. In this case, the holding element is made of the first material. Alternatively or additionally, the holding element is designed as an indentation in the first material. The indentation can be provided in an area that is on the inside with respect to the peripheral edge of the first layer. In particular, the holding element can be designed as a tab that has an indentation.

According to a further advantageous embodiment of the invention, the indentation is designed to engage a holding device of an injection molding tool. The holding device can comprise a movable holding arm for this purpose. The indentation can be designed to receive one end of the movable holding arm. In particular, the indentation is designed to positively engage the holding device of an injection molding tool. The end of the holding arm is preferably held in a positively locking manner. In particular, the indentation is designed to complement the contour of the tip of the holding arm.

The holding element and the holding device remain firmly connected to each other, in particular when an external force acts in a direction perpendicular to the first layer.

According to a further advantageous embodiment of the invention, the decorative layer is a layer of an IMD film or a label to be transferred. Alternatively, the decorative layer is part of an insert film.

The IMD film preferably has a decorative layer and a carrier layer, wherein the decorative layer can comprise several decorative layers. The carrier layer is preferably removed at the end of the process for producing the component. Therefore, the finished component preferably does not comprise the carrier layer of the IMD film.

As an alternative to an IMD film, an insert film can be used, whereby an insert film has a decorative layer and a carrier layer. In contrast to the IMD film, the carrier layer of the insert film remains in the layer structure. Therefore, when manufactured with an insert film, the finished component preferably also includes the carrier layer.

The carrier layer of an IMD film and/or insert film can comprise at least one carrier layer. The carrier layer can preferably have several layers, individually, multiple times or in combination selected from: PET carrier and/or release layer and/or thermoplastic carrier.

The one or more layers of the carrier layer can each cover the entire surface or each cover part of the surface. The one or more layers of the carrier layer can each overlap in areas of the surface and/or be adjacent to one another in areas of the surface. The adjacent arrangements can be spaced apart relative to one another or directly adjacent to one another without any space relative to one another.

According to a further advantageous embodiment of the invention, a further decorative layer and/or a further decorative layer comprising at least one further decorative layer is arranged between the first layer and the second layer. The further decorative layer and/or the further decorative layer can be applied to the first layer by hot stamping and/or cold stamping and/or digital printing and/or functional foil bonding (FFB). The further decorative layer and/or the further decorative layer is therefore preferably arranged between the first layer made of thermoplastic and the second layer made of polyurethane.

The further decorative layer or the further decorative layer can preferably have several layers, individually, multiple times or in combination selected from: primer layer, adhesive layer, adhesion promoter layer, color layer, color lacquer layer, functional layer, in particular optical functional layer, metal layer, reflection layer, HRI layer (HRI = High Refractive Index), replication layer with optically active and/or optically variable structures, in particular optically active relief structures, preferably diffractive structures and/or holograms and/or refractive structures and/or matt structures. The one or more layers of the further decorative layer are or are preferably applied in the process for producing the further decorative layer. The one or more layers of the further decorative layer can each be present over the entire surface or partially. The one or more layers of the further decorative layer or the further decorative layer can each overlap in areas and/or be adjacent to one another in areas. The adjacent arrangement can be spaced apart relative to one another or directly adjacent to one another without space relative to one another.

The decorative layer and the further decorative layer or the further decorative layer advantageously complement each other in the formation of a design, in particular in conjunction with transillumination technologies. The one or more layers of the decorative layer and/or the decorative layer and/or the further decorative layer can each overlap in some areas and/or be adjacent to each other in some areas. The adjacent arrangement can be spaced apart relative to each other or directly adjacent to each other without space relative to each other.

According to a further advantageous embodiment of the invention, the first layer comprises exactly one holding element. The holding element is preferably designed to run all the way around the component. The holding element is particularly preferably designed to run all the way around the component. In this case, the holding element extends all the way around the edge that runs around the first layer.

Alternatively, the first layer can comprise several holding elements. In particular, an even or odd number of holding elements can be provided. Between 2 and 20 holding elements are preferred. elements, particularly preferably between 2 and 16 holding elements, more preferably between 2 and 12 holding elements.

According to a further advantageous embodiment of the invention, the first layer comprises two, three, four, five, six, eight, ten or twelve holding elements. The holding elements are preferably arranged at a distance from one another along the edge of the first layer. The holding elements are preferably spaced equally apart from one another. However, the spacing of the holding elements can also vary. The holding elements are preferably arranged symmetrically to one another. The holding elements can preferably be arranged in pairs. A pair can be arranged opposite one another, in particular symmetrically and/or diametrically opposite one another.

For example, the edge of the first layer forms a rectangle, in particular a square. In this case, the first layer can comprise two holding elements, which are arranged on two opposite sections of the edge, i.e. on two opposite sides of the rectangle or square. As a further example, in this case the first layer can comprise four holding elements. A holding element can be arranged on each section of the edge, i.e. on each side of the rectangle or square, so that two holding elements are arranged opposite one another in pairs. The holding elements are preferably arranged in the middle of the respective side of the rectangle or square.

In a further example, the edge of the first layer forms a triangle, in particular an equilateral triangle. In this case, the first layer can comprise three holding elements. A holding element can be arranged on each section of the edge, i.e. on each side of the triangle or equilateral triangle. The holding elements are preferably arranged in the middle of the respective side of the triangle or equilateral triangle.

In a further example, the edge of the first layer forms a hexagon, in particular an equilateral hexagon. In this case, the first layer can comprise six holding elements. A holding element can be arranged on each section of the edge, i.e. on each side of the hexagon or the equilateral hexagon, so that two holding elements are arranged opposite one another in pairs. The holding elements are preferably arranged in the middle of the respective side of the hexagon or the equilateral hexagon.

According to a further advantageous embodiment of the invention, the first layer has a wall thickness of 0.5 mm to 10 mm. The first layer preferably has a wall thickness of 1 mm to 5 mm. The first layer particularly preferably has a wall thickness of 1.5 mm to 3 mm. The first layer preferably has a flat and/or smooth surface facing the second layer.

In the context of the present application, the wall thickness of a layer can also be referred to as the “layer thickness” of the layer or as the “layer thickness” or “thickness” of the layer. The wall thickness extends in the direction of the layer structure of the component.

According to a further advantageous embodiment of the invention, the second layer has a wall thickness of 0.2 mm to 50 mm. In particular, the second layer has a wall thickness of 0.2 mm to 30 mm. Preferably, the second layer has a wall thickness of 0.3 mm to 15 mm. Preferably, the second layer has a wall thickness of 0.5 mm to 5 mm. Particularly preferably, the second layer has a wall thickness of 0.8 mm to 3 mm. Preferably, only individual structures have the full wall thickness.

The second layer preferably forms geometries and/or structures, in particular complicated geometries and/or structures. These geometries and/or structures can, for example, comprise abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, tips and/or arches. In particular, the second layer can have particularly thick walls and/or abrupt wall thickness jumps.

In particular by means of laser processing and/or mechanical processing and/or by using tool structures, it is possible to produce exposed relief structures in the second layer, which is preferably made of polyurethane, with a minimum line thickness and/or a minimum laserable dot diameter of 5 µm to 150 µm, preferably 10 µm to 100 µm. This makes it possible to produce the finest details, in particular for motifs and/or alphanumeric information. It is also possible to to combine such fine structures with coarser, macroscopic structures, either in a laterally adjacent combination or as an overlay of a coarse structure with a fine structure. This can be achieved in particular by combining several processing steps, for example to produce coarse 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 to this and/or superimposed thereon with a minimum line thickness and/or a minimum laserable point diameter of 5 µm to 150 µm, preferably 10 µm to 100 µm. However, it is also possible for coarse structures and fine structures to be present together as a tool structure and thus molded in the second layer, which is preferably made of polyurethane. The depth of the relief structures can be between 0.001 mm and the maximum wall thickness of the second layer, which is preferably made of polyurethane, in particular between 0.001 mm and 50 mm, preferably between 0.001 mm and 30 mm, preferably between 0.001 mm and 15 mm.

Advantageously, components according to the invention can have a wide range of wall thicknesses. In particular, components according to the invention can have particularly thin and/or particularly thick wall thicknesses. Advantageously, components 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 alone.

According to a further advantageous embodiment of the invention, the third layer has a wall thickness of 0.2 mm to 50 mm. In particular, the third layer has a wall thickness of 0.2 mm to 30 mm. Preferably, the third layer has a wall thickness of 0.3 mm to 15 mm. Preferably, the third layer has a wall thickness of 0.5 mm to 5 mm. Particularly preferably, the third layer has a wall thickness of 0.8 mm to 3 mm. In this case, the third layer is arranged in particular complementary to the second layer. This means that the structures formed in the second layer are preferably balanced out by the third layer. Preferably, the third layer has a flat and/or smooth surface facing away from the second layer.

1. a) Bereitstellen eines eine Haltevorrichtung sowie eine erste und zweite Kavitätshälfte umfassenden Spritzgusswerkzeugs,
2. b) Einbringen einer eine Dekorlage mit zumindest einer Dekorschicht umfassenden Folie in die erste Kavitätshälfte,
3. c) Schließen des Spritzgusswerkzeugs durch Einsetzen der zweiten Kavitätshälfte in die erste Kavitätshälfte, so dass ein an der Folie anliegender erster Hohlraum entsteht,
4. d) Beschichten der Folie mit einem ersten Material unter Ausbildung einer ersten Schicht durch Einbringen des ersten Materials in den ersten Hohlraum, wobei die erste Schicht mit zumindest einem Halteelement derart ausbildet wird, dass die Haltevorrichtung formschlüssig zum Halteelement angeordnet ist,
5. e) Entfernen der zweiten Kavitätshälfte, wobei die mit der ersten Schicht beschichtete Folie in der ersten Kavitätshälfte verbleibt, indem das Halteelement durch die Haltevorrichtung gehalten wird.

According to the invention, the method for producing a component having a layer structure, in particular a layer structure with at least two layers, preferably for producing the component according to the invention, comprises the following steps, in particular in the following order:

1. a) providing an injection molding tool comprising a holding device and a first and second cavity half,
2. b) introducing a film comprising a decorative layer with at least one decorative layer into the first cavity half,
3. c) closing the injection moulding tool by inserting the second cavity half into the first cavity half so that a first cavity is created adjacent to the film,
4. d) coating the film with a first material to form a first layer by introducing the first material into the first cavity, wherein the first layer is formed with at least one holding element such that the holding device is arranged in a form-fitting manner with the holding element,
5. e) removing the second cavity half, wherein the film coated with the first layer remains in the first cavity half by holding the holding element by the holding device.

The holding device is preferably movable and/or comprises movable components, in particular a movable clamping frame and/or at least one movable holding arm.

After the film has been introduced into the first cavity half in step b) and/or before the injection molding tool is closed in step c), the holding device, in particular the clamping frame, is preferably moved against the film. The movement preferably takes place in a direction perpendicular to a plane formed by the film. The film is thereby preferably pressed against the first cavity half. The film is preferably fixed between the holding device, in particular between the clamping frame, and the first cavity half. See also step I) below.

In step d), the first material is preferably formed by at least one thermoplastic. Coating the film can therefore also be referred to as back-injection molding of the film. Alternatively, the first material can be polyurethane.

The coating or back-injection of the film in step d) preferably takes place on the back of the film, in particular on a primer layer formed by the film. The primer layer is preferably designed as an adhesive layer for a connection with the thermoplastic of the first layer. The film is preferably an IMD film or insert film.

The coating or back-injection of the film with the first material to form the first layer is preferably carried out in step d) directly on the film.

When coating or back-injecting the film in step d), the first layer with the at least one holding element is preferably formed in such a way that the holding device is positively connected to the holding element. Preferably, a holding arm formed by the holding device is arranged in a positively locking manner to the holding element and/or is positively connected to the holding element. In particular, the first layer can be formed as a carrier layer. The wall thickness or thickness of the first layer can be dimensioned such that the component achieves a predetermined mechanical stability. The mechanical stability can have a flexural rigidity or torsional strength.

• f) Schließen des Spritzgusswerkzeugs durch Einsetzen der dritten Kavitätshälfte in die erste Kavitätshälfte, so dass ein zweiter Hohlraum entsteht,
• g) Beschichten der mit der ersten Schicht beschichteten Folie mit einem zweiten Material unter Ausbildung einer zweiten Schicht durch Einbringen, insbesondere Injizieren, des zweiten Materials in den zweiten Hohlraum.

According to an advantageous embodiment of the invention, the injection molding tool comprises a third cavity half. The method additionally comprises the following steps, which are preferably carried out after step e), in particular in the following order:

• f) closing the injection mould by inserting the third cavity half into the first cavity half, so that a second cavity is created,
• g) coating the film coated with the first layer with a second material to form a second layer by introducing, in particular injecting, the second material into the second cavity.

Changing the cavity half from the second to the third cavity half can be done using turntable, sliding table and/or indexable plate technology, for example. Changing to the third cavity half can also be done manually.

The second cavity created in step f) preferably lies directly on the first layer. Alternatively, a further decorative layer and/or a further decorative layer comprising at least one further decorative layer can be applied to the side of the first layer facing away from the film (see step k) below). In this case, the second cavity preferably lies directly on the further decorative layer and/or the further decorative layer.

The coating or flooding with the second material to form the second layer is preferably carried out in step g) on the surface of the first layer facing away from the film, preferably directly on the first layer.

Alternatively, a further decorative layer and/or a further decorative layer comprising at least one further decorative layer can be applied to the side of the first layer facing away from the film (see step k) below). In this case, the coating or flooding with the second material to form the second layer in step g) preferably takes place directly on the surface of the further decorative layer and/or the further decorative layer facing away from the first layer. The surface of the further decorative layer and/or the further decorative layer facing away from the first layer preferably forms a primer layer. The primer layer is preferably designed as an adhesive layer and/or adhesion promoter layer for a connection to the polyurethane of the second layer.

It is also possible for the further decorative layer and/or the further decorative layer comprising at least one further decorative layer to be applied only in regions on the side of the first layer facing away from the film. In this case, the coating or flooding with the second material to form the second layer in step g) preferably takes place in regions directly on the first layer and in regions directly on the surface of the further decorative layer and/or the further decorative layer facing away from the first layer.

In the present application, the term “region” 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 first layer can have at least a first region and at least one second region, wherein each of the two or more regions occupies a defined area in the plane formed by the first layer. The respective layers, films or plies preferably extend parallel to one another. In particular, the first layer preferably extends parallel to the further decorative layer and/or the further decorative ply.

The term “regionally” is preferably understood in the present application in the same way as the term “region” was used above.

By completing step g), the manufacture of the component is preferably achieved.

In step g), the second material is preferably polyurethane. Coating the film coated with the first layer can therefore also be referred to as flooding the first layer with polyurethane.

The second material in step g) is particularly preferably a mixture, in particular a mixture that forms polyurethane. The mixture is therefore preferably introduced into the second cavity, in particular injected. The film coated with the first layer is preferably coated with the mixture in step g). The first layer can be directly flooded and/or poured over with the mixture. Alternatively, the surface of the further decorative layer and/or the further decorative layer facing away from the first layer can be directly flooded and/or poured over with the mixture. It is also possible for the first layer to be directly flooded and/or poured over with the mixture in some areas and/or for the surface of the further decorative layer and/or the further decorative layer facing away from the first layer to be directly flooded and/or poured over with the mixture in some areas.

Preferably, the first layer in step g) is completely flooded and/or poured over by the mixture, directly or indirectly.

The term "flooding" in the sense of the present application can be overflooding, underflooding, flooding and/or flooding around. Different orientations of the resulting component in the closed mold halves are therefore possible. The first layer and/or the further decorative layer and/or the further decorative layer are each covered by the mixture at least in part on their surface facing away from the film. To simplify the language, the term "flooding" is used in particular in this application. The above-mentioned meanings can be read as well.

In this application, the second layer formed from polyurethane is also referred to as polyurethane layer.

The polyurethane layer is preferably applied to the first layer and/or the further decorative layer and/or the further decorative layer in step g) by at least partially flooding and/or pouring over the first layer and/or the further decorative layer and/or the further decorative layer, each on its surface facing away from the film, with at least one solvent-containing, preferably flowable, polyurethane-containing composition and subsequent hardening.

Preferably, the term “flowable polyurethane-containing composition” is understood to mean a polyurethane-containing composition which preferably has a dynamic viscosity at a temperature of 25°C in a range from 2 mPas to 1500 mPas, preferably from 10 mPas to 1000 mPas, more preferably from 10 mPas to 500 mPas, preferably determined according to the method described in 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.

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

As already explained above, a further decorative layer and/or further decorative layer can be applied to the first layer. The further decorative layer and/or further decorative layer preferably has a primer layer on the surface facing away from the first layer for a connection with the polyurethane of the second layer. The primer layer is preferably a layer which is at least partially not yet fully cured primer layer, in particular adhesion promoter layer. During the curing, preferably complete curing, of the primer layer, which is at least partially not yet fully cured, and/or the polyurethane layer applied thereon, free isocyanate groups contained in the primer layer can, for example, react with free groups reactive toward isocyanate groups in the solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer.

As a result, the adhesion of the polyurethane layer to the primer layer after curing according to the process according to the invention, preferably according to step q) (see below), is preferably significantly improved.

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 have free, reactive groups, preferably isocyanate groups or groups reactive towards isocyanate groups and/or corresponding capped, reactive groups which release the corresponding reactive group again at a temperature in a range from 30°C to 180°C.

For example, the at least one solvent-containing, preferably flowable, polyurethane-containing composition as described above can be applied to the primer layer 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 has two or more groups reactive towards isocyanate groups, wherein preferably 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 is used in molar excess.

For example, polyurethane-containing dispersions, polyurethane-containing resins and/or polyurethane solutions comprise the aforementioned prepolymers with free groups reactive toward isocyanate groups, which may be crosslinked or uncrosslinked, the aforementioned prepolymers with capped groups reactive toward isocyanate groups, which may be crosslinked or uncrosslinked, or mixtures thereof and/or the aforementioned isocyanate prepolymers, which may be crosslinked or uncrosslinked, the aforementioned capped 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 comprises at least one organic solvent, for example ethyl acetate, 2-butanone, acetone, toluene, xylenes or mixtures thereof.

It is also preferred that at least one solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer, which comprises the aforementioned isocyanate prepolymers, is water-free. The aforementioned capped isocyanate prepolymers, on the other hand, can be present as an aqueous dispersion.

More preferably, a polyurethane layer used to produce it comprises at least one solvent-containing, preferably flowable, polyurethane-containing composition which comprises the aforementioned prepolymers with free groups reactive towards isocyanate groups, which may be crosslinked or uncrosslinked, the aforementioned prepolymers with capped groups reactive towards isocyanate groups, which may 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.

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

The surfaces or walls of the cavity halves 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.

The introduction, in particular injection, 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 injection molding tool, for example at a temperature of 60°C to 160°C, preferably for a period of 60 s to 600 s.

After removal from the injection mold, the component is preferably stored for approx. 24 hours for residual curing before further use.

During the curing, preferably complete curing, of the primer layer, which is at least partially not yet completely cured, and the polyurethane layer applied thereon, free isocyanate groups contained in the primer layer can, for example, react with free groups reactive toward isocyanate groups of the solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer.

Preferably, a layer is 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 exhibit more than 95% crosslinking.

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

In particular, by means of laser processing and/or 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 point diameter of 5 µm to 150 µm, preferably 10 µm to 100 µm. This makes it possible to produce the finest details, particularly for motifs and/or alphanumeric information. It is also possible to combine such fine structures with coarser, macroscopic structures, either in a laterally adjacent combination or as an overlay of a coarse structure with a fine structure. This can be achieved in particular by combining several of the above-mentioned process steps, for example to produce coarse 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 to and/or superimposed thereon with a minimum line thickness and/or a minimum laserable point diameter of 5 µm to 150 µm, preferably 10 µm to 100 µm. However, it is also possible for coarse structures and fine structures to be present together as a tool structure and thus molded into 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 0.001 mm and 50 mm, preferably between 0.001 mm and 30 mm, preferably between 0.001 mm and 15 mm.

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

Accurate registration means the positioning accuracy of two or more layers, elements, areas and/or layers relative to one another. The registration accuracy should be within a specified tolerance and as low as possible. At the same time, the registration 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 protection against counterfeiting. Accurate positioning can be achieved in particular using sensory, preferably optically detectable register marks. 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 process according to the invention preferably has transparent or reduced light-permeable properties.

In step g) and/or in an additional step preceding step g), a polyurethane-forming mixture is preferably provided at a mixing head of the injection molding tool. For this purpose, components of the polyurethane-forming mixture are preferably mixed with one another at the mixing head. The mixture thus provided is preferably flowable. The mixture can be a solvent-containing and polyurethane-containing composition. The components preferably comprise at least one polyol and one isocyanate.

The mixture provided is in particular formed 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 comprise several components, individually or in combination selected from polyol, isocyanate, catalyst, release agent, additive.

Preferably, a chemical reaction starts when the mixture is provided. The chemical reaction is preferably an exothermic reaction. Furthermore, the chemical reaction is preferably a crosslinking reaction in which molecular polymer chains are preferably formed. Preferably, crosslinks are formed between the polymer chains. Preferably, polyurethane is formed in the crosslinking reaction. Preferably, the additional step takes place immediately before step g), i.e. the components forming the mixture are mixed with one another immediately before injection into the closed cavity halves.

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

The mixture is preferably thin when injected into the closed cavity halves in step g). Preferably, the viscosity at the start of injection into the closed cavity halves is in a range between 100 mPas to 300 mPas, preferably 120 mPas to 200 mPas, at a mixture temperature of 40°C to 100°C, preferably at a mixture temperature of 50°C to 75°C, particularly preferably at a mixture temperature of 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 hardened polyurethane layer is formed at the end of the chemical reaction.

The mixture provided preferably has reactive groups. The mixture provided particularly preferably 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 at a temperature in the range of 30°C to 180°C.

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

The term “curing” or “hardening” preferably refers to 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 curing or hardening can preferably be carried out by cooling, i.e. 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, i.e. 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 comprises at least one, preferably organic, polymer and/or at least one precursor thereof.

The term "polymer" is preferably understood to mean a substance which 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 which form at least one organic polymer by chemical reaction, preferably chain polymerization, polyaddition and/or polycondensation. A constitutional repeating unit (CRU) is preferably 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” preferably refers to 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 which can participate in the formation of the corresponding unbranched or branched polymer by 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 constitutional repeating units of the polymer. A reactive molecule, for example monomer, oligomer and optionally polymer, preferably has at least one reactive functional group.

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

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

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

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

• h) Entfernen der dritten Kavitätshälfte oder Entfernen der ersten Kavitätshälfte, wobei das Bauteil in der Haltevorrichtung verbleibt, indem das Halteelement durch die Haltevorrichtung gehalten wird,
• i) Freigeben des Halteelements durch die Haltevorrichtung,
• j) Entformen des Bauteils.

According to a further advantageous embodiment of the invention, the method additionally comprises the following steps, which are preferably carried out after step g), in particular in the following order:

• h) removing the third cavity half or removing the first cavity half, the component remaining in the holding device by holding the holding element by the holding device,
• i) Releasing the holding element through the holding device,
• j) Demoulding the component.

The film coated with the first and second layers is already referred to as a component here.

Preferably, when removing the third cavity half in step h), the component remains in the first cavity half.

Preferably, an adhesive force of the polyurethane (PUR) of the second layer to the third cavity half is smaller than an adhesive force of the thermoplastic of the first layer to the first cavity half. $${\text{F}}_{\text{Adhesion PUR to third cavity half}}<{\text{F}}_{\text{Adhesion of thermoplastic to first cavity half}}$$

Particularly preferably, an adhesive force of the holding element and/or the holding elements on the holding arm and/or on the holding arms is greater than an adhesive force of the second layer, preferably made of polyurethane, on the third cavity half. As a result, the component preferably remains with the holding device in the first cavity half. Preferably, the film remains pressed against the first cavity half by the holding device, in particular by the clamping frame.

If the first cavity half is removed in step h), the component preferably remains in the third cavity half.

Preferably, the holding element is released in step i) by moving the movable holding arm back from the holding element. The movable holding arm is preferably designed as a piston. Preferably, the holding device comprises several holding arms. The component can have one holding element or several holding elements. The holding arms are preferably each moved out of the holding element or each moved out of the corresponding holding element.

The holding arms, which are preferably designed as pistons, can be retracted along their axis in the holding device. The direction of movement of the holding arms preferably forms a demolding angle to a layering plane of the layer structure. The demolding angle is preferably 1° to 89°, particularly preferably 1° to 60°. By retracting the holding arms, the positive connection between the respective holding arm and the holding element and/or the corresponding holding element is overcome.

After the holding arms have been retracted, the clamping frame is preferably released from the film. To do this, the clamping frame is preferably moved. The clamping frame is preferably moved in the direction of the layer structure.

Any vacuum that may exist between the film and the first cavity half is preferably flooded with ambient air. This allows the component to be removed from the injection molding tool.

Furthermore, it is possible to produce several components parallel to one another by using turntable technology, cube technology and/or indexable plate technology.

Polyurethane is not thermoplastic, but a reaction product with an initially very low viscosity. Polyurethane can therefore mold geometries and/or structures, in particular complicated geometries and/or structures. The method according to the invention can therefore advantageously be used particularly flexibly with regard to special geometry specifications. Components with geometries and/or structures, in particular complicated geometries and/or structures, can be produced. These geometries and/or structures can, for example, comprise abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, tips and/or arches. In particular, the components can have particularly thick walls and/or abrupt jumps in wall thickness. In comparison to the injection molding process with thermoplastic materials, very little and/or very few geometric distortions and/or sink marks and/or cavities arise. The components according to the invention therefore advantageously have a high optical quality.

Preferably, before and/or during and/or after the application of the second layer, preferably made of polyurethane, in step g), the second layer can be modified and/or structured, preferably by inserting/placing particles on the first layer and/or by using tool structures on the third cavity half used in step f) and/or by subsequently processing the second layer by means of process steps selected individually or in combination from laser processing, overprinting, hot stamping, cold stamping, blind stamping, mechanical processing.

In particular by means of laser processing and/or mechanical processing and/or by using tool structures, it is possible to produce exposed relief structures in the second layer, which is preferably made of polyurethane, with a minimum line thickness and/or a minimum laserable dot diameter of 5 µm to 150 µm, preferably 10 µm to 100 µm. This makes it possible to produce the finest details, in particular for motifs and/or alphanumeric information. It is also possible to combine such fine structures with coarser, macroscopic structures, either in a laterally adjacent combination or as an overlay of a coarse structure with a fine structure. This can be achieved in particular by combining several of the above-mentioned process steps, for example to produce coarse 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 to and/or superimposed thereon with a minimum line thickness and/or a minimum laserable point diameter of 5 µm to 150 µm, preferably 10 µm to 100 µm. However, it is also possible for coarse structures and fine structures to be present together as a tool structure and thus molded in the second layer, which is preferably made of polyurethane. The depth of the relief structures can be between 1 µm and the maximum wall thickness of the second layer, which is preferably made of polyurethane, in particular between 0.001 mm and 50 mm, preferably between 0.001 mm and 30 mm, preferably between 0.001 mm and 15 mm.

• k) Applizieren einer weiteren Dekorschicht und/oder einer weiteren zumindest eine weitere Dekorschicht umfassenden Dekorlage auf der der Folie abgewandten Seite der ersten Schicht.

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

• k) Applying a further decorative layer and/or a further decorative layer comprising at least one further decorative layer on the side of the first layer facing away from the film.

The additional decorative layer and/or the additional decorative layer can be applied to the first layer by hot stamping and/or cold stamping and/or digital printing and/or functional foil bonding (FFB). The additional decorative layer and/or the additional decorative layer is preferably applied to the first layer made of thermoplastic and flooded with polyurethane in step g) to form the second layer.

Furthermore, it is possible that the further decorative layer and/or the further decorative layer comprising at least one further decorative layer is only applied in regions on the side of the first layer facing away from the film.

Advantageously, the decorative layer and the further decorative layer or the further decorative layer complement each other in the formation of a design, particularly in conjunction with transillumination technologies.

According to a further advantageous embodiment of the invention, the film is introduced in step b) with its carrier side adjacent to the first cavity half.

According to a further advantageous embodiment of the invention, the film is an IMD film. The IMD film is fed into the first cavity half in step b) as film roll material or inserted into the first cavity half as a label. Alternatively, the film can be an insert film. In this case, the insert film is inserted into the first cavity half in step b).

• l) Andrücken der die Dekorlage umfassenden Folie an die erste Kavitätshälfte durch die Haltevorrichtung, insbesondere durch einen durch die Haltevorrichtung ausgebildeten Klemmrahmen.

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

• l) Pressing the film comprising the decorative layer onto the first cavity half by means of the holding device, in particular by means of a clamping frame formed by the holding device.

Step I) is preferably carried out before closing the injection molding tool from step c). Preferably, the holding device, in particular the clamping frame, is moved against the film. The movement preferably takes place in a direction perpendicular to a plane formed by the film. The film is thereby preferably pressed against the first cavity half. Preferably, the film is fixed by the holding device, in particular by the clamping frame.

• m) Evakuieren der ersten Kavitätshälfte, so dass ein Vakuum zwischen der die Dekorlage umfassenden Folie und der ersten Kavitätshälfte hergestellt wird.

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

• m) Evacuating the first cavity half so that a vacuum is created between the film comprising the decorative layer and the first cavity half.

Preferably, step m) is carried out immediately after step b) and/or immediately after step i). Alternatively, step m) can be carried out during step c) or immediately after step c).

Preferably, the vacuum between the film comprising the decorative layer and the first cavity half is also maintained during steps c) to g). In the case of removal of the third cavity half in step h), the vacuum between the film comprising the decorative layer and the first cavity half is preferably also maintained during step h).

By evacuating the first cavity half, the film and/or the resulting component is advantageously held stably in the first cavity half. Furthermore, by evacuating the first cavity half, air inclusions or cavities in the first layer in step d) and/or in the second layer in step g) are advantageously prevented. This ensures good quality of the component.

According to a further advantageous embodiment of the invention, the first material is formed by an injection molding material, in particular by at least one thermoplastic, or by polyurethane.

According to a further advantageous embodiment of the invention, the second material is a flooding material, in particular polyurethane.

Polyurethane is not thermoplastic, but a reaction product with an initially very low viscosity. Polyurethane can therefore mold geometries and/or structures, in particular complicated geometries and/or structures. The component according to the invention, in particular the second layer of the component according to the invention, can therefore have geometries and/or structures, in particular complicated geometries and/or structures. These geometries and/or structures can, for example, comprise abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, tips and/or arches. In particular, the component, in particular the second layer of the component, can have particularly thick walls and/or abrupt jumps in wall thickness. In comparison to the injection molding process with thermoplastic materials, very little and/or very few geometric distortions and/or sink marks and/or cavities arise. The components according to the invention therefore advantageously have a high optical quality.

The first material is preferably transparent, in particular a transparent thermoplastic or transparent polyurethane.

The second material is preferably transparent, in particular transparent polyurethane.

It is also conceivable that the first material and/or the second material is translucent or opaque and/or colored. The first material and the second material can have different degrees of transmission.

In the present application, a film, layer or ply with a transmission greater than 70% is preferably referred to as transparent. With a transmission between 50% and 70%, the film, layer or ply is preferably referred to as translucent. With a transmission of less than 50%, the film, layer or ply is preferably referred to as opaque. The percentage values (% values) mentioned relate in particular to a transmission in the wavelength range perceptible to the human eye. The wavelength range perceptible to the human eye is preferably assumed to be the wavelength range from 380 nm to 780 nm.

• n) Schließen des Spritzgusswerkzeugs durch Einsetzen der vierten Kavitätshälfte in die erste Kavitätshälfte, so dass ein dritter Hohlraum entsteht,
• o) Beschichten der zweiten Schicht mit einem dritten Material unter Ausbildung einer dritten Schicht durch Einbringen, insbesondere Injizieren, des dritten Materials in den dritten Hohlraum,
• p) Entfernen der vierten Kavitätshälfte oder Entfernen der ersten Kavitätshälfte, wobei das Bauteil in der Haltevorrichtung verbleibt, indem das Halteelement durch die Haltevorrichtung gehalten wird.

According to an advantageous embodiment of the invention, the injection molding tool comprises a fourth cavity half. The method additionally comprises the following steps, which are preferably carried out between the removal of the third cavity half in step h) and step i), in particular in the following order:

• n) closing the injection mould by inserting the fourth cavity half into the first cavity half, so that a third cavity is created,
• o) coating the second layer with a third material to form a third layer by introducing, in particular injecting, the third material into the third cavity,
• p) removing the fourth cavity half or removing the first cavity half, wherein the component remains in the holding device by the holding element being held by the holding device.

The third material is preferably a flooding material, in particular polyurethane. Coating the second layer can therefore also be referred to as flooding the first layer with polyurethane. The third material is preferably transparent, in particular transparent polyurethane.

Changing the cavity half from the third to the fourth cavity half can be done using turntable, sliding table and/or indexable plate technology, for example. Changing to the fourth cavity half can also be done manually.

The third cavity created in step n) is preferably located directly adjacent to the second layer.

The coating or flooding with the third material to form the third layer is preferably carried out in step o) on the surface of the second layer facing away from the film, preferably directly on the second layer.

By completing step o), the manufacture of the component is preferably achieved.

The film coated with the first, second and third layers is already referred to as a component here.

Preferably, when removing the fourth cavity half in step p), the component with the holding device remains in the first cavity half.

Preferably, an adhesive force of the polyurethane (PUR) of the third layer to the fourth cavity half is smaller than an adhesive force of the thermoplastic of the first layer to the first cavity half. $${\text{F}}_{\text{Adhesion PUR to fourth cavity half}}<{\text{F}}_{\text{Adhesion of thermoplastic to first cavity half}}$$

Particularly preferably, an adhesive force of the holding element and/or the holding elements on the holding arm and/or on the holding arms is greater than an adhesive force of the third Layer on the fourth cavity half. As a result, the component preferably remains with the holding device in the first cavity half. Preferably, the film remains pressed against the first cavity half by the holding device, in particular by the clamping frame.

If the first cavity half is removed in step p), the component preferably remains in the fourth cavity half.

According to a further advantageous embodiment of the invention, the second layer and the third layer are each made of a flooding material, in particular polyurethane. In this embodiment, the second and the third material are each a flooding material, in particular polyurethane. The second material is preferably translucent or opaque and/or colored. The third material is preferably transparent. The second layer preferably forms geometries and/or structures, in particular complicated geometries and/or structures. These geometries and/or structures can, for example, include abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, tips and/or arches. In particular, the second layer can have particularly thick walls and/or abrupt jumps in wall thickness. The third layer is preferably arranged directly on the second layer. The third layer preferably covers the geometries and/or structures formed by the second layer. The third layer preferably has a smooth free surface or a free surface structured in a different way than the second layer. The third layer therefore preferably forms a protective layer on the second layer. Advantageously, the geometries and/or structures formed by the second layer are protected from contamination and/or damage by the third layer and remain visible through it.

Preferably, the vacuum between the film comprising the decorative layer and the first cavity half is also maintained during steps n) and o). In the case of removal of the fourth cavity half in step p), the vacuum between the film comprising the decorative layer and the first cavity half is preferably also maintained during step p).

The third material in step o) is particularly preferably a mixture, in particular a polyurethane-forming mixture. To avoid repetition, reference is made to the statements on the mixture forming the second material in step g). These statements apply accordingly to the third material in step o). In particular, the term "polyurethane layer" can also apply to the third layer.

Advantageous embodiments of the invention are explained below, which can relate to step g) and/or step o). To simplify the language, uniform terms are used. The term "closed cavity halves" can be understood as the second cavity in relation to step g) and/or as the third cavity in relation to step o). The term "polyurethane layer" can be understood as the second layer in relation to step g) and/or as the third layer in relation to step o).

According to a further advantageous embodiment of the invention, the mixture in step g) and/or in step o) is introduced, in particular injected, into the closed cavity halves with a filling pressure selected from a range of 70 bar to 140 bar, preferably from 80 bar to 100 bar. In step g), the mixture is preferably introduced, in particular injected, into the second cavity. In step o), the mixture is preferably introduced, in particular injected, into the third cavity.

According to a further advantageous embodiment of the invention, the polyurethane layer is formed in the closed cavity halves as a result of the introduction, in particular injection, of the mixture in step g) and/or in step o) at a temperature selected from a range from 40°C to 160°C, preferably from 60°C to 140°C, particularly 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, an exothermic reaction starts in the mixture when the polyurethane-forming mixture is provided at the mixing head. This exothermic reaction preferably heats up the mixture formed in the step g) and/or in step o) the mixture is introduced into the closed cavity halves. Depending on the current temporal 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 roughly constant process temperature. At the start 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, with increasing thermal energy being released, the tool temperature, which is kept largely constant, then leads to a cooling of the mixture which is heating up as a result of the reaction, 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 cavity halves are preferably pre-heated to a temperature selected from a range of 40°C to 160°C, preferably 60°C to 140°C, particularly preferably 80°C to 120°, before the mixture is introduced, in particular injected, in step g) and/or in step o). The temperature of the mixture at the start of the chemical reaction and/or immediately after the mixture has been mixed and/or immediately upon injection into the closed cavity halves is preferably lower than the temperature of the cavity halves (mold temperature). 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 preferably takes on the preset temperature of the cavity halves (mold temperature) as time progresses and/or as the reaction progresses.

Preferably, a temperature difference for cooling the component formed in the closed cavity halves is 0K to 100K, preferably 0K to 50K, particularly preferably 0K to 30K. The temperature difference for cooling the component formed in the closed cavity halves is thus 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.

• q) Härten des Gemischs innerhalb und/oder außerhalb der geschlossenen Kavitätshälften 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 g) and/or after step o):

• q) Curing the mixture inside and/or outside the closed cavity halves to form the polyurethane layer.

The duration of the curing process within the closed cavity halves is preferably 10 seconds to 120 seconds, particularly preferably 20 seconds to 90 seconds, further preferably 30 seconds to 70 seconds.

This is in particular 2 to 10 times the pot life of the mixture, preferably 3 to 7 times the pot life of the mixture. The pot life is the processability period or service life of the reactive mixture.

The component is preferably cooled in the closed cavity halves during the curing process. The duration of the curing process within the closed cavity halves can also be referred to as the cooling time. After the cooling time has ended, step h) is preferably carried out immediately. The cavity halves are opened. The cooling time depends on the degree of curing of the polyurethane and can vary as described above. The initially liquid polyurethane must have changed to the solid state so that deformation does not occur after the cavity halves are opened. For this purpose, the temperature of the tool cavity, i.e. in particular the cavity halves, preferably exceeds the ambient temperature by at least 5 K, preferably by 10 K. $${\text{T}}_{\text{Tool cavity}}>{\text{T}}_{\text{Vicinity}}+5\text{K}$$

The duration of the curing process outside the closed cavity halves, in particular on a holding device with the shape of the component, 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 polyurethane layer that forms hardens polyurethane layer as the chemical crosslinking reaction progresses. Preferably, a completely cured polyurethane layer is formed at the end of the chemical crosslinking reaction.

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

The curing according to step q) is preferably carried out 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 with a further decorative layer and/or further decorative layer applied to the first layer, the further decorative layer and/or further decorative layer has a primer layer, preferably a primer layer that is at least partially not yet fully cured, in particular an adhesion promoter layer, on the surface facing away from the first layer for a connection to the polyurethane of the second layer. The primer layer that is at least partially not yet fully cured is preferably cured together with the mixture applied to it and/or with the polyurethane layer applied to it, preferably completely cured. In the process, cross-links preferably form between the polyurethane layer and the primer layer. The polyurethane layer is preferably bonded to the primer layer in a material-locking manner.

The composite of the first layer and/or the further decorative layer and/or the further decorative layer with the polyurethane layer is preferably dimensionally stable. Preferably, the polyurethane layer cannot be removed from the first layer and/or the further decorative layer and/or the further decorative layer without causing damage.

• r) 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 i) and/or step j):

• r) Remove the carrier layer of the film.

This advantageous embodiment therefore preferably relates to the design of the film as an IMD film.

After carrying out step r), preferably only the decorative layer of the IMD film remains on the component.

A release layer of the IMD film can be arranged completely or partially on the decorative layer after removal of the carrier layer from the film and/or completely or partially on the carrier layer.

According to a further advantageous embodiment of the invention, the film in step b) is provided as a roll and/or as a continuous film and/or as a sheet and/or is introduced into the cavity half by means of film feed device technology. In particular, an IMD film can preferably be provided as a roll and/or as a continuous film. An IMD film can also be provided as a sheet. In particular, an insert film can preferably be provided as a sheet. An insert film can also be provided as a roll and/or as a continuous film.

Preferably, the method is carried out as an IMD method (IMD = In-Mold Decoration). In this case, the film comprising the decorative layer is conveyed as a transfer film with a carrier layer and a decorative layer having the decorative layer, in particular as a roll product, and is introduced into the first cavity half in particular according to step b).

Compared to other decoration processes such as painting using wet paints, the decoration process using paint transfer technology advantageously enables a much greater variety of designs. This makes it possible to create individual images, technical designs, haptic surfaces and many other design variants.

• s) Reinigen der Folie und/oder des Bauteils, vorzugsweise der ersten, zweiten und/oder dritten Schicht, insbesondere durch zumindest eine Bürste und/oder ein Gebläse und/oder eine Absaugeinrichtung.

According to a further advantageous embodiment of the invention, the method comprises the further following step or steps b), e), h), i), j) and/or p) comprise the further following sub-step:

• s) Cleaning the film and/or the component, preferably the first, second and/or third layer, in particular by means of at least one brush and/or a blower and/or a suction device.

• t) Bedrucken des Bauteils, vorzugsweise der zweiten und/oder dritten Schicht, insbesondere in zumindest einem ersten und/oder zweiten Bereich, vorzugsweise allein oder in Kombination ausgewählt aus Inkjetdruck, Tiefdruck, Siebdruck, Flachdruck, Hochdruck, Flexodruck, Tampondruck.

According to a further advantageous embodiment of the invention, the method comprises the further following step or step j) comprises the further following sub-step:

• t) printing the component, preferably the second and/or third layer, in particular in at least a first and/or second region, preferably alone or in combination selected from inkjet printing, gravure printing, screen printing, planographic printing, letterpress printing, flexographic printing, pad printing.

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

According to a further advantageous embodiment of the invention, the method comprises the further following step or step b) comprises the further following sub-step:

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

• v) Zuschneiden des Bauteils mittels Stanzen oder Wasserstrahlschneiden oder Laserschneiden.

According to a further advantageous embodiment of the invention, the method comprises the further following step or step j) comprises the further following sub-step:

• v) Cutting the component by punching or water jet cutting or laser cutting.

The cutting preferably refers to external cutting.

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

Preferably, the method may comprise the further following step or step j) may comprise the further following sub-step:

• w) Dividing the component into individual panels, in particular in the case of roll goods with multiple panels or in the case of sheets with multiple panels.

According to a further advantageous embodiment of the invention, the component obtained in step j) 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 equipment, consumer goods, documents, security elements, labels and/or electronic articles.

The process steps and sub-steps mentioned are described serially (running one after the other). The process steps and sub-steps mentioned can also run at least partially parallel to one another, in particular for producing several components according to the invention. The rotary plate technology and/or cube technology and/or indexable plate technology is preferably used for this purpose.

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

One advantage of the invention is that the decorative layer comprising at least one decorative layer, the first layer and possibly further decorative layers and/or further application layers are protected by the second and/or third layer lying above it, which is preferably made of polyurethane, as a protective layer. This enables advantageous effects, such as the creation of an increased optical depth effect.

Advantageously, the decorative layer comprising at least one decorative layer is only coated on one side with the further layer structure. In particular, the decorative layer comprising at least one decorative layer is not encapsulated on both sides. Therefore, the decorative layer comprising at least one decorative layer is advantageously accessible for further processing. In particular, the layer structure according to the invention enables direct laser processing of the decorative layer or decorative layer without having to laser through an injection molding material.

Furthermore, there are many possibilities for integrating structures. Structures can be provided in one cavity half of the injection molding tool, for example. Such a structure can be applied to the second and/or third layer, in particular to the layer made of polyurethane. protective layer, so that the structure is visible on the front of the finished component. Furthermore, such a structure can be reproduced on the first layer so that the structure is visible on the back of the finished component. It should be emphasized that when the structure is introduced on the back, the decorative layer or decorative layer also reproduces the structure very well. Micro- or nanostructures can be provided as structures, for example.

Furthermore, rear structures, which are reflected by the decorative layer or an IMD film covering it, are clearly visible as a design element. Rear structures can also be created using a laser. A further application can also be carried out using hot stamping and/or cold stamping and/or digital printing and/or functional foil bonding (FFB).

The decoration process using a transfer film, such as an IMD film, i.e. using a 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 a transfer film, it is possible to dispense with one or more subsequent process steps following the decoration, such as separate overprinting or lasering of lettering, symbols, etc. This in turn advantageously saves costs on decoration. A transfer film could already have all of these decorative elements such as decorative printing, negative decorations such as lettering or symbols, etc. in the layer structure of the transfer layer.

According to the invention, an injection molding tool is claimed which comprises a holding device and a first, second and third cavity half. The injection molding tool is claimed for carrying out a method for producing a component having a layer structure according to one of claims 1 to 12, and/or for carrying out a method according to one of claims 13 to 22. The holding device is designed to hold the at least one holding element formed on the first layer.

The holding device is preferably movable and/or comprises movable components, in particular a movable clamping frame and/or at least one movable holding arm.

Preferably, the injection molding tool additionally comprises a fourth cavity half.

According to an advantageous embodiment of the invention, the holding device comprises a clamping frame. The clamping frame is designed to produce a tight connection between the first cavity half and the film comprising the decorative layer, so that a vacuum can be produced between the film comprising the decorative layer and the first cavity half.

The clamping frame can preferably be controlled hydraulically, mechanically, electromechanically and/or pneumatically. The clamping frame preferably presses the film comprising the decorative layer against the first cavity half. The clamping frame preferably presses the film along a closed circumferential line against the first cavity half. The clamping frame preferably has an annular shape for this purpose. The ring shape can preferably be rectangular. The clamping frame preferably presses itself against a primer layer of the film designed as an adhesive layer for a connection to the first layer.

According to a further advantageous embodiment of the invention, the clamping frame is designed in one part or in multiple parts, in particular in two parts.

According to a further advantageous embodiment of the invention, the holding device comprises at least one movable holding arm. The holding arm can be controlled hydraulically, mechanically, electromechanically and/or pneumatically in order to move the holding arm away from the holding element and/or from the first layer.

The movable holding arm is preferably designed as a piston. The holding device preferably comprises a plurality of holding arms. The holding arms, which are preferably designed as pistons, can be moved along their axis in the holding device. In particular, the holding arm or arms can be moved away from the holding element and/or from the first layer.

In particular, the movable holding arm or arms can be connected to the clamping frame. Preferably, the movable holding arm or arms can be movably mounted in or on the clamping frame. In particular, the movable holding arm or arms can be driven out of the clamping frame in the direction of the holding element or into the clamping frame, i.e. away from the holding element.

The number of holding arms of the holding device and the number of holding elements provided on the first layer can be the same. In contrast, however, several holding arms can also correspond to one holding element. The number, arrangement and orientation of the holding arms depends in particular on the geometry and size of the component.

According to a further advantageous embodiment of the invention, the direction of movement of the holding arm to a layering plane of the layer structure forms a demolding angle of 1° to 89°, preferably a demolding angle of 1° to 60°.

The method according to the invention described above can be carried out with an injection molding tool that has one or more features of the injection molding tool according to the invention. The method according to the invention described above is preferably carried out with the injection molding tool according to the invention.

Of course, the above-mentioned material characteristics can also be applied equivalently in a process or the above-mentioned process characteristics can be applied in the product.

• 1 zeigt schematische Ansichten zu einem ersten erfindungsgemäßen Bauteil.
• 2 zeigt schematische Ansichten zu einem zweiten erfindungsgemäßen Bauteil.
• 3 zeigt ein Flussdiagramm zu einem beispielhaften erfindungsgemäßen Verfahren.
• 4 zeigt Ansichten zu den einzelnen Schritten des in 3 dargestellten beispielhaften erfindungsgemäßen Verfahrens bei der Herstellung des ersten erfindungsgemäßen Bauteils.
• 5 zeigt Ansichten zu den einzelnen Schritten des in 3 dargestellten beispielhaften erfindungsgemäßen Verfahrens bei der Herstellung des zweiten erfindungsgemäßen Bauteils.
• 6 zeigt verschiedene Beispiele für eine Strukturierung einzelner Schichten eines erfindungsgemäßen Bauteils.
• 7 zeigt einen schematischen Aufbau einer (a) IMD-Folie und einen schematischen Aufbau einer (b) Insert-Folie jeweils zum Bereitstellen einer zwischen einer ersten Schicht (Thermoplast) und einer zweiten Schicht (PUR) angeordneten weiteren Dekorlage.
• 8 zeigt einen schematischen Aufbau einer (a) IMD-Folie und einen schematischen Aufbau einer (b) Insert-Folie jeweils zum Bereitstellen einer Dekorlage zum Beschichten mit einer ersten Schicht (Thermoplast).

The invention is explained below using several embodiments with the aid of the accompanying drawings. The embodiments shown are therefore not to be understood as limiting.

• 1 shows schematic views of a first component according to the invention.
• 2 shows schematic views of a second component according to the invention.
• 3 shows a flow chart of an exemplary method according to the invention.
• 4 shows views of the individual steps of the 3 illustrated exemplary method according to the invention in the production of the first component according to the invention.
• 5 shows views of the individual steps of the 3 illustrated exemplary method according to the invention in the production of the second component according to the invention.
• 6 shows various examples of structuring individual layers of a component according to the invention.
• 7 shows a schematic structure of an (a) IMD film and a schematic structure of an (b) insert film, each for providing a further decorative layer arranged between a first layer (thermoplastic) and a second layer (PUR).
• 8th shows a schematic structure of an (a) IMD film and a schematic structure of an (b) insert film, each for providing a decorative layer for coating with a first layer (thermoplastic).

In 1 shows schematic views of a first component according to the invention. 1 (a) shows a schematic sectional view of the first component according to the invention. 1 (b) shows a schematic plan view of the first component according to the invention. The first component according to the invention has a layer structure. The layer structure is formed in this order by a decorative layer 1, a first layer 3, a further decorative layer 2 and a second layer 4. The first layer 3 is formed by a thermoplastic. The first layer 3 is therefore also referred to as a thermoplastic layer. The first layer 3 has, for example, a layer thickness of 2 mm. The second layer 4 is formed by polyurethane. The second layer 4 is therefore also referred to as a polyurethane layer. The second layer 4 has, for example, a layer thickness of 1 mm. In the present example, the decorative layer 1 is a layer of an IMD film to be transferred. The decorative layer 1 comprises, in this order, a protective layer, a decorative layer and a primer layer. In the present example, the primer layer is designed as an adhesive layer for a connection to the thermoplastic of the first layer 3.

In a modification of the first component according to the invention, the additional decorative layer 2 is omitted. In this case, the layer structure is formed in this order by a decorative layer 1, a first layer 3 and a second layer 4. The other features discussed here also apply in the same way to this modification of the first component according to the invention.

In the present example, the first layer 3 forms two holding elements. The two holding elements are arranged symmetrically to one another on two opposite sides of the component. In the first component according to the invention, the holding elements are each designed as outwardly projecting tabs 5. The first layer 3 and the two tabs 5 are formed in one piece. The tabs 5, like the first layer 3, are made of thermoplastic. In the present example, the tabs 5 each have an indentation 6 at their outwardly projecting end. These indentations 6 each enable the engagement of a movable holding arm 11 of a holding device provided on an injection molding tool.

1 (c) shows a detailed view as a schematic sectional view. In addition to the holding arm 11, the holding device comprises a clamping frame 10, which presses the film having the decorative layer 1, in the present example IMD film, onto the first cavity half 7. The holding device can also have further holding arms 11, in the present example a further holding arm 11 (not shown in the detailed view). Each holding arm 11 is accommodated in a bore in the clamping frame 10 so as to be movable along its axis. The outer end of the holding arm 11 forms a projection which engages in a form-fitting manner in the indentation 6 provided on the tab 5. In this way, the holding device blocks movement of the component in both an upward and a downward direction. This means that the holding device blocks movement of the component in both directions perpendicular to the first layer 3. Furthermore, the two holding arms 11 of the holding device are arranged symmetrically to one another and opposite one another, corresponding to the holding elements of the component. Therefore, a lateral movement of the component, i.e. a movement in the layering plane, is also prevented by the two opposing holding arms 11. This advantageously enables the component to be held securely in the holding device. In the present example, the holding arm 11 is designed as a piston which is movable along its axis. The holding arm 11 thus enables the holding element and thus the component to be released by moving back out of the indentation 6. The holding arm 11 can be controlled electromechanically for this purpose.

2 shows schematic views of a second component according to the invention. 2 (a) shows a schematic sectional view of the second component according to the invention. 2 B) shows a schematic plan view of the second component according to the invention. The second component according to the invention has a layer structure. The layer structure has the same sequence as in the first component according to the invention. Likewise, in a modification of the second component according to the invention, the further decorative layer 2 can be dispensed with. To avoid repetition, reference is made to the explanations for the first component according to the invention, which apply identically here.

The first layer 3 also forms two holding elements in the second component according to the invention. The two holding elements are also provided symmetrically to one another on two opposite sides of the component. In contrast to the first component according to the invention, the holding elements in the second component according to the invention are designed without the outwardly protruding tabs. The holding elements are each designed as an indentation 6 in the first layer. The indentations each extend over a surface area over which the underlying decorative layer 1 also extends. In the present example, the additional decorative layer 2 above also extends over these surface areas. In the present example, the second layer 4 is set back compared to the layers below it, so that it does not cover the layers below it in a peripheral edge area. In the present example, the second layer 4 accordingly does not extend over the surface areas spanned by the indentations. The surface area spanned by the second layer 4 can also be flush with the surface area of the first layer 2.

The indentations 6 in turn enable the engagement of a movable holding arm 11 of a holding device provided on an injection molding tool. 2 (c) shows a detailed view as a schematic sectional view. The holding device comprises, in addition to the holding arm 11, a clamping frame 10, which presses the film having the decorative layer 1, in the present example IMD film, onto the first cavity half 7. The holding device can additionally have further holding arms 11, in the present example a further holding arm 11 (not shown in the detailed view). Each holding arm 11 is movably accommodated along its axis in a hole in the clamping frame 10. The outer end of the The holding arm 11 forms a projection which engages in a form-fitting manner in the indentation 6 provided in the first layer 3. In this way, the holding device blocks movement of the component in both an upward and a downward direction. This means that the holding device blocks movement of the component in both directions perpendicular to the first layer 3. Furthermore, the two holding arms 11 of the holding device are arranged symmetrically to one another and opposite one another, corresponding to the holding elements of the component. Therefore, lateral movement of the component, i.e. movement in the layering plane, is also prevented by the two opposing holding arms 11. This advantageously enables the component to be held securely in the holding device. In the present example, the holding arm 11 is designed as a piston which is movable along its axis. The holding arm 11 thus enables the holding element and thus the component to be released by moving back out of the indentation 6. The holding arm 11 can be controlled electromechanically for this purpose.

3 shows a flow chart of an exemplary method according to the invention.

4 shows views of the individual steps of the 3 illustrated exemplary method according to the invention in the production of the first component according to the invention. In this case, tabs 5 with indentations 6 are formed on the first layer 3.

5 shows views of the individual steps of the 3 illustrated exemplary method according to the invention in the production of the second component according to the invention. In this case, indentations 6 are formed in the first layer 3 without the provision of tabs.

The steps of the exemplary method according to the invention are used together for the 3 to 5 explained. The method is carried out using an injection molding tool. The injection molding tool comprises the holding device and a first 7, second 8 and third cavity half 9. The holding device has a clamping frame 10 and two symmetrically opposite holding arms 11 corresponding to the two indentations 6 to be produced.

The following steps are preferably carried out one after the other.

In a step S01, an IMD film is inserted into the first cavity half 7. The IMD film is inserted into the first cavity half 7 in such a way that the carrier side of the IMD film rests against the first cavity half 7. The back of the IMD film, which has the decorative layer 1, will subsequently face the injection molding material. After insertion, the IMD film is pressed firmly against the first cavity half 7 by a clamping frame 10. The clamping frame 10 has a ring-shaped configuration when viewed from above. The ring shape is rectangular. The clamping frame 10 presses the IMD film firmly against the first cavity half 7 along a closed circumferential line. In addition to pressing the IMD film against the first cavity half 7 by the clamping frame 10, a vacuum is created between the IMD film and the first cavity half 7 so that the IMD film is sucked against the first cavity half 7.

In a step S02, the injection molding tool is closed by inserting the second cavity half 8 into the first cavity half 7. This creates a first cavity on the back of the IMD film, which has the decorative layer 1. The first cavity is delimited by the decorative layer 1, by the second cavity half 8 and by the holding arms 11 provided in the clamping frame 10. The clamping frame 10 and the holding arms 11 together form the holding device. In addition, the first cavity can be partially delimited by the first cavity half 7. The first cavity corresponds to the volume of the first layer 3 to be produced by means of back-injection molding. In the case of the first component according to the invention, the first cavity therefore also includes the volume of the tabs 5 to be produced together with the first layer 3 (see 4 , step 2). In addition, the first cavity in this case has a recess at the outer end of the volume of the tabs. The recesses are formed by a projection provided at the end of the holding arm 11 protruding into the first cavity. In the case of the second component according to the invention, the first cavity has the recesses to be produced in the first layer 3 (see 5 , step 2). In this case too, the indentations are each formed by a projection provided at the end of the holding arm 11 projecting into the first cavity.

In a step S03, the IMD film is directly back-injected with a thermoplastic on its rear side, which has the decorative layer 1. The first cavity is filled with the thermoplastic. The first layer 3 is formed. In the case of the first component according to the invention, the two tabs 5 are also formed together with the first layer 3 (see 4 , step 3). In this case, the tabs 5 each have a Indentation 6 at its outer end. The projection provided at the end of the respective holding arm 11 therefore engages in the corresponding indentation 6 in a form-fitting manner. In the case of the second component according to the invention, the two indentations 6 are formed in the first layer 3 in accordance with the indentations previously formed in the first cavity by the projections provided at the end of the holding arms 11 (see 5 , step 3). In this case too, the projection provided at the end of the respective holding arm 11 engages in a form-fitting manner in the corresponding recess 6.

In a step S04, the injection molding tool is opened after a cooling time of, for example, 60 seconds. To do this, the second cavity half 8 is removed. The holding elements are held by the holding arms 11 of the holding device. The clamping frame 10 also continues to press the IMD film onto the first cavity half 7 and the vacuum between the IMD film and the first cavity half 7 is maintained. Therefore, the IMD film coated with the first layer 3 remains safe and dimensionally stable in the first cavity half 7 when the injection molding tool is opened.

In a step S05, the injection molding tool is closed by inserting the third cavity half 9 into the first cavity half 7. This creates a second cavity adjacent to the first layer 3. The second cavity is also delimited by the third cavity half 9. The second cavity corresponds to the volume of the second layer 4 to be produced by flooding with polyurethane.

Alternatively, in further embodiments, a further decorative layer and/or a further decorative layer 2 comprising at least one further decorative layer can first be arranged on the first layer 3. When the injection molding tool is closed by inserting the third cavity half 9 into the first cavity half 7 (step S05), a second cavity is created which is adjacent to the first layer 3, the further decorative layer and/or the further decorative layer. The second cavity is also again delimited by the third cavity half 9. The second cavity also corresponds to the volume of the second layer 4 to be produced by flooding with polyurethane.

Changing the cavity half from the second 8 to the third cavity half 9 can be done, for example, by means of turntable, sliding table and/or indexable plate technology.

In a step S06, the surface of the first layer 3 facing away from the IMD film is flooded with polyurethane. The second cavity is filled with the polyurethane. The second layer 4 is formed from polyurethane. When the second layer 4 is completed, the IMD film is coated with the first 3 and the second layer 4. The first layer 3 has the holding elements described above. A component according to the invention has thus already been realized.

In the present example, the first layer 3 is immediately flooded with polyurethane. In the further embodiments in which a further decorative layer and/or a further decorative layer comprising at least one further decorative layer is arranged on the first layer 3 (see alternative in step S05), the further decorative layer, the further decorative layer and/or the first layer 3 are flooded with polyurethane in step S06.

In a step S07, the injection molding tool is opened after a cooling time of, for example, 60 seconds. To do this, the third cavity half 9 is removed. The holding elements continue to be held by the holding arms 11 of the holding device. In particular, an adhesive force of the holding elements on the holding arms 11 is greater than an adhesive force of the second layer 4 made of polyurethane on the third cavity half 9. In addition, the clamping frame 10 continues to press the IMD film onto the first cavity half 7 and the vacuum between the IMD film and the first cavity half 7 is maintained. Therefore, when the injection molding tool is opened, the component remains safe and dimensionally stable in the first cavity half 7.

In a step S08, the holding elements are released by the holding device. For this purpose, the holding arms 11 of the holding device are each moved out of the corresponding holding element. In the present example, the holding arms 11 designed as pistons are retracted along their axis in the holding device. The direction of movement of the holding arms forms a demolding angle 12 of 30° with respect to the plane of the first layer 3. By retracting the holding arms 11, the form fit between the respective holding arm 11 and the corresponding holding element is overcome. After the holding arms 11 have retracted, the clamping frame 10 is released from the IMD film. In addition, the evacuation between the IMD film and the first cavity half 7 is ended. The component can thus be removed from the injection molding tool.

After step S08, a carrier layer and a release layer of the IMD film can be removed from the component in a further step not shown in the figures. Further explanations can be found in 8 (a) and the corresponding description.

In a further step (not shown), the two holding elements designed as tabs 5 can be removed. The tabs 5 can be removed by cutting (for example with a knife) and/or by laser cutting.

6 shows various examples of structuring individual layers of a component according to the invention.

In a first example ( 6 (a) ), the decorative layer 1 has a surface structure. The surface structure can include or reinforce design elements. Furthermore, the surface structure can produce haptic and/or optical effects. The surface structure can include, for example, micro- or nanostructures.

The surface structure can be provided on the decorative layer 1 of the IMD film to be inserted into the injection molding tool before the method according to the invention is carried out. The surface structure can be applied, in particular molded, to the decorative layer 1 through the first cavity half 7. Furthermore, the surface structure can be provided on the decorative layer 1 in a further step after the method according to the invention has been carried out. For this purpose, post-processing can be carried out using laser, embossing and/or milling, for example. Furthermore, a further application can be carried out using digital printing and/or functional foil bonding (FFB).

In a second example ( 6 (b) ), the decorative layer 1 has a surface structure that was created by two processing steps. For example, the decorative layer 1 can already have its own surface structure before the method according to the invention is carried out. In addition, a surface structure can be molded onto the decorative layer 1 through the first cavity half 7.

In a third example ( 6 (c) ), the second layer 4 made of polyurethane has a surface structure. This surface structure can also include or reinforce design elements. Furthermore, this surface structure can produce haptic and/or optical effects. The surface structure can include, for example, micro- or nanostructures.

This surface structure can be molded onto the second layer 4 through the third cavity half 9. Furthermore, this surface structure can be produced in a further step after carrying out the method according to the invention on the second layer 4. For this purpose, post-processing can be carried out by means of laser, embossing and/or milling, for example.

In a fourth example ( 6 (d) ) both the decorative layer 1 and the second layer 4 made of polyurethane have a surface structure. The possibilities shown for the first to third examples again apply to the respective surface structure. In particular, the surface structure can be molded onto the decorative layer 1 through the first cavity half 7 and the surface structure can be molded onto the second layer 4 through the third cavity half 9.

7 shows a schematic structure of an (a) IMD film 20 and a schematic structure of an (b) insert film 30, each for providing a further decorative layer 2 arranged between a first layer 3 made of a thermoplastic and a second layer 4 made of polyurethane. The further decorative layer 2 can be seen in the finished component from the front, i.e. from a first surface. Therefore, in relation to the further decorative layer 2, it is also referred to as a first surface decoration.

The layer structure of an IMD film 20 or insert film 30 introduced for the additional decorative layer 2 is described below. The sequence of the layers corresponds to the sequence in the layer structure of the resulting or finished component.

The IMD film 20 has a first primer layer 21. The first primer layer 21 is formed by an adhesive layer for a connection with the thermoplastic of the first layer 3 of the component. In the finished component, the first primer layer 21 lies directly against the first layer 3 formed from a thermoplastic. The first primer layer 21 is immediately followed by a decorative layer 22. The decorative layer 22 is immediately followed by a second primer layer 23. The second primer layer 23 is formed by an adhesive layer for a connection to the polyurethane of the second layer 4 of the component. In the finished component, the second primer layer 23 lies directly against the second layer 4 made of polyurethane. The first primer layer 21, the decorative layer 22 and the second primer layer 23 together form the layer of the IMD film 20 to be transferred, which forms the decorative layer 2 in the finished component. In the structure of the IMD film 20, the second primer layer 23 is immediately followed by a release layer 24. The release layer 24 is immediately followed by a carrier layer 25. The carrier layer 25 is formed by a PET film. The release layer 24 and the carrier layer 25 are detached from the IMD film 20 before flooding with polyurethane (step S06).

The insert film 30 has a carrier layer 31. The carrier layer 31 is a thermoplastic film. In the finished component, the carrier layer 31 lies directly against the first layer 3 made of a thermoplastic. The carrier layer 31 is immediately followed by a third primer layer 32. The third primer layer 32 is formed by an adhesive layer for connecting to the carrier layer 31 designed as a thermoplastic film. The third primer layer 32 is immediately followed by a decorative layer 33. The decorative layer 33 is immediately followed by a fourth primer layer 34. The fourth primer layer 34 is formed by an adhesive layer for connecting to the polyurethane of the second layer 4 of the component. In the finished component, the fourth primer layer 34 lies directly against the second layer 4 made of polyurethane.

8th shows a schematic structure of an (a) IMD film 40 and a schematic structure of an (b) insert film 50, each for providing a decorative layer 1 for coating with a first layer 3 made of a thermoplastic. The decorative layer 1 is located at the back of the finished component, i.e. on a second surface. Therefore, in relation to the decorative layer 1, it is also referred to as a second surface decoration.

The layer structure of an IMD film 40 or insert film 50 used for the decorative layer 1 is described below. The sequence of the layers corresponds to the sequence in the layer structure of the resulting or finished component.

The IMD film 40 has a carrier layer 41. The carrier layer 41 is formed by a PET film. The IMD film 40 is inserted into the first cavity half 7 in step S01 such that the carrier layer 41 of the IMD film 40 rests against the first cavity half 7. The carrier layer 41 is immediately followed by a release layer 42. The carrier layer 41 and the release layer 42 can be detached from the IMD film 40 after steps S01 to S08 have been carried out, i.e. after the component has been completed. In the structure of the IMD film 20, the release layer 42 is immediately followed by a protective layer 43. After the carrier layer 41 and release layer 42 have been detached, the protective layer 43 can form a surface of the finished component. The protective layer 43 is immediately followed by a decorative layer 44. The decorative layer 44 is immediately followed by a fifth primer layer 45. The fifth primer layer 45 is formed by an adhesive layer for a connection with the thermoplastic of the first layer 3 of the component. The fifth primer layer 45 is back-injected with thermoplastic in the process according to the invention and in the finished component lies directly against the first layer 3 formed from the thermoplastic. The protective layer 43, the decorative layer 44 and the fifth primer layer 45 together form the layer of the IMD film 40 to be transferred, which forms the decorative layer 1 in the finished component.

The insert film 50 has a carrier layer 51. The carrier layer 51 is a thermoplastic film. The insert film 50 is inserted into the first cavity half 7 in accordance with step S01 such that the carrier layer 51 rests against the first cavity half 7. The carrier layer 31 is immediately followed by a sixth primer layer 52. The sixth primer layer 52 is formed by an adhesive layer for a connection to the carrier layer 51 designed as a thermoplastic film. The sixth primer layer 52 is immediately followed by a decorative layer 53. The decorative layer 53 is immediately followed by a seventh primer layer 54. The seventh primer layer 54 is formed by an adhesive layer for a connection to the thermoplastic of the second layer 3 of the component. The seventh primer layer 54 is back-injected with thermoplastic in the process according to the invention and in the finished component lies directly against the first layer 3 formed from the thermoplastic.

It is clear to the person skilled in the art that the above-mentioned embodiments of the devices, equipment, methods or method steps can be combined with one another as desired and do not represent any limitation, in particular in their design and combination.

List of reference symbols

1

Decorative layer

2

additional decorative layer

3

first layer

4

second layer

5

Tab

6

indentation

7

first cavity half

8th

second cavity half

9

third cavity half

10

Clamp frame

11

Holding arm

12

Draft angle

20

IMD film

21

first primer layer

22

Decorative layer

23

second primer layer

24

Release layer

25

Carrier layer

30

Insert foil

31

Carrier layer

32

third primer layer

33

Decorative layer

34

fourth primer layer

40

IMD film

41

Carrier layer

42

Release layer

43

Protective layer

44

Decorative layer

45

fifth primer layer

50

Insert foil

51

Carrier layer

52

sixth primer layer

53

Decorative layer

54

seventh primer 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 accepts no liability for any errors or omissions.

Cited patent literature

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

Cited non-patent literature

• EN ISO 3219:1994-10 [0085]

Claims (27)

Component having a layer structure, in particular a layer structure with at least three layers, characterized in that the layer structure comprises a decorative layer (1), wherein the decorative layer (1) comprises at least one decorative layer, that a first layer (3) made of a first material is arranged on the decorative layer (1), that a second layer (4) made of a second material is arranged on the first layer (3), and that the first layer (3) has a peripheral edge and comprises at least one holding element or is connected to at least one holding element, wherein the holding element extends along the edge of the first layer (3). Component according to Claim 1 , characterized in that the first material is formed by an injection molding material, in particular by at least one thermoplastic, or by polyurethane, and/or that the second material is a flooding material, in particular polyurethane. Component according to Claim 1 or 2 , characterized in that a third layer made of a third material is arranged on the second layer (4), and that the third material is preferably a flooding material, in particular polyurethane. Component according to one of the preceding claims, characterized in that the holding element is designed to hold the component in an injection molding tool. Component according to one of the preceding claims, characterized in that the holding element is designed as an outwardly projecting tab (5), wherein the holding element is formed from the first material, and/or that the holding element is designed as an indentation (6) in the first material. Component according to one of the preceding claims, characterized in that the indentation (6) is designed for engagement with a holding device of an injection molding tool, in particular that the indentation (6) is designed for positive engagement with a holding device of an injection molding tool. Component according to one of the preceding claims, characterized in that the decorative layer (1) is a layer of an IMD film or a label to be transferred, or that the decorative layer (1) is part of an insert film. Component according to one of the preceding claims, characterized in that a further decorative layer and/or a further decorative layer (2) comprising at least one further decorative layer is arranged between the first layer (3) and the second layer (4). Component according to one of the preceding claims, characterized in that the first layer (3) comprises exactly one holding element, wherein the holding element is preferably designed to run all the way around the component, wherein the holding element is particularly preferably designed to run completely all the way around the component. Component according to one of the preceding claims, characterized in that the first layer (3) comprises two, three, four, five, six, eight, ten or twelve holding elements. Component according to one of the preceding claims, characterized in that the first layer (3) has a wall thickness of 0.5 mm to 10 mm, that the first layer (3) preferably has a wall thickness of 1 mm to 5 mm, that the first layer (3) particularly preferably has a wall thickness of 1.5 mm to 3 mm. Component according to one of the preceding claims, characterized in that the second layer (4) has a wall thickness of 0.2 mm to 50 mm, that the second layer (4) in particular has a wall thickness of 0.2 mm to 30 mm, that the second layer (4) preferably has a wall thickness of 0.3 mm to 15 mm, that the second layer (4) preferably has a wall thickness of 0.5 mm to 5 mm, that the second layer (4) particularly preferably has a wall thickness of 0.8 mm to 3 mm. Method for producing a component having a layer structure, in particular a layer structure with at least two layers, preferably a component according to one of the Claims 1 until 12 , preferably injection molding process, the process comprising the following steps, in particular in the following order: a) providing an injection molding tool comprising a holding device and a first (7) and second cavity half (8), b) introducing a film comprising a decorative layer (1) with at least one decorative layer into the first cavity half (7), c) closing the injection molding tool by inserting the second cavity half (8) into the first cavity half (7) so that a first cavity is created which rests against the film, d) coating the film with a first material to form a first layer (3) by introducing the first material into the first cavity, the first layer (3) being formed with at least one holding element such that the holding device is arranged in a form-fitting manner with the holding element, e) removing the second cavity half (8), the film coated with the first layer (3) remaining in the first cavity half (7) by holding the holding element by the holding device. Procedure according to Claim 13 , characterized in that the injection molding tool comprises a third cavity half (9), and that the method additionally comprises the following steps, which are preferably carried out after step e), in particular in the following order: f) closing the injection molding tool by inserting the third cavity half (9) into the first cavity half (7) so that a second cavity is created, g) coating the film coated with the first layer (3) with a second material to form a second layer (4) by introducing the second material into the second cavity. Procedure according to Claim 14 , characterized in that the method additionally comprises the following steps, which are preferably carried out after step g), in particular in the following order: h) removing the third cavity half (9) or removing the first cavity half (7), wherein the component remains in the holding device by the holding element being held by the holding device, i) releasing the holding element by the holding device, j) demolding the component. Method according to one of the Claims 13 until 15 , characterized in that the method additionally comprises the following step, which is preferably carried out between step e) and step f): k) applying a further decorative layer and/or a further decorative layer (2) comprising at least one further decorative layer on the side of the first layer (3) facing away from the film. Method according to one of the Claims 13 until 16 , characterized in that in step b) the film is introduced with its carrier side adjacent to the first cavity half (7). Method according to one of the Claims 13 until 17 , characterized in that the film is an IMD film, wherein the IMD film is fed into the first cavity half (7) as film roll material in step b) or is inserted as a label, or that the film is an insert film and is inserted into the first cavity half (7) in step b). Method according to one of the Claims 13 until 18 , characterized in that the method additionally comprises the following step, which is preferably carried out after step b): I) pressing the film comprising the decorative layer (1) onto the first cavity half (7) by means of the holding device, in particular by means of a clamping frame (10) formed by the holding device. Method according to one of the Claims 13 until 19 , characterized in that the method additionally comprises the following step, which is preferably carried out after step b) and/or after step I): m) evacuating the first cavity half (7) so that a vacuum is created between the film comprising the decorative layer (1) and the first cavity half (7). Method according to one of the Claims 13 until 20 , characterized in that the first material is formed by an injection molding material, in particular by at least one thermoplastic, or by polyurethane, and/or that the second material is a flooding material, in particular polyurethane. Method according to one of the Claims 13 until 21 , characterized in that the injection molding tool comprises a fourth cavity half, and that the method additionally comprises the following steps, which are preferably carried out between the removal of the third cavity half (9) in step h) and step i), in particular in the following order: n) closing the injection molding tool by inserting the fourth cavity half into the first cavity half (7) so that a third cavity is created, o) coating the second layer (4) with a third material to form a third layer by introducing the third material into the third cavity, p) removing the fourth cavity half or removing the first cavity half (7), wherein the component remains in the holding device by the holding element being held by the holding device. Injection molding tool comprising a holding device and a first (7), second (8) and third cavity half (9) for carrying out a method for producing a component having a layer structure according to one of the Claims 1 until 12 , and/or for carrying out a method according to one of the Claims 13 until 22 , characterized in that the holding device is designed to hold the at least one holding element formed on the first layer (3). Injection molding tool according to Claim 23 , characterized in that the holding device comprises a clamping frame (10), wherein the clamping frame (10) is designed to produce a tight connection of the first cavity half (7) with the film comprising the decorative layer (1), so that a vacuum can be produced between the film comprising the decorative layer (1) and the first cavity half (7). Injection molding tool according to Claim 23 or 24 , characterized in that the clamping frame (10) is designed in one part or in several parts. Injection molding tool according to one of the Claims 23 until 25 , characterized in that the holding device comprises at least one movable holding arm (11), wherein the holding arm can be controlled hydraulically, mechanically, electromechanically and/or pneumatically in order to move the holding arm (11) away from the holding element and/or from the first layer (3). Injection molding tool according to Claim 26 , characterized in that the direction of movement of the holding arm (11) to a layering plane of the layer structure forms a demolding angle (12) of 1° to 89°, preferably forms a demolding angle (12) of 1° to 60°.

Images