FILM MOLDING TOOL, METHOD FOR PRODUCING A FILM MOLDING TOOL, AND USE OF A FILM MOLDING TOOL

Abstract

The invention relates to a film forming tool for laminating a component with a laminating element or for molding a thermoplastic film with an embossed geometry; an alternative method for embossed shell production and use of a respective film forming tool.

In particular, the invention relates to a manufacturing method for embossed shells which saves both manufacturing time and manufacturing costs and which allows a long service life as well as a high molding quality.

For this purpose, the mold shell of a film forming tool is provided with a ceramic layer which has an embossment structure, allowing a transfer of the embossment structure to the laminating element with the laminating method.

Claims

1. Film forming tool for laminating a component with a laminating element or for molding a film, wherein the film forming tool has a mold shell, characterized in that the mold shell has a metal spray coating produced by metal spraying.

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

3. Film forming tool according to claim 1, characterized in that a surface of the mold shell contains ceramics or consists of ceramics.

4. Film forming tool according to claim 1, characterized in that the surface of the mold shell has a negative embossment structure.

5. Film forming tool according to claim 1, characterized in that the surface of the mold shell is permeable to air.

6. Film forming tool according to claim 1, characterized in that the mold shell has a supporting structure on its back side.

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

8. Film forming tool according to claim 6, characterized in that the supporting structure has webs.

9. Film forming tool according to claim 6, characterized in that part of the supporting structure is made of aluminum.

10. Film forming tool according to claim 6, characterized in that an interspace of the supporting structure contains aluminum gravel.

11. Film forming tool according to claim 1, characterized in that the mold shell contains aluminum gravel on its back side.

12. Film forming tool according to claim 1, characterized in that the film forming tool has a temperature adjustment unit.

13. Film forming tool according to claim 1, characterized in that the temperature adjustment unit has a cooling channel.

14. Film forming tool according to claim 13, characterized in that the cooling channel contains copper.

15. Film forming tool according to claim 13, characterized in that part of the cooling channel extends into the metal spray coating.

16. Film forming tool according to claim 13, characterized in that part of the cooling channel extends into the supporting structure.

17. Film forming tool according to claim 13, characterized in that part of the cooling channel extends into the aluminum gravel.

18. Film forming tool according to claim 1, characterized in that the film forming tool has a cooling plate.

19. Film forming tool according to claim 18, characterized in that the cooling plate is even.

20. Film forming tool according to claim 18, characterized in that part of the cooling channel extends into the cooling plate.

21. Method of manufacturing a film forming tool, according to claim 1, characterized in that a ceramic layer is applied onto a positive model, the ceramics having an embossment, and a metal layer is sprayed onto the ceramic layer.

22. Method of manufacturing a film forming tool, according to claim 1, characterized in that a ceramic lacquer is sprayed onto a positive model and hardened, resulting in a ceramic layer, the positive model having an embossment, and a metal layer is sprayed onto the ceramic layer.

23. Method of manufacturing a film forming tool according to claim 21, characterized in that the mold shell, consisting of a ceramic layer and a metal layer, is perforated.

24. Method of manufacturing a film forming tool according to claim 21, characterized in that the mold shell is perforated by means of a laser.

25. Method of manufacturing a film forming tool according to claim 21, characterized in that a cooling channel is embedded in the mold shell.

26. Method of manufacturing a film forming tool according to claim 21, characterized in that the mold shell is connected to a supporting structure.

27. Method of manufacturing a film forming tool according to claim 21, characterized in that a cooling channel is embedded in the supporting structure.

28. Method of manufacturing a film forming tool according to claim 21, characterized in that the supporting structure is connected to a cooling plate.

29. Method of manufacturing a film forming tool according to claim 21, characterized in that a cooling channel is embedded in the cooling plate.

30. Method of manufacturing a film forming tool according to claim 21, characterized in that the mold shell is back-filled with aluminum gravel.

31. Method of manufacturing a film forming tool according to claim 21, characterized in that a cooling channel is embedded in the aluminum gravel.

32. Use of a film forming tool according to one of claims 1 through 20 claim 1 for manufacturing and laminating a component, the laminated component having an embossment, or for molding a film from an embossed film forming tool.

Description

[0160] In the following, the invention will be explained in more detail by means of two examples of embodiment for manufacturing a mold shell, as well as four examples of embodiment for extending a mold shell to form a complete film forming tool, with reference to the drawing wherein

[0161] FIG. 1 schematically shows a first variant for manufacturing a mold shell,

[0162] FIG. 2 schematically shows a second variant for manufacturing a mold shell,

[0163] FIG. 3 schematically shows a first variant for constructing a film forming tool,

[0164] FIG. 4 schematically shows a second variant for constructing a film forming tool,

[0165] FIG. 5 schematically shows a third variant for constructing a film forming tool and

[0166] FIG. 6 schematically shows a fourth variant for constructing a film forming tool.

[0167] The first type of manufacturing method for a mold shell 1, shown in FIG. 1, substantially consists of three method steps. (These steps are schematically shown in the individual images of FIG. 1, from left to right.) The mold shell 1 substantially consists of a ceramic film 3 and a metal spray coating 4.

[0168] In the first method step (left image) of the first manufacturing method of the mold shell 1, shown in FIG. 1, the ceramic film 3 is applied on the milled positive model 2.

[0169] The positive model 2 has no embossment (not shown). The ceramic film 3 has an embossment (not shown) which is applied in the direction of the positive model 2.

[0170] In the second method step (central image) of the first manufacturing method of the mold shell 1 in FIG. 1, the metal spray coating 4 is applied on the back side of the applied ceramic film 3 by means of a metal spray unit 5. The metal spray coating 4 stiffens the mold shell 1 which consists of the ceramic film 3 and the metal spray coating 4.

[0171] After the metal spray coating 4 has been completely applied and hardened, the positive model 2 is separated from the mold shell 1 (not shown).

[0172] In the third method step (right image) of the first manufacturing method of the mold shell 1, shown in FIG. 1, the mold shell 1 is perforated by means of a laser 6.

[0173] The second type of manufacturing method for a mold shell 11, shown in FIG. 2, substantially consists of three method steps which are schematically shown in the images in FIG. 1 from left to right). The mold shell 11 substantially consists of a ceramic lacquer 13 and a metal spray coating 14.

[0174] In the first method step (left image) of the second manufacturing method of the mold shell 11, shown in FIG. 2, the ceramic lacquer 13 is applied on the milled positive model 12 by means of a lacquering unit 15.

[0175] The positive model 12 has an embossment (not shown).

[0176] In the second method step (central image) of the second manufacturing method of the mold shell 11, shown in FIG. 2, the metal spray coating 14 is applied on the back side of the applied ceramic lacquer 13 by means of a metal spray unit 16. The metal spray coating 14 stiffens the mold shell 11 consisting of ceramic lacquer 13 and metal spray coating 14.

[0177] After the metal spray coating 14 has been completely applied and hardened, the positive model 12 is separated from the mold shell 11 (not shown).

[0178] In the third method step (right image) of the second manufacturing method of the mold shell 11, shown in FIG. 2, the mold shell 11 is perforated by means of a laser 17.

[0179] The first type of film forming tool 20, shown in FIG. 3, substantially consists of a mold shell 21 and a supporting structure 24.

[0180] The mold shell 21 substantially consists of a ceramic layer 22 (ceramic film or ceramic lacquer) and a metal spray coating 23.

[0181] The supporting structure 24 substantially consists of a cooling plate 25 and webs 26. The supporting structure 24 stiffens the mold shell 21 to form the film forming tool 20.

[0182] The film forming tool 20 has cooling channels 27 in the cooling plate 25 by means of which the temperature of the film forming tool 20 can be adjusted.

[0183] The second type of film forming tool 30, shown in FIG. 4, substantially consists of a mold shell 31 and a supporting structure 35.

[0184] The mold shell 31 substantially consists of a ceramic layer 32 (ceramic film or ceramic lacquer) and a metal spray coating 33.

[0185] The supporting structure 35 substantially consists of a cooling plate 36 and webs 37. The supporting structure 35 stiffens the mold shell 31 to form the film forming tool 30.

[0186] The film forming tool 30 has cooling channels 34 in the metal spray coating 33 by means of which the temperature of the film forming tool 30 can be adjusted.

[0187] The third type of film forming tool 40, shown in FIG. 5, substantially consists of a mold shell 41 and a supporting structure 44.

[0188] The mold shell 41 substantially consists of a ceramic layer 42 (ceramic film or ceramic lacquer) and a metal spray coating 43.

[0189] The supporting structure 44 substantially consists of a cooling plate 45 and webs 46. The supporting structure 44 stiffens the mold shell 41 to form the film forming tool 40.

[0190] The film forming tool 40 has cooling channels 47 in the webs 46 of the supporting structure 44 by means of which the temperature of the film forming tool 40 can be adjusted.

[0191] The fourth type of film forming tool 50, shown in FIG. 6, substantially consists of a mold shell 51 and a supporting structure 54.

[0192] The mold shell 51 substantially consists of a ceramic layer 52 (ceramic film or ceramic lacquer) and a metal spray coating 53.

[0193] The supporting structure 54 substantially consists of a cooling plate 55 and aluminum gravel 56. The aluminum gravel 56 backfills the mold shell 51 and fills the space between the mold shell 51 and the cooling plate 55, complementing and stiffening the mold shell 51 to form the film forming tool 50.

[0194] The film forming tool 50 has cooling channels 57 which extend through the aluminum gravel 56 and by means of which the temperature of the film forming tool 50 can be adjusted.

LIST OF REFERENCE NUMBERS

[0195] 1 mold shell

[0196] 2 positive model

[0197] 3 ceramic film

[0198] 4 metal spray coating

[0199] 5 metal spraying unit

[0200] 6 laser

[0201] 11 mold shell

[0202] 12 positive model

[0203] 13 ceramic lacquer

[0204] 14 metal spray coating

[0205] 15 lacquering unit

[0206] 16 metal spraying unit

[0207] 17 laser

[0208] 20 film forming tool

[0209] 21 mold shell

[0210] 22 ceramic layer

[0211] 23 metal spray coating

[0212] 24 supporting structure

[0213] 25 cooling plate

[0214] 26 web

[0215] 27 cooling channel

[0216] 30 film forming tool

[0217] 31 mold shell

[0218] 32 ceramic layer

[0219] 33 metal spray coating

[0220] 34 cooling channel

[0221] 35 supporting structure

[0222] 36 cooling plate

[0223] 37 web

[0224] 40 film forming tool

[0225] 41 mold shell

[0226] 42 ceramic layer

[0227] 43 metal spray coating

[0228] 44 supporting structure

[0229] 45 cooling plate

[0230] 46 web

[0231] 47 cooling channel

[0232] 50 film forming tool

[0233] 51 mold shell

[0234] 52 ceramic layer

[0235] 53 metal spray coating

[0236] 54 supporting structure

[0237] 55 cooling plate

[0238] 56 aluminum gravel

[0239] 57 cooling channel