Injection molded component and method for producing injection molded component

Abstract

The invention relates to an injection-molded component (1) for a motor vehicle, comprising a first film insert (2) having a first printed region (3), a second film insert (4) having a second printed region (5), and a transparent plastic layer (6) arranged between the first film insert (2) and the second film insert (4), the first printing region (3) is designed to act as a shutter for partially covering (U) the second printing region.

Description

Technical Field

[0001] The invention relates to an injection-molded component having the features of independent claim 1 , a method having the features of independent claim 8 , and a motor vehicle having the features of independent claim 14 . Background Art

[0002] Today, it is common to design a number of individual parts of a motor vehicle as injection-molded components. For example, decorative shields are often injection-molded, since this allows for fast, efficient and form-fitting manufacturing. Injection-molded components must not only meet crash safety requirements, but are also often used to enable motor vehicle manufacturers to meet other functions. For example, it is common to manufacture decorative shields that have both sensor functions and those that do not. To this end, transparent and flat surfaces must be provided. At the same time, the decorative shields should be visually prominent and eye-catching in order to increase visibility and therefore safety. Currently, in order to increase visibility and value, decorative shields are produced with the aid of geometric structures, for example by three-dimensional embossing and / or coloring, for example monochrome or polychromatic, metallic effects. This can be produced either by a paint / PVD process or by printed film inserts.

[0003] Only two-dimensional designs can be achieved with films and lacquers. Although visual effects can be introduced, these remain static at different viewing angles, i.e. visibility is therefore not increased. It is also possible to introduce true 3D embossing, but this loses sensor suitability, for example for radar. Such three-dimensional effects are often no longer recognizable in warm-colored appearances, i.e. under lighting conditions, because these embossings only leave a two-dimensional impression under light. Summary of the invention

[0004] The object of the present invention is therefore to at least partially eliminate the above-mentioned disadvantages in injection-molded components for motor vehicles. In particular, the object of the present invention is to provide an injection-molded component for motor vehicles and a method for producing an injection-molded component for motor vehicles, which increase visibility and thus safety in a simple and cost-effective manner.

[0005] The above-mentioned object is achieved by an injection-molded component having the features of independent claim 1, a method having the features of independent claim 8 and a motor vehicle having the features of independent claim 14. Further features and details of the invention are obtained from the dependent claims, the description and the drawings. Features and details described in connection with the injection-molded component according to the invention naturally also apply in connection with the method according to the invention and / or in connection with the motor vehicle according to the invention, and vice versa, respectively, so that reference can always be made to each other with respect to the disclosure of the various aspects of the invention.

[0006] According to the present invention, an injection-molded component for a motor vehicle is provided, which has a first film insert with a first printed area, a second film insert with a second printed area, and a transparent plastic layer arranged between the first film insert and the second film insert, wherein the first printed area is designed to act as a shield (Blende) for partially covering the second printed area.

[0007] In the present case, a printed area is to be understood as a region of the respective film insert which has a print. The print is applied prior to production of the injection-molded component by means of a printing method, preferably screen printing or digital printing. It should be noted that the first and second film inserts have different patterns and / or colors, for example, a color gradient (fading) or a mirror reflection can be applied, in particular a color gradient which is still visible to the human eye despite the shielding effect of the shielding part produced by the first printed area.

[0008] The shielding effect of the first film insert is understood to mean that the first film insert is not completely printed through the first printed area, but has at least one transparent area. The second film insert is arranged so that the second printed area can be seen through at least one transparent area of ​​the first film insert. In other words, the unprinted area of ​​the first film insert allows the second printed area of ​​the second film insert to be seen.

[0009] Due to the arrangement of the first and second film inserts and the plastic layer located between them, not only a depth effect but also a three-dimensional effect is produced. This increases the visibility of the injection-molded component. The injection-molded component can be a decorative cover for a radiator grille, a tailgate, a C-pillar or a B-pillar. Due to the increased perception due to the depth effect and the three-dimensional effect, not only a visual effect is achieved, but also an increase in safety due to visibility.

[0010] Because the arrangement according to the invention of the layer or film insert, there is no need for embossed and therefore expensively manufactured parts to produce visual effects. In addition, not only material and therefore cost are saved, but also injection molded components can be manufactured in a more efficient and cost-effective manner.

[0011] The simple structure produced by means of the membrane insert allows one or more smooth surfaces which have a high sensor suitability, for example for radar.

[0012] It is conceivable within the scope of the invention that the plastic layer has a thickness of 3 to 7 mm, preferably 4.5 to 6.5 mm, further preferably 5 to 6 mm.

[0013] For the desired depth effect and three-dimensional effect, a certain distance between the printed layers is useful. This distance depends on the desired effect and the selected color gradient or pattern. The depth effect can be ensured with a plastic layer thickness of between 3 and 7 millimeters.

[0014] It may be advantageous within the scope of the invention if the plastic layer is produced from polymethyl methacrylate and / or polycarbonate.

[0015] These materials can be easily manufactured by injection molding and have sufficient strength for the respective fields of use. In addition, these materials have a transparency suitable for sensor use.

[0016] It can be provided within the scope of the invention that a light source is provided for coupling light into the plastic layer, said light source being designed to extend at least partially around the circumference of the injection-molded component.

[0017] The light source can be a lamp, for example a lamp with LEDs, or can be a light hose composed of various LEDs. The light source can be arranged at one side of the injection molded component or at opposite sides or can be arranged around the entire circumference of the injection molded component.

[0018] The effect is intensified by means of illumination with a light source, ie the depth effect and / or the 3D effect is more prominent and thus also more visible. This is particularly advantageous in dark environments, for example in a tunnel or at night.

[0019] According to the invention, it is conceivable that the first film insert has a surface facing away from the plastic layer, which surface has a coating.

[0020] This surface can be exposed to the surroundings and thus to environmental influences. The coating thus protects the injection-molded component from external influences and thus increases the durability of the injection-molded component.

[0021] It is also conceivable for the second film insert to have a third film insert or a viewing surface, in particular a display, on the surface facing away from the plastic layer.

[0022] The third film insert can achieve an even more extreme depth effect and has a positive effect on the visual appearance. It is conceivable that a display is glued behind the second film insert. This second film insert can then be adapted to the surroundings in order to thereby increase visibility and safety. It is conceivable that the light intensity and / or color scheme can be adapted to the surroundings or the light conditions or the traffic situation.

[0023] It is optionally possible within the scope of the invention that the first printed area and the second printed area are designed in such a way that a transparent area is provided for the measurement by the optical sensor.

[0024] The transparent area is preferably suitable for sensors. Thus, sensors, in particular optical sensors such as radar, lidar or cameras, can be arranged behind the injection-molded component.

[0025] Another aspect of the invention is a method for producing an injection-molded component for a motor vehicle, in particular the above-described injection-molded component. The method is characterized by the following method steps:

[0026] - printing a first film insert with a first printed area,

[0027] - printing a second film insert with a second printed area,

[0028] - Provide injection molding molds,

[0029] - positioning the first membrane insert in the injection molding mold,

[0030] - positioning the second membrane insert in the injection molding mold,

[0031] -Inject the plastic material into the injection molding mold,

[0032] - Cooling the injection molding mold,

[0033] - Removing the injection molded component from the injection molding mold.

[0034] The method allows rapid, simple and cost-effective production of injection-molded components for motor vehicles that have a visual effect and at the same time increase safety.

[0035] The print of the first or second print area can be produced by means of screen printing or digital printing.

[0036] Furthermore, within the scope of the invention it can be provided that at least one centering pin of the injection molding tool receives at least one receptacle of the first film insert part and / or at least one receptacle of the second film insert part during a corresponding positioning process.

[0037] This simplifies the positioning of the first and second membrane inserts and ensures that the positioning can be performed more accurately. It is conceivable that a plurality of centering pins are provided in order to position the first and second membrane inserts. It is particularly advantageous here that the first and second membrane inserts can be positioned using the same centering pin. The receiving portion of the first and second membrane inserts corresponding to the centering pin is preferably designed so that the receiving portion of the first and second membrane inserts can be penetrated by the centering pin. In order to fix the first and second membrane inserts, the centering pin can have a groove for receiving the membrane insert.

[0038] According to the invention, it is conceivable that at least three centering pins are provided, wherein each of the centering pins is associated with a receptacle of the first film insert and a receptacle of the second film insert.

[0039] By using at least three centering pins, the position can be better determined during the injection molding process. As already mentioned, it is conceivable to also use more centering pins. The number of centering pins depends on the size of the injection molded component.

[0040] It can be advantageous within the scope of the invention for the injection molding tool to have a cavity, wherein the cavity is filled with a coating material in order to coat the surface of the first membrane insert that is associated with the surroundings.

[0041] The cavity corresponds to the thickness of the coating. The same material or different materials can be used for this purpose. The coating serves as a protective part to protect the injection molded component from environmental influences.

[0042] It is conceivable within the scope of the invention to anneal the injection-molded component in an additional step at a temperature between 100° C. and 140° C., preferably between 110° C. and 130° C., further preferably between 115° C. and 125° C.

[0043] Annealing the component reduces the internal stresses of the injection-molded component, ie the service life of the injection-molded component is increased by annealing.

[0044] It can be provided within the scope of the invention that the first film insert and / or the second film insert is preformed before positioning, the preform being produced by thermoforming or high-pressure forming.

[0045] Preforming is useful if the injection-molded component has a curvature. By preforming, the film insert can be adapted to the shape of the injection-molded component to be injected.

[0046] The abovementioned object is also achieved by a motor vehicle according to the invention comprising an injection-molded component as described above. BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Further advantages, features and details of the invention are obtained from the following description, in which a number of exemplary embodiments of the invention are described in detail with reference to the drawings. The features mentioned in the claims and in the description may be essential to the invention individually or in any combination. The invention is illustrated in the following drawings:

[0048] Figure 1 A schematic diagram showing a cross-sectional view of an injection molded component,

[0049] Figure 2 A schematic diagram shows a method for producing an injection-molded component. DETAILED DESCRIPTION

[0050] exist Figure 1 to Figure 2 In the drawings, elements having the same function and mode of action are respectively provided with the same reference numerals.

[0051] exist Figure 1 Schematically shows an injection molded component 1 for a motor vehicle. The injection molded component 1 has a first film insert 2 with a first printed area 3, a second film insert 4 with a second printed area 5, and a transparent plastic layer 6 arranged between the first film insert 2 and the second film insert 4, wherein the first printed area 3 is designed to act as a shielding part for partially covering the second printed area 5.

[0052] The plastic layer 6 has a thickness D of 3 to 7 millimeters and is made of polycarbonate.

[0053] Furthermore, a light source 7 is provided for coupling light into the plastic layer 6, which extends partially around the circumference of the injection-molded component 1 and is arranged according to the embodiment of the present invention. Figure 1 Arranged on the side of the plastic layer 6.

[0054] For protection against environmental influences, the first film insert 2 has a coating 9 on the side facing away from the plastic layer 6 .

[0055] Furthermore, the second film insert 4 has a viewing surface 8 , in the present case a display 11 , on the surface facing away from the plastic layer.

[0056] Furthermore, the first printed area 3 and the second printed area 5 are designed in such a way that transparent areas 12 are provided for measurement by the optical sensor 13 .

[0057] exist Figure 2 1 shows a method 100 for producing the above-mentioned injection-molded component 1, wherein the method 100 is characterized by the following method steps:

[0058] - printing 110 a first film insert 2 with a first printed area,

[0059] - printing 120 a second film insert 4 with a second printed area,

[0060] - providing 130 an injection molding mold 17,

[0061] - positioning 140 the first membrane insert 2 in the injection molding mold 17,

[0062] - positioning 150 the second membrane insert 4 in the injection molding mold 17,

[0063] - injecting 160 plastic material into the injection mould 17,

[0064] - Cooling 170 the injection molding mold 17,

[0065] The injection-molded component 1 is removed from the injection-molding mold 17 .

[0066] For positioning, at least one centering pin 14 of the injection molding tool 17 receives at least one receptacle of the first film insert part 2 and at least one receptacle of the second film insert part 4. For this purpose, the centering pins 14 each have a groove.

[0067] At least three centering pins 14 are provided for an injection-molded component 1 (not fully shown), wherein each of the centering pins 14 is associated with a receptacle of the first film insert 2 and a receptacle of the second film insert 4 .

[0068] In order to coat 190 the surface 8 of the first film insert 2 facing away from the plastic layer, the injection molding tool 17 has a cavity which is filled with the coating material 19 .

[0069] Optionally, the injection-moulded component 1 may be annealed 200 at a temperature between 100° C. and 140° C. in an additional step in order to reduce internal stresses.

[0070] If it is an injection-molded component 1 with a large curvature, the first film insert 2 and the second film insert 4 can optionally be preformed before positioning, wherein the preform 210 is produced by thermoforming or high-pressure forming.

[0071] Reference numerals list

[0072] 1Injection molding components

[0073] 2First membrane insert

[0074] 3First printing area

[0075] 4 Second membrane insert

[0076] 5 Second printing area

[0077] 6 plastic layers

[0078] 7 Light Source

[0079] 8 sides

[0080] 9. Cladding

[0081] 10Third film insert, visual surface

[0082] 11 Display

[0083] 12 Areas

[0084] 13 Sensors

[0085] 14 Centering pin

[0086] 15 Reception Department

[0087] 16 slots

[0088] 17Injection molding mold

[0089] 18 Cavity

[0090] 19Coating material

[0091] U Cover

[0092] DThickness

[0093] 100 Methods

[0094] 110 Printing the first film insert

[0095] 120 Printing the second film insert

[0096] 130 offers

[0097] 140 Positioning the first membrane insert

[0098] 150 Positioning the second membrane insert

[0099] 160 Injection

[0100] 170 Cooling

[0101] 180 Remove

[0102] 190 coating

[0103] 200 annealing

[0104] 210 Preform

Claims

1. An injection molded component (1) for a motor vehicle, the injection molded component comprising: a first film insert (2) with a first printed area (3), a second film insert (4) with a second printed area (5), and a transparent plastic layer (6) arranged between the first film insert (2) and the second film insert (4), The first printing area (3) is designed to function as a shielding portion for partially covering (U) the second printing area (5).

2. The injection-molded component (1) according to claim 1, characterized in that The plastic layer (6) has a thickness (D) of 3 to 7 mm, preferably 4.5 to 6.5 mm, more preferably 5 to 6 mm.

3. The injection-molded component (1) according to at least one of the preceding claims, characterized in that The plastic layer (6) is made of polymethyl methacrylate (PMMA) and / or polycarbonate (PC).

4. The injection-molded component (1) according to at least one of the preceding claims, characterized in that A light source (7) is provided for coupling light into the plastic layer (6), wherein the light source (7) is designed to extend at least partially around the circumference of the injection-molded component (1).

5. The injection-molded component (1) according to at least one of the preceding claims, characterized in that The first film insert (2) has a surface (8) facing away from the plastic layer (6), said surface (8) having a coating (9).

6. The injection-molded component (1) according to at least one of the preceding claims, characterized in that The second film insert (4) has a third film insert (10) or a viewing surface (10), in particular a display (11), on the surface (8) facing away from the plastic layer (6).

7. The injection-molded component (1) according to at least one of the preceding claims, characterized in that The first printed area (3) and the second printed area (5) are designed such that a transparent area (12) is provided for measurement by an optical sensor (13).

8. A method (100) for producing an injection-molded component (1), in particular an injection-molded component (1) according to any one of claims 1 to 7, wherein: The method (100) is characterized by the following method steps: - printing (110) a first film insert (2) with a first printed area (3), - printing (120) a second film insert (4) with a second printed area (5), - providing (130) an injection molding die (17), - positioning (140) the first membrane insert (2) in the injection molding mold (17), - positioning (150) the second membrane insert (4) in the injection mould (17), - injecting (160) plastic material into the injection mould (17), - cooling (170) the injection molding mold (17), - Removing (180) the injection-moulded component (1) from the injection-moulding mould (17).

9. The method (100) according to claim 8, characterized in that At least one centering pin (14) of the injection molding tool (17) receives at least one receptacle (15) of the first film insert (2) and / or at least one receptacle (15) of the second film insert (4) during a corresponding positioning process.

10. The method (100) according to claim 9, characterized in that At least three centering pins (14) are provided, each of which is associated with a receptacle (15) of a first membrane insert (2) and a receptacle (15) of a second membrane insert (4).

11. The method (100) according to at least one of the preceding claims 8 to 10, characterized in that The injection molding tool (17) has a cavity (18) which is filled with a coating material (19) for coating (190) the surface (8) of the first membrane insert (2) that is associated with the surroundings.

12. The method (100) according to at least one of the preceding claims 8 to 11, characterized in that In an additional step, the injection-molded component ( 1 ) is annealed ( 200 ) at a temperature between 100° C. and 140° C., preferably between 110° C. and 130° C., further preferably between 115° C. and 125° C.

13. The method (100) according to at least one of the preceding claims 8 to 12, characterized in that The first film insert (2) and / or the second film insert (4) are preformed before positioning, and the preform (210) is established by thermoforming or high pressure forming.

14. A motor vehicle comprising an injection-moulded component (1) according to any one of claims 1 to 7.

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