EP1610963A2 - Method for insert molding decorative films - Google Patents

Method for insert molding decorative films

Info

Publication number
EP1610963A2
EP1610963A2 EP04718631A EP04718631A EP1610963A2 EP 1610963 A2 EP1610963 A2 EP 1610963A2 EP 04718631 A EP04718631 A EP 04718631A EP 04718631 A EP04718631 A EP 04718631A EP 1610963 A2 EP1610963 A2 EP 1610963A2
Authority
EP
European Patent Office
Prior art keywords
protective element
film
decorated
thermoplastic
mold cavity
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP04718631A
Other languages
German (de)
French (fr)
Inventor
Roland KÜNZEL
Axel Kaminski
Winfried Kohl
Klaus Schürmann
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Covestro Deutschland AG
Original Assignee
Bayer MaterialScience AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Bayer MaterialScience AG filed Critical Bayer MaterialScience AG
Publication of EP1610963A2 publication Critical patent/EP1610963A2/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14795—Porous or permeable material, e.g. foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14836—Preventing damage of inserts during injection, e.g. collapse of hollow inserts, breakage
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C3/00—Processes, not specifically provided for elsewhere, for producing ornamental structures
    • B44C3/02—Superimposing layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C2045/1486—Details, accessories and auxiliary operations
    • B29C2045/14868—Pretreatment of the insert, e.g. etching, cleaning
    • B29C2045/14877—Pretreatment of the insert, e.g. etching, cleaning preheating or precooling the insert for non-deforming purposes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14688—Coating articles provided with a decoration

Definitions

  • the invention relates to a method for the back injection of decorated foils with a thermoplastic, in which the decorated foil is protected from washing out.
  • Foiling behind is a widely used process for the design of surfaces.
  • a decorated film is shaped, trimmed and then placed in the injection mold and back-molded.
  • the decor is protected by the transparent foil on the outside.
  • the decor is exposed to high thermal loads and shear stresses, which leads to washouts in the area of the injection points. It is known to cover the decorative layer with a protective layer in order to avoid washing out, so that the melt does not come into direct contact with the decorative layer.
  • Such a protective layer consists, for example, of polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA), acrylonitrile-styrene-acrylate (ASA). It is either applied directly during the manufacture of a component by means of coextrusion or subsequently laminated with the aid of adhesion promoters. This process is described, for example, in P. Enewoldsen, H. Braun, Foil Back Injection Molding - Decorating in an Injection Molding Machine, KU Ku tstoffe 89 (1999) 9, pages 102-104.
  • PC polycarbonate
  • ABS acrylonitrile-butadiene-styrene
  • PMMA polymethyl methacrylate
  • ASA acrylonitrile-styrene-acrylate
  • a disadvantage of this method is that protection of the entire surface is actually not necessary, since leaching occurs only locally at the injection points. The cost of materials is therefore higher than necessary. Furthermore, this multilayer structure can lead to a reduced adhesion of the decorative layer to the entire component.
  • a major disadvantage, however, is the lack of three-dimensional deformation. Thermoforming is only possible to a limited extent, since in most cases the adhesive sealer with which the protective layer is applied to the decorative layer leads to the formation of gas bubbles between the layers. Furthermore, with such multilayer films, only deformation below the softening point is possible. The high pressure forming process used for this is limited in its deformation area.
  • the injection mold can also be adapted so that the shear rate and the throughput, eg volume throughput, are lower per injection point. This requires however, a higher number of gating points, which results in an increased number of weld lines and, associated therewith, a loss of strength at the weld lines.
  • a method is also known in which the decorative layer is partially overprinted with a clear lacquer, for example a two-component polyurethane lacquer, in the area of the injection points.
  • a clear lacquer for example a two-component polyurethane lacquer
  • the invention is therefore based on the object of developing a method for the back injection of decorated foils, in which wash-outs on the decorated foil in the region of the melt inlet openings into the foil cavity of the injection mold are avoided.
  • the invention accordingly relates to a method for injecting decorated foils with a thermoplastic plastic, the foil being in full contact with the inner wall of the mold cavity, which is characterized in that the decorated foil before injecting in the region of one or more inlet openings for the thermoplastic material is provided with a protective element in the mold cavity.
  • the protective element is applied to the decorative layer of the decorated film opposite one or more inlet openings, so that the plastic melt does not come into contact with the decor in the region of the injection point when it is injected into the mold cavity.
  • the protective element serves as a thermal insulator. It prevents the heat of the thermoplastic from melting on the printing ink during back injection and flowing with the melt.
  • the protective element also offers mechanical protection by preventing the melt from coming into direct contact with the decorated film. In this way, the protective element protects the printing ink from the high shear stresses when injecting in the area of the injection points.
  • the area of the protective element depends on the area of the washout.
  • the size of the inlet opening through which the thermoplastic enters the injection mold essentially determines the area of the washout.
  • the area of the protective element is preferably at least twice, preferably at least ten times, the cross section of the respectively opposite inlet opening.
  • the protective element is preferably a net, fabric, braid or fleece made of metal, plastic and / or natural material and / or a foil made of metal and / or plastic.
  • metal plastic and / or natural material
  • foil made of metal and / or plastic.
  • metals aluminum, copper, alloys or steel
  • plastics elastomers or thermoplastics can be used as plastics elastomers or thermoplastics.
  • the plastics can optionally also be provided with reinforcing and / or fillers, for example glass fibers.
  • the protective element can consist, for example, of the following plastics: polycarbonate (PC), acrylonitrile butadiene styrene (ABS), styrene acrylonitrile (SAN), polybutylene terephthalate (PBT), polyamide (PA), thermoplastic polyurethane (TPU), polyethylene terephthalate ( PET), polystyrene (PS), polyoxymethylene (POM), popoley rubber, in particular polypropylene (PP), polyester, polymethyl methacrylate (PMMA), thermoplastic polyvinyl chloride (PVC) or mixtures of thermoplastic materials.
  • PC polycarbonate
  • ABS acrylonitrile butadiene styrene
  • SAN styrene acrylonitrile
  • PBT polybutylene terephthalate
  • PA polyamide
  • TPU thermoplastic polyurethane
  • PET polyethylene terephthalate
  • PS polystyrene
  • POM polyoxymethylene
  • Cotton, cellulose, hemp, flax or cork can be selected.
  • a combination of the fabrics and / or materials mentioned is also possible.
  • the thickness of the protective element depends on the amount of plastic injected through the inlet opening.
  • the protective element preferably has a thickness of at least 50 ⁇ m.
  • the protective element is preferably applied to the decorated film by means of an adhesive binding.
  • Adhesives used for this purpose are, for example, aqueous polyurethane dispersions, aqueous acrylate copolymer dispersions and polyurethanes dissolved in organic solvents.
  • the protective element can also be applied by heating the film and then pressing the protective element with the film.
  • the protective element can be applied to the decorated film by welding.
  • the method according to the invention enables direct gating without washing out. It is therefore not necessary to spray on tabs or pins.
  • Direct injection also has the advantage that cascade technology, i.e. the delayed activation of the entry openings can be used.
  • cascade technology i.e. the delayed activation of the entry openings can be used.
  • no structural changes to the injection mold are necessary, e.g. the introduction of additional gates to reduce the volume throughput per gate.
  • the protective element can also be adapted to the local shape of the decorated film.
  • the material and processing costs are i. Compared to conventional methods, it is less, since the amount of material for protection is reduced to a minimum and only a protective element has to be applied locally instead of a full-surface protective layer.
  • unfilled or reinforced or reinforced fillers are used, such as polycarbonate, acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile (SAN), polybutylene terephthalate (PBT), polyamide ( PA), thermoplastic polyurethane (TPU), polyethylene terephthalate (PET), polystyrene (PS), polyoxymethylene (POM), polyolefms, e.g. polyethylene (PE), polypropylene (PP), polyester, polymethyl methacrylate (PMMA), elastomer-modified blends, thermoplastic PVC or mixtures of thermoplastic materials.
  • ABS acrylonitrile-butadiene-styrene
  • SAN styrene-acrylonitrile
  • PBT polybutylene terephthalate
  • PA polyamide
  • TPU thermoplastic polyurethane
  • PET polyethylene terephthalate
  • PS polystyrene
  • POM polyoxym
  • the layer thickness of the back-molded thermoplastic varies greatly depending on the application.
  • the thickness of the plastic layer is preferably 1 to 6 mm. However, it can vary from a few tenths of a millimeter to more than 10 mm (thermoplastic foam casting).
  • the decorated film consists, for example, of polycarbonate, ABS, cellulose esters, polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polymethyl methacrylate (PMMA), PVC, polyester, polysulfones, polyether sulfones, polyether ether ketones (PEEK) ), Polyaryl ether sulfones, polyurethane (PU) and polyamide (PA).
  • functional multilayer films, films made from plastic mixtures, blends or films provided with reinforcing and / or fillers can also be used.
  • the film is decorated, for example, using the screen printing process.
  • Other possible processes for decorating the film are painting, laminating, pad printing, offset, thermal transfer, high pressure (incl. Flexo), planographic printing, gravure printing, inkjet, photography, thermography, magnetography, ionography, electrography.
  • the usual printing colors e.g. Screen printing inks used.
  • FIG. 1 shows a schematic illustration of a film 2 with decorative layer 6, which is inserted into the mold cavity 7 of an injection molding tool 1 and which is in full contact with the inner wall of the mold cavity 7.
  • the decorative layer 6 is provided with a protective element 4.
  • the thermoplastic 3 Via the inlet opening 5 of the injection molding tool 1, the thermoplastic 3 enters the mold cavity 7 for the back injection of the film 2 provided with a decorative layer 6. example
  • the example describes the injection molding of a decorated foil for an engine cover.
  • the film was a film made of polycarbonate (PC), which was screen-printed on the back with a solution of synthetic synthetic resins in organic solvents (Noriphan® HTR from Pröll, Germany). After printing, the film was thermoformed and then trimmed. Protective elements made of polycarbonate with an area of 24 ⁇ 75 mm 2 were then applied to the printed film in the area of the injection points.
  • the protective elements were provided with an adhesive agent made of polyurethane, dissolved in organic solvents (Mecotherm® L110 from Kissel and Wolf, Germany).
  • the film provided with protective elements was placed in the mold cavity of the injection mold and back-injected with polyamide 6. The size of the bleed was 50 x 3.6 mm 2 .
  • the mass of thermoplastic material per gate was 80 g.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

The invention relates to a method for insert molding decorative films (2) with a thermoplastic material (3) in a mold cavity (7) having one or more inlet openings (5) for the thermoplastic material (3). The film (2) rests against the inner wall of the mold cavity (7) in an all-over manner, and the decorated film (2) is provided with a protective element (4) in the vicinity of at least one inlet opening (5) before insert molding.

Description

Verfahren zum Hinterspritzen von dekorierten FolienProcess for the back injection of decorated foils
Die Erfindung betrifft ein Verfahren zum Hinterspritzen von dekorierten Folien mit einem thermoplastischen Kunststoff, bei dem die dekorierte Folie vor Auswaschungen geschützt wird.The invention relates to a method for the back injection of decorated foils with a thermoplastic, in which the decorated foil is protected from washing out.
Das Folienhinterspritzen ist ein vielfach angewendetes Verfahren zur Gestaltung von Oberflächen. Dabei wird eine dekorierte Folie umgeformt, beschnitten und anschließend in das Spritzgießwerkzeug gelegt und hinterspritzt. Bei rückseitig bedruckten Folien ist das Dekor zwar durch die außenliegende transparente Folie geschützt. Beim Hinterspritzen von rückseitig bedruckten Folien ist das Dekor jedoch hohen thermischen Belastungen und Scherspannungen ausgesetzt, was zu Auswaschungen im Bereich der Anspritzpunkte fuhrt. Es ist bekannt, zur Vermeidung von Aus- Waschungen die Dekorschicht mit einer Schutzschicht zu überziehen, so dass die Schmelze nicht direkt mit der Dekorschicht in Berührung kommt. Eine solche Schutzschicht besteht beispielsweise aus Polycarbonat (PC), Acrylnitril-Butadien-Styrol (ABS), Polymethylmethacrylat (PMMA), Acrylnitril-Styrol-Acrylat (ASA). Sie wird entweder direkt bei der Herstellung eines Bauteils mittels Coextrusion aufgebracht oder nachträglich mit Hilfe von Haftvermittlern lami- niert. Dieses Verfahren wird beispielsweise beschrieben in P. Enewoldsen, H. Braun, Folienhinterspritzen - Dekorieren in der Spritzgießmaschine, KU Ku tstoffe 89 (1999) 9, Seite 102-104.Foiling behind is a widely used process for the design of surfaces. A decorated film is shaped, trimmed and then placed in the injection mold and back-molded. In the case of foils printed on the back, the decor is protected by the transparent foil on the outside. When injecting back-printed foils, however, the decor is exposed to high thermal loads and shear stresses, which leads to washouts in the area of the injection points. It is known to cover the decorative layer with a protective layer in order to avoid washing out, so that the melt does not come into direct contact with the decorative layer. Such a protective layer consists, for example, of polycarbonate (PC), acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA), acrylonitrile-styrene-acrylate (ASA). It is either applied directly during the manufacture of a component by means of coextrusion or subsequently laminated with the aid of adhesion promoters. This process is described, for example, in P. Enewoldsen, H. Braun, Foil Back Injection Molding - Decorating in an Injection Molding Machine, KU Ku tstoffe 89 (1999) 9, pages 102-104.
Ein Nachteil dieses Verfahrens liegt darin, dass ein Schutz der gesamten Fläche eigentlich nicht notwendig ist, da Auswaschungen nur lokal an den Anspritzpunkten auftreten. Der Materialaufwand ist somit höher als notwendig. Des weiteren kann dieser Mehrschichtaufbau insgesamt zu einer reduzierten Haftung der Dekorschicht auf dem gesamten Bauteil führen. Ein wesentlicher Nachteil stellt aber die mangelnde dreidimensionale Verformung- dar. Ein Thermoformen ist nur bedingt möglich, da in den meisten Fällen der Haftveπnittler, mit dem die Schutzschicht auf die Dekorschicht aufgebracht wird, zur Gasblasenbildung zwischen den Schichten führt. Ferner ist bei solchen mehrschichtigen Folien nur eine Verformung unterhalb des Erweichungspunktes möglich. Das dazu verwendete High Pressure Forming Verfahren ist aber in seiner Verformungsfläche begrenzt.A disadvantage of this method is that protection of the entire surface is actually not necessary, since leaching occurs only locally at the injection points. The cost of materials is therefore higher than necessary. Furthermore, this multilayer structure can lead to a reduced adhesion of the decorative layer to the entire component. A major disadvantage, however, is the lack of three-dimensional deformation. Thermoforming is only possible to a limited extent, since in most cases the adhesive sealer with which the protective layer is applied to the decorative layer leads to the formation of gas bubbles between the layers. Furthermore, with such multilayer films, only deformation below the softening point is possible. The high pressure forming process used for this is limited in its deformation area.
Es ist ferner bekannt, zur Verbesserung der äπneabführung die dekorierte Folie vor dem Hinterspritzen mit Hilfe eines Kältesprays zu kühlen. Dabei wird die Folie mindestens so stark gekühlt, . dass die Wärme der Schmelze nicht ausreicht, um die Druckfarbe zum Schmelzen zu bringen und zu verschieben. Nachteilig dabei ist jedoch, dass relativ dünne Folien mit einer Dicke von etwa 100 μm nicht ausreichend gekühlt werden können, da sie zu schnell wieder Wärme aufnehmen. Alternativ kann auch das Spritzgießwerkzeug so angepasst werden, dass die Schergeschwindigkeit und der Durchsatz, z.B. Volumendurchsatz, pro Anspritzpunkt niedriger sind. Dies erfordert jedoch eine höhere Zahl von Anspritzpunkten, was eine erhöhte Zahl von Bindenähten und, damit verbunden, ein Festigkeitsverlust an den Bindenähten zur Folge hat.It is also known to cool the decorated film before injecting with the help of a cold spray to improve the drainage. The film is cooled at least as much,. that the heat of the melt is not sufficient to melt and shift the printing ink. However, it is disadvantageous that relatively thin foils with a thickness of approximately 100 μm cannot be adequately cooled, since they absorb heat again too quickly. Alternatively, the injection mold can also be adapted so that the shear rate and the throughput, eg volume throughput, are lower per injection point. This requires however, a higher number of gating points, which results in an increased number of weld lines and, associated therewith, a loss of strength at the weld lines.
Bekannt ist weiterhin ein Verfahren, bei dem die Dekorschicht partiell im Bereich der Anspritzpunkte mit einem Klarlack, beispielsweise einem Zweikomponenten-Polyurethanlack, überdruckt wird. Dieses Verfahren kann jedoch nicht im Bereich von Verformungen angewendet werden, da der Lack nach dem Aushärten nicht mehr verformbar ist.A method is also known in which the decorative layer is partially overprinted with a clear lacquer, for example a two-component polyurethane lacquer, in the area of the injection points. However, this method cannot be used in the area of deformations because the lacquer can no longer be deformed after curing.
Der Erfindung liegt deshalb die Aufgabe zugrunde, ein Verfahren zum Hinterspritzen von dekorierten Folien zu entwickeln, bei dem Auswaschungen an der dekorierten Folie im Bereich der Eintrittsöffnungen für die Schmelze in den Foπiihohlraum des Spritzgießwerkzeugs vermieden werden.The invention is therefore based on the object of developing a method for the back injection of decorated foils, in which wash-outs on the decorated foil in the region of the melt inlet openings into the foil cavity of the injection mold are avoided.
Gegenstand der Erfindung ist demnach ein Verfahren zum Hinterspritzen von dekorierten Folien mit einem thermoplastischen Kunststoff, wobei die Folie an der Innenwand des Formhohlraums vollflächig anliegt, welches dadurch gekennzeichnet ist, dass die dekorierte Folie vor dem Hinterspritzen im Bereich einer oder mehrerer Eintrittsöffnungen für den thermoplastischen Kunststoff in den Forrnhohlraum mit einem Schutzelement versehen wird.The invention accordingly relates to a method for injecting decorated foils with a thermoplastic plastic, the foil being in full contact with the inner wall of the mold cavity, which is characterized in that the decorated foil before injecting in the region of one or more inlet openings for the thermoplastic material is provided with a protective element in the mold cavity.
Das Schutzelement wird auf die Dekorschicht der dekorierten Folie gegenüber einer oder mehreren Eintrittsöff ungen aufgebracht, so dass die Kunststoffschmelze beim Einspritzen in den Formhohlraum im Bereich des Anspritzpunktes nicht mit dem Dekor kontaktiert. Das Schutzelement dient zum einen als thermischer Isolator. Es verhindert, dass die Wärme des thermo- plastischen Kunststoffs beim Hinterspritzen die Druckfarbe anschmilzt und mit der Schmelze mitfließt. Zum anderen bietet das Schutzelement auch einen mechanischen Schutz, indem es den direkten Kontakt der Schmelze mit der dekorierten Folie verhindert. Dadurch schützt das Schutzelement die Druckfarbe vor den hohen Schubspannungen beim Hinterspritzen im Bereich der Anspritzpunkte.The protective element is applied to the decorative layer of the decorated film opposite one or more inlet openings, so that the plastic melt does not come into contact with the decor in the region of the injection point when it is injected into the mold cavity. The protective element serves as a thermal insulator. It prevents the heat of the thermoplastic from melting on the printing ink during back injection and flowing with the melt. On the other hand, the protective element also offers mechanical protection by preventing the melt from coming into direct contact with the decorated film. In this way, the protective element protects the printing ink from the high shear stresses when injecting in the area of the injection points.
Die Fläche des Schutzelements ist von der Fläche der Auswaschung abhängig. Die Größe der Ein- trittsöffnung, durch die der thermoplastische Kunststoff in das Spritzgießwerkzeug eintritt, bestimmt im Wesentlichen die Fläche der Auswaschung. Die Fläche des Schutzelements beträgt bevorzugt mindestens das Zweifache, vorzugsweise mindestens das Zehnfache, des Querschnitts der jeweils gegenüberliegenden Eintrittsöffnung.The area of the protective element depends on the area of the washout. The size of the inlet opening through which the thermoplastic enters the injection mold essentially determines the area of the washout. The area of the protective element is preferably at least twice, preferably at least ten times, the cross section of the respectively opposite inlet opening.
Das Schutzelement ist vorzugsweise ein Netz, Gewebe, Geflecht oder Vlies aus Metall, Kunststoff und/oder Naturstoff und/oder eine Folie aus Metall und/oder Kunststoff. Als Metalle können beispielsweise Aluminium, Kupfer, Legierungen oder Stahl eingesetzt werden. Als Kunststoffe können Elastomere oder Thermoplaste verwendet werden. Die Kunststoffe können gegebenenfalls auch mit Verstärkungs- und/oder Füllstoffen, z.B. Glasfasern, versehen sein. Das Schutzelement kann beispielsweise aus folgenden Kunststoffen bestehen: Polycarbonat (PC), Acrylnitril-Buta- dien-Styrol (ABS), Styrol-Acrylnitril (SAN), Polybutylenterephthalat (PBT), Polyamid (PA), thermoplastisches Polyurethan (TPU), Polyethylenterephthalat (PET), Polystyrol (PS), Polyoxy- methylen (POM), Poplyolefme, insbesondere Polypropylen (PP), Polyester, Polymethylmethacry- lat (PMMA), thermoplastisches Polyvinylchlorid (PVC) oder Mischungen von thermoplastischen Kunststoffen.The protective element is preferably a net, fabric, braid or fleece made of metal, plastic and / or natural material and / or a foil made of metal and / or plastic. For example, aluminum, copper, alloys or steel can be used as metals. As plastics elastomers or thermoplastics can be used. The plastics can optionally also be provided with reinforcing and / or fillers, for example glass fibers. The protective element can consist, for example, of the following plastics: polycarbonate (PC), acrylonitrile butadiene styrene (ABS), styrene acrylonitrile (SAN), polybutylene terephthalate (PBT), polyamide (PA), thermoplastic polyurethane (TPU), polyethylene terephthalate ( PET), polystyrene (PS), polyoxymethylene (POM), popoley rubber, in particular polypropylene (PP), polyester, polymethyl methacrylate (PMMA), thermoplastic polyvinyl chloride (PVC) or mixtures of thermoplastic materials.
Als Naturstoff kann z.B. Baumwolle, Cellulose, Hanf, Flachs oder Kork gewählt werden. Eine Kombination der genannten Flächengebilde und/oder Materialien ist ebenso möglich.As a natural substance e.g. Cotton, cellulose, hemp, flax or cork can be selected. A combination of the fabrics and / or materials mentioned is also possible.
Die Dicke des Schutzelements hängt ab von der Menge des durch die Eintrittsöffnung eingespritzten Kunststoffs. Das Schutzelement weist bevorzugt eine Dicke von mindestens 50 μm auf.The thickness of the protective element depends on the amount of plastic injected through the inlet opening. The protective element preferably has a thickness of at least 50 μm.
Bevorzugt wird das Schutzelement mittels einer Klebebindung auf der dekorierten Folie aufgebracht. Als Klebstoffe kommen hierfür beispielsweise wässrige Polyurethan-Dispersionen, wässrige Acrylat-Copolymer-Dispersionen und in organischen Lösungsmitteln gelöste Polyurethane zum Einsatz. Alternativ kann das Schutzelement auch dadurch aufgebracht werden, dass die Folie erwärmt wird und anschließend das Schutzelement mit der Folie verpresst wird. Außerdem kann das Schutzelement auf der dekorierten Folie durch Schweißen aufgebracht werden.The protective element is preferably applied to the decorated film by means of an adhesive binding. Adhesives used for this purpose are, for example, aqueous polyurethane dispersions, aqueous acrylate copolymer dispersions and polyurethanes dissolved in organic solvents. Alternatively, the protective element can also be applied by heating the film and then pressing the protective element with the film. In addition, the protective element can be applied to the decorated film by welding.
Das erfindungsgemäße Verfahren ermöglicht die Direktanspritzung ohne Auswaschungen. Es ist also keine Anspritzung über Laschen oder Zapfen notwendig. Die Direktanspritzung hat außerdem den Vorteil, dass die Kaskadentechnik, d.h. die zeitversetzte Ansteuerung der Eintrittsöffnungen, ausgenutzt werden kann. Darüber hinaus sind keine konstruktiven Änderungen am Spritzgießwerkzeug nötig, wie z.B. die Einführung weiterer Anschnittstellen zur Verringerung des Volumendurchsatzes pro Anschnittsteile. Das Schutzelement kann ferner der lokalen Form der dekorierten Folie angepasst werden. Weiterhin ist der Materialaufwand und der Bearbeitungsaufwand i. Vgl. zu herkömmlichen Verfahren geringer, da die Materialmenge für den Schutz auf eine Mindestmenge reduziert wird und anstelle einer vollflächigen Schutzschicht nur lokal ein Schutzelement aufgebracht werden muss.The method according to the invention enables direct gating without washing out. It is therefore not necessary to spray on tabs or pins. Direct injection also has the advantage that cascade technology, i.e. the delayed activation of the entry openings can be used. In addition, no structural changes to the injection mold are necessary, e.g. the introduction of additional gates to reduce the volume throughput per gate. The protective element can also be adapted to the local shape of the decorated film. Furthermore, the material and processing costs are i. Compared to conventional methods, it is less, since the amount of material for protection is reduced to a minimum and only a protective element has to be applied locally instead of a full-surface protective layer.
Zum Hinterspritzen der dekorierten Folien nach dem erfindungsgemäßen Verfahren werden unge- füllte oder mit Verstärkungs- und/oder Füllstoffen versehene thermoplastische Kunststoffe wie Polycarbonat, Acrylnitril-Butadien-Styrol (ABS), Styrol-Acrylnitril (SAN), Polybutylenterephthalat (PBT), Polyamid (PA), thermoplastisches Polyurethan (TPU), Polyethylenterephthalat (PET), Polystyrol (PS), Polyoxymethylen (POM), Polyolefme, z.B. Polyethylen (PE), Polypropylen (PP), Polyester, Polymethylmethacrylat (PMMA), elastomermodifϊzierte Blends, thermoplastisches PVC oder Mischungen von thermoplastischen Kunststoffe eingesetzt.In order to inject the decorated foils using the method according to the invention, unfilled or reinforced or reinforced fillers are used, such as polycarbonate, acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile (SAN), polybutylene terephthalate (PBT), polyamide ( PA), thermoplastic polyurethane (TPU), polyethylene terephthalate (PET), polystyrene (PS), polyoxymethylene (POM), polyolefms, e.g. polyethylene (PE), polypropylene (PP), polyester, polymethyl methacrylate (PMMA), elastomer-modified blends, thermoplastic PVC or mixtures of thermoplastic materials.
Die Schichtdicke des hinterspritzten thermoplastischen Kunststoffs variiert stark in Abhängigkeit von der Anwendung. Bevorzugt beträgt die Dicke der Kunststoffschicht 1 bis 6 mm. Sie kann jedoch von wenigen zehntel Millimetern bis zu größer 10 mm variieren (Thermoplastschaumguss).The layer thickness of the back-molded thermoplastic varies greatly depending on the application. The thickness of the plastic layer is preferably 1 to 6 mm. However, it can vary from a few tenths of a millimeter to more than 10 mm (thermoplastic foam casting).
Die dekorierte Folie besteht beispielsweise aus Polycarbonat, ABS, Celluloseester, Polyethylen (PE), Polypropylen (PP), Polyethylenterephthalat (PET), Polybutylenterephthalat (PBT), Polymethylmethacrylat (PMMA), PVC, Polyester, Polysulfone, Polyethersulfone, Polyetheretherke- tone (PEEK), Polyarylethersulfone, Polyurethan (PU) und Polyamid (PA). Des weiteren können auch funktionale Mehrschichtfolien, Folien aus Kunststoffmischungen, Blends oder mit Verstärkungs- und/oder Füllstoffen versehene Folien eingesetzt werden.The decorated film consists, for example, of polycarbonate, ABS, cellulose esters, polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polymethyl methacrylate (PMMA), PVC, polyester, polysulfones, polyether sulfones, polyether ether ketones (PEEK) ), Polyaryl ether sulfones, polyurethane (PU) and polyamide (PA). Furthermore, functional multilayer films, films made from plastic mixtures, blends or films provided with reinforcing and / or fillers can also be used.
Das Dekorieren der Folie erfolgt beispielsweise im Siebdruckverfahren. Weitere mögliche Verfahren zum Dekorieren der Folie sind Lackieren, Kaschieren, Tampondruck, Offset, Thermotransfer, Hochdruck (inkl. Flexo), Flachdruck, Tiefdruck, InkJet, Fotografie, Thermografie, Magnetografie, lonografie, Elektrografie.The film is decorated, for example, using the screen printing process. Other possible processes for decorating the film are painting, laminating, pad printing, offset, thermal transfer, high pressure (incl. Flexo), planographic printing, gravure printing, inkjet, photography, thermography, magnetography, ionography, electrography.
Zum Dekorieren der Folie werden die für die jeweiligen Verfahren üblichen Drückfarben, z.B. Siebdruckfarben, verwendet.To decorate the film, the usual printing colors, e.g. Screen printing inks used.
Nachfolgend wird die Erfindung anhand der beigefügten Figur 1 näher erläutert.The invention is explained in more detail below with reference to the attached FIG. 1.
Figur 1 zeigt eine schematische Darstellung einer in den Formhohlraum 7 eines Spritzgießwerkzeuges 1 eingelegten Folie 2 mit Dekorschicht 6, welche an der Innenwand des Formhohlraums 7 vollflächig anliegt. Die Dekorschicht 6 ist mit einem Schutzelement 4 versehen. Über die Ein- trittsöff ung 5 des Spritzgießwerkzeuges 1 tritt der thermoplastische Kunststoff 3 zum Hinterspritzen der mit einer Dekorschicht 6 versehenen Folie 2 in den Formhohlraum 7 ein. BeispielFIG. 1 shows a schematic illustration of a film 2 with decorative layer 6, which is inserted into the mold cavity 7 of an injection molding tool 1 and which is in full contact with the inner wall of the mold cavity 7. The decorative layer 6 is provided with a protective element 4. Via the inlet opening 5 of the injection molding tool 1, the thermoplastic 3 enters the mold cavity 7 for the back injection of the film 2 provided with a decorative layer 6. example
Das Beispiel beschreibt das Hinterspritzen einer dekorierten Folie für eine Motorabdeckung. Bei der Folie handelte es sich um eine Folie aus Polycarbonat (PC), die im Siebdruckverfahren rückseitig mit einer Lösung von synthetischen Kunstharzen in organischen Lösungsmitteln (No- riphan® HTR der Firma Pröll, Deutschland) bedruckt wurde. Nach dem Bedrucken wurde die Folie mittels Thermoformen verformt und anschließend beschnitten. Dann wurden Schutzelemente aus Polycarbonat mit einer Fläche von 24 x 75 mm2 im Bereich der Anspritzpunkte auf die bedruckte Folie aufgebracht. Dazu wurden die Schutzelemente mit einem Hafrvermittler aus Polyurethan, gelöst in organischen Lösungsmitteln, (Mecotherm® L110 der Firma Kissel und Wolf, Deutschland) versehen. Die mit Schutzelementen versehene Folie wurde in den Formhohlraum des Spritzgusswerkzeugs eingelegt und mit Polyamid 6 hinterspritzt. Die Größe des Anschnitts betrug 50 x 3,6 mm2. Die Masse an thermoplastischem Kunststoff pro Anschnitt betrug 80 g. The example describes the injection molding of a decorated foil for an engine cover. The film was a film made of polycarbonate (PC), which was screen-printed on the back with a solution of synthetic synthetic resins in organic solvents (Noriphan® HTR from Pröll, Germany). After printing, the film was thermoformed and then trimmed. Protective elements made of polycarbonate with an area of 24 × 75 mm 2 were then applied to the printed film in the area of the injection points. For this purpose, the protective elements were provided with an adhesive agent made of polyurethane, dissolved in organic solvents (Mecotherm® L110 from Kissel and Wolf, Germany). The film provided with protective elements was placed in the mold cavity of the injection mold and back-injected with polyamide 6. The size of the bleed was 50 x 3.6 mm 2 . The mass of thermoplastic material per gate was 80 g.

Claims

Patentansprüche: claims:
1. Verfahren zum Hinterspritzen von dekorierten Folien (2) mit einem thermoplastischen Kunststoff (3) in einem Formhohlraum (7) mit einer oder mehreren Eintrittsöffnungen (5) für den thermoplastischen Kunststoff (3), wobei die Folie (2) an der Innenwand des Form- hohlraums (7) vollflächig anliegt, dadurch gekennzeichnet, dass die dekorierte Folie (2) vor dem Hinterspritzen im Bereich mindestens einer Eintrittsöffnung (5) mit einem Schützelement (4) versehen wird.1. Process for back-molding of decorated foils (2) with a thermoplastic (3) in a mold cavity (7) with one or more inlet openings (5) for the thermoplastic (3), the foil (2) on the inner wall of the The mold cavity (7) bears over the entire surface, characterized in that the decorated film (2) is provided with a protective element (4) in the area of at least one inlet opening (5) before the back molding.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass die Fläche des Schutzelements (4) mindestens das Zweifache, vorzugsweise mindestens das Zehnfache, des Querschnitts der gegenüberliegenden Eintrittsöffnung (5) beträgt.2. The method according to claim 1, characterized in that the area of the protective element (4) is at least twice, preferably at least ten times, the cross section of the opposite inlet opening (5).
3. Verfahren nach einem der Ansprüche 1 oder 2, dadurch gekennzeichnet, dass das Schutzelement (4) ein Netz, Gewebe, Geflecht oder Vlies aus Metall, Kunststoff und/oder Naturstoff und/oder eine Folie aus Metall und/oder Kunststoff ist.3. The method according to any one of claims 1 or 2, characterized in that the protective element (4) is a mesh, fabric, braid or fleece made of metal, plastic and / or natural material and / or a film made of metal and / or plastic.
4. Verfahren nach einem der Ansprüche 1-3, dadurch gekennzeichnet, dass das Schutzelement (4) mittels einer Klebeverbindung auf der dekorierten Folie (2) aufgebracht wird.4. The method according to any one of claims 1-3, characterized in that the protective element (4) is applied by means of an adhesive connection on the decorated film (2).
5. Verfahren nach einem der Ansprüche 1-3, dadurch gekennzeichnet, dass das Schutzelement (4) mittels Erwärmen und anschließendem Verpressen auf der dekorierten Folie (2) aufgebracht wird.5. The method according to any one of claims 1-3, characterized in that the protective element (4) by means of heating and then pressing on the decorated film (2) is applied.
6. Verfahren nach einem der Ansprüche 1-3, dadurch gekennzeichnet, dass das6. The method according to any one of claims 1-3, characterized in that the
Schutzelement (4) durch Schweißen auf der dekorierten Folie (2) aufgebracht wird. Protective element (4) is applied by welding to the decorated film (2).
EP04718631A 2003-03-21 2004-03-09 Method for insert molding decorative films Withdrawn EP1610963A2 (en)

Applications Claiming Priority (2)

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DE10312610A DE10312610A1 (en) 2003-03-21 2003-03-21 Process for the back injection of decorated foils
PCT/EP2004/002390 WO2004082926A2 (en) 2003-03-21 2004-03-09 Method for insert molding decorative films

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WO2004082926A3 (en) 2005-03-31
WO2004082926A2 (en) 2004-09-30
DE10312610A1 (en) 2004-09-30

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