PRODUCTION OF A COMPONENT BY INJECTION MOULDING

Abstract

In a method for producing a component (500) from a translucent plastic material (50), which comprises a front side having n contours (51), and in particular n raised contours, and a rear side covered with a colored film (40), initially an injection molding tool (100) is provided, which comprises a first tool part (10) and a second tool part (20), which together enclose a cavity (30) having the contours of the component (500) to be produced when the tool is closed. A surface of the first tool part (10) represents a negative of the front side of the component (500) and comprises n structures (11), in particular n indentations, corresponding to the n contours (51) of the component. A surface of the second tool part (20) represents a negative of the rear side of the component (500). The film (40) is positioned on the surface of the second tool part (20). The injection molding tool (100) is closed, and plasticized plastic material (50) is injected into the formed cavity (30). After the plasticized plastic material (50) has cured, the component (500) provided with the film (40) is demolded. In this method, the surface of the second tool part (20) is provided with n elevations (21), and the film (40) is provided with n cut-outs (43), prior to positioning, such that the n elevations (21) on the surface of the second tool part (20) engage in the n cut-outs (43) of the film during the positioning of the film (40).

Claims

1. A method for producing a component from a translucent plastic material, the component comprising a front side having n contours, and a rear side covered with a colored film, comprising: a. providing an injection molding tool, comprising a first tool part and a second tool part, which together enclose a cavity having the contours of the component to be produced when the tool is closed, comprising: a surface of the first tool part representing a negative of the front side of the component and comprising n structures, corresponding to the n contours; and a surface of the second tool part representing a negative of the rear side of the component; b. positioning the film on the surface of the second tool part; c. closing the injection molding tool and injecting a plasticized plastic material into the cavity; and d. demolding the component provided with the film after the plasticized plastic material has cured, wherein e. the surface of the second tool part comprises n elevations; and f. the film comprises n cut-outs, prior to positioning, such that the n elevations on the surface of the second tool part engage the n cut-outs of the film during the positioning of the film.

2. The method according to claim 1, further comprising at least one of the following: a. positioning the n structures in the surface of the first tool part and the n elevations on the surface of the second tool part such that each of the n structures in the cavity is located opposite one of the n elevations after the tool has been closed; b. positioning the n structures in the surface of the first tool part and the n elevations on the surface of the second tool part such that each of the n cut-outs of the film, as viewed perpendicularly to the front side and/or to the rear side of the component, overlaps with one of the n contours in the demolded component; and c. the n cut-outs of the film and the n contours on the front side of the component, as viewed perpendicularly to the front side and/or to the rear side of the component, having the same outline.

3. The method according to claim 1, further comprising at least one of the following: a. designing the n elevations on the surface of the second tool part to be lowerable; and b. prior to demolding the component, lowering the n elevations of the second tool part.

4. The method according to claim 1, further comprising at least one of the following: a. the film comprises a lacquer film or a transfer lacquer film comprising a lacquer layer on a carrier layer; and b. positioning the lacquer film or the transfer lacquer film, with the carrier layer ahead, on the surface of the second tool part.

5. The method according to claim 1, further comprising: a. assigning a one light source to the rear side of the component.

6. The method according to claim 1, further comprising at least one of the following: a. the component comprising a trim part for a vehicle body; b. the component comprising a cover panel for a vehicle body; c. with the exception of the areas having the n contours on the front side, the component having a substantially uniform thickness; and d. with the exception of the areas having the n contours on the front side, the front side and the rear side of the component being oriented substantially parallel to one another.

7. The method according to claim 1, comprising at least one of the following: a. partially or completely coating the front side of the component; and b. opaquely coating the surfaces of the n contours on the front side of the component.

8. An injection molding tool for producing a component from plastic material, the component to be produced comprising a front side having n contours, and a rear side covered with a colored film, comprising: a. the injection molding tool comprises a first tool part and a second tool part, which together enclose a cavity having the contours of the component to be produced when the tool is closed, with a surface of the first tool part representing a negative of the front side of the component and comprising n structures corresponding to the n contours; and a surface of the second tool part representing a negative of the rear side of the component; b. the surface of the second tool part comprises n elevations; and c. the n structures in the surface of the first tool part and the n elevations on the surface of the second tool part are positioned such that each of the n structures in the cavity is located opposite one of the n elevations after the tool has been closed.

9. The injection molding tool according to claim 8, wherein, a. the n elevations on the surface of the second tool part are configured to be lowerable.

10. A component produced from a translucent plastic material by injection molding, the component comprising a front side having n contours, and a rear side covered with a colored film, the film having n cut-outs, in the area of which the component is not covered with film, and each of the n cut-outs, as viewed perpendicularly to the front side and/or to the rear side of the component, overlapping one of the n contours on the front side of the component.

11. The component according to claim 10, wherein the component is produced by the method according to claim 1.

12. The component according to claim 10, wherein, a. the rear side of the component has a planar surface.

13. The component according to claim 10, further comprising at least one of the following: a. the film is a lacquer film and comprises a lacquer layer on a carrier layer; and b. the lacquer film is positioned, with the lacquer layer ahead, on the rear side of the component.

14. The component according to claim 10, further comprising at least one of the following: a. the component is a trim part for a vehicle body; b. the component is a cover panel for a vehicle body; c. the surfaces of the n contours on the front side of the component are lacquered and/or chrome-plated; and d. a light source is positioned towards the rear side of the component.

15. The component according to claim 10, wherein, a. n is a number from 1 to 1000.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0099] In the drawings:

[0100] FIG. 1 shows a schematic illustration of the first tool part and of the second tool part of the injection molding tool according to the invention in a longitudinal sectional view;

[0101] FIG. 2 shows a schematic illustration of the first tool part and of the second tool part of the injection molding tool according to the invention with a positioned colored film;

[0102] FIG. 3 shows a schematic illustration of the first tool part and of the second tool part of the injection molding tool according to the invention with plastic material injected;

[0103] FIG. 4 shows a schematic illustration of the first tool part and of the second tool part of the injection molding tool according to the invention with plastic material injected and lowered elevations on the second tool part;

[0104] FIG. 5 shows a schematic sectional illustration of an injection-molded component produced according to the invention;

[0105] FIG. 6 shows a schematic sectional illustration of an injection-molded component produced according to the invention with illumination from behind; and

[0106] FIG. 7 shows a visual impression of an injection-molded component produced according to the invention which is illuminated from behind.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0107] FIG. 1, in a schematic longitudinal sectional view, shows a first tool part 10 and a second tool part 20, which together form or enclose a cavity 30 of an injection molding tool 100. The cavity 30 defines the contours of the injection-molded component to be produced. The surface of the first tool part 10, which faces the cavity 30, is a negative of the front side of the component and, for this purpose, comprises several structures 11, in particular indentations, which predefine the contours on the front side of the component to be produced. The surface of the second tool part 20 which faces the cavity 30 represents a negative of the rear side of the component, wherein this surface of the second tool part 20 is designed with several elevations 21. The elevations 21 can be lowered into the second tool part 20, so that the surface of the tool part 20 which faces the cavity 30 can form a planar surface.

[0108] As is shown in FIG. 2, a colored film 40 is placed onto the surface of the second tool part 20 before the plasticized plastic material is injected into the cavity 30 of the tool 100. The colored film 40 comprises a carrier layer 41, in particular a plastic film, and a pigmented or color-imparting layer, in particular a lacquer layer 42, arranged thereon. The colored film 40 has cut-outs 43, which, in terms of the shape thereof, and in particular in terms of the outline thereof, correspond to the contours on the front side of the component to be produced. Within the scope of the method according to the invention, the cut-outs 43 are placed so as to be located exactly opposite the contours on the front side of the component to be produced, on the rear side of the component to be produced, and thus omit the color design in the areas or the outlines of the contours of the component on the rear side. The elevations 21 on the surface of the second tool part 20 are used to precisely position the colored film 40 on the rear side of the component to be produced. For this purpose, the elevations 21 engage in the cut-outs 43 of the colored film 40, thereby allowing the colored film to be precisely positioned on the surface of the second tool part 20. Furthermore, the film 40 is prevented from sliding out of place.

[0109] FIG. 3 illustrates the injection of the plasticized plastic material 50 into the cavity of the injection molding tool 100 defined by the first tool part 10 and the second tool part 20. During the injection molding operation, the colored film 40 is held exactly in the position thereof by the elevations 21 of the second tool part 20. For enhanced adhesion of the plasticized plastic material 50 to the colored film 40, the colored film 40 can be provided with an adhesive compound on the side thereof which faces the plastic material 50. On the front side of the component, the raised contours 51 are created so as to correspond to the indentations 11 of the first tool part 10 during the injection molding process.

[0110] The plastic material 50 of the component to be produced is, in particular, a transparent thermoplastic material, such as polymethyl methacrylate, polycarbonate or polyamide, and in particular PA12.

[0111] FIG. 4 shows the elevations 21 being lowered into the second tool part 20 during the injection molding process. As a result of this measure, the impressions formed by the elevations 21 in the component to be produced can be completely filled with plasticized plastic material, so that a planar surface is imparted to the rear side of the component to be produced.

[0112] A sectional view of the component 500 thus producible is shown in FIG. 5. The component 500 comprises a base body made of the plastic material 50 and, on the rear side of the component, the colored film 40, which has cut-outs 43 in the areas that are located opposite the contours 51 on the front side of the component.

[0113] The surfaces of the contours 51 are hot stamped with chromium film 52, or coated otherwise, in this configuration of the component. Furthermore, two connecting points 53 for the further installation of the component 500 are added to the rear side of the component. The connecting points 53 were produced during the further injection molding process in the manner known per se. The connecting points 53 can, for example, be made of PC/ABS (polycarbonate/acrylonitrile butadiene styrene).

[0114] If necessary, the front side of the component 500 can be provided with a further coating, for example with a clear lacquer, which offers protection and a scratch-resistant surface of the component front side. This may be very useful, for example, when polycarbonate is used as the thermoplastic material.

[0115] FIG. 6 illustrates the component 500 produced by injection molding being illuminated from behind. Light sources 200 are arranged on the rear side of the component 500, which shine light into the transparent base body of the component 500 in the area of the cut-outs 43 of the colored film 40. The remaining areas of the colored film 40 form an opaque layer, which does not allow visible radiation to pass. The chromium film coating 52 on the surfaces of the contours 51 also does not allow radiation to pass, so that the radiation exits the base body of the component 500 in the area of the outlines of the contours 51, and thereby achieves an illumination effect that exclusively causes the outlines of the contours 51 to shine.

[0116] FIG. 7 illustrates this visual effect for an illumination of the component 500 from behind. The raised contours 51 on the front side of the component 500 have a star-shaped design, and the illumination from behind causes the light to surround the outlines of the star-shaped contours 51 in an exactly defined manner.

[0117] Overall, the production process of the component 500 according to the invention, using the injection molding tool 100 according to the invention, allows a component 500 having a rear color design by means of a colored film 40 to be produced, in which the areas having the contours 51 on the front side of the component 500, these being, for example, three-dimensionally appearing stars, can be deliberately illuminated with precise positioning. At the same time, the application of the rear colored film 40 can ensure a color design that extends all the way to the component edge.