WO2018149428A1

WO2018149428A1 - Film molding tool, method for producing a film molding tool and use of a film molding tool

Info

Publication number: WO2018149428A1
Application number: PCT/DE2017/000418
Authority: WO
Inventors: Edgar P. Nimmergut
Original assignee: Kiefel Gmbh
Priority date: 2017-02-17
Filing date: 2017-12-12
Publication date: 2018-08-23
Also published as: DE102017007963A1

Abstract

The invention relates to a film molding tool for laminating a component with a laminating element or for molding a thermoplastic film from a grained geometry, an alternative method for lower die production and the use of a corresponding film molding tool. In particular, the invention relates to a production method for a lower die that reduces both production time and production costs, exhibits long service lives and also provides high molding quality. To do this, a thin shell mold of a film molding tool is produced from nickel by means of electrochemical deposition and stiffened by means of metal spraying, wherein the metal spray layer incorporates a honeycomb-shaped woven fabric.

Description

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

The invention relates to a film forming tool, a method for producing a film forming tool and a use of a film forming tool. Automotive surfaces are often made with film that is applied to backing parts in a laminating process or other process. An alternative to the lamination process is in particular a foaming process.

The film usually has a surface graining, which is either already produced during the film production or transferred to the film during an impression process or is formed during the laminating process with a grained film molding tool.

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

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

| Confirmation copy | Advantage of the embossing during the lamination process or the Abformprozesses is that the grain structure is produced in the three-dimensional state of the film and thus no so-called grain loss can occur by expansion, as is often the case with alternative methods. A scar loss is understood to mean a negative impairment of the optical or haptic grain quality on the carrier part of the foil. A shell mold with a negative grain structure is often also called Narbschale and often galvanically produced. For this purpose, nickel is deposited on a positive model of the outer contour of the finished component with a positive grain structure until a layer thickness of approximately 4 mm has formed.

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

In addition to producing a surface texture in a steel shell by means of etching, this can also be made with a laser. Another variant offers a plastic shell with a negative grain structure, which is produced in the casting process and for the lamination of components or the molding of films in small series is well suited.

The known shell molds with a negative grain structure (Narbschalen) have in common that they are often permeable to air, so that the necessary force between the film and the shell mold can be achieved. The air permeability can be generated by perforation, for example by discrete openings created by means of lasing or etching, or by a material-specific microporosity of the shell mold. For lamination or molding in the production operation of large series, a grain pan with a tempering system and a substructure, often in the form of a support structure, is added to a complete tool.

A method for laminating a component by a laminating tool is disclosed in DE 10 2013 203 408 AI.

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

According to a first aspect of the invention, the object is achieved by a film forming tool for laminating a component with a laminating element or for molding a film, wherein the film forming tool has a mold shell, wherein the mold shell has two material layers made of different materials, wherein a first material layer consists of nickel and a second layer of material comprising a sprayed layer of metal.

Conceptually, the following is explained:

First of all, it should be expressly pointed out that, in the context of the present patent application, indefinite articles and numbers such as "a", "two" etc. should as a rule be understood as "at least" information, ie as "at least one ...", "At least two ..." etc., unless expressly stated in the respective context or it is obvious or technically imperative for the skilled person that there only "exactly one ...", "exactly two ..." etc. can be meant.

Furthermore, it should be expressly pointed out that in the context of the present patent application a "part" of something should be understood to mean that it can also be the whole part of something.

Under "film shapes" is here optionally "laminating" or "molding" understood. "Laminating" is understood to mean the joining of several layers of the same or different materials, in particular a layer may be a film, which is also referred to as a "laminating element". In general, the laminating of components is understood to mean the laminating of a laminating element with the component to be laminated, which serves as a carrier part, wherein the laminating element can achieve surface graining during laminating.

"Molding" is understood to mean the shaping of a molded element, in particular a film, with a film molding tool, whereby the molded molding element can acquire a surface grain during molding A "film forming tool" is understood to mean, optionally, a tool for laminating a component with a laminating element or a tool for molding a molded element. Often one and the same film forming tool can be used both for laminating a component with a laminating element and for molding a molded element, wherein the respective laminating and molding processes have differences.

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

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

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

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

110 materials.

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

It is built up during thermal spraying, in particular during metal spraying, because the 120 spraying particles flatten more or less depending on the process and material as they impinge on the component surface, primarily sticking together by mechanical clamping and Depending on the chosen process design, the quality characteristics of sprayed coatings are low porosity, good adhesion to the component, freedom from cracks and a homogeneous microstructure. The prior art has heretofore provided that the mold shell was galvanically produced by a film forming tool, with nickel being deposited on a positive model of the finished component, ie with a positive grain structure, until a layer thickness of approximately 4 mm had been formed. During the electroplating process, mechanical corrections to the component had to be made manually from time to time, so that this process was expensive and time-consuming. An essential feature here was the comparatively high thickness of the nickel layer with a thickness of approx. 4 mm, which required high process times for depositing the nickel and was necessary for the rigidity of the shell mold.

Alternatively, the prior art has heretofore provided that the shell mold of a foil forming tool was milled from a steel block. Another alternative known in the prior art has heretofore been that the mold shell of a plastic sheet molding tool has been produced in a casting process or by a lamination process.

Notwithstanding, it is proposed here that the surface of the molding shell facing the laminating element or the molding element in the laminating process or in the molding process is made of nickel, which is deposited galvanically on a positive model and a back layer of the molding shell is produced by metal spraying.

Thus, it is conceivable that a layer of nickel is electrodeposited on a positive model and this nickel layer is supplemented and / or reinforced by metal spraying, wherein the nickel layer is in particular stiffened by the metal spraying.

The stiffening of the electrodeposited nickel layer by metal spraying makes it possible to advantageously allow comparatively thin nickel layers for the surface of the shell mold, whereby the process of galvanic deposition of the nickel layer can be significantly shortened and the costs for the nickel layer can be drastically reduced. Advantageously, it can be achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality. Furthermore, the film forming tool can have a high molding quality of the positive model even without the need for subsequent processing.

In particular, it can be achieved that the production time for a galvanically produced nickel shell can be drastically reduced. In experiments of the inventor has been shown that the production time can be halved.

The sprayed layer of metal preferably has a honeycomb-shaped structure. Conceptually, the following is explained:

"Honeycomb" is understood to mean a cellular material pattern which is composed of individual cavities A honeycomb cell structure can consist of closed and open cavities.

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

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

Conceptually, the following is explained:

A "negative fringe structure" has a surface of a component, in particular the surface of a shell mold designed as a negative mold shell, whereby the contour of the shell mold is reversed to the object or model to be molded and the model has a grain structure a negative scar structure on.

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

It is conceivable, for example, a shell mold with an outer layer of nickel, which carries the Narbinformation and is stiffened by a layer of metal, which was applied by injection molding, so that the shell mold has the necessary dimensional stability.

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

With the embossing during the lamination process or the molding process can also be advantageously achieved that the grain structure is generated in the three-dimensional state of Kaschierelementes or the mold element and thus no grain loss can occur. In particular, it can be achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality. Furthermore, the film forming tool can have a high impression quality of the positive model even without the need for post-processing. Preferably, the surface of the mold shell is permeable to air.

Conceptually, the following is explained:

By "air-permeable" is meant that the surface of the shell mold is permeable to air, so air can penetrate the surface of the shell mold. Specifically, among other things, it is conceivable that the laminating element or the mold element is sucked into the mold shell by a vacuum applied to the rear side of the mold shell, so that the force necessary to emboss the laminating element or the mold element can take place between the laminating element and the shell mold.

In a particularly suitable embodiment, the material of the mold shell is permeable to air. Thus, it is conceivable that the sprayed layer produced by metal spraying has a porosity which makes the sprayed layer of the mold shell and thus suitable design of the nickel layer the entire mold permeable to air, so that the laminating element or the mold element by a vacuum applied to the back of the mold shell vacuum in the mold shell can be sucked. Alternatively, in one embodiment, it is conceivable that a mold shell consisting of a plurality of material layers is permeable to air as a result of the properties of the material layers; in particular, the mold shell can have material layers of different materials. Specifically, among other things, it is conceivable that a mold shell consisting of a galvanically deposited nickel layer and a metal spray layer has a cross-material porosity that makes the mold shell permeable to air, so that the laminating element or the mold element is sucked into the mold shell by a vacuum applied to the back of the mold shell can. In particular, it is conceivable that both the electrodeposited nickel layer and the metal sprayed layer are made microporous. Advantageously, it can thus be achieved that the laminating process or the molding process can be carried out inexpensively and with comparatively short throughput times, in spite of high qualitative standards.

In addition, if desired, it can be achieved that the embossing of the laminating element can take place during laminating. If the air permeability of the molding shell is based on the use of porous materials, it can be achieved in particular advantageously that the molding shell does not have to be perforated separately in a separate process step.

Optionally, the shell mold on a back on a support structure.

Conceptually, the following is explained: A "support structure" is understood to mean a type of skeleton which stiffens the shell mold behind the material layer forming the surface of the shell mold.

Advantageously, it can be achieved that the overall shape of the shell can be made very stiff, whereby the quality of the laminated components or the molded form elements increases, especially with respect to the reproducibility of components with different only within tolerances component geometries.

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

Preferably, the support structure and the shell mold are connected to a releasable connection element, wherein the connection element is adapted to be able to combine different form shells with the support structure.

A connecting element is a component for directly or indirectly connecting a plurality of other components, In particular, a connecting element allows a detachable connection between two components or between a component and an assembly or between two assemblies a screw, a rivet or an adhesive. Specifically, it is conceivable, inter alia, that a support structure is adapted to be alternately combined with different shell molds by a connecting element. Thus, it is concretely conceivable that a change of the surface geometry for the laminating element or the mold element can be made possible by an exchange of a mold shell. Advantageously, it can be achieved that a station for laminating and / or molding of components can be used more flexibly by interchangeable shell molds and can be quickly and inexpensively adapted to changing requirements, whereby the cost of laminating and / or molding, especially for small batches, can sink. Optionally, the support structure is honeycomb.

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

The support structure preferably has webs.

Conceptually, the following is explained: A "bridge" is a part of a framework, which is constructed of webs.

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

Optionally, part of the support structure is made of aluminum. Advantageously, it can be achieved that the material-specific characteristics of aluminum targeted according to the specific requirements of the support structure can apply. Concretely, the use of aluminum can improve the heat conduction in the support structure and / or make the support structure lighter. The film molding tool preferably has a temperature control. Conceptually, the following is explained:

A "temperature control" is a device with which the temperature in a component can be influenced in a targeted manner, whereby a temperature control can be provided with a temperature control, which is set up to maintain the temperature of a component in a predefined range.

"Cooling" can also be understood here as "heating". In particular, a cooling device can also cool at one area and simultaneously heat at another area.

Advantageously, it can thus be achieved that the film forming tool can be adjusted to an optimum operating temperature by the tempering.

Optionally, the temperature control on a cooling channel.

Conceptually, the following is explained:

A "cooling channel" is a channel through which a fluid can flow, wherein the fluid absorbs a heat flow from the environment of the cooling channel or delivers a heat flow to the surroundings of the cooling channel.

Advantageously, it can thus be achieved that the film forming tool can have liquid cooling, whereby all the advantages of liquid cooling can be transferred to the film forming tool. In particular, a liquid cooling allows a very fast reaction and efficient cooling of components. Preferably, the temperature control is completely integrated into the support structure, wherein the temperature is adapted to be used for different shell molds can.

Concretely, among other things, it is conceivable that the tempering system is completely integrated in the support structure, whereby an exchange of shell molds requires no adjustments or modifications to the temperature, whereby a change in the surface geometry of a mold with a tempering for the laminating element or the mold element by a Replacement of a mold shell can be made possible.

Advantageously, it can thus be achieved that a temperature-controlled station for laminating and / or molding of components can be used more flexibly by means of a shell which can be exchanged independently of the temperature control and adapted quickly and cost-effectively to changing requirements, whereby the costs for laminating and / or or the molding, especially in small series, may decline.

Optionally, the film forming tool has a cooling plate.

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

Advantageously, it can thus be achieved that the film forming tool can be cooled efficiently. Heat flows can be distributed particularly well in a cooling plate, whereby a homogenization of the temperatures in the film molding tool is supported.

Preferably, the cooling plate is flat.

Advantageously, it can be achieved that the cooling plate has a flat surface and thus is particularly well suited for positive connection with another component or another assembly. In particular, such a standardized Interface for mounting and changing of molds within a station or plant for laminating and / or molding of components can be achieved, whereby the design of molds in the area of a mounting interface is standardized and assembly or changing of molds can be accelerated. The cooling plate serves in a functional unit to homogenize the temperatures in the mold and to simplify assembly and replacement processes.

According to a second aspect of the invention, the object solves a method for producing a film forming tool, in particular for producing a film forming tool according to a first aspect of the invention, wherein a metal layer is sprayed onto an electrochemically deposited nickel layer.

Conceptually, the following is explained:

A "metal layer" is understood as meaning a material layer which consists predominantly of a metallic material.

An "electrochemically deposited nickel layer" is understood as meaning a material layer of nickel which has been electrochemically (galvanically) deposited.

The state of the art has hitherto provided that the surface of the film forming tool, which comes into operative connection with the laminating element or during the molding process with a molding element during the laminating process, was either molded by the electroplating process or molded with plastic in a casting process a steel block was worked out. Especially with a negative skin structure having shell molds, the grain structure was directly molded, worked out with a cutting tool or chemically etched out of the material. In this case, molding tools are known in the prior art, which in particular have an electrolytically deposited nickel layer. In the prior art, this electrochemically deposited nickel layer has a comparatively high thickness of approximately 4 mm. During the electroplating process, mechanical corrections to the component had to be made manually from time to time, so that this process was expensive and time-consuming. The comparatively high thickness of the nickel layer of about 4 mm essentially had the effect that the nickel layer considered individually was sufficiently rigid and dimensionally stable.

By way of derogation, it is proposed here for the surface of the film forming tool, which comes into operative connection with the laminating element during the laminating process or during the molding process with the molding element, to use a nickel layer. This electrochemically deposited nickel layer is stiffened by combining the reverse side with a metal layer applied by metal spraying to form a shell mold. This shell mold is then supplemented in subsequent steps with a support structure and optionally with a temperature control and thus completed to form a film forming tool. Advantageously, this can be achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality.

In particular, it can advantageously be achieved that the production time for a galvanically produced nickel shell can be seriously reduced; in particular, the production time can be halved.

In other words, it can advantageously be achieved that the production times for a film molding tool can be shortened and that the rigidity and dimensional stability of a molding shell produced in this way can be increased, whereby a high molding quality and a long service life of the film molding tool can be achieved. Preferably, the sprayed layer of metal is reinforced. Conceptually, the following is explained:

A "reinforcement" is understood to mean a reinforcement of one object by another, which has a higher compressive or tensile strength or a greater durability against further influences of the environment.If an object is reinforced in this way, it will be "reinforced".

Advantageously, this can be achieved by the fact that the mold is additionally stiffened by the reinforcement connected to the metal spray layer, whereby a more dimensionally stable shell mold can be achieved with a longer service life. It can also be advantageously achieved that the shell mold can have a lower weight with comparable rigidity.

Optionally, the sprayed layer of metal is reinforced with a honeycomb structure.

Advantageously, it can thus be achieved that a particularly lightweight and rigid support structure for the shell mold of a film forming tool can be achieved. It should be expressly understood that the subject matter of the second aspect may be advantageously combined with the subject matter of the first aspect of the invention.

According to a third aspect of the invention, the object is achieved by a method for producing a film molding tool, in particular for producing a film molding tool according to the first aspect of the invention, in particular method according to the second aspect of the invention, wherein a honeycomb structure is soldered to an electrochemically deposited nickel layer.

Conceptually, the following is explained: "Soldering" is understood to mean a thermal process for materially joining materials, wherein a liquid phase is produced by melting a solder or by diffusion at the interfaces. was made, is also called "soldered".

The state of the art has heretofore provided that the surface of the film forming tool, which comes into operative contact with the laminating element during the laminating process, was either molded by the electroplating process, molded in a casting process with plastic, or worked out of a steel block. Especially with a negative skin structure having shell molds, the grain structure was directly molded, worked out with a cutting tool or chemically etched out of the material. In this case, molding tools are known in the prior art, which in particular have an electrochemically deposited nickel layer. In the prior art, this electrochemically deposited nickel layer has a comparatively high thickness of approximately 4 mm. During the electroplating process, mechanical corrections to the component had to be made manually from time to time, so that this procedure was expensive and time-consuming. The comparatively high thickness of the nickel layer of about 4 mm essentially had the effect that the nickel layer considered individually was sufficiently rigid and dimensionally stable.

By way of derogation, it is proposed here for the surface of the film forming tool, which comes into operative connection with the laminating element during the laminating process or during the molding process with the molding element, to use a nickel layer. This electrochemically deposited nickel layer is stiffened by soldering the back surface of the electrodeposited nickel layer to a honeycomb structure, whereby the flexural rigidity and the dimensional stability of the nickel shell can be drastically increased. Such a mold shell with a soldered honeycomb structure is supplemented in subsequent steps with a support structure and optionally with a temperature control and thus completed to form a film forming tool.

Advantageously, this can be achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality.

In particular, it can be advantageously achieved that the production time for a galvanically produced nickel shell can be seriously reduced; in particular, the production time can be halved. In other words, it can be advantageously achieved that the production times for a film molding tool can be shortened and that the rigidity and dimensional stability of a molded shell produced in this way can be increased, whereby a high molding quality and a long service life of the film molding tool can be achieved.

Preferably, a metal layer is sprayed onto the honeycomb structure and / or the nickel layer.

Specifically, it is conceivable, inter alia, that the honeycomb structure soldered on the rear side of the electrochemically deposited nickel layer is combined with a metal layer applied by metal spraying.

Such a mold shell with a soldered honeycomb structure and a metal sprayed layer is then supplemented in subsequent steps with a support structure and optionally with a temperature control and thus completed to form a film forming tool.

Advantageously, this can be achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, inexpensive, comparatively fast and can be produced with high impression quality.

In other words, it can advantageously be achieved that the production times for a film molding tool can be shortened and that the rigidity and dimensional stability of a molding shell produced in this way can be increased, whereby a high molding quality and a long service life of the film molding tool can be achieved.

Optionally, the sprayed layer of metal is mechanically reworked.

Conceptually, the following is explained:

"Mechanical post-processing" is understood to mean a group of manufacturing processes that give a workpiece a certain geometric shape by removing excess material from blanks in a mechanical way in the form of chips.The most important mechanical reworking methods are, in particular, turning, drilling, milling and Grind.

Specifically, it is conceivable inter alia that a shell mold is mechanically reworked, which has no sprayed layer of metal. Thus, inter alia, it is conceivable that only the galvanically produced nickel layer or the combination of a galvanically produced nickel layer with a soldered honeycomb structure or the combination of a galvanically produced nickel layer with a soldered honeycomb structure and a sprayed layer of metal is mechanically reworked.

Specifically, it is also conceivable, inter alia, that the mechanical post-processing relates only to the material of the sprayed layer and / or the material of the soldered honeycomb structure and / or the material of the galvanically produced nickel layer.

It is concretely conceivable, among other things, that the mechanical reworking prepares connecting elements for the connection of the shell mold with cooling plates. Advantageously, this can be achieved that the shell mold receives a defined geometric shape at the mechanically reworked points. Advantageously, the mold shell can be connected at these locations with another component, wherein the joint has defined geometric surfaces, so that the geometry of the shell mold defined with the geometry of the connected component can be continued.

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

Conceptually, the following is explained:

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

Specifically, it is conceivable, among other things, that the perforation is produced with a cutting tool. The distances between the perforation can be chosen homogeneous and uniformly distributed or inhomogeneous executed. Advantageously, it can thereby be achieved that the laminating tool is suitable for allowing a perforation on the rear side of the mold shell to act on the laminating element so that the force necessary to emboss the laminating element can take place between the laminating element and the shell mold. Optionally, the mold shell is perforated with a laser.

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

Preferably, the mold shell is connected to a cooling plate. Advantageously, it can thus be achieved that the film forming tool can be cooled efficiently. Heat flows can be distributed particularly well in a cooling plate, whereby a homogenization of the temperatures is supported in the film forming tool.

Optionally, the mold shell is connected to a support structure.

Advantageously, it can thus be achieved that the mold shell as a whole can be made very rigid, as a result of which the quality of the laminated components or the molded mold elements increases, in particular with regard to the reproducibility of components with component geometries which differ only within narrow tolerances.

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

Preferably, a cooling channel is embedded in the support structure.

Advantageously, it can thus be achieved that the support structure can be cooled efficiently and quickly.

Optionally, the electrochemically deposited nickel layer is deposited on a silicone blank.

Conceptually, the following is explained:

A "blank" is a workpiece that is intended for further processing, in particular a blank is a positive model for producing a foil forming tool. A "silicone blank" is a blank made of the material silicon. Specifically, among other things, it is conceivable, among other things, that a silicone blank is used as the positive model for the nickel layer to be deposited electrochemically, which comes into operative connection with the laminating element during the laminating process or during the molding process.

Silicones have unique properties. They can be produced very well by casting and, as a casting, offer a high degree of accuracy in molding, especially with complex model geometries. In addition, silicones have optimal surface properties, making them suitable as an optimal blank for an electrochemical process. Thus, silicones are self-releasing, so that with a silicone mold can be dispensed with a release agent during casting, so again the surface fidelity of the casting or the electrochemically produced nickel layer can be improved. In addition, silicones are very elastic, so that they can be removed from the electrochemically produced nickel layer easily and non-destructively. Due to the non-destructive removal of the silicone blank, it can be reused as a positive model.

It can advantageously be achieved hereby that a detail-faithful surface structure can be achieved even with complex grained surfaces with a silicone blank.

In addition, it can be advantageously achieved that the silicone blank can be produced easily and inexpensively.

In addition, the silicone blank can be removed from the electrochemically produced nickel layer easily and non-destructively, whereby it can also be reused. The silicone blank preferably has a grain structure.

It is concretely conceivable, inter alia, that the silicone blank already has a grain structure, whereby it does not have to be transferred to the laminating element or the forming element in a subsequent step after the laminating of a laminating element or the molding of a shaped element.

In concrete terms, this allows the negative scar structure to be transferred directly from the grain structure of the silicone blank to the shell mold, so that the relief of the shell mold, in particular, runs inversely to the relief of the positive model. Advantageously, this can be achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality. Furthermore, the laminating tool can have a high degree of quality with regard to the negative grain structure even without the need for post-processing. The negative scar structure can be extremely robust.

Optionally, the silicone blank has a cold-cured silicone rubber.

Cold-crosslinked silicone rubber types have the advantage that the surfaces of cold-crosslinked silicones can be hydrophilized. On the other hand, hot-crosslinked silicones have a superhydrophobic surface. A hydrophilic surface is particularly advantageous for use in an electrochemical process.

Advantageously, this can be achieved by the use of cold-crosslinked silicones, a hydrophilic silicone surface can be achieved, which increases the quality of the nickel shell produced electrochemically on the silicone blank.

The silicone blank is preferably cast in a mold which has a support for the silicone blank, a silicone casting of a model template and a support for the negative shell. It is concretely conceivable, inter alia, that the use of a support for the silicone blank allows the silicone blank not to be embodied as a full-volume positive model, but merely a thin-walled surface for the positive model.

Thus, it can be advantageously achieved that the silicone blank can be cast better during its production and demolded without destruction after the electrochemical production of the nickel shell.

Advantageously, it can be achieved by this aspect that the silicone blank is directly conforming to its exact shape also used for the electrochemical process, so that overall a dimensionally accurate silicone blank can be achieved, which can also be demoulded non-destructive.

In addition, it can be advantageously achieved by the use that can be dispensed by the use of the silicone casting on a release agent between the mold and silicone casting in the casting of the silicone blank, whereby the detail and the dimensional accuracy of the surface to be reached is not deteriorated by a release agent.

Furthermore, the use of a support for the silicone negative shell allows this not to be performed as a full volume model, but that the silicone casting of the model template can only represent a thin walled surface for the model and thus allows the silicone casting of the model template in its use as Molded part can be demoulded non-destructive.

Optionally, the silicone blank and / or the support for the silicone blank can be demoulded without destruction after the electrochemical deposition of the nickel layer and / or after spraying the metal layer on the nickel layer.

Advantageously, it can thereby be achieved that the silicone blank and / or the support for the silicone blank can be reused. The silicone casting of the model template is preferably cast in a mold which has the support for the silicone blank, the model template and the support for the negative shell.

Advantageously, this can be achieved that the silicone casting of the model template does not have to be executed as a full volume model, but that the silicone casting of the model template can only represent a thin-walled surface for the model and thus allows the silicone casting of the model template in its use as a molding for the Casting of the silicone blank after casting can be demoulded non-destructive.

Optionally, the model template is made of epoxy resin.

Thus, it is concretely conceivable, among other things, that a model template made of epoxy resin is cast by a softer negative impression. Epoxy resin is a very durable, long-lasting and hard material, so that a model of epoxy resin can be stored well over years and reused several times.

Advantageously, this can be achieved that a long storable, dimensionally stable model template is achieved, which can be reused many times.

Preferably, the model template is reusable. Advantageously, this can be achieved by the fact that the model template can be used over and over again to produce an electrochemically produced nickel shell thereof after the above-described process steps. Thus, a mold shell of a film forming tool after damage easily, quickly and even after many years in which the model template was stored, be replaced inexpensively. Optionally, the epoxy resin molds are molded in a mold having the support for the silicone blank, a silicone casting of a model and the support for the negative shell. Advantageously, this can be achieved that the model template is made directly so that it fits to the support for the silicone blank so that it can also be poured later in a subsequent process step on this edition. Thus, it is also advantageously possible that the model template only has to be cast as a thin surface and consequently does not need so much material and is not so heavy, which makes storage advantageous over years.

In addition, using a silicone casting of the model can provide a release agent that is not needed for casting the model artwork so that the surface fidelity and surface details of the silicone casting can be used by the model.

Preferably, the surface of the model template of epoxy resin is post-processed after casting. Advantageously, it can thereby be achieved that a final model contouring of the model template with the desired surface can be achieved.

Optionally, the silicone casting of a model is cast in a mold having the negative shell support and a model.

Advantageously, it can thereby be achieved that the silicone casting of the model fits directly to the negative shell and so the negative shell can be used unchanged during the subsequent process steps, whereby costs can be saved.

Preferably, the model has wood.

Advantageously, can be achieved by the fact that the model can be processed by the low hardness of wood comparatively easy and fast with high level of detail.

Optionally, the model is coated before the silicone casting. It is conceivable, among other things, that the model made of wood is sealed with a coating and the surface texture of the wood is simultaneously smoothed.

In addition, it is specifically conceivable, among other things, that the coating of the model is used as a release agent for the silicone casting.

Advantageously, this can be achieved by the fact that the surface quality of the model can be increased by the coating and that the silicone casting can be easily removed and destroyed without destruction.

Preferably, the coating of the model has a grain structure. Specifically, it is conceivable, inter alia, that the model already has a grain structure, whereby it can be transferred from process step to process step to all subsequently required casts, models and shapes, so that the relief of the shell mold, in particular, runs inversely to the relief of the model.

Advantageously, this can be achieved that a mold shell for a film forming tool, which has a long service life and is suitable for mass production, can be produced inexpensively, comparatively quickly and with high impression quality. Furthermore, the laminating tool can have a high degree of quality with regard to the negative grain structure even without the need for post-processing. The negative scar structure can be extremely robust. It is to be expressly understood that the subject matter of the third aspect may be advantageously combined with the subject matter of the foregoing aspects of the invention, cumulatively either alone or in any combination.

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

The invention will be explained in more detail below with reference to a manufacturing process sequence for the production of a mold shell and of an exemplary embodiment of a film mold with reference to the drawing. Show there

1 shows schematically a flowchart for the production process of a film forming tool,

Fig. 2 shows schematically a foil forming tool in a section. The production process 1 in FIG. 1 for producing a film forming tool 2 consists essentially of the first phase 3 for producing the electrochemically deposited nickel layer 4 in FIG. 1a and the second phase 5 for further processing of the electrochemically deposited nickel layer 4 to the film forming tool 2 in FIG. 1b. The first phase 3 in FIG. 1 a for the production of the electrochemically deposited nickel layer 4 is subdivided chronologically into the production of a wood model 6, the application of a release agent 7 on the wooden model 6, the production of a silicone casting 8 of the wooden model 6, the casting of a model template 9 of the silicone casting 8, the production of a silicone casting 10 of the model template 9, the production of a silicone blank 11 of the silicone casting 10 and the production of a nickel layer 4 by electrochemical deposition 12.

The wooden model 6 has the advantage that the material wood can be processed comparatively easily and quickly with simultaneously high level of detail. Concretely, the model would not be made of wood concrete. In the production of the wood model 6 this is already provided with a grain structure. This grain structure is maintained during the subsequent process steps and can be found on the model template 9 and the silicone blank 11 again.

From the wooden model 6, a silicone casting 8 is produced and from the model template 9, a silicone casting 10 is produced, so that the silicone casting 8 and the silicone casting 10 have a negative grain structure, the relief of which runs inversely to the relief of the wood model 6 and the negative grain structure precisely on the Narbstruktur the wood model 6, the model template 9 and the silicone blank 11 fits, so that the grain structure of the wood model 6 is transferred step by step over the corresponding process steps on the silicone blank 11. It can thereby be achieved that the grain structure of the wood model 6 can be transferred to the nickel layer 4 deposited electrochemically on the silicon blank 11, which has a negative grain structure whose relief runs inversely to the relief of the wood model 6.

Before the silicone casting 8 is poured off the wooden model 6, the wooden model 6 is coated with a release agent 7. Concretely, it is also conceivable that the wood model 6 is not coated with a release agent 7 prior to producing a silicone casting 8, but the release agent seals the surface texture of the wood model 6 and increases the likelihood that the silicone casting 8 will be easily demoulded from the wood model 6 without destruction can be. To produce the silicone casting 8, a support 13 for the negative shell is furthermore used. The silicone casting 8 can also be produced without the support 13 for the negative shell, however, the support 13 for the negative shell enables a thin-walled silicone casting 8 of the wooden model 6, which can be demolded easily and non-destructively.

The support 13 for the negative shell can also be used in the subsequent process steps for casting a model template 9 of the silicone casting 8, for producing a silicone casting 10 of the model template 9 and for producing a silicone blank 11 of the silicone casting 10.

After the production of a silicone casting 8 from the wooden model 6, a model template 9 is cast. Specifically, it is conceivable, inter alia, that the model template 9 is cast from epoxy resin. Epoxy resin is a very durable, durable and hard material, so model epoxy resin 9 can be stored well over years and reused several times, so that any damaged nickel layer 4 can be rebuilt faster. For the preparation of the model Vorläge 9 continue a support 14 is used for a blank. The model template 9 can be produced without the support 14 for a blank, but allows the support 14 for a blank thin-walled and lightweight model template 9, which can be stored excellent.

The support 14 for a blank can also be used in the subsequent process steps for producing a silicone casting 10 of the model template 9 and for producing a silicone blank 11 of the silicone casting 10.

Specifically, it is conceivable, among other things, that the model template 9 is also cast from a material other than epoxy resin. In particular, it is concretely conceivable that, instead of the model template 9, the silicone blank 11 is cast directly and subsequently the nickel layer 4 is produced by electrochemical deposition.

Subsequent to the production of the model template 9, the silicone casting 10 is produced by the model template 9. The silicone casting 10 has the advantage of being easy to demould and non-destructive, and moreover, each of the silicone moldings 8, 10, 11 has the advantage of being able to be used as a casting mold without the need for release agent 7.

In the next step, the silicone blank 11 is produced as a cast from the silicone casting 10.

The silicone blank 11 is then used in the electrochemical deposition 12 for the production of the nickel layer 4. The silicone blank can be removed from the nickel layer 4 in a simple and non-destructive manner and reused just like the other silicone moldings 8, 10.

After the nickel layer 4 has been deposited electrochemically, the second phase 5 begins for further processing of the electrochemically deposited nickel layer 4 to form the film forming tool 2.

The second phase 5 in FIG. 1 b for the further processing of the electrochemically deposited nickel layer 4 to form the film mold 2 is subdivided chronologically into the soldering of a previously produced honeycomb structure 15 on the back side of the nickel layer 4, the spraying of a metal layer 16 onto the back side of the nickel layer 4 and the honeycomb structure 15, the mechanical reworking 17 of the shell mold 18, the demoulding 19 of mechanically reworked shell mold 18, the drilling 20 of vacuum channels, the cold plate fixture 21 for connecting previously manufactured cold plates 22 with the shell mold 18 and the support structure attachment 23 of a previously prepared support structure 24th , The honeycomb structure 15 is soldered onto the nickel layer 4. Alternatively, the honeycomb structure 15 may also be laid or glued onto the nickel layer 4.

Subsequently, the back side of the nickel layer 4 and the honeycomb structure 15 are stiffened by metal spraying 16 with a metal layer. Thereafter, the mold shell 18 is mechanically reworked, wherein the metal layer applied by metal spraying 16 and / or the honeycomb structure 15 and / or the nickel layer 4 is mechanically processed so that the already prepared cooling plates 22 can be connected to the mold shell 18 after removal 19.

Subsequently, the mold shell 18 is perforated by means of drilling 20. This can be done by means of a mechanical processing or with a laser.

After drilling 20 of the shell mold 18, the cooling plates 22 are connected to the shell mold 18.

Subsequently, the mold shell 18 is completed by means of the already produced support structure 24 to form a film forming tool 2. The film molding tool 30 in FIG. 2 essentially has a molding shell 31 with a nickel layer 32, a honeycomb-shaped structure 33, a cooling plate 34 and a support structure 35.

The mold shell 31 essentially consists of a honeycomb-shaped structure 33 which has been soldered to the nickel layer 32. The mold shell 31 was supplemented with the support structure 35 and the cooling plate 34 to form the film 30.

The film forming tool may have cooling channels (not labeled) that allow active cooling of the film forming tool 30. The cooling plate 34 serves to achieve a homogeneous temperature distribution in the film forming tool 30. In this case, the cooling plate 34 can be tempered both active and passive.

Overall, the film forming tool 30 is designed by its structure with the nickel layer 32, the honeycomb structure 33 and the support structure 35 is very robust and dimensionally stable. It can be used in particular for laminating a laminating element or for molding a molded element, with high numbers of pieces being able to be achieved.

The rigid design of the film forming tool 30 allows a high impression quality, which can be maintained by the homogeneous temperature control through the cooling channels and the cooling plate 34 during all operating conditions.

List of reference numbers used

1 manufacturing process

2 foil forming tool

3 first phase

4 nickel layer

5 Second phase

6 wooden model

7 release agent

8 silicone casting

9 model template

10 silicone casting

1 1 silicone blank

12 Electrochemical deposition

13 edition

14 edition

15 Honeycomb structure

16 metal syringes

17 Mechanical reworking

18 shape shell

19 Demoulding

20 drilling

21 cold plate mounting

22 cooling plates

23 support structure attachment

24 support structure

30 foil forming tool

31 shape shell

32 nickel layer

33 honeycomb structure

34 cooling plate œtützstruktur

Claims

claims:

A film forming tool for laminating a component with a laminating element or for molding a film, wherein the film forming tool has a mold shell, characterized in that the mold shell comprises two material layers made of different materials, wherein a first material layer consists of nickel and a second material layer of a sprayed layer Metal has.

2. foil forming tool according to claim 1, characterized in that the sprayed layer of metal has a honeycomb-shaped structure.

3. foil forming tool according to one of claims 1 or 2, characterized in that the surface of the shell mold has a negative grain structure.

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

5. foil forming tool according to one of the preceding claims, characterized in that the mold shell has a support structure on a back side.

6. foil forming tool according to claim 5, characterized in that the support structure and the shell mold are connected to a releasable connecting element, wherein the connecting element is adapted to be able to combine different shell molds with the support structure.

7. foil forming tool according to one of claims 5 or 6, characterized in that the support structure is honeycomb-shaped.

8. foil forming tool according to one of claims 5 to 7, characterized in that the support structure has webs.

9. foil forming tool according to one of claims 5 to 8, characterized in that a part of the support structure consists of aluminum.

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

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

12. The film forming tool according to one of the preceding claims, characterized in that the temperature control is completely integrated in the support structure, wherein the temperature is adapted to be used for different shell molds can.

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

14. film forming tool according to claim 13, characterized in that the cooling plate is flat.

15. A method for producing a foil mold, in particular for producing a foil mold according to one of the preceding claims, characterized in that a metal layer is sprayed onto an electrochemically deposited nickel layer.

16. A method for producing a film forming tool according to claim 15, characterized in that the sprayed layer of metal is reinforced.

17. A method for producing a film forming tool according to claim 15, characterized in that the sprayed layer of metal is reinforced with a honeycomb-shaped structure.

18. A method for producing a film forming tool, in particular for producing a film forming tool according to one of claims 1 to 14, in particular method according to claim 15 to 17, characterized in that a honeycomb-shaped structure is soldered to an electrochemically deposited nickel layer.

19. A method for producing a film forming tool according to claim 18, characterized in that a metal layer is sprayed onto the honeycomb structure and / or the nickel layer.

20. A method for producing a film forming tool according to one of claims 15 to 19, characterized in that the sprayed layer of metal is mechanically reworked.

21. A method for producing a film forming tool according to one of claims 15 to 20, characterized in that the existing ceramic layer and metal layer mold shell is perforated.

22. A method for producing a film forming tool according to one of claims 15 to 21, characterized in that the mold shell is perforated with a laser.

23. A method for producing a film forming tool according to one of claims 15 to 22, characterized in that the mold shell is connected to a cooling plate.

24. A method for producing a film forming tool according to one of claims 15 to 23, characterized in that the mold shell is connected to a support structure.

25. A method for producing a foil mold according to one of claims 15 to 24, characterized in that a cooling channel is embedded in the support structure.

26. A method for producing a film forming tool according to one of claims 15 to 25, characterized in that the electrochemically deposited nickel layer is deposited on a silicone blank.

27. A method for producing a film forming tool according to one of claims 15 to 26, characterized in that the silicone blank has a grain structure.

28. A method for producing a film forming tool according to one of claims 15 to 27, characterized in that the silicone blank has a cold-crosslinked silicone rubber.

29. A method for producing a film forming tool according to one of claims 15 to 28, characterized in that the silicone blank is cast in a mold having a support for the silicone blank, a silicone casting of a model template and a support for the negative shell.

30. A method for producing a film forming tool according to one of claims 15 to 29, characterized in that the silicone blank and / or the support for the silicone blank after the electrochemical deposition of the nickel layer and / or after spraying the metal layer on the nickel layer can be demoulded non-destructive ,

31. A method for producing a film forming tool according to one of claims 15 to 30, characterized in that the silicone casting of the model template is cast in a mold having the support for the silicone blank, the model template and the support for the negative shell.

32. A method for producing a film forming tool according to one of claims 15 to 31, characterized in that the model Vorläge is made of epoxy resin.

33. A method for producing a film forming tool according to one of claims 15 to 31, characterized in that the model template is reusable.

34. A method for producing a film forming tool according to one of claims 15 to 33, characterized in that the model template is molded of epoxy resin in a mold having the support for the silicone blank, a silicone casting of a model and the support for the negative shell.

35. A method for producing a film forming tool according to one of claims 15 to 34, characterized in that the surface of the model template made of epoxy resin is post-processed after casting.

36. A method for producing a foil mold according to any one of claims 15 to 35, characterized in that the silicone casting of a model is cast in a mold having the support for the negative shell and a model.

37. A method for producing a film forming tool according to one of claims 15 to 36, characterized in that the model comprises wood.

38. A method for producing a film forming tool according to one of claims 15 to 37, characterized in that the model is coated before the silicon casting.

39. A method for producing a film forming tool according to one of claims 15 to 38, characterized in that the coating of the model has a grain structure.

40. Use of a film forming tool according to one of claims 1 to 14 for producing and laminating a component, wherein the laminated component has a scar, or for molding a film from a grained film molding tool.