Method for manufacturing a plastic composite cover and associated plastic composite cover, arrangement and use

Abstract

Method for producing a plastic composite cover (1) in a layered structure (2, 3, 4, 5) especially for a motor vehicle: Arranging at least one first plastic film (2) in a first forming tool (21a, 21b) such that a first cavity (22) is formed between the first plastic film (2) and the first forming tool (21a, 21b); subsequent back injection molding of at least the first plastic film (2) in a first thermally forming process step by introducing a first thermoplastic into the first cavity (22) in order to produce a partial layer structure (2, 4) as a molded part, wherein the partial layer structure (2, 4) comprises at least the first plastic film (2) and a first layer (4) formed by the first thermoplastic, and the first plastic film (2) defines an outer surface (13) on its side facing away from the first layer (4); and subsequent, at least partial, demolding of the partial layer structure (2, 4) from the first forming tool (21a, 21b); subsequent arrangement of the partial layer structure (2, 4) in a second forming tool (22a, 22b) forming a second cavity (23) between the outer surface (13) and the second forming tool (22a, 22b); subsequent flooding of the second cavity (23) with a casting resin; subsequent hardening of the casting resin to form a thin layer of casting resin (5) adjacent to the outer surface (13) of the partial layer structure (2, 4) and to obtain a plastic composite cover (1) from the casting resin layer (5) and at least the partial layer structure (2, 4), the outer surface (14) formed by the casting resin layer (5) being defined by a surface (15) of the second shaping tool (22a, 22b) that bounds the second cavity (23); subsequent demolding of the plastic composite cover (1) from the second forming tool (22a, 22b), characterized by the fact that the surface (14) of the casting resin layer (5) after demolding the plastic composite cover (1) has several edges (16) extending over the surface (14), each having a maximum radius of curvature of less than 0.6 mm; that at least the first thermoplastic of the first layer (4) and the first plastic film (2) and the casting resin layer (5) are transparent; that in the arranging step a second plastic film (3) is further arranged in the first forming tool (21a, 21b) such that the first plastic film (2) and the second plastic film (3) are spaced apart from each other forming the first cavity (22) and in the subsequent back injection molding of the first plastic film and the second plastic film in the first thermally forming process step the first layer (4) is formed between the plastic film (2) and the second plastic film (3); or alternatively: Arranging the partial layer structure (2, 4) and the second plastic film (3) in a third forming tool, forming a third cavity between the first layer (4) and the second plastic film (3); and Subsequent back injection molding of the second plastic film (3) in a second thermoforming process step, introducing a second thermoplastic into the third cavity to supplement the partial layer structure (2, 4) by a second layer made of the second thermoplastic and by the second plastic film (3), wherein the first layer (4) and the second layer are arranged adjacent to each other between the first plastic film (2) and the second plastic film (4) via a common interface; and subsequent, at least partial, demolding from the third forming tool; and that the second plastic film (3) is coated with a metallic translucent material.

Description

[0001] The invention relates to a method for manufacturing a composite plastic cover, an associated composite plastic cover, its arrangement, and its use. Currently, the use of covers made of glass materials in the passenger compartment of motor vehicles is preferred for a variety of reasons. On the one hand, the coolness felt upon touch is perceived as haptically pleasant, and on the other hand, the high transparency of the glass material and the elegance of the surfaces created by it are generally perceived as very high-quality. Disadvantages include the comparatively high manufacturing costs and the weight of such covers, especially when the cover needs to have a certain thickness so that three-dimensional surface contours can be integrated into it.Furthermore, the risk of breakage and the resulting splintering pose a significant risk of injury, thus precluding the integration of covers made entirely or partially of glass materials into the dashboard area of ​​motor vehicles. Manufacturing a cover from plastic, particularly by thermoforming, carries the risk that the cover, especially with relatively thin and large covers, will exhibit internal stresses that quickly lead to unsightly cracking. While it is also known to produce such covers by overmolding plastic films as composite plastic parts, if the plastic film forms the outer visible surface, the contour formed by the plastic film is usually aesthetically disadvantageous, particularly at edges or similar transitions, so that the impression imitating a glass material is not achieved.

[0002] A method for producing a plastic composite cover and a plastic composite cover according to the respective preamble of the independent claims are each known from EP 1 743 756 A1. Generic methods and covers are also known from DE 10 2013 114 276 A1 and CH 708 048 A2.

[0003] Against this background, there was a need for a method for producing a generic plastic composite cover that is comparatively lightweight, durable, and has a high-quality appearance that at least approximates that of glass materials. This problem is solved by a method for producing a plastic composite cover according to claim 1. Equally advantageous uses and correspondingly advantageous plastic composite covers are each the subject of the dependent claims. Advantageous embodiments are each the subject of the dependent claims. The description, particularly in conjunction with the figures, further characterizes and specifies the invention.

[0004] The invention relates to a method for manufacturing a composite plastic cover, particularly for a motor vehicle. According to the invention, a step of the arrangement process is provided in which a first plastic film is arranged in a first forming tool such that a first cavity is formed between the first plastic film and the forming tool. The term "plastic film" is to be interpreted broadly, so that only a film-shaped substrate made of a plastic, such as a thermoplastic, preferably a polycarbonate or a polymethyl methacrylate, is required, which may additionally be coated, for example, by vapor deposition with a metallic coating, or coated with an anti-reflective, scratch-resistant, or abrasion-resistant coating.

[0005] According to the invention, a subsequent back injection molding of the first plastic film takes place in a first thermally forming process step, in which a first thermoplastic, such as polycarbonate, is introduced into the first cavity to produce a partial layer structure as a molded part, wherein the partial layer structure comprises the first plastic film and a first layer formed by the first thermoplastic. The first plastic film defines an outer surface located on a side of the first plastic film facing away from the first layer, while the first layer defines an outer interface of the partial layer structure on the side facing away from the first plastic film, or preferably abuts a second layer made of a thermoplastic or a second plastic film.

[0006] In a subsequent demolding step, for example after the surface solidification of the first layer or later, the previously produced molded part is at least partially demolded.

[0007] According to the invention, the demolded partial layer structure is then arranged in a second molding tool, forming a second cavity between the outer surface of the first plastic film and the second molding tool. In a subsequent step, the second cavity is flooded with a casting resin. In a further step, the casting resin is cured, also called crosslinking, to form a resin layer adjacent to the outer surface of the first plastic film and to obtain a composite plastic cover consisting of the resin layer and at least the partial layer structure. According to the invention, the outer surface of the composite plastic cover formed by the resin layer is determined by the surface of the second molding tool that defines the second cavity. Thus, the second cavity defines the shape of the outer surface of the resin layer facing away from the first plastic film.

[0008] In a subsequent step, the plastic composite cover produced in this way is demolded from the second, shaping tool.

[0009] By producing the resin layer using molds, its outer surface is determined by the shape of the tool, allowing for the creation of any desired contours. These contours can be visually appealing, for example, by creating relatively sharp-edged transitions. According to the invention, these transitions have an edge radius of no more than 0.6 mm. A resin layer is considered "thin," for example, if its maximum thickness is no more than 1 / 10 of the maximum thickness of the composite plastic cover. For example, the average thickness of the resin layer is 0.2 to 3 mm. Preferably, the maximum thickness of the resin layer is less than 1 mm, and more preferably less than 0.7 mm.This thin layer, compared to the overall thickness of the plastic cover, minimizes, firstly, stresses in the plastic cover caused by shrinkage during the curing of the casting resin, and secondly, minimizes color disturbances due to yellowing. Further steps for micro-coating or surface treatment of the casting resin layer may be included. For example, additional micro-coatings can be applied to the surface of the casting resin layer to increase its tensile strength. Micro-coatings are defined as coatings with a thickness of a few to several decades of micrometers.

[0010] Preferably, the casting resin is a polyurethane-containing casting resin, wherein the polyurethane is preferably an aliphatic polyurethane or a thermoplastic polyurethane. The casting resin may further comprise additional fillers or additives, for example, additives to improve the resistance of the casting resin to UV radiation.

[0011] According to a preferred embodiment of the method, a composite plastic cover is produced with two plastic films spaced apart from each other and connected, preferably by a material bond, via one or more layers of thermoplastic. This "sandwich structure" of the two plastic films and the thermoplastic layer(s) creates a stabilizing, dimensionally accurate, and, in particular, stress-neutral base. This "sandwich structure" can withstand any stresses that may arise from the shrinkage process of the casting resin and contributes to the dimensional stability of the composite plastic cover.

[0012] According to the invention, in the aforementioned step of arranging the first plastic film, a second plastic film is arranged in the first molding tool at a distance from the first plastic film, so that the first cavity is formed between the films. During the aforementioned back injection molding of the first plastic film, the second plastic film is also laterally back-injected in the first thermal molding process step, whereby the first layer is formed between the first and second plastic films. Subsequently, demolding is carried out, at least partially, from the first molding tool.The term plastic film is to be interpreted broadly with regard to the second plastic film, so that only a film-shaped substrate made of a plastic, such as a thermoplastic plastic, preferably a polycarbonate or a polymethyl methacrylate, is mandatory, which may additionally be coated, for example by vapor deposition, metallically coated, anti-reflective, scratch-resistant or coated to increase abrasion resistance.

[0013] According to an alternative, multi-stage variant of the previously described process for manufacturing a composite plastic cover comprising two plastic films, in a step following demolding from the first mold, the partial layer structure with a second plastic film is arranged in a third mold, whereby a third cavity is formed between the first layer and the second plastic film. The third mold may incorporate parts of the first mold.

[0014] In this alternative embodiment according to the invention, a subsequent injection molding of the second plastic film takes place in a second thermally forming process step, with the introduction of a second thermoplastic, such as a polycarbonate, into the third cavity, in order to supplement the partial layer structure by a second layer made of the second thermoplastic and by the second plastic film, in order to obtain a layer structure as a plastic composite cover, in which the first layer and the second layer are arranged adjacent to each other between the first plastic film and the second plastic film via a common interface.

[0015] In a subsequent step, for example after the surface solidification of the second layer or later, demolding takes place from the third tool. Preferably, at least the first layer and the second layer are bonded together after demolding.

[0016] In both variants described above, additional surface treatment or surface finishing steps and / or steps for removing sprue parts and burrs from the plastic composite cover may also be provided.

[0017] It is also conceivable to take steps in which the first and second plastic films, which are part of the composite plastic cover, are coated for the first time or additionally after demolding.

[0018] It has been shown that, by using two plastic films, durable, comparatively lightweight, yet expansive and also stress-free covers can be produced, which also have visually attractive properties and whose haptic and external appearance can be adjusted almost arbitrarily at reasonable costs by appropriate coating of the outer films.

[0019] In one embodiment, the step of flooding with the casting resin can be carried out between the two thermally forming process steps; however, it is preferably provided that the flooding step is carried out subsequently.

[0020] According to the invention, the first thermoplastic of the first layer, the first plastic film, and the casting resin layer are transparent. According to the invention, the second plastic film is coated with a metallic translucent coating, for example, by vapor deposition such as chemical or physical vapor deposition, sputtering, or so-called non-conductive vacuum metallizing (NCVM). Preferably, the coating is applied in a step preceding the respective assembly step.

[0021] According to a preferred embodiment, the optical refractive indices of the cast resin layer, the first plastic film, and the first thermoplastic of the first layer differ from each other by no more than 0.2, preferably 0.1. Preferably, they have the same color according to DIN 5033, or are colorless or achromatic. This allows an optical "depth" similar to that of a crystal to be created.

[0022] According to a preferred embodiment, at least the first plastic film and the outer surface of the cast resin layer have one or more three-dimensional contours, preferably each a contour formed from flat surfaces, and more preferably a contour forming one or more edges. For example, rhomboid, faceted, and / or prismatic structures are provided on the surface of the cast resin layer and the first plastic film. Preferably, the surface of the cast resin layer and the first plastic film are faceted multiple times to imitate the optical appearance of a cut diamond. In one embodiment, the first and second plastic films are flat in the demolded composite plastic cover. For optical reasons, the first plastic film, the surface of the cast resin layer, and the second plastic film preferably form one or more three-dimensional contours, preferably each a contour formed from flat surfaces.Because the surface of the resin layer is formed by casting molds, visually attractive light-refracting effects can occur, making the cover appear more attractive.

[0023] Preferably, the first plastic film and the outer surface of the casting resin layer have consecutive contours. This means that the contours of the first plastic film and the surface of the casting resin layer are designed to tend towards parallel alignment, without necessarily having to be strictly parallel, thus aiming for a uniform thickness of the casting resin layer. Preferably, both the first and the second plastic film are multiply faceted.

[0024] Preferably, the maximum extent of the first plastic film is at least 10 times, preferably at least 20 times, and even more preferably at least 30 times, greater than a minimum dimension, also called minimum thickness, of the resulting composite plastic cover. The minimum dimension is determined by a cut made through the composite plastic cover perpendicular to the maximum extent of the first plastic film and is the minimum thickness of this cut.

[0025] To achieve improved sealing of the second cavity, for example in the area between the second forming tool and the partial layer structure, the second forming tool is arranged adjacent to the first plastic film in such a way that the first plastic film extends laterally beyond the casting resin layer.

[0026] Preferably, during back injection molding, the first thermoplastic and the second thermoplastic are injected in a direction parallel to the first plastic film during the first thermal forming process step and during the second thermal forming process step.

[0027] The invention further relates to a composite plastic cover for a motor vehicle with a layered structure. According to the invention, the layered structure comprises a first plastic film and optionally a second plastic film. The layered structure further comprises at least one first layer made of a first thermoplastic, arranged adjacent on one side to the first plastic film, and adjoining a second plastic film either directly or via a second layer made of a second thermoplastic. In the latter preferred embodiment, the first layer and the second layer are arranged adjacent to one another, forming a common interface, and the interface extends between the first plastic film and the second plastic film and is spaced apart from these two films.According to the invention, the first plastic film and the second plastic film are materially bonded and spaced apart from each other via the first layer or via the first layer and a second layer made of a second thermoplastic, which is materially bonded to the first layer.

[0028] According to the invention, a casting resin layer is provided adjacent to the first plastic film on the side of the first plastic film facing away from the first layer, which forms an outer surface of the plastic composite cover.

[0029] It has been shown that the plastic composite cover according to the invention is particularly durable, comparatively lightweight, and yet can be extended without exhibiting strong internal stresses. Furthermore, it possesses visually appealing properties. The resin layer allows for free and arbitrary shaping of its surface in a single molding process step.

[0030] According to the invention, at least the first thermoplastic of the first layer, the first plastic film, and the casting resin layer are transparent. According to the invention, the second plastic film is coated with a metallic translucent material, for example, by vapor deposition such as chemical or physical vapor deposition, sputtering, or so-called non-conductive vacuum metallizing (NCVM).

[0031] According to a preferred embodiment, the optical refractive indices of the cast resin layer, the first plastic film, and the first thermoplastic of the first layer differ from each other by no more than 0.2, preferably 0.1. Preferably, they have the same color according to DIN 5033, or are colorless or achromatic. This allows an optical "depth" similar to that of a crystal to be created.

[0032] According to a preferred embodiment of the composite plastic cover, at least the first plastic film and the outer surface of the cast resin layer have one or more three-dimensional contours, preferably each a contour formed from flat surfaces, and more preferably a contour forming one or more straight edges. In one embodiment, the first and second plastic films are flat in the demolded composite plastic cover. For optical reasons, the first plastic film, the surface of the cast resin layer, and the second plastic film preferably form one or more three-dimensional contours, preferably each a contour formed from flat surfaces. This allows for optically attractive light-refracting effects, which make the cover appear more appealing. For example, one or more prismatic contours are provided.This can create visually appealing light-refracting effects that make the cover appear more attractive.

[0033] Preferably, the first plastic film and the outer surface of the casting resin layer have contours that follow each other. This means that the contours of the first plastic film and the surface of the casting resin layer are designed to tend towards parallel alignment, without necessarily being strictly parallel, thus aiming for a uniform thickness of the casting resin layer. It is also preferred that the respective contour of the second plastic film follows that of the first plastic film. For example, the first plastic film is convex, while at the corresponding point, the second plastic film is concave relative to the adjacent layer.

[0034] It is preferably provided that the maximum extent of the first plastic film is at least 10 times, preferably at least 20 times, and even more preferably at least 30 times, greater than a minimum dimension of the resulting plastic composite cover.

[0035] Preferably, at least the first layer and the second layer are bonded together. Even more preferably, the first plastic film is bonded together with the first layer, and the first layer is bonded together with the second layer, while furthermore, the second layer is bonded together with the second plastic film.

[0036] The invention further relates to the arrangement comprising the plastic composite cover in one of the previously described embodiments and a light source for backlighting the plastic composite cover, such that its outer surface, formed by the cast resin layer, is backlit by the light of the light source. Preferably, the light source is arranged such that the plastic composite cover, which has a layered structure, is penetrated by the light of the light source in a direction following the stacking direction of its layers.

[0037] The invention further relates to the use of the plastic composite cover in one of the previously described embodiments in a motor vehicle.

[0038] The invention is explained in more detail with reference to the following figures. The figures are to be understood as examples only and each represents merely one preferred embodiment. They show: Fig. 1 a perspective view of an embodiment of the plastic composite cover according to the invention; Fig. 2 a sectional view of the arrangement 10 according to the invention from the in Fig. 1 plastic composite cover shown and a light source 11; Fig. 3a-c each schematically represent the initial, final and intermediate states of the inventive method for producing the plastic composite cover from Fig. 1.

[0039] The composite plastic cover 1 according to the invention is intended for use in a motor vehicle (not shown) and is arranged, for example, in a dashboard or center console belonging to the vehicle. It serves as an aesthetically pleasing cover for a backlit function display. The composite plastic cover 1 is elongated, so the first plastic film 2 belonging to the composite plastic cover 1 has a maximum dimension I that exceeds the minimum dimension D of the composite plastic cover 1 by a multiple. The minimum dimension D is defined by the minimum thickness of the composite plastic cover 1 in the stacking direction of the layers or films of the composite plastic cover 1. Its maximum extent relative to the first plastic film 2 is denoted by I and is more than 50 cm, such as 1 m.The minimum dimension D of the composite plastic cover 1 in the stacking direction of its layers and films, such as the first plastic film 2 and the second plastic film 3, is in the range of 1 to 3 cm. The layer structure includes a cast resin layer 5, which, when installed as intended, defines an outer surface 14 facing the vehicle occupant. From the vehicle occupant's perspective, the first plastic film 2 is located beneath the cast resin layer 5. Adjacent to and materially bonded to the first plastic film 2 is a first layer 4 made of a first transparent thermoplastic. The side of the first layer 4 facing away from the vehicle occupant borders the second plastic film 3, which is behind the vehicle occupant's view, and is materially bonded to it.The second plastic film 3 is metallically vapor-coated to be translucent in certain areas, while furthermore an opaque printing, representing a symbol or a pictogram, is partially provided to realize a function indicator.

[0040] Due to the thermal injection molding process used in manufacturing, the first plastic film 2 is bonded to the first layer 4, and the latter is bonded to the second plastic film 3. A relatively thin layer of casting resin 5 is applied to the surface of the first plastic film 2 facing away from the first layer 4 by means of a mold. The outer surface 14 of this layer, facing the vehicle occupant, is essentially determined by the mold used to produce the casting resin layer 5 during the molding step. It should be noted that the representation in the figures is not to scale. This casting resin layer 5 is faceted multiple times and thus has pronounced edges 16 that mimic the visual impression of a glass surface.This surface of the casting resin layer 5, but also the first plastic film 2, and to some extent also the second plastic film 3, exhibit contours 6 due to their multiple faceting, which are formed three-dimensionally by angularly abutting, planar surfaces and thus form contours 6 that create straight edges 16 at the abutting surfaces and thus, due to the possible multiple reflections, imitate the optical impression of a polished crystal.

[0041] Fig. Figure 2 shows an arrangement 10 according to the invention from the one shown in Fig. Figure 1 shows a composite plastic cover 1 and a light source 11. The light source 11 is an SMD LED mounted on a circuit board 12 and positioned on the side of the composite plastic cover 1 facing away from the vehicle occupant. It couples light into the composite plastic cover 1 via a diffuser layer 7 and the second plastic film 3, with the side of the second plastic film 2 facing away from the vehicle occupant defining the light entry surface. The light penetrates the composite plastic cover 1 in the stacking direction of the layers or films, thus passing through the transparent second plastic film 3, the transparent first layer 4, the transparent first plastic film 2, and the cast resin layer 5, which is transparent at least in its cured state.To avoid interface reflections and thereby imitate the optical effect of a glass material, the transparent second plastic film 3, the transparent first layer 4, the transparent first plastic film 2, and the cast resin layer 5, which is transparent at least in its hardened state, each have an approximately identical refractive index. This means that the refractive indices do not differ by more than 0.2, preferably 0.1. To prevent unwanted scattered light and / or the interference of extraneous light, the light source 11 is arranged in a light channel 9, which is laterally sealed off by the walls 8.

[0042] The Fig. Figures 3a to 3c describe an embodiment of the inventive method for producing a plastic composite cover 1 in a layered structure 2, 3, 4, particularly for a motor vehicle. Fig. Figure 3a shows the arrangement of a first transparent plastic film 2 in a part 21a of a first forming tool 21a, 21b and the arrangement of a second transparent plastic film 3 in a further part 21b of the first forming tool 21a, 21b, wherein in Fig. 3a shows the completion of the first tool 21a, 21b, such that a first cavity 22 is formed between the first plastic film 2 and the second plastic film 3, which is arranged at a distance from the first plastic film 2. As already shown in Fig. As indicated in 3a, a subsequent lateral back-injection of the first plastic film 2 takes place via the feed area 24 in a first thermally forming process step, with the introduction of a first thermoplastic into the first cavity 22, so that a partial layer structure 2, 3, 4 is produced as a molded part. The partial layer structure 2, 3, 4 is formed by the first plastic film 2 and a first layer 4 formed by the first thermoplastic, as well as the second plastic film 3.

[0043] In a subsequent step, at least a partial demolding of the sublayer structure 2, 3, 4 takes place by removing part 21a. In a subsequent step in Fig. In step 3b, the partial layer structure 2, 3, 4 is subsequently arranged in a second forming tool 22a, 22b, forming a second cavity 23 between the second tool and the first plastic film 2. More precisely, the cavity is formed between the surface 13 of the first plastic film 2 and the second tool, here part 22a. To achieve improved sealing of the second cavity 23, for example in the area between the second forming tool 22a, 22b and the partial layer structure 2, 3, 4, the second forming tool 22a, 22b is arranged adjacent to the first plastic film 2 such that the first plastic film 2 will laterally extend beyond the subsequently produced casting resin layer.

[0044] The second cavity 23 is then flooded with a casting resin via the feed 25. Here too, the feed direction is essentially parallel to the first film 2. In a subsequent step, the composite plastic cover 1 is demolded. In a further step, the casting resin is cured, also called crosslinking, to form a resin layer 5 adjacent to the surface 13 of the first plastic film 2 and to seal the composite plastic cover 1. Fig. 1. The outer surface 14 of the plastic composite cover 1, formed by the casting resin layer 5, is determined by the surface 15 of the second shaping tool 22a, 22b, which bounds the second cavity 23. Thus, the second cavity 23 defines the shape of the outer surface 14 of the casting resin layer 5, the side facing away from the first plastic film 2.

[0045] In a subsequent step, the plastic composite cover 1 produced in this way is demolded from the second, shaping tool 22a, 22b, as Fig. 3c shows. It can then be provided that the plastic composite cover 1 is cut to size or milled to dimensions, as indicated, for example, by the cutting lines S.

[0046] By producing the resin layer 5 using molds, its outer surface 14 is determined by the shape of the second tool, thus allowing any desired contours to be incorporated into the surface. These contours can be visually appealing, for example, by creating relatively sharp-edged transitions, i.e., edges 16. These edges have a maximum radius of 0.6 mm. The average thickness of the resin layer 5 is, for example, 0.2 to 3 mm. Reference symbol list: 1 Plastic composite cover 2 first plastic film 3 second plastic film 4 first shift 5. Casting resin layer 6 Contour 7 Diffuser layer 8 wall 9 light channel 10 Arrangement 11 light bulbs 12 circuit boards 13 Surface 14 opposite surface 15 area 16 edge 21a, 21b first shaping tool 22a, 22b second shaping tool 22 first cavity 23 second cavity 24 Feed area 25 Feed D Minimum dimension S section line

Claims

[1] Method for producing a plastic composite cover (1) in a layered structure (2, 3, 4, 5) especially for a motor vehicle: Arranging at least one first plastic film (2) in a first forming tool (21a, 21b) such that a first cavity (22) is formed between the first plastic film (2) and the first forming tool (21a, 21b); subsequent back injection molding of at least the first plastic film (2) in a first thermally forming process step by introducing a first thermoplastic into the first cavity (22) in order to produce a partial layer structure (2, 4) as a molded part, wherein the partial layer structure (2, 4) comprises at least the first plastic film (2) and a first layer (4) formed by the first thermoplastic, and the first plastic film (2) defines an outer surface (13) on its side facing away from the first layer (4); and subsequent, at least partial, demolding of the partial layer structure (2, 4) from the first forming tool (21a, 21b); subsequent arrangement of the partial layer structure (2, 4) in a second forming tool (22a, 22b) forming a second cavity (23) between the outer surface (13) and the second forming tool (22a, 22b); subsequent flooding of the second cavity (23) with a casting resin; subsequent hardening of the casting resin to form a thin layer of casting resin (5) adjacent to the outer surface (13) of the partial layer structure (2, 4) and to obtain a plastic composite cover (1) from the casting resin layer (5) and at least the partial layer structure (2, 4), the outer surface (14) formed by the casting resin layer (5) being defined by a surface (15) of the second shaping tool (22a, 22b) that bounds the second cavity (23); subsequent demolding of the plastic composite cover (1) from the second forming tool (22a, 22b), characterized by , that the surface (14) of the casting resin layer (5) after demolding the plastic composite cover (1) has several edges (16) extending over the surface (14), each having a maximum radius of curvature of less than 0.6 mm; that at least the first thermoplastic of the first layer (4) and the first plastic film (2) and the casting resin layer (5) are transparent; that in the arranging step a second plastic film (3) is further arranged in the first forming tool (21a, 21b) such that the first plastic film (2) and the second plastic film (3) are spaced apart from each other forming the first cavity (22) and in the subsequent back injection molding of the first plastic film and the second plastic film in the first thermally forming process step the first layer (4) is formed between the plastic film (2) and the second plastic film (3); or alternatively: Arranging the partial layer structure (2, 4) and the second plastic film (3) in a third forming tool, forming a third cavity between the first layer (4) and the second plastic film (3); and Subsequent back injection molding of the second plastic film (3) in a second thermoforming process step by introducing a second thermoplastic into the third cavity in order to supplement the partial layer structure (2, 4) by a second layer made of the second thermoplastic and by the second plastic film (3), wherein the first layer (4) and the second layer are arranged adjacent to each other between the first plastic film (2) and the second plastic film (4) via a common interface; and subsequent, at least partial, demolding from the third forming tool; and that the second plastic film (3) is coated with a metallic translucent material. [2] Method according to the preceding claim, wherein at least the flooding step is carried out after the second thermally forming process step. [3] Method according to the preceding claim, wherein at least the casting resin layer (5), the first plastic film (2) and the first thermoplastic of the first layer (4) have an optical refractive index that differs from each other by no more than 0.2, preferably 0.

1. [4] Method according to one of the preceding claims, wherein at least the first plastic film (2) and the outer surface (14) of the cast resin layer (5) have one or more three-dimensional contours (6), preferably each a contour formed from planar surfaces, most preferably a contour forming one or more straight edges (16). [5] Method according to the preceding claim, wherein the first plastic film (2) and the outer surface (14) of the casting resin layer (5) form successive contours. [6] Method according to one of the preceding claims, wherein at least the first layer (4) and the first plastic film (2) are joined by material bonding. [7] Method according to one of the preceding claims, wherein a maximum extent of the first plastic film (2) is at least 10 times, preferably at least 20 times, more preferably at least 30 times, greater than a minimum dimension of the obtained plastic composite cover (1). [8] Method according to any of the preceding claims, wherein the casting resin is a polyurethane-containing casting resin. [9] Method according to one of the preceding claims, wherein the second forming tool (22a, 22b) is arranged adjacent to the first plastic film (2) during flooding such that the first plastic film (2) extends laterally beyond the hardened casting resin layer (4). [10] Plastic composite cover (1) in a layered structure, comprising at least one first plastic film (2); a first layer (4) made of a first thermoplastic arranged adjacent on one side to the first plastic film (2); a thin, preferably adjacent, casting resin layer (5) arranged on the side of the plastic film (2) facing away from the first layer (4), which defines or forms an outer surface (14) of the plastic composite cover (1). characterized by , that furthermore, a second plastic film (3) is provided, and the first plastic film (2) and second plastic film (3) are materially bonded and spaced apart from each other over the first layer (4) or over the first layer and a second layer made of a second thermoplastic which is materially bonded to the first layer; that the second plastic film (3) is coated with a metallic translucent material; that the surface (14) of the casting resin layer (5) has several edges (16) extending over the surface (14), each having a maximum radius of curvature of less than 6 mm; that at least the first thermoplastic of the first layer (4), the first plastic film (2) and the casting resin layer (5) are transparent. [11] Plastic composite cover (1) according to the preceding claim, wherein at least the cast resin layer (5), the first plastic film (2) and the first thermoplastic of the first layer (4) have an optical refractive index that differs from each other by no more than 0.2, preferably 0.

1. [12] Plastic composite cover (1) according to one of the preceding claims 10 or 11, wherein at least the first plastic film (2) and the outer surface (14) of the cast resin layer (5) have one or more three-dimensional contours (6), preferably each a contour formed from planar surfaces, most preferably a contour forming one or more straight edges (16). [13] Plastic composite cover (1) according to the preceding claim, wherein the first plastic film (2) and the outer surface (14) of the cast resin layer (5) form successive contours. [14] Plastic composite cover (1) according to any one of the preceding claims 10 to 13, wherein a maximum extent of the first plastic film (2) is at least 10 times, preferably at least 20 times, more preferably at least 30 times, greater than a minimum dimension of the plastic composite cover (1). [15] Arrangement (10) comprising the plastic composite cover (1) according to one of the preceding claims 10 to 14 and a light source (11) for backlighting the plastic composite cover (1), such that at least its outer surface (14) formed by the casting resin layer (5) is backlit by the light of the light source (11). [16] Use of the plastic composite cover (1) according to any one of the preceding claims 10 to 14 in a motor vehicle.

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