DE102007009583B4 - Process for producing a composite molding - Google Patents

Abstract

Method for producing a composite molded part made of plastic with at least one partially provided plastic film, wherein in a first step, the plastic film for the outside metallization is partially printed with a primer, - in a second process step, possibly in addition to the inside - And / or the outside of the printed plastic ink-printed film is brought in a high pressure through a die in a desired shape, - in a third step, the cutting of the molded plastic film part takes place - in a fourth step, the molded plastic film part or parts into a first Tool half of a Hinterspritzwerkzeuges be inserted, and - in a fifth step after closing the tool with the second half of the preformed plastic film part or parts by means of plastic behind spraying and - in a sixth step in an electroless plating bath or in a plating bath or by vapor deposition, the metallization of the surfaces of the plastic film parts takes place on the surfaces provided with adhesion promoter.

Description

The invention relates to a method for producing a composite molding made of plastic with at least one partially provided plastic film.

From the DE 102 34 125 A1 is an illuminable plastic injection molded part with a display function, in particular as a control panel for a switching device, known. In the visible surface area, the part has an electroluminescent film that is positively connected to the plastic injection-molded part. On a second surface region of the plastic injection molded part conductor tracks for the voltage supply of the electroluminescent film are applied. To produce such a plastic injection-molded part, a method is proposed in which an electroluminescent film is back-injected with a metallizable, thermoplastic plastic material in an injection mold and then a metal layer is applied to line-shaped regions of the plastic injection molded part for producing printed conductors to terminal contacts of the electroluminescent. In this document, the so-called 3-D MID technology is described, can be used at the same time as electrical circuits and components with the surfaces of almost arbitrarily shaped injection molded parts made of thermoplastic materials. For the production of 3-D MID components, the 2K injection process with subsequent selective metallization as well as the hot embossing of metal foils on injection-molded substrate surfaces is described. As a further advantage, the back molding of the patterned conductor tracks film is called. Here, first conductor tracks are applied to the film and then the film thus produced is back-injected. Also, a decorative print on the one and the circuit diagram on the other side of the film may be applied.

In the method for producing a plastic injection-molded part described in the aforementioned patent application, the electroluminescent film is provided with a metallizable thermoplastic material in an injection mold and the application of a metal layer to line-shaped regions of the plastic injection molded part for producing printed conductors and connection contacts for the electroluminescent film. In a particular embodiment, it is provided that the metallizable thermoplastic material is laser-activatable and, prior to the application of the metal layer, the line-shaped regions of the plastic injection-molded part are first activated by means of a laser. Laser-activatable metallisable thermoplastic materials have metal particles in the plastic mass. By means of a laser in the areas to be metallized, the metal particles are exposed by a small amount of the plastic material is removed. By means of a chemical metal coating, which can be effected without current, a metal layer for the production of the conductive paths is subsequently applied to the laser-activated regions. Such a deposited metal layer can then be galvanically reinforced in a known manner. The electroluminescent film has a surface design, the z. B. corresponds to a key to be produced. This film is placed in an injection mold and back-injected in this, wherein a positive and material-locking connection between the EL film and the plastic material takes place. For contacting the same can then be applied in the manner described, the conductor tracks.

From the DE 10 2005 007 864 A1 is a trim device for covering photometrically not relevant sections of a luminaire assembly of suitable plastic known, the entire surface is uniformly treated and, for example, mirror-finished. For this purpose, on the visible surface a coating, for. As aluminum, chromium and / or silver or an alloy thereof, evaporated. Instead of CVD (Chemical Vapor Deposition) or PVD (Physical Vapor Deposition), other methods are discussed there to apply the metal layer, e.g. As spraying, vapor deposition, deposition, spin coating, sputtering or the like. As an alternative, the attachment of a metal-coated plastic film or a plastic-coated metal foil is addressed, with which the base trim can be laminated.

From the DE 10 2004 060 453 A1 is a multilayer plastic part for decorative elements and / or functional elements of a transparent support member with applied layers known which have two opposite sides, wherein on one side of the support member at least in some areas an optically active layer is applied, which is associated with a diaphragm, which prevents the light transmission in partial areas and which can be backlit with a light source. It is further stated that the optically active layers of both metals, such as aluminum or chromium, or even of metal alloys consisting of chromium and aluminum or nickel and chromium, or of metal compounds, such as titanium nitrite (TiN) or titanium carbide (TiC), or other colored translucent layers, such as paint, color or film layers can exist. By means of a laser ablation process, a complete or partial starting from the first side and / or the second side of the plastic part Ablation of the metal layer can be achieved. For this purpose, the laser beam strikes the optically active layer, which is arranged on the first side, and dissolves the metal layer by heating and Absprengprozesse, so that a light transmission is achieved.

• a) eine Kunststofffolie, die auf einer Seite beschichtet ist, in eine erste Hälfte eines geöffneten Spritzgießwerkzeugs eingelegt wird,
• b) das Werkzeug geschlossen wird, indem die zweite Hälfte des Werkzeugs auf die erste Hälfte aufgebracht wird,
• c) die Folie im Werkzeug mit Kunststoff zur Erzeugung eines Formteils hinterspritzt wird,
• d) das Werkzeug nach Abkühlung geöffnet und die zweite Hälfte des Werkzeugs entfernt werden,
• e) danach das Werkzeug mittels einer Werkzeughälfte, die gegebenenfalls mit externem Formtrennmittel versehen ist, wieder geschlossen wird und dabei eine Kavität zwischen der Wand dieser Werkzeughälfte und dem Formteil erzeugt wird,
• f) in die Kavität ein Lack eingespritzt wird, und
• g) das Werkzeug nach Aushärtung des Lackes geöffnet wird und das lackierte Formteil entnommen wird.

From the DE 10 2004 062 477 A1 a method for producing a composite part of several layers is known, wherein

• a) a plastic film coated on one side is placed in a first half of an opened injection mold,
• b) the tool is closed by applying the second half of the tool to the first half,
• c) the film in the tool is back-injected with plastic to produce a molded part,
• d) the tool is opened after cooling and the second half of the tool is removed,
• e) thereafter the tool is closed again by means of a tool half, optionally provided with an external mold release agent, thereby producing a cavity between the wall of this mold half and the mold part,
• f) a paint is injected into the cavity, and
• g) the tool is opened after curing of the paint and the painted part is removed.

The film used is preferably a transparent film of plastic material, such as polycarbonate (PC), polymethyl methacrylate (PMMA), styrene acrylonitrile (SAN) and cyclopolyolefin copolymers (COC), transparent polyamide and blends of these plastics. As plastic for the back molding preferably PC, PMMA, SAN and COC is used. The plastics for the back molding are also preferably transparent according to this document. Metallization is not mentioned in this document.

From the DE 199 57 850 A1 For example, a method of coating a support member with a cover material and associated apparatus is known. The cover material is z. B. a plastic film. The flat cover material is acted upon directly with a pressurized fluid and formed by the direct isostatic action of the pressure fluid three-dimensionally on the support member. The coating of the carrier material with the reference material thus takes place without mechanical contact in a press die, preform punch or a membrane. As a result, a particularly good surface quality can be achieved. As pressure fluid, a gas is used under a pressure in the range of 20 bar to 300 bar. As a film material, a plastic film or a metal foil can be used. The plastic films may optionally be provided with a hardcoat coating to increase scratch resistance. It is also possible to use a two-layered combination of plastic film and metal foil.

The applied in relation to the subject invention method for producing a three-dimensional decorative molding is z. B. from the earlier utility model application DE 20 2006 019 658 U1 the applicant, which is specially used for the deformation of films coated with synthetic or natural fibers or with fibrous material. The coating is located at the bottom of the film. This high pressure method is further from the EP 0 943 410 A1 and from the EP 0 371 425 B1 as well as from the DE 41 13 568 C2 known.

• – Bereitstellen einer Bauteil-Form,
• – Anpassen einer Folie an die Form,
• – Einlegen der Folie in die Form,
• – zumindest teilweises Hinterfüllen der Folie in der Form mit mindestens einer Kunststoffschicht, wobei mindestens ein Loch in der Folie mit vorgegebener Kontur vor dem Hinterfüllen eingebracht wird und durch das Hinterfüllen bewirkt wird, dass der Kunststoff das Loch verfüllt.

From the DE 10 2004 012 467 B4 is a vehicle foil component and a method for its production with the following steps:

• Providing a component mold,
• - fitting a foil to the mold,
• Inserting the foil into the mold,
• - At least partially backfilling the film in the mold with at least one plastic layer, wherein at least one hole in the film with a predetermined contour is introduced before the backfilling and is caused by the backfilling that the plastic filled the hole.

The document further specifies that in a preferred embodiment of the component, the plastic is electrochromic and in particular contains polyaniline. Another suitable eletrochromeric plastic should be polymeta-toluidine. The plastic itself may be a thermoset, in particular a synthetic resin, or a thermoplastic. The deformation of the film takes place in the tool during injection molding. Furthermore, there is no indication as to how a metallization or galvanic coating or electroless plating should take place.

From the WO 2006/114429 A2 is a metallizable film or plate made of a plastic mixture, known. In particular, it contains 50 to 95 wt .-% of a metal powder having average particle diameters of 0.01 to 100 microns with specific particle diameters and potential assignment. A galvanic layer can be applied to this layer, without further pretreatment. This metallic layer can be applied to an A component, for. B. of thermoplastics, such as polyethylene, polypropylene or ABS (acrylonitrile-butadiene-styrene) or ASA (acrylonitrile-styrene-acrylate) apply. The films or plates are thermoformed over a large area, which is known to occur at temperatures in the range of ≥ 200 °. The moldings are then back-injected or backfoamed, back-poured or installed as a pressed part. The outer one Layer is provided as a current-depositing layer to which copper, chromium, silver, gold and / or nickel layers are applied in the galvanic bath. The application can also be carried out by vacuum evaporation, irradiation or spraying. The polymer bodies provided with special metal layers may be trim strips, exterior mirrors, grille fronts, wind deflectors and exterior body parts as well as door sills, door panels, spare parts, wheel covers.

There is in particular the desire for decorative parts in the automotive sector, metallized surfaces and edges visibly appear in appearance, for. B. highlight the functional elements and boundary lines and edges in a metallic effect. The invention is therefore based on the object of specifying a method which enables the production of a specially manufactured composite molding made of plastic with at least one partially provided plastic film, the at least partially metallized surfaces or lines or stripes and / or incorporated in the metallic surface in the field of plastic film Has symbols, surface elements and characters.

• – in einem ersten Schritt die Kunststofffolie für die außenseitige Metallisierung mit einem Haftvermittler partiell bedruckt wird,
• – in einem zweiten Verfahrensschritt die eventuell zusätzlich an der Innen- und/oder der Außenseite mit Druckfarbe bedruckte Kunststofffolie im Hochdruckverfahren berührungslos über eine Matrize in eine gewünschte Form gebracht wird,
• – in einem dritten Verfahrensschritt der Zuschnitt des ausgeformten Kunststofffolienteils erfolgt,
• – in einem vierten Schritt das ausgeformte Kunststofffolienteil oder die -teile in eine erste Werkzeughälfte eines Hinterspritzwerkzeuges eingelegt werden, und
• – in einem fünften Schritt nach dem Verschließen des Werkzeuges mit der zweiten Hälfte das vorgeformte Kunststofffolienteil oder die -teile mittels Kunststoff hinterspritzt werden und
• – in einem sechsten Schritt in einem stromlosen chemischen Metallisierungsbad oder in einem Galvanisierungsbad oder durch Bedampfen die Metallisierung der Oberflächen der Kunststofffolienteile an den mit Haftvermittler versehenen Flächen erfolgt.

The object is achieved by the method specified in claim 1 for producing a composite molding made of plastic with at least one partially provided plastic film, wherein when using a non-metallizable plastic film

• - In a first step, the plastic film for the outside metallization is partially printed with a primer,
• In a second method step, the plastic film optionally additionally printed on the inside and / or the outside with printing ink is brought into a desired shape in a contactless manner via a die in the high-pressure method,
• In a third method step, the blank of the molded plastic film part is cut,
• - In a fourth step, the molded plastic film part or parts are inserted into a first mold half of a Hinterspritzwerkzeuges, and
• - In a fifth step after closing the tool with the second half of the preformed plastic film part or the parts are back-injected by means of plastic and
• - In a sixth step in an electroless plating bath or in a plating bath or by vaporization, the metallization of the surfaces of the plastic film parts takes place at the areas provided with primer.

The object is also achieved by a method for producing a composite molding made of plastic with at least one partially provided plastic film in conjunction with the features of claim 2. Advantageous further method steps are specified in claim 3.

The production of a composite molding according to the invention can be further realized in that in a first process step, the plastic film for the inside metallization is partially printed with a primer, that in a second process step, the metallization in the partial region of the applied adhesion promoter takes place, that in a third Process step the metallized and / or additionally printed on the inside with color plastic film is brought in a high pressure through a die in a desired shape and in a fourth step, the molded plastic film part or parts are inserted into a first mold half of a Hinterspritzwerkzeuges and that in one further step after closing the tool with the second half, the preformed plastic film part or parts are back-injected by means of plastic.

Alternatively, however, the production method can also provide that the metallization takes place, for example, in edge regions subsequently after the film has been injected behind it. The method then provides that in a first process step on the outside of the plastic films in the region of the desired metallization coating adhesion promoter is applied, that in a further step and in the high pressure process, the plastic film parts are formed, that in a third step, the preformed plastic film parts in a first Inserted mold half and after closing with a second mold half are back-injected with plastic, that in a further, step after removal of the molding from the tool, the plastic film part with the primer layer in a plating bath for electroless shutdown galvanized and / or galvanized and that in one Another step is a galvanic Nachmetallisierung.

If further printing is to be carried out, it is also recommended, in an upstream step after the metallization, to print using inks with colored pigments.

A composite part, which is manufactured according to the teaching of claim 1, is characterized in that the plastic film consists of a material with partially machined zones, which can be electroless metallized or electroplated in a galvanized bath acted upon with electricity or metallized with metal, wherein the plastic film either metallized or galvanized on the inside or on the outside and back-injected with plastic. Of the Cutting the plastic film can cover the entire visible surface of the composite molding or even be provided only partially.

It is also possible to provide a non-electroplatable or not provided with appropriately machinable zones plastic film with openings that cut free those areas that are electroless metallized or galvanized or vapor-deposited with metal, and to inject the plastic film with such a plastic, the de-energized metallizable or electroplated or partially for the electroless or electroplating or vapor deposition with metal can be processed in those places that fill the cut-out areas of the plastic film, these areas are at least partially electroless metallizable or electroplated or metallized with metal.

In one embodiment, the plastic film of electroless metallisable material, eg. B. of ABS, and is as a whole in the high pressure process three-dimensional preformed so that it reproduces the desired surface contour of the composite molding at the corresponding partial locations. After the deformation process, either the parts are cut out or cut open by introducing apertures the frame structure having parts in order to insert them for injection molding in a mold half and to inject behind with a connectable plastic. For example, the back-injected body made of polycarbonate. Before the deformation process in the high-pressure process on the inside or on the inside of the film also prints can be applied, provided that it is transparent at the inside mounting. The metallization of the film can basically be done before or after the back molding. The metallization can be carried out without current in a chemo-galvanic bath or in a current-carrying galvanic bath or by vapor deposition. These procedures are all known. Plastics can in principle be vaporized as finished or semifinished with metals, by reduction, for. As with hydrazine, of metal ions, similar to the mirror fabrication, coat with metals and particularly well chemo-galvanic and partly also metallize galvanized, z. B. chrome plating, nickel plating, copper plating, silver plating, gold plating, u. a. Also, a galvanic amplification of chemically applied metal layers is possible. For this purpose, in principle, the various plastics are suitable, from which the film can be produced, as well as a plastic, which forms the body of the composite molding by injection. Also, the surface of the film can be wetted with adhesion promoters, which favor or enable the metallization.

The plastic film that needs to be provided on the composite molding only partially or extends over the entire visible surface, on the inside, ie the side that is back-injected with plastic, metallized, z. B. chromed, or have partial surfaces that are metallized. Alternatively, however, the metallization layer can also be applied on the outside or the partial areas can be metallized. The metallization itself takes place when mounted on the inside before the back molding. When mounted on the outside, this can be applied before the back molding, but also alternatively after the back injection, applied for the purpose on the outside of the film prior to application or injection molding primer for the electroless metal deposition in a chemical metallization or the metallizable film is processed so that it is partially metallizable. The methods for this are known, as already explained above with reference to the prior art. However, the metallization layer can also be applied by vapor deposition, both on the inside and on the outside. Again, the known methods can be used. By combining plastic body and plastic film, it is possible to preform the plastic film or film parts before injection molding in an injection mold according to the desired surface contour in the high pressure process. The films or film sections that are to be metallized, for example, in the edge regions, are inserted into a first mold half and back-injected after shooting the tool with a plastic compound, so that a composite molded part is formed. This composite molding may already have the metallization on the film. However, these can also, if the specific zones are coated or prepared with adhesion promoters, subsequently metallized in a chemical metallization and possibly reinforced by galvanization.

The applied high-pressure method for non-contact deformation of the film sections is also described in the beginning with reference to the prior art and can be used here. Also, the known films mentioned above can be used to be deformed by the printing process to three-dimensional bodies, which are then back-injected to form a composite molding. For metallization, especially when it comes to achieving special metallic optical effects, chromium, silver, aluminum and their alloys are particularly suitable. But also gloss copper layers can be applied. Furthermore, the film itself may also be a film which is through-dyed or transparent; a transparent film or else a film provided with luminescent pigments can also be used.

If the plastic film translucent zones or translucent and opaque zones, the z. B. are produced by printing, so it is possible to provide channels or openings in the back-injected plastic, which are covered by these games or connected to a translucent sublayer, by the light of a light source, for. B. an LED, can pass. Thus, for example, punctiform or slit-shaped backlighting can be realized in a simple manner. If a metal layer is introduced in this area, ornaments, signs or symbols can be introduced by removing the metal layer in this area by laser, so that they can be backlit. The same can also be achieved in the area if, for example, a translucent plastic is used for the back molding and only a thinner carrier layer is applied.

The invention will be explained in the following with reference to the composite components shown schematically in the drawings.

In the 1A to 1E an example is shown in which the film used 1 is not electroplated while the plastic 5 the molding is galvanisable. 1A shows a plastic film 1 in flat dimension, 1B a tailored contour 2 with breakthrough 3 and end faces 4 , This cut film is in a known manner by means of a galvanisable plastic 5 back-molded. This plastic closes flush with the surface of the film 1 from. After inserting the prefabricated composite molding in a galvanic bath 6 ( 1D ) will, as out 1E visible, only a metal layer as galvanic layer 8th Applied to the surface of the body while the surface of the film 1 is not metallized.

In the 2A to 2E is shown that differs from the example according to the 1A to 1E Even with three-dimensional design of the plastic film, the same partial coating of the composite molding is possible. The plastic film 1 is first preformed three-dimensionally in the high-pressure process and the contour 2 according to 2 B tailored as well as a breakthrough 3 brought in. The faces of the film are how out 4C can be seen from the galvanisable plastic 5 embedded in the injection body. The prefabricated part is then placed in a galvanic bath 6 mounted and the molded body made of galvanisable plastic to the cathode of the DC voltage source 7 connected so that in the desired manner, a galvanic coating of the surface of the body takes place, consisting of the plastic film 1 protrudes. The inside coating can be prevented in a known manner by applying a non-electroplatable layer.

A processing of partially galvanized or metallized or vaporized film is also possible. In principle, such a film can also be deformed in the high-pressure method with appropriate technical shaping.

LIST OF REFERENCE NUMBERS

1

Plastic film

2

Contour / outline blank

3

Clear Cut / Breakthrough

4

front

5

non-galvanisable plastic

6

electroplating bath

7

DC voltage source

8th

plating

9

Plastic top

Claims (3)

A method for producing a composite molding made of plastic with at least one partially provided plastic film, wherein when using a non-metallizable plastic film - In a first step, the plastic film for the outside metallization is partially printed with a primer, In a second method step, the plastic film optionally additionally printed on the inside and / or the outside with printing ink is brought into a desired shape in a contactless manner via a die in the high-pressure method, In a third method step, the blank of the molded plastic film part is cut, - In a fourth step, the molded plastic film part or parts are inserted into a first mold half of a Hinterspritzwerkzeuges, and - In a fifth step after closing the tool with the second half of the preformed plastic film part or the parts are back-injected by means of plastic and - In a sixth step in an electroless plating bath or in a plating bath or by vaporization, the metallization of the surfaces of the plastic film parts takes place at the areas provided with primer. Method for producing a composite molding made of plastic with at least one partially provided plastic film, wherein - in a first step on the outside of the plastic films in the region of the desired metallization coating adhesion promoter is applied, - in a second step in the high pressure process, the plastic film parts are formed - In a third step, the preformed plastic film parts are inserted into a first mold half and back-molded after closing with a second mold half with plastic, and - in a fourth step after removal of the molded part from the tool, the plastic film part with the primer layer in a chemical bath to electroless deposition or placed in a galvanic bath for metallization or galvanic Nachmetallisierung. A process for producing a composite molded article according to one of claims 1 or 2, characterized in that before the deformation of the plastic film in the high-pressure process, the inside and / or outside printing by means of printing inks is carried out with color pigments.

Images