MULTI-COMPONENT FLAT PLASTIC MOULDED PART

Abstract

Multi-component flat plastic visible molded part, which has: a first planar component (110) made of a first plastic; a second component (120) made of a second plastic, which is attached to an area (112_1) of a first surface (112) of the first component (110) covered by the second component (120), wherein the second component (120) has a surface (122) facing away from the first component (110), which continues into a free-standing side wall contour (122_1) which merges into a region (112_2) of the first surface (112) not covered by the second component, and wherein an edge is formed on the first surface (112) at the boundary line (GL) between the region (112_1) of the first surface (112) covered by the second component (120) and the region (112_2) of the first surface (112) not covered by the second component (120), the edge leading into a section of the first component (110) that is recessed relative to the uncovered region (112_2) of the first surface (112) adjacent to the boundary line (GL).

Description

[0001] The invention relates to a multi-component, flat, visible plastic molded part.

[0002] Multi-component, flat, visible plastic molded parts are used in many areas of technology. For example, they are used as body components in the automotive industry.

[0003] Visible molded parts must have a visually flawless surface free of any visual defects. Particular difficulties arise with multi-component visible molded parts at the interface between the two components, as tensions exist there that can lead to material delamination between the components and thus to visible defects.

[0004] If the two components of the visible molded part are coated with a paint finish, this can increase the risk of optical defects developing at the dividing line between the components. The paint can penetrate the transition between the two components and detach them. This creates a visually noticeable defect line in the transition area between the two components.

[0005] EP 1 491 317 A1 describes a container with a data carrier that is fixed to the container wall by means of a cover material layer. The cover material can protrude beyond the surface of the wall layer.

[0006] DE 10 2012 211 951 A1 describes a decorative part for a motor vehicle, which has a carrier part 1 and a cover layer made of a second plastic component that partially or completely covers the carrier part.

[0007] US 2005 / 0 116 384 A1 describes a method for producing a coated product, wherein the coating can be located in a recessed edge portion of a carrier component of the product.

[0008] WO 2014 / 130 982 A1 describes a display of an electronic device, such as a smartphone, which has an edge region composed of two plastic components.

[0009] US 6 168 742 B1 describes a method for injection molding a motor vehicle part, in which a visible edge of the part is realized by means of an injection molding process, so that an edge of a paint layer on the visible side is hidden by a surface discontinuity.

[0010] One objective underlying the invention can be seen in the creation of a multi-component, flat, visible plastic molded part that exhibits flawless optical and mechanical properties, particularly in the transition area between the two components. In particular, painted, flat, visible molded parts should be able to be produced without defects.

[0011] A multi-component, flat plastic visible molded part has a first flat component made of a first plastic and a second component made of a second plastic. The second component is attached to a region of a first surface of the first component that is covered by the first component. The second component has a surface facing away from the first component, which continues into a free-standing side wall contour that merges into a region of the first surface not covered by the second component. At the boundary line between the region of the first surface covered by the second component and the region of the first surface not covered by the second component, an edge is formed on the first surface. The edge leads into a section of the first component that is recessed relative to the uncovered region of the first surface adjacent to the boundary line.

[0012] The edge provides space for the second component, enabling improved cohesion between the first and second components, thereby reducing the risk of optical defects. Furthermore, the edge offers the possibility of creating a smoother (i.e., kink-free or low-kink) transition between the freestanding sidewall contour of the second component and the area of ​​the first surface not covered by the second component, which can also improve the optical properties.

[0013] The edge can be sharp-edged, thereby enhancing the effect according to the invention. In this case, the surface of the second component, which defines the covered area of ​​the first surface, can, for example, have a straight line leading into (and ending at) the boundary line.

[0014] Alternatively, the edge can also have a rounded shape. This also makes it possible to design the transition between the freestanding sidewall contour of the second component and the area of ​​the first surface not covered by the second component with a smooth or largely smooth surface.

[0015] When using a rounded edge, a surface of the second component that defines the covered area of ​​the first surface can have a concave profile that flows into (and ends at) the boundary line. The second component can then taper into a point with concave boundary surfaces (formed by the aforementioned concave profile and any rounding of the freestanding sidewall contour).

[0016] The freestanding sidewall contour can transition (both with a rounded and a sharp edge on the first surface) without kinks into the area of ​​the first surface not covered by the second component. The kink-free transition between the surfaces of the two components can improve the optical properties. For example, in the presence of an optical coating (e.g., a lacquer), after application, the optical coating substance (e.g., lacquer solution) cannot accumulate between the two components (at a kink) and corrode between them.

[0017] The freestanding sidewall contour can transition into the area of ​​the first surface not covered by the second component via a curve. It is also possible for the freestanding sidewall contour to transition into the area of ​​the first surface not covered by the second component via an inclined surface.

[0018] Preferably, a surface of the second component that defines the covered area of ​​the first component has a curve directed toward the first surface. This avoids an angular shape of the two contacting surfaces of the first and second components.

[0019] The first component of the multi-component plastic molded part can be transparent, allowing an optical defect to be seen through the first component at the transition between the two components. The second component can be opaque and / or black.

[0020] As already mentioned, the multi-component plastic visible molded part can have an optical coating, in particular a lacquer layer, which covers the transition between the side wall contour of the second component and the area of ​​the first surface not covered by the second component.

[0021] The optical coating (e.g., lacquer) can be opaque and / or black. In this case, the transition between the two components should not be visible. However, if an optical defect occurs, caused by partial dissolution of the component transition, it will appear as a "white line."

[0022] Alternatively, the optical coating can also be a transparent coating (e.g., lacquer) – for example, an anti-fog coating. If the component junction is damaged, a "glitter line" appears as an optical defect.

[0023] The multi-component plastic visible molded part can be a glazing plastic component, wherein the first component is the support component of the glazing plastic component and the second component forms a frame surrounding the glazing plastic component.

[0024] The multi-component plastic visible molded part can be, for example, a vehicle body part, a vehicle headlight cover or a vehicle window or roof glazing.

[0025] In the following, exemplary embodiments are explained with reference to the drawings. Identical or corresponding parts are provided with the same reference numerals. Features of the illustrated exemplary embodiments can be selectively combined with one another, provided they are not alternative or technically exclusive features. Furthermore, features of the exemplary embodiments can be selectively omitted, provided they are not described in the description as mandatory features.

[0026] Fig. 1 shows a schematic perspective view of an exemplary multi-component, flat plastic visible molded part before the possible subsequent painting in rear view.

[0027] Fig. 2 shows a partial sectional view of the Fig. 1 shown plastic visible molded part along the section line AA after painting according to the state of the art.

[0028] Fig. 3 shows a partial sectional view of the Fig. 1 along the section line AA according to a first embodiment of the invention, wherein the plastic visible molded part is still in the injection mold.

[0029] Fig. 4 shows a partial sectional view of the Fig. 1 along the section line AA according to a second embodiment of the invention, wherein the plastic visible molded part is still in the injection mold.

[0030] Fig. 5 shows a partial sectional view of the Fig. 4 shown plastic visible molded part after painting according to the second embodiment of the invention along the section line AA of the Fig. 1.

[0031] After Fig. 1, an embodiment of a multi-component, planar plastic visible molded part 100 may comprise a first planar component 110 made of a first plastic and a second component 120 made of a second plastic. The first plastic and the second plastic may be different plastic materials. In particular, the first plastic may be a transparent plastic, for example, while the second plastic may be opaque and / or black.

[0032] In the example of a plastic visible molded part 100 shown here, the second component 120 is provided as a frame-like structure that surrounds the edge of the first component 110. The first component 110 forms the main part (support component) of the visible molded part 100, while the second component 120, which may surround the visible molded part 100, can provide, for example, functional elements, add-on parts, brackets (not shown) for mounting the visible molded part 100, and the like. Such visible molded parts 100 are also referred to as two-component components (2K components) and are used in many areas of technology, for example in the automotive sector as body parts, for example, vehicle front covers, headlight covers, window and roof glazing, etc.

[0033] The plastic molded part 100 shown here schematically and in simplified form is, for example, a car front cover. The second component 120, also referred to as the black border, is attached to the rear (underside) of the first component 110 in the example shown here. This means that Fig. 1 shows a rear view, while the front surface of the visible molded part 100 can be formed entirely by the first component 110.

[0034] As described in more detail below, the back of the visible molded part 100 can be fully coated, for example, with an opaque and / or black optical coating (e.g., a lacquer layer - not shown). The lacquer layer, together with the first component, creates the glazed appearance of the visible molded part 100. Furthermore, after the lacquer coating, transparent patterns can be created in the visible molded part 100, for example, by selective laser ablation of the lacquer layer.

[0035] For other visible molded parts 100 of the 2K design, the optical coating (if present) can also be transparent. This is the case, for example, with headlight covers, where anti-fog coatings are used as transparent coatings.

[0036] Fig. 2 shows the structure of such a visible molded part 100 in the region of the transition between the two components 110, 120 according to the prior art. Arrow B (viewing direction) points to the visible side (front side) of the visible molded part 100. The second component 120 is molded onto the first component 110 as a raised structure. A kink is located in the transition between a freestanding sidewall contour 122_1 of the second component 120 and an area 112_2 of a first surface 112 of the first component 110 not covered by the second component 120. The first surface 112 of the first component has a straight line in the transition area between the freestanding sidewall contour 122_1 of the second component 120 and the area 112_2 not covered by the second component 120.

[0037] Fig. 2 further shows a lacquer layer 130 that was applied to the back of the visible molded part 100 after the two-component injection molding process. The lacquer layer 130 covers the crease. The lacquer accumulates there after its application and, as already described, can lead to a visual defect line by damaging the plastic connection between the components. This defect line is recognizable from the visible side (viewing direction B) as a visual defect ("white line" or "glitter line"). Such a visual defect can also arise without a lacquer layer due to even slight detachment of the two components in the transition area.

[0038] Fig. 3 shows a partial sectional view of an example of a visible molded part 100 according to the invention in the area of ​​the 2K connection. As in Fig. 2, the second component 120 made of the second plastic is attached to a region 112_1 of a first surface 112 of the first component 110. A region 112_2 of the first surface 112 adjacent to the region 112_1 of the first surface 112 is not covered by the second component 120. The boundary line between the covered region 112_1 and the uncovered region 112_2 of the first surface 112 is illustrated by the reference symbol GL.

[0039] At this boundary line GL, an edge is formed on the first surface 112. The edge leads into a recessed portion of the first component 110 (relative to the uncovered region 112_2 of the first surface 112 adjacent to the boundary line).

[0040] The surface 122 of the second component 120 facing away from the first component 110 transitions toward the boundary line GL into a freestanding (i.e., not covered by the first component 110) sidewall contour 122_1. The edge creates more space for the second component 120 in the region of this transition.

[0041] For example, the free-standing sidewall contour 122_1 of the second component 120 can transition without kinks into the region 112_2 of the first surface 112 not covered by the second component 120. The kink-free transition between the first component 110 and the second component 120 ensures that an optical coating (e.g., paint) has a smooth surface in the transition region, ie, topographical surface structures are avoided, which can lead to uneven paint accumulation.

[0042] The kink-free or smooth-surfaced transition region between the uncovered area 112_2 of the first surface 112 and the sidewall contour 122_1 at the boundary line GL can be flat or rounded. If the transition region is flat, it can be located essentially in a plane parallel to the main plane of the first component 110.

[0043] The freestanding sidewall contour 122_1 can, for example, transition via a curve 122_1R into the region 112_2 of the first surface 112 not covered by the second component 120. The curve 122_1R can begin (as viewed from the boundary line) directly at the boundary line GL, or the beginning of the curve 122_1R can be positioned at a certain distance from the boundary line GL. Alternatively, it is possible for the free-standing sidewall contour 122_1 to transition via an inclined surface (not shown) into the region 112_2 of the first surface 112 not covered by the second component 120, in which case a kink is present in the transition region (provided that the surface 112_2 of the elevation 116, which opens into the boundary line GL and is described in more detail below, does not continue the inclined surface linearly - in this case, an inclined surface of the free-standing sidewall contour 122_1 ending at the boundary line GL can also enable a kink-free transition).The angle between such an inclined surface of the free-standing side wall contour 122_1 and the main plane of the first component 110 can, for example, be equal to or less than 50° or 30° or 10°, with a transition with fewer kinks being created towards smaller angles.

[0044] As in Fig. As shown in Figure 3, the second component 120 is mounted in a recessed portion of the first component 110. A surface 124 of the second component 120, which defines the covered area 112_1 of the first surface 112, may have a convex curve 124R directed toward the first surface 112.

[0045] In the Fig. In the embodiment illustrated in Figure 3, this surface 124 of the second component 120 has a concave profile that flows into the boundary line GL. The concave profile 124_1 and the curve 124R of the surface 124 can thus have an S-shaped configuration. The covered region 112_1 of the first surface 112 can be complementary in shape to the surface 124 of the second component 120.

[0046] The recess of the first component 110, in which the second component 120 is mounted, can be created by a protrusion 116 (e.g., a wall thickness thickening) of the first component 110. The protrusion 116 can extend around the visible molded part 100 at the inner edge of the second component 120. The protrusion 116 can form a sealing ridge that supports the sealing of the mold cavity for the injection of the second component 120.

[0047] On both sides of the elevation 116, the first surface 112 can have a flat profile both in the covered area 112_1 and in the uncovered area 112_2, which, for example - as in Fig. 3 - can lie in the same plane.

[0048] The elevation 116 is limited in height because excessive wall thickness differences of the first component 110 lead to visual defects (sink marks). The height of the elevation and / or reduced wall thickness of the second component 120 can be, for example, approximately 0.6 mm with a base wall thickness of the first component 110 of, for example, 5 mm. For visible molded parts 100 with a small wall thickness (i.e., a base wall thickness) of the first component 110 of approximately 3 mm, the height of the elevation 116 should be, for example, a maximum of approximately 0.5 mm or less.

[0049] The first component 110 further has a second surface 114 which lies opposite the first surface 112. The visible molded part 100 can have a constant wall thickness (distance between the first surface 112 and the second surface 114) with the exception of the elevation 116. However, it is also possible for the first component 110 to be realized without an elevation 116. Especially in this case, but also generally, the wall thickness of the first component 110 where the second component 120 is attached (i.e., in the covered region 112_1 of the first surface 112) can be smaller than the wall thickness in the exposed region of the first component 110 (i.e., in the uncovered region 112_2 of the first surface 112). Both the second surface 114 and the first surface 112 (outside the elevation 116, if present) can extend parallel to the main plane of the first component 110.

[0050] In Fig. 3 shows the visible molded part 100 within an injection molding tool for injecting the second component 120 onto the already manufactured first component 110. The cavity-side tool half is designated by reference numeral 310, and the core-side tool half is designated by reference numeral 320.

[0051] Fig. 4 shows a second embodiment of a visible molded part 100 according to the invention. The second embodiment differs from the first embodiment ( Fig. 3) for example, merely by the fact that the edge on the first surface 112 of the first component 110 is sharp-edged. This means that a sharp-edged shape of the first component 110 is created at the edge of the recessed section with an edge along the boundary line GL, which, however, is not visually apparent. This second embodiment, just like the first embodiment, allows for a kink-free or smooth transition between the first component 110 and the second component 120 for the optical coating (e.g., paint) to be applied later if necessary.

[0052] Otherwise, this can Fig. 4 is identical to the embodiment of the Fig. 3, whereby, to avoid repetition, reference is made to the above description.

[0053] In both embodiments, the (rounded or sharp) edge can cause the first surface 112 to bend by an angle between, for example, 50° and 90°. The radius of the rounding 124R can be, for example, 0.3 mm. The radii of the rounding of the freestanding sidewall contour 122_1R and / or the rounding between the surface 122 facing away from the first component 110 and the freestanding sidewall contour 122_1 of the second component 120 can be, for example, 0.5 mm. The rise radius of the left side of the elevation 116 can be, for example, 3.5 mm, and the height of the elevation 116 can be, for example, 0.5 mm. In the first embodiment ( Fig. 3), the radius of the rounded edge (ie the radius of the concave profile 124_1 of the second component 120) can be, for example, 0.3 mm. In the second embodiment ( Fig. 4) With a sharp edge, the (unavoidable) edge radius can be within the range of the minimum radius feasible in terms of tool technology. Edge radii between these two limits (rounded edge and sharp edge) are also possible. The larger the edge radius, the lower the cohesion between the two components 110 and 120 in the transition area and thus the greater the risk that stress differences between components 110, 120 will lead to a separation of components 110, 120 at the boundary line GL and thus to an optical defect. Therefore, small edge radii or sharp-edged contours ( Fig. 4) may be preferred. This means that, in order to ensure good filling of the injection cavity or connection between the first component 110 and the second component 120 in the area of ​​the boundary line GL, the length of the reduced-wall-thickness end region of the second component 120 should be kept as short as possible, while ensuring a kink-free or low-kink design.

[0054] Fig. 5 shows the visible molded part 100 according to the second embodiment ( Fig. 4) after demolding from the injection mold 310, 320 and the (optional) subsequent application of the lacquer layer 130 to the first component 110 and the second component 120. The lacquer layer 130 can cover the entire rear side of the visible molded part 100 or, for example, the entire exposed surface 112_2 of the first component 110 and at least a part of the second component 120. In particular, it covers the transition, including the boundary line GL, between the side wall contour 122_1 of the second component 120 and the area 112_2 of the first surface 112 not covered by the second component 120. As can be seen from Fig. As can be seen from Figure 5, the lacquer layer 130 in the example shown here has a surface-conforming, kink-free and smooth surface.

[0055] From the viewing direction B, the boundary line GL between the first component 110 and the second component 120 is not visible. Thus, a visually flawless painted two-component visible molded part 100 is created.

[0056] The representations in all figures are true to scale, ie dimensions such as radii, wall thicknesses and the like as well as relationships between dimensions (larger, smaller, equal) can be taken directly from the figures.

[0057] The dimensions of the visible molding 100 (see Fig.1) can vary widely. For example, the lateral dimensions of the visible molded part 100 can be equal to or greater than 200 mm or 400 mm. The wall thickness of the first component 110 can, for example, be between 1 mm and 10 mm and is, for example, 4.5 mm. The wall thickness of the second component 120 can, for example, also be between 1 mm and 10 mm and is, for example, between 2.0 mm and 2.5 mm.

Claims

[1] Multi-component flat plastic visible molded part, which has: a first planar component (110) made of a first plastic; a second component (120) made of a second plastic, which is attached to an area (112_1) of a first surface (112) of the first component (110) covered by the second component (120), wherein the second component (120) has a surface (122) facing away from the first component (110), which continues into a free-standing side wall contour (122_1) which merges into a region (112_2) of the first surface (112) not covered by the second component, and wherein an edge is formed on the first surface (112) at the boundary line (GL) between the region (112_1) of the first surface (112) covered by the second component (120) and the region (112_2) of the first surface (112) not covered by the second component (120), the edge leading into a section of the first component (110) that is recessed relative to the uncovered region (112_2) of the first surface (112) adjacent to the boundary line (GL). [2] Multi-component plastic visible molded part according to claim 1, wherein the edge is sharp-edged. [3] Multi-component plastic visible molded part according to claim 2, wherein a surface (124) of the second component (120) defining the covered area (112_1) of the first surface (112) has a straight line (124_2) terminating in the boundary line (GL). [4] Multi-component plastic visible molded part according to claim 1, wherein the edge is rounded. [5] Multi-component plastic visible molded part according to claim 4, wherein a surface (124) of the second component (120) defining the covered area (112_1) of the first surface (112) has a concave profile (124_1) terminating in the boundary line (GL). [6] Multi-component plastic visible molded part according to one of the preceding claims, wherein the free-standing side wall contour (122_1) merges without kinks into the area (112_2) of the first surface (112) not covered by the second component (120). [7] Multi-component plastic visible molded part according to one of the preceding claims, wherein the free-standing side wall contour (122_1) merges via a curve (122_1R) into the area (112_2) of the first surface (112) not covered by the second component (120). [8] Multi-component plastic visible molded part according to one of the preceding claims, wherein a surface (124) of the second component (120) defining the covered area (112_1) of the first surface (112) has a rounding (124R) directed towards the first surface (112). [9] Multi-component plastic visible molded part according to one of the preceding claims, wherein the first component (110) is transparent. [10] Multi-component plastic visible molded part according to one of the preceding claims, wherein the second component (120) is opaque and / or black. [11] Multi-component plastic visible molded part according to one of the preceding claims, which further comprises an optical coating, in particular a lacquer layer (130), which covers the transition between the side wall contour (122_1) of the second component (120) and the area (112_2) of the first surface (112) not covered by the second component. [12] Multi-component plastic visible molded part according to claim 11, wherein the optical coating (130) is opaque and / or black. [13] Multi-component plastic visible molded part according to claim 11, wherein the optical coating (130) is transparent. [14] Multi-component plastic visible molding according to one of the preceding claims, wherein a second surface (114) of the first component (110) opposite the first surface (112) is a visible surface of the plastic visible molding (100). [15] Multi-component plastic visible molded part according to one of the preceding claims, which is a glazing plastic component, wherein the first component (110) is the support component of the glazing plastic component and the second component (120) forms a frame surrounding the glazing plastic component. [16] Multi-component plastic visible molded part according to one of the preceding claims, which is a motor vehicle body part, a motor vehicle headlight cover or a motor vehicle window or roof glazing.

Images