Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
  • B44C1/16—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like
  • B44C1/165—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like for decalcomanias; sheet material therefor
  • B44C1/17—Dry transfer
  • B44C1/1712—Decalcomanias applied under heat and pressure, e.g. provided with a heat activable adhesive
• • 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
• • 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
  • B29C45/14811—Multilayered articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/40—Layered products comprising a layer of synthetic resin comprising polyurethanes
• • 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
  • B44C3/025—Superimposing layers to produce ornamental relief structures
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C5/00—Processes for producing special ornamental bodies
  • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
  • B44C5/0453—Ornamental plaques, e.g. decorative panels, decorative veneers produced by processes involving moulding
• • 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
  • B29C2045/14737—Coating articles provided with a decoration decorations printed on the insert by a digital imaging technique
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
  • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
  • B29K2995/0025—Opaque
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
  • B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent
  • B29K2995/0026—Transparent
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/40—Properties of the layers or laminate having particular optical properties
  • B32B2307/41—Opaque
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/40—Properties of the layers or laminate having particular optical properties
  • B32B2307/412—Transparent
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2451/00—Decorative or ornamental articles

Definitions

• the invention relates to a transfer film, a plastic injection molded part and a method for their production.
• IMD In-Mould-Decoration
• the following steps are carried out, in particular in the order given: a) providing a carrier layer, b) providing a transfer layer comprising a decorative layer, wherein the transfer layer is or will be arranged on the carrier layer, c) applying one or more shaped elements to the carrier layer, wherein the one or more shaped elements have a three-dimensional shape and are applied in register with the decorative layer.
• the object is further achieved by means of a transfer film, in particular an IMD transfer film.
• the transfer film is preferably produced using the method according to the invention.
• the transfer film has a carrier layer and a transfer layer comprising a decorative layer, the transfer layer being arranged on the carrier layer.
• the transfer film also includes one or more shaped elements, the one or more shaped elements being applied to the carrier layer and in register with the decorative layer.
• the object is further achieved by means of a method for producing a plastic injection molded part that is coated with a transfer film, in particular an IMD transfer film.
• the transfer film is preferably produced by the method according to the invention for producing a transfer film and/or a transfer film according to the invention.
• the method for producing the plastic injection molded part comprises the following steps, in particular in the order given: x1) Providing a transfer film, the transfer film having a carrier layer and a transfer layer comprising a decorative layer, the transfer layer being or being arranged on the carrier layer , x2) providing one or more shaped elements on the carrier layer, wherein the one or more shaped elements have a three-dimensional shape and are or will be applied in register with the decorative layer, x3) back-injection molding of the transfer film with an injection molding compound, with the effect of the injection molding compound on the transfer film in the transfer layer, an impression of the three-dimensional shape of the one or more shaped elements is introduced in register with the decorative layer.
• the method for producing the plastic injection molded part is therefore in particular an IMD injection molding method.
• the task is further solved by a plastic injection molded part.
• the plastic injection molded part is in particular produced with the method according to the invention for producing the plastic injection molded part.
• the plastic injection molded part comprises an injection molding compound and a transfer layer of a transfer film, in particular an IMD transfer film, back-injected with the injection molding compound.
• the transfer film is produced in particular with the method according to the invention for producing a transfer film and/or a transfer film according to the invention.
• the transfer layer comprises a decorative layer and has an impression of a three-dimensional shape, the impression being introduced in register with the decorative layer.
• the molding of the three-dimensional shape is therefore in particular not just the shape of a mold half of an injection molding machine.
• the mold is preferably a mold that is additionally made in the shape of the transfer layer, which is produced by a mold half on which the carrier layer and/or the one or more mold elements rest when the transfer film is back-injected with the injection molding compound will.
• haptic and/or tactile elements and/or depth effects can be produced on the surface of the plastic injection molded part. Furthermore, it is achieved that the haptic and/or tactile elements and/or the depth effects register accurately with both decorative elements and/or backlighting masks and/or functional components, such as e.g.
• Backlighting and / or touch sensors of the plastic injection molded part can be produced. It is possible here that the X-ray properties of the plastic injection-molded part are not impaired. In particular, it is possible to use haptic and/or tactile elements and/or depth effects on a Provide plastic injection molded part that ensure improved operation and / or perception in use of the plastic injection molded part through their register-accurate arrangement to the decorative layer and optionally to a mask layer and / or functional components.
• the impression of the three-dimensional shape is always arranged in register with the decorative layer by applying the one or more shaped elements in register with the decorative layer, a precise impression of the arrangement of the various components of the plastic injection-molded part is retained.
• all functional components can also be arranged in register with the impression of the three-dimensional shape and at the same time with the decorative layer and optionally a mask layer, so that the functional components can work and be operated precisely.
• Registered or in register or precisely in register or in register or register accuracy is to be understood as meaning a positional accuracy of two or more layers relative to one another.
• the register accuracy of several elements and/or layers to one another is an important feature in order to increase process reliability.
• the positionally accurate positioning can be carried out in particular by means of sensory, preferably optically detectable fiducial marks or register marks. These registration marks or register marks can either represent special separate elements or areas or layers or themselves be part of the elements or areas or layers to be positioned.
• a layer and/or a ply is to be understood in particular as meaning an essentially flat structure which is preferably designed over the whole area or in the form of a pattern and is preferably itself single-layered or multi-layered.
• a haptic element is to be understood in particular as an element that can be perceived haptically.
• a tactile element is to be understood in particular as an element that can be perceived tactilely.
• a functional component is in particular a component with an electrical, in particular electronic, function.
• a functional component is preferably to be understood as a component that enables interaction with a user, preferably through information input and/or information output.
• the providing comprises applying the transfer layer comprising at least the decorative layer to the carrier layer.
• the one or more shaped elements are preferably partially applied to the carrier layer and/or applied in partial areas with a greater thickness than in other partial areas.
• Layers can be applied to the carrier layer in particular directly onto the carrier layer or indirectly via one or more further layers. Regions, and in particular also partial regions, are preferably specified when viewed perpendicularly to a plane and/or main surface spanned by the transfer film or a respective layer and preferably include all parts of the transfer film and/or the plastic injection molded part that overlap with this plane and/or main surface.
• the transfer layer is or will be applied to a first side of the carrier layer and the one or more shaped elements are or will be applied to a second side of the carrier layer opposite the first side.
• the impression is and/or is arranged in particular in such a way that the impression does not impair the transillumination properties of the transfer layer, in particular the decorative layer and/or the mask layer, and/or the injection molding compound.
• the impression is arranged in such a way that the impression essentially has no influence on the wavelength, in particular the color, and/or the scattering and/or the brightness and/or the luminance of a Radiation that transmits the transfer layer, in particular the light that transmits through the viewing area of the transfer layer.
• the transfer layer, in particular the protective layer of the transfer layer can be uniformly transilluminated in the visible area, in particular if the transfer layer already has the impression.
• the impression expediently does not overlap with the visible area, or if the impression overlaps with the visible area, it is ensured that the transfer layer, in particular the protective layer of the transfer layer, has essentially no changes in layer thickness in the visible area. This can be achieved, for example, if the visible area is completely overlapped by the impression. It is also possible for the one or more shaped elements to have a constant layer thickness, at least in the visible area.
• Transillumination properties are understood to mean, for example, in particular the light scattering and/or the luminous intensity and/or the light color and/or the wavelength and/or the luminance and/or the emission angle.
• Back injection molding of the transfer film with the injection molding compound preferably takes place at a temperature of the injection molding compound in a range from 200.degree. C. to 300.degree.
• the injection molding compound preferably includes or consists in particular of ABS, ASA, PA, PP, PC, PMMA, SAN, TPO or a mixture of two or more of the materials mentioned.
• the transfer film Before the transfer film is back-injected, the transfer film is preferably arranged in an injection molding machine on a mold half, in particular arranged between two mold halves, the mold halves being closed before back-injection.
• the transfer film By back-injecting the transfer film with the injection molding compound, the transfer film is pressed in particular against one half of the mold and forms a shape that is complementary to the half of the mold.
• the mold of the plastic injection molded part is or will be formed in particular by means of the one or more mold elements. It is possible that the one or more shaped elements and/or the carrier layer are then removed from the plastic injection molded part or are removed in particular in the finished plastic injection molded part.
• a three-dimensional shape of the shaped elements and/or the mold is to be understood in particular as meaning that the dimensions in all three spatial directions essentially contribute to the shape of the one or more shaped elements or the mold.
• the three-dimensional shape is or will be at least one surface of the transfer layer, in particular additionally to a curvature created by a mold half of the injection molding machine.
• the one or more shaped elements preferably form one or more motifs or include them and/or are introduced into the transfer film in particular to form one or more motifs, in particular the mold in the plastic injection-molded article.
• the outer contours of a projection of the one or more shaped elements and/or the molding in a plane to follow the outer contours of a particularly two-dimensional motif.
• the three-dimensional shape includes a two-dimensional motif and the two-dimensional motif is preferably provided with a spatial structure, for example by the two-dimensional motif being provided with a height in a third spatial direction.
• the height of the two-dimensional motif is, for example, the thickness or height of a shaped element and/or the height of the molding.
• a three-dimensional form is a motif that can only be represented by a spatial structure.
• a motif is selected, for example, from or a combination of a figurative representation, image, symbol, logo, coat of arms, portrait, pattern, alphanumeric character, in particular 3D writing, which can preferably be positive and/or negative images.
• the motifs can be provided for depth effects and/or haptic and/or tactile elements.
• a recessed area is produced in the transfer layer, the recessed area preferably being formed by the molding and in particular having a positive image of the one or more mold elements. It is also possible that when the transfer film is back-injected with the injection molding compound of step x3), a raised area is formed in the transfer layer, which in particular has a negative image of the one or more shaped elements. It is therefore possible for the raised area and/or the recessed area and/or the molding to form one or more motifs which, in particular, are complementary to the one or more Motifs of one or more shape elements are.
• a raised area is in particular an area in which there is no shaped element in the transfer film and/or in which the transfer layer is deformed in the direction of the carrier layer during back injection with the injection molding compound.
• a recessed area is in particular an area in which there is a shaped element in the transfer film and/or in which the transfer layer does not or essentially does not move in the direction of the carrier layer during back injection with the injection molding compound.
• the raised and/or the recessed area can be a continuous area or, alternatively or additionally, can comprise one or more partial areas that are separate from one another.
• the transfer layer is or is preferably arranged at least on a boundary line between a region with the one or more shaped elements and a region without shaped elements, preferably when viewed perpendicularly to a plane spanned by the transfer film. This makes it possible for the transfer layer to be deformed in register with the decorative layer, for example by the action of pressure and/or heat on the transfer film, in particular by producing the raised area and the recessed area.
• one or more first layers of the one or more shaped elements may comprise or consist of a digital ink, preferably an inkjet ink, preferably a UV inkjet ink.
• a digital ink preferably an inkjet ink, preferably a UV inkjet ink.
• one or more first layers of the one or more shaped elements are applied using a digital printing method, preferably an inkjet printing method, preferably a UV inkjet printing method.
• one or more layers of the one or more shaped elements can be crosslinkable or crosslinkable, in particular by means of radiation, preferably UV radiation.
• radiation preferably UV radiation.
• CMYK cyan, magenta, yellow, black
• special colors for example white or metallic colors.
• one or more layers of the one or more shaped elements are or will be applied by means of gravure printing and/or flexographic printing and/or screen printing. It is thus also possible for one or more layers of the one or more shaped elements of the transfer film to comprise an intaglio printing ink and/or a flexographic printing ink and/or a screen printing ink.
• the one or more shaped elements may have one or more layers.
• step c) and/or two or more layers of the one or more shaped elements are applied overlapping one another in the transfer film and/or the one or more shaped elements are applied at least partially by means of 3D printing.
• 3D printing can be understood to mean, for example, Selective Laser Sintering (SLS), Fused Deposition Modeling (FDM) and/or Stereolithography (SLA).
• At least two different printing methods to be used to apply the one or more shaped elements.
• at least one layer of the one or more shaped elements applied last in step c) is applied using a digital printing method, preferably an inkjet printing method, preferably a UV inkjet printing method.
• At least one layer of the one or more shaped elements which forms an outer surface of the transfer film, has or consists of a digital printing ink, preferably an inkjet printing ink, preferably a UV inkjet printing ink.
• a spatial separation of applications of different layers in step c) can be achieved.
• This enables, for example, individualization, preferably in the form of small areas, in particular before and/or after transport, storage and in particular shortly before and/or at the site of production of the plastic injection-molded part.
• an impression with different heights is or is produced in the plastic injection-molded part by means of different heights of the one or more mold elements. This is achieved in particular by using appropriate settings in the digital printing process, preferably the number of overlapping inks and/or layers of a feature, the individual ink droplet sizes, the UV curing parameters, the coating weight of each ink and/or a combination thereof. It is therefore possible for the transfer film to have one or more shaped elements of different heights and/or for the plastic injection molded part to have an impression with different heights and/or depths, in particular partial areas of the raised area with different heights and/or partial areas of the recessed area with different heights having.
• the layer thickness of a layer of the one or more shaped elements applied by means of digital printing is preferably in a range from 0.5 ⁇ m to 50 ⁇ m, in particular in a range from 1 ⁇ m to 25 ⁇ m.
• At least one shaped element of the one or more shaped elements printed by means of digital printing has a layer thickness of 1 ⁇ m to 200 ⁇ m.
• the layer thickness of at least one shaped element of the one or more shaped elements is in particular in a range from 1 ⁇ m to 200 ⁇ m.
• preferably several, preferably all, layers of the at least one shaped element are applied by means of digital printing and in particular in an overlapping manner.
• a layer of the one or more shaped elements printed by means of gravure printing to have a layer thickness in a range from 1 ⁇ m to 25 ⁇ m and/or for a layer of the one or more shaped elements printed by means of screen printing to have a layer thickness in a range of 1 ⁇ m up to 100 pm.
• the height of the impression of the plastic injection molded part which is achieved in particular in the method for producing the plastic injection molded part, is preferably in a range from 1 ⁇ m to 200 ⁇ m.
• Irradiation of the one or more shaped elements in particular by means of UV radiation, one or more irradiation steps being carried out, which are preferably carried out after step c) and/or during step c), in particular before at least one layer of the one or more shaped elements is applied is applied in an overlapping manner to at least one other layer of the two or more layers of the one or more mold elements.
• the irradiation during step c), in particular before onto at least one layer of the one or more shaped elements overlapping onto at least one other layer of the two or more layers of the one or more shaped elements is applied is advantageous because this increases the viscosity of the respective lower layer so that this layer does not run and on the other hand subsequent layers receive a more stable substrate. It is conceivable that overlapping layers are cured in between so that they do not run, for example, and a higher height-to-width ratio can thereby be achieved, for example.
• the one or more form elements are or are preferably from the class of polyacrylates and/or polymethacrylates, polyurethanes, in particular from the group of polyester polyols, polyether polyols, polycarbonate polyols, polyacrylate polyols and/or combinations of these polymers, polyesters, polyethers, polyolefins, epoxy resins and/or formed from derivatives of the above.
• these formulations can be either non-crosslinked or further crosslinked, preferably using isocyanates, carbodiimides, melamines and/or aziridines and/or derivatives of the compounds mentioned.
• the one or more shaped elements can also and in particular be made up of radiation-curing acrylates and/or methacrylates, consisting of polyacrylate acrylates (“acrylic acrylates”), polyurethane acrylates, polyester acrylates, polycarbonate acrylates and/or polyether acrylates and/or copolymers of the aforementioned.
• the radiation-curing formulations in particular the radiation-curing acrylates and/or methacrylates, are preferably oligomers.
• An oligomer is in particular a molecule with a number of monomers in a range from 2 to 100.
• the one or more shaped elements preferably contain, in particular in addition to the polyacrylates mentioned, further UV-curable acrylate monomers and/or methacrylate monomers and/or are produced from them.
• these monomers contain in particular one or more acrylate groups and/or preferably further subgroups such as, for example, alkyl, aryl, cycloalkyl, cycloalkylaryl, alkoxyalkyl, alkoxyaryl, thionyl, thionylaryl, cyclothionyl, cyclothionylaryl, alkoxythionyl, cycloalkoxythionyl, alkoxycyclothionyl, cycloalkoxycyclothionyl, alkoxythionylaryl, cycloalkoxythionylaryl, alkoxycyclothionylaryl and/or cycloalkoxycyclothionylaryl groups.
• the one or more shaped elements can consist of a radiation-curing dual-cure lacquer, in particular in terms of a combination of the aforementioned.
• Dual cure coatings can consist of different polymers or oligomers that have unsaturated acrylate groups and/or methacrylate groups.
• these functional groups can in turn be radically crosslinked with one another.
• at least two or more alcohol groups are preferably also used for thermal pre-crosslinking in the first step. These alcohol groups can be crosslinked in particular with multifunctional isocyanates or melamine-formaldehyde resins.
• UV raw materials such as epoxy acrylates, polyether acrylates, polyester acrylates and, in particular, polyacrylate acrylates come into consideration as preferably unsaturated oligomers or polymers.
• HDI hexamethylene diisocyanate
• IPDI isophorone diisocyanate
• the melamine crosslinkers can come from the group of the fully etherified, the imino types and/or the benzoguanamines.
• the one or more shaped elements are or will be, e.g. constructed as a layer of paint.
• the color layer can consist of or include colorants and/or pigments, in particular also optically variable pigments and/or metallic pigments.
• the one or more shaped elements can also be or will be equipped with fillers such as HDK (highly disperse silicic acid), in particular to optimize rheological properties.
• the one or more mold elements are or will be provided with parting agents, in particular to improve the detachment properties from an injection mold, in particular from the mold half that is in contact with the one or more mold elements in step x3).
• the release agents are preferably silicones.
• these silicones can in turn be equipped with side chains which carry radiation-curable groups.
• These groups are or are preferably formed from the classes of radiation-curing acrylates and/or methacrylates consisting of and/or comprising acrylate acrylates, urethane acrylates, ester acrylates, carbonate acrylates and/or ether acrylates and/or copolymers of the above.
• Each of these groups, as well as the silicone itself, can in turn carry, in particular, end groups which preferably contribute to thermal crosslinking in the one or more formulations.
• the melamine crosslinkers are selected in particular from the group of the fully etherified, the imino types and/or the benzoguanamines.
• the silicones can also carry subgroups which, in particular, do not contribute to crosslinking but nevertheless have a targeted influence on the properties of the silicone in question.
• These subgroups can be, for example, from one or more of the classes of alkyl, aryl, cycloalkyl, cycloalkylaryl, alkoxyalkyl, alkoxyaryl, thionyl, thionylaryl, cyclothionyl, cyclothionylaryl, Alkoxythionyl, cycloalkoxythionyl, alkoxycyclothionyl, cycloalkoxycyclothionyl, alkoxythionylaryl, cycloalkoxythionylaryl, alkoxycyclothionylaryl or cycloalkoxycyclothionylaryl groups can be selected.
• the one or more shaped elements preferably contain what are known as UV initiators, in particular for initiating radiation curing, if this is in particular UV radiation curing.
• the UV initiators are preferably selected from the class of ⁇ -alkoxy, ⁇ -hydroxy or ⁇ -amino aryl ketones and/or the class of acylphosphine oxides.
• Acylphosphine oxides are used in particular because of their particularly suitable absorption properties in the UV-LED range, preferably in combination with UV inkjet printing of the one or more shaped elements.
• the one or more molding elements may contain additives.
• additives In order to integrate these additives into the three-dimensional network, they are typically provided with radiation-curing or thermally crosslinkable groups or combinations thereof.
• Tertiary amines and/or acrylate amines are preferably added to the one or more mold elements, in particular to minimize chain breaks during radiation curing due to reactions of the radicals formed with oxygen molecules in the air and/or to reduce the migration of radical chains to the surface of the mold element.
• these additives are preferably also provided with radiation-curing or thermally crosslinkable groups or combinations thereof.
• the raised area and/or the lowered area prefferably have a minimum line width and/or a minimum dot size in a range of 0.025 mm to 0.1 mm.
• the minimum line thickness is to be understood in particular as the minimum width of an area.
• the minimum spot size is the minimum diameter of an area with a circular base.
• the recessed area preferably for generating a positive image of the one or more shaped elements, in particular in the event that the one or more shaped elements are or will be applied by means of digital printing, has a minimum line width and/or minimum point size of greater than 0.025mm.
• the raised area prefferably has a minimum line width and/or minimum point size of greater than 0.040mm.
• the recessed area preferably for generating a negative image of the one or more shaped elements, in particular in the event that the one or more shaped elements are or will be applied by means of gravure printing, has a minimum line width and/or minimum point size of greater than 0.075mm.
• the raised area prefferably has a minimum line width and/or minimum point size of greater than 0.12mm.
• the recessed area is preferably used to produce a negative image of the one or more shaped elements, particularly in the event that the one or more shaped elements are or will be applied by means of screen printing, has a minimum line width and/or minimum point size of greater than 0.10 mm.
• the raised area prefferably has a minimum line width and/or minimum point size of greater than 0.15mm.
• a positive shaped element is understood to mean a single shaped element which, after back-injection molding, causes a recessed area in the carrier layer when viewed in cross-section.
• a negative shaped element is understood to mean one or more full-surface shaped elements which, after back-injection molding, produce a raised region of the carrier layer when viewed in cross section.
• the one or more shaped elements have a higher dimensional stability than the carrier layer and/or the transfer layer, preferably than at least one layer of the transfer layer.
• a higher dimensional stability is to be understood in particular as a higher deformation resistance when the transfer film is back-injected with the injection-molding compound.
• the one or more shaped elements are preferably mechanically stable and/or have mechanical stability, in particular in the case of back injection with an injection molding compound, preferably in an IMD injection molding process, preferably in step x3).
• the mechanical stability is here in particular the stability of the one or more mold elements compared to the through the injection molding compound, especially when back-injecting the transfer film with the Injection molding compound, acting load understood.
• the one or more mold elements are preferably sufficiently hard and produce a sufficiently strong connection to the carrier film in order to withstand the high pressure that is generated during back-injection molding in particular.
• the one or more shaped elements preferably have a glass transition temperature of more than 200.degree.
• the one or more shaped elements prefferably have an essentially constant compressive strength up to a temperature of 200°C. This ensures, in particular, that the transfer layer is deformed when pressure and/or heat is applied to the transfer film, in particular when the transfer film is back-injected with the injection molding compound. Furthermore, in particular, a high edge sharpness of the impression is made possible.
• the mechanical stability is determined based on the difference in height when comparing the height of the one or more shaped elements before and after back-injection of the transfer film with the injection molding compound, the height of the one or more shaped elements after back-injection of the transfer film with the injection molding compound corresponds to the height of the molding of the plastic injection molded part.
• the impression preferably has a height in a range from 90% to 100% of the height of the one or more shaped elements of the transfer film before back-injection with the injection molding compound.
• the temperatures occurring in the injection molding tool during back injection in particular the temperature of the injection molding compound, are in a range from 150° C. to 500° C., in particular in a range from 200° C. to 300° C.
• the pressures occurring in the injection mold during back injection in particular the internal pressure of the injection mold, are in a range from 300 bar to 1000 bar, in particular in a range from 400 bar to 800 bar.
• the height of the impression is preferably determined on the plastic injection molded part, in particular based on the height difference between an outer surface of the transfer layer in the recessed area and an adjacent outer surface of the transfer layer in a raised area.
• An outer surface is in particular an exposed surface, preferably after the carrier layer has been separated.
• the height of the one or more shaped elements is measured in particular before the transfer film is back-injected.
• the measurement of the height of the impression and/or the one or more shaped elements and/or the line width and/or the point size is carried out in particular by means of a scanning electron microscope (SEM).
• the impression has a height of 90% of the height of the one or more shaped elements before the transfer film was back-injected with the injection molding compound, in particular if the carrier layer has a layer thickness of 50 ⁇ m and preferably consists of PET. It is also possible that the impression after the injection molding compound is back-injected has a height of 100% of the height of the one or more shaped elements before the transfer film is back-injected with the injection molding compound, in particular if the carrier layer has a layer thickness of 75 ⁇ m and preferably consists of PET.
• the height of the one or more shaped elements is retained or is just as high before back-injection of the transfer film with the injection molding compound as after back-injection.
• the layer thickness of the carrier layer has no influence on the edge sharpness, so that the one or more shaped elements do not have to have any coarser structures in relation to the edge sharpness.
• the edge sharpness describes the "sharpness" or accuracy or exactness with which the structures produced push through or stand out through the carrier film.
• the decorative layer has one or more decorative elements.
• the one or more layers of the decorative layer and/or the one or more decorative elements are or are preferably applied in the method for producing the transfer film.
• the one or more layers of the decorative layer and/or the one or more decorative elements can each be present over the entire area or in each case partially.
• the one or more layers of the decorative layer and/or the one or more decorative elements can overlap in areas and/or be adjacent to one another in areas.
• the mutually adjacent arrangement may be spaced relative to each other or directly adjacent to each other with no space relative to each other.
• the one or more shaped elements are preferably arranged in at least two different directions in register with the decorative layer.
• the two different directions are in particular aligned orthogonally to one another and/or span a plane which is parallel to a main surface of the carrier layer.
• At least one shaped element of the one or more shaped elements to be arranged in register with at least one decorative element or one or more decorative elements is, the at least one decorative element preferably forms a separate motif.
• a separate motif is in particular not an endless motif and/or has border lines visible in the two different directions in the transfer film and/or the plastic injection molded part.
• the one or more shaped elements and the one or more decorative elements can in each case overlap in areas and/or be adjacent to one another in areas.
• the mutually adjacent arrangement may be spaced relative to each other or directly adjacent to each other with no space relative to each other.
• the register tolerance between the one or more shaped elements and the decorative layer is preferably in a range from 0.05 mm to 1.0 mm, preferably in a range from 0.05 mm to 0.2 mm.
• the register tolerance between the one or more shaped elements and the decorative layer is in particular a maximum of 1.0 mm, preferably a maximum of 0.2 mm. It is thus also possible that the register tolerance between the impression and the decorative layer is preferably in a range from 0.05 mm to 1.0 mm, preferably in a range from 0.05 mm to 0.2 mm, and/or at a maximum 1.0 mm, preferably at most 0.2 mm.
• a register tolerance in the range of 0.05 mm to 0.2 mm is achieved in particular if the one or more shaped elements are applied using a digital printing method, preferably using ink jet printing, preferably UV ink jet printing. If the one or more shaped elements are applied by means of screen printing, a register tolerance in the range from 0.2 mm to 1.0 mm is possible. The register tolerance is preferably achieved in each case between one or more shaped elements of the one or more shaped elements and one or more associated decorative element of the one or more decorative elements.
• Decorative layer in particular the position of one or more decorative elements, one or associated with multiple features.
• the one or more shaped elements are then preferably aligned when being applied to the carrier layer in step c) depending on the position of the decorative layer, in particular the position of one or more decorative elements that are associated with one or more shaped elements.
• the transfer layer has a masking area and/or a visible area.
• the method preferably comprises the following step, in particular before and/or after step c): b1) providing and/or generating a masking area and/or a visible area in the transfer layer.
• the visible area is preferably produced in the transfer layer in or after step b1) and/or the transfer layer of the transfer film preferably already has a visible area in step b1).
• the viewing area preferably has a transmittance that is in particular higher than the transmittance of the masking area, preferably by a value of at least 10% and/or in a range from 10% to 100% higher than the transmittance of the masking area.
• the viewing area preferably has a transmittance of more than 50%, in particular more than 75%.
• the masking area preferably has a transmittance of less than 50%, in particular less than 20%, preferably less than 5%.
• the transmittance relates in particular to electromagnetic waves, preferably with wavelengths that are visible to the human eye.
• the transfer layer is particularly transparent to light visible to the human eye in the visible area.
• the transfer layer is in particular opaque to light that is visible to the human eye.
• Opaque means in particular having a transmittance of 0% to 10%.
• Transparent means in particular having a transmittance of 10% to 100%.
• the masking area is or is formed in particular by means of a mask layer which reduces the transmittance of the transfer layer in the masking area.
• the mask layer it is possible for the mask layer to be used as a backlighting mask, for example when the plastic injection molded part is equipped with one or more light sources, in particular one or more LEDs and/or one or more displays.
• HRI High Refractive Index
• optically active and/or optically variable structures in particular one or more optically active relief structures, preferably one or more diffractive structures and/or holograms and/or refractive structures and/or matt structures.
• At least one reflection layer of the one or more reflection layers is or will be arranged on the relief structure, in particular arranged directly on the relief structure and/or at least in regions or over the entire surface of the relief structure.
• the one or more color layers may be colored, not colored, each colored differently, transparent and/or opaque. It is also possible for further transparent layers to be arranged between the colored layers.
• the one or more reflection layers are preferably opaque and/or transparent. It is also possible that the one or more reflection layers are or will be applied over the entire surface or partially.
• An HRI layer is in particular a layer with a high refractive index, preferably higher than 1.5.
• the one or more HRI layers preferably comprise or consist of one or more of the following materials: ZnS, SiC>2, TiO2 and/or ZrO2 and/or the like.
• the one or more metal layers preferably include or consist of one or more of the following materials: aluminum, chromium, indium, copper and/or alloys thereof. It is also possible for one or more reflection layers of the one or more reflection layers to have a number of different properties from those mentioned above.
• the above properties can be exhibited in particular by the one or more layers of the mask layer and/or the one or more layers of the decorative layer and/or one or more decorative elements.
• the mask layer and/or the decorative layer can have one or more layers.
• the mask layer is or is preferably applied by means of a digital printing process, in particular by means of ink jet printing, preferably UV ink jet printing, gravure printing and/or screen printing.
• the mask layer has a layer thickness in a range from 1 ⁇ m to 100 ⁇ m.
• the mask layer is applied by means of the digital printing method, preferably ink jet printing, preferably UV ink jet printing, a layer thickness of the mask layer in a range from 1 ⁇ m to 50 ⁇ m is possible.
• a layer thickness of the mask layer in a range from 1 ⁇ m to 30 ⁇ m is preferably possible.
• a layer thickness of the mask layer in a range from 5 ⁇ m to 100 ⁇ m is preferably possible.
• step x3) b2) creating a visible area in the transfer layer, the visible area being in register with the one or more mold elements, the impression and/or the decorative layer is or is arranged and the mask layer is partially removed in the visible area and/or the transmittance of the transfer layer is increased in the visible area.
• the mask layer is preferably also applied first in an area which forms the visible area after the mask layer has been processed in this area.
• the viewing area is generated here by means of a laser.
• the visible area is particularly preferably produced by means of a laser after step x3) has been carried out, in particular the transfer film having been back-injected with the injection molding compound and after the injection molding compound has hardened.
• the one or more shaped elements and the visible area and/or the masking area, in particular the masking layer are or are arranged in the transfer film in precise register with one another.
• the one or more shaped elements and the visible area and/or the masking area, in particular the mask layer are arranged in register with one another.
• the register tolerance between the one or more shaped elements and the visible area and/or the masking area, in particular between the one or more shaped elements and the mask layer is preferably in a range of 0.05 mm to 1.0 mm, preferably in a range of 0 .05mm to 0.2mm.
• the register tolerance between the one or more shaped elements and the visible area and/or the masking area, in particular between the one or more shaped elements and the mask layer is in particular a maximum of 1.0 mm, preferably a maximum of 0.2 mm.
• the register tolerance between the impression and the visible area and/or the masking area, in particular between the impression and the mask layer preferably in a range from 0.05 mm to 1.0 mm, preferably in a range of 0.05 mm to 0.2 and/or at most 1.0 mm, preferably at most 0.2 mm.
• the register tolerance in the range of 0.05 mm to 0.2 mm is achieved in particular if the one or more shaped elements are applied using a digital printing method, preferably using ink jet printing, preferably UV ink jet printing. If the shaped elements are applied by means of screen printing, the register tolerance in the range from 0.2 mm to 1.0 mm is possible.
• the register tolerance between the decorative layer and the visible area and/or the masking area, in particular between the decorative layer and the mask layer, is preferably in a range from 0.1 mm to 0.4 mm and/or at most 0.4 mm.
• the register tolerance in the range from 0.1 mm to 0.4 mm is achieved in particular if the mask layer is or will be applied, preferably inline, by means of a gravure printing process. In this case, the mask layer is implemented in particular inline with step c). It is also possible for the decorative layer to be applied inline with the application of the mask layer and in particular step c).
• the carrier layer is preferably unrolled from a roll and, in particular, is not rolled up or temporarily stored between the steps.
• the decorative layer, the mask layer, the separating layer, the protective layer and/or the primer may be applied inline.
• the plastic injection-molded part it is made possible for the plastic injection-molded part to have a visible area and/or a masking area, in particular formed by means of a mask layer, in register with the molding and the decorative layer.
• a visible area and/or a masking area in particular formed by means of a mask layer
• the maximum register tolerance between the one or more shaped elements and/or the decorative layer and/or the visible area and/or the masking area, in particular the mask layer to be in a range from 0.15 mm to 0.6 mm.
• the maximum register tolerance between the impression and/or the decorative layer and/or the visible area and/or the masking area, in particular the mask layer is in a range from 0.15 mm to 0.6 mm.
• the maximum register tolerance indicates here in particular the maximum deviation from a target value of the relative position of two of the components mentioned in relation to one another.
• the viewing area is or is formed in particular by one or more voids and/or gaps, particularly in the mask layer, and/or includes one or more voids and/or gaps, particularly in the mask layer. It is also possible that the viewing area is arranged congruently with the one or more shaped elements, at least in partial areas, and/or that the masking area does not overlap with the one or more shaped elements. For example, it is possible that the visible area of the one or more voids and/or gaps is or is formed in an opaque layer and/or which comprises one or more voids and/or gaps, the opaque layer for example covering the masking area or a part thereof and/or forms the mask layer.
• the visible area is or will be formed by one or more voids and/or gaps, in particular in the mask layer, and/or one or more voids and/or gaps, in particular in the mask layer.
• the transfer layer is deformed in such a way that the one or more recesses and/or voids are at least partially filled with the transfer layer. In this way, in particular, the edge sharpness of the impression and the register accuracy can be improved.
• Congruent here preferably means that the boundary lines of the one or more shaped elements and the viewing area overlap one another, in particular when viewed perpendicularly to a plane spanned by the transfer film, preferably the viewing area.
• the transfer layer is or will be provided with at least one first protective layer, in particular for the formation of an outer surface of the transfer layer facing the carrier layer. It is possible here for the first protective layer to be provided at least in regions and/or over the entire area in the transfer layer.
• the protective layer is in particular a protective lacquer layer.
• the protective layer preferably has a layer thickness in a range from 2 ⁇ m to 10 ⁇ m.
• the at least one first protective layer preferably has at least one binder selected from the group consisting of polyurethane resins, polyurethane dispersions, acrylic resins, methacrylic resins, phenolic resins, epoxy resins, polyureas, melamine resins, aminoplasts, polyester resins, alkyd resins, polyamide resins, vinyl ester resins and mixtures thereof, preferably polyurethane resins, Polyurethane dispersions, phenolic resins, epoxy resins, polyureas, melamine resins, aminoplasts, polyester resins, alkyd resins, polyamide resins and mixtures thereof, is selected.
• binder selected from the group consisting of polyurethane resins, polyurethane dispersions, acrylic resins, methacrylic resins, phenolic resins, epoxy resins, polyureas, melamine resins, aminoplasts, polyester resins, alkyd resins, polyamide resins and mixtures thereof, is selected.
• the at least one first protective layer comprises, in particular in a not yet fully cured state, preferably at least one binder which has free isocyanate groups and/or free opposite isocyanate groups reactive groups, preferably amino groups and/or hydroxy groups, and/or correspondingly masked analogs thereof.
• Suitable binders are preferably from the group consisting of polyurethane resins, polyurethane dispersions, phenolic resins, epoxy resins, polyureas, melamine resins, amino resins, polyester resins, alkyd resins, polyamide resins and mixtures thereof, more preferably polyurethane resins, polyurethane dispersions, phenolic resins, polyureas, melamine resins, amino resins, polyester resins, alkyd resins , polyamide resins and mixtures thereof.
• the at least one binder contained in the at least one first protective layer in particular in a not yet fully cured state, has no free, ethylenically unsaturated groups.
• the at least one first protective layer comprises, in particular in a not yet fully cured state, at least one aqueous, non-crosslinked or crosslinked polyurethane dispersion, which preferably has free groups that are reactive toward isocyanate groups, more preferably amino groups and/or Hydroxy groups, or at least one uncrosslinked or crosslinked polyurethane resin, which preferably has isocyanate groups and/or blocked analogs thereof or groups that are reactive toward isocyanate groups, more preferably amino groups and/or hydroxy groups, and/or correspondingly disguised analogs thereof, or consists of.
• the protective lacquer layer is formed from a PMMA-based lacquer. It is also possible for the protective lacquer layer to include or consist of a radiation-curing dual cure lacquer.
• a dual-cure paint is or will be thermally pre-crosslinked in liquid form, in particular in a first step during and/or after its application.
• the Dual Cure lacquer is or will be in a second step after the processing of the transfer film, in particular after the transfer film has been back-injected with the injection molding compound and/or preferably after the mold has been formed in step x3), in particular using high-energy radiation, preferably UV Radiation, radically post-crosslinked.
• Dual cure coatings of this type can consist of various polymers or oligomers that have unsaturated acrylate or methacrylate groups.
• these functional groups are or are radically crosslinked with one another.
• these polymers or oligomers preferably contain at least two or more alcohol groups. These alcohol groups can be crosslinked with multifunctional isocyanates or melamine-formaldehyde resins.
• UV raw materials such as, in particular, epoxy acrylates, polyether acrylates, polyester acrylates and/or acrylate acrylates are preferably used as preferably unsaturated oligomers or polymers.
• TDI total ultraviolet light
• HDI hexamethylene diisocyanate
• IPDI isophorone diisocyanate
• PMMA polymethyl methacrylate
• the carrier layer comprises in particular one of the following materials or a combination of the following materials or consists of: polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), polycarbonate (PC) or biaxially oriented polypropylene (BOPP).
• PET polyethylene terephthalate
• PMMA polymethyl methacrylate
• PC polycarbonate
• BOPP biaxially oriented polypropylene
• the carrier layer has in particular a layer thickness in a range from 12 ⁇ m to 100 ⁇ m, preferably in a range from 50 ⁇ m to 75 ⁇ m.
• a sufficiently thick carrier layer ensures in particular that the transfer film is not damaged during back-injection with the injection molding compound, for example by preventing the edges of the one or more shaped elements from being pressed too hard through the carrier layer.
• the carrier layer has a degree of stretching before tearing in a range from 110% to 135%.
• the degree of stretching is in particular the quotient of the length of the carrier layer in the direction of stretching based on the corresponding length of the carrier layer in the unstretched state.
• the degree of stretching also means, in particular, an average stretchability.
• the carrier layer it is also possible for the carrier layer to have a tensile strength in a range from 15 kpsi to 50 kpsi, preferably in a range from 27 kpsi to 31 kpsi and/or a modulus of elasticity in a range from 100 kpsi to 1000 kpsi, preferably in a range from 300 kpsi to 700 kpsi.
• the carrier layer is uncoated. It is also possible that the carrier layer is provided with a coating or has a coating on at least one of its main surfaces, and in particular at least on its side facing away from the transfer layer, or on both of its main surfaces.
• the coating is or will be formed in particular from a polymer. This makes it possible, for example, for the side of the carrier layer that is provided with the one or more shaped elements and/or for the application of the one or more shaped elements is provided, which has a coating which, in particular, ensures adequate adhesion of the one or more shaped elements to the carrier layer. It is also possible that the coating serves to protect the transfer layer during transport or back-injection.
• the coating of the carrier layer preferably has a layer thickness in a range from 0.2 ⁇ m to 5 ⁇ m, preferably in a range from 1 ⁇ m to 3 ⁇ m.
• the coating of the carrier layer is formed in particular from one or more of the following components, includes one or more of the following components or consists of: polyacrylates, polymethacrylates, polyurethanes, in particular polyester polyols, polyether polyols, polycarbonate polyols and/or polyacrylate polyols, polyesters, polyethers, polyolefins, epoxy resins and/or derivatives of the components mentioned.
• the coating of the carrier layer is or becomes crosslinkable or crosslinked, in particular by one or more of the following components: isocyanates, carbodiimides, melamines, aziridines and/or derivatives of the components mentioned.
• the coating of the carrier layer is preferably radiation-curable.
• the coating is or will be radiation-cured.
• the coating preferably has a dual cure lacquer. With regard to the Dual Cure paint, reference is made in particular to the above statements.
• the transfer film is or is provided with a primer layer, in particular for the formation of an outer surface of the transfer layer facing away from the carrier layer.
• the primer layer is in particular an adhesive layer and/or an adhesion promoter layer, preferably comprising or consisting of one or more of the following substances: PMMA, PVC, polyester, polyurethane, chlorinated polyolefins, polypropylene, epoxy resins, polyurethane polyols in combination with deactivated isocyanates, inorganic fillers .
• the primer layer has a layer thickness in a range from 1 ⁇ m to 50 ⁇ m. It is also possible that the primer layer is or is applied by means of ink jet printing, gravure printing, screen printing and/or slot casting. It is also expedient for the transfer film to have a separating layer between the carrier layer and the transfer layer. The carrier layer can preferably be detached from the transfer layer by means of the separating layer.
• the decorative layer is arranged indirectly on the carrier layer and one or more layers, such as the separating layer, are arranged between the carrier layer and the decorative layer.
• the separating layer is or will preferably be applied by means of gravure printing and/or slot casting, preferably applied to the carrier layer.
• the method for producing the plastic injection-molded part prefferably has the following step: x4) Separating the carrier layer from the transfer layer by means of and/or with the separating layer.
• the transfer layer is preferably detached from the carrier layer. It is therefore possible that the plastic injection-molded part, in particular, does not have the carrier layer and the one or more shaped elements of the transfer film.
• the plastic injection molded part prefferably be provided with one or more functional components and/or with one or more functional components during or after the transfer film is back-injected with the injection molding compound is provided.
• the one or more functional components are or will be arranged in particular on the opposite side of the injection molding compound from the transfer layer.
• the one or more functional components preferably have at least one of the following components: one or more sensors, in particular one or more touch sensors, one or more lamps, in particular one or more displays, one or more LEDs, one or more light-conducting components, one or multiple boards and/or combinations thereof.
• Backlighting for example, is integrated into the plastic injection-molded part by means of the one or more light sources.
• backlighting it is possible for backlighting to be provided as a separate component comprising one or more LEDs on a circuit board, with the one or more LEDs preferably being connected to the circuit board via a soldered connection.
• the one or more illuminants, in particular in the form of LEDs, preferably the backlighting, are or will preferably be arranged in an in particular register-accurate overlap with the viewing area, preferably directly behind and/or in the viewing area.
• the plastic injection molded part prefferably has one or more diffuser layers and/or one or more light guide layers.
• the one or more illuminants in particular in the form of LEDs, preferably in the form of backlighting, are or are preferably by means of gluing, screwing, ultrasonic welding, soldering, clamping; Hot staking, infrared welding integrated into the plastic injection molded part.
• the one or more lamps are in the plastic injection-molded part or are preferably arranged on the side of the transfer layer facing away from the carrier layer, in particular before the back-injection molding of the transfer film in step x3) and/or during the back-injection molding with the transfer layer and optionally connected to the transfer layer via the injection molding compound.
• the one or more lamps are or are introduced into the plastic injection-molded part, in particular after back-injection with the plastic compound of step x3), in particular with the lamps being introduced into the injection-molded compound and/or with the Injection molding compound are connected or are.
• the one or more sensors in particular touch sensors, to be or are arranged on or within the transfer film before the transfer film is back-injected with the injection molding compound. It is also possible that the one or more sensors, in particular the one or more touch sensors, are preferably arranged on the side of the transfer layer facing away from the carrier layer before the back injection molding of the transfer film in step x3) and during the back injection molding with the transfer layer and optionally via the Injection molding compound are or are connected to the transfer layer.
• At least one sensor in particular at least one touch sensor, which is one or more sensors, is preferably not part of the transfer film and/or is not integrated into the plastic injection-molded part as part of the transfer film. It is also possible for this at least one sensor, in particular a touch sensor, to be applied subsequently, preferably on the side of the injection molding compound opposite the transfer layer. In this case, it is possible for the at least one sensor to be or is bonded to the injection molding compound, preferably over a large area in an optional recess formed by the component geometry.
• the one or more sensors are glued into the injection molding compound, in particular manually and/or mechanically, in particular after the injection molding compound has hardened.
• the one or more sensors are inserted into the injection molding machine, preferably manually and/or mechanically, for example by means of a robot, expediently arranged between the tool halves of the injection molding machine.
• a primer that ensures adhesion to the injection molding compound is or is arranged beforehand.
• the one or more sensors are connected to the injection molding compound. It is also possible to back-inject the transfer film at the same time as injecting the injection molding compound. This makes it possible to decorate a front side of the plastic injection-molded part with the transfer film and at the same time to attach one or more sensors, in particular touch sensors, to the rear side of the plastic injection-molded part.
• the one or more sensors (9), in particular touch sensors, are embossed onto the plastic injection-molded part, preferably using a stroke embossing machine or a rolling machine at elevated temperatures and pressures.
• the one or more sensors, in particular For this purpose, touch sensors preferably have a primer on the back, which ensures adhesion to the plastic injection-molded part.
• the one or more functional components and the one or more shaped elements, the impression, the decorative layer, the visible area and/or the masking area, preferably the mask layer, are or are preferably arranged in register with one another. It is also possible that the register tolerance between the one or more functional components and the one or more form elements, the molding, the decorative layer, the visible area and/or the masking area, in particular the masking layer, is a maximum of 0.3 mm, in particular a maximum of 0. 2 mm.
• the one or more functional components are in particular the one or more sensors, preferably one or more touch sensors, and/or the one or more light sources, in particular the one or more LEDs and/or the one or more displays.
• the register tolerance between the impression and the one or more functional components, in particular the one or more sensors, preferably touch sensors, and/or the one or more light sources, preferably displays and/or LEDs is a maximum of 0.3 mm, in particular less than Use of IML and/or lamination. More preferably, the register tolerance between the decorative layer and the one or more functional components, in particular the one or more sensors, preferably touch sensors, and/or the one or more light sources, preferably displays and/or LEDs, is at most 0.2 mm, in particular less than Use of FFB.
• step c) and/or in step c) in particular the position in which the one or more shaped elements are applied to the carrier layer is set as a function of the position of one or more fiducial marks.
• the one or more fiducials are detected for this purpose in particular by means of at least one sensor, using the one or more fiducials the position of one or more layers of the decorative layer, in particular the one or a plurality of decorative elements, the visible area, the masking area, in particular the mask layer, the first protective layer and/or the primer layer in relation to the carrier layer and/or one another.
• the visible area, the masking area, in particular the mask layer, the first protective layer and/or the primer layer are or will be, preferably during the application of the respective layer, corresponding fiducial marks assigned to the respective layer are applied and/or generated.
• Such registration marks are, for example, crosses, circles and/or triangles.
• the fiducial marks are preferably applied to at least one outside and/or one edge of the transfer film so that they can be read out, in particular by means of at least one sensor. It is also possible for at least parts of one or more motifs of the decorative layer and/or the mask layer to be used as fiducial marks.
• the one or more shaped elements and preferably associated fiducial marks are applied to the side of the carrier layer opposite the transfer layer.
• the position of the one or more functional components is determined using the associated fiducial marks of one or more layers of the decorative layer, in particular the one or more decorative elements, the visible area, the Masking area, in particular the mask layer, the first protective layer, the primer layer and/or the one or more shaped elements is or is aligned.
• a printed and/or sprayed sensor outline is used for applying one or more touch sensors.
• the printed and/or sprayed sensor outline is one printed on the respective transfer film and/or markings that are sprayed or present in the injection molded part due to tool design.
• the printed and/or sprayed sensor outline is or is preferably arranged to one or more fiducials of the fiducials assigned to the one or more shaped elements, the decorative layer, the visible area and/or the masking area, in particular the mask layer.
• the respective touch sensor is preferably connected to the plastic injection-molded part and its components in register by means of the printed and/or injected sensor outline.
• the method for producing the plastic injection molded part further includes the following step, in particular after the separation of the carrier layer of step x4):
• the plastic injection molded part prefferably has at least one second protective layer formed with a polyurethane-containing composition and/or with a polyurea-containing composition on an outer surface, preferably on the transfer layer.
• At least the impression and/or an area comprising the impression and/or a motif formed by the impression is or will be flooded.
• the plastic injection-molded part looks haptic, but is haptically smooth when you stroke it. It is hereby possible to give the plastic injection-molded part a special visual depth effect at this point through the combination of the molding and the polyurethane flooding and/or the polyurea flooding.
• the at least one first protective layer and the at least one second protective layer are advantageously matched to one another.
• the polyurethane Flooding and/or polyurea flooding a particular distinction is made between flooding as part of an IMD process and open flooding.
• the polyurethane flooding and/or the polyurea flooding is carried out in particular as part of an IMD process, ie preferably in a closed system.
• the flooding with a polyurethane-containing composition is carried out in particular as part of the back-injection molding of the transfer layer with the injection molding compound, preferably during or immediately after step x3), i.e. preferably in a closed system, in particular when the mold halves of the injection molding machine are in a closed state.
• free isocyanate groups for example, which are contained in the at least one first protective layer of the transfer layer, can therefore be compared with free, opposite Groups capable of reacting with isocyanate groups of the preferably flowable, two-component polyurethane-containing composition used to produce the at least one second protective layer. This preferably significantly improves the adhesion of the at least one second protective layer on the at least one first protective layer of the transfer layer after curing.
• the polyurethane precursors preferably polyol-containing and polyisocyanate-containing components
• the heat of reaction formed during the reaction of the polyurethane precursors preferably results in heating to a temperature of from 60° C. to 180° C., preferably from 80° C. to 120° C.
• the flooding with the polyurethane-containing composition is carried out as part of an open flooding.
• the surface tension of the solvent-free or solvent-containing, preferably flowable, polyurethane-containing reaction mixture used to produce the at least one second protective layer is used, in particular in the outer edge region of the component to be flooded.
• the at least one second protective layer is preferably applied to the Component, in particular the plastic injection molded part, flooded. Curing preferably takes place in particular by appropriate storage, preferably for a period in the range from 2 s to 60 s, of the flooded plastic injection-molded part at a temperature in the range from 20° C. to 100° C.
• free isocyanate groups contained in the at least one first protective layer can react with free groups that are reactive toward isocyanate groups of the ones used to produce the at least one second protective layer, preferably flowable, two-component polyurea-containing composition. This preferably significantly improves the adhesion of the at least one second protective layer on the at least one first protective layer of the transfer layer after curing.
• the one, preferably flowable, polyurea-containing reaction mixture used to produce the at least one second protective layer is anhydrous.
• the polyurea precursors preferably the (poly)amine-containing and/or polyisocyanate-containing component
• the heat of reaction formed during the reaction of the polyurea precursors preferably results in heating to a temperature of from 60° C. to 180° C., preferably from 80° C. to 120° C.
• 3a, 3b, 3c schematically a transfer film and a plastic injection molded part
• 5a, 5b, 5c schematically a transfer film and a plastic injection molded part
• 6a, 6b, 6c schematically a transfer film and a plastic injection molded part
• Fig. 10a, 10b schematically a positive mold element before and after back injection
• Fig. 11a, 11b schematically a negative mold element before and after back injection.
• FIG. 1 schematically shows a method for producing a transfer film.
• the Transfer film is in particular an IMD transfer film.
• the following steps are carried out, in particular in the order given: a) providing 101 a carrier layer, b) providing 102 a transfer layer comprising a decorative layer, the transfer layer being or being arranged on the carrier layer, c) applying 103 one or more shaped elements onto the carrier layer, wherein the one or more shaped elements have a three-dimensional shape and are applied in register with the decorative layer.
• the transfer film is in particular an IMD transfer film. It is possible here for the transfer film to be a transfer film as described for the other figures and/or to be produced using a method described for this purpose.
• the method for producing the plastic injection molded part comprises at least the following steps, in particular in the order given: x1) providing 201 a transfer film, the transfer film having a carrier layer and a transfer layer comprising a decorative layer, the transfer layer being or being arranged on the carrier layer, x2) Providing 202 one or more shaped elements on the carrier layer, wherein the one or more shaped elements have an impression and are or will be applied in register with the decorative layer, x3) Injection molding 203 of the transfer film with an injection molding compound, whereby the effect of the injection molding compound on the transfer film in the transfer layer, an impression of the three-dimensional shape of the one or more shaped elements is introduced in register with the decorative layer.
• the transfer film 1 is in particular an IMD transfer film.
• the transfer film 1 is preferably produced as described for example in relation to FIG.
• the transfer foil 1 has a carrier layer 3 and a transfer layer 2.
• the transfer layer 2 includes a decorative layer 21 and is arranged on the carrier layer 3 .
• the transfer film 1 comprises a shaped element 40, the shaped element 40 being applied to the carrier layer 2 and in register with the decorative layer 21. It is also possible for several shaped elements 40 to be arranged on the carrier layer 3 .
• the one or more mold elements 40 rest in particular on a mold half of the injection molding machine.
• the injection molding compound can adhere to the transfer film 1, in particular to the exposed side of a primer.
• FIG. 3b schematically shows a plastic injection molded part 10.
• the plastic injection molded part 10 is produced, for example, as described for one of FIGS. 1, 2 and 3a.
• the plastic injection molded part 10 comprises an injection molding compound 5 and a transfer layer 2 of a transfer film 1 back-injected with the injection molding compound 5 .
• the transfer film 1 is in particular an IMD transfer film, preferably as described for FIG. 1 and/or FIG. 3a and/or produced as described for FIG. 1 and/or FIG. 3a.
• the transfer layer 1 comprises a decorative layer 21 and has an impression 41 of a three-dimensional shape. The impression 41 is introduced here in register with the decorative layer 21 .
• Areas such as areas 71 , 72 , 81 and 82 are viewed in particular on a main surface spanned by a respective layer or the transfer film 1 , preferably from right to left in FIG. 3 or vice versa. Regions, and in particular also partial regions, preferably include all of the planes spanned by the transfer film 1 or a respective layer and/or the main surface when viewed perpendicularly to this plane Flat and/or main surface Overlapping parts of the transfer film 1 and/or the plastic injection molded part 10.
• the mold 41 of the plastic injection molded part is or will be formed in particular by means of the one or more mold elements 40 .
• the impression 41 thus forms in particular a shape that is complementary to the three-dimensional shape of the one or more shaped elements 40 .
• the one or more mold elements 40 can preferably be removed from the plastic injection-molded part 10 , in particular together with the carrier layer 3 . It is also conceivable that at least the carrier layer 3 and optionally the one or more shaped elements 40 and/or remnants thereof still adhere to the plastic injection-molded part 10 . In this way, in particular, protection of the surface of the plastic injection-molded part 10 can be guaranteed, e.g. during transport and/or storage.
• the carrier layer 3 is pressed at least in certain areas against the mold half and as a result the impression 41 of the one or more mold elements 40 in the transfer layer 21 is formed, with the molding 41 enabling the haptics and/or the depth effect in particular.
• the one or more shaped elements 40 have a three-dimensional shape, here in particular in comparison to the carrier layer 3 and the transfer layer 2, in that both the height of the shaped element 40 and the dimensions in the other spatial directions contribute significantly to the shape of the shaped element 40. which is the case in particular since the height of the mold 41 of the plastic injection-molded part 10 is dependent on the shape of the mold element 40 .
• the three-dimensional shape includes, for example, a two-dimensional motif and the two-dimensional motif is or is preferably provided with a spatial structure, for example by the thickness or height of the two-dimensional motif, here along the horizontal, is specifically increased in particular.
• the carrier layer 3 is preferably a PET carrier layer. With regard to other possible materials and an optional coating of the carrier layer 3, reference is made in particular to the statements above.
• the carrier layer 3 has a layer thickness of 75 ⁇ m, for example, which is the case in particular for use in the automotive sector. It is also possible for the carrier layer 3 to have a layer thickness of 50 ⁇ m, for example for the production of laptop sleeves.
• the carrier layer 3 it is possible for the carrier layer 3 to have a degree of stretching before it tears in a range from 110% to 135%. The degree of stretching is in particular the quotient of the length of the carrier layer in the direction of stretching based on the corresponding length of the carrier layer in the unstretched state. The degree of stretching also means, in particular, an average stretchability.
• the carrier layer has, in particular, an average extensibility of 25%.
• the direction of the average extensibility is in this case related in particular to an X-direction and/or a Y-direction.
• the X-direction for example in FIG. 3a, preferably points along a horizontal line and/or the Y-direction, for example in FIG. 3a, points along a vertical line.
• the carrier layer prefferably has a tensile strength in a range from 15 kpsi to 50 kpsi, preferably in a range from 27 kpsi to 31 kpsi and/or a modulus of elasticity in a range from 100 kpsi to 1000 kpsi, preferably in a range from 300 kpsi to 700 kpsi.
• the provision comprises applying the transfer layer comprising at least the decorative layer 21 to the carrier layer 3 .
• the one or more shaped elements 40 are preferably partially applied to the carrier layer 3 . It is also possible that the one or more shaped elements 40 are or will be applied in partial areas with a greater thickness than in other partial areas. Applying the one or more shape elements 40 to the carrier layer 3 can in particular take place directly on the carrier layer 3 or indirectly via one or more further layers. A height or thickness is measured, for example, in FIG. 3b in particular along a horizontal line.
• the transfer layer 2 is applied to the carrier layer 3 and then in particular the one or more shaped elements 40 are applied to the carrier layer 3 in precise register at least with respect to the decorative layer 21, in particular to the side of the carrier layer 3 opposite the transfer layer 2.
• one or more first layers of the one or more shaped elements 40 have or consist of a digital printing ink.
• the digital ink is an inkjet ink, preferably a UV inkjet ink.
• one or more first layers of the one or more shaped elements 40 are applied using a digital printing method, preferably an inkjet printing method, preferably a UV inkjet printing method.
• a digital printing method preferably an inkjet printing method, preferably a UV inkjet printing method.
• one or more layers of the one or more shaped elements to be crosslinkable or crosslinkable, in particular by means of radiation, preferably UV radiation.
• the register tolerance is improved by means of digital printing methods, in particular UV inkjet printing methods.
• digital printing methods in particular UV inkjet printing methods.
• one or more layers of the one or more shaped elements 40 are or will be applied by means of gravure printing and/or screen printing. It is thus also possible for one or more layers of the one or more shaped elements 40 of the transfer film to comprise an intaglio printing ink and/or a screen printing ink. In particular, it is possible for the one or more shaped elements 40 to have one or more layers. Preferably, in step c) and/or in the transfer film 1, two or more layers of the one or more shaped elements 40 are applied overlapping one another and/or the one or more shaped elements 40 are applied at least partially by means of 3D printing.
• At least two different printing methods to be used to apply the one or more shaped elements 40 .
• at least one layer of the one or more shaped elements 40 applied last in step c) to be applied using a digital printing method, preferably an inkjet printing method, preferably a UV inkjet printing method.
• At least one layer of the one or more shaped elements 40 which forms an outer surface of the transfer film 1, has or consists of a digital printing ink, preferably an inkjet printing ink, preferably a UV inkjet printing ink.
• a spatial separation of applications of different layers in step c) can be achieved.
• This enables, for example, an individualization, preferably in the form of small areas, in particular before and/or after transport, storage and in particular shortly before and/or at the location of the production of the plastic injection-molded part 10 .
• an impression 41 with different heights is or is produced in the plastic injection molded part 10 by means of different heights of the one or more mold elements 40 .
• the transfer film 1 to have one or more shaped elements 40 of different heights and/or for the plastic injection molded part 10 to have an impression 41 with different heights and/or depths, in particular partial areas of the raised area 82 with different heights and/or partial areas of the having recessed area 81 with different heights.
• the layer thickness of a layer of the one or more shaped elements 40 applied by means of digital printing is preferably in a range from 0.5 ⁇ m to 50 ⁇ m, in particular in a range from 1 ⁇ m to 25 ⁇ m.
• At least one shaped element of the one or more shaped elements 40 printed by means of digital printing may have a layer thickness of 1 ⁇ m to 200 ⁇ m.
• the layer thickness of at least one shaped element of the one or more shaped elements 40 is in particular in a range from 1 ⁇ m to 200 ⁇ m.
• preferably several, preferably all, layers of the at least one shaped element are applied by means of digital printing and in particular in an overlapping manner.
• a layer of the one or more shaped elements 40 printed by means of gravure printing to have a layer thickness in a range from 1 ⁇ m to 25 ⁇ m and/or for a layer of the one or more shaped elements 40 printed by means of screen printing to have a layer thickness in a range of 1 pm to 100 pm.
• the method prefferably has the following step: irradiating the one or more mold elements 40, in particular by means of UV irradiation, with one or more irradiation steps being carried out, which are preferably carried out after step c) and/or during the step c), in particular before at least one other layer of the two or more layers of the one or more shaped elements is applied to at least one layer of the one or more shaped elements in an overlapping manner. It is conceivable that overlapping layers are cured in between so that they do not run, for example, and a higher height-to-width ratio can be achieved as a result.
• composition of the one or more shaped elements 40 reference is made in particular to the above statements.
• a recessed area 81 is produced in the transfer layer 2, with the recessed area 81 preferably being formed by the impression 41.
• the recessed area 81 thus has, in particular, a positive image of the one or more shaped elements 40 .
• a raised region 82 is also possible for a raised region 82 to be formed in the transfer layer 2 when the transfer film 1 is back-injected with the injection molding compound 5 in step x3).
• the raised area 82 thus has, in particular, a negative image of the one or more shaped elements 40 .
• the raised area 82 and/or the recessed area 81 can be a contiguous area or, alternatively or additionally, can comprise one or more partial areas that are separate from one another. It is therefore possible for the raised area 82, the recessed area 81 and/or the molding 41 to form one or more motifs which, in particular, are complementary to the one or more
• Motifs of one or more form elements 40 are.
• the raised area 82 is arranged in particular where there is no shaped element 40 in the transfer film 1 and/or in which the transfer layer 3 is deformed in the direction of the carrier layer 3 during back injection with the injection molding compound 5 .
• the recessed area 81 is arranged in particular where the one or more mold elements 40 are present in the transfer film 1 and/or in which the transfer layer 2 does not or essentially does not move in the direction of the carrier layer 3 during back injection with the injection molding compound 5.
• the raised area 82 and/or the lowered area 81 can have a minimum line width and/or a minimum point size in a range of 0.025 mm to 0.1 mm, particularly when the one or more features 40 are UV digitally printed are or will be upset.
• the point size in Fig. 3b and 3c would be the distance from the upper to the lower dashed marking of the area 81.
• the line thickness would preferably be the distance from the top to the bottom dashed mark of the area 81 of the section plane shown.
• the recessed area 81 it is possible for the recessed area 81 to have a minimum lineweight and/or minimum point size greater than 0.025mm and/or the raised area 82 to have a minimum lineweight and/or minimum point size greater than 0.040mm, particularly for the case that the one or more shaped elements 40 are or will be applied by means of digital printing. It is also possible that the recessed area 81 has a minimum line width and/or minimum point size greater than 0.075 mm and/or the raised area 82 has a minimum line width and/or minimum point size greater than 0.12 mm, in particular for in the event that the one or more shaped elements 40 are or will be applied by means of gravure printing.
• the recessed area 81 prefferably has a minimum line width and/or minimum point size of greater than 0.10 mm and/or for the raised area 82 to have a minimum line width and/or minimum point size of greater than 0.15 mm, in particular in the event that the one or more shaped elements 40 are or will be applied by means of screen printing.
• a positive shaped element 40 is understood to mean a detached shaped element 40 which, after back-injection molding, produces a recessed region 81 in the carrier layer 3 when the cross section is viewed.
• Such a positive mold element 40 is shown in Figures 10a and 10b. 10a shows the positive mold element 40 before back-injection molding and FIG. 10b shows the positive mold element 40 after back-moulding.
• a negative shaped element 40 is understood to mean one or more full-surface shaped elements which, after back-injection molding, produce a raised region 82 of the carrier layer 3 when the cross section is viewed.
• Such a negative mold element 40 is shown in Figures 11a and 11b.
• 11a shows the negative mold element before back-injection molding
• FIG. 11b shows the negative mold element after back-moulding.
• the shaped element 40 is preferably flush or almost flush with the surface of the carrier layer after the back-injection molding, so that no difference between the positive and negative shaped element 40 can be felt and/or felt with the fingertips .
• the one or more shaped elements 40 have a higher dimensional stability than the carrier layer 3 and/or the transfer layer 2, preferably as at least one layer of the transfer layer 2.
• Higher dimensional stability means in particular a higher deformation resistance during back-injection molding 203 of the transfer film 1 with the injection molding compound 5 to understand.
• the one or more shaped elements 40 are preferably mechanically stable and/or have mechanical stability, in particular in the case of back injection with the injection molding compound 5, preferably in an IMD Injection molding process, ie in particular in step x3).
• the mechanical stability is understood here in particular as the stability of the one or more shaped elements 40 with respect to the load acting through the injection molding compound 5, in particular when the transfer film 1 is back-injected 203 with the injection molding compound 5.
• the one or more shaped elements 40 are preferably sufficiently hard and produce a sufficiently strong connection to the carrier film 3 in order to withstand the high pressure that is generated during back-injection molding 203 in particular.
• the one or more shaped elements 40 preferably have a glass transition temperature of more than 200.degree.
• the one or more shaped elements 40 prefferably have an essentially constant compressive strength up to a temperature of 200°C. This ensures, in particular, the deformation of the transfer layer 3 when the transfer film 1 is subjected to pressure and/or heat, in particular when the transfer film 1 is back-injected with the injection molding compound, and in particular enables high edge sharpness of the impression 41 .
• the mechanical stability is determined based on the difference in height when comparing the height of the one or more shaped elements 40 before and after back-injection molding 203 of the transfer film 1 with the injection molding compound 5, with the height of the one or more shaped elements 40 after back-injection molding 203 of the transfer film 1 with the injection molding compound 5 corresponds to the height of the impression 41 of the plastic injection molded part 10 .
• the impression 41 preferably has a height in a range from 90% to 100% of the height of the one or more shaped elements 40 of the transfer film 1 before the back injection molding 203 with the injection molding compound 5 .
• the temperatures occurring in the injection molding tool during back injection in particular the temperature of the injection molding compound, are in a range from 150° C. to 500° C., in particular in a range from 200° C. to 300° C.
• the pressures occurring in the injection molding tool during back injection is or is in a range from 300 bar to 1000 bar, in particular in a range from 400 bar to 800 bar.
• the mold 41 it is possible, for example, for the mold 41 to have a height of 90% of the height of the one or more molded elements 40 before back-injection molding 203 of the injection-molding compound 5 after back-injecting 203 of the injection-molding compound 5, in particular if the carrier layer 3 has a layer thickness of 50 ⁇ m and preferably consists of PET. It is also possible for the mold 41 after the injection molding compound to be back-injected to have a height of 100% of the height of the one or more mold elements 40 before the transfer film 1 is back-injected with the injection molding compound 5, particularly if the carrier layer 3 is one layer thick of 75 ⁇ m and preferably consists of PET.
• the height of the one or more shaped elements 40 is retained or is just as high before the back injection molding 203 of the transfer film 1 with the injection molding compound 5 as after the back injection molding.
• the height of the impression 41 is preferably determined on the plastic injection molded part 10 based on the height difference between an outer surface of the transfer layer 2 in the recessed area 81 and an adjacent outer surface of the transfer layer 2 in a raised area 82 .
• the height of the one or more shaped elements 40 is measured in particular before the transfer film 1 is back-injected 203 .
• the measurement of the height of the impression 41 and/or the one or more shaped elements 40 and/or the line width and/or the point size is carried out in particular by means of a scanning electron microscope (SEM).
• the height of the impression 41 of the plastic injection-molded part 10, which is achieved in particular in the method for producing the plastic injection-molded part 10, is preferably in a range from 1 ⁇ m to 200 ⁇ m.
• the one or more shaped elements 40 are preferably arranged in the transfer film 1 or in step c) in at least two different directions in register with the decorative layer 21 .
• one direction shows along the line of sight and the other along a vertical line.
• the one or more shaped elements 40 both in the running direction of the carrier layer 3 and transversely to the running direction of the carrier layer 3 in register with the decorative layer 21, in particular in register with separate decorative elements, for example separate ones Motives to apply the decorative layer 21.
• at least one shaped element of the one or more shaped elements 40 it is possible for at least one shaped element of the one or more shaped elements 40 to be arranged in register with at least one decorative element of one or more decorative elements, with the at least one decorative element preferably forming a separate motif.
• a separate motif is in particular not an endless motif and/or has border lines visible in the two different directions in the transfer film 1 and/or the plastic injection-molded part 10 .
• the impression 41 or at least a partial area of the impression 41 to be or will be arranged in register with at least one decorative element in one or more decorative elements.
• the register tolerance between the one or more shaped elements 40 and the decorative layer is preferably in a range from 0.05 mm to 1.0 mm, preferably in a range from 0.05 mm to 0.2 mm.
• the register tolerance between the one or more shaped elements 40 and the decorative layer 21 is in particular a maximum of 1.0 mm, preferably a maximum of 0.2 mm. It is thus also possible that the register tolerance between the impression 41 and the decorative layer 21 is preferably in a range from 0.05 mm to 1.0 mm, preferably in a range from 0.05 mm to 0.2 mm, and/or is at most 1.0 mm, preferably at most 0.2 mm.
• a register tolerance in the range of 0.05 mm to 0.2 mm is achieved in particular if the one or more shaped elements 40 are applied using a digital printing method, preferably using ink jet printing, preferably UV ink jet printing. If the one or more shaped elements 40 are applied by means of screen printing, a register tolerance in the range from 0.2 mm to 1.0 mm is possible.
• FIG. 3c shows the plastic injection molded part 10 shown in FIG. 3b, except that the plastic injection molded part 10 also has a functional component 6.
• the functional component 6 is preferably arranged in register with the molding 61 and in register with the decorative layer 21 .
• the transfer film 1 and/or the plastic injection molded part 10 may have a visible area 71 and/or a masking area 72 .
• the viewing area 71 is provided in particular so that further components can be arranged at least temporarily visible through the transfer layer 2 in the plastic injection molded part 10 on the side of the injection molding compound 5 opposite the transfer layer 2 .
• the masking area 72 is provided in particular for the purpose that the further components arranged in the plastic injection molded part 10 on the side of the injection molding compound 5 opposite the transfer layer 2 are covered through the transfer layer 2 in the masking area.
• the method preferably comprises the following step, in particular before and/or after step c): b1) providing and/or generating a masking area 72 and/or a visible area 71 in the transfer layer 3.
• the viewing area 71 preferably has a transmittance that is in particular higher than the transmittance of the masking area 72, preferably by a value of at least 10% and/or in a range from 10% to 100% higher than the transmittance of the masking area.
• the viewing area 71 preferably has a transmittance of more than 50%, in particular more than 75%, on.
• the masking area preferably has a transmittance of less than 50%, in particular less than 20%, preferably less than 5%.
• the transmittance relates in particular to electromagnetic waves, preferably with wavelengths visible to the human eye.
• the transfer layer 3 is preferably transparent to light that is visible to the human eye.
• the transfer layer 3 is in particular opaque to light that is visible to the human eye.
• the viewing area 71 is also possible for the viewing area 71 to be produced in the transfer layer 3, in particular in a mask layer, in or after step b1).
• the plastic injection-molded part 10 is in particular provided with one or more functional components 6 and/or is provided with one or more functional components 6 during or after back-injection molding 203 of the transfer film 1 with the injection molding compound 5 .
• the one or more functional components 6 are or will be arranged in particular on the side of the injection molding compound 5 opposite the transfer layer 2 .
• the one or more functional components preferably have at least one of the following components: one or more sensors, in particular one or more touch sensors, one or more lamps, in particular one or more displays, one or more LEDs, one or more light-conducting components, one or multiple boards and/or combinations thereof.
• Backlighting for example, is integrated into the plastic injection-molded part 10 by means of the one or more light sources.
• backlighting it is possible for backlighting to be provided as a separate component comprising one or more LEDs on a circuit board, with the one or more LEDs preferably being connected to the circuit board via a soldered connection.
• the one or more illuminants, in particular in the form of LEDs, preferably the backlighting, are or will preferably overlap in particular in a register-accurate manner with the viewing area 71, preferably directly behind and/or in the viewing area 71, arranged.
• the plastic injection molded part 10 it is also possible for the plastic injection molded part 10 to have one or more diffuser layers and/or one or more light guide layers.
• the one or more illuminants in particular in the form of LEDs, preferably in the form of backlighting, are or are preferably integrated into the plastic injection molded part by means of gluing, screwing, ultrasonic welding, soldering, clamping, hot caulking, infrared welding.
• the one or more lamps are in the plastic injection molded part 10 or are preferably arranged on the side of the transfer layer 2 facing away from the carrier layer 3 and/or at the Rear injection molding 203 connected to the transfer layer 2 and optionally via the injection molding compound 5 to the transfer layer 2. It is also possible that the one or more lamps, preferably the one or more LEDs, are or are introduced into the plastic injection molded part, in particular after back-injection with the plastic compound of step x3), in particular with the lamps being introduced into the injection molding compound and/or or connected to the injection molding compound or are.
• the one or more sensors in particular touch sensors, to be or are arranged on or within the transfer film 1 before the transfer film 1 is back-injected with the injection molding compound 5 . It is also possible that the one or more sensors, in particular the one or more touch sensors, are preferably arranged before the back injection molding 203 of the transfer film 1 in step x3) on the side of the transfer layer 2 facing away from the carrier layer 3 and during the back injection molding 203 with the Transfer layer 2 and optionally connected via the injection molding compound 5 to the transfer layer 3 or are.
• At least one sensor in particular at least one touch sensor, which is one or more sensors, is preferably not part of the transfer film 1 and/or not as part of the transfer film 1 in the Plastic injection molded part 10 is integrated. It is also possible for this at least one sensor, in particular a touch sensor, to be applied subsequently, preferably on the side of the injection molding compound 5 opposite the transfer layer 2 . It is possible here for the at least one sensor to be or is bonded to the injection molding compound 5, preferably over a large area in an optional recess formed by the component geometry.
• the one or more touch sensors can be introduced into the plastic injection-molded part 10 after back-injection molding 203 with the injection-molding compound 5 of step x3), in particular to be connected to the injection-molding compound 5 and/or to be attached to the injection-molding compound 5.
• IML laminating, in-mold labeling
• FFB functional foil bonding
• the one or more functional components 6 are preferably attached in register with the mold 41 and the decorative layer 21 .
• Fig. 4a shows a schematic plan view of a transfer film 1 and/or of a plastic injection-molded part 10 coated with the transfer layer 2 of the transfer film 1.
• Fig. 4b and Fig. 4c show schematic representations of a sectional plane, which in Fig is shown by the transfer film 1 or by the plastic injection molded part 10 .
• the transfer film 1 it is particularly possible here for the transfer film 1 to be the transfer film 1 described with reference to FIG. 3 and/or to be produced as described with reference to FIG. 1 or 3 .
• the plastic injection molded part 10 is the plastic injection molded part 10 described with reference to FIG. 2 and/or is produced as described with reference to FIG. 2 or FIG. 3 .
• the Transfer layer 2 also has a primer layer 23 , a mask layer 22 , a protective layer 24 and a separating layer 8 .
• the separating layer 8, the protective layer 24, the decorative layer 21, the mask layer 22 and the primer layer 23 are applied to the carrier layer 3, preferably in the order given, one after the other in order to obtain a transfer film 1, preferably as shown in FIG. 4b.
• the plastic injection-molded part 10 can be produced by means of back-injection molding 203 of the transfer film 1 .
• the primer layer 23 forms, in particular, an outer surface of the transfer layer 2 facing away from the carrier layer 3.
• the primer layer 23 in the plastic injection molded part 10 forms an outer surface of the transfer layer 2 facing the injection molding compound 5.
• the primer layer 23 is in particular an adhesive layer and/or an adhesion promoter layer.
• a protective layer 24 is also arranged on the side of the transfer layer 2 facing the carrier layer 3 .
• the protective layer 24 preferably forms a surface of the transfer layer 2 facing the carrier layer 3 of the transfer film 1 or an exposed surface of the transfer layer 2 after the carrier layer 3 has been detached, as can be seen in particular in FIG. 4c .
• the protective layer 24 is in particular a protective lacquer layer.
• the protective layer preferably has a layer thickness in a range from 1 ⁇ m to 50 ⁇ m.
• the protective layer 24, in particular in the form of the protective lacquer layer, is preferably applied by means of gravure printing and/or slot casting, preferably applied to the carrier layer 3 and an optional separating layer 8.
• the visible area 71 and the recessed area 81 are shown, for example, in the form of a telephone symbol and preferably include all parts of the transfer film 1 or the plastic injection molded part 10 that overlap with the telephone symbol.
• the minimum line width here is preferably the smallest distance between two opposite points the boundary line of the depressed area 81, in particular the telephone symbol.
• the impression 41 in particular in the form of the recessed area 81, to be in register with the mask layer 22 and/or in particular in register in the visible area 71, and in particular to the phone icon.
• the one or more shaped elements 40 to be arranged in the masking area 82 so that the raised area 82 is arranged in the visible area 71 with precise register.
• the mask layer 22 reduces the transmittance of the transfer layer 2 , in particular in the visible wavelength range, resulting in the visible area 71 and the masking area 72 of the transfer layer 3 .
• the mask layer 22 is preferably arranged on a side of the decorative layer 21 that faces away from the carrier layer 2 and/or on a side of the decorative layer 21 that faces the injection molding compound 5 .
• the mask layer 22 it is possible for the mask layer 22 to be used as a backlighting mask, for example if the plastic injection-molded part 10 is equipped with functional components 6, as shown by way of example in FIG include multiple LEDs and / or one or more displays.
• the mask layer 22 is or is preferably applied by means of a digital printing process, in particular by means of ink jet printing, preferably UV ink jet printing, gravure printing and/or screen printing.
• the mask layer has a layer thickness in a range from 1 ⁇ m to 100 ⁇ m.
• the mask layer is applied by means of the digital printing method, preferably ink jet printing, preferably UV ink jet printing, a layer thickness of the mask layer in a range from 1 ⁇ m to 50 ⁇ m is possible.
• a layer thickness of the mask layer 22 in a range from 1 ⁇ m to 30 ⁇ m is preferably possible.
• a layer thickness of the mask layer 22 in a range from 5 ⁇ m to 100 ⁇ m is preferably possible.
• the impression 41 is and/or is arranged in particular in such a way that the impression 41 has the transillumination properties of the transfer layer 3, in particular the decorative layer 21 and/or the mask layer 22, and/or or the injection molding compound 5 is not affected.
• the impression 41 has essentially no influence on the wavelength, in particular the color, and/or the scattering of a radiation transmitting through the viewing area 71 of the transfer layer 3, in particular of the light visible to the human eye transmitting through the viewing area 71 of the transfer layer 3.
• the transfer layer 3, in particular the protective layer 24 of the transfer layer 4 can be uniformly transilluminated in the viewing area 71.
• the impression 41 preferably does not include any changes in layer thickness in the visible area 71. This can be achieved, for example, if the visible area 71 is completely overlapped by the impression 41 and in particular by the recessed area 81.
• shaped elements 40 of the transfer film 1 preferably have a constant layer thickness at least in the visible region 71 .
• the impression 41 and the visible area 71 and/or the masking area 72, in particular the mask layer 22, are also arranged in register with one another.
• the register tolerance between the one or more shaped elements 40 and the viewing area 71 and/or the masking area 72, in particular between the one or more shaped elements 40 and the mask layer 22, is preferably in a range of 0.05 mm to 1.0 mm in a range from 0.05 mm to 0.2 mm.
• the register tolerance between the one or more shaped elements 40 and the visible region 71 and/or the masking region 72, in particular between the one or more shaped elements 40 and the mask layer 22, is in particular a maximum of 1.0 mm, preferably a maximum of 0.2 mm.
• the register tolerance in the range of 0.05 mm to 0.2 mm is achieved, for example, if the one or more shaped elements 40 are applied using a digital printing method, preferably using inkjet printing, preferably UV inkjet printing. If the one or more shaped elements 40 are applied by means of screen printing, the register tolerance in the range from 0.2 mm to 1.0 mm is possible.
• the aforementioned limits for the register tolerance also apply to the register tolerance between the mold 41 and the mask layer 22 in the plastic injection molded part 10 or in its manufacturing process.
• the register tolerance between the decorative layer 21 and the visible area 71 and/or the masking area 72, in particular between the decorative layer 21 and the mask layer 22, is preferably in a range from 0.1 mm to 0.4 mm and/or at most 0.4 mm.
• the register tolerance in the range of 0.1 mm to 0.4 mm is achieved in particular if the mask layer 22 is or will be applied, preferably inline, by means of a gravure printing process.
• the plastic injection-molded part 10 has a visible area 71 and/or a masking area 72 , in particular formed by means of the mask layer 22 , in register with the molding 41 and the decorative layer 21 . It is thus possible, for example, to backlight the viewing area 71 and to enable interaction by means of further functional components, such as touch sensors, which can advantageously be carried out in a particularly simple, intuitive and/or precise manner. In particular, the visual appearance is particularly spectacular.
• the maximum register tolerance between the one or more shaped elements 40 and/or the decorative layer 21 and/or the visible area 71 and/or the masking area 72, in particular the masking layer 22, is in a range from 0.15 mm to 0 .6mm.
• the maximum register tolerance indicates here in particular the maximum deviation from a target value of the relative position of two of the components mentioned in relation to one another, for example between a shaped element and the decorative layer 21 .
• the limits for the register tolerance also apply to the register tolerance between the mold 41 and the decorative layer 21 and/or the visible area and/or the masking area, in particular the mask layer 22, in the plastic injection molded part 10 .
• the plastic injection-molded part 10 can in particular have the one or more functional components 6 described with reference to FIG. 3c or can be provided for the functional components 6 to be applied in a later step.
• the one or more functional components 6 are or are preferably attached to the one or more shaped elements 40, to the mold 41, to the decorative layer 21 and to the mask layer 22 and/or to the visible area 71 in precise register. It is possible here for the register tolerance between the one or more functional components 6 and the impression 41 , the decorative layer 21 , the visible area 71 and/or the mask layer 22 to be a maximum of 0.3 mm, in particular a maximum of 0.2 mm.
• the one or more components 6 include at least one touch sensor, which is arranged in register with the impression 41 and deviates by a maximum of 0.2 mm from a target position in relation to a position of the decorative layer 21 and the impression 41 .
• the mask layer 22 is preferably also applied first in a region which forms the visible region 71 after the mask layer 22 has been processed in this region.
• the viewing area 71 is generated here by means of a laser.
• the viewing area 71 is produced by means of a laser after step x3) has been carried out, in particular with the transfer film 1 having been back-injected with the injection molding compound 5 and after the injection molding compound 5 has hardened.
• the viewing area 71 is or is formed in particular by one or more voids and/or recesses, in particular in the mask layer 22 . It is also possible that the viewing area 71 is arranged congruently with the one or more shaped elements 40 at least in partial areas and/or that the masking area 72 does not overlap with the one or more shaped elements 40 .
• the visible area 71 is or is formed by one or more voids and/or recesses in an opaque layer, the opaque layer forming, for example, the masking area 72 or a part thereof and/or the mask layer 22 .
• the visible area 71 preferably also includes further layers, such as at least the decorative layer 21 .
• the visible area 71 is or will be formed by one or more voids and/or recesses, in particular in the mask layer 22 .
• the one or more voids and/or recesses are at least partially filled with the transfer layer 2 .
• the transfer layer 2 is deformed in such a way that the one or more recesses and/or voids are at least partially filled with the transfer layer 2. In this way, in particular, the edge sharpness of the impression 41 and the register accuracy can be improved.
• fiducial marks are or are preferably applied.
• registration marks are, for example, crosses, circles and/or triangles.
• the fiducial marks are each applied to at least one outside and/or one edge of the transfer film 1 so that they can be read, in particular by means of at least one sensor. It is also possible for at least parts of one or more motifs of the decorative layer 21 and/or the mask layer 22 to be used as fiducial marks.
• the one or more shaped elements 40 and preferably the fiducial marks associated with the one or more shaped elements 40 are applied to the side of the carrier layer 3 opposite the transfer layer 2 .
• step c) and/or in step c) for example, the position in which the one or more shaped elements 40 are applied to the carrier layer 3 is set as a function of the position of the fiducial marks assigned to the decorative layer 21 and the mask layer 22 .
• the position of the one or more functional components 6 can be determined using the assigned fiducial marks of one or more layers of the decorative layer 21, the mask layer 22 and/or of the one or more mold elements 40 is or is aligned.
• a printed and/or sprayed sensor outline is used to apply one or more touch sensors.
• the printed and/or sprayed sensor outline is a marking printed and/or sprayed on the respective touch sensor.
• the printed and/or sprayed sensor outline is or is preferably arranged relative to one or more fiducials of the fiducials assigned to the one or more shaped elements 40, the decorative layer 21, the visible area 71 and/or the masking area 72, in particular the mask layer 22.
• the respective touch sensor is preferably connected to the plastic injection-molded part 10 and its components in a register-accurate manner by means of the printed and/or injected sensor outline, in particular by means of appropriate tool design and fiducial marks.
• the transfer film 1 has an optional separating layer 8 between the carrier layer 3 and the transfer layer 2 .
• the transfer layer 2 can be detached from the carrier layer 3 in particular by means of the separating layer 8 .
• the carrier layer 3 with the shaped element 40 has been detached from the transfer layer 2.
• FIG. 4c the carrier layer 3 with the shaped element 40 has been detached from the transfer layer 2.
• FIG. The separating layer 8 preferably has a layer thickness in a range from 1 ⁇ m to 5 ⁇ m.
• the separating layer 8 is or will preferably be applied by means of gravure printing and/or slot casting, preferably applied to the carrier layer.
• each decorative element 210 in particular each letter, to be arranged in register with the shaped element 40 as well as with the visible area 71 and correspondingly in particular also with the masking area 72 and the mask layer 22.
• the position of one or more decorative elements 210 assigned to one or more shaped elements 40 is detected by means of at least one sensor. It is conceivable here for the decorative elements 210 themselves to be used as fiducial marks. With regard to further properties of the decorative layer 21 and the decorative elements 210, reference is made in particular to the above statements.
• Fig. 6a, 6b and 6c show in particular that described for Fig. 4a, 4b and 4c
• the recessed area 81 is not arranged in the viewing area 71 here, for example.
• an arrangement of the shaped element 40 in register with the decorative layer 21 and in particular also with the visible area 71 is provided.
• a precisely operable and working control element can be integrated, for example by means of haptic and visual information.
• the plastic injection-molded part can be provided with functional components 6 arranged in register with the mold 41, such as lighting means and/or touch sensors.
• FIGS. 7a, 7b and 7c show in particular the transfer film described for FIGS. 4a, 4b and 4c, the plastic injection molded part described and the methods described, except that the protective layer 25 is also shown in FIG. 7c.
• the method for producing the plastic injection molded part 10 further comprises the following step, which is carried out in particular after the carrier layer 3 has been separated from the transfer layer 2 of step x4):
• the plastic injection-molded part 10 looks haptic, but is haptically smooth when you stroke it. It is hereby possible, the plastic injection molded part 10 by the combination of Impression 41 and the polyurethane flooding or polyurea flooding at this point to give a special visual depth effect. In particular, signs of wear and tear, for example due to abrasion, can also be reduced in this way.
• the protective layer 24 and the protective layer 25 are advantageously matched to one another.
• composition of the protective layers 24 and 25 reference is made in particular to the above statements regarding the at least one first protective layer and the at least one second protective layer.
• FIG. 8 shows a plastic injection molded part 10 as described for one of FIGS. 3, 4, 5 and/or 6.
• the plastic injection molded part 10 has a sensor 9, for example, which is in particular a touch sensor.
• the sensor 9 is arranged on the injection-molding compound 5 on its side opposite the transfer layer 2 .
• the plastic injection-molded part 10 here has, for example, a circuit board 11 with an LED 12 which is connected to the sensor 9 via a light barrier 13 .
• the sensor 9 is preferably in direct contact with the surrounding components, preferably the injection-molding compound 5.
• at least one adhesive layer, at least one diffuser layer and/or at least one light guide layer to be provided between sensor 9 and injection molding compound 5 .
• the LED 12 is positioned in register with the visible area 71 and the decorative layer 21 and the molding 41 .
• FIG. 9 shows a further schematic embodiment variant of a transfer film 1, in particular IMD transfer film 1, having a carrier layer 3, a transfer layer 2 comprising a decorative layer 21, the transfer layer 2 being arranged on the carrier layer 3, and comprising one or more shaped elements 40, wherein the one or more shaped elements 40 are applied to the carrier layer 3 and in register with the decorative layer 21 .
• the transfer layer 2 in this exemplary embodiment also has a protective layer, which is arranged between the decorative layer 21 and the separating layer 8, and a mask layer 22 and a primer 23, which are arranged underneath the decorative layer.
• the mask layer 22 is provided in the masking areas 72 and is not provided in the viewing areas 71 .
• the one or more features are provided in the raised areas 82 and are not provided in the recessed areas 81 .

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• Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Mechanical Engineering (AREA)
• Injection Moulding Of Plastics Or The Like (AREA)
• Ink Jet Recording Methods And Recording Media Thereof (AREA)
• Decoration By Transfer Pictures (AREA)
• Laminated Bodies (AREA)
• Moulds For Moulding Plastics Or The Like (AREA)

Applications Claiming Priority (2)

Publications (1)

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Family Applications (1)

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• 2020
  • 2020-08-06 DE DE102020120754.9A patent/DE102020120754A1/de active Pending
• 2021
  • 2021-07-15 JP JP2023507655A patent/JP2023539434A/ja active Pending
  • 2021-07-15 CN CN202180066942.8A patent/CN116323240A/zh active Pending
  • 2021-07-15 MX MX2023001484A patent/MX2023001484A/es unknown
  • 2021-07-15 US US18/019,124 patent/US20230302845A1/en active Pending
  • 2021-07-15 WO PCT/EP2021/069680 patent/WO2022028838A1/de active Application Filing
  • 2021-07-15 KR KR1020237007593A patent/KR20230047445A/ko unknown
  • 2021-07-15 EP EP21745752.2A patent/EP4192693A1/de active Pending
  • 2021-07-15 CA CA3187470A patent/CA3187470A1/en active Pending

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