Cover disc, injection molding method, injection mold, motor vehicle lamp and motor vehicle

Abstract

The invention relates to a cover disc (1) for a motor vehicle lamp, the cover disc (1) having an inner face (2), an outer face (3) opposite the inner face (2), a transparent body (4), an opaque body (5) and a coating (6), the coating (6) having a PU polyurethane, the transparent body (4), the opaque body (5) and the coating (6) being produced continuously in one piece, preferably in an injection molding process, in such a way that the transparent body (4), the opaque body (5) and the coating (6) are coated on the outer face (3). The covering layer (6) completely covers the transparent body (4) and only partially covers the opaque body (5) when viewed from the outer surface (3) in the direction of the inner surface (2), in such a way that the outer surface (3) is formed only on the covering layer (6) and on the opaque body (5). The invention also relates to an injection molding method for producing a cover disc (1) and to an injection molding tool (100).

Description

Field of the Invention

[0001] The present invention relates to a cover disk for a motor vehicle lamp, wherein the cover disk has an inner surface, an outer surface opposite the inner surface, a transparent body, an opaque body, and a coating, wherein the coating has PU polyurethane. Background Art

[0002] Such a cover disk can be connected to a housing, for example, by screwing, latching, or preferably at least bonding, so as to form a closed space with the housing. Such cover disks are well known and must meet certain requirements especially when used in motor vehicle lamps. On the one hand, such a cover disk should be at least partially transmissive to visible light. On the other hand, such a cover disk should meet aesthetic requirements, and thus in most cases, an opaque body and a transparent body are continuously formed, so that at least a part of the cover disk appears bright and is transmissive to visible light. In addition, a coating is used to make the transparent region of such a cover disk at least somewhat resistant to scratches, chemicals, or ultraviolet light to a certain extent.

[0003] In addition to hard coating coatings (which are treated with corresponding solvents in the form of paint), coatings are also known that have polyurethane or simply PU to protect such cover disks. The advantage of such a coating made of PU polyurethane is especially that the application process can be integrated into a fully automated injection molding manufacturing, as described, for example, in EP3878620A1.

[0004] Since such a coating with PU polyurethane can only be introduced via an airtight cavity in a fully automated injection molding process due to its low viscosity in the form to be treated, an overflow cavity is required in the injection mold. to accommodate the air displaced by the coating material in the cavity. The overflow cavity results in a molding at the cover disk. The molding must be separated after the injection process and sealed at the separation site at high cost. The result is a longer process time and weakened surface properties at the separation site. Summary of the Invention

[0005] Therefore, the object of the present invention is to provide a cover disk, an injection molding method, and an injection mold to at least partly overcome the mentioned disadvantages without significantly affecting the appearance of the cover disk.

[0006] This task is solved by means of the cover plate mentioned at the beginning, wherein the transparent body, the opaque body and the cladding are manufactured continuously in one piece, preferably by injection molding, i.e., such that the outer surface is only formed at the cladding and the opaque body, wherein the cladding completely covers the transparent body in the direction from the outside to the inside and only partially covers the opaque body, wherein the region of the cladding that completely covers the transparent body forms the useful section of the cladding and wherein the region of the cladding that only partially covers the opaque body forms at least one first partial section of the cladding, which first partial section is at least partially formed in the overflow cavity during the injection of the cladding.

[0007] Advantageously, the useful section of the cladding has a thickness between 0.1 mm and 0.9 mm when observed from the outside in the direction to the inside.

[0008] Preferably, the first partial section of the cladding has a thickness that is less than or equal to, preferably equal to, the thickness of the useful section of the cladding.

[0009] In an advantageous design, the region of the cladding that only partially covers the opaque body additionally forms a second partial section, which second partial section is formed separately from the first partial section in the pouring cavity during the injection of the cladding. Thereby, the subsequent separation and sealing of the pouring site of the cladding are eliminated.

[0010] In order to ensure the best properties of the useful section, the second partial section is preferably formed along the outside substantially at opposite regions of the cladding.

[0011] Preferably, the opaque body has a material that is resistant at least to external influences selected from the group of external influences, which group includes influences caused by adverse climatic conditions, mechanical influences, influences caused by solar radiation or the influence of chemicals.

[0012] For example, there is resistance of the material to the influence caused by adverse climatic conditions when at least one test selected from the group of tests (which includes DIN EN 60068-2-2, e.g., v2008-05; PV 1200, e.g., v2004-10; PV 3930, e.g., v2008-03; DIN EN ISO 6270-1, e.g., 2018-04) does not result in significant visible changes such as color changes, loss of gloss, cracks or blisters.

[0013] For example, when the characteristic value obtained according to the test of DIN EN ISO 20567-1, such as v2017-07, is less than or equal to 3, preferably less than or equal to 2, the material has resistance to mechanical action or influences such as impacts by gravel. Alternatively or additionally, when a specific turbidity as defined, for example, in DIN EN ISO 13803, such as v2015-02, is less than or equal to the turbidity of a reference material according to the test of DIN EN ISO 20566, such as v2021-06, resistance of the material to mechanical action or influences that occur, for example, in the case of a cleaning device can exist. Such a reference material is, for example, the cladding material UVKC3000k.

[0014] For example, when the material does not have significantly visible changes, such as color change, loss of gloss, cracks or bubbles, according to the test of, for example, PV 3930, such as v2022-04, there is resistance of the material to the influence of solar radiation and the associated UV load.

[0015] For example, when the material does not have significantly visible changes, such as color change, loss of gloss, cracks or bubbles, according to the test of ISO 16750-5, such as v2010-04, there is resistance of the material to the influence of chemicals. The chemicals set in the test can depend on the "installation location" of the material. In a purposeful use, the chemicals corresponding to the "installation location" [D], i.e., "installed externally", can be "carrying" or "lasting" (tragend).

[0016] If a certain number of test cycles should be able to be specified in the above-mentioned test standards, at least one single test cycle should be carried out in order to then evaluate the resistance of the material to be tested to the mentioned external influences.

[0017] Furthermore, the object of the present invention is solved by an injection molding method for producing a cover disk for a motor vehicle lamp, wherein the injection molding method comprises the following steps:

[0018] · Providing an injection mold for forming a first cavity,

[0019] · Injecting a transparent body into the first cavity,

[0020] · Providing an injection mold for forming a second cavity,

[0021] · Injecting an opaque body into the second cavity,

[0022] wherein either the first cavity is partially limited by the opaque body or the second cavity is partially limited by the transparent body, i.e., such that the transparent body and the opaque body are integrally and continuously connected to each other during injection molding,

[0023] · Provide an injection mold for forming a pouring cavity, the pouring cavity being partly bounded by a transparent body and partly by an opaque body,

[0024] wherein the opaque body partly bounds at least one overflow cavity which is part of the pouring cavity,

[0025] · Inject a cladding into the pouring cavity by injecting a cladding material into the pouring cavity, wherein the cladding material comprises PU polyurethane,

[0026] wherein during the injection process of injecting into the pouring cavity, air present in the pouring cavity is displaced by the cladding material into the at least one overflow cavity,

[0027] · Demold the cover plate.

[0028] Advantageously, it can be arranged that during injection of the cladding material into the pouring cavity, the pouring cavity is filled with the cladding material against gravity.

[0029] Advantageously, it is arranged that the opaque body is injection molded with a material or has a material which is resistant at least to external influences selected from the group of external influences including influences caused by adverse climatic conditions, mechanical influences, influences caused by solar radiation or influences of chemicals.

[0030] Furthermore, the object of the present invention is solved by an injection mold for producing a cover plate for a motor vehicle lamp, wherein the injection mold has a first mold half and a second mold half,

[0031] wherein the first mold half is configured to receive an injection molded cover plate blank having a transparent body and an opaque body integrally continuous with the transparent body,

[0032] wherein a pouring cavity can be formed in a closed manner between the first mold half and the second mold half, the pouring cavity being partly bounded by the second mold half, partly by the transparent body of the cover plate blank that can be received by the first mold half and partly by the opaque body of the cover plate blank,

[0033] wherein the pouring cavity has at least one overflow cavity which is configured to receive air when the air present in the pouring cavity is displaced due to injection of the cladding material into the pouring cavity,

[0034] wherein the at least one overflow cavity is substantially partly bounded by the second mold half and partly by the opaque body of the cover plate blank that can be received by the first mold half.

[0035] Advantageously, it can be arranged such that the at least one overflow cavity is arranged in the closed form of the mold half substantially at the most distant position against the flow path of the cladding material during injection and with reference to the pouring point of the cladding material, the flow path starting from this pouring point.

[0036] The invention furthermore relates to a motor vehicle lamp having the mentioned cover plate or having a cover plate produced by the mentioned injection molding method.

[0037] Furthermore, the invention relates to a motor vehicle having such a motor vehicle lamp. Description of the Drawings

[0038] The invention is explained below on the basis of exemplary and non - limiting drawings. Among them

[0039] Figure 1 a front view of the cover plate is shown,

[0040] Figure 2 a sectional view of the cover plate is shown,

[0041] Figures 3a to 3d the individual steps of the injection molding method are schematically shown,

[0042] Figure 4 a sectional view of the motor vehicle lamp is shown, and

[0043] Figure 5 the motor vehicle is shown. Detailed Description of the Invention

[0044] The invention is explained below alternately on the basis of Figure 1 and Figure 2 in more detail.

[0045] Figure 1 The cover plate 1 is shown in an orthographic view from the front. The cover plate 1 has an inner face 2 and an outer face 3 opposite the inner face 2. Thus, "front" relates to the direction obtained from the inner face 2 of the cover plate 1 towards the outer face 3. Only the outer face 3 of the cover plate 1 can be seen in the shown view. The following surface part of the cover plate 1 can be called the outer face 3, which surface part can be subjected to certain external influences in the installed state or the intended use of the cover plate 1. In contrast, the following surface part can be called the inner face 2 of the cover plate 1, i.e., the one that is not subjected to external influences or at least less external influences in the installed state or the intended use of the cover plate 1, since it is protected by the housing 7, for example.

[0046] External influences can particularly include those caused by adverse weather conditions, those caused by mechanical actions such as stone impacts, ice crushers, etc., those caused by solar radiation or associated UV loads, and chemical influences such as acids, alcohols, cleaning agents, or oils.

[0047] Therefore, the cover plate 1 or the surface portion of the cover plate 1 that may be subject to external influences (i.e., the outer surface 3) must be resistant to at least certain external influences. The resistance can be evaluated according to multiple criteria, for example.

[0048] For example, when at least one test selected from the group of tests (which includes DIN EN 60068-2-2, such as v2008-05; PV 1200, such as v2004-10; PV 3930, such as v2008-03; DIN EN ISO 6270-1, such as 2018-04) does not result in significant visible changes, such as color changes, loss of gloss, cracks or blisters, there is resistance of the material to the effects caused by adverse climatic conditions.

[0049] For example, when the test according to DIN EN ISO 20567-1, such as v2017-07, gives a characteristic value less than or equal to 3, preferably less than or equal to 2, the material has resistance to mechanical action or the effects such as stone impacts. Alternatively or additionally, when a specific turbidity as defined, for example, in DIN EN ISO 13803, such as v2015-02, is less than or equal to the turbidity of a reference material according to the test according to DIN EN ISO 20566, such as v2021-06, there can be resistance of the material to mechanical action or the effects that occur, for example, in the case of cleaning equipment. Such a reference material is, for example, the cladding material UVKC3000k.

[0050] For example, when the material does not have significant visible changes, such as color changes, loss of gloss, cracks or blisters, according to the test according to PV 3930, such as v2022-04, there is resistance of the material to the effects of solar radiation and the associated UV load.

[0051] For example, when the material does not have significant visible changes, such as color changes, loss of gloss, cracks or blisters, according to the test according to ISO 16750-5, such as v2010-04, there is resistance of the material to the effects of chemicals. The chemicals set in the test can depend on the "installation location" of the material. In a suitable use, the chemicals corresponding to the "installation location" [D], i.e., "installed externally", can be persistent.

[0052] If a certain number of test cycles should be able to be specified in the above-mentioned test criteria, then at least one single test cycle should be carried out in order to then evaluate the resistance of the material to be tested to the mentioned external influences.

[0053] Alternatively or additionally, depending on the market of use, specific basic requirements can also be permanent. If the cover plate 1 is used in a motor vehicle lamp 8, specific ECE regulations (United Nations Economic Commission for Europe vehicle regulations), CCC regulations (Compulsory Certification Management Regulations for Products), or FMVSS regulations (Federal Motor Vehicle Safety Standards) can be considered, for example, with regard to resistance to external influences.

[0054] As can be seen in Figure 2 , the cover plate 1 has a transparent body 4, an opaque body 5, and a coating 6. Figure 2 A sectional view along the A-A line from Figure 1 is shown. The transparent body 4, the opaque body 5, and the coating 6 form a one-piece continuous cover plate body between the inner surface 2 and the outer surface 3. In other words, the transparent body, the opaque body 5, and the coating 6 are arranged between the inner surface 2 and the outer surface 3, where the inner surface 2 and the outer surface 3 are surface parts of the cover plate 1 and together form the entire surface of the cover plate 3. Preferably, the cover plate 1 is manufactured by an injection molding method. The injection molding method will be described later.

[0055] The coating 6 is made of or at least has PU polyurethane. Here, the coating 6 is preferably configured to be transparent. The coating 6 can be applied according to a low-pressure injection molding method, such as reaction injection molding. The advantage of such a coating 6 made of PU polyurethane is in particular that mechanical deformations, such as scratches, can be smoothed again by heat input into the coating 6. Such heat input can already be present in sufficient amounts by ambient heat. In particular, sunlight incident on the coating 6 can ensure the corresponding heat input. It is also conceivable that, for example, a light source ensures the necessary heat input at the coating 6 of the cover plate 1. For example, a correspondingly applied and scratched material can be tensioned again within a few seconds at 60 °C and thus the existing scratches can be eliminated.

[0056] As can be seen, the outer surface 3 is only formed at the coating 6 and the opaque body 5. This means that the surface part of the cover plate 1 that may be subject to external influences during purposeful use is only formed by the coating 6 and the opaque body 5. Importantly, the outer surface 3 is not formed at the transparent body 4. The transparent body 4 can be made of or at least have PC polycarbonate or PMMA polymethyl methacrylate. These materials are characterized by high light transmittance in the visible range and are therefore particularly suitable for use in motor vehicle lamps 8. However, these materials are vulnerable to at least some of the above-mentioned external influences and therefore require a corresponding coating 6 that is resistant to one, several, or all of the above-mentioned influences. The transparent body 4 can also be colored. For example, the transparent body 4 can be colored red.

[0057] The opaque body 5 can be made of or at least have a material which is resistant to at least one, several or all of the external influences mentioned above. Preferably, the opaque body 5 is resistant to the influence of chemicals. For example, thermoplastic terpolymers, preferably ABS acrylonitrile-butadiene-styrene, are considered as possible materials for the opaque body 5. The opaque body 5 can thus be made of ABS acrylonitrile-butadiene-styrene or at least have this material. For example, the opaque body 5 can be made of a composition of PC polycarbonate and ABS acrylonitrile-butadiene-styrene. Thus, the opaque body 5 can have a lower light transmittance compared to the transparent body 4. Therefore, "opaque" should not be compulsorily understood as a material that is completely light-impermeable. In addition, the opaque body 5 can also be colored.

[0058] It is possible to impose fewer requirements on the resistance of the opaque body 5 with respect to external influences, since a certain resistance is ensured in other ways. For example, by using the cover plate 1 purposefully in the vehicle lamp 8, the opaque body 5 can be protected from specific external influences by protective elements such as the engine hood, covering elements, shields or bumpers. For example, such protective elements are designed to protect the opaque body 5 of the cover plate 1 at the outside 3 from external influences such as solar radiation and the accompanying UV load as well as from external mechanical actions. Therefore, in such a purposeful use of the cover plate 1 and in combination with the protective elements mentioned, a part of the resistance to external influences can be dispensed with for the area formed by the opaque body 5 at the outside 3.

[0059] Viewed from the outside 3 in the direction of the inner side 2, the cladding 6 completely covers the transparent body 4. Viewed from the outside 3 in the direction of the inner side 2, the opaque body 5 is only partially covered by the cladding 6. The area of the cladding 6 that completely covers the transparent body 4 forms a useful section 6a, which is thus part of the cladding 6. Although only a single useful section 6a is shown, it is conceivable that there are several useful sections. In particular, in designs with a correspondingly designed opaque body 5, several transparent windows can be formed, whereby there are several useful sections if necessary. Conversely, viewed again from the outside 3 in the direction of the inner side 2, the areas of the cladding 6 that only partially cover the opaque body 5 form partial sections 6b, 6c, 6d of the cladding 6. Therefore, the areas of the cladding 6 that only partially cover the opaque body 5 form at least one first partial section 6b. The first partial section 6b is formed in the overflow cavity 31 during the injection process of the cladding 6.

[0060] A partial covering of the second part section 6c of the opaque body 5 by the cladding 6 can be formed here in the casting cavity during the injection process of the cladding 6. A partial covering of the third part section 6d of the opaque body 5 by the cladding 6 can be formed here in another overflow cavity during the injection process of the cladding 6. The injection process includes injecting the cladding 6 in the pouring cavity 30, which has at least one overflow cavity 31.

[0061] The surface properties of the first part section 6b or all part sections 6b, 6c, 6d can be different from those of the useful part section 6a. For example, the air that can be displaced into the overflow cavity 31 during the injection process of the cladding material results in a meniscus formation along the edge regions of the first part section 6b and the third part section 6d (shown in Figure 1 . Compared to the useful part section 6a, the second part section 6c formed in the casting cavity during the injection process of the cladding 6 can have differences in surface properties due to the pouring point. However, the first part section 6b or all part sections 6b, 6c, 6d are not noticeable or only barely noticeable to the observer in the direction of viewing from the outside 3 towards the inside 2 because they partially cover the opaque body 5.

[0062] Although only a limited number of part sections 6b, 6c, 6d are shown, any number of part sections can be provided. Therefore, depending on the geometry and shape of the cover plate 1, i.e., depending on the geometry and shape of the transparent body 5 and the opaque body 5, other part sections can be envisioned. All part sections 6b, 6c, 6d can be connected to each other by the useful part section 6a. Therefore, the part sections 6b, 6c, 6d are not directly connected to each other. The useful part section 6a and the part sections 6b, 6c, 6d together form the cladding 6.

[0063] Viewed from the outside 3 in the direction of the inside 2, the cladding 6 has a certain thickness. The thickness can be between 0.1 mm and 0.9 mm. Preferably, the thickness of the useful part section 6a of the cladding 6 is the same at all locations of the cladding 6.

[0064] Similarly, the first part section 6b of the cladding 6 has a thickness such that it is less than or equal to, preferably equal to, the thickness of the useful part section 6a and can thus also be between 0.1 mm and 0.9 mm. The same can apply to the second part section 6c and / or the third part section 6d of the cladding 6 or to all other part sections.

[0065] The second part section 6c of the cladding 6 shown (which is formed separately from the first part section 6b in the casting cavity during the injection process of the cladding 6) preferably forms along the outside 3 at opposite regions of the cladding 6. This achieves improved surface properties of the cladding 6, in particular of the useful part section 6a of the cladding 6.

[0066] In the following, according to Figures 3a to 3d an exemplary injection molding method will be explained in more detail. For the sake of clarity here, the drawings only show the fragment of the cover plate 1 presented in Figure 2 dashed lines.

[0067] The injection molding method comprises a plurality of steps, the chronological order of which does not have to be compulsorily in the order now described. As long as it is logically applicable, the steps can also be carried out in another order.

[0068] In one step, referring to Figure 3a , an injection mold is provided for forming a first cavity 10. A cavity represents a cavity that is as closed as possible, into which injection molding material can be injected. The necessary sealing of the cavity 10 depends here on the material to be injected. For example, thermoplastics such as PC polycarbonate, PMMA polymethyl methacrylate or ABS acrylonitrile-butadiene-styrene allow a smaller sealing at the edge region of the cavity due to their relatively high viscosity, whereby for example mold degassing can be achieved.

[0069] The first cavity 10 is filled with the corresponding injection molding material in order to thereby produce the transparent body 4. Thus, the first cavity 10 determines the shape of the transparent body 4, which is produced by injection molding in the first cavity 10 and after the injected injection molding material has hardened. The possible materials for the transparent body 4 have already been mentioned.

[0070] In a further step, referring to Figure 3b , an injection mold is provided for forming a second cavity 20. The second cavity 20 determines the shape of the opaque body 5, which is produced by injection molding in the second cavity 20 and after the injected injection molding material has hardened. The possible materials for the opaque body 5 have already been mentioned.

[0071] In the shown device, the second cavity 20 is partially bounded by the transparent body 4. The following variant of the injection molding method is also possible, namely, first injecting the opaque body 5 and then injecting the transparent body 4. In this case, the opaque body 5 will partially limit the first cavity 10. It is important that the transparent body 4 and the opaque body 5 are integrally and continuously connected to each other during the injection molding method.

[0072] In a further step, referring to Figure 3c, an injection mold 100 is provided for forming a pouring cavity 30. The pouring cavity 30 defines the shape of the cladding 6, which is produced by injecting into the pouring cavity 30 and after the injected cladding material has hardened. Although here the term "injection molding" is used in connection with a cladding material having PU polyurethane, the process can also be referred to as "fluten". As already mentioned, the cladding material can be introduced into the pouring cavity 30 by a low-pressure injection molding method, such as reactive injection molding. The pouring cavity 30 is bounded in part by a transparent body 4 and in part by an opaque body 5, so that after the cladding 6 has been injected into the pouring cavity 30, the transparent body 4, the opaque body and the cladding 6 are integrally and continuously connected. Additionally, the pouring cavity 30 is bounded by a second mold half 120 of the injection mold 100, wherein a first mold half 110 of the injection mold 100 carries the opaque body 5 and the transparent body 4 integrally and continuously with the opaque body. The transparent body 4 and the opaque body 5 integrally and continuously therewith can be jointly referred to as an injection-molded cover disk blank 40, which is thus carried by the first mold half 110 or can be accommodated by the first mold half. The pouring cavity 30 is preferably at least as airtight as possible.

[0073] Thus, in the closed form of the injection mold 100 between the first mold half 110 and the second mold half 120, as shown, a pouring cavity 30 can be formed, which is bounded in part by the second mold half 120, in part by the transparent body 4 of the cover disk blank 40 that can be accommodated by the first mold half 110, and in part by the opaque body 5 of the cover disk blank.

[0074] The opaque body 5 partly bounds an overflow cavity 31. The overflow cavity 31 is part of the pouring cavity 30, by means of which the part of the pouring cavity 30 bounded only by the transparent body 4 and the second mold half 120 is enlarged. Thus, the overflow cavity 31, in addition to the connection to the remaining cavity of the pouring cavity 30, is bounded only by the opaque body 5 and by the second mold half 120.

[0075] Thereby, the pouring cavity 30 has at least one overflow cavity 31, which is provided for accommodating air when the air present in the pouring cavity 30 is displaced and, if possible, compressed by injecting the cladding material into the pouring cavity 30.

[0076] The provision of the cavities 10, 20, 30 can be achieved, for example, by known multi-component injection molding methods. Without limitation, here, for example, a flip plate mechanism or a rotary plate mechanism can be considered.

[0077] The cladding 6 is formed by injecting a cladding material into the pouring cavity 30. The air present in the pouring cavity 30 is displaced by the cladding material into the overflow cavity 31 during the injection process and is compressed there if possible. A part of the overflow cavity 31 is filled with the cladding material. This part then forms the first partial section 6b of the cladding 6. See Figure 1 It should be noted that the projection of the boundary of the overflow cavity is shown in dashed lines around the first partial section 6b and the third partial section 6d.

[0078] Preferably, the pouring cavity 30 is filled with the cladding material against gravity in order to achieve improved surface properties of the cladding 6. For this purpose, the injection mold provided can be designed or rotated accordingly to form the pouring cavity 30.

[0079] To form the cladding 6 in the pouring cavity 30, the injection mold 100 has at least one pouring point (not shown), from which the flow path of the cladding material starts during the injection of the cladding material. A "pouring point" can also be understood as a pouring area or a pouring film. The pouring point preferably opens into the mentioned pouring cavity in which the second partial section 6c of the cladding 6 can be formed. Improved surface properties of the cladding 6, in particular of the useful section 6a of the cladding 6, are also achieved in that the overflow cavity 31 is arranged in the closed form of the mold halves 110, 120 substantially at the most distant position against the flow path and with reference to the pouring point. If the injection mold 100 is additionally designed such that the pouring cavity 30 can be filled with the cladding material against gravity, the best surface properties of the cladding 6, in particular of the useful section 6a, are achieved.

[0080] The volume of the overflow cavity 31 depends on factors such as the injection pressure, the cladding material, and the shape of the cladding 6. The volume of the overflow cavity 31 is preferably selected such that the overflow cavity can accommodate all the air present in the pouring cavity 30 in a compressed form if possible during the injection process. If there are multiple overflow cavities, the possible volume relates to the total volume of all the overflow cavities.

[0081] In a further, preferably final step, see Figure 3d , the cover plate 1 is demolded. For this purpose, the first mold half 110 and the second mold half 120 are moved away from each other and the cover plate 1 is ejected. The cover plate 1 having the opaque body 5, the transparent body 4, and the cladding 6 can then be connected, for example glued, to the housing 7 if required.

[0082] Figure 4The cover plate 1 is shown when used in a motor vehicle lamp 8 in accordance with the destination, wherein the cover plate 1 is connected to the housing 7, whereby the inner surface 2 of the cover plate 1 is protected from one, several or all of the mentioned external influences. A lamp module, in particular an LED lamp module, can be arranged in the interior region of the motor vehicle lamp.

[0083] Figure 5 A motor vehicle 9 is shown in which such a motor vehicle lamp 8 is installed. Such a motor vehicle lamp 8 can be, for example, a tail lamp, a fog lamp, a signal lamp or a radiator grille illumination device.

[0084] The invention is not limited to the shown embodiments, but is defined by the total scope of protection. The individual aspects of the invention or the embodiments can also be employed and combined with each other. Any reference signs are exemplary and are only used for easier readability and not as a limitation.

Claims

1. A cover plate (1) for a motor vehicle lamp (8), wherein the cover plate (1) has inner face(2), an outer surface (3) opposite to the inner surface (2), Transparent body (4), Opaque body (5) and The coating (6) comprises PU polyurethane, It is characterized in that The transparent body (4), the opaque body (5) and the coating (6) are produced in one piece and continuously, preferably by injection molding. That is, the outer surface (3) is formed only at the cover layer (6) and at the opaque body (5), wherein the coating (6) completely covers the transparent body (4) and only partially covers the opaque body (5) when viewed from the outer side (3) in the direction of the inner side (2), The area of ​​the coating (6) that completely covers the transparent body (4) forms a useful section (6a) of the coating, and the area of ​​the coating (6) that only partially covers the opaque body (5) forms at least one first partial section (6b) of the coating (6), which is at least partially formed in the overflow cavity (31) during the injection of the coating (6).

2. The covering disk (1) according to claim 1, wherein the useful section (6a) of the coating (6) has a thickness of between 0.1 mm and 0.9 mm, as viewed from the outer surface (3) in the direction of the inner surface (2).

3. The covering disk (1) according to any of the preceding claims, wherein the thickness of the first partial section (6b) of the coating (6) is less than or equal to, preferably equal to, the thickness of the useful section (6a) of the coating (6).

4. The cover plate (1) according to any of the preceding claims, wherein the region of the coating (6) which only partially covers the opaque body (5) additionally forms a second partial section (6c), which is formed separately from the first partial section (6b) in the casting cavity during the injection of the coating (6). 5 . The covering disk ( 1 ) according to claim 4 , wherein the second partial section ( 6 c ) is formed along the outer surface ( 3 ) substantially at opposite regions of the coating ( 6 ).

6. Cover tray (1) according to any of the preceding claims, wherein the opaque body (5) comprises a material which is resistant at least with respect to external influences selected from the group of external influences, the group comprising influences caused by unfavorable climatic conditions, mechanical influences, influences caused by solar radiation or influences of chemicals.

7. An injection molding method for producing a cover plate (1) for a motor vehicle lamp, wherein the injection molding method comprises the following steps: Providing an injection mold for forming the first cavity (10), Injection molding a transparent body (4) in the first cavity (10), Providing an injection mold for forming the second cavity (20), Injection molding an opaque body (5) in the second cavity (20), wherein the first cavity (10) is partially bounded by the opaque body (5) or the second cavity (20) is partially bounded by the transparent body (4) in such a way that the transparent body (4) and the opaque body (5) are continuously connected to each other in one piece during injection molding, providing an injection mould for the shaping of a pouring cavity (30), said pouring cavity (30) being limited partly by said transparent body (4) and partly by said opaque body (5), The opaque body (5) partially limits at least one overflow cavity (31), and the at least one overflow cavity (31) is a part of the pouring cavity (30). injection molding a coating (6) in the pouring cavity (30) by injecting a coating material into the pouring cavity (30), wherein the coating material comprises PU polyurethane, wherein during the injection process into the casting chamber (30), air present in the casting chamber (30) is displaced by the coating material into the at least one overflow chamber (31), De-mould the cover plate (1).

8. The injection molding method according to claim 7, wherein during the injection molding of the coating material into the casting cavity (30), the casting cavity (30) is filled with the coating material against gravity.

9. Injection molding method according to any one of claims 7 to 8, wherein the opaque body (5) is injection molded from a material or has a material that is resistant at least to external influences selected from a group of external influences, the group including influences caused by unfavorable climatic conditions, mechanical influences, influences caused by solar radiation or influences of chemicals.

10. An injection mold (100) for producing a cover disk (1) for a motor vehicle lamp, wherein the injection mold (100) comprises a first mold half (110) and a second mold half (120), The first mold half (110) is configured to receive an injection molded cover plate blank (40), wherein the cover plate blank (40) has a transparent body (4) and an opaque body (5) which is continuous with the transparent body in one piece. A pouring cavity (30) can be formed in a closed form between the first mold half (110) and the second mold half (120), wherein the pouring cavity (30) is partially limited by the second mold half (120), partially by a transparent body (4) of a cover plate blank (40) that can be accommodated by the first mold half (110), and partially by an opaque body (5) of the cover plate blank (40), The pouring chamber (30) has at least one overflow chamber (31), which is configured to receive air when the air present in the pouring chamber (30) is displaced due to the coating material being injected into the pouring chamber (30). The at least one overflow cavity (31) is partially bounded by the second mold half (120) and partially by an opaque body (5) of a cover tray blank (40) that can be received by the first mold half (110).

11. An injection mold (100) according to claim 10, wherein the at least one overflow cavity (31) is arranged in a closed form of the mold half (110, 120) at a position farthest away from the flow path of the coating material during injection and with reference to a pouring point of the coating material, the flow path starting from the pouring point.

12. A motor vehicle light (8) having a cover disk (1) according to any one of claims 1 to 6 or having a cover disk (1) produced by an injection molding method according to any one of claims 7 to 9.

13. A motor vehicle (9) having a motor vehicle light (8) according to claim 12.

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