Injection-Molded Component and Method for Manufacturing an Injection-Molded Component

Abstract

An injection-molded component for a motor vehicle, including a first film insert having a first printed area, a second film insert having a second printed area, and a transparent plastic layer disposed between the first film insert and the second film insert. The first printed area is configured to act as a cover for partially covering the second printed area.

Claims

1.-14. (canceled)

15. An injection-molded component for a motor vehicle, comprising: a first foil insert comprising a first print region; a second foil insert comprising a second print region; and a transparent polymer layer disposed between the first foil insert and the second foil insert, wherein the first print region is configured as a panel for coverage of sections of the second print region.

16. The injection-molded component according to claim 15, wherein the polymer layer has a thickness of 3 to 7 mm, preferably 4.5 to 6.5 mm, further preferably 5 to 6 mm.

17. The injection-molded component according to claim 15, wherein the polymer layer is made from polymethyl-methacrylate (PMMA) and/or polycarbonate (PC).

18. The injection-molded component according to claim 15, further comprising: a light source configured for coupling of light into the polymer layer, wherein the light source is configured to run at least partly around a circumference of the injection-molded component.

19. The injection-molded component according to claim 15, wherein the first foil insert has a surface that faces away from the polymer layer, and wherein the surface has a coating.

20. The injection-molded component according to claim 15, wherein the second foil insert, on a surface that faces away from the polymer layer, has a third foil insert or an optical surface, especially a display.

21. The injection-molded component according to claim 15, wherein the first print region and the second print region are configured such that transparent regions are provided for measurement by optical sensors.

22. A method of producing an injection-molded component, wherein the injection-molded component comprises a first foil insert comprising a first print region; a second foil insert comprising a second print region; and a transparent polymer layer disposed between the first foil insert and the second foil insert, wherein the first print region is configured as a panel for coverage of sections of the second print region, the method comprising: printing the first foil insert with the first print region; printing the second foil insert with the second print region; providing an injection mold; positioning the first foil insert in the injection mold; positioning the second foil insert in the injection mold; injecting a polymer material into the injection mold; cooling the injection mold; and removing the injection-molded component from the injection mold.

23. The method according to claim 22, further comprising accepting, by at least one centering pin of the injection mold, at least one acceptor in the first foil insert and/or at least one acceptor in the second foil insert in a respective positioning operation.

24. The method according to claim 23, further comprising: providing at least three centering pins, wherein each of the centering pins is assigned an acceptor of the first foil insert and an acceptor of the second foil insert.

25. The method according to claim 22, wherein the injection mold has a cavity, and the method further comprising filling the cavity with a coating material for coating a surface of the first foil insert which is assigned to an environment.

26. The method according to claim 22, further comprising subjecting the injection-molded component to heat treatment at a temperature between 100 C. and 140 C., preferably between 110 C. and 130 C., further preferably between 115 C. and 125 C.

27. The method according to claim 22, further comprising preforming the first foil insert and/or the second foil insert prior to positioning, wherein the preforming is established by thermoforming or high-pressure forming.

28. A motor vehicle comprising an injection-molded component according to claim 15.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] FIG. 1 is a schematic diagram of a section view through an injection-molded component.

[0049] FIG. 2 is a schematic diagram of the method/process for producing an injection-molded component.

DETAILED DESCRIPTION OF THE DRAWINGS

[0050] Elements having the same function and effect are given the same reference numerals in FIGS. 1 and 2.

[0051] FIG. 1 is a schematic diagram of an injection-molded component 1 for a motor vehicle. The injection-molded component 1 has a first foil insert 2 having a first print region 3, a second foil insert 4 having a second print region 5, and a transparent polymer layer 6 disposed between the first foil insert 2 and the second foil insert 4, wherein the first print region 3 is configured as a panel for coverage U of sections of the second print region 5.

[0052] The polymer layer 6 has a thickness D of 3 to 7 mm and is made from polycarbonate.

[0053] In addition, a light source 7 is provided for coupling of light into the polymer layer 6, where the light source 7 runs partly around the circumference of the injection-molded component 1 and, according to FIG. 1, is disposed laterally on the polymer layer 6.

[0054] For protection from environmental influences, the first foil insert 2 has a coating 9 on a surface facing away from the polymer layer 6.

[0055] In addition, the second foil insert 4 has an optical surface 8, in the present case a display 11, on a surface facing away from the polymer layer.

[0056] In addition, the first print region 3 and the second print region 5 are configured such that transparent regions 12 are provided for measurement by optical sensors 13.

[0057] FIG. 2 shows the method/process 100 for producing an above-described injection-molded component 1, wherein the process 100 comprises the steps of: [0058] printing 110 a first foil insert 2 with a first print region, [0059] printing 120 a second foil insert 4 with a second print region, [0060] providing 130 an injection mold 17, [0061] positioning 140 the first foil insert 2 in the injection mold 17, [0062] positioning 150 the second foil insert 4 in the injection mold 17, [0063] injecting 160 a polymer material into the injection mold 17, [0064] cooling 170 the injection mold 17, [0065] removing the injection-molded component 1 from the injection mold 17.

[0066] For positioning, at least one centering pin 14 in the injection mold 17 accepts at least one acceptor in the first foil insert 2 and at least one acceptor in the second foil insert 4. For this purpose, the centering pin 14 has a groove in each case.

[0067] For an injection-molded component 1, which is not shown completely, at least three centering pins 14 are provided. Each of these centering pins 14 is assigned an acceptor in the first foil insert 2 and an acceptor in the second foil insert 4.

[0068] For coating 190 of the surface 8 of the first foil insert 2 that faces away from the polymer layer, the injection mold 17 has a cavity filled with a coating material 19.

[0069] It is optionally possible for the injection-molded component 1 to be subjected to heat treatment 200 in an additional step at a temperature between 100 C. and 140 C. in order to dissipate residual stress.

[0070] In the case of a large, curved injection-molded component 1, the first foil insert 2 and the second foil insert 4 may optionally be preformed prior to positioning, where the preforming 210 is established by thermoforming or high-pressure forming.

LIST OF REFERENCE NUMERALS

[0071] 1 injection-molded component [0072] 2 first foil insert [0073] 3 first print region [0074] 4 second foil insert [0075] 5 second print region [0076] 6 polymer layer [0077] 7 light source [0078] 8 surface [0079] 9 coating [0080] 10 third foil insert, optical surface [0081] 11 display [0082] 12 regions [0083] 13 sensors [0084] 14 centering pin [0085] 15 acceptor [0086] 16 groove [0087] 17 injection mold [0088] 18 cavity [0089] 19 coating material [0090] U coverage [0091] D thickness [0092] 100 process [0093] 110 printing of a first foil insert [0094] 120 printing of a second foil insert [0095] 130 providing [0096] 140 positioning of the first foil insert [0097] 150 positioning of the second foil insert [0098] 160 injection [0099] 170 cooling [0100] 180 removing [0101] 190 coating [0102] 200 heat treatment [0103] 210 preforming