DE202020102525U1 - Molded multi-layer component with functional capabilities - Google Patents

Abstract

Shaped multi-layer component with functional capabilities comprising:
a rigid spray body (10) made of a first polymeric material, which comprises a main surface (11) which can be melted without being destroyed within a first melting temperature range;
a coating film (20) with functional capabilities and comprising, at least in one layer in contact with the main surface (11) of the spray body (10), a second material which is meltable without destruction within the first melting temperature range, said layer on the main surface (11) the spray body (10) is heat-welded;
characterized in that
the main surface (11) of the spray body (10) is smooth and flat or is smooth and has radii of curvature greater than 20 mm;
the coating film (20) also contains an electrically conductive functional material (21) flexible, mixed with or arranged on the second polymeric material, forming at least one conductive circuit in connection with a power source, said functional electrically conductive material (21) within the first melting temperature range is stable;
so that a spraying process of the spray body (10) within an injection mold, which contains the coating film (20) with the electrically conductive functional material (21), produces the hot welding of the coating film (20) on the spray body (10) without destroying the conductive circuit.

Description

Technical field

The present invention relates to the field of multi-layer molded components with functional capabilities, that is, components that have a particular shape that consist of multiple superimposed layers and that have the ability to perform additional functions in addition to the inherent functions of the initially designed component.

State of the art

Multi-layer components are known, which are formed by means of a molding process known as “in-mold decoration”, which consists of inserting a film with printed decorative motifs into a mold, closing the mold and melting it inject polymeric material into said mold, which will remain in contact with said film. The decorative motifs are finally transferred to the surface of the molded component.

The process known as "in-mold labeling" is also known, which is similar to in-mold decoration, but does not only transfer printed decorative motifs, but also a label that is made of paper or made of paper Can be plastic, with a visible printed surface y with a surface that adheres to the molded component.

The utility model CN208283675U also describes a process which is similar to the previously described processes by which a functional layer is adhered which provides an optical filter on a transparent molded component which is intended to be used as glasses or as an eye protection shield.

None of the documents known from the prior art enable active functional capabilities to be obtained, that is to say to be regulated or changed as desired, with the economic and robust advantages which the products obtained with the aforementioned manufacturing processes provide.

Brief description of the invention

• • einen starren Spritzkörper hergestellt aus einem ersten polymeren Material, welcher eine Hauptfläche umfasst, die ohne Zerstörung innerhalb eines ersten Schmelztemperaturbereiches schmelzbar ist;
• • eine Beschichtungsfolie mit funktionellen Fähigkeiten, welche, mindestens in einer Schicht in Kontakt mit der Hauptfläche des Spritzkörpers, ein zweites Material umfasst, welches ohne Zerstörung innerhalb des ersten Schmelztemperaturbereiches schmelzbar ist, wobei die genannte Schicht an der Hauptfläche des Spritzkörpers heißgeschweißt ist.

The present invention relates to a molded multilayer component having functional capabilities, in a manner known per se in the industry:

• A rigid injection molded body made of a first polymeric material which comprises a main surface which can be melted without being destroyed within a first melting temperature range;
• A coating film with functional capabilities which, at least in one layer in contact with the main surface of the spray body, comprises a second material which can be melted without being destroyed within the first melting temperature range, the layer being heat-welded to the main surface of the spray body.

That is, a component is known which comprises a body made of a first polymeric material which is molded and is provided with a main surface on which a coating film having functional capabilities is adhered by means of hot welding, which functionalities correspond to the own functionalities of the Add body made of polymeric material.

The first polymeric material, for its formation, must be melted at a temperature which is within the first melting temperature range and injected into a mold which is at the temperature mentioned.

• • dass die Hauptfläche des Spritzkörpers glatt und flach ist oder glatt ist und Krümmungsradien größer als 20 mm aufweist; und
• • dass die Beschichtungsfolie außerdem ein funktionelles elektrisch leitendes flexibles Material enthält, mit dem zweiten polymeren Material gemischt oder darauf angeordnet, unter Bildung mindestens eines leitenden Schaltkreises in Verbindung mit einer Stromquelle, wobei das genannte funktionelle elektrisch leitende Material innerhalb des ersten Schmelztemperaturbereiches stabil ist.

The proposed component also contains, in a manner not known in the art,

• • that the main surface of the spray body is smooth and flat or smooth and has radii of curvature greater than 20 mm; and
• • that the coating film also contains a functional, electrically conductive, flexible material, mixed with or arranged on the second polymeric material, with the formation of at least one conductive circuit in conjunction with a power source, the said functional, electrically conductive material being stable within the first melting temperature range.

It is therefore proposed that the coating film integrates one or more conductive circuits which are formed from a functional, electrically conductive, flexible material, so that the passage of current through the proposed component is permitted, the current mentioned being able to be used for the component to be provided with several active functional abilities, such as optical, acoustic, light-giving, thermal, sensitive functional abilities, etc.

It is proposed that the electrically conductive functional material be made from a material that is selected to be stable within the first melting temperature range, that is, that the electrically conductive functional material does not undergo any change when heated to a temperature, which is within the first temperature range mentioned. This enables the at least one conductive circuit to be integrated into the coating film prior to the hot welding of the coating film on the spray body during the molding of the spray body, without the heat generated during the said process damaging the conductive circuit mentioned.

The electrically conductive functional material which is integrated in the coating film will be flexible, but if the said coating film is excessively bent, there could be a risk that the conductive circuitry will be broken. In order to avoid this problem, it is proposed that the main surface of the spray body, on which the coating film adheres, be smooth and flat or smooth and have radii of curvature greater than 20 mm, thereby ensuring that there is no excessive adhesion of the coating film to the spray body Bends of the coating film mentioned occur.

Said electrically conductive functional material can, for example, be printed or adhered to the surface of the remainder of the coating film. This embodiment enables tailor-made conductive circuitry to be implemented with any desired configuration.

Alternatively, it is contemplated that the electrically conductive functional material be added in the form of an additive dispersed within the second material that forms the coating film, said second material being provided with higher functional capabilities of the power line. In such a case, the shape and arrangement of the coating film will determine the conductive circuit obtained.

According to the preferred manufacturing method of the present component, the coating film is arranged within a mold, which conductive circuitry is formed from the electrically conductive functional material before the mold is closed.

The first polymeric material is then melted and injected into the mold so that it becomes full, and thus it comes into contact with the above-mentioned layer of the coating film made of a second material, said coating film being pressed against the wall of the mold.

The temperature of the first molten material melts at least a superficial part of the second material of the coating film, so that the fusion of both the first and the second material is effected.

The second material may be the same or different polymeric material than the first polymeric material, or may be a heat activated adhesive.

When the mold is opened, the resulting component is removed, which will have adhered to the coating film on the main surface of the spray body.

In order to simplify the manufacturing process, the coating film can temporarily be attached to a strip which crosses the mold before and during the spraying process, and is detached therefrom at the end of the spraying process. Moving the strip allows a new coating film to be positioned within the mold before the manufacturing process is repeated.

The coating film with the electrically conductive functional material is therefore heat-sealed on the spray body during the spraying process within the injection mold.

According to a preferred embodiment of the invention, the spray body is transparent, the coating film is transparent and the electrically conductive functional material is also, at least in part of the coating film, a transparent material. This application will enable the proposed component to be used as glasses or eye protection shield, such as helmet shields, with active functional capabilities being integrated in the shield or glasses mentioned.

In one embodiment, the electrically conductive functional material, in at least a portion of the coating film, may contain a semiconductive material that provides an electrical resistance that is selected to dissipate at least half of the current transmitted thereby in the form of heat, so that functional Active heating capabilities are provided.

If desired, functional skills of active heating and in one To obtain transparent electrically conductive functional material, it is proposed that the electrically conductive material is an indium and tin oxide.

If the multilayer component is a transparent eye protection shield, which is integrated, for example, in a helmet, or a pair of glasses, the use of said indium and tin oxide as a coating layer, which covers the majority of the transparent multilayer component, enables said shield or glasses is made clear in cold environments or that it is steamed up by the application of a current thereby.

The functional capabilities of active heating can also be useful in non-transparent multilayer components, for example for defrosting in cold environments, for heating interfaces that have to be operated by a user, such as in steering wheels, handlebars, mice, or for seats or benches. Consideration is given to their integrated use in clothing or other accessories in contact with the user's body, ideally a rigid hollow housing to protect body parts such as boots, helmets, knee pads, etc.

It is additionally proposed that the coating film also contain a protective layer made of a third polymeric material, the electrically conductive material being protected between the protective layer and the spray body. Said protective layer can also smooth the surface of the coating film by covering the irregularities that the presence of the conductive circuit can cause.

The surface of the protective layer can optionally contain printed patterns.

The mentioned at least one conductive circuit can, for example, be connected to at least one light-emitting diode which is integrated in the coating film, such as an LED (light emiting diode) or an OLED (organic light emiting diode) which is printed on the coating film is and / or can be connected to a sensor which is integrated in the coating film, such as a temperature sensor, moisture sensor, photoluminescence sensor, acoustic sensor, vibration sensor, pressure sensor.

It is also proposed that the electrically conductive functional material, in at least part of the coating film, may contain a photochromic material which can form one or more pixels of a liquid crystal display. The application can be combined, for example, with a transparent multilayer component as described above in order to show information thereon, or even to change the transparency thereof by means of the photochromic material mentioned.

According to another embodiment, the at least one circuit mentioned can contain at least one antenna integrated in the coating film, which is defined, for example, by the conductive circuit itself in a spiral configuration, so that the transmission or reception of radio signals is made possible by means of the multilayer component mentioned.

It is proposed that the first polymeric material and / or the second polymeric material is preferably PET, polyester or a mixture thereof.

It is also proposed that the electrically conductive functional material, in at least part of the coating film, may contain graphene, which is a material with known electrically conductive properties and which also provides other functionalities, such as, for example, an increase in the breaking or abrasion resistance. Said graphene can be mixed with the second material or can be deposited thereon.

It should be understood that the references to geometric positions, such as, for example, parallel, vertical, tangential, etc., deviations of up to ± 5 ° with respect to the theoretical position defined by the designation mentioned.

It should also be understood that each value range provided cannot be optimal in its extreme values and that it requires adaptations of the invention so that the extreme values mentioned can be used, the said adaptations being part of the scope of a person skilled in the art.

Other features of the invention will appear in the detailed description of an embodiment that follows.

Figure list

• 1 eine Explosionsansicht einer rechteckigen Mehrschichtkomponente wie die Vorgeschlagene zeigt, bestehend aus einem Spritzkörper aus polymerem Material mit einer flachen und glatten Hauptfläche, auf welcher eine Beschichtungsfolie aus polymerem Material heißgeschweißt ist, auf welcher es einen leitenden Schaltkreises gibt, definiert durch ein elektrisch leitendes Material, welches auf der genannten Beschichtungsfolie gedruckt ist, welche eine Leuchtdiode enthält, all dies mit einer Schutzschicht überzogen;
• 2 die in 1 gezeigte Mehrschichtkomponente im zusammengefügten Zustand zeigt;
• 3 ein Implementierungsbeispiel der in 1 und 2 gezeigten Mehrschichtkomponente zeigt, wobei die genannte Mehrschichtkomponente wie ein Helm geformt ist, welcher in dessen Hinterteil die Leuchtdiode integriert, um die Sichtbarkeit des Trägers des erwähnten Helms zu verbessern;
• 4 eine abgeflachten Explosionsansicht eines anderen Ausführungsbeispiels der Mehrschichtkomponente zeigt, in welchem sie als transparente Helmschild eingesetzt wird und in welchem der leitende Schaltkreis, in der zentralen Hauptzone des Schildes, ein transparentes halbleitendes Material enthält, welches mindestens des dadurch übertragenen Stroms in Form von Hitze zerstreut.

The foregoing and other advantages and features will be more fully understood from the following detailed description of an embodiment with reference to the accompanying drawings, which are to be interpreted in an illustrative rather than a restrictive manner, in which:

• 1 an exploded view of a rectangular multilayer component as the proposed shows, consisting of an injection molding of polymeric material with a flat and smooth main surface, on which a coating film of polymeric material is heat-welded, on which there is a conductive circuit defined by an electrically conductive material, which is printed on said coating film, which contains a light-emitting diode, all of which is covered with a protective layer;
• 2nd in the 1 multi-layer component shown in the assembled state;
• 3rd an implementation example of the in 1 and 2nd multilayer component shown, said multilayer component being shaped like a helmet which integrates the light-emitting diode in the rear part thereof in order to improve the visibility of the wearer of the said helmet;
• 4th shows a flattened exploded view of another embodiment of the multilayer component, in which it is used as a transparent helmet shield and in which the conductive circuit, in the central main zone of the shield, contains a transparent semiconducting material which dissipates at least the current thereby transmitted in the form of heat.

Detailed description of an embodiment

The accompanying figures show illustrative, non-limiting embodiments of the present invention.

1 and 2nd show a multi-layer component formed from a spray body 10th made of a first polymeric material and which has a flat and smooth main surface 11 Are defined. The first polymeric material melts without suffering damage when exposed to a temperature that is within a first temperature range, and solidifies when its temperature is less than said first temperature range. This enables the injection molded body to be manufactured within a mold by means of an injection molding process.

In this example the spray body is 10th a rectangular part with a constant thickness.

On the main area 11 of the spray body 10th is a coating film 20 made of a second material, which is preferably also polymeric, heat-welded. The second material is selected such that it melts within the first temperature range mentioned without suffering destruction. This enables the introduction of the coating film already formed 20 into the injection mold before the spray body 10th is manufactured in the form mentioned. When the first molten material is injected into the closed mold, the coating film will come into contact with the first molten material so that it is heated and thus heat welded and pressed against one of the walls of the mold.

In the present exemplary embodiment, there is on the coating film 20 a conductive circuit made of an electrically conductive material 21 is defined. In this example it is proposed that the conductive circuit contact terminals, which are symbolized in this example by means of two circles, a light emitting diode 23 which, for example, one on the coating film 20 can be printed OLED device, and interconnects, which are also on the coating film 20 are printed and the contact terminals with the LED 23 connect, so that when connecting the contact terminals to a power source such as battery, the light emitting diode 23 emits light.

All components that make up the conductive circuit are made of different electrically conductive materials 21 , are selected to be stable when heated to a temperature within the first temperature range, that is, they will not be damaged and will continue to act as a conductive circuit even if they are heated to a temperature within the first temperature range be heated. This enables said conductive circuit to be made of electrically conductive material 21 on the coating film 20 is defined before said coating film 20 is inserted into the mold and before the spray body 10th is manufactured within the stated form as described above, without this damaging the conductive circuit.

Finally, and optionally, it is suggested that the one on the coating sheet 20 printed conductive circuit by means of a protective layer 22 made of a third polymeric material, which ideally also remains stable when heated to temperatures within the first temperature range. This example suggests that the protective layer 22 the contact terminals and also the light emitting diode 23 leaves uncovered, although the latter would not be necessary if the protective layer 22 is made of a transparent or translucent material.

The protective layer 22 can be printed with decorative motifs, preferably with ink, which is also stable at the temperatures of the first temperature range.

An implementation example of this multilayer component is given in 3rd shown in which it has been used to manufacture the dome of a helmet, which has a light-emitting diode in the rear 23 integrated, which is connected to electrical conductors.

The conductive terminals of the conductive circuit can be connected to a battery outside the helmet by means of a plug, or the helmet can integrate a battery which has the light-emitting diode 23 provided.

4th shows an exploded view of another embodiment in which the multilayer component is a transparent helmet shield. In this case, the spray body 10th and the coating film is transparent and has a uniform thickness in order to avoid distortions.

In this case, the electrically conductive material 21 , which covers the central section of the shield, a film of semiconducting material 24th Made from indium and tin oxide, which is transparent and which is heated when it is traversed by electricity so that the shield can be made clear. Conductive circuitry channels the current to two connection terminals, which are located around the two opposite joints, where the shield connects to the rest of the helmet.

The present invention permits many other applications, including, for example, sensors or antennas in the conductive circuit in which some or all of the layers of the multilayer component are transparent or translucent, etc.

The present invention therefore enables the integration of circuits in spray bodies in a simple and inexpensive manner by means of an in-mold decoration or in-mold labeling technique.

It is to be understood that the different parts that form the invention and are described in one embodiment are free with the parts that can be combined in other different embodiments, even if this combination has not been expressly described, provided that there is no impairment in the combination exists.

QUOTES INCLUDE IN THE DESCRIPTION

This list of documents listed by the applicant has been generated automatically and is only included for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent literature cited

• CN 208283675 U [0004]

Claims (17)

Shaped multi-layer component with functional capabilities comprising: a rigid molded body (10) made of a first polymeric material which includes a major surface (11) that is fusible without destruction within a first melting temperature range; a coating film (20) with functional capabilities and comprising, at least in one layer in contact with the main surface (11) of the spray body (10), a second material which is meltable without destruction within the first melting temperature range, said layer on the main surface (11) the spray body (10) is heat-welded; characterized in that the main surface (11) of the spray body (10) is smooth and flat or is smooth and has radii of curvature greater than 20 mm; the coating film (20) also contains an electrically conductive functional material (21) flexible, mixed with or arranged on the second polymeric material, forming at least one conductive circuit in connection with a power source, said functional electrically conductive material (21) within the first melting temperature range is stable; so that a spraying process of the spray body (10) within an injection mold, which contains the coating film (20) with the electrically conductive functional material (21), produces the hot welding of the coating film (20) on the spray body (10) without destroying the conductive circuit. Multilayer component after Claim 1 , in which the spray body (10) is transparent, the coating film (20) is transparent and the electrically conductive functional material (21), at least in part of the coating film (20), is a transparent material. Multilayer component after Claim 1 , in which the coating film (20) also contains a protective layer (22) made of a third polymeric material, the electrically conductive material (21) between the protective layer (22) and the spray body (10) remaining protected. Multilayer component after Claim 3 in which the surface of the protective layer (22) contains printed patterns. Multilayer component according to one of the preceding claims, in which the electrically conductive functional material (21), in at least part of the coating film (20), contains a semiconducting material (24) which provides an electrical resistance which is selected to be at least half dissipate the electricity thereby transmitted in the form of heat, so that functional capabilities of the active heating are provided. Multilayer component after Claim 5 , in which the electrically conductive material (21), in at least part of the coating film (20), is an indium and tin oxide. Multi-layer component according to one of the preceding claims, in which said at least one conductive circuit is connected to at least one light-emitting diode (23) which is integrated in the coating film (20). Multilayer component after Claim 7 , in which the light-emitting diode (23) is an LED or an OLED. Multi-layer component according to one of the preceding claims, in which said at least one conductive circuit is connected to at least one sensor which is integrated in the coating film (20). Multilayer component after Claim 9 , in which the sensor is selected between temperature sensor, humidity sensor, photoluminescence sensor, acoustic sensor, vibration sensor, pressure sensor. Multilayer component according to one of the preceding claims, in which the electrically conductive functional material (21), in at least part of the coating film, contains a photochromic material. Multilayer component after Claim 11 in which the photochromic material forms one or more pixels of a liquid crystal display. Multilayer component according to one of the preceding claims, in which the first polymeric material and / or the second material is made of PET, polyester or a mixture thereof. Multilayer component according to one of the preceding claims, in which the electrically conductive functional material (21) contains graphene in at least part of the coating film (20). Multi-layer component according to one of the preceding claims, in which said at least one conductive circuit contains at least one antenna integrated in the coating film (20). Multilayer component after Claim 2 , in which the multilayer component is part of a pair of glasses or an eye protection shield. Multilayer component according to one of the preceding claims, in which the multilayer component is a rigid hollow housing for protecting body parts or a helmet.

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