EP3573802A1

EP3573802A1 - Film molding tool, method for producing a film molding tool, and use of a film molding tool

Info

Publication number: EP3573802A1
Application number: EP17816400.0A
Authority: EP
Inventors: Rupert Gschwendtner; Bernd Stein
Original assignee: Kiefel GmbH
Current assignee: Persico SpA
Priority date: 2017-01-20
Filing date: 2017-11-13
Publication date: 2019-12-04
Also published as: CN110461562A; CA3053970A1; WO2018133889A1; US20210252748A1; DE112017006873A5

Abstract

The invention relates to a film molding tool for laminating a component with a laminating element or for molding a thermoplastic film with a grained geometry, to an alternative method for producing grain shells, and to the use of a corresponding film molding tool. In particular, the invention relates to a method for producing grain shells, said method saving on production time and production costs, producing long service lives, and additionally allowing a high molding quality. For this purpose, the molding shell of a film molding tool is provided with a ceramic layer which has a grained structure and thus allows the grained structure to be transferred onto the laminating element during the lamination method.

Description

FOIL MOLDING TOOL, METHOD FOR MANUFACTURING A FOIL MOLDING TOOL, AND USE OF A FOIL MOLDING TOOL

The invention relates to a film forming tool, a method for producing a film forming tool and a use of a film forming tool. Automotive surfaces are often made with foil, which is applied to backing parts in a laminating process. It is known that the carrier part is laminated either with an already grained film or alternatively with a smooth film, wherein in the case of the smooth film a grain during lamination is achieved by means of a grained upper tool. Furthermore, it is known that a grained film or a smooth film are deformed with a film forming tool, wherein smooth films are often embossed during deformation. The deformed films are then backfoamed and / or back-injected in a separate step.

If the surface graining is transferred to the film by means of an impression process, a molding shell is used in the molding machine, which has a surface texture, which is also referred to as a negative grain structure and causes an impression of the film during the impression taking. The force required for embossing the film force between the film and the shell mold can be achieved by suction of the surface by means of vacuum, by applying compressed air, by mechanical contact pressure or by a combination of the aforementioned methods.

If the surface graining is produced during the laminating process, a mold shell with a surface texture is used in the laminating plant, which causes embossing of the film during lamination. The necessary for embossing the film The action of force between the film and the mold shell can be achieved by suction of the surface by means of vacuum, by application of compressed air, by mechanical contact pressure or by a combination of the aforementioned methods.

The advantage of embossing during the laminating process or the molding process is that the grain structure is produced in the three-dimensional state of the film and thus no so-called grain loss due to expansion can occur, as is often the case in alternative processes. A scar loss is understood to mean a negative impairment of the optical or haptic grain quality on the carrier part of the foil.

A shell mold with a negative grain structure is often also called Narbschale and often galvanically produced. For this purpose, nickel is deposited on a positive model of the outer contour of the finished component with a positive grain structure until a layer thickness of approximately 4 mm has formed.

As a variant of a nickel shell with a negative grain structure, a milled steel shell is used, which has obtained a negative grain structure by means of etching. The production of a steel shell is faster compared to a galvanically produced nickel shell.

In addition to producing a surface texture in a steel shell by means of etching, this can also be manufactured with a laser.

Another variant offers a plastic shell with a negative grain structure, which is produced in a casting process and is well suited for the lamination of components or the shaping of foils in small batches.

All known mold pan with a negative grain structure (Narbschalen) have in common that they are often permeable to air, so that the necessary force between the film and the shell mold can be achieved. The air permeability can be produced by a perforation, for example by discrete openings produced by means of lasers or etching, or by a material-specific microporosity of the shell mold.

For lamination or molding in the production operation of large series, a grain pan with a tempering system and a substructure, often in the form of a support structure, is added to a complete tool. A method for laminating a component by a film forming tool is disclosed in DE 10 2013 203 408 AI.

The invention has for its object to provide the prior art an improvement or an alternative.

According to a first aspect of the invention, the object is achieved by a film forming tool for laminating a component with a laminating element or for molding a film, wherein the film forming tool has a mold shell, wherein the mold shell has a sprayed layer of metal produced by metal spraying.

Conceptually, the following is explained:

First of all, it should be expressly pointed out that, in the context of the present patent application, indefinite articles and numbers such as "a", "two" etc. should as a rule be understood as "at least" information, ie as "at least one ...", "At least two ..." etc., unless expressly stated in the respective context or it is obvious or technically imperative for the skilled person that only "exactly one" exactly two ... "etc. may be meant there. Furthermore, it should be expressly noted that in the context of the present patent application, a "part" of something should be understood that it may also be the whole part of something. Under "film forms" here both, so either "laminating" or "molding" understood.

75 "Laminating" is understood to mean the joining of several layers of identical or different materials, in particular one layer is a film, which is also referred to as a "laminating element". In general, the lamination of components is understood as the lamination of a laminating element with the component to be laminated, it being possible for the laminating element to acquire a surface grain when laminating.

The term "molding" is understood as meaning the shaping of a shaped element, in particular a foil, with a foil forming tool, whereby the shaped element can acquire a surface grain during the molding, in particular the molded molded element can be used as a surface in the automobile, wherein the molded shaped element, in particular a foil is connected in a subsequent process with a carrier element.

The term "film forming tool" is understood to mean, optionally, a tool for laminating a component with a laminating element or a tool for molding a molded element, often one and the same film forming tool can be used both for laminating a component with a laminating element and for molding a molded element respective processes for laminating and for

90 molding differences have.

A film forming tool has at least one mold shell, which is usually supplemented by a support structure and a tempering system.

A "foil" refers to a thin metal, ceramic or plastic sheet.

A "grain" is the structuring of a surface, so also of

A grain is characterized by the haptic and visual properties of a surface. A "bowl shell" refers to a bowl-shaped structure with a specific shape, which can be made of a variety of materials and combinations of materials.They are used to shape other components and 100 transfer the shape of their surface to the component to be molded vice versa to the article or model to be molded, which is why a mold shell is often referred to as a "negative mold shell". The object to be formed or the "model" of this object is often referred to as the "positive model".

A "material layer" is understood as meaning a layer of a material, wherein the material layer may have a layer thickness in the region of one or more atomic layers, or a material layer may have gaps in which the material of the material layer can not be found a material layer is a coherent layer of atoms of one

110 materials.

"Metal spraying" is understood to mean a process for spraying metal, which belongs to the surface coating process., In particular, metal spraying includes thermal spraying and cold gas spraying. In metal spraying, metal is deposited as filler material inside or outside a spray gun. 115 melted, accelerated in a gas stream in the form of spray particles and thrown onto the surface of the component to be coated, the component surface is usually not melted and only a small thermal load.

It is built up during thermal spraying, in particular during metal spraying, because the 120 spraying particles flatten more or less depending on the process and material as they impinge on the component surface, primarily sticking together by mechanical clamping and The quality characteristics of sprayed coatings are low porosity, good adhesion to the component, freedom from cracks and a homogeneous microstructure. Previously, the state of the art provided that the mold shell was galvanically produced by a foil mold, wherein nickel was deposited on a positive model of the finished component, ie with a positive grain structure, until a layer thickness of approximately 4 mm had been formed , During the electroplating process, mechanical corrections to the component had to be made manually from time to time, so that this process was expensive and time-consuming.

Alternatively, the prior art has heretofore provided that the shell mold of a foil forming tool was milled from a steel block.

Another alternative known in the prior art has hitherto been that the molded shell of a plastic sheet molding tool has been produced in a casting process or by a lamination process.

Notwithstanding, it is proposed here that the shell mold, a region of the shell mold or a layer of the shell mold is produced by metal spraying.

It is concretely conceivable, inter alia, that a layer of metal is applied by metal spraying on a positive model, and this metal layer later yields the shell, a region of the shell or a layer of the shell.

It is also conceivable that an existing part of a mold shell or a layer of a mold shell is supplemented and / or reinforced by metal spraying.

Specifically, it is conceivable inter alia that the film forming tool is used for laminating carrier parts with a grained or smooth film. It is also concretely conceivable inter alia that the film forming tool is used to deform a grained or smooth film. Advantageously, it can be achieved that a mold shell for a film forming tool which has a long service life and is suitable for mass production is inexpensive, comparatively fast and can be produced with high impression quality. Furthermore, the film forming tool can have a high molding quality of the positive model even without the need for post-processing.

The mold shell preferably has two material layers made of different materials.

It is specifically conceivable, inter alia, that the shell mold of a film forming tool can be constructed from different materials.

It is conceivable, for example, to construct the shell mold in two layers, each with different materials.

Furthermore, it is conceivable to use different materials in different areas of the shell mold. Thus, it can be achieved that the characteristics of different materials can be targeted in accordance with the specific requirements of deviating areas in the mold shell, by using different materials at different points of the mold shell.

In a specific embodiment, a material having a high abrasion resistance could thus be used on the surface of the shell mold, wherein a second layer located lower has a deviating material and is responsible for the necessary rigidity of the shell mold.

Advantageously, it can thus be achieved that the properties of deviating materials are combined in such a way that the properties of the shell mold as a whole are improved.

In particular, it can be advantageously achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality can. Furthermore, the film forming tool can have a high molding quality of the positive model even without the need for subsequent processing.

Optionally, a surface of the shell mold ceramic or consists of ceramic.

Ceramic has a high surface hardness and thus a high degree of abrasion resistance.

Thus, it is conceivable to design the surface of the molding shell from a layer of ceramic and to apply to this layer of ceramic, for example, a thicker or equally thick layer of metal in the metal spraying process.

The ceramic layer itself can be produced in various ways.

Advantageously, it can thus be achieved that the mold shell has a very high abrasion resistance due to the ceramic surface and at the same time possesses the necessary dimensional stability and rigidity due to the metal layer applied in the metal spraying process.

In particular, can be achieved so advantageous that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality. Furthermore, the film forming tool can have a high impression quality of the positive model even without the need for post-processing.

Preferably, the surface of the shell mold has a negative grain structure.

Conceptually, the following is explained:

A "negative fringe structure" comprises a surface of a component, in particular a mold shell constructed as a negative mold shell, whereby the relief of the mold shell extends inversely to the object or model to be molded and the model has a scar structure. The negative mold shell thus has a negative grain structure.

This makes possible a film forming tool which has a mold shell with a negative grain structure and thus bears the scar information for the component to be laminated or molded, so that embossing of the laminating element during the laminating process or a film can take place during the molding process.

Conceivable is a shell mold with an outer layer of ceramic, which carries the Narbin formation and is stiffened by a layer of metal, which was applied by spraying, so that the shell mold has the necessary dimensional stability.

Specifically, it is conceivable inter alia that the film forming tool is used for laminating carrier parts, wherein an originally smooth film is embossed during lamination with a grain structure, so that the surface of the laminated component then has a grain structure.

It is also concretely conceivable inter alia that the film forming tool is used to deform a smooth film, wherein the film also receives a grain structure during deformation. This thus deformed and grained foil can be backfoamed and / or back-injected in a second step, resulting in a component with a grained surface.

Advantageously, it can thus be achieved that a molded shell with high abrasion resistance and high dimensional stability can be produced, with which the embossing of the laminating element can take place during the laminating process or a film during a molding process.

With the embossing during the lamination process or during the molding process can also be advantageously achieved that the grain structure in the three-dimensional state the film is produced and thus no grain loss can occur, as is often the case with alternative methods.

In particular, can be achieved so advantageous that a mold shell for a film forming tool which has a long service life and is suitable for mass production is cost, relatively quickly and can be produced with high impression quality. Furthermore, the film forming tool can have a high impression quality of the positive model even without the need for post-processing.

Optionally, the surface of the mold shell is permeable to air. Conceptually, the following is explained:

By "air-permeable" is meant that the surface of the shell mold is permeable to air, so air can penetrate the surface of the shell mold.

It is concretely conceivable, inter alia, that the laminating element is sucked into the mold shell by a vacuum applied to the back of the mold shell, so that the force required to emboss the laminating element between the laminating element and the shell mold or the force required to emboss the film between the film and the shell mold can be made.

In a particularly suitable embodiment, the material of the mold shell is permeable to air. Thus, it is conceivable that the sprayed layer produced by metal spraying has a porosity which makes the mold shell permeable to air, so that the laminating element and / or the film can be sucked into the mold shell by means of a vacuum applied to the back of the mold shell.

Furthermore, in a particularly suitable embodiment, it is conceivable that a mold shell consisting of several material layers is permeable to air as a result of the properties of the material layers, in particular the mold shell has material layers of different materials. So it is conceivable, among other things, that a consisting of a ceramic layer and a metal spray layer mold shell has a cross-material porosity, which makes the mold shell permeable to air, so that the laminating element and / or the film can be sucked by a vacuum applied to the back of the mold shell in the mold shell. In particular, it is conceivable that both the ceramic layer and the metal sprayed layer are made microporous.

Advantageously, it can thus be achieved that the lamination process and / or the molding process can take place simultaneously with high qualitative standards and also cost-effectively and quickly.

In addition, it can be advantageously achieved that the embossing of the laminating element during lamination or the embossing of the molding element can take place during molding.

If the air permeability of the mold shell arises through the use of porous materials, it can be achieved, in particular, advantageously that the mold shell does not have to be perforated extra.

The mold shell preferably has a support structure on a rear side. Conceptually, the following is explained:

A "support structure" is understood to be a type of skeleton which stiffens the shell mold behind the material layer forming the surface of the shell mold.

Advantageously, it can be achieved that the overall shape of the shell is very stiff, whereby the quality of the laminated components increases, especially with regard to the reproducibility of components with only within tolerances deviating component geometries. In particular, can be achieved so advantageous that a mold shell for a film forming tool which has a long service life and is suitable for mass production is cost, relatively quickly and can be produced with high impression quality. Furthermore, the film forming tool can have a high impression quality of the positive model even without the need for post-processing. Optionally, the support structure is honeycomb.

Conceptually, the following is explained:

By "honeycomb" is meant a cellular material pattern constructed of individual cavities.

Advantageously, it can thus be achieved that a particularly light and rigid support structure for the shell mold of a film forming tool can be achieved.

The support structure preferably has webs.

Conceptually, the following is explained:

A "bridge" is a part of a framework, which is constructed of webs.

Advantageously, it can thus be achieved that a particularly light and stiff support structure for the shell mold of a film forming tool can be achieved, which moreover enables cost-effective production.

Optionally, part of the support structure is made of aluminum.

Advantageously, it can be achieved that the characteristics of aluminum can be targeted according to the specific requirements of the support structure to advantage. The use of aluminum can concretely improve the heat conduction in the support structure or make the support structure lighter.

Preferably, a gap of the support structure Alugrieß on. Conceptually, the following is explained:

"Alugrieß" refers to a grain size of an elementary aluminum granulate.The grain size of Aluminiumgrieß is usually between 0.3 mm and 1 mm.

It is expressly pointed out that "Alugrieß" is also understood to mean a composite material consisting of elemental aluminum granules and a matrix, in particular the matrix comprises resin or synthetic resin, the resin being in particular epoxy resin or other thermosets or thermoplastics Matrix have a hardener that cures the resin or resin.

Advantageously, it can thus be achieved that the intermediate space of the support structure can be compacted with aluminum grit, as a result of which the thermal conductivity and the rigidity of the film forming tool increase with a simultaneously low weight.

Optionally, the shell mold on the back Alugrieß. Advantageously, it can be achieved that the shell mold is stiffened by the Alugrieß on the back and as a whole very stiff, whereby the quality of the laminated components increases, especially with regard to the reproducibility of components with only within tolerances deviating component geometries.

Optionally, the film forming tool has a temperature control. Conceptually, the following is explained:

A "temperature control" is a device with which the temperature in a component can be influenced, whereby a temperature control can be provided with a temperature control, which is set up to keep the temperature of a component within a predefined range. Under "cooling" can be understood in the context of this document, "warming". In particular, a cooling device can also cool at one area and simultaneously heat at another area.

Advantageously, it can thus be achieved that the film forming tool can be adjusted by the temperature control to an optimum operating temperature. The temperature control preferably has a cooling channel.

Conceptually, the following is explained:

A "cooling channel" is a channel through which a fluid can flow, wherein the fluid absorbs or releases a heat flow from the vicinity of the cooling channel.

Advantageously, it can thus be achieved that the film mold tool can have a liquid cooling, whereby all the advantages of liquid cooling can be transferred to the film molding tool. Liquid cooling allows very fast and efficient cooling of components.

Optionally, the cooling channel on copper.

Advantageously, it can thus be achieved that the characteristics of copper can be brought to bear in a targeted manner in accordance with the specific requirements of a cooling channel. Copper is a soft, malleable material that is particularly well suited to conduct heat flow.

A cooling channel made of copper thus allows a well malleable and efficient cooling channel with a particularly high reaction rate of the cooling effect. Preferably, a part of the cooling channel extends into the sprayed layer of metal. Advantageously, it can thus be achieved that the cooling output emanating from a cooling channel can be brought into effect directly in the sprayed layer of metal, so that the surface of the film forming tool can be tempered very responsively.

Optionally, a part of the cooling channel extends into the support structure. Advantageously, it can thus be achieved that the support structure can be cooled efficiently and responsively.

Preferably, a part of the cooling channel extends into the Alugrieß.

Advantageously, it can thus be achieved that an area of the foil mold made of aluminum mesh can be cooled efficiently and with rapid reaction. Optionally, the film forming tool has a cooling plate.

Conceptually, the following is explained:

A "cooling plate" is a component which, in addition to other functionalities, also has special properties that enable efficient cooling of surrounding components.

Advantageously, it can thus be achieved that the film forming tool can be cooled efficiently. Heat flows can be distributed particularly well in a cooling plate and temperatures can homogenize in a cooling plate.

Preferably, the cooling plate is flat.

Advantageously, it can be achieved that the cooling plate has a flat surface and thus is particularly well suited for positive connection with another component.

Optionally, a part of the cooling channel extends into the cooling plate. Advantageously, it can be achieved that the cooling plate can be cooled by a liquid cooling efficient and fast reaction.

According to a second aspect of the invention, the object solves a method for producing a film forming tool, in particular for producing a film forming tool according to the first aspect of the invention, wherein a ceramic layer is applied to a positive model, wherein the ceramic has a grain, and a metal layer on the ceramic layer is sprayed on.

The state of the art has hitherto provided that the surface of the film forming tool, which comes into operative connection with the laminating element or during the molding process during the laminating process, was either molded by the electroplating process or molded in a casting process with plastic a steel block was worked out. Especially with a negative skin structure having shell molds, the grain structure was directly molded, worked out with a cutting tool or chemically etched out of the material.

By way of derogation, it is proposed here for the surface of the film forming tool, which during the laminating process with the laminating element or during the molding process comes into operative connection with a film, to directly use a ceramic which already has a negative grain structure. In the process, this ceramic layer is stiffened by combining the rear side with a metal layer applied by metal spraying to form a shell mold. This shell mold is then supplemented in subsequent steps with a support structure and optionally with a temperature control and thus completed to form a film forming tool. For example, it is conceivable to use a ceramic film which already has a negative grain structure in the production of the film molding tool for the surface. The grain structure of such a ceramic film can be done, inter alia, by a previous embossing or a previous casting of a corresponding model having a grain structure.

A conceivable embodiment of a grained ceramic film suitable for the described method is the product Cera-Shibo from Eschmann Textures International GmbH.

Advantageously, this can be achieved that a mold shell for a film mold tool which has a long service life and is suitable for mass production is cost, relatively quickly and can be produced with high impression quality. Further, without the need for post-processing, the film-forming tool can have a high degree of quality with regard to the negative grain structure. The negative scar structure can be very robust. It should be expressly understood that the subject matter of the second aspect may be advantageously combined with the subject matter of the first aspect of the invention.

According to a third aspect of the invention, the object solves a method for producing a film molding tool, in particular for producing a film molding tool according to the first aspect of the invention, in particular a method according to the second aspect of the invention, wherein a ceramic paint is sprayed onto a positive model and cured, so that a ceramic layer is formed, wherein the positive model has a scar, and a metal layer is sprayed onto the ceramic layer.

Conceptually, the following is explained:

A "varnish" is a liquid or powdered coating material that is applied thinly to objects and built up into a continuous, solid film by chemical or physical processes, In particular, a varnish may also be a ceramic varnish, which is also referred to as a ceramic varnish. The prior art has hitherto provided that the surface of the film forming tool, which comes into operative connection with the laminating element during the laminating process or during the molding process, was either molded in the electroplating process, was molded in a casting process with plastic or worked out of a steel block. In particular, in the case of mold shells having a negative grain structure, the grain structure was formed directly, worked out with a cutting tool or chemically etched out of the material.

By way of derogation, it is proposed here, starting from a positive model with a grain structure, to apply a lacquer of ceramic to the positive model and to stiffen this lacquer with a metal layer applied by metal spraying and to expand it into a shell mold. This mold shell is then supplemented in subsequent steps with a support structure and optionally with a temperature control, thus completing a film molding tool.

In this way, the negative scar structure is transferred directly from the ceramic paint on the grain structure of the positive model to the shell mold, so that the relief of the shell mold, in particular, runs in reverse to the relief of the positive model. Advantageously, this can be achieved that a mold shell for a film forming tool which has a long service life and is suitable for mass production is cost, relatively fast and can be produced with high impression quality. Further, without the need for post-processing, the film-forming tool can have a high degree of quality with regard to the negative grain structure. The negative scar structure can be extremely robust.

Preferably, the mold shell consisting of the ceramic layer and the metal layer is perforated.

Conceptually, the following is explained: By "perforating" is meant a perforation of hollow bodies or flat objects The arrangement, amount, shape and size of the holes can be homogeneous and / or inhomogeneous.

Specifically, the perforation can be caused by a cutting tool. The distances between the perforation can be chosen homogeneous and uniformly distributed or inhomogeneous executed. Advantageously, it can thereby be achieved that the film forming tool is suitable for allowing a perforation applied to the back of the mold shell to act on the laminating element and / or the film, so that the force required to emboss the laminating element and / or the film the laminating element and the shell mold or between the film and the shell mold can be done.

Optionally, the mold shell is perforated with a laser.

Advantageously, this can be achieved that the perforation can be performed very fine-pored and with thin perforation channels.

Preferably, a cooling channel is embedded in the mold shell. Advantageously, this can be achieved that the film forming tool can be adjusted by a temperature control to an optimum operating temperature. The tempering can have a liquid cooling, whereby all the benefits of liquid cooling can be transferred to the film forming tool. Liquid cooling allows very fast and efficient cooling of components. In particular, it can thus be advantageously achieved that the cooling output emanating from a cooling channel can be brought into effect directly in the sprayed layer of metal, so that the surface of the film forming tool can be tempered very rapidly. Optionally, the mold shell is connected to a support structure. Advantageously, can be achieved thereby that the overall shape of the shell is very stiff, whereby the quality of the laminated components increases, especially with regard to the reproducibility of components with only within small tolerances deviating component geometries.

Preferably, a cooling channel is embedded in the support structure. Advantageously, this can be achieved in that the support structure can be cooled efficiently and fast reaction.

Optionally, the support structure is connected to a cooling plate.

Advantageously, this can be achieved by the fact that the film forming tool can be cooled efficiently. Heat flows can be distributed particularly well in a cooling plate and temperatures can homogenize in a cooling plate.

Preferably, a cooling channel is embedded in the cooling plate.

Advantageously, this can be achieved by the fact that the cooling plate can be cooled by liquid cooling efficient and fast reaction.

Optionally, the mold shell is backed with aluminum grilling.

Conceptually, the following is explained: "Backfilling" is understood to mean the lining and / or filling of cavities and / or undercuts in the support structure of the film forming tool.

It can thereby be advantageously achieved that the intermediate space of the support structure can be compacted with aluminum grit, as a result of which the thermal conductivity and the rigidity of the film forming tool increase with a simultaneously low weight.

Preferably, a cooling channel is embedded in the Alugrieß.

Advantageously, it can be achieved thereby that an area of the foil forming tool made of aluminum mesh can be cooled efficiently and with rapid reaction.

It is to be expressly understood that the subject matter of the third aspect may be advantageously combined with the subject matter of the foregoing aspects of the invention, cumulatively either alone or in any combination.

According to a fourth aspect of the invention, the object solves a use of a film forming tool according to the first aspect of the invention for producing and laminating a component, wherein the laminated component has a grain, or for molding a film of a grained film molding tool.

It is understood that the advantages of a film forming tool according to the first aspect of the invention for laminating a component with a laminating element or for molding a film, wherein the film forming tool has a mold shell, wherein the mold shell has a sprayed metal layer produced by metal spraying, as above describe directly the use of a film forming tool according to the first aspect of the invention for producing and laminating a component, wherein the laminated component has a grain and for molding a film from a grained film molding tool. It should be expressly understood that the subject matter of the fourth aspect may be advantageously combined with the subject matter of the foregoing aspects of the invention, cumulatively either singly or in any combination.

The invention will be explained in more detail below with reference to two exemplary embodiments for producing a molded shell and four exemplary embodiments for expanding a molded shell to form a complete foil mold with reference to the drawing. Show there

1 shows schematically a first variant for producing a mold shell,

2 schematically shows a second variant for producing a mold shell,

3 shows schematically a first variant for constructing a film forming tool,

4 schematically shows a second variant for constructing a film forming tool, FIG. 5 schematically shows a third variant for constructing a film forming tool and FIG

Fig. 6 shows schematically a fourth variant for the construction of a film forming tool.

The first variant of a manufacturing method for a shell mold 1 in Figure 1 consists essentially of three process steps (the process steps are each shown schematically with partial figures in the figure 1 running from left to right). The molded shell 1 consists essentially of a ceramic film 3 and a metal spray layer 4.

In the first process step (left partial image) of the first manufacturing process of the mold shell 1 in FIG. 1, the ceramic film 3 is applied to the milled positive model 2.

The positive model 2 has no grain (not shown). The ceramic film 3 has a grain (not shown) which is applied in the direction of the positive model 2. In the second process step (middle partial illustration) of the first production method of the shell 1 in FIG. 1, the metal spray layer 4 is applied to the back of the applied ceramic foil 3 with a metal spraying device 5. The metal spray layer 4 reinforces the molded shell 1 consisting of ceramic film 3 and metal spray layer 4.

After the metal spray layer 4 is fully applied and fully cured, the positive model 2 is separated from the shell mold 1 (not shown).

In the third process step (right partial image) of the first manufacturing process of the mold shell 1 in FIG. 1, the mold shell 1 is perforated with a laser 6. The second variant of a manufacturing method for a shell mold 11 in Figure 2 consists essentially of three process steps (the process steps are each shown schematically with partial figures in Figure 1 running from left to right). The mold shell 11 consists essentially of a ceramic varnish 13 and a metal spray layer 14. In the first process step (left partial image) of the second manufacturing process of the mold shell 11 in Figure 2 is applied to the milled positive model 12 of the ceramic paint 13 with a Lackiergerät 15.

The positive model 12 has a grain (not shown).

In the second process step (middle partial illustration) of the second production method of the shell 11 in FIG. 2, the metal spray layer 14 is applied to the rear side of the applied ceramic lacquer 13 with a metal spraying device 16. The metal spray layer 14 stiffens the shell 11 consisting of ceramic varnish 13 and metal spray layer 14.

After the metal spray coating 14 is fully applied and fully cured, the positive model 12 is separated from the mold pan 11 (not shown). In the third process step (right-hand part illustration) of the second production method of the shell 11 in FIG. 2, the shell 11 is perforated with a laser 7.

The first variant of a film forming tool 20 in FIG. 3 consists essentially of a mold shell 21 and a support structure 24. The mold shell 21 consists essentially of a ceramic layer 22 (ceramic film or ceramic varnish) and a metal spray layer 23.

The support structure 24 consists essentially of a cooling plate 25 and webs 26. The support structure 24 stiffens the mold shell 21 to the film forming tool 20th

The film forming tool 20 has cooling channels 27 in the cooling plate 25, through which the film forming tool 20 can be tempered.

The second variant of a film forming tool 30 in FIG. 4 consists essentially of a mold shell 31 and a support structure 35.

The mold shell 31 essentially consists of a ceramic layer 32 (ceramic film or ceramic varnish) and a metal spray layer 33. The support structure 35 consists essentially of a cooling plate 36 and webs 37. The support structure 35 stiffens the mold shell 31 to form the film mold 30.

The film molding tool 30 has cooling channels 34 in the metal spray layer 33, by means of which the film molding tool 30 can be tempered.

The third variant of a film forming tool 40 in FIG. 5 consists essentially of a mold shell 41 and a support structure 44.

The mold shell 41 consists essentially of a ceramic layer 42 (ceramic foil or ceramic lacquer) and a metal spray layer 43. The support structure 44 consists essentially of a cooling plate 45 and webs 46. The support structure 44 stiffens the mold shell 41 to the film mold 40. The film mold 40 has cooling channels 47 in the webs 46 of the support structure 44, through which the film mold 40 can be tempered.

The fourth variant of a foil forming tool 50 in FIG. 6 consists essentially of a shell 51 and a support structure 54.

The mold shell 51 consists essentially of a ceramic layer 52 (ceramic foil or ceramic lacquer) and a metal spray layer 53.

The support structure 54 consists essentially of a cooling plate 55 and Alugrieß 56. The Alugrieß 56 behind the mold shell 51 and fills the space between the mold shell 51 and the cooling plate 55, whereby the mold shell 51 is added to the film mold 50 and stiffened. The film forming tool 50 has cooling channels 57 that run through the aluminum ring 56 and through which the film forming tool 50 can be tempered.

List of reference numbers used

1 bowl

2 positive model

3 ceramic foil

4 metal spray coating

5 metal sprayer

6 lasers

11 mold shell

12 positive model

13 ceramic paint

14 metal spray coating

15 paint sprayer

16 metal sprayer

17 lasers

20 foil forming tool

21 shell mold

22 ceramic layer

23 metal spray coating

24 support structure

25 cooling plate

26 footbridge

27 cooling channel

30 foil forming tool

31 shape shell

32 ceramic layer

33 metal spray layer

34 cooling channel

35 support structure

36 cooling plate

37 footbridge Foil molding tool

Ceramic layer Metal spray layer Support structure Cooling plate

web

cooling channel

Foil mold Mold shell Ceramic layer Metal spray layer Support structure Cooling plate

granular aluminum

cooling channel

Claims

claims:

A film forming tool for laminating a component with a laminating element or for molding a film, wherein the film forming tool has a mold shell, characterized in that the mold shell has a sprayed metal layer produced by metal spraying.

2. foil mold according to claim 1, characterized in that the shell mold has two layers of material made of different materials.

3. foil forming tool according to one of claims 1 or 2, characterized in that a surface of the shell mold ceramic or consists of ceramic.

4. foil forming tool according to one of the preceding claims, characterized in that the surface of the shell mold has a negative grain structure.

5. foil forming tool according to one of the preceding claims, characterized in that the surface of the shell mold is permeable to air.

6. Foil mold according to one of the preceding claims, characterized in that the mold shell has a support structure on a rear side.

7. foil forming tool according to claim 6, characterized in that the support structure is honeycomb-shaped.

8. foil forming tool according to one of claims 6 or 7, characterized in that the support structure comprises webs.

9. foil forming tool according to one of claims 6 to 8, characterized in that a part of the support structure consists of aluminum.

10. foil forming tool according to one of claims 6 to 9, characterized in that a gap of the support structure Alugrieß has.

11. foil forming tool according to one of claims 1 to 5, characterized in that the shell mold on the back Alugrieß has.

12. Film forming tool according to one of the preceding claims, characterized in that the film forming tool has a temperature.

13. Film forming tool according to one of the preceding claims, characterized in that the temperature has a cooling channel.

14. Foil mold according to claim 13, characterized in that the cooling channel comprises copper.

15. Film forming tool according to one of claims 13 or 14, characterized in that a part of the cooling channel extends into the sprayed layer of metal.

16. Foil mold according to one of claims 13 to 15, characterized in that a part of the cooling channel extends into the support structure.

17. Film forming tool according to one of claims 13 to 16, characterized in that a part of the cooling channel extends into the Alugrieß.

18. Film forming tool according to one of the preceding claims, characterized in that the film forming tool has a cooling plate.

19. Foil mold according to claim 18, characterized in that the cooling plate is flat.

20. The film forming tool according to one of claims 18 or 19, characterized in that a part of the cooling channel extends into the cooling plate.

21. A method for producing a film forming tool, in particular for producing a film forming tool according to one of the preceding claims, characterized in that a ceramic layer is applied to a positive model, wherein the ceramic has a grain, and a metal layer is sprayed onto the ceramic layer.

22. A method for producing a film forming tool, in particular for producing a film forming tool according to one of claims 1 to 20, in particular method according to claim 21, characterized in that a ceramic paint is sprayed onto a positive model and cured, so that a ceramic layer is formed, wherein the positive model has a grain, and a metal layer is sprayed onto the ceramic layer.

23. A method for producing a film forming tool according to any one of claims 21 or 22, characterized in that the existing ceramic layer and metal layer mold shell is perforated.

24. A method for producing a film forming tool according to one of claims 21 to 23, characterized in that the mold shell is perforated with a laser.

25. A method for producing a film forming tool according to one of claims 21 to 24, characterized in that a cooling channel is embedded in the mold shell.

26. A method for producing a film forming tool according to one of claims 21 to 25, characterized in that the mold shell is connected to a support structure.

27. A method for producing a film forming tool according to one of claims 21 to 26, characterized in that a cooling channel is embedded in the support structure.

28. A method for producing a film forming tool according to one of claims 21 to 27, characterized in that the support structure is connected to a cooling plate.

29. A method for producing a film forming tool according to one of claims 21 to 28, characterized in that a cooling channel is embedded in the cooling plate.

30. A method for producing a film forming tool according to any one of claims 21 to 29, characterized in that the shell mold is backed with Alugrieß.

31. A method for producing a film forming tool according to one of claims 21 to 30, characterized in that a cooling channel is embedded in the Alugrieß. Use of a foil forming tool according to one of claims 1 to 20 for producing and laminating a component, wherein the laminated component has a scar, or for molding a foil from a grained foil forming tool.