Forming tool for producing a decorative semi-finished product for a molded part and method for producing a molded part

Abstract

Forming tool (10) for producing a decorative semi-finished product (11) for a molded part (12), wherein the molded part (12) is formed or can be formed at least from the decorative semi-finished product (11), wherein the decorative semi-finished product (11) comprises at least one decorative layer (13) with a front side (14) designed as a visible side and a rear side (15) opposite the front side (14), and has a lacquer system (16) on its front side (14), wherein the forming tool (10) comprises at least a first upper mold (17) and a lower mold (18) which form a cavity (19) between them for producing the decorative semi-finished product (11), wherein the cavity (19) specifies the intended shape of the decorative semi-finished product (11), characterized in that the forming tool (10) is designed to form the decorative semi-finished product (11) into the shape predetermined by the cavity (19) and to cure the paint system (16), wherein the first upper mold (17) and / or the lower mold (18) is transparent or translucent, wherein one or more first light sources (20) for curing the lacquer system (16) are arranged in the first upper mould (17) and / or in the lower mould (18), wherein the one or more first light sources (20) are or comprise UV light sources, and wherein one or more second light sources (21) are arranged in the first upper mold (17) and / or in the lower mold (18), wherein the one or more second light sources (21) are or comprise IR light sources, wherein the manufacturing tool (10) has a control device (22) for controlling the light sources (20; 21), wherein the one or more first light sources (20) and / or the one or more second light sources (21) are individually controllable, so that the one or more first light sources (20) and / or the one or more second light sources (21) are independently activatable.

Description

[0001] The invention relates to a forming tool for producing a decorative semi-finished product for a molded part and a method for producing a molded part, in particular a decorative and / or trim part designed as a molded part for a vehicle interior.

[0002] Numerous decorative and trim components are installed in the vehicle interior, such as door panels, console and instrument panels. These decorative and trim components also include control buttons and their covers.

[0003] The forming tool is intended and / or designed to produce a decorative semi-finished product for a molded part. The molded part is formed from at least the decorative semi-finished product or can be formed from the decorative semi-finished product.

[0004] The decorative semi-finished product comprises at least one decorative layer with a front side formed as a visible side and a back side opposite the front side, and has a lacquer system on its front side.

[0005] The forming tool comprises at least a first upper mold and a lower mold, which form a cavity between them for producing the decorative semi-finished product, wherein the cavity specifies the intended shape of the decorative semi-finished product.

[0006] Until now, semi-finished products, especially foil and / or aluminum semi-finished products, that were impregnated and / or printed with a coating system, especially dual-cure coating systems, required two separate production steps: a pressing process with high pressure and high temperature, and a curing process in a UV tunnel. These separate processes require a lot of energy, effort, and time, and are labor- and cost-intensive.

[0007] For the prior art, reference is made to WO 2010 / 064 733 A1, DE 20 2006 002 835 U1, DE 10 2008 000 714 A1 and US 2015 / 306 627 A1.

[0008] From the publication DE 10 2008 000 714 A1, a method and a device for coating in a mold are known, wherein the mold core of the device is made of a translucent material. A layer of reflective material is applied to the surface of the product formed by the mold core, and light sources, a light sensor, and a video camera are installed in the mold core. The in-mold coating process involves injecting a liquid dye or other liquid coating material into the gap between the translucent mold core and the semi-finished product after the semi-finished product manufactured by injection molding or other industrial processes has been inserted into the mold and after the mold has been closed.

[0009] US 2015 / 306627 A1 discloses a method for coating a workpiece using a coating device. The coating device comprises a transparent cover plate and an ultraviolet light source device. The workpiece is placed in the coating device. The coating material is injected into the coating device to coat the workpiece. The coating material is a material curable with ultraviolet light. The ultraviolet light source emits ultraviolet light, and the ultraviolet light penetrates the transparent cover plate to cure the coating material on the workpiece.

[0010] The present invention is based on the object of providing a novel forming tool, in particular a forming tool, which enables the production of decorative semi-finished products for molded parts, in which the aforementioned problems are at least largely avoided. Furthermore, the object of the invention is to provide a novel method, in particular a method, which enables the production of molded parts, in which the aforementioned problems are also at least largely avoided.

[0011] The object is achieved with regard to the forming tool by the features of claim 1 and with regard to the method by the features of claim 6. Advantageous embodiments and further developments are specified in the respective dependent claims.

[0012] The invention is characterized in that the forming tool is designed for forming the decorative semi-finished product into the shape predetermined by the cavity and for curing the lacquer system, wherein the first upper mold and / or the lower mold is transparent or translucent, wherein one or more first light sources for curing the lacquer system are arranged in the first upper mold and / or in the lower mold, wherein the one or more first light sources are or comprise UV light sources, and wherein one or more second light sources are arranged in the first upper mold and / or in the lower mold, wherein the one or more second light sources are or comprise IR light sources, wherein the production tool has a control device for controlling the light sources, wherein the one or more first light sources and / or the one or more second light sources are individually controllable,so that the one or more first light sources and / or the one or more second light sources can be activated independently of one another.

[0013] A significant advantage of the invention is that the decorative semi-finished product can be formed and the lacquer system of the decorative semi-finished product can be cured using a single manufacturing tool.

[0014] It is preferably provided that the molded part comprises a carrier, in particular a plastic carrier, wherein the carrier is arranged on the back of the decorative layer, wherein the carrier is preferably injection-molded onto the back of the decorative layer.

[0015] The decorative layer is or comprises, in particular, a metal, for example, aluminum, or a foil or fabric, for example, a carbon fabric and / or a fiberglass fabric and / or a polyester fabric. The coating system is preferably a dual-cure coating system.

[0016] A further development of the invention provides that the first upper mold and / or the lower mold is formed from, in particular, transparent and / or translucent, glass and / or plastic.

[0017] It may be provided that the UV light sources are or include UV tubes or UV LEDs.

[0018] The one or more second light sources are provided, in particular, for irradiating the decorative semi-finished product in order to increase the flexibility of the decorative layer. The IR light sources can be or comprise IR tubes or IR LEDs.

[0019] Preferably, the one or more first light sources and / or the one or more second light sources are arranged in or on the first upper mold in such a way that the radiation direction of the light sources is directed towards the cavity.

[0020] It can be provided that the forming tool comprises at least a first upper mold and at least one second upper mold, in particular made of steel, wherein the first upper mold is provided and / or designed for processing the decorative semi-finished product with a first pressure at a first temperature and the second upper mold is provided and / or designed for processing the decorative semi-finished product with a second pressure at a second temperature, wherein the second pressure is higher than the first pressure and / or the second temperature is higher than the first temperature.

[0021] Furthermore, it can be provided that the forming tool has an exchange device, in particular a rotating device, for exchanging the first upper mold and the second upper mold.

[0022] The method according to the invention is intended and / or designed for producing a molded part, in particular a decorative and / or trim part for the vehicle interior, a) wherein the molded part is formed from at least one decorative semi-finished product, b) wherein the decorative semi-finished product comprises at least one decorative layer with a front side formed as a visible side and a back side opposite the front side, and has a lacquer system on its front side, c) wherein the method is carried out at least partially with a forming tool, in particular a forming tool according to the invention, c1) wherein the forming tool comprises at least a first upper mold and a lower mold, which form a cavity between them for producing the decorative semi-finished product, wherein the cavity specifies the intended shape of the decorative semi-finished product, c2) wherein the forming tool is designed to form the decorative semi-finished product into the shape specified by the cavity and to cure the lacquer system, in particular simultaneously, c3) wherein the first upper mold and / or the lower mold is transparent or translucent, wherein one or more first light sources for curing the lacquer system are arranged in the first upper mold and / or in the lower mold, wherein the one or more first light sources are or comprise UV light sources, and wherein one or more second light sources are arranged in the first upper mold and / or in the lower mold, wherein the one or more second light sources are or comprise IR light sources, wherein the one or more first light sources and / or the one or more second light sources are individually controllable, such that the one or more first light sources and / or the one or more second light sources can be activated independently of one another.

[0023] The method according to the invention comprises the steps: d) providing a decorative material intended to form the decorative layer, e) coating or impregnating the decorative layer with a lacquer system to form the decorative semi-finished product, f) Opening the forming tool by moving apart an upper mold and the lower mold of the forming tool, g) introducing, in particular inserting, the decorative semi-finished product into the forming tool, in particular the cavity of the forming tool, h) forming the decorative semi-finished product by bringing together an upper mould and the lower mould of the forming tool, in particular by providing pressure and temperature, i) activating the one or more first light sources to cure the paint system by irradiation with the first light source(s), j) Opening the forming tool by moving apart an upper mold and the lower mold of the forming tool, k) Removing the decorative semi-finished product from the forming tool, l) Forming a molded part with the decorative semi-finished product.

[0024] The decorative layer is preferably coated and / or impregnated with a dual-cure paint system.

[0025] After coating the decorative layer with the coating system and especially before inserting the decorative semi-finished product into the forming tool, the coating system can already partially cure via the isocyanate and / or OH groups.

[0026] The movement of the first upper mold and the lower mold together is preferably carried out with a predetermined and / or defined pressure.

[0027] Preferably, the one or more second light sources are provided to increase the flexibility of the decorative layer by irradiating the decorative semi-finished product with the second light source(s).

[0028] It can be provided that the one or more second light sources are activated after the decorative semi-finished product has been introduced into the forming tool and before the upper mold and the lower mold are moved together for forming, and / or the one or more second light sources are deactivated after the upper mold and the lower mold have been moved together for forming.

[0029] By activating one or more second light sources, the decorative semi-finished product, for example with a decorative layer made of a film or fabric, gains greater flexibility and can be better deformed.

[0030] Preferably, the one or more first light sources are activated after the upper mold and the lower mold have been moved together for forming, and / or in particular after the one or more second light sources have been deactivated.

[0031] The coating system cures by means of the one or more first light sources, in particular by radical polymerization.

[0032] To form the molded part, the decorative semi-finished product can be subjected to further processing steps. For example, the decorative semi-finished product can be back-injected with a plastic to form a carrier on the back of the decorative layer in an injection mold.

[0033] According to one embodiment of the method, the forming tool comprises at least one first upper mold and at least one second upper mold, in particular made of steel, wherein the decorative semi-finished product is formed by means of the second upper mold and the paint system is cured by means of the first upper mold.

[0034] Preferably, the second upper mold is inserted first, followed by the first upper mold. The forming tool may be provided with an exchange device, in particular a rotating device, for exchanging the first upper mold and the second upper mold.

[0035] It can further be provided that the decorative semi-finished product is processed with a first pressure at a first temperature while the first upper mold is inserted, and the decorative semi-finished product is processed with a second pressure at a second temperature while the second upper mold is inserted, wherein the second pressure is higher than the first pressure and / or the second temperature is higher than the first temperature.

[0036] The invention will be explained in more detail below with regard to further features and advantages by means of the description of exemplary embodiments and with reference to the accompanying schematic drawings. Fig. 1 a schematic representation of a molded part that can be produced using the method according to the invention and the forming tool according to the invention in a sectional view; Fig. 2 a schematic representation of an embodiment of a forming tool according to the invention in a sectional view according to a first state; Fig. 3 a schematic representation of an embodiment of a forming tool according to the invention in a sectional view according to a second state.

[0037] Corresponding parts and components are also designated by the same reference numerals throughout the various embodiments.

[0038] Fig. 2 and Fig. 3 show a forming tool 10 according to the invention for producing a decorative semi-finished product 11 for a molded part 12. In Fig. 2 the forming tool is shown in a first, open state, whereas in Fig. 3 the forming tool 10 is shown in a second, closed state. The molded part 12 is shown schematically in Fig. 1, wherein the molded part 12 according to Fig. 1 is formed from the decorative semi-finished product 11 and a carrier 23. The decorative semi-finished product 11 comprises a decorative layer 13 with a front side 14 designed as the visible side and a back side 15 opposite the front side 14, and has a paint system 16 on its front side 14. The decorative layer 13 can be aluminum or a foil or a fabric, for example a carbon fabric and / or a glass fiber fabric and / or a polyester fabric. The paint system 16 is a dual-cure paint system. The carrier 23 is a plastic carrier injection-molded onto the back side 15 of the decorative layer 13.

[0039] Fig. 2 and Fig. 3 shows that the forming tool 10 comprises a first upper mold 17 and a lower mold 18, which form a cavity 19 between them for producing the decorative semi-finished product 11. The cavity 19 specifies the intended shape of the decorative semi-finished product 11. The forming tool 10 is designed both for forming the decorative semi-finished product 11 into the shape specified by the cavity 19 and for curing the paint system 16. The first upper mold 17 is transparent, with a plurality of first light sources 20 for curing the paint system 16 being arranged in the first upper mold 17. The first upper mold 17 is formed from transparent and / or translucent glass or plastic. The first light sources 20 are UV light sources, in particular UV tubes or UV LEDs.

[0040] Furthermore, a plurality of second light sources 21 are arranged in the first upper mold 17, wherein the second light sources 21 are provided for irradiating the decorative semi-finished product 11 in order to increase the flexibility of the decorative layer 13. The second light sources 21 are IR light sources, in particular IR tubes or IR LEDs.

[0041] The first and second light sources 20, 21 are arranged in the first upper mold 17 such that the radiation direction of the light sources 20, 21 is directed towards the cavity 19.

[0042] The manufacturing tool 10 also has a control device 22 for controlling the light sources 20; 21, wherein the first light sources 20 and the second light sources 21 are individually controllable, so that the first light sources 20 and the second light sources 21 can be activated independently of one another.

[0043] According to one embodiment variant of the invention (not shown in the figures), the forming tool 10 can comprise, in addition to the first upper mold 17, a second upper mold made of steel, wherein the first upper mold 17 is provided and / or designed for processing the decorative semi-finished product 11 with a first pressure at a first temperature and the second upper mold is provided and / or designed for processing the decorative semi-finished product 11 with a second pressure at a second temperature, wherein the second pressure is higher than the first pressure and the second temperature is higher than the first temperature. In this case, the forming tool 10 additionally has an exchange device, in particular a rotating device, for exchanging the first upper mold 17 and the second upper mold.When high pressures and temperatures are required, such as for bonding or shaping rigid materials, two different upper molds can be used: a second upper mold made of steel that allows for high pressures and temperatures, and a first upper mold 17 made of transparent glass or plastic. After the rigid decorative semi-finished product 11 has been formed with the second upper mold made of steel, UV curing can be carried out with the first, transparent upper mold.

[0044] An embodiment of a method according to the invention for producing a, for example in Fig. 1, designed as a molded part 12, for the vehicle interior.

[0045] The molded part 12 is formed from a decorative semi-finished product 11, wherein the decorative semi-finished product 11 comprises a decorative layer 13 with a front side 14 formed as the visible side and a rear side 15 opposite the front side 14, and has a coating system 16 on its front side 14. The coating system 16 is a dual-cure coating system 16.

[0046] The procedure is partly carried out using the Fig. 2 and Fig. 3. The forming tool 10 has a first upper mold 17 and a lower mold 18, which form a cavity 19 between them for producing the decorative semi-finished product 11, wherein the cavity 19 predetermines the intended shape of the decorative semi-finished product 11. The forming tool 10 is designed both for forming the decorative semi-finished product 11 into the shape predetermined by the cavity 19 and for curing the paint system 16. The first upper mold 17 is transparent, with a plurality of first light sources 20 for curing the paint system 16 being arranged in the first upper mold 17. Furthermore, second light sources 21 are arranged in the first upper mold 17, wherein the second light sources 21 are provided for increasing the flexibility of the decorative layer 13 by irradiating the decorative semi-finished product 11 with the second light sources 21.The first light sources 20 are UV light sources, whereas the second light sources 21 are IR light sources. The procedure includes the following steps:

[0047] First, according to a first step d), a decorative material intended for forming the decorative layer 13 is provided. The decorative layer 13 is then coated or impregnated with a dual-cure coating system 16 to form the decorative semi-finished product 11, according to a step e). After coating or impregnating the decorative layer 13 with the coating system 16, the coating system 16 can already partially cure via the isocyanate and OH groups.

[0048] Subsequently, according to a step f), the forming tool 10 is opened by moving the first upper mold 17 and the lower mold 18 apart. The decorative semi-finished product 11 is then inserted into the cavity 19 of the forming tool 10 according to a further step g), as shown in Fig. 2 shown.

[0049] After the decorative semi-finished product 11 has been introduced into the forming tool 10, the second light sources 21 are activated, whereby the flexibility of the decorative layer 13 is increased by irradiating the decorative semi-finished product 11 with the second light sources 21.

[0050] Subsequently, according to a step h), the decorative semi-finished product 11 is formed by moving the first upper mold 17 and the lower mold 18 of the forming tool 10 together, providing a predetermined pressure and a predetermined temperature, as in Fig. 3. After the upper mold 17 and the lower mold 18 have been moved together for forming, the second light sources 21 are deactivated. Subsequently, according to step i), the first light sources 20 are activated to cure the coating system 16 by irradiation with the first light sources 20. The coating system 16 then cures by radical polymerization using the first light source 20.

[0051] After the curing of the lacquer system 16, the forming tool 10 is opened by moving the first upper mold 17 and the lower mold 18 of the forming tool 10 apart according to a step j) and the decorative semi-finished product 11 is removed from the forming tool 10 according to a further step k).

[0052] Subsequently, according to step l), the molded part 12 is formed with the decorative semi-finished product 11. To form the molded part 12, the decorative semi-finished product 11 is fed to further processing steps. Fig. 1, the decorative semi-finished product 11 is back-injected in an injection mold (not shown in the figures) on the back 15 of the decorative layer 13 with a plastic to form a carrier 23. List of reference symbols 10 Forming tool 11 Decorative semi-finished products 12 molded part 13 decorative layer 14 Front 15 Back 16 Paint system 17 first upper form 18 subform 19 Cavity 20 first light source 21 second light source 22 Control device 23 carriers

Claims

[1] Forming tool (10) for producing a decorative semi-finished product (11) for a molded part (12), wherein the molded part (12) is formed or can be formed at least from the decorative semi-finished product (11), wherein the decorative semi-finished product (11) comprises at least one decorative layer (13) with a front side (14) designed as a visible side and a rear side (15) opposite the front side (14), and has a lacquer system (16) on its front side (14), wherein the forming tool (10) comprises at least a first upper mold (17) and a lower mold (18) which form a cavity (19) between them for producing the decorative semi-finished product (11), wherein the cavity (19) specifies the intended shape of the decorative semi-finished product (11), characterized by , that the forming tool (10) is designed to form the decorative semi-finished product (11) into the shape predetermined by the cavity (19) and to cure the paint system (16), wherein the first upper mold (17) and / or the lower mold (18) is transparent or translucent, wherein one or more first light sources (20) for curing the lacquer system (16) are arranged in the first upper mould (17) and / or in the lower mould (18), wherein the one or more first light sources (20) are or comprise UV light sources, and wherein one or more second light sources (21) are arranged in the first upper mold (17) and / or in the lower mold (18), wherein the one or more second light sources (21) are or comprise IR light sources, wherein the manufacturing tool (10) has a control device (22) for controlling the light sources (20; 21), wherein the one or more first light sources (20) and / or the one or more second light sources (21) are individually controllable, so that the one or more first light sources (20) and / or the one or more second light sources (21) are independently activatable. [2] Forming tool according to claim 1, characterized by that the first upper mold (17) and / or the lower mold (18) is made of glass and / or plastic. [3] Forming tool according to one of the preceding claims, characterized by that the one or more first light sources (20) are arranged in or on the first upper mold (17) in such a way that the radiation direction of the light sources (20) is directed towards the cavity (19). [4] Forming tool according to one of the preceding claims, characterized byin that the forming tool (10) comprises at least a first upper mold (17) and at least one second upper mold, wherein the first upper mold (17) is provided and / or designed for processing the decorative semi-finished product (11) with a first pressure at a first temperature and the second upper mold is provided and / or designed for processing the decorative semi-finished product (11) with a second pressure at a second temperature, wherein the second pressure is higher than the first pressure and / or the second temperature is higher than the first temperature. [5] Forming tool according to claim 4, characterized by that the forming tool (10) has an exchange device for exchanging the first upper mold (17) and the second upper mold. [6] Method for producing a molded part (12), a) wherein the molded part (12) is formed from at least one decorative semi-finished product (11), b) wherein the decorative semi-finished product (11) comprises at least one decorative layer (13) with a front side (14) designed as a visible side and a rear side (15) opposite the front side (14), and has a lacquer system (16) on its front side (14), c) wherein the method is carried out at least partially with a forming tool (10), c1) wherein the forming tool (10) comprises at least a first upper mold (17) and a lower mold (18) which form a cavity (19) between them for producing the decorative semi-finished product (11), wherein the cavity (19) specifies the intended shape of the decorative semi-finished product (11), c2) wherein the forming tool (10) is designed to form the decorative semi-finished product (11) into the shape predetermined by the cavity (19) and to cure the lacquer system (16), c3) wherein the first upper mold (17) and / or the lower mold (18) is transparent or translucent, wherein one or more first light sources (20) for curing the lacquer system (16) are arranged in the first upper mold (17) and / or in the lower mold (18), wherein the one or more first light sources (20) are or comprise UV light sources, and wherein one or more second light sources (21) are arranged in the first upper mold (17) and / or in the lower mold (18), wherein the one or more second light sources (21) are or comprise IR light sources, wherein the one or more first light sources (20) and / or the one or more second light sources (21) are individually controllable, so that the one or more first light sources (20) and / or the one or more second light sources (21) are independently activatable, the method comprising the steps of: d) providing a decorative material intended to form the decorative layer (13), e) coating or impregnating the decorative layer (13) with a lacquer system (16) to form the decorative semi-finished product (11), f) opening the forming tool (10) by moving apart an upper mold (17) and the lower mold (18) of the forming tool (10), g) inserting the decorative semi-finished product (11) into the forming tool (10), h) forming the decorative semi-finished product (11) by bringing together an upper mold (17) and the lower mold (18) of the forming tool (10), i) activating the one or more first light sources (20) to cure the paint system (16) by irradiation with the first light source(s) (20), j) opening the forming tool (10) by moving apart an upper mold (17) and the lower mold (18) of the forming tool (10), k) removing the decorative semi-finished product (11) from the forming tool (10), l) Forming a molded part (12) with the decorative semi-finished product (11). [7] Method according to claim 6, characterized by that by means of the one or more second light sources (21) the flexibility of the decorative layer (13) is increased by irradiating the decorative semi-finished product (11) with the second light source(s) (21). [8] Method according to claim 7, characterized by that the one or more second light sources (21) are activated after the decorative semi-finished product (11) has been introduced into the forming tool (10) and before the upper mold (17) and the lower mold (18) are moved together for forming, and / or that the one or more second light sources (21) are deactivated after the upper mold (17) and the lower mold (18) have been moved together for forming. [9] Method according to one of claims 6 to 8, characterized bythat the one or more first light sources (20) are activated after the upper mold (17) and the lower mold (18) have been moved together for forming. [10] Method according to one of claims 6 to 9, characterized by in that the forming tool (10) comprises at least one first upper mold (17) and at least one second upper mold, wherein the decorative semi-finished product (11) is formed by means of the second upper mold and the lacquer system (16) is cured by means of the first upper mold (17). [11] Method according to claim 10, characterized by that the decorative semi-finished product (11) is processed with a first pressure at a first temperature while the first upper mold (17) is inserted, and the decorative semi-finished product (11) is processed with a second pressure at a second temperature while the second upper mold is inserted, wherein the second pressure is higher than the first pressure and / or the second temperature is higher than the first temperature.

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