WO2020212234A1

WO2020212234A1 - Method for producing a decorated plastic part, and decorated plastic part

Info

Publication number: WO2020212234A1
Application number: PCT/EP2020/060065
Authority: WO
Inventors: Karin Salzmann; Stefanie Heidl
Original assignee: Burg Design Gmbh
Priority date: 2019-04-16
Filing date: 2020-04-08
Publication date: 2020-10-22
Also published as: EP3956151A1; DE102019110030A1; CN113710498A

Abstract

The invention relates to a decorated plastic part (1) and to a method for producing a decorated plastic part, having the steps of: • - providing a film (10), for example comprising a carrier layer (11) and a decorative layer (12), • - applying at least one plastic material (20) onto at least some regions of the film during a processing operation, and • - introducing imperfections (61, 62) into the film such that the imperfections can be optically detected, in particular through the plastic material, after the processing operation, in particular by means of a depth effect, 3D effect, and/or transparency effect.

Description

Process for producing a decorated plastic part and a decorated plastic part

The invention relates to a method for producing a decorated

Plastic part and a decorated plastic part.

To decorate a plastic part, it is described in DE 4331167 A1, for example, to apply one or more layers of color pigments to the surface of a granulate. These granules then become one

Plastics processing machine fed, melted and then processed into a plastic part by means of an extruder.

A disadvantage of such a procedure is that the control of the resulting optical effects and thus the optical

Design options for the optical decoration of the plastic part are very limited.

The invention is based on the object of the decoration of

To improve plastic parts and in particular inexpensive novel to enable optical effects, in particular 3D effects and depth effects when decorating plastic parts.

This object is achieved by a method of making a decorated

Plastic part solved, which includes the following steps:

- Providing a slide,

- At least regionally application of at least one plastic material to the film in a processing process,

Introduction of imperfections in the film in such a way that the imperfections are optically recognizable after the processing process, in particular are optically recognizable through a depth effect and / or 3D effect and / or transparency effects.

This object is further achieved by a decorated plastic part, the plastic part at least one film and at least one on the film

has plastic material applied in some areas in a processing process, with imperfections being introduced into the film in such a way that the

Defects are recognizable after the processing process, in particular are optically recognizable by a depth effect and / or 3D effect and / or transparency effect.

The invention achieves the advantage that a large number of different decorative effects of the plastic part can be achieved cost-effectively by means of one and the same starting products, namely the film and the plastic material. There are many, depending on the type of defects introduced

different optical decorations and optical effects can be achieved. For a different decoration it is no longer necessary to use different, To provide specially manufactured starting materials for this purpose, but different optical decorations can be very inexpensive by a corresponding pretreatment and / or variation of the

Processing process can be achieved. It is furthermore advantageous here that optical decorations can also be achieved by appropriately introducing defects and choosing the parameters of the processing process, which otherwise can only be achieved by complex and cost-intensive processes. For example, it is possible to achieve depth effects and / or 3D effects also by means of a film whose film layer and / or whose decorative layers do not produce such effects and, for example, only one

convey two-dimensional uniform color impression. This surprising effect can probably be explained by the fact that when the plastic material is applied in the area of the imperfections, corresponding areas of the film layer and / or the decorative layers are changed in their spatial position and / or orientation in relation to areas in which there are no imperfections, and thereby correspondingly the The plane of reflection and / or the angle of reflection of the incident light is changed accordingly locally, which in turn

Generated depth effect and / or 3D effects and / or transparency effects.

Advantageous developments of the invention are indicated in the subclaims.

The film can be single-layer, for example a solid-colored plastic film or a single-layer metal film, for example made of aluminum or copper. The foil can also be a paper or a paper-like material e.g. Be TESLIN®.

The film can also be multilayered and in particular have at least one carrier layer and at least one decorative layer. The plastic material is preferably used before the film is applied

melted. When the plastic material is applied, the melted plastic material is then brought into contact with the film. As a result, the advantage is achieved that, on the one hand, the local alignment or position of partial areas of the film can be set well with the aid of the imperfections. This, probably due to the application of a "liquid" medium. Furthermore, the advantage is achieved that this alignment or spatial position is then “preserved” when the plastic material cools. Studies have shown that particularly impressive depth effects and / or 3D effects can be achieved through these measures.

In this case, the term “position” is in particular the spatial position in relation to a main surface of the plastic part and in particular that of the film

understood opposite surface of the plastic material after performing the processing.

“Alignment” here means in particular the local solid angle of the plane spanned by a main surface of the decorative layer or film in relation to a main surface of the plastic part and in particular that of the film

A local change in the alignment is formed in particular in that a partial area of the film layer and / or a decorative layer of the film against a main surface of the plastic part or that of the film

remote side of the plastic material "tilts" and so locally the

The angle of reflection of the incident light is changed accordingly. A local change in the situation includes a change in

Alignment also a change in the vertical positioning and / or the horizontal local spacing of the partial area of the decorative layer or the film from a main surface of the plastic part or that of the film

opposite side of the plastic material. This also changes the running length of the light until it strikes the decorative layer or film.

A thermoplastic is preferably used as the plastic material

Plastic material, preferably containing polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), polypropylene (PP) and / or polystyrene (PS) is used.

The plastic material preferably has a glass transition temperature between 60 ° Celsius and 300 ° Celsius, in particular between 90 ° Celsius and 200 ° Celsius, more preferably between 100 ° Celsius and 150 ° Celsius.

It has proven to be particularly advantageous to press the plastic material against the film in at least one phase of the processing process with a pressure between 10 bar and 700 bar, preferably between 10 bar and 300 bar.

Investigations have shown that corresponding changes in the film layer and / or one or more decorative layers of the film, in particular local changes in position or orientation changes, are achieved through the corresponding application of mechanical force in the area of the imperfections, and this improves the visual perceptibility of the imperfections, in particular contribute to the achievement of 3D effects and depth effects. The plastic material is preferably applied to the film at a temperature between 60 ° Celsius and 300 ° Celsius, more preferably between 200 ° Celsius and 250 ° Celsius. Investigations have shown that, due to the resulting temperature input, changes in the position and / or orientation of subregions of the film and in particular of one or more decorative layers of the film are favored and the quality of the decorative effects is thus further improved.

The imperfections are preferably optically recognizable after the processing process by one or more of the effects described below:

The imperfections are preferably due to regional, local openings and / or regional, local creases and / or folds and / or

Overlaps visible in the film layer.

The imperfections are preferably recognizable by regionally, local detachment of one or more decorative layers from the carrier layer, in particular in the area of the imperfections. In the area of the detachment of one or more of the decorative layers, it is possible here on the one hand for the detached

Subregions of the decorative layer are mechanically connected to one or more layers of the film in regions, but in the region of the

The separation point is changed accordingly, the spatial position and / or alignment of the one or more decorative layers.

Furthermore, it is also possible that in the area of the separation point the one or more decorative layers are no longer mechanically connected to a layer of the film are coupled, but are separated from the film, in particular dispersed as platelet-shaped particles behind the plastic material.

Preferably, after the processing process, the imperfections are visually recognizable in that in the area of the imperfections there is a local change in the position of partial areas of the film layer and / or one or more of the

Decorative layers, in particular a local change in the alignment of subregions of the film layer and / or of one or more of the decorative layers, has taken place. As already stated above, this creates a local

Changes the angle of reflection and / or the length of the incident light. The local change in the location of the

The film layer and / or one or more of the decorative layers of subregions, in particular in the “volume” of the plastic material, causes shading effects. These two effects also form the basis for generating depth effects and 3D effects.

Preferably, after the processing process, the imperfections are visually recognizable by a local severing and with the destruction of the film layer and / or of one or more decorative layers of the film. As a result of this effect, the optical effect of the one or more decorative layers is correspondingly extinguished or changed locally and a corresponding local optical change is thereby achieved.

The melted plastic material is preferably applied to the film in such a way that the melted plastic material covers the film at least in some areas on at least one main surface of the film. The melted plastic material is preferably applied to the film in such a way that the melted plastic material completely covers at least one main surface of the film and / or envelops the film. This has the advantage that the application of the plastic material preserves local “changes” in the one or more decorative layers of the film particularly well and protects them from environmental influences.

The film is preferably encased on all sides by the plastic material in the course of the processing process. This has the advantage that the film layer and / or one or more decorative layers are securely in front

Environmental influences as well as mechanical and thermal loads from further processing are protected.

The plastic material is preferably made of a transparent or translucent plastic material. A transparent plastic material is understood to mean a plastic material that is visible in the

Wavelength range has a transmissivity of more than 70%, preferably more than 80%, more preferably more than 90%. A translucent plastic material is understood to mean a plastic material that has a transmissivity between 70% and 10% in the visible wavelength range,

preferably between 70% and 30%, more preferably between 70% and 40%.

With such a configuration of the plastic material, the advantage is achieved that the imperfections are optically recognizable through the plastic material after the processing process and thus the decorative effects achieved by the manufacturing process are visually recognizable when viewed from the side of the plastic material and through the plastic material. The plastic material is preferably an optically scattering plastic material. Under an optically scattering

Plastic material is understood to mean a plastic material which scatters at least 10%, preferably more than 20%, more preferably 50% of the incident light in transmission and / or reflection.

Investigations have surprisingly shown that such a choice of plastic material can achieve further interesting optical effects. In particular, a broadening of the viewing angle range is achieved under which depth and / or 3D effects are visible.

The appropriate setting of the plastic material to the desired

The scattering effect is more appropriate in particular through the addition

inorganic pigments or additives that act as scattering centers for the incident light.

The information given above with regard to transmissivity and scattering preferably relates to the plastic material after the processing process has been carried out, i.e. H. on a layer thickness of the plastic material as it is present after the processing process has been carried out.

Preferably, the plastic material is so on the film in the

Processing process applied that the visual appearance of the plastic part is changed in the area of the defect.

In particular, the processing process is selected so that during the processing process by thermal and / or chemical and / or mechanical influences the optical appearance of the film in the area of the imperfections is changed in a visually recognizable manner The optical result is thus largely brought about by the processing process and in particular by a corresponding application and / or introduction of the plastic material onto and / or into the film. The “imperfections” thus only locally define the areas in which the corresponding during the manufacturing process and in particular when the plastic material is applied

Changes in one or more decorative layers of the film are brought about, which ultimately lead to the visual recognizability of the imperfections

Execution of the processing process.

As a result, the great advantage is achieved that the imperfections can be introduced by means of simple and inexpensive methods and no complex processing steps are necessary, and optical effects can thereby be achieved which cannot be achieved even by complex preprocessing of the film.

The imperfections and / or one or more of the decorative layers in the area of the imperfections are preferably changed in the processing process by the conditions prevailing there, in particular pressure and / or temperature. A corresponding change is hereby made in particular by warping and / or deforming the film and / or one or more of the

Causes decorative layers of the film in the area of the imperfections.

A change is also preferably brought about by tearing the film and / or one or more decorative layers of the film in the area of the imperfections. A change is further preferably brought about by detaching one or more decorative layers of the film in the area of the imperfections.

A change is further preferred by enlarging a local one

Cutting through and / or plastic deformation of the film or one or more of the decorative layers of the film in the area of the imperfections is effected, preferably by more than 100%, preferably by more than 500%.

It is also preferred if one or more of the decorative layers of the film in the vicinity of the imperfections are destroyed, largely destroyed and / or their optical effect changed during the processing process.

The above-mentioned measures can be achieved individually or also combined with one another in the processing process.

It is further preferred that the local optical change of the film that occurred in the area of the introduced imperfections is preserved by solidifying the plastic material at the end of the processing process. This can be done, for example, by appropriate cooling of the plastic material and / or hardening of the plastic material, in particular by means of thermal hardening, radiation hardening or electron beam hardening.

The defects can be in the film before and / or during the

Processing process are introduced. Preferably the

Defects are introduced into the film before the plastic material is applied. The following measures in particular have proven effective for introducing the interfering points:

One or more of the imperfections can be formed by introducing predetermined breaking points, so that first imperfections are present in the film, which are formed by predetermined breaking points.

Predetermined breaking points are understood to mean, in particular, local, in particular point or line-shaped areas of the film in which the material structure of the film is mechanically weakened compared to surrounding areas,

in particular in that one or more layers of the film are at least partially severed in this area or otherwise weakened in their cohesion with respect to the surrounding areas.

These predetermined breaking points can preferably be introduced into the film through mechanical damage to one or more layers of the films, in particular through local mechanical damage to the carrier layer and / or one or more of the decorative layers of the film.

To introduce the first imperfections, in particular one or more layers of the film, in particular the carrier layer and / or one or more of the decorative layers, are at least partially severed. This is preferably done mechanically, in particular by means of cutting, punching, scratching or engraving.

Furthermore, it is also possible to introduce the first imperfections at least one or more layers of the film by means of irradiation, in particular by means of a laser, an electron beam or a thermal source partially, for example by evaporation of material of the respective layer, to cut through and / or to weaken the material of the respective layer accordingly.

Furthermore, to introduce the first imperfections, at least one layer of the film can be partially severed locally in the area of the first imperfections, in particular by means of etching, or the material can be “weakened” accordingly.

By introducing the first imperfections, it is when cutting through the

Carrier layer and also the decorative layers are possible, preferably to dissolve the composite of the film as a coherent structure and separate film parts are created. These film parts can preferably have an area of approximately 1 mm ² to 1,000,000 mm ² , preferably an area of approximately 5 mm ² to 90,000 mm ² .

It is also advantageous here that one or more of the first predetermined breaking points differ from one another, in particular in the lateral one

Differentiate the areal extent and / or areal shape of the severed layers, the depth of the severance of layers or the strength of the weakening of layers of the film. This makes it possible to use different optical effects and effects in different sub-areas of the

To achieve plastic part using one and the same film.

One or more imperfections, hereinafter referred to as second imperfections, are preferably formed by bending points. For this purpose, when the second imperfections are introduced, one or more layers of the film, in particular the carrier layer and / or one or more of the decorative layers in the area of the bending points, are particularly plastically deformed and / or broken by bending and / or a local detachment of one or more by bending

Caused decorative layers of at least one adjacent layer of the film.

Bending points are understood to mean in particular corresponding local areas, for example point-shaped or linear areas of the film, in which a corresponding local, previously described change in the film has been achieved by a bending load.

The second imperfections are preferably introduced by locally bending the film, in particular by kinking and / or creasing and / or folding and / or twisting the film.

It is particularly advantageous here to close the film one or more times at least by 180 ° in order to introduce one or more second imperfections

twist. This is particularly the case when using films which have at least two decorative layers with different optical appearances, which are visible from different main surfaces of the film in incident light and / or transmitted light. By introducing such imperfections, a correspondingly large local tilt is caused in the partial area of the film, which in addition to a corresponding change in the angle of reflection of the incident light also causes a corresponding change in the visual appearance due to the special decorative layer structure.

Here, too, it is advantageous that one or more of the second predetermined breaking points differ from one another, in particular in the lateral one

Surface expansion and / or surface shape, the deformation and / or the broken layers and / or in the local bending radius of the film in the area of the Imperfections. This has the advantage that different decorative effects can be achieved in the plastic part with one and the same film.

The imperfections can be introduced regularly and / or randomly and / or pseudo-randomly according to a regular or irregular grid in the form of a predetermined decoration.

It is also possible here for different groups of defects to be introduced, each of which is arranged in a different pattern. For example, a first group of defects, which is arranged according to a regular grid, a second group of defects, which according to a predetermined pattern, for example consisting of

alphanumeric characters or a picture template are arranged, a third group of defects, which are arranged randomly or pseudo-randomly. These measures make it possible to achieve different decorative effects using one and the same film in the plastic part.

The measures described above are preferably combined with one another in order to achieve complex, visually appealing decorations on the plastic part.

The film can be pretreated before the processing to ensure the adhesion and / or the wettability between the film and the

To improve plastic material. One or more of the following processing methods are preferably carried out as pre-treatment:

Surface activation, in particular through gassing, flame exposure,

Plasma treatment, fluorination, irradiation, cleaning, coating. In addition to the plastic material, one or more other plastic materials are preferably applied to the film during the processing process. In particular, the plastic material can be applied to one main surface of the film and the further plastic material to the other main surface of the film.

The film is preferably fed to the processing process two or more times. Complex depth and 3D effects can be achieved by superimposing the decorative effects.

According to a preferred embodiment, it is the

Processing process around an extrusion process and in the

Plastic material around an extrusion material of the extrusion process. It is preferred here that the plastic material is brought into contact with the film before the extrusion rollers.

The extrusion process can be formed by an extrusion process in which an extrusion takes place, or a coextrusion is also carried out.

However, the processing process can also be another processing process, in particular a process selected from the lamination process, in particular using a roller laminator or a lifting press, lamination process, deep-drawing process, injection molding process.

In the case of an injection molding process, the plastic material is applied to the film in particular by back injection, over injection and / or flooding. The production of a film insert is not absolutely necessary for this. Rather, it is sufficient if the film is completely or partially in the injection mold is introduced and is brought into contact with the injection molding material on one or both sides.

These processing processes can also be combined with one another.

For example, after an extrusion process has been carried out, the plastic part produced in this way can then be back-injected and / or flooded and / or deep-drawn and / or laminated.

The plastic part can be treated after the manufacturing process, in particular to improve the adhesion and / or the wettability between the plastic part and any coatings to be subsequently applied to the plastic part. One or more of the following processing methods are preferably carried out as treatment: surface activation, in particular by gassing, flame treatment, plasma treatment, fluorination, irradiation, cleaning, coating.

Furthermore, after an extrusion process, it is possible, in particular, to use the plastic part which is present there in particular flat and undeformed

to refine further processing steps, here in particular by screen printing and / or digital printing and / or hot stamping and / or cold stamping and / or thermal transfer printing and / or laser marking and / or lamination.

In particular after an injection molding process or deep-drawing process has taken place, it is possible that the 3D deformed part now present by means of further

To refine processing steps, here in particular by digital printing and / or hot stamping and / or cold stamping and / or thermal transfer printing and / or

Laser marking and / or lamination. These processing steps can be carried out individually or in combination on the plastic part after an extrusion process or after a 3D deformation process on the visible side in order to create special protective layers and / or haptic effects and / or further decorative layers such as full-surface or partial-surface decors, gradients and / or matt To apply effects and / or gloss effects and / or full-surface or partial opacity, in particular as defined transparent areas within an opaque layer, for example to produce areas that can be illuminated from behind.

These processing steps can each take place individually or in combination on the plastic part after an extrusion process or after a 3D deformation process, alternatively or additionally also on the side facing away from the visible side of the plastic part, for example to achieve full or partial opacity of the plastic part, or to achieve special Lighting effects e.g. in the form of a backlighting area, in particular as defined transparent areas within an opaque layer, for example to generate backlit areas, or also to provide technical advantages, for example with regard to durability and / or adhesive forces and / or wetting properties of surfaces, here in particular for further subsequent processing steps such as e.g. To achieve injection molding.

The layer thicknesses in screen printing are between 1 pm and 50 pm, preferably between 5 pm and 30 pm, particularly preferably between 5 pm and 15 pm.

For example, these layer thicknesses are achieved with application quantities of liquid paint of 5 g / m ³ to 20 g / m ³ for a layer thickness between 5 μm and 30 μm. The screen printing layer can be transparent or translucent or also opaque. A transparent screen printing layer is understood to mean a screen printing layer which, in the visible wavelength range, has a transmissivity of more than 70%, preferably more than 80%, more preferably more than 90%. A translucent screen printing layer is understood to mean a screen printing layer which has a transmissivity between 70% and 10%, preferably between 70% and 30%, more preferably between 70% and 40%, in the visible wavelength range. Under an opaque

Screen printing layer is understood to be a screen printing layer which, in the visible wavelength range, has a transmissivity between 40% and 0%, preferably between 30% and 0%, more preferably between 10% and 0%.

The screen printing layer can consist of several sub-layers that

one above the other and / or next to one another. Each of the sub-layers can in each case be transparent or translucent or opaque in the visible spectral range, so that the screen-printed layer can consist of several sub-regions, each of which can have a different transmissivity in the visible spectral range.

Furthermore, a transparent protective varnish can be applied by screen printing, which has one or more components selected from an uncrosslinked acrylate, from polyurethane, from UV-crosslinkable acrylate, from chemically crosslinkable acrylate (using isocyanate, melamine, carbodiimide, etc.), optionally in addition is provided with inorganic auxiliaries (e.g. SiOx, etc.) and / or with release agents. This protective lacquer can be applied over the entire surface or only in partial areas on the surface of the plastic part and / or on the

Plastic part existing layers be applied. It is also possible, after the processing process has been carried out, to apply one or more additional layers to the plastic material and / or the film for forming the plastic part. For this purpose, one or more of the processing processes described above are preferably used, for example screen printing, digital printing, lamination, lamination, deep drawing, injection molding or extrusion.

The film is preferably a laminating film or

Transfer film.

A transfer film is formed here by a film in which the carrier layer can be detached from the one or more decorative layers and in particular also has one or more detachment layers. The use of a film of this type has the advantage that local detachment of one or more decorative layers by introducing imperfections is particularly easy, in particular because of the one or more detachment layers provided in the layer structure.

The carrier layer is preferably made of polyethylene terephthalate (PET) or polymethyl methacrylate (PMMA).

The layer thickness of the carrier layer is preferably between 10 μm and 200 μm, more preferably between 25 μm and 75 μm.

The one or more decorative layers of the film preferably each consist of a lacquer layer which is colored with one or more dyes and / or pigments. Next are the one or more decorative layers Foil in each case preferably formed from one or more of the following layers:

A decorative layer can be formed by a metal layer and / or several, in particular different metal layers, in particular of different colors. The different colors of the metal layer can be caused by a coloring of the metal by a translucent color layer and / or by the intrinsic color of the metal.

A decorative layer can be formed by a reflection layer, in particular consisting of one or more H RI (H RI = High Refraction Index) or LRI (LRI = Low Refraction Index) layers. ZnS or SiOx layers are preferably used as HRI layers.

A decorative layer can be formed by a relief layer having an optically active surface relief.

This relief layer preferably consists of a thermoplastic or UV-curable lacquer in which the optically active surface relief is shaped by means of an embossing tool.

The optically active surface relief is preferably a diffractive structure, in particular a hologram, a matt structure, in particular an isotropic or anisotropic matt structure, a refractive structure, preferably a microlens structure, a zero-order diffraction grating.

A decorative layer can consist of a thin film element, which generates a color shift effect by interference, and / or a layer for generating Color effects are formed in transmitted light by means of plasmon resonance, for example a translucent metal layer in which a relief structure is shaped with a period below the wavelength of visible light or which is structured according to a grid with a period below the wavelength of visible light.

The aforementioned decorative layers can be combined with one another in any combination in the film. The decorative layers can be present in the film over the entire surface, but also partially and in pattern form.

The decorative layers preferably have a layer thickness between 0.01 μm and 20 μm.

The plastic part can be used for various applications: It is advantageous if the plastic part is used in the automotive sector, in particular as an external body part or as an external attachment or as part of the interior

Motor vehicle is used in consumer electronics or in

Household appliances area, in particular as a chassis part of an electronic or electrical device, is used in the furniture industry, for example as a furniture part, in the packaging industry, for example as a packaging film.

In the following, the invention is explained by way of example on the basis of several exemplary embodiments with the aid of the accompanying drawings. Fig. 1 shows a sectional view of a film

Fig. 2 shows a sectional view of a film

Fig. 3 illustrates schematically one

Processing

FIGS. 4a to 4c each show a sectional view of a

Plastic part

Fig. 5 and Fig. 6 show schematic representations for

Clarification of the position of a

Plastic part

Fig. 7a shows a schematic representation for

Clarification of the position of a

Plastic part.

FIG. 7b shows a sectional view of the plastic part according to FIG. 7a.

8a shows a schematic representation for

Clarification of the position of a

Plastic part.

FIG. 8b shows a sectional view of the plastic part according to FIG. 8a. 9a shows a schematic representation for

Clarification of the manufacture of a

Plastic part.

FIG. 9b shows a sectional view of the plastic part according to FIG. 9a.

1 and 2 illustrate the structure of a film by way of example. The film is preferably formed from a transfer film or laminating film. Furthermore, it is also possible for the film, as already stated above, to also have a single-layer structure.

The film according to FIG. 1 is a transfer film. The film 10 according to FIG. 1 has a carrier layer 11, a release layer 13, one or more protective layers 14, one or more decorative layers 12 and one or more adhesive and / or bonding layers 15. The film has a front main surface 1 1 1 and a rear main surface 1 12.

The main area becomes an outer boundary surface of a body

understood, which not only has a subordinate surface area.

The carrier layer 1 1 is preferably made of a plastic that bonds well with the applied plastic material. The carrier layer 1 1 can be painted, vapor-deposited and / or primed on one or both sides in order to in particular the interlayer adhesion to the applied

To improve plastic material.

The carrier layer 11 is preferably made of PET. This is preferably a PET carrier material which is used for the subsequent

Processing process is "optimized". For example, a flexible, deep-drawable PET carrier material can be used for better deep-drawability. A UV-stabilized PET carrier material can be used for better UV resistance.

It is also possible that the carrier layer 11 consists of a different material, in particular ABS or ABS-PC or PC or PMMA or polyurethane or TPU or TPE. Furthermore, it is also possible for the carrier layer to consist of one or more sub-layers, which preferably consist of one of the

the aforementioned materials. Depending on the manufacturing process, it is advantageous here to select the carrier layer 11 from a material which is elastic or rigid, dissolves, detaches and / or melts.

The layer thickness of the carrier layer 11 is preferably between 10 μm and 500 μm, more preferably between 25 μm and 150 μm.

The release layer 13 is preferably made of a wax, optionally

solvent-based or aqueous (e.g. PE, cellulose). It is also advantageous if the release layer 13 consists of a crosslinkable OH-functionalized acrylate, in particular isocyanate, melamine, carbodiimide. The release layer can also consist of a combination of such materials. The layer thickness of the release layer 13 is preferably between 0.1 μm and 5 μm, more preferably between 0.5 μm and 3 μm. The release layer 13 can also be dispensed with if the layers of the film 10 adjacent to the carrier layer 11 are formulated accordingly that the interlayer adhesion between these layers is so low that these layers can be released from the carrier layer 11 without destroying these layers . Furthermore, it is also possible that not just one release layer

13 is provided in the film 10, but two or more release layers 13 are provided.

The protective layer 14 preferably consists of a protective lacquer layer. This protective varnish preferably consists of an uncrosslinked acrylate, polyurethane and / or UV-crosslinkable or traditionally crosslinkable acrylate, in particular isocyanate, melamine, carbodiimide. Inorganic auxiliaries, in particular SiOx and “release agents”, can also be added to the protective lacquer layer.

The protective layer 14 can furthermore also consist of one or more protective lacquer layers, each of these protective lacquer layers preferably offering protection against special environmental influences.

The layer thickness of the protective layer 14 is preferably between 1 μm and 10 μm, more preferably between 2 μm and 6 μm.

The protective layer 14 can also be dispensed with. This because the

The manufacturing process for the plastic part is then applied to the film 10

Plastic material is applied, which the protective function of the protective layer

14 can take over for the subsequent one or more decorative layers 12. The one or more decorative layers 12 are preferably composed of one or more lacquer layers.

These lacquer layers preferably contain one or more by means of one

Layers colored by dye or pigment. These have in particular an uncrosslinked acrylate, polyurethane, crosslinkable OH-functionalizable acrylates, in particular isocyanate, melamine, carbodiimide as binders, dyes and / or pigments, in particular organic or inorganic pigments and / or

Additives such as dispersing additives.

Optically variable pigments, in particular

Liquid crystal pigments, interference layer pigments or diffractive pigments are used. In addition to the use of dyes and / or pigments, it is also possible to use dyes and / or pigments which have luminescent and / or phosphorescent properties.

Furthermore, the decorative layers 12 can also consist of one or more of the aforementioned layers, that is to say in particular also consist of real metal layers, for example a vapor-deposited layer of chromium, tin, aluminum, copper, indium, silver or gold.

The individual decorative layers 12 can be flat as well as partially in the sense of a decorative design and / or in the sense of an optical and / or

electrical function are applied.

The layer thickness of a decorative layer 12 is preferably between 0.1 μm and 20 μm, more preferably between 0.5 μm and 10 μm. The adhesive and / or bonding layer 15 preferably consists of at least one lacquer layer, and depending on the area of application, in particular "automotive", "consumer electronics", "packaging" and their technical requirements, in particular light stability, the corresponding lacquer structures can vary. The adhesive and / or bonding layer 15 preferably consists of a hot-melt adhesive layer, in particular containing polyvinyl chloride (PVC),

low-melting acrylate, polyurethane.

The layer thickness of the adhesive and / or adhesion promoting layer 15 is

preferably between 0.5 pm and 10 pm, preferably between 1 pm and 4 pm.

The adhesive and / or bonding layer 15 can also be dispensed with.

2 shows the layer structure of a laminating film 10. This laminating film comprises a carrier layer 11, an adhesion promoting layer 16, one or more

Protective layers 14, one or more decorative layers 12 and one or more adhesive and / or adhesion promoting layers 15.

The laminating film shown in FIG. 2 is basically like that shown in FIG

Transfer film built up, except that instead of the release layer 13 the

Adhesion promoter layer 16 is provided.

The carrier layer 11, the protective layer 14, the one or more decorative layers 12 and the adhesive and / or bonding layer 15 are here like the

The carrier layer 12, the protective layer 14, the one or more decorative layers 12 and the adhesive and / or bonding layer 15 are built up according to FIG. 1, so that reference is made to the preceding statements in this regard. The adhesion promoting layer 16 improves the interlayer adhesion between the one or more decorative layers 12 and the carrier layer 11

Adhesion-promoting layer 16 preferably consists of a highly crosslinkable acrylate system, in particular melamine or isocyanate.

The layer thickness of the adhesion promoter layer 16 is preferably between 0.5 gm and 10 gm, more preferably between 1 gm and 4 gm.

3 now illustrates the basic sequence of a method for producing a decorated plastic part by means of an extrusion device 50:

First, a film 10, preferably the film 10 according to FIG. 1 and / or FIG. 2, is provided, which has a carrier layer, in particular the carrier layer 11 and one or more decorative layers, in particular the decorative layers 12. In addition to these layers, the film 10 can also have one or more further layers, as explained above with reference to FIGS. 1 and 2. However, it is also possible that the film consists only of the carrier layer 11 and a decorative layer 12 or the carrier layer 11 and several decorative layers 12 or that the film is only present as a single-layer film, for example as a single-layer opaque or translucent plastic material or as a single-layer metal foil, for example Aluminum or copper.

As shown in FIG. 3, the film 10 is fed to a processing process. In the exemplary embodiment according to FIG. 3, the processing process is an extrusion process. For this purpose, an extruder 52 is made of one

A plastic granulate 21 is supplied to the storage container 51. The plastic granulate 21 is melted in the extruder 52 and a

Melted plastic material 20 with pressures between 10 bar to 300 bar or 700 bar and temperatures between 60 ° C and 300 ° C are extruded.

The plastic material 20 is an extrudable one

Plastic material, in particular containing PC, ABS, PMMA, PP and / or PS.

The plastic material 20 is here preferably transparent or translucent. However, it is also possible that the plastic material 20 has opaque optical

Has properties, d. H. in particular the transparency of the plastic material in the visible wavelength range is less than 80%, more preferably less than 90%, more preferably less than 99%. It is also advantageous if the plastic material 20 is colored and / or the plastic material 20 has scattering properties.

The film 10 is now preferably provided with predetermined breaking points before being fed to the manufacturing process and, as shown in FIG. 3, fed to the extrusion process. As shown in FIG. 3, the melted plastic material 20 is applied to the film 10 and then the film 10 with the applied, still liquid plastic material 20 is placed in a roller gap between two

Extrusion rollers 53 introduced. The melted plastic material 20 is then pressed against the film 10 by the extrusion rollers 53. Due to the high temperatures and pressures occurring here, the appearance of the film 10 in the area of the imperfections is preferably visually visibly changed compared to the area without imperfections, as already described above.

The roller spacing between the extrusion rollers 53 is preferably between 0.5 mm and 5 mm, more preferably between 50 μm and 200 μm. How already stated above, is the temperature of the melted

Plastic material when pressed against the film 10, preferably between 60 ° C and 300 ° C, more preferably between 210 and 240 ° C.

These process parameters are dependent on the one selected

Plastic material 20 and the film 10 are adjusted accordingly so that, as set out above, preferably those described above are optically recognizable

Changes in the film are brought about, in particular adjusted in such a way that by local arching and / or deformation of the film 10 in the area of the defect, by tearing the film 10, the one or more decorative layers 12 of the film 10 in the region of the defect, and / or by detachment of one or more

Decorative layers 12 of the film 10 in the area of the defect and / or through

Enlargement of a local severing and / or plastic deformation of the film 10 of the one or more decorative layers 12 of the film in the area of the

Defects the defects are optically recognizable and in particular are optically recognizable by a depth effect and / or 3D effect and / or transparency effect.

It is also possible that the extrusion rollers 53 have one or more

Have surface reliefs, for example have a matt and / or glossy and / or embossed and / or brushed surface relief and by the corresponding profiling of one or both extrusion rollers 53, corresponding profilings are additionally embossed into the surfaces of the plastic part during the processing process. The extrusion rollers can have a surface that comes into contact with the plastic material

have a uniform surface relief or alternatively have different surface areas adjacent to one another, each with different surface reliefs or also largely smooth areas. This means that locally different surfaces can then be produced on the plastic part, for example Matt / gloss effects or only locally limited optically and / or tactilely perceptible surface reliefs or smooth areas without relief.

After the processing process has been carried out, at least one subsequent processing process is preferably carried out in order to reinforce, change or optimize the optical effects of the plastic part, to protect the material to be introduced, and to meet the requirements of special industries.

Defects are introduced into the film 10, in particular into the carrier layer 11 and / or one or more of the decorative layers 12, during and / or before the extrusion process by a wide variety of types of preprocessing. This is preferably done before the film 10 and the plastic material 20 are brought together in the extrusion process.

With the aid of FIGS. 4a to 4c, various possibilities for introducing defects will now be explained by way of example.

A basic possibility for introducing imperfections is to introduce predetermined breaking points in one or more layers of the film 10. The predetermined breaking points are introduced here through local mechanical damage or weakening of one or more layers of the film 10, in particular the carrier layer 11 and / or one or more of the decorative layers 12.

One possibility for this is, for example, by means of a

Cutting tool or punching tool to sever one or more layers of the film 10 partially or completely in the area of the respective predetermined breaking point.

The predetermined breaking point can be a punctiform lateral formation, in particular when a punching tool is used and / or have a linear lateral extent, in particular when a cutting tool is used.

An embodiment of a plastic part 1, during the production of which such defects 61 were introduced into the film 10, is shown in FIG. 4a:

The plastic part 1 according to FIG. 4a has the film 10 with the carrier layer 11 and the one or more decorative layers 12, of which only one in FIG. 4a

Decorative layer 12 is shown by way of example. The plastic part 1 also has this

Plastic material 20.

In the area of the breakpoints 61 designed as predetermined breaking points there are holes in the processing process, either due to the already performed severing of the film 10 when the predetermined breaking points are introduced and / or due to the corresponding tearing of the predetermined breaking points in this area due to the "weakening" of the film 10 and the high pressures / temperatures that act on it in the manufacturing process. Through these "holes" during the

Processing process plastic material 20 reach the side of the plastic part 1 which is opposite the side on which the plastic material 20 is applied.

The plastic material 20 can thus spread out at these points on the opposite surface of the plastic part 1, as a result of which the film 10 and in particular the decorative layer 12 is correspondingly bulged and / or frayed in the edge region of the imperfections 61, as also indicated in FIG thus corresponding local changes in the position and / or orientation of

Surface areas of the decorative layer 12 in the area of the imperfections 61 is effected. Instead of introducing the imperfections 61 by means of a cutting tool or punching tool, one or more layers of the film 10 can also be "weakened", for example by means of a scratching tool, for example processing by means of a wire frame, or also by means of irradiation and / or by means of chemical pre-processing as already explained above.

The intensity of these processing steps is chosen so that the decorative layers 12 detach at the processed points and / or predetermined breaking points arise, which then lead to a corresponding tearing and / or severing of the layer package of the film 10 in this area and subsequently during the processing process lead to an optical recognizability of the defects caused thereby.

It is advantageous here if the film 10 has larger penetrations (regular and / or irregular) so that the plastic material 20 can penetrate between the films 10 and no areas without a flaft composite can form.

It is also advantageous for introducing defects, one or more

Bring bending points into the film 10. This is illustrated below with reference to FIGS. 4b and 4c:

To introduce imperfections 62, the film 10 is bent one or more times in such a way that one or more bending points are introduced into the film, in the area of which one or more layers of the film 10 are plastically deformed and / or broken and / or through bending Bending causes a local detachment of one or more decorative layers 12 from at least one adjacent layer of the film. In Fig. 4b an embodiment is shown in which defects 62 in the form of bending points are introduced into the film 10, in the area of which one or more layers of the film 10 are plastically deformed by bending: Fig. 4b shows this

Plastic part 10 with the plastic material 20 and the film 10, which the

Carrier layer 11 and one or more decorative layers 12, of which only one decorative layer 12 is shown in FIG. 4b for reasons of simplicity. As indicated in FIG. 4, in the area of the imperfections 62 the carrier layer 11 and the decorative layer 12 of the film 10 are plastically deformed by bending, so that one or more of the decorative layers 12 in their position and / or in the area of the bending points

Alignment have been changed locally and in particular, as in Fig. 4b

clearly shows that corresponding local surface areas of the decorative layer 12 are tilted relative to the main surface of the plastic part 1 opposite the film 10.

The bending points can be introduced here in particular by crumpling the film 10, by bending the film 10, by folding the film 10 and / or twisting the film 10. The bending points in this case preferably have a linear shape and can be adjusted accordingly through the selection of the bending tool, both with regard to their lateral extension and the one to be introduced

Bending radius can be determined. Furthermore, it is also possible, through targeted feeding of the film 10, to achieve a corresponding introduction of bending points into the film 10, for example by iteratively changing the web tension

Twisting of the film is effected by appropriate feeding.

As illustrated in FIG. 4b, the plastic deformation caused by the imperfections 62 is “preserved” and “stabilized” accordingly by the plastic material 20. It is also possible that in the area of the bending points by the

corresponding breakage and / or weakening of one or more layers of the film 10, a corresponding “tearing open” of the layer package of the film 10 during the processing process, similar to the exemplary embodiment according to FIG. 4a, and thereby also, under certain circumstances, partial predetermined breaking points in one or more several of the decorative layers 12 are brought about, which produce similar optical effects as the predetermined breaking points according to FIG. 4b.

Furthermore, it is also possible, as illustrated in the exemplary embodiment according to FIG. 4c, that a local detachment of one or more decorative layers is effected in the processing process in the area of the bending points

Exemplary embodiment according to FIG. 4c, the plastic part 1 with the plastic material 20 and the film 10 comprising the carrier layer 11 and one or more

Decorative layers 12, one of which is shown in FIG. 4c for reasons of simplicity

Decorative layer 12 is shown:

As shown there, is in the area of the imperfections 62 by the corresponding

Weakening of the interlayer adhesion between the carrier layer 11 and the decorative layer 12 in these areas due to the bending load, a partial detachment of the decorative layer 12 has been caused by the pressure load in the processing process. In the area of the imperfections 62, partial areas of the decorative layer 12 are provided which, due to the detachment, have a significant change in the spatial position / orientation compared to areas of the decorative layer 12 which have not been subjected to a corresponding bending load. For example, in the area of the imperfections 62, the surface normals of the decorative layer 12 are corresponding to those of the opposite main surface of the

Plastic part 1 tilts, resulting in corresponding optical changes with regard to the reflective properties of the plastic part in this area.

By introducing bending points, it is thus possible to achieve effects according to FIG. 4b, effects according to FIG. 4c and / or effects according to FIG. 4a and thereby corresponding optically recognizable changes and in particular depth and / or 3D changes in the area of the imperfections. Effects and / or transparency effects in

To effect plastic part.

To position the bending points, the film can be inserted into the

Plastic material can be rotated mechanically one or more times around an axis, in particular the longitudinal axis. This can be done at different angles, which enables a different appearance of the defects introduced as a result in a subsequent rolling out of the material. The speed of the twisting and the throughput speed of the extrudate have an influence on the visual appearance of the imperfections caused by this.

It is particularly advantageous here that with a rotation of 180 ° and

corresponding decorative layer structure depending on the twist the color of the

Decorative layers 12 changes and so shows a corresponding change in the visual appearance.

It is advantageous here if a film 10 is used which, when viewed from the front and / or back, has a different optical appearance

Appearance generated. For example, a colored metallized film can be used as film 10, which is only colored on the front side by a further glazed decorative layer on the metal layer, so that the film has a gold-colored impression, for example, when viewed from the front in incident light and gives a silver metallic impression when viewed from the rear in incident light.

The film 10 can be introduced flat and with uniform tension or with laterally varying tension / tension. By laterally varying tension / tension, it is possible, through appropriate interaction with the thermal conditions and / or the flow rate of the

Plastic material from the extruder 52 and the roller pressure and spacing of the extruder rollers 53 to bring about a random and / or regular introduction of defects. The tension and / or the tension of the film 10 can be varied manually and / or by means of appropriate mechanical film feeding devices. In particular, it is possible to modify the tension and / or the tension of the film 10 arbitrarily with manual intervention. Alternatively or in addition, it is also possible to modify the feed speed and / or the feed angle of the film by means of targeted control of a film feed device.

For example, corresponding servomotors or other actuators and control elements of the film feed device can be controlled with a corresponding program. This effect can further be achieved by a local melting of layers of the film 10 and / or a local floating and / or

Pushing away layers of the film 10 are reinforced by the plastic material 20. It can also be varied in which position the film in the

Plastic material 20 comes to rest, in particular, for example, in the middle of the plastic part 1, in its edge area or over the entire surface.

In all of the above embodiments, when the film 10 is introduced into the plastic material 20, the film can be fed in the most varied of ways:

stretched / largely smoothed out, compressed / severely deformed,

slack / tight, twisted, etc. This can be evenly depending on the desired effect or unevenly. For example, the film is loosely and wrinkled at the beginning and inserted under tension in the following phase, and this can be repeated iteratively accordingly.

Furthermore, it is also possible that the film and the plastic material 20 are brought together in such a way that the film 10 lies on the front and / or rear side of the plastic material 20 and / or one or more times next to one another. In addition, it is also possible to use not just one film 10, but two or more different films 10 with the plastic material 20 in the processing process

to merge. It is particularly advantageous here if these foils 10 have a different visual appearance.

It is also possible that foils 10 multiple times on top of the other

Processing process are supplied and so for example in

Processing process the plastic material 20 is brought into contact with two or more foils 10 in the processing process. For example, one film 10 is provided on the front and one on the back, and thus one

Composite body consisting of the plastic material 20 and two or more, preferably enveloped by the plastic material 20 foils 10 is created.

In particular, the process achieves the following optical effects:

Basically, in the finished extrudate, the additionally introduced material, i. H. the one or more foils 10 and the introduction of the imperfections 61, 62 special optical effects, in particular a depth effect.

The depth effect can be achieved by the different ways of introducing the imperfections 61, 62 and the different ways of introducing the film 10 in the Processing process vary. If the film 10 is positioned in the plastic part (rather) on the underside, this creates a much stronger depth effect than if the film 10 in the plastic part is (more) on the front.

A depth effect in the form of a “folds” or a relief image with pronounced fleas and depths is preferred.

By appropriately introducing bending points, further effects can be achieved in the form of a sequence of waves that occur one behind the other, can be small / large as well as convex / concave and can also be varied in size in a targeted manner distributed over the surface.

The expression of the depth effect and / or 3D effect and / or transparency effect is brought about by the size and position change of partial areas of one or more of the decorative layers 12 in the area of the imperfections, which can be achieved by setting the strength of the bending, twisting and the strength and size of the introduced impurities can be locally strengthened or weakened.

Further depth effects are brought about by the fact that in the area of the imperfections the position of one or more decorative layers 12 in the volume of the

Plastic material 20 changes locally. This looks optically as if the decorative layer 12 or the decorative layers 12 were in areas in the plastic material

"float" at different heights.

The depth effect is also brought about by a real shadow cast inside the plastic part. If the plastic material 20 is selected to be transparent or translucent and the film is placed on the front of the plastic material, throws this casts a shadow on the layer of the plastic part lying on the back of the plastic material 20. Used in a further processing step

For example, a layer of lacquer in the background by means of screen printing, d. H. Applied to the back, which lets this shadow come into its own, underlines the depth effect again.

The degree of glazing of the plastic material 20 also influences the optical depth effect. If the film 10 is completely on the surface of the

Plastic material 20, it is clearly visible. However, if it is in deeper areas, it appears at this point - depending on the degree of glaze

Plastic material - diffuse, so that corresponding depth effects are created.

Basically, the result is that the depth effect and shadow formation increase as the layer thickness of the plastic material 20 in the plastic part 1 increases.

Coextrusion is preferred. If the film 10 lies on a surface of the plastic material 20, it is not protected from external influences. A

Coextrusion leads to a complete sheathing of the film 10, in particular the one or more decorative layers 12, and in particular leads to the following advantages:

In this way, on the one hand, complete protection of the one or more decorative layers is achieved. Furthermore, the entire surface of the extrudate is the same

Material properties. Further processing steps such as

Screen printing, digital printing, hot stamping, cold stamping, thermal transfer printing,

Thermoforming, back injection made easier. In particular, this creates a uniform lacquer connection and a smooth, homogeneous surface, which

for example, good suction in a screen printing machine is guaranteed. The coextrusion can take place directly in the manufacturing process. Different material combinations are also conceivable depending on the requirements. As shown in Fig. 5, for example:

FIG. 5 illustrates the exemplary embodiment in which a film 10 comprising the carrier layer 11 and at least one decorative layer 12 is brought into contact with the plastic material 20 on both sides in the processing process. This is preferably achieved in that the extrusion process according to FIG. 3 is modified in such a way that the plastic material 20 before the film 10 runs into the nip of the extrusion rollers 53 not only on one side with the

Melted plastic material 20 is brought into contact, but instead the plastic material 20 is applied to both sides of the film 10.

It is also possible that this coextrusion is not directly in the

Processing process, but takes place in a subsequent processing step.

In addition to using the same plastic material, it is also possible here for different plastic materials to be applied to the two sides of the film 10. For example, a plastic material 20 consisting of ABS can be applied on one side and a plastic material 20 consisting of PC on the other side.

In addition to and / or after the coextrusion, further subsequent processing steps can take place. Subsequent printing is particularly advantageous here,

for example by means of screen printing or digital printing in order to, as explained above,

To intensify depth effects as well as further color effects and / or transparency effects and / or flint lighting effects and / or flap effects as well as surface finishes, in particular to generate matt, glossy. Deep drawing, back injection molding, flooding, painting, laser marking, trimming, polishing, cleaning, quality control are further possible further processing steps individually or in combination.

Several examples for the implementation of the procedure are described below:

Example 1 :

The film 10 has, as the upper decorative layer 12, an elastic, in particular colored yellow, colored layer and, as the second, underlying decorative layer 12, an aluminum layer. The film 10 thus conveys a gold-metallic color impression when viewed from the front in incident light, and a silver-metallic color impression when viewed from the rear.

This film 10 is cut, for example, with a cutting tool for introducing predetermined breaking points and, for example, by means of folding and / or

Crumple and / or crumple processed in such a way that a large number of bending points are introduced into the film. In this example, this processing is done manually. After a large number of imperfections have been introduced into the film 10 in this way, this is fed to the extrusion process according to FIG. 3, a liquid, transparent PC being used as the plastic material 20.

As a result, the effects explained in FIGS. 4a to 4c show a large number of new design effects and a strong depth effect, despite the smooth surface of the plastic part 1 on the main surface of the plastic part 1 opposite the film 10. Example 2:

The film 10 used is a film consisting of a deep-drawable PET film as the carrier layer 11, a translucent color layer as the first decorative layer 12 and a chrome layer as the second decorative layer 12 underneath.

This film is introduced into the processing process according to FIG. 3 and is twisted several times during the introduction and during the extrusion process in order to introduce imperfections in the film 10. This is preferably done alternately from left to right in a range of the angle of rotation from 0 ° to 180 °, in a cycle of 3 seconds. After a period of approximately 12 seconds, the film 10 is turned once through 360 ° (that is, rotated twice through 180 °) and this sequence is then repeated iteratively. This is random or pseudo-random the

The tension of the film 10 when it is introduced into the nip of the extrusion rollers 53 varies. The distance between the rollers is 0.5 mm, with a flow rate of the plastic material 20 of 4.8 m per minute.

A translucent ABS is used here as the plastic material 20, which, as already explained above with reference to FIG. 3, is brought into contact with the film 10 in a melted and thus liquid state.

In a subsequent step, the plastic part manufactured in this way is made from the

Flaup extruder coextruded with another small extruder. This contains a transparent PC, which is applied to the plastic part with a thickness of 0.5 mm. This creates a plastic sheet made of several layers with a material thickness of 1 mm. The transparent PC forms the top layer of the extrudate and at the same time the film 10 is completely encased by the coextrusion and protected from external influences. The plastic part produced in this way is then assembled as sheet goods and screen-printed on the front, i.e. the front main surface, which is formed by the transparent PC plastic material, is printed over the entire surface with a solvent-based hybrid paint, in particular a glossy clear paint, and is thus protected. The thickness of this lacquer layer is preferably in the range between 1 μm and 20 μm, for example 10 μm.

This lacquer layer is then printed again in pattern form by screen printing with a solvent-based hybrid lacquer, in particular a matt haptic lacquer. The layer thickness of this lacquer layer is preferably between 5 and 50 μm, more preferably between 20 μm and 25 μm. The full-surface glossy protective clear lacquer and the patterned matt haptic lacquer result in optically recognizable matt / gloss effects and tactile, rough / smooth effects.

The plastic part produced after this processing is carried out is illustrated in Fig. 6:

This plastic part has the plastic film 10 with the carrier layer 11 and the two decorative layers 12, the plastic material 20 made of a translucent ABS applied thereon in the processing according to FIG. 3, the substrate 30 coextruded thereon made of a transparent PC plastic material, the transparent lacquer layer printed thereon 32 and the lacquer layer 33 printed thereon. The upper decorative layer 12 is formed by a colored lacquer layer structured in the form of a decor and the lower decorative layer 12 is formed by a chrome layer.

The layer made of the plastic material 20 has a layer thickness of, for example, 500 μm, the substrate 30 has a layer thickness of, for example, 500 μm Lacquer layer 32 has, for example, a layer thickness of 20 μm and lacquer layer 33 made of the matt haptic lacquer has, for example, a layer thickness between 20 μm and 25 μm.

The film 10 and its carrier layer 11 as well as the decorative layers 12 have a layer thickness in the area already mentioned above and are thus made much thinner than the layer made of the plastic material 20. Due to the introduction of the imperfections, the decorative layers 12, as also illustrated with reference to FIGS. 4a to 4c, are correspondingly indicated in regions

different spatial position and orientation within the volume of the layer made of the plastic material 20, so that the optical effects already described above, in particular depth effects,

Transparency effects and color effects can be generated.

For example, the decoration of the upper decorative layer 12 can be seen on the lower decorative layer 12 in certain areas and only the visual effect of the lower decorative layer 12 is visible in other areas. Depending on the angle and

Tension during insertion, e.g. overlapping / smooth,

stretched / compressed, the decor of the upper decorative layer 12 and the

Chrome surface of the lower decorative layer 12 is also visually interconnected

Interaction occur, for example clearly delimited next to one another or provided in overlapping partial areas. The central position of the film 10 in the overall structure of the plastic part further enhances the optical depth effect. This is further enhanced by the screen printing on the front of the

Reinforced plastic part, in particular the lacquer layer 33 printed on in the form of a decoration.

So throw both the decorative layers 12 and the screen-printed decor of the Lacquer layer 33 as layers with comparatively low transparency cast a shadow on the substrate. Depending on the tension of the film 10 when it is introduced, the film 10 is folded in a wide variety of shapes and sizes, and small folds concentrated several times over from large, individual folds, and thus, due to the imperfections introduced as a result, correspondingly varying, optically variable effects are generated.

Example 3:

As illustrated by FIG. 7a, a plate 31 is first made of a

preferably transparent polycarbonate on the front side in the form of a pattern with a colored lacquer layer 32, preferably screen-printed. The plates 31 preferably have a layer thickness of 750 μm. The lacquer layer 32 is

preferably in a layer thickness of 1 μm to 20 μm, preferably 5 μm to 15 μm, for example 10 μm. The paint is

preferably a one-component acrylate system.

A lacquer layer 33 is then printed over the entire surface, which is preferably a full-area, matt and transparent protective lacquer layer. A solvent-based hybrid paint is preferably used as the paint.

The lacquer is preferably printed in a layer thickness of 1 μm to 20 μm, preferably 5 μm to 15 μm, for example 10 μm.

The substrate 30 produced in this way is then deformed using a deep-drawing mold at a tool temperature of approximately 100 ° Celsius and a deformation temperature of approximately 140 ° Celsius. Processes such as milling and UV irradiation, trimming, cleaning, etc. are optionally carried out. In a subsequent step, as already explained above, in the film 10 with the carrier layer 11 and the one or more decorative layers 12,

For example, a decorative layer 12 formed from a chrome layer, impurities introduced, for example by appropriate creasing, folding, cutting, punching, etc.

The film 10 pretreated in this way is then provided on the edge in areas with an adhesive layer 40, for example polyimide stickers with a layer thickness of 50 μm, and thus attached to the back of the thermoformed substrate 30. Furthermore, it is also possible for the imperfections to be introduced into the film 10 only after it has been fastened to the substrate 30 and / or the introduction of the imperfections to take place in the film 10 before and after the fastening. It is quite advantageous, for example, to introduce predetermined breaking points by means of a cutting tool only after the film 10 has been attached to the substrate 30.

After this pretreatment, the substrate 30 is with the film 10 in a

Injection mold inserted and back-injected with the plastic material 20, for example a transparent polycarbonate, at a mold temperature of 65 ° Celsius.

During the injection molding process, the melted plastic material 20 is applied to the film 10 and by the prevailing during the injection molding process

Temperatures and pressures of the film 10 visually in the range of

The predetermined breaking points are changed, as already mentioned above with reference to FIGS. 4a to 4c

clarified.

During the injection molding process, the film 10 is thus enclosed between the substrate 30 and the back-molded substrate, formed by the plastic material 20, and is, as already explained above, in its spatial position and during the injection molding process Alignment in the volume of the plastic material locally positioned differently.

This effect is illustrated by way of example in FIG. 7b: FIG. 7b shows the plastic part after the injection molding process has been carried out: the plastic part has on the

The substrate 30 with the plate 31 and the lacquer layers 32 and 33 are on top. This is followed by the composite of plastic material 20 and film 10. As indicated in FIG. 7b, the spatial position and alignment of the carrier layer 11 and the one or more decorative layers 12 of the film 10 in the volume of the plastic material 20 are changed in the area of the imperfections, whereby the optical effects already explained above, in particular an optical depth effect, are generated.

The plastic part produced in this way has a very strong optical depth effect and shadow effect. This is because the film 10 is distributed in the depth of the substrate consisting of the plastic material 20 and so the regions of the film 10 lying in the upper region of this substrate cast a shadow on the regions of the film 10 lying in the lower region of this substrate.

Due to the transparent layers of the film 10, for example the

Carrier layer 11 and the upper decorative layer 12 made of a translucent color layer, the plastic part can be used in the areas where there is no covering,

opaque screen printing varnish was applied, be backlit. When backlighting, interesting plays of light result from the sub-areas of the decorative layer 12 and / or film 10, which are in the depth of the volume of the

Distribute plastic material 20. The lighting effects can have different, novel appearances. In particular, the different positions of the film parts in the plastic material result in different ones

Refractions and reflections. Another special light effect can be achieved through different transparency through more or less often superimposed Foil parts are created, which results in different degrees of transparency in the respective areas. Ultimately, these lighting effects can occur individually as well as in combination.

Example 4:

The plastic part produced according to example 2 with the printed substrate 30 and the film 10 “flowing” in the plastic material 20 is individualized and / or personalized as the base material in a further processing step. Business cards or other personal items, for example, are made from this. For

Business cards are punched and / or lasered from the basic material, for example, in credit card format. Personalization then takes place by means of hot stamping and / or digital printing and / or

Laser marking and / or punching etc.

Example 5:

The film 10 used is a film consisting of a deep-drawable PET film as the carrier layer 11, a translucent color layer as the first decorative layer 12 and an aluminum layer as the second decorative layer 12 underneath. The film thus has an orange-metallic or gold-colored appearance.

The film 10 is fed manually to the extrusion process according to FIG. 3, a liquid, transparent PC being used as the plastic material 20, which, as already explained above with reference to FIG. 3, is brought into contact with the film 10 in a melted and therefore liquid state. The tension of the film when it is introduced into the roll gap between the two extrusion rolls 35 is varied randomly or pseudo randomly or not by chance. The plastic material 20 has a layer thickness of, for example, 750 μm. The distance between the rollers is 0.5 mm, with a flow rate of the plastic material 20 of 4.8 m per minute.

After a cooling step, the plastic part produced in this way is packaged as sheet goods 31 and screen printed on the back, that is to say on the rear

Main surface of the plastic part, which is formed by the transparent PC plastic material as well as by the metal orange foil, is screen-printed in a pattern with a colored lacquer 32, in particular with a solvent-based black lacquer, preferably printed twice. The lacquer is preferably printed on in a layer thickness of 1 μm to 20 μm, preferably in a layer thickness of 5 μm to 15 μm, for example in a layer thickness of 10 μm.

Then the front, i.e. the front main surface of the

Plastic part, which is formed by the transparent PC plastic material as well as by the metal orange foil, printed in pattern form in screen printing with a colored varnish, in particular with a solvent-based white varnish 33. The paint is preferably in a layer thickness of 1 pm to 20 pm, preferably in one

Layer thickness from 5 pm to 15 pm, for example printed in a layer thickness of 10 pm.

The plastic part produced in this way is then deformed using a deep-drawing mold at a tool temperature of about 80 ° C to 120 ° C, preferably 100 ° C and a deformation temperature of about 100 ° C to 180 ° C, preferably 140 ° C.

The deformed plastic part is then trimmed, in particular milled and cleaned. In a subsequent step, a further film 10, in particular with a carrier layer 11 and decorative layers 12 arranged thereon, is provided. As already explained above, impurities are then introduced into this further film, for example similar to the orange-metallic film already mentioned above, for example by appropriate creasing, folding, cutting, punching, etc. It is also possible to use this further film without To introduce imperfections.

Subsequently, the further film pretreated in this way is provided on the edge in areas with an adhesive layer, for example polyimide stickers with a layer thickness of about 50 μm, and thus on the back of the thermoformed

Plastic part attached. Furthermore, it is also possible for the imperfections to be introduced into the film only after it has been fastened to the plastic part and / or the introduction of the imperfections into the film before and after fastening on the

Plastic part takes place. It is advantageous, for example, to introduce predetermined breaking points by means of a cutting tool only after the film has been attached to the plastic part.

After this pretreatment, the plastic part with the further film is placed in an injection mold and at a mold temperature of about 40 ° C to 90 ° C, preferably 65 ° C with the plastic material, for example a

back-molded transparent polycarbonate. In a further step that will

Plastic part with the other film still flooded with polyurethane on the front.

In the injection molding process, the melted plastic material is applied to the further film and to the plastic part and through the

Injection molding process prevailing temperatures and pressures the film accordingly optically changed in the area of the predetermined breaking points, as already illustrated above with reference to FIGS. 4a to 4c.

During the injection molding process, the further film is thus enclosed between the plastic part and the injected plastic material and is used during the

Injection molding process, as already explained above, in their spatial location and

Alignment in the volume of the plastic material locally positioned differently.

This effect is illustrated by way of example in FIG. 8b: FIG. 8b shows the plastic part after the injection molding process has been carried out: the plastic part has on the

The substrate 30 with the plate 31 and the lacquer layers 32 and 33 are on top. This is followed by the composite of plastic material 20 and film 10. As indicated in FIG. 8b, the spatial position and alignment of the carrier layer 11 and the one or more decorative layers 12 of the film 10 in the volume of the plastic material 20 are changed in the area of the imperfections, whereby the optical effects already explained above, in particular an optical depth effect, are generated.

Due to the transparent layers of the film 10, for example the

opaque screen printing varnish was applied, be backlit. With backlighting, interesting plays of light result from the sub-areas of the Decorative layer 12 and / or film 10, which are distributed in the depth of the volume of the plastic material 20. The lighting effects can have different, novel appearances. In particular, the different positions of the film parts in the plastic material result in different ones

Refractions and reflections. Another special light effect can result from different transparency due to more or less often superimposed foil parts, which results in different degrees of transparency in the respective areas. Ultimately, these lighting effects can occur individually as well as in combination.

Example 6:

The decorative layers 12 located on the carrier layer 11 of the foil 10 are partially arranged with an injection-unstable adhesion promoter 16 (e.g. hot-melt adhesive) on the carrier layer 11, which in the desired design, pattern-like or flat on the foil, in particular on the the carrier layer 1 1 facing side of the decorative layers is applied. That is, this adhesion promoter layer is arranged between the carrier layer 11 and the decorative layers 12. In this case, “injection unstable” means that this bonding agent 16

is thermally and mechanically unstable, in particular at the pressures and temperatures occurring during an injection molding process, and is also liquefied and washed away, especially when it is hit by liquefied injection molding material. In particular, the injection-unstable adhesion promoter 16 is significantly less thermally and mechanically stable than areas of the decorative layer 12 without this injection-unstable adhesion promoter 16 therein

Injection molding process. The back of the film, ie with the carrier material side, can be laminated onto a further carrier material 11, for example polycarbonate, PMMA or ABS.

In an injection molding process, the points at which the injection-unstable adhesion promoter 16 is located (due to the action of heat and / or the injection molding pressure) are removed from the carrier material 20 and from the composite of

Decorative layers 12 are released and can thus flow into the injected plastic material 11. The remaining injection-stable areas 15 of the decorative layer 12, however, remain in position on the carrier material 20. This creates a decoration with a previously defined release decoration (the places where the injection-unstable adhesion promoter 16 was), with at the same time interesting depth and depth Light effects, due to the detached decorative particles floating behind, as indicated in FIG. 9b.

List of reference numbers:

I plastic part

10 slide

I I carrier layer

12 decorative layer

13 release layer

14 protective layer

15 adhesive and / or bonding layer

16 adhesion promoter layer

20 plastic material

21 plastic granulate

30 substrate

31 plate

32 layer of paint

33 layer of paint

40 adhesive layer

50 extruder

51 Reservoir

52 extruder

53 extrusion roller

61 Interference

62 Interference

I I I main area

112 main area

Claims

Expectations :

1. A method for producing a decorated plastic part (1), comprising the steps,

- providing a film (10),

- at least regionally applying at least one

Plastic material (20) on the film (10) in a processing process,

- Introduction of imperfections (61,62) into the film (10) in such a way that the imperfections (61,62) are optically recognizable after the processing process, in particular through the plastic material (10), in particular through a depth effect and / or 3D Effect and / or transparency effects are visually recognizable.

2. The method according to claim 1,

characterized ,

that the film (10) has at least one carrier layer (11) and at least one decorative layer (12) or that the film (10) is formed in one layer, in particular from a layer of plastic or metal or paper.

3. The method according to any one of the preceding claims,

characterized ,

that the plastic material (20) is melted before being applied to the film (10) and when the plastic material (20) is applied, the melted plastic material (20) is brought into contact with the film (10).

4. The method according to any one of the preceding claims,

characterized ,

that the melted plastic material (20) is applied to the film (10) in such a way that the melted plastic material (20) touches the film on at least one main surface (111, 112)

Covered in areas, preferably covered and / or enveloped over the entire area.

5. The method according to any one of the preceding claims,

characterized ,

that the film (10) is enveloped on all sides by the plastic material (20) during the processing process.

6. The method according to any one of the preceding claims,

characterized ,

that the plastic material is a thermoplastic plastic material, in particular containing PET, ABS, PMMA, PP, PS.

7. The method according to any one of the preceding claims,

characterized ,

that the plastic material (20) is a transparent or translucent plastic material.

8. The method according to any one of the preceding claims,

characterized ,

that the plastic material (20) is an optically diffusing plastic material.

9. The method according to any one of the preceding claims,

characterized ,

that the plastic material (20) has a glass transition temperature between 60 ° C and 300 ° C, preferably between 90 ° C and 150 ° C.

10. The method according to any one of the preceding claims,

characterized ,

that the plastic material with a pressure between 10 bar and 700 bar, preferably between 10 bar and 300 bar and / or at a temperature between 60 ° C and 300 ° C, in particular between 210 ° C and 240 ° C, against the film (10 ) is pressed.

11. The method according to any one of the preceding claims,

characterized ,

that the faults (61, 62) before and / or during the

Processing process are introduced.

12. The method according to any one of the preceding claims,

characterized ,

that the imperfections (61, 62) are introduced into the film (10) before the plastic material (20) is applied.

13. The method according to any one of the preceding claims,

characterized ,

that the imperfections (61,62) by regional detachment of one or a plurality of decorative layers (12) from the carrier layer (11) and / or a local change in the position of partial areas one or more

Decorative layers, in particular a local tilting against a main surface of the plastic part, and / or a local separation of one or more decorative layers (12) are optically recognizable.

14. The method according to any one of the preceding claims, characterized

characterized in that the imperfections (61, 62) are changed in the processing by the conditions prevailing there, in particular pressure and / or temperature, in particular by warping and / or deformation of the film (10) in the area of the imperfections (61, 62) , by

Tearing of the film (10) or one or more decorative layers (12) of the film in the area of the imperfections (61, 62), by detaching one or more decorative layers (12) of the film in the area of the imperfections and / or enlargement of a local severance and / or plastic deformation of the film or one or more of the decorative layers (12) of the film in the area of the imperfections, preferably by more than 15 percent, more preferably by more than 40 percent, more preferably by more than 60 percent.

15. The method according to any one of the preceding claims,

characterized ,

that by applying the plastic material the optical

The appearance of the plastic part in the area of the imperfections is changed.

16. The method according to any one of the preceding claims,

characterized ,

that during the processing one or more of the Decorative layers (12) of the film in the vicinity of the imperfections (61, 62) are destroyed or largely destroyed.

17. The method according to any one of the preceding claims,

characterized ,

that during the manufacturing process the optical appearance of the film (10) in the area of the imperfections is visually recognizable compared to an area without imperfections due to thermal and / or mechanical and / or chemical influences.

18. The method according to any one of the preceding claims,

characterized ,

that the local optical change of the film occurring in the area of the introduced imperfections is preserved by the solidified plastic material.

19. The method according to any one of the preceding claims,

characterized ,

that one or more first imperfections (61) of the imperfections of

Predetermined breaking points are formed, with the introduction of the first

Defects due to mechanical damage to one or more layers of the film (10), predetermined breaking points in several layers of the film, in particular in one or more of the decorative layers of the film.

20. The method according to claim 19,

characterized ,

that to introduce the first imperfections (61) one or more

Layers of the film (10) are at least partially severed, in particular mechanically, in particular by cutting, punching, scratching, engraving, at least partially separated, and / or by means of irradiation, in particular by means of a laser, an electron beam or a thermal source and / or chemically, in particular by means of etching, at least partially severed and / or weakened will.

21. The method according to any one of claims 19 and 20,

characterized ,

that one or more first predetermined breaking points differ from one another

differentiate, in particular in the lateral extent or surface shape, the severed layers and / or the depth of the severance of layers of the film.

22. The method according to any one of the preceding claims,

characterized ,

that one or more second imperfections (62) of the imperfections of

Bending points are formed, with the introduction of the second

Defects (62) in particular one or more layers of the film (10) in the area of the bending points are plastically deformed and / or broken by bending and / or causing local detachment of one or more decorative layers of the film from at least one adjoining layer of the film by bending becomes.

23. The method according to claim 22,

characterized ,

that the second imperfections (62) are introduced by locally bending the film (10), in particular by kinking and / or folding and / or twisting the film.

24. The method according to claim 22 and or 23,

characterized ,

that the film (10) is rotated one or more times to at least 180 ° to introduce the imperfections and the film is rotated at least two

Has decorative layers (12) with different optical appearances, which are visible from different face surfaces (111, 112) of the film in incident light and / or in transmitted light.

25. The method according to any one of claims 22 and 24,

characterized ,

that one or more second imperfections differ from one another, in particular in the lateral surface extent and / or surface shape, the plastic deformation and / or broken layers and / or in the local bending radius of the film and / or one of the decorative layers of the film in the area of the imperfection.

26. The method according to one of the preceding claims,

characterized ,

that the imperfections (61) are introduced according to a regular or irregular grid or randomly or pseudo-randomly.

27. The method according to any one of the preceding claims,

characterized ,

that in the processing process two or more different

Plastic materials (20) are applied to the film (10), in particular applied to opposite main surfaces (111, 112) of the film.

28. The method according to any one of the preceding claims,

characterized , that the film (10) is fed two or more times to the manufacturing process.

29. The method according to any one of the preceding claims,

characterized ,

that the manufacturing process is an extrusion process and the plastic material is an extrusion material of the

Extrusion process.

30. The method according to claim 29,

characterized,

that the plastic material (20) is brought into contact with the film (10) before the extrusion rollers.

31. The method according to one of the preceding claims,

characterized ,

that the manufacturing process is a process selected from: injection molding process, lamination process, deep drawing process.

32. Method according to one of the preceding claims,

characterized ,

that after the processing process has been carried out, one or more further layers (31, 32, 33) are applied to the plastic material (20) and / or the film (10) for forming the plastic part.

33. Method according to one of the preceding claims,

characterized ,

that the film is a transfer film or laminating film.

34. Method according to one of the preceding claims,

characterized ,

that the carrier layer of the film is selected from: PTT, PCM, PMM

35. Method according to one of the preceding claims,

characterized ,

that the carrier layer (11) of the film has a layer thickness between 10 μm and 200 μm.

36. Method according to one of the preceding claims,

characterized ,

that the decorative layer (12) of the film or one or more of the

Decorative layers (12) are selected from: lacquer layer, in particular containing one or more colorants and / or pigments, metal layer, in particular made of several different metals, reflective layer, in particular consisting of one or more HRI or LRI layers, relief layer having an optically active surface relief,

in particular a diffractive structure, a hologram, a matt structure, a refractive structure, in particular a microlens structure

Zero order diffraction grating, a thin film element that generates a color shift effect through interference, a layer for generating color effects in transmitted light by means of plasmon resonance.

37. The method according to one of the preceding claims,

characterized ,

that the one or more decorative layers are partially pattern-shaped or over the entire area, in particular with a layer thickness between 0.1 μm and 20 μm.

38. Decorated plastic part, in particular produced according to one of claims 1 to 37,

characterized,

that the plastic part (1) has a film (10) and one that is applied to the film at least in some areas in a processing process

Has plastic material (20), with defects (61,62) being introduced into the film such that the defects (61,62) after

Processing process, in particular through the plastic material (20), are optically recognizable, in particular through a depth effect and / or 3D effect and / or transparency effects are optically recognizable.