Component having a layered structure, method for manufacturing the component and injection mold for manufacturing the component

Abstract

Component comprising a layered structure, in particular a layered structure with at least three layers, characterized in that the layered structure comprises a decorative layer (1), wherein the decorative layer (1) comprises at least one decorative layer, that a first layer (3) made of a first material is arranged on the decorative layer (1), that a second layer (4) made of a second material is arranged on the first layer (3), and that the first layer (3) has a circumferential edge and comprises or is connected to at least one retaining element, wherein the retaining element extends along the edge of the first layer (3).

Description

[0001] The invention relates to a component having a layered structure, a method for manufacturing the component and an injection mold for manufacturing the component and / or an injection mold for carrying out the method for manufacturing the component.

[0002] Components with a layered structure are known as injection-molded articles in the prior art.

[0003] DE 10221482 C1 discloses a device for producing a molded part from a hardening injection molding material, which is decorated during injection molding using the IMD process (IMD = In-Mold Decoration) with an embossing foil comprising a carrier film and a decorative layer that can be removed from the carrier layer. The embossing foil is placed into an open injection mold, with the decorative layer of the embossing foil facing the upper part of the mold. The injection mold is closed, and liquid injection molding material is injected through an injection channel into the cavity of the injection mold, whereby the embossing foil conforms to the visible side of the molded part. The embossing foil bonds with the injection molding material via its decorative layer, and the material is removed from the injection mold after hardening. After peeling the carrier film away from the decorative layer, the decorated molded part is complete.Such decorated injection-molded articles are used particularly in automotive interior parts such as door trims, instrument panel trims, gearshift lever trims and center console trims, in automotive exterior parts such as door impact protection strips and covers on A, B and C pillars, in the audio and video sector for decorative trims on radio and television housings, and in the telecommunications sector for housing shells of mobile devices such as mobile phones or navigation devices.

[0004] Insert molding (IM) is a combined process of hot stamping, vacuum forming or deep drawing, and casting, particularly injection molding. Compared to the IMD process, insert molding offers the possibility of greater deformation of the foil. This is advantageous, for example, when highly profiled and shaped parts are required. First, a thin, vacuum-formable stamping foil is hot- or cold-stamped onto a substrate, such as an ABS film (thickness approximately between 200 µm and 750 µm, ABS = acrylonitrile butadiene styrene). This substrate, coated with the decorative layer of the stamping foil, is then vacuum-formed under heat. The vacuum-formed layers of stamping foil and substrate form the so-called "insert" and are cut or die-cut to precise contours. The “insert” is positioned in an injection mold, the mold is filled with plastic (the “insert” is back-injected), then the decorated injection-molded part is removed from the injection mold.

[0005] The process of coating objects, such as injection-molded parts, with polyurethane (PU) is also known from the prior art. For this, an object to be coated is positioned in a mold that has two mold halves. One mold half holds the object to be coated, and the second mold half forms a slightly larger cavity than the object. PU is introduced into this space, and the object to be coated is then flooded with PU. Two-component PU systems (2K-PU) are also known, which cure within a short time, particularly a few seconds, after mixing the components and / or immediately during and / or after the coating process (while the mold halves are still closed). By the time the mold is opened, the PU is already sufficiently hard.

[0006] The international patent application WO 2019 / 034361 A2 discloses a component manufactured by injection molding with a thermoplastic material, in which a surface protection is additionally applied to the film coating by flooding with polyurethane.

[0007] The production of this well-known component requires two separate manufacturing units. This makes production relatively complex, time-consuming, and expensive.

[0008] Furthermore, according to the current state of the art, the film, and thus also the decorative layer and / or decorative layer, is encapsulated between the injection molding material and the overmolding material, i.e., between the thermoplastic and polyurethane. Such an arrangement severely restricts the possibilities of X-ray inspection and subsequent processing of the decorative layer.

[0009] The German patent application DE 100 21 808 A1 relates to a tool for overmolding glass panes.

[0010] The German patent application DE 39 26 017 A1 relates to a method for manufacturing a glass pane for sunroofs of motor vehicles.

[0011] The invention is based on the objective of eliminating the disadvantages of the prior art. In particular, it aims to provide a versatile and adaptable component, a simple and cost-effective method for manufacturing the component, and a device for manufacturing the component or for carrying out the manufacturing process. Preferably, the component is to be manufactured with at least one polyurethane layer. Preferably, the component should be easily manufactured using injection molding. For this purpose, an injection mold is to be provided. In particular, mass production of the component in high quantities is to be enabled.

[0012] According to the invention, this problem is solved by a component according to the subject matter of claim 1, by a method according to the subject matter of claim 13, and by an injection mold according to the subject matter of claim 23. Advantageous embodiments of the invention are specified in the dependent claims.

[0013] According to the invention, a component is created which has a layered structure, in particular a layered structure with at least three layers. The layered structure or the component comprises at least one decorative layer, wherein the decorative layer comprises at least one decorative layer. A first layer made of a first material is arranged on the decorative layer. The first layer is preferably arranged directly on the decorative layer.

[0014] The decorative layer or decorative layer may preferably comprise several layers, selected individually, multiple times, or in combination from: primer layer, adhesive layer, adhesion promoter layer, color layer, lacquer layer, masking layer, spacer layer, light guide layer, functional layer, in particular an optical functional layer, metal layer, reflective layer, HRI layer (HRI = High Refractive Index), replication layer with optically active and / or optically variable structures, in particular optically active relief structures, preferably diffractive structures and / or holograms and / or refractive structures and / or matte structures. The one or more layers of the decorative layer are or are preferably applied during the process for producing the decorative layer. The one or more layers of the decorative layer may each be present over the entire surface or each partially.The one or more layers of the decorative layer can overlap in certain areas and / or be adjacent to each other in certain areas. The adjacent arrangement can be spaced apart or directly adjacent without any space between them.

[0015] In particular, the decorative layer can comprise a primer layer and / or an adhesive layer. The primer layer and / or adhesive layer is preferably arranged directly on one of the at least one decorative layer. Preferably, the primer layer and / or the adhesive layer is bonded to the first layer. In this case, the first layer is arranged directly on the primer layer and / or adhesive layer. The first layer is preferably formed from at least one thermoplastic.

[0016] A second layer made of a second material is arranged on top of the first layer. The second layer can be arranged directly on top of the first layer. Alternatively, at least one further layer, in particular another decorative layer and / or another decorative layer comprising a further decorative layer, can be arranged between the first layer and the second layer. The second layer is preferably made of polyurethane. The second layer can also be referred to as a protective layer.

[0017] The additional decorative layer can preferably comprise several layers, selected individually, multiple times, or in combination from: primer layer, adhesive layer, adhesion promoter layer, color layer, lacquer layer, functional layer, in particular an optical functional layer, metal layer, reflective layer, HRI layer (HRI = High Refractive Index), replication layer with optically active and / or optically variable structures, in particular optically active relief structures, preferably diffractive structures and / or holograms and / or refractive structures and / or matte structures. The one or more layers of the additional decorative layer are preferably applied during the process for producing the additional decorative layer. The one or more layers of the additional decorative layer can each be present over the entire surface or each partially.The one or more layers of the additional decorative layer can overlap in certain areas and / or be adjacent to each other in certain areas. The adjacent arrangement can be spaced apart relative to each other or directly adjacent without any space between them.

[0018] The first layer has a circumferential edge, preferably a closed circumferential edge. The first layer comprises at least one retaining element or is connected to at least one retaining element, in particular integrally. The retaining element is preferably formed from the first material. The retaining element extends along the edge of the first layer. The retaining element may extend partially along the edge of the first layer. Alternatively, the retaining element may extend completely along the edge of the first layer. Due to the formation of the retaining element, the first layer can also be referred to as a support layer. The wall thickness or thickness of the first layer can be dimensioned, and / or the first material can be selected, such that the component achieves a predetermined mechanical stability. This mechanical stability can be defined as flexural stiffness or torsional strength.

[0019] Preferably, the retaining element extends at least in a direction perpendicular to the layer structure. Thus, the retaining element preferably extends substantially in a plane in which the area of ​​the first layer also lies. Particularly preferably, the retaining element extends substantially in a direction perpendicular to the layer structure. Particularly preferably, the retaining element extends exclusively in planes in which the area of ​​the first layer also lies. Alternatively, the retaining element can also extend partially in the direction of the layer structure. It is therefore also possible that the retaining element partially leaves the plane in which the area of ​​the first layer lies.

[0020] The retaining element is preferably designed such that the component is held and / or fixed firmly by an interaction between the retaining element and at least one retaining arm of a holding device. In particular, the retaining element is designed such that the component is held and / or fixed firmly by the engagement of at least one retaining arm of a holding device with the retaining element. The engagement of the retaining arm can occur directly at the circumferential edge of the first layer. In this case, it is particularly possible for the retaining arm to engage in an area of ​​the first layer that lies inside the circumferential edge. Such an area can, in particular, be formed by a recess. This will be discussed in more detail below.

[0021] Alternatively, the retaining element can include a contour extending from the circumferential edge of the first layer and / or a projection on the circumferential edge of the first layer. In this case, the interaction with the retaining arm takes place in an area of ​​the first layer located externally with respect to the circumferential edge. The interaction can be achieved by the retaining arm engaging with the retaining element and / or the retaining element engaging with the retaining arm. The contour and / or projection itself can also have a recess. Such a contour or projection can, in particular, be formed by a tab. This will be discussed in more detail below.

[0022] Advantageously, the component is held or fixed by the retaining element in two opposite directions, specifically under tension and compression. In one embodiment, the retaining element can fix the component in an injection mold. This is particularly useful for facilitating simple manufacturing even when changing cavity halves or mold parts. The advantageous tension and compression fixation of the component by the retaining element allows for the exchange of cavity halves or mold parts on both sides of the component without negatively impacting the manufacturing process.

[0023] The retaining element can be used to fix the finished component to another part, for example by snapping or gluing it. Alternatively, the retaining element can also be removed after the component has been manufactured. For example, by separating it, preferably by cutting and / or breaking it off. Preferably, the retaining element can have corresponding predetermined breaking points. Alternatively or additionally, the retaining element can be removed by milling.

[0024] Even if the terms "holding element" and "holding arm" are used in the singular in the explanations, the person skilled in the art understands that the characteristics mentioned can also apply to all holding elements and / or holding arms when several are present. Similarly, when holding element and / or holding arm are described in the plural, the person skilled in the art understands that the characteristics mentioned can also apply when only one holding element and / or only one holding arm is present.

[0025] An advantage of the invention lies in the fact that the decorative layer comprising at least one decorative layer, the first layer, and optionally further decorative layers and / or further application layers are protected by the overlying, outer second and / or third layer, preferably made of polyurethane, as a protective layer. This enables additional effects, such as the creation of enhanced optical depth.

[0026] Advantageously, the decorative layer, comprising at least one decorative layer, is coated with the further layer structure only on one side. In particular, the decorative layer, comprising at least one decorative layer, is not encapsulated on both sides. Therefore, the decorative layer, comprising at least one decorative layer, is advantageously accessible for further processing. In particular, the layer structure according to the invention allows direct laser processing of the decorative layer without the need to laser through an injection-molded material. Laser processing allows, in particular, the selective removal, especially ablation, of one or more layers of the decorative layer and / or the selective modification of one or more layers of the decorative layer. Such a modification includes, for example, bleaching and / or changing the color of one or more layers of the decorative layer.

[0027] Furthermore, this opens up a wide range of possibilities for structural integration. Structures, particularly relief structures, can be incorporated, for example, into one cavity half of the injection mold. Such a structure can be applied to the second and / or third layer, specifically the polyurethane protective layer, and can be designed to match the relief structure of the injection mold, making it visible on the front of the finished component. Alternatively, the same structure can be applied to the first layer, making it visible on the back of the finished component. It is worth noting that when the structure is applied to the back, the decorative layer also effectively replicates the structure.In particular, relief structures can include, for example, one or more microstructures and / or nanostructures, preferably one or more diffractive structures and / or holograms and / or refractive structures and / or matte structures.

[0028] Furthermore, reverse-side structures, which are formed by the decorative layer or an IMD film encompassing it, are highly visible as a design element. These reverse-side structures can also be created using a laser. Laser processing allows for the selective removal, particularly ablation, of one or more layers of the decorative layer, thereby creating a visually perceptible, flat texture and / or surface relief. Additional application can then be achieved through hot stamping, cold stamping, digital printing, and / or functional foil bonding (FFB).

[0029] The component can advantageously be used in automotive engineering as a body part in the exterior, or as a functional and / or decorative part in the interior. In particular, it can be used for automotive interior parts such as door sills, trim strips in instrument panels, gearshift lever covers and center console trims; for automotive exterior parts such as door impact protection strips and covers on A-, B- and C-pillars; in the audio and video sector for decorative trim strips on radio and television housings; and in the telecommunications sector for housing shells of mobile devices such as cell phones or navigation systems.

[0030] Further advantageous embodiments of the invention are described in the dependent claims.

[0031] According to an advantageous embodiment of the invention, the first material is formed by an injection molding material, in particular by at least one thermoplastic, or by polyurethane.

[0032] According to a further advantageous embodiment of the invention, the second material is a flooding material, in particular polyurethane.

[0033] Polyurethane is not thermoplastic, but rather a reaction product with a very low initial viscosity. Therefore, polyurethane can mold geometries and / or structures, particularly complex geometries and / or structures. The component according to the invention, and in particular the second layer of the component according to the invention, can therefore have geometries and / or structures, especially complex geometries and / or structures. These geometries and / or structures can, for example, include abrupt or continuous changes in cross-section, in particular tapers, corners, edges, peaks, and / or arcs. Preferably, the component, and in particular the second layer of the component, can have particularly thick walls and / or abrupt changes in wall thickness. Compared to injection molding with thermoplastic materials, very little and / or very few geometric distortions and / or sink marks and / or cavities occur when flooding with polyurethane.The components according to the invention therefore advantageously exhibit a high optical quality.

[0034] The first material is preferably transparent, in particular a transparent thermoplastic or transparent polyurethane.

[0035] The second material is preferably transparent, in particular transparent polyurethane.

[0036] It is also conceivable that the first material and / or the second material is translucent or opaque and / or colored. The first and second materials can have different degrees of transmission.

[0037] In the present application, a film, layer, or material with a transmission greater than 70% is preferably referred to as transparent. With a transmission between 50% and 70%, the film, layer, or material is preferably referred to as translucent. With a transmission of less than 50%, the film, layer, or material is preferably referred to as opaque. The percentage values ​​mentioned refer in particular to transmission in the wavelength range perceptible to the human eye. The wavelength range perceptible to the human eye is preferably assumed to be the wavelength range from 380 nm to 780 nm.

[0038] According to a further advantageous embodiment of the invention, a third layer made of a third material is arranged on the second layer. Preferably, the third layer is arranged directly on the second layer. The third material is preferably a flooding material, in particular polyurethane. The third material is preferably transparent, in particular transparent polyurethane.

[0039] According to a further advantageous embodiment of the invention, the second and third layers are each formed from a flooding material, in particular polyurethane. In this embodiment, the second and third materials are therefore each flooding materials, in particular polyurethane. Preferably, the second material is translucent or opaque and / or colored. Preferably, the third material is transparent. Preferably, the second layer forms geometries and / or structures, in particular complex geometries and / or structures. These geometries and / or structures can, for example, include abrupt or continuous changes in cross-section, in particular tapers, corners, edges, points, and / or arcs. In particular, the second layer can have particularly thick walls and / or abrupt changes in wall thickness.The third layer is preferably arranged directly on top of the second layer. The third layer preferably covers the geometries and / or structures formed by the second layer. The third layer preferably has a smooth, free surface or a free surface structured differently than the second layer. Thus, the third layer preferably forms a protective layer on top of the second layer. Advantageously, the geometries and / or structures formed by the second layer are protected from contamination and / or damage by the third layer and remain visible. To smooth the structures of the second layer, several layers of the third layer may be provided.

[0040] According to a further advantageous embodiment of the invention, the holding element is designed to hold the component in an injection mold. This allows the component to be fixed in the injection mold.

[0041] According to a further advantageous embodiment of the invention, the retaining element is designed as an outwardly projecting tab. In this case, the retaining element is formed from the first material. Alternatively or additionally, the retaining element is designed as a recess in the first material. The recess can be provided in a region located inside the circumferential edge of the first layer. In particular, the retaining element can be designed as a tab which has a recess.

[0042] According to a further advantageous embodiment of the invention, the indentation is designed to engage a holding device of an injection mold. The holding device can comprise a movable holding arm. The indentation can be designed to receive one end of the movable holding arm. In particular, the indentation is designed for the positive engagement of the holding device of an injection mold. Preferably, the end of the holding arm is held in a positive-locking manner. In particular, the indentation is designed to be complementary to the contour of the tip of the holding arm.

[0043] The holding element and the holding device remain firmly connected to each other, especially when subjected to an external force acting in a direction perpendicular to the first layer.

[0044] According to a further advantageous embodiment of the invention, the decorative layer is a transferable layer of an IMD film or a label. Alternatively, the decorative layer is a component of an insert film.

[0045] The IMD film preferably has a decorative layer and a carrier layer, the decorative layer potentially comprising several decorative layers. The carrier layer is preferably removed at the end of the component manufacturing process. Therefore, the finished component preferably does not include the carrier layer of the IMD film.

[0046] As an alternative to an IMD film, an insert film can be used, which consists of a decorative layer and a carrier layer. Unlike the IMD film, the carrier layer remains in the layer structure of the insert film. Therefore, when manufactured with an insert film, the finished component preferably also includes the carrier layer.

[0047] The carrier layer of an IMD film and / or insert film can comprise at least one carrier layer. The carrier layer can preferably have several layers, selected individually, multiple times, or in combination from: PET carrier and / or release layer and / or thermoplastic carrier.

[0048] The one or more layers of the carrier layer can each be present over the entire surface or partially. The one or more layers of the carrier layer can overlap in certain areas and / or be adjacent to each other in certain areas. The adjacent arrangement can be spaced apart relative to each other or directly adjacent without any space between them.

[0049] According to a further advantageous embodiment of the invention, a further decorative layer and / or a further decorative layer comprising at least one further decorative layer is arranged between the first layer and the second layer. The further decorative layer and / or the further decorative layer can be applied to the first layer by hot stamping and / or cold stamping and / or digital printing and / or functional foil bonding (FFB). The further decorative layer and / or the further decorative layer is therefore preferably arranged between the first layer, which is made of thermoplastic, and the second layer, which is made of polyurethane.

[0050] The additional decorative layer can preferably comprise several layers, selected individually, multiple times, or in combination from: primer layer, adhesive layer, adhesion promoter layer, color layer, lacquer layer, functional layer, in particular an optical functional layer, metal layer, reflective layer, HRI layer (HRI = High Refractive Index), replication layer with optically active and / or optically variable structures, in particular optically active relief structures, preferably diffractive structures and / or holograms and / or refractive structures and / or matte structures. The one or more layers of the additional decorative layer are preferably applied during the process for producing the additional decorative layer. The one or more layers of the additional decorative layer can each be present over the entire surface or each partially.The one or more layers of the additional decorative layer(s) can overlap in certain areas and / or be adjacent to each other in certain areas. The adjacent arrangement can be spaced apart or directly adjacent without any space between them.

[0051] Advantageously, the decorative layer and the subsequent decorative layer(s) complement each other in the formation of a design, particularly in conjunction with transillumination technologies. The one or more layers of the decorative layer and / or the decorative layer and / or the subsequent decorative layer can overlap in certain areas and / or be adjacent to each other in certain areas. The adjacent arrangement can be spaced apart or directly adjacent without any space between them.

[0052] According to a further advantageous embodiment of the invention, the first layer comprises exactly one retaining element. The retaining element is preferably configured to extend around the entire circumference of the component. Particularly preferably, the retaining element is configured to extend completely around the entire circumference of the component. In this case, the retaining element extends fully along the edge surrounding the first layer.

[0053] Alternatively, the first layer can comprise several retaining elements. In particular, an even or odd number of retaining elements can be provided. Preferably, between 2 and 20 retaining elements are provided, more preferably between 2 and 16 retaining elements, and further preferably between 2 and 12 retaining elements.

[0054] According to a further advantageous embodiment of the invention, the first layer comprises two, three, four, five, six, eight, ten, or twelve retaining elements. The retaining elements are preferably spaced apart from one another along the edge of the first layer. The retaining elements are preferably spaced equally apart. However, the spacing of the retaining elements can also vary. The retaining elements are preferably arranged symmetrically to one another. The retaining elements can preferably be arranged in pairs. A pair can be arranged opposite each other, in particular symmetrically and / or diametrically opposite each other.

[0055] For example, the edge of the first layer forms a rectangle, particularly a square. In this case, the first layer can comprise two retaining elements arranged on two opposite sections of the edge, i.e., on two opposite sides of the rectangle or square. Alternatively, the first layer can comprise four retaining elements. In this case, a retaining element can be arranged on each section of the edge, i.e., on each side of the rectangle or square, so that two retaining elements are arranged in pairs opposite each other. Preferably, the retaining elements are arranged in the middle of each respective side of the rectangle or square.

[0056] In another example, the edge of the first layer forms a triangle, in particular an equilateral triangle. In this case, the first layer can comprise three retaining elements. A retaining element can be arranged on each segment of the edge, that is, on each side of the triangle or equilateral triangle. Preferably, the retaining elements are each arranged in the middle of the respective side of the triangle or equilateral triangle.

[0057] In another example, the edge of the first layer forms a hexagon, in particular an equilateral hexagon. In this case, the first layer can comprise six retaining elements. A retaining element can be arranged on each segment of the edge, that is, on each side of the hexagon or equilateral hexagon, so that two retaining elements are arranged opposite each other in pairs. Preferably, the retaining elements are arranged in the middle of each respective side of the hexagon or equilateral hexagon.

[0058] According to a further advantageous embodiment of the invention, the first layer has a wall thickness of 0.5 mm to 10 mm. Preferably, the first layer has a wall thickness of 1 mm to 5 mm. Particularly preferably, the first layer has a wall thickness of 1.5 mm to 3 mm. The first layer preferably has a flat and / or smooth surface facing the second layer.

[0059] For the purposes of this application, the wall thickness of a layer can also be referred to as the "layer thickness" or the "layer thickness" of the layer. The wall thickness extends in the direction of the layer structure of the component.

[0060] According to a further advantageous embodiment of the invention, the second layer has a wall thickness of 0.2 mm to 50 mm. In particular, the second layer has a wall thickness of 0.2 mm to 30 mm. Preferably, the second layer has a wall thickness of 0.3 mm to 15 mm. More preferably, the second layer has a wall thickness of 0.5 mm to 5 mm. Particularly preferably, the second layer has a wall thickness of 0.8 mm to 3 mm. Preferably, only individual structures have the full wall thickness.

[0061] Preferably, the second layer forms geometries and / or structures, in particular complex geometries and / or structures. These geometries and / or structures can, for example, include abrupt or continuous changes in cross-section, in particular tapers, corners, edges, peaks, and / or arcs. In particular, the second layer can have particularly thick walls and / or abrupt changes in wall thickness.

[0062] In particular, by means of laser processing and / or mechanical processing and / or the use of tool structures, it is possible to create exposed relief structures in the second layer, preferably made of polyurethane, with a minimum line thickness and / or a minimum laserable point diameter of 5 µm to 150 µm, preferably 10 µm to 100 µm. This allows for the production of the finest details, especially for motifs and / or alphanumeric information. It is also possible to combine such fine structures with coarser, macroscopic structures, either in a laterally adjacent combination or as a superimposition of a coarse structure with a fine structure.This can be achieved in particular by combining several processing steps, for example, to create coarse structures with dimensions of the individual structural elements from 0.5 mm to 50 mm in combination with laser processing and / or mechanical processing adjacent to and / or superimposed thereon with a minimum line thickness and / or a minimum laserable point diameter of 5 µm to 150 µm, preferably from 10 µm to 100 µm. It is also possible, however, for coarse and fine structures to be present together as a tool structure and thus molded in the second layer, preferably made of polyurethane. The depth of the relief structures can be between 0.001 mm and the maximum wall thickness of the second layer, preferably made of polyurethane, in particular between 0.001 mm and 50 mm, preferably between 0.001 mm and 30 mm, and more preferably between 0.001 mm and 15 mm.

[0063] Advantageously, components according to the invention can have a wide range of wall thicknesses. In particular, components according to the invention can have particularly thin and / or particularly thick wall thicknesses. Advantageously, components according to the invention can have both particularly thin and particularly thick wall thicknesses. Such wall thicknesses are very difficult or impossible to achieve using only an injection molding process with thermoplastic materials.

[0064] According to a further advantageous embodiment of the invention, the third layer has a wall thickness of 0.2 mm to 50 mm. In particular, the third layer has a wall thickness of 0.2 mm to 30 mm. Preferably, the third layer has a wall thickness of 0.3 mm to 15 mm. More preferably, the third layer has a wall thickness of 0.5 mm to 5 mm. Particularly preferably, the third layer has a wall thickness of 0.8 mm to 3 mm. The third layer is arranged in a complementary manner to the second layer. That is, the structures formed in the second layer are preferably compensated for by the third layer. Preferably, the third layer has a flat and / or smooth surface facing away from the second layer.

[0065] According to the invention, the method for manufacturing a component having a layered structure, in particular a layered structure with at least two layers, preferably for manufacturing the component according to the invention, comprises the following steps, in particular in the following order: a) Providing an injection mold comprising a holding device and a first and second cavity half, b) Inserting a foil comprising a decorative layer with at least one decorative layer into the first half of the cavity, c) Closing the injection mold by inserting the second cavity half into the first cavity half, so that a first cavity is created that is in contact with the film, d) Coating the film with a first material to form a first layer by introducing the first material into the first cavity, wherein the first layer is formed with at least one retaining element such that the retaining device is arranged in a form-fitting manner to the retaining element, e) Removal of the second cavity half, whereby the film coated with the first layer remains in the first cavity half by holding the holding element through the holding device.

[0066] The holding device is preferably movable and / or includes movable components, in particular a movable clamping frame and / or at least one movable holding arm.

[0067] After the film is inserted into the first cavity half in step b) and / or before the injection mold is closed in step c), the holding device, in particular the clamping frame, is preferably moved against the film. This movement preferably occurs in a direction perpendicular to a plane formed by the film. The film is thereby preferably pressed against the first cavity half. Preferably, the film is fixed between the holding device, in particular between the clamping frame, and the first cavity half. See also step I) below.

[0068] In step d), the first material is preferably formed by at least one thermoplastic. The coating of the film can therefore also be described as back-injection of the film. Alternatively, the first material can be polyurethane.

[0069] The coating or back-injection of the film in step d) preferably takes place on the back side of the film, in particular on a primer layer formed by the film. The primer layer is preferably designed as an adhesive layer for bonding with the thermoplastic of the first layer. The film is preferably an IMD film or insert film.

[0070] In step d), the coating or injection molding of the film with the first material to form the first layer is preferably carried out directly on the film.

[0071] In step d) of the coating or back-injection process of the film, the first layer is preferably formed with the at least one retaining element such that the retaining device is positively connected to the retaining element. Preferably, a retaining arm formed by the retaining device is positively connected to the retaining element and / or positively connected to the retaining element. In particular, the first layer can be designed as a carrier layer. The wall thickness or thickness of the first layer can be dimensioned, and / or the material can be selected, such that the component achieves a predetermined mechanical stability. This mechanical stability can be defined as flexural stiffness or torsional strength.

[0072] According to an advantageous embodiment of the invention, the injection mold comprises a third cavity half. The method further comprises the following steps, which are preferably carried out after step e), in particular in the following order: f) Closing the injection mold by inserting the third cavity half into the first cavity half, so that a second cavity is created, g) Coating the film coated with the first layer with a second material, forming a second layer by introducing, in particular injecting, the second material into the second cavity.

[0073] Switching the cavity half from the second to the third cavity half can be achieved, for example, using rotary table, sliding table, and / or indexable plate technology. The switch to the third cavity half can also be performed manually.

[0074] The second cavity created in step f) preferably lies directly adjacent to the first layer. Alternatively, a further decorative layer and / or a further decorative layer comprising at least one further decorative layer can be applied to the side of the first layer facing away from the film (see step k) below). In this case, the second cavity preferably lies directly adjacent to the further decorative layer and / or the further decorative layer.

[0075] The coating or flooding with the second material to form the second layer takes place in step g) preferably on the surface of the first layer facing away from the film, preferably directly on the first layer.

[0076] Alternatively, a further decorative layer and / or a further decorative layer comprising at least one further decorative layer can be applied to the side of the first layer facing away from the film (see step k) below). In this case, the coating or flooding with the second material, forming the second layer in step g), preferably takes place directly on the surface of the further decorative layer and / or the further decorative layer facing away from the first layer. The surface of the further decorative layer and / or the further decorative layer facing away from the first layer preferably forms a primer layer. The primer layer is preferably designed as an adhesive layer and / or adhesion promoter layer for bonding with the polyurethane of the second layer.

[0077] Furthermore, it is possible that the additional decorative layer and / or the additional decorative layer comprising at least one further decorative layer are applied only partially to the side of the first layer facing away from the film. In this case, the coating or flooding with the second material, forming the second layer in step g), preferably takes place partially directly on the first layer and partially directly on the surface of the additional decorative layer and / or the additional decorative layer facing away from the first layer.

[0078] In this application, the term "area" is understood to mean, in particular, a defined surface of a layer, film, or layer within the plane formed by the respective layer, film, or layer. For example, the first layer may have at least one first area and at least one second area, each of the two or more areas occupying a defined surface within the plane formed by the first layer. Preferably, the respective layers, films, or layers extend parallel to one another. In particular, the first layer preferably extends parallel to the further decorative layer and / or the further decorative layer.

[0079] The term “in a specific area” is preferably understood in the present application in the same way as the term “area” is defined above.

[0080] Completing step g) preferably results in the production of the component.

[0081] In step g), the second material is preferably polyurethane. Coating the film coated with the first layer can therefore also be described as flooding it with the first layer of polyurethane.

[0082] Particularly preferably, the second material in step g) is a mixture, especially a polyurethane-forming mixture. Preferably, the mixture is introduced into the second cavity, particularly by injection. Preferably, the film coated with the first layer is coated with the mixture in step g). The first layer can be directly flooded and / or poured over by the mixture. Alternatively, the surface of the further decorative layer and / or the further decorative layer facing away from the first layer can be directly flooded and / or poured over by the mixture. Furthermore, it is possible that the first layer is partially flooded and / or poured over by the mixture, and / or that the surface of the further decorative layer and / or the further decorative layer facing away from the first layer is partially flooded and / or poured over by the mixture.

[0083] Preferably, in step g) the first layer is directly or indirectly completely flooded and / or poured over by the mixture.

[0084] The term "flooding" can, within the meaning of this application, refer to flooding, submerging, inundating, and / or surrounding. Thus, different orientations of the emerging component within the closed mold halves are possible. The first layer and / or the subsequent decorative layer and / or the subsequent decorative layer are each covered by the mixture, at least partially, on their surface facing away from the film. For the sake of linguistic simplicity, this application primarily uses the term "flooding." The meanings mentioned above can be inferred from this.

[0085] In this application, the second layer formed from polyurethane is also referred to as the polyurethane layer.

[0086] The application of the polyurethane layer to the first layer and / or the further decorative layer and / or the further decorative layer is preferably carried out in step g) by at least partially flooding and / or pouring the first layer and / or the further decorative layer and / or the further decorative layer on its surface facing away from the film with at least one solvent-containing, preferably flowable, polyurethane-containing composition and subsequent hardening.

[0087] Preferably, the term "flowable polyurethane-containing composition" is understood to mean a polyurethane-containing composition which preferably has a dynamic viscosity at a temperature of 25°C in the range of 2 mPas to 1500 mPas, preferably from 10 mPas to 1000 mPas, more preferably from 10 mPas to 500 mPas, preferably determined according to the method described in DIN EN ISO 3219:1994-10, for example using a HAAKE Viscotester® VT550, more preferably using a cylinder measuring device NV and a measuring cup NV.

[0088] The at least one solvent-containing, preferably flowable, polyurethane-containing composition preferably comprises free, reactive groups, preferably free isocyanate groups or free groups reactive towards isocyanate groups, and / or corresponding disguised, reactive groups which release the corresponding reactive group again at a temperature in the range of 30°C to 180°C.

[0089] As explained above, a further decorative layer and / or decorative layer can be applied to the first layer. This further decorative layer and / or decorative layer preferably has a primer layer on the surface facing away from the first layer to ensure adhesion to the polyurethane of the second layer. The primer layer is preferably a primer layer, in particular an adhesion promoter layer, that is not yet fully cured, at least in some areas.During the curing, preferably complete curing, of the primer layer, which is at least partially not yet fully cured, and / or the polyurethane layer applied to it, for example, free isocyanate groups contained in the primer layer can react with free groups reactive towards isocyanate groups in the solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer.

[0090] This preferably significantly improves the adhesion of the polyurethane layer to the primer layer after curing according to the inventive method, preferably according to step q) (see below).

[0091] Preferably, at least one solvent-containing, preferably flowable, polyurethane-containing composition is selected from the group consisting of polyurethane-containing dispersions, polyurethane-containing resins, polyurethane solutions, compositions of polyurethane precursors (2K-PUR systems) and mixtures thereof, which preferably also have free, reactive groups, preferably isocyanate groups or groups reactive towards isocyanate groups and / or corresponding disguised, reactive groups that release the corresponding reactive group again at a temperature in the range of 30°C to 180°C.

[0092] For example, the at least one solvent-containing, preferably flowable, polyurethane-containing composition as described above can be applied to the primer layer as compositions of polyurethane precursors (2K-PUR systems), in particular as a mixture of at least one of the aforementioned compounds with two or more isocyanate groups and at least one of the aforementioned compounds having two or more groups reactive towards isocyanate groups, wherein preferably either the at least one compound with two or more isocyanate groups or the at least one compound having two or more groups reactive towards isocyanate groups is used in molar excess.

[0093] For example, polyurethane-containing dispersions, polyurethane-containing resins and / or polyurethane solutions contain the aforementioned prepolymers with free groups reactive towards isocyanate groups, which may be cross-linked or uncross-linked, the aforementioned prepolymers with capped groups reactive towards isocyanate groups, which may be cross-linked or uncross-linked, or mixtures thereof and / or the aforementioned isocyanate prepolymers, which may be cross-linked or uncross-linked, the aforementioned capped isocyanate prepolymers, which may be cross-linked or uncross-linked, or mixtures thereof.

[0094] Furthermore, the polyurethane-containing composition used to produce the polyurethane layer preferably comprises at least one solvent-containing, preferably flowable, polyurethane-containing composition and at least one organic solvent, for example ethyl acetate, 2-butanone, acetone, toluene, xylenes or mixtures thereof.

[0095] A further preferred option is an at least one solvent-containing, preferably free-flowing, polyurethane-containing composition used for the production of the polyurethane layer, comprising the aforementioned anhydrous isocyanate prepolymers. The aforementioned disguised isocyanate prepolymers, on the other hand, can be present as an aqueous dispersion.

[0096] Further preferably, a polyurethane layer used for production comprises at least one solvent-containing, preferably flowable, polyurethane-containing composition, comprising the aforementioned prepolymers with free groups reactive towards isocyanate groups, which may be cross-linked or uncross-linked, the aforementioned prepolymers with capped groups reactive towards isocyanate groups, which may be cross-linked or uncross-linked, or mixtures thereof, water and / or at least one organic solvent, for example ethyl acetate, 2-butanone, acetone, toluene, xylenes or mixtures thereof.

[0097] When using 2K-PUR systems, the polyurethane precursors, for example, polyol-containing and isocyanate-containing components, are preferably stored separately and only combined in the mixing head when required. The heat of reaction generated during the reaction of the polyurethane precursors preferably leads to a temperature of 60°C to 180°C, more preferably 80°C to 120°C.

[0098] The surfaces or walls of the cavity halves can also preferably have a temperature in the range of 40°C to 160°C, preferably in the range of 80°C to 120°C.

[0099] The introduction, in particular the injection, of the at least one solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer is preferably carried out via a mixing head, preferably at a pressure of less than 10 bar.

[0100] A first curing phase can be initiated by applying heat to the injection mold, for example at a temperature of 60°C to 160°C, preferably for a period of 60 s to 600 s.

[0101] After removal from the injection mold, the component is preferably stored for approximately 24 hours for residual curing before further use.

[0102] During the curing, preferably complete curing, of the primer layer, which is at least partially not yet fully cured, and the polyurethane layer applied to it, for example, free isocyanate groups contained in the primer layer can react with free groups reactive towards isocyanate groups in the solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer.

[0103] Preferably, a layer is referred to as "cured" within the meaning of the present invention if the polymer components capable of crosslinking, preferably binders, for example free isocyanate groups and / or free groups reactive towards isocyanate groups, of the respective layer exhibit crosslinking to more than 95%.

[0104] Preferably, the polyurethane layer can be modified and / or structured before and / or during and / or after the application of the polyurethane layer in step g) and / or in step o), preferably by inserting / placing particles onto the primer layer and / or by using tool structures during the application in step g) and / or in step o) and / or by subsequent processing of the polyurethane layer by means of process steps selected individually or in combination from laser processing, overprinting, hot stamping, cold stamping, blind stamping, mechanical processing.

[0105] In particular, by means of laser processing and / or mechanical processing and / or the use of tool structures, it is possible to create exposed relief structures in the polyurethane layer with a minimum line thickness and / or a minimum laserable point diameter of 5 µm to 150 µm, preferably from 10 µm to 100 µm. This allows for the production of the finest details, especially for motifs and / or alphanumeric information. It is also possible to combine such fine structures with coarser, macroscopic structures, either in a laterally adjacent combination or as a superimposition of a coarse structure with a fine structure.This can be achieved in particular by combining several of the aforementioned process steps, for example, to generate coarse structures with dimensions of the individual structural elements from 0.5 mm to 50 mm in combination with laser processing and / or mechanical processing adjacent to and / or superimposed thereon, with a minimum line thickness and / or a minimum laserable point diameter of 5 µm to 150 µm, preferably from 10 µm to 100 µm. It is also possible, however, for coarse and fine structures to be present together as a tool structure and thus molded in the polyurethane layer. The depth of the relief structures can be between 1 µm and the maximum wall thickness of the polyurethane layer, in particular between 0.001 mm and 50 mm, preferably between 0.001 mm and 30 mm, and more preferably between 0.001 mm and 15 mm.

[0106] Preferably, the polyurethane layer and / or the primer layer can be modified to match existing design features and / or motifs in the decorative layer and / or subsequent decorative layers. For example, a surface texture can be arranged to match a wood grain, particularly in the decorative layer and / or subsequent decorative layers, and / or a tactilely and / or visually perceptible structure can be arranged to match a motif, particularly in the decorative layer and / or subsequent decorative layers.The structures mentioned can be produced, for example, by process steps selected individually or multiple times or in combination from the use of tool structures during application in step g) and / or o), laser processing, overprinting, embossing, mechanical processing.

[0107] Register accuracy refers to the positional accuracy of two or more layers, elements, areas, and / or strata relative to each other. The register accuracy should fall within a predefined tolerance and be as low as possible. At the same time, the register accuracy of multiple layers, elements, areas, and / or strata relative to each other is an important characteristic for increasing process reliability and / or product quality, as well as counterfeit protection. Precise positioning can be achieved, in particular, using sensor-based, preferably optically detectable, register markers. These register markers can either represent specific, separate layers, elements, areas, and / or strata or be themselves part of the layers, elements, areas, and / or strata to be positioned.

[0108] A polyurethane layer produced by the inventive method preferably has transparent or reduced light-transmitting properties.

[0109] In step g) and / or in an additional step preceding step g), a polyurethane-forming mixture is preferably provided at a mixing head of the injection mold. For this purpose, components of the polyurethane-forming mixture are preferably mixed together at the mixing head. The mixture thus provided is preferably free-flowing. The mixture can be a solvent-containing and polyurethane-containing composition. The components preferably comprise at least one polyol and one isocyanate.

[0110] The mixture provided is in particular composed of a polyol and an isocyanate and preferably includes further chemical additives.

[0111] In other words, the polyurethane-forming mixture can be a solvent-containing and polyurethane-containing composition and, in particular, may have several components, selected individually or in combination from polyol, isocyanate, catalyst, release agent, additive.

[0112] Preferably, a chemical reaction is initiated upon preparation of the mixture. This chemical reaction is preferably exothermic. Furthermore, the chemical reaction is preferably a crosslinking reaction in which molecular polymer chains are preferably formed. Preferably, crosslinks form between the polymer chains. Preferably, polyurethane is formed during the crosslinking reaction. Preferably, the additional step takes place immediately before step g), meaning that the components forming the mixture are mixed together immediately before injection into the closed cavity halves.

[0113] In particular, the chemical reaction is initiated by mixing the two polyurethane-forming components, polyol and isocyanate. Preferably, a crosslinking reaction occurs, forming the molecular polymer chains. The crosslinking reaction is preferably exothermic. Preferably, the polyol and isocyanate components remain separate before the mixing process and are only combined immediately before injection into the closed cavity halves according to step g). This prevents premature chemical reaction. Advantageously, this allows the rheological flow properties of the mixture to be maintained for injection into the closed cavity halves in step g).

[0114] Preferably, the mixture is low-viscosity when injected into the closed cavity halves in step g). Preferably, the viscosity at the beginning of injection into the closed cavity halves is in the range between 100 mPas and 300 mPas, preferably 120 mPas and 200 mPas, at a mixture temperature of 40°C to 100°C, preferably at a mixture temperature of 50°C to 75°C, and particularly preferably at a mixture temperature of 60°C to 70°C.

[0115] Preferably, the viscosity of the mixture and / or the polyurethane layer forming increases as the chemical crosslinking reaction progresses until the end of the reaction. Preferably, the mixture and / or the polyurethane layer forming hardens as the chemical crosslinking reaction progresses. Preferably, a fully cured polyurethane layer is formed at the end of the chemical reaction.

[0116] The mixture provided preferably has reactive groups. Particularly preferably, the mixture provided has at least two reactive groups, preferably three or more.

[0117] Preferably, each component of the mixture has at least two reactive groups, preferably three or more. In particular, the polyol preferably has at least two reactive groups, preferably three or more. Furthermore, the isocyanate preferably has at least two reactive groups, preferably three or more.

[0118] The reactive groups can preferably be free reactive groups and / or disguised reactive groups that release the corresponding reactive group again at a temperature in the range of 30°C to 180°C.

[0119] The presence of three or more reactive groups preferably enables the formation of cross-links to form the polyurethane layer.

[0120] The term "curing" or "hardening" preferably refers to the transition from a liquid or plastically deformable state to a solid state of a substance or mixture of substances under standard conditions (temperature: 25°C, pressure: 1013 mbar).

[0121] The curing or hardening process can preferably be carried out by cooling, i.e. by reducing the temperature below the freezing point and / or below the glass transition temperature of a substance or mixture of substances, and / or by physical drying, i.e. by removing at least one liquid component, for example solvent, and / or by chemical reaction, for example by chain polymerization, polyaddition and / or polycondensation.

[0122] The term “polymeric component and / or precursor thereof” preferably refers to a substance or mixture of substances which comprises at least one, preferably organic, polymer and / or at least one precursor thereof.

[0123] The term "polymer" preferably refers to a substance composed of preferably at least 10 structural units, so-called constitutional repeating units, which may be identical or different from one another and which form at least one organic polymer through chemical reaction, preferably chain polymerization, polyaddition, and / or polycondensation. Preferably, a constitutional repeating unit (CRU) is the smallest repeating group of atoms within a polymer.

[0124] A polymer according to the invention can be unbranched or branched.

[0125] The term “precursor of a polymeric component” preferably refers to monomers or monomer mixtures as well as oligomers and mixtures thereof, which can each combine to form the corresponding unbranched or branched polymer, preferably by chemical reaction, more preferably by chain polymerization, polyaddition and / or polycondensation.

[0126] The term “reactive functional group” preferably refers to a functional group that can participate in the formation of the corresponding unbranched or branched polymer through chemical reaction, more preferably chain polymerization, polyaddition and / or polycondensation.

[0127] Monomers or monomer mixtures within the meaning of the invention are preferably low-molecular-weight, reactive molecules or mixtures of reactive molecules, each of which can combine to form the corresponding unbranched or branched polymer by chemical reaction, more preferably chain polymerization, polyaddition and / or polycondensation, thereby forming a constitutional repeating unit of the polymer. Preferably, a reactive molecule, for example monomer, oligomer and optionally polymer, has at least one reactive functional group.

[0128] The term “oligomer” preferably refers to a substance composed of preferably 2 to 9 constitutional repeating units, which may be identical or different from each other and which may preferably combine to form an unbranched or branched polymer by chemical reaction, more preferably chain polymerization, polyaddition and / or polycondensation.

[0129] The term “cured polymeric component” preferably refers to a polymeric substance or a mixture of polymeric substances that has a solid state under standard conditions (temperature: 25°C, pressure: 1013 mbar) and is preferably not plastically deformable.

[0130] According to a further advantageous embodiment of the invention, the third cavity half forms a negative for the second layer, which is preferably made of polyurethane. The cavity half preferably has mold cavity areas of varying thicknesses to create different wall thicknesses for the second layer.

[0131] Preferably, the cavity half has at least one first molded cavity area for producing the first wall thickness of the second layer and at least one second molded cavity area for producing the second wall thickness of the second layer. The first wall thickness can differ from the second wall thickness by, in particular, 5% to 75%, preferably by 10% to 50%.

[0132] According to a further advantageous embodiment of the invention, the method additionally comprises the following steps, which are preferably carried out after step g), in particular in the following order: h) Removal of the third cavity half or removal of the first cavity half, whereby the component remains in the holding device by holding the holding element through the holding device, i) Release of the holding element by the holding device, j) Demolding of the component.

[0133] The film coated with the first and second layers is already referred to here as a component.

[0134] Preferably, when removing the third cavity half in step h), the component remains in the first cavity half.

[0135] Preferably, the adhesive strength of the polyurethane (PUR) of the second layer to the third cavity half is less than the adhesive strength of the thermoplastic of the first layer to the first cavity half. FHaftung PUR to the third cavity half <FHaftung Thermoplast zu ersten Kavita¨tsha¨lfte

[0136] Particularly preferred is an adhesive force of the holding element(s) on the holding arm(s) that is greater than the adhesive force of the second layer, preferably made of polyurethane, on the third cavity half. This allows the component to preferably remain in the first cavity half with the holding device. Preferably, the film remains pressed against the first cavity half by the holding device, in particular by the clamping frame.

[0137] If the first cavity half is removed in step h), the component preferably remains in the third cavity half.

[0138] Preferably, the release of the retaining element in step i) is achieved by retracting the movable retaining arm from the retaining element. The movable retaining arm is preferably designed as a piston. Preferably, the retaining device comprises several retaining arms. The component can have one or more retaining elements. The retaining arms are preferably moved out of the retaining element or out of the corresponding retaining element.

[0139] The retaining arms, preferably designed as pistons, can be retracted along their axis within the holding device. The direction of movement of the retaining arms preferably forms a demolding angle relative to a layer plane of the layer structure. The demolding angle is preferably 1° to 89°, particularly preferably 1° to 60°. Retracting the retaining arms overcomes the positive locking between the respective retaining arm and the holding element and / or the corresponding holding element.

[0140] After the holding arms are retracted, the clamping frame is preferably detached from the film. This is preferably done by moving the clamping frame, preferably in the direction of the layer structure.

[0141] Any vacuum that may exist between the film and the first cavity half is preferably filled with ambient air. This allows the component to be removed from the injection mold.

[0142] Furthermore, it is possible to manufacture several components in parallel to each other by using rotary table technology, cube technology and / or indexable plate technology.

[0143] Polyurethane is not thermoplastic, but rather a reaction product with a very low initial viscosity. Therefore, polyurethane can mold geometries and / or structures, particularly complex geometries and / or structures. The process according to the invention is thus advantageously particularly flexible with regard to specific geometric requirements. Components with geometries and / or structures, especially complex geometries and / or structures, can be produced. These geometries and / or structures can, for example, include abrupt or continuous changes in cross-section, in particular tapers, corners, edges, peaks, and / or arcs. In particular, the components can have particularly thick walls and / or abrupt changes in wall thickness. Compared to injection molding with thermoplastic materials, very little and / or very few geometric distortions and / or sink marks and / or cavities occur.The components according to the invention therefore advantageously exhibit a high optical quality.

[0144] Preferably, before and / or during and / or after the application of the second layer, preferably made of polyurethane, in step g), the second layer can be modified and / or structured, preferably by inserting / placing particles onto the first layer and / or by using tool structures on the third cavity half used in step f) and / or by subsequently processing the second layer by means of process steps selected individually or in combination from laser processing, overprinting, hot stamping, cold stamping, blind stamping, mechanical processing.

[0145] In particular, by means of laser processing and / or mechanical processing and / or the use of tool structures, it is possible to create exposed relief structures in the second layer, preferably made of polyurethane, with a minimum line thickness and / or a minimum laserable point diameter of 5 µm to 150 µm, preferably 10 µm to 100 µm. This allows for the production of the finest details, especially for motifs and / or alphanumeric information. It is also possible to combine such fine structures with coarser, macroscopic structures, either in a laterally adjacent combination or as a superimposition of a coarse structure with a fine structure.This can be achieved in particular by combining several of the aforementioned process steps, for example, to generate coarse structures with dimensions of the individual structural elements from 0.5 mm to 50 mm in combination with laser processing and / or mechanical processing adjacent to and / or superimposed thereon with a minimum line thickness and / or a minimum laserable point diameter of 5 µm to 150 µm, preferably from 10 µm to 100 µm. It is also possible, however, for coarse and fine structures to be present together as a tool structure and thus molded in the second layer, preferably made of polyurethane. The depth of the relief structures can be between 1 µm and the maximum wall thickness of the second layer, preferably made of polyurethane, in particular between 0.001 mm and 50 mm, preferably between 0.001 mm and 30 mm, and more preferably between 0.001 mm and 15 mm.

[0146] According to a further advantageous embodiment of the invention, the method additionally comprises the following step, which is preferably carried out between step e) and step f): k) Applying a further decorative layer and / or a further decorative layer comprising at least one further decorative layer to the side of the first layer facing away from the film.

[0147] The additional decorative layer and / or layer can be applied to the first layer by hot stamping and / or cold stamping and / or digital printing and / or functional foil bonding (FFB). The additional decorative layer and / or layer is preferably applied to the thermoplastic first layer and, in step g), flooded with polyurethane to form the second layer.

[0148] Furthermore, it is possible that the additional decorative layer and / or the additional decorative layer comprising at least one further decorative layer is only applied in certain areas to the side of the first layer facing away from the foil.

[0149] Advantageously, the decorative layer and the further decorative layer or further decorative layer complement each other in the formation of a design, especially in conjunction with X-ray technologies.

[0150] According to a further advantageous embodiment of the invention, in step b) the film is inserted with its carrier side abutting the first cavity half.

[0151] According to a further advantageous embodiment of the invention, the film is an IMD film. In step b), the IMD film is fed into the first cavity half as film roll material or inserted into the first cavity half as a label. Alternatively, the film can be an insert film. In this case, the insert film is inserted into the first cavity half in step b).

[0152] According to a further advantageous embodiment of the invention, the method additionally comprises the following step, which is preferably carried out after step b): I) Pressing the foil comprising the decorative layer onto the first cavity half by the holding device, in particular by a clamping frame formed by the holding device.

[0153] Step I) is preferably performed before closing the injection mold from step c). Preferably, the holding device, in particular the clamping frame, is moved against the film. The movement preferably occurs in a direction perpendicular to a plane formed by the film. This preferably presses the film against the first cavity half. Preferably, the film is fixed by the holding device, in particular by the clamping frame.

[0154] According to a further advantageous embodiment of the invention, the method additionally comprises the following step, which is preferably carried out after step b) and / or after step I): m) Evacuating the first half of the cavity so that a vacuum is created between the foil encompassing the decorative layer and the first half of the cavity.

[0155] Preferably, step m) is performed immediately after step b) and / or immediately after step I). Alternatively, step m) can be performed during step c) or immediately after step c).

[0156] Preferably, the vacuum between the film containing the decorative layer and the first cavity half is maintained during steps c) to g). In the case of removing the third cavity half in step h), the vacuum between the film containing the decorative layer and the first cavity half is preferably maintained during step h).

[0157] Evacuating the first half of the cavity advantageously holds the film and / or the emerging component stably within that half. Furthermore, evacuating the first half of the cavity advantageously prevents air inclusions or voids in the first layer in step d) and / or in the second layer in step g). This ensures good component quality.

[0158] According to a further advantageous embodiment of the invention, the first material is formed by an injection molding material, in particular by at least one thermoplastic, or by polyurethane.

[0159] According to a further advantageous embodiment of the invention, the second material is a flooding material, in particular polyurethane.

[0160] Polyurethane is not thermoplastic, but rather a reaction product with a very low initial viscosity. Therefore, polyurethane can mold geometries and / or structures, particularly complex geometries and / or structures. The component according to the invention, and in particular the second layer of the component according to the invention, can therefore have geometries and / or structures, especially complex geometries and / or structures. These geometries and / or structures can, for example, include abrupt or continuous changes in cross-section, in particular tapers, corners, edges, peaks, and / or arcs. In particular, the component, and in particular the second layer of the component, can have particularly thick walls and / or abrupt changes in wall thickness. Compared to injection molding with thermoplastic materials, very little and / or very few geometric distortions and / or sink marks and / or voids occur.The components according to the invention therefore advantageously exhibit a high optical quality.

[0161] The first material is preferably transparent, in particular a transparent thermoplastic or transparent polyurethane.

[0162] The second material is preferably transparent, in particular transparent polyurethane.

[0163] It is also conceivable that the first material and / or the second material is translucent or opaque and / or colored. The first and second materials can have different degrees of transmission.

[0164] In the present application, a film, layer, or layer with a transmission greater than 70% is preferably referred to as transparent. With a transmission between 50% and 70%, the film, layer, or layer is preferably referred to as translucent. With a transmission of less than 50%, the film, layer, or layer is preferably referred to as opaque. The percentage values ​​mentioned refer in particular to transmission in the wavelength range perceptible to the human eye. The wavelength range perceptible to the human eye is preferably assumed to be the wavelength range from 380 nm to 780 nm.

[0165] According to an advantageous embodiment of the invention, the injection mold comprises a fourth cavity half. The method further comprises the following steps, which are preferably carried out between the removal of the third cavity half in step h) and step i), particularly in the following order: n) Closing the injection mold by inserting the fourth cavity half into the first cavity half, so that a third cavity is created, o) Coating the second layer with a third material to form a third layer by introducing, in particular injecting, the third material into the third cavity, p) Removal of the fourth cavity half or removal of the first cavity half, whereby the component remains in the holding device by holding the holding element through the holding device.

[0166] The third material is preferably a flood coating material, in particular polyurethane. Coating the second layer can therefore also be described as flooding the first layer with polyurethane. The third material is preferably transparent, in particular transparent polyurethane.

[0167] Switching between the third and fourth cavity halves can be achieved, for example, using rotary table, sliding table, and / or indexable plate technology. The switch to the fourth cavity half can also be performed manually.

[0168] The third cavity created in step n) is preferably located directly adjacent to the second layer.

[0169] The coating or flooding with the third material to form the third layer takes place in step o) preferably on the surface of the second layer facing away from the film, preferably directly on the second layer.

[0170] Completing step o) preferably results in the production of the component.

[0171] The film coated with the first, second and third layers is already referred to here as a component.

[0172] Preferably, when removing the fourth cavity half in step p), the component with the holding device remains in the first cavity half.

[0173] Preferably, the adhesive strength of the polyurethane (PUR) of the third layer to the fourth cavity half is less than the adhesive strength of the thermoplastic of the first layer to the first cavity half. FHaftung PUR to the fourth cavit¨tshaftte <FHaftung Thermoplast zu ersten Kavita¨tsha¨lfte

[0174] Particularly preferred is an adhesive force of the holding element(s) on the holding arm(s) greater than the adhesive force of the third layer, preferably made of polyurethane, on the fourth cavity half. This allows the component to preferably remain in the first cavity half with the holding device. Preferably, the film remains pressed against the first cavity half by the holding device, in particular by the clamping frame.

[0175] If the first cavity half is removed in step p), the component preferably remains in the fourth cavity half.

[0176] According to a further advantageous embodiment of the invention, the second and third layers are each formed from a flooding material, in particular polyurethane. In this embodiment, the second and third materials are therefore each flooding materials, in particular polyurethane. Preferably, the second material is translucent or opaque and / or colored. Preferably, the third material is transparent. Preferably, the second layer forms geometries and / or structures, in particular complex geometries and / or structures. These geometries and / or structures can, for example, include abrupt or continuous changes in cross-section, in particular tapers, corners, edges, points, and / or arcs. In particular, the second layer can have particularly thick walls and / or abrupt changes in wall thickness.The third layer is preferably arranged directly on top of the second layer. The third layer preferably covers the geometries and / or structures formed by the second layer. The third layer preferably has a smooth, free surface or a free surface structured differently than the second layer. Thus, the third layer preferably forms a protective layer on top of the second layer. Advantageously, the geometries and / or structures formed by the second layer are protected from contamination and / or damage by the third layer and remain visible through it.

[0177] Preferably, the vacuum between the film containing the decorative layer and the first cavity half is maintained during steps n) and o). In the case of removing the fourth cavity half in step p), the vacuum between the film containing the decorative layer and the first cavity half is preferably maintained during step p).

[0178] Particularly preferred is the third material in step o), a mixture, especially a polyurethane-forming mixture. To avoid repetition, reference is made to the descriptions of the mixture forming the second material in step g). These descriptions apply accordingly to the third material in step o). In particular, the term "polyurethane layer" can also apply to the third layer.

[0179] Advantageous embodiments of the invention, which may relate to step g) and / or step o), are explained below. For the sake of simplicity, uniform terms are used. The term "closed cavity halves" can be understood as the second cavity with respect to step g) and / or as the third cavity with respect to step o). The term "polyurethane layer" can be understood as the second layer with respect to step g) and / or as the third layer with respect to step o).

[0180] According to a further advantageous embodiment of the invention, the mixture is introduced, in particular injected, into the closed cavity halves in step g) and / or step o) at a filling pressure selected from a range of 70 bar to 140 bar, preferably from 80 bar to 100 bar. In step g), the mixture is preferably introduced, in particular injected, into the second cavity. In step o), the mixture is preferably introduced, in particular injected, into the third cavity.

[0181] According to a further advantageous embodiment of the invention, the polyurethane layer forms in the closed cavity halves as a result of the introduction, in particular injection, of the mixture in step g) and / or in step o) at a temperature selected from a range of 40°C to 160°C, preferably from 60°C to 140°C, particularly preferably from 80°C to 120°C, and / or at a pressure selected from a range of 3 bar to 100 bar, preferably from 5 bar to 50 bar, particularly preferably from 8 bar to 30 bar.

[0182] Advantageously, lower temperatures are required to form the polyurethane layer than when using thermoplastic materials in the injection molding process.

[0183] Preferably, an exothermic reaction in the mixture starts when the polyurethane-forming mixture is supplied to the mixing head. This exothermic reaction preferably heats the mixture introduced into the closed cavity halves in step g) and / or step o). Depending on the current phase of the exothermic reaction, it is advantageous to temper the mixture, in particular to heat or cool it, so that the exothermic reaction takes place at a relatively constant process temperature. At the beginning of the exothermic reaction, the mixture is therefore heated by the tool temperature, which is then higher than the mixture temperature.As the exothermic reaction progresses and more thermal energy is released, the largely constant tool temperature leads to a cooling of the mixture, which is heated by the reaction. This is because the tool temperature temporarily falls below the mixture temperature, which is influenced by the exothermic reaction. The tool temperature remains largely constant during the exothermic reaction.

[0184] The cavity halves are preferably pre-tempered to a temperature selected from a range of 40°C to 160°C, preferably 60°C to 140°C, and particularly preferably 80°C to 120°C, before the mixture is introduced, especially injected, according to step g) and / or step o). Preferably, the temperature of the mixture at the beginning of the chemical reaction and / or immediately after mixing the mixture and / or immediately upon injection into the closed cavity halves is lower than the temperature of the cavity halves (mold temperature). Preferably, due to the low thermal conductivity of polyurethane (approximately 0.020 W / Km to 0.040 W / Km), the mixture and / or the polyurethane layer forming will reach the pre-set temperature of the cavity halves (mold temperature) over time and / or as the reaction progresses.

[0185] Preferably, the temperature difference for cooling the component formed in the closed cavity halves is 0K to 100K, preferably 0K to 50K, and particularly preferably 0K to 30K. The temperature difference for cooling the component formed in the closed cavity halves is thus advantageously much lower than in the injection molding of thermoplastic materials.

[0186] Advantageously, lower pressures are required to form the polyurethane layer than when using thermoplastic materials in injection molding.

[0187] According to a further advantageous embodiment of the invention, the method additionally comprises the following step, which is preferably carried out after step g) and / or after step o): q) Hardening of the mixture inside and / or outside the closed cavity halves, forming the polyurethane layer.

[0188] The duration of the hardening process within the closed cavity halves is preferably 10 seconds to 120 seconds, particularly preferably 20 seconds to 90 seconds, and more preferably 30 seconds to 70 seconds.

[0189] These are, in particular, 2 to 10 times the pot life of the mixture, preferably 3 to 7 times the pot life of the mixture. The pot life is the processing time or service life of the reactive mixture.

[0190] Preferably, the component is cooled within the closed cavity halves during the curing process. The duration of the curing process within the closed cavity halves can also be referred to as the cooling time. After the cooling time has elapsed, step h) is preferably carried out immediately. In this step, the cavity halves are opened. The cooling time depends on the degree of curing of the polyurethane and can vary as described above. The initially liquid polyurethane must have solidified so that no deformation occurs after the cavity halves are opened. For this purpose, the temperature of the mold cavity, i.e., in particular the cavity halves, preferably exceeds the ambient temperature by at least 5 K, preferably by 10 K. TToolcavitat>TEnvironment+5 K

[0191] The duration of the hardening process outside the closed cavity halves, particularly on a holding device with the shape of the component, is preferably 5 minutes to 90 minutes, more preferably 5 minutes to 45 minutes.

[0192] Preferably, the viscosity of the mixture and / or the polyurethane layer forming increases as the chemical crosslinking reaction progresses. Preferably, the mixture and / or the polyurethane layer forming hardens as the chemical crosslinking reaction progresses. Preferably, a fully cured polyurethane layer is formed at the end of the chemical crosslinking reaction.

[0193] Preferably, in step q) the mixture is completely cured to form the polyurethane layer.

[0194] The hardening according to step q) is preferably carried out at a temperature selected from a range of 20°C to 160°C, preferably from 20°C to 120°C.

[0195] In the case of a configuration with a further decorative layer and / or further decorative layer applied to the first layer, the further decorative layer and / or further decorative layer has a primer layer, preferably a primer layer that is at least partially not yet fully cured, in particular an adhesion promoter layer, on the surface facing away from the first layer for bonding with the polyurethane of the second layer. The primer layer, which is at least partially not yet fully cured, is preferably cured together with the mixture applied to it and / or with the polyurethane layer applied thereto, preferably fully cured. Cross-linking preferably forms between the polyurethane layer and the primer layer. The polyurethane layer is preferably bonded to the primer layer in a metallurgical manner.

[0196] The composite material consisting of the first layer and / or the subsequent decorative layer and / or further decorative layer with the polyurethane layer is preferably dimensionally stable. Preferably, the polyurethane layer cannot be removed from the first layer and / or the subsequent decorative layer and / or further decorative layer without damage.

[0197] According to a further advantageous embodiment of the invention, the method additionally comprises the following step, which is preferably carried out after step i) and / or step j): r) Removal of the backing layer of the film.

[0198] This advantageous design therefore preferably refers to the design of the film as an IMD film.

[0199] After performing step r), preferably only the decorative layer of the IMD film remains on the component.

[0200] A release layer of the IMD film may be located completely or partially on the decorative layer after the carrier layer has been removed from the film, and / or may be located completely or partially on the carrier layer.

[0201] According to a further advantageous embodiment of the invention, in step b) the film is provided as roll stock and / or as continuous film and / or as a sheet and / or is introduced into the cavity half by means of a film feed device. In particular, an IMD film can preferably be provided as roll stock and / or as continuous film. An IMD film can also be provided as a sheet. In particular, an insert film can preferably be provided as a sheet. An insert film can also be provided as roll stock and / or as continuous film.

[0202] Preferably, the process is carried out as an IMD process (IMD = In-Mold Decoration). In this process, the film comprising the decorative layer is conveyed as a transfer film with a carrier layer and a decorative layer containing the decorative layer, particularly as roll stock, and is introduced into the first cavity half, particularly according to step b).

[0203] Compared to other decoration methods such as wet painting, the decoration process using lacquer transfer technology offers a significantly greater design versatility. This allows for the creation of individual images, technical designs, tactile surfaces, and many other design variations.

[0204] According to a further advantageous embodiment of the invention, the method comprises the following further step, or step b), e), h), i), j) and / or step p) includes the following further sub-step: s) Cleaning the film and / or component, preferably the first, second and / or third layer, in particular by means of at least one brush and / or a blower and / or a suction device.

[0205] According to a further advantageous embodiment of the invention, the method comprises the following further step or step j) includes the following further sub-step: t) Printing of the component, preferably of the second and / or third layer, in particular in at least a first and / or second area, preferably alone or in combination selected from inkjet printing, gravure printing, screen printing, planographic printing, letterpress printing, flexographic printing, pad printing.

[0206] According to a further advantageous embodiment of the invention, the method includes the following further step or step b) comprises the following further sub-step: u) Pretreatment of the film, preferably the primer layer, in particular by means of a process selected alone or in combination from corona treatment, flame treatment, plasma treatment.

[0207] According to a further advantageous embodiment of the invention, the method comprises the following further step or step j) includes the following further sub-step: v) Cutting the component by means of punching, waterjet cutting or laser cutting.

[0208] The cutting preferably refers to cutting from the outside.

[0209] Preferably the method may include the further following step or step j) may include the further following sub-step: w) Dividing the component into individual units, especially in the case of roll goods containing multiple units or sheets containing multiple units.

[0210] According to a further advantageous embodiment of the invention, the component obtained in step j) is selected from the group consisting of display, touch field, panel, bezel, and functional element, in particular from the following areas: white goods, motor vehicles, aviation, ships, household appliances, telecommunications equipment, consumer goods, documents, security elements, labels and / or electronic articles.

[0211] The process steps and substeps mentioned are described serially (running one after the other). These process steps and substeps can also run at least partially in parallel, particularly for the production of multiple components according to the invention. For this purpose, rotary table technology and / or cube technology and / or indexable plate technology are preferably used.

[0212] It is further possible that the process steps and substeps are performed once or several times. In particular, process steps and substeps can be repeated. The preferred sequence of process steps has at least the order of step a) - step b) - step c) - step d) - step e) - step f) - step g) - step h) - step i) - step j), whereby, in particular, further steps or substeps may be inserted between these steps.

[0213] An advantage of the invention lies in the fact that the decorative layer comprising at least one decorative layer, the first layer, and optionally further decorative layers and / or further application layers are protected by the overlying, outer second and / or third layer, preferably made of polyurethane, as a protective layer. This enables advantageous effects, such as the creation of enhanced optical depth.

[0214] Advantageously, the decorative layer, comprising at least one decorative layer, is coated with the further layer structure only on one side. In particular, the decorative layer, comprising at least one decorative layer, is not encapsulated on both sides. Therefore, the decorative layer, comprising at least one decorative layer, is advantageously accessible for further processing. In particular, the layer structure according to the invention allows direct laser processing of the decorative layer without having to laser through an injection-molded material.

[0215] Furthermore, this opens up a wide range of possibilities for structural integration. For example, structures can be incorporated into one cavity half of the injection mold. Such a structure can be applied to the second and / or third layer, specifically the polyurethane protective layer, so that the structure is visible on the front side of the finished component. Alternatively, such a structure can be applied to the first layer, making it visible on the back side of the finished component. It is worth noting that when the structure is applied to the back, the decorative layer also very effectively replicates the structure. Micro- or nanostructures, for example, can be used as the basis for these structures.

[0216] Furthermore, reverse-side structures, which are incorporated into the decorative layer or an IMD film covering it, are highly visible as a design element. These reverse-side structures can also be created using a laser. Additional application is possible via hot stamping, cold stamping, digital printing, and / or functional foil bonding (FFB).

[0217] Decoration using a transfer film, such as an IMD film (i.e., a lacquer transfer technology), allows for significantly greater design versatility compared to other decoration methods like wet painting. This enables the creation of individual images, technical designs, tactile surfaces, and many other design variations. By using transfer film for decoration, it is possible to eliminate one or more subsequent processing steps, such as separate overprinting or laser cutting of lettering, symbols, etc. This can advantageously reduce decoration costs. A transfer film can incorporate all these decorative elements, such as decorative printing and negative decorations like lettering or symbols, directly into the layer structure of the transfer layer.

[0218] According to the invention, an injection mold is claimed which comprises a holding device as well as a first, second, and third cavity half. The injection mold is claimed for carrying out a method for producing a component having a layer structure according to any one of claims 1 to 12, and / or for carrying out a method according to any one of claims 13 to 22. The holding device is configured to hold the at least one holding element formed on the first layer.

[0219] The holding device is preferably movable and / or includes movable components, in particular a movable clamping frame and / or at least one movable holding arm.

[0220] Preferably, the injection mold also includes a fourth cavity half.

[0221] According to an advantageous embodiment of the invention, the holding device comprises a clamping frame. The clamping frame is designed to create a tight connection between the first cavity half and the film comprising the decorative layer, so that a vacuum can be created between the film comprising the decorative layer and the first cavity half.

[0222] The clamping frame is preferably hydraulically, mechanically, electromechanically, and / or pneumatically actuated. The clamping frame preferably presses the film containing the decorative layer against the first cavity half. Preferably, the clamping frame presses the film against the first cavity half along a closed, circumferential line. For this purpose, the clamping frame preferably has a ring-shaped form. The ring shape can preferably be rectangular. The clamping frame preferably presses against a primer layer of the film, which is designed as an adhesive layer for bonding with the first layer.

[0223] According to a further advantageous embodiment of the invention, the clamping frame is designed in one piece or in multiple parts, in particular in two parts.

[0224] According to a further advantageous embodiment of the invention, the holding device comprises at least one movable holding arm. The holding arm can be controlled hydraulically, mechanically, electromechanically and / or pneumatically in order to move the holding arm away from the holding element and / or from the first layer.

[0225] The movable holding arm is preferably designed as a piston. Preferably, the holding device comprises several holding arms. The holding arms, preferably designed as pistons, can be moved along their axis within the holding device. In particular, the holding arm(s) can be moved away from the holding element and / or from the first layer.

[0226] In particular, the movable holding arm(s) can be connected to the clamping frame. Preferably, the movable holding arm(s) can be movably mounted in or on the clamping frame. In particular, the movable holding arm(s) can be driven out of the clamping frame towards the holding element or into the clamping frame, i.e., away from the holding element.

[0227] The number of holding arms of the holding device and the number of holding elements provided on the first layer can be the same. Conversely, several holding arms can also correspond to one holding element. The number, arrangement, and orientation of the holding arms depend in particular on the geometry and size of the component.

[0228] According to a further advantageous embodiment of the invention, the direction of movement of the holding arm to a layering plane of the layer structure forms a demolding angle of 1° to 89°, preferably a demolding angle of 1° to 60°.

[0229] The above-described method according to the invention can be carried out with an injection mold that has one or more features of the injection mold according to the invention. Preferably, the above-described method according to the invention is carried out with the injection mold according to the invention.

[0230] Of course, the above-mentioned material characteristics can also be applied equivalently in a process, or the above-mentioned process characteristics can be applied in the product.

[0231] The invention is explained below by way of example using several embodiments and the accompanying drawings. The embodiments shown are therefore not to be understood as limiting. Fig. Figure 1 shows schematic views of a first component according to the invention. Fig. Figure 2 shows schematic views of a second component according to the invention. Fig. Figure 3 shows a flowchart for an exemplary method according to the invention. Fig. 4 shows views of the individual steps of the process. Fig. 3 exemplary methods according to the invention for the manufacture of the first component according to the invention. Fig. 5 shows views of the individual steps of the in Fig. 3 exemplary methods according to the invention for the manufacture of the second component according to the invention. Fig. Figure 6 shows various examples of structuring individual layers of a component according to the invention. Fig. Figure 7 shows a schematic structure of (a) an IMD film and a schematic structure of (b) an insert film, each for providing an additional decorative layer arranged between a first layer (thermoplastic) and a second layer (PUR). Fig. Figure 8 shows a schematic structure of (a) an IMD film and a schematic structure of (b) an insert film, each for providing a decorative layer for coating with a first layer (thermoplastic).

[0232] In Fig. Figure 1 shows schematic views of a first component according to the invention. Fig. Figure 1 (a) shows a schematic sectional view of the first component according to the invention. Fig. Figure 1(b) shows a schematic top view of the first component according to the invention. The first component according to the invention has a layered structure. The layered structure is formed, in this order, by a decorative layer 1, a first layer 3, a further decorative layer 2, and a second layer 4. The first layer 3 is formed by a thermoplastic. The first layer 3 is therefore also referred to as the thermoplastic layer. The first layer 3 has, for example, a thickness of 2 mm. The second layer 4 is formed by polyurethane. The second layer 4 is therefore also referred to as the polyurethane layer. The second layer 4 has, for example, a thickness of 1 mm. In the present example, the decorative layer 1 is a layer of an IMD film to be transferred. The decorative layer 1 comprises, in this order, a protective layer, a decorative layer, and a primer layer.In the present example, the primer layer is designed as an adhesive layer for bonding with the thermoplastic of the first layer 3.

[0233] In a modification of the first component according to the invention, the further decorative layer 2 is omitted. In this case, the layer structure is formed in this order by a decorative layer 1, a first layer 3, and a second layer 4. The other features discussed here also apply in the same way to this modification of the first component according to the invention.

[0234] In the present example, the first layer 3 forms two retaining elements. The two retaining elements are arranged symmetrically to each other on two opposite sides of the component. In the first component according to the invention, the retaining elements are each designed as outwardly projecting tabs 5. The first layer 3 and the two tabs 5 are formed in one piece. The tabs 5, like the first layer 3, are made of thermoplastic. In the present example, the tabs 5 each have a recess 6 at their outwardly projecting end. These recesses 6 each allow a movable retaining arm 11 of a holding device provided on an injection mold to engage.

[0235] Fig. Figure 1(c) shows a detailed schematic sectional view. The holding device comprises, in addition to the holding arm 11, a clamping frame 10, which presses the film bearing the decorative layer 1, in this example an IMD film, against the first cavity half 7. The holding device can also have further holding arms 11, in this example one additional holding arm 11 (not shown in the detailed view). Each holding arm 11 is movably mounted along its axis in a bore in the clamping frame 10. The outer end of the holding arm 11 forms a projection that engages positively in the recess 6 provided on the tab 5. In this way, the holding device blocks movement of the component in both an upward and a downward direction. That is, the holding device blocks movement of the component in both directions perpendicular to the first layer 3.Furthermore, the two holding arms 11 of the holding device are arranged symmetrically to each other and opposite each other, corresponding to the holding elements of the component. Therefore, lateral movement of the component, i.e., movement in the layering plane, is prevented by the two opposing holding arms 11. This advantageously enables secure holding of the component in the holding device. In this example, the holding arm 11 is designed as a piston that is movable along its axis. By retracting from the recess 6, the holding arm 11 releases the holding element and thus the component. The holding arm 11 can be controlled electromechanically for this purpose.

[0236] Fig. Figure 2 shows schematic views of a second component according to the invention. Fig. Figure 2 (a) shows a schematic sectional view of the second component according to the invention. Fig. Figure 2(b) shows a schematic top view of the second component according to the invention. The second component according to the invention has a layered structure. The layered structure has the same sequence as that of the first component according to the invention. Likewise, in a modification of the second component according to the invention, the further decorative layer 2 can be omitted. To avoid repetition, reference is made to the explanations relating to the first component according to the invention, which apply identically here.

[0237] The first layer 3 also forms two retaining elements in the second component according to the invention. These two retaining elements are also symmetrically positioned on opposite sides of the component. In contrast to the first component according to the invention, the retaining elements in the second component according to the invention are formed without the outwardly projecting tabs. The retaining elements are each formed as a recess 6 in the first layer. Each recess extends over a surface area over which the underlying decorative layer 1 also extends. In the present example, the further decorative layer 2 above also extends over these surface areas. In the present example, the second layer 4 is set back from the layers below, so that it does not cover the layers below in a circumferential edge area.In this example, the second layer 4 does not extend over the areas defined by the indentations. The area defined by the second layer 4 can also be flush with the area defined by the first layer 2.

[0238] The indentations 6 in turn each allow the engagement of a movable holding arm 11 of a holding device provided on an injection molding tool. Fig. Figure 2(c) shows a detailed schematic sectional view. The holding device comprises, in addition to the holding arm 11, a clamping frame 10, which presses the film bearing the decorative layer 1, in this example an IMD film, against the first cavity half 7. The holding device can also have further holding arms 11, in this example one additional holding arm 11 (not shown in the detailed view). Each holding arm 11 is movably mounted along its axis in a bore in the clamping frame 10. The outer end of the holding arm 11 forms a projection that engages positively in the recess 6 provided in the first layer 3. In this way, the holding device blocks movement of the component in both an upward and a downward direction. That is, the holding device blocks movement of the component in both directions perpendicular to the first layer 3.Furthermore, the two holding arms 11 of the holding device are arranged symmetrically to each other and opposite each other, corresponding to the holding elements of the component. Therefore, lateral movement of the component, i.e., movement in the layering plane, is prevented by the two opposing holding arms 11. This advantageously enables secure holding of the component in the holding device. In this example, the holding arm 11 is designed as a piston that is movable along its axis. By retracting from the recess 6, the holding arm 11 releases the holding element and thus the component. The holding arm 11 can be controlled electromechanically for this purpose.

[0239] Fig. Figure 3 shows a flowchart for an exemplary method according to the invention.

[0240] Fig. 4 shows views of the individual steps of the process. Fig. Figure 3 illustrates an exemplary method according to the invention for the production of the first component according to the invention. In this case, tabs 5 with indentations 6 are formed on the first layer 3.

[0241] Fig. 5 shows views of the individual steps of the in Fig. 3. Exemplary method according to the invention for the production of the second component according to the invention. In this case, indentations 6 are formed in the first layer 3 without the provision of tabs.

[0242] The steps of the exemplary method according to the invention are described jointly for the Fig. Sections 3 to 5 are explained. The process is carried out using an injection mold. The injection mold comprises the holding device as well as a first 7, second 8 and third cavity half 9. The holding device has a clamping frame 10 and, corresponding to the two indentations 6 to be produced, two symmetrically opposed holding arms 11.

[0243] The following steps should preferably be carried out one after the other.

[0244] In step S01, an IMD film is inserted into the first cavity half 7. The IMD film is inserted into the first cavity half 7 such that the carrier side of the IMD film rests against the first cavity half 7. The reverse side of the IMD film, which has the decorative layer 1, will therefore later face the injection molding material. After insertion, the IMD film is pressed firmly against the first cavity half 7 by a clamping frame 10. The clamping frame 10 has a ring-shaped form in top view. The ring shape is rectangular. The clamping frame 10 presses the IMD film firmly against the first cavity half 7 along a closed circumferential line. In addition to pressing the IMD film against the first cavity half 7 by the clamping frame 10, a vacuum is created between the IMD film and the first cavity half 7, so that the IMD film is drawn against the first cavity half 7.

[0245] In step S02, the injection mold is closed by inserting the second cavity half 8 into the first cavity half 7. This creates a first cavity on the reverse side of the IMD film, which has the decorative layer 1. The first cavity is bounded by the decorative layer 1, by the second cavity half 8, and by the retaining arms 11 provided in the clamping frame 10. The clamping frame 10 and the retaining arms 11 together form the holding device. The first cavity may also be partially bounded by the first cavity half 7. The first cavity corresponds to the volume of the first layer 3 to be produced by back injection molding. In the case of the first component according to the invention, the first cavity therefore also includes the volume of the tabs 5 to be produced together with the first layer 3 (see Figure 1). Fig. 4, step 2). In addition, in this case, the first cavity has an indentation at the outer end of the volume of the tabs. The indentations are formed by a projection provided at the end of the retaining arm 11 extending into the first cavity. In the case of the second component according to the invention, the first cavity has the indentations to be produced in the first layer 3 (see Fig. 5, step 2). In this case, too, the indentations are formed by the projection of a protrusion provided at the end of the retaining arm 11 into the first cavity.

[0246] In step S03, the IMD film is directly back-injected with a thermoplastic on its reverse side, which has the decorative layer 1. The first cavity is filled with the thermoplastic, forming the first layer 3. In the case of the first component according to the invention, the two tabs 5 are also formed together with the first layer 3 (see figure). Fig. 4, step 3). In this case, the tabs 5 each have a recess 6 at their outer end, corresponding to the indentations previously molded in the first cavity. The projection provided at the end of each retaining arm 11 therefore engages positively in the corresponding recess 6. In the case of the second component according to the invention, the two recesses 6 are formed in the first layer 3, corresponding to the indentations previously molded in the first cavity by the projections provided at the end of the retaining arms 11 (see Fig. 5, step 3). In this case as well, the projection provided at the end of the respective retaining arm 11 therefore engages in a form-fitting manner in the corresponding recess 6.

[0247] In step S04, the injection mold is opened after a cooling period of, for example, 60 seconds. For this, the second cavity half 8 is removed. The retaining elements are held in place by the retaining arms 11 of the holding device. Likewise, the clamping frame 10 continues to press the IMD film against the first cavity half 7, and the vacuum between the IMD film and the first cavity half 7 is maintained. Therefore, when the injection mold is opened, the IMD film coated with the first layer 3 remains securely and dimensionally stable in the first cavity half 7.

[0248] In step S05, the injection mold is closed by inserting the third cavity half 9 into the first cavity half 7. This creates a second cavity adjacent to the first layer 3. The second cavity is also bounded by the third cavity half 9. The volume of the second cavity corresponds to the volume of the second layer 4, which is produced by flooding with polyurethane.

[0249] Alternatively, in further embodiments, a further decorative layer and / or a further decorative layer 2 comprising at least one further decorative layer can first be arranged on the first layer 3. When the injection mold is closed by inserting the third cavity half 9 into the first cavity half 7 (step S05), a second cavity is thus created adjacent to the first layer 3, the further decorative layer, and / or the further decorative layer. The second cavity is also bounded by the third cavity half 9. The second cavity also corresponds to the volume of the second layer 4, which is produced by flooding with polyurethane.

[0250] The change of the cavity half from the second 8 to the third cavity half 9 can be carried out, for example, using rotary table, sliding table, and / or indexable plate technology.

[0251] In step S06, the surface of the first layer 3 facing away from the IMD film is flooded with polyurethane. This fills the second cavity with polyurethane, forming the second layer 4. With the completion of the second layer 4, the IMD film is coated with both the first layer 3 and the second layer 4. The first layer 3 incorporates the retaining elements described above. Thus, a component according to the invention is already realized.

[0252] In the present example, the first layer 3 is immediately flooded with polyurethane. In further embodiments, where a further decorative layer and / or a further decorative layer comprising at least one further decorative layer is arranged on the first layer 3 (see alternative in step S05), the further decorative layer, the further decorative layer and / or the first layer 3 are flooded with polyurethane in step S06.

[0253] In step S07, the injection mold is opened after a cooling period of, for example, 60 seconds. For this, the third cavity half 9 is removed. The retaining elements continue to be held by the retaining arms 11 of the holding device. In particular, the adhesive force of the retaining elements on the retaining arms 11 is greater than the adhesive force of the second layer 4, formed from polyurethane, on the third cavity half 9. Furthermore, the clamping frame 10 continues to press the IMD film against the first cavity half 7, and the vacuum between the IMD film and the first cavity half 7 is maintained. Therefore, the component remains securely and dimensionally stable in the first cavity half 7 when the injection mold is opened.

[0254] In step S08, the holding elements are released by the holding device. For this purpose, the holding arms 11 of the holding device are each moved out of the corresponding holding element. In this example, the holding arms 11, which are designed as pistons, are retracted along their axis within the holding device. The direction of movement of the holding arms forms a demolding angle 12 of 30° with respect to the plane of the first layer 3. By retracting the holding arms 11, the positive locking between the respective holding arm 11 and the corresponding holding element is overcome. After the holding arms 11 have retracted, the clamping frame 10 is released from the IMD film. Furthermore, the evacuation between the IMD film and the first cavity half 7 is completed. Thus, the component can be removed from the injection mold.

[0255] Following step S08, in a further step (not shown in the figures), a carrier layer and a release layer of the IMD film can be detached from the component. Further explanations can be found in... Fig. 8 (a) and the accompanying description.

[0256] In a further step (not shown), the two retaining elements designed as tabs 5 can be removed. The tabs 5 can be removed by cutting (for example with a knife) and / or by laser cutting.

[0257] Fig. Figure 6 shows various examples of structuring individual layers of a component according to the invention.

[0258] In a first example ( Fig. 6 (a)) The decorative layer 1 has a surface structure. The surface structure can include or enhance design elements. Furthermore, the surface structure can create haptic and / or optical effects. The surface structure can, for example, include micro- or nanostructures.

[0259] The surface structure can be provided on the decorative layer 1 of the IMD film to be inserted into the injection mold prior to carrying out the inventive method. The surface structure can be applied to the decorative layer 1 through the first cavity half 7, in particular by molding. Furthermore, the surface structure can be provided on the decorative layer 1 in a further step after carrying out the inventive method. This can be achieved, for example, by post-processing using a laser, embossing, and / or milling. Alternatively, a further application can be carried out using digital printing and / or Functional Foil Bonding (FFB).

[0260] In a second example ( Fig. 6 (b)) The decorative layer 1 has a surface structure that was created by two processing steps. For example, the decorative layer 1 can already have its own surface structure before the process according to the invention is carried out. In addition, a surface structure can be molded onto the decorative layer 1 by the first cavity half 7.

[0261] In a third example ( Fig. 6 (c)) The second layer 4, formed from polyurethane, has a surface structure. This surface structure can also include or reinforce design elements. Furthermore, this surface structure can produce haptic and / or optical effects. The surface structure can, for example, include micro- or nanostructures.

[0262] This surface structure can be molded onto the second layer 4 by the third cavity half 9. Furthermore, this surface structure can be produced on the second layer 4 in a further step after carrying out the inventive method. For this purpose, post-processing can be carried out, for example, by laser, embossing and / or milling.

[0263] In a fourth example ( Fig. 6 (d)) Both the decorative layer 1 and the second layer 4, formed from polyurethane, have a surface structure. The possibilities shown for the first to third examples apply to the respective surface structures. In particular, the surface structure can be molded onto the decorative layer 1 by the first cavity half 7, and the surface structure onto the second layer 4 can be molded onto the third cavity half 9.

[0264] Fig. Figure 7 shows a schematic structure of (a) an IMD film 20 and a schematic structure of (b) an insert film 30, each for providing a further decorative layer 2 arranged between a first layer 3 made of a thermoplastic and a second layer 4 made of polyurethane. The further decorative layer 2 is visible from the front in the finished component, i.e., from a first surface. Therefore, the further decorative layer 2 is also referred to as a first surface decoration.

[0265] The following describes the layer structure of an IMD film 20 or insert film 30 applied for the subsequent decorative layer 2. The sequence of layers corresponds to the sequence in the layer structure of the resulting or finished component.

[0266] The IMD film 20 has a first primer layer 21. The first primer layer 21 is formed by an adhesive layer for bonding with the thermoplastic of the first layer 3 of the component. In the finished component, the first primer layer 21 lies directly adjacent to the first layer 3, which is made of thermoplastic. The first primer layer 21 is immediately followed by a decorative layer 22. The decorative layer 22 is immediately followed by a second primer layer 23. The second primer layer 23 is formed by an adhesive layer for bonding with the polyurethane of the second layer 4 of the component. In the finished component, the second primer layer 23 lies directly adjacent to the second layer 4, which is made of polyurethane. The first primer layer 21, the decorative layer 22, and the second primer layer 23 together form the layer of the IMD film 20 to be transferred, which forms the decorative layer 2 in the finished component.In the structure of the IMD film 20, a release layer 24 immediately follows the second primer layer 23. A carrier layer 25 immediately follows the release layer 24. The carrier layer 25 is formed by a PET film. The release layer 24 and the carrier layer 25 are removed from the IMD film 20 before flooding with polyurethane (step S06).

[0267] The insert film 30 has a carrier layer 31. The carrier layer 31 is a thermoplastic film. In the finished component, the carrier layer 31 lies directly adjacent to the first layer 3, which is made of a thermoplastic. A third primer layer 32 immediately follows the carrier layer 31. The third primer layer 32 consists of an adhesive layer for bonding to the thermoplastic carrier layer 31. A decorative layer 33 immediately follows the third primer layer 32. A fourth primer layer 34 immediately follows the decorative layer 33. The fourth primer layer 34 consists of an adhesive layer for bonding to the polyurethane of the second layer 4 of the component. In the finished component, the fourth primer layer 34 lies directly adjacent to the second layer 4, which is made of polyurethane.

[0268] Fig.Figure 8 shows a schematic structure of (a) an IMD film 40 and a schematic structure of (b) an insert film 50, each for providing a decorative layer 1 for coating with a first layer 3 made of a thermoplastic. The decorative layer 1 is located at the rear of the finished component, i.e., on a second surface. Therefore, the decorative layer 1 is also referred to as a second surface decoration.

[0269] The following describes the layer structure of an IMD film 40 or insert film 50 applied for decorative layer 1. The sequence of layers corresponds to the sequence in the layer structure of the resulting or finished component.

[0270] The IMD film 40 has a carrier layer 41. The carrier layer 41 is formed by a PET film. In step S01, the IMD film 40 is inserted into the first cavity half 7 such that the carrier layer 41 of the IMD film 40 is in contact with the first cavity half 7. The carrier layer 41 is immediately followed by the release layer 42. The carrier layer 41 and the release layer 42 can be removed from the IMD film 40 after steps S01 to S08 have been carried out, i.e., after the component is finished. In the structure of the IMD film 40, a protective layer 43 immediately follows the release layer 42. After the carrier layer 41 and release layer 42 have been removed, the protective layer 43 can form a surface of the finished component. The protective layer 43 is immediately followed by a decorative layer 44. The decorative layer 44 is immediately followed by a fifth primer layer 45.The fifth primer layer 45 is formed by an adhesive layer for bonding with the thermoplastic of the first layer 3 of the component. In the inventive process, the fifth primer layer 45 is back-injected with thermoplastic and, in the finished component, lies directly adjacent to the first layer 3 formed from the thermoplastic. The protective layer 43, the decorative layer 44, and the fifth primer layer 45 together form the layer of the IMD film 40 to be transferred, which forms the decorative layer 1 in the finished component.

[0271] The insert film 50 has a carrier layer 51. The carrier layer 51 is a thermoplastic film. The insert film 50 is placed into the first cavity half 7 according to step S01 such that the carrier layer 51 abuts the first cavity half 7. A sixth primer layer 52 immediately follows the carrier layer 31. The sixth primer layer 52 consists of an adhesive layer for bonding with the thermoplastic carrier layer 51. A decorative layer 53 immediately follows the sixth primer layer 52. A seventh primer layer 54 immediately follows the decorative layer 53. The seventh primer layer 54 consists of an adhesive layer for bonding with the thermoplastic of the second layer 3 of the component.In the inventive process, the seventh primer layer 54 is back-injected with thermoplastic and lies directly adjacent to the first layer 3 formed from the thermoplastic in the finished component. Reference symbol list 1 decorative layer 2 additional decorative layers 3 first shift 4 second shift 5 tabs 6 indentation 7 first cavity half 8 second cavity half 9 third cavity half 10 clamping frames 11 Support arm 12 demolding angles 20 IMD foil 21 first primer layer 22 decorative layer 23 second primer layer 24 Delamination layer 25 carrier layer 30 insert foil 31 Carrier layer 32 third primer layer 33 decorative layer 34 fourth primer layer 40 IMD film 41 Carrier layer 42 Delamination layer 43 Protective layer 44 decorative layers 45 fifth primer layer 50 insert foil 51 Carrier layer 52 sixth primer layer 53 Decorative layer 54 seventh primer layer

Claims

[1] Component having a layered structure, in particular a layered structure with at least three layers, characterized by , that the layer structure comprises a decorative layer (1), wherein the decorative layer (1) comprises at least one decorative layer, that a first layer (3) made of a first material is arranged on the decorative layer (1), that a second layer (4) made of a second material is arranged on the first layer (3), and that the first layer (3) has a circumferential edge and comprises or is connected to at least one retaining element, wherein the retaining element extends along the edge of the first layer (3). [2] Component according to claim 1, characterized by that the first material is formed by an injection molding material, in particular by at least one thermoplastic, or by polyurethane, and / or that the second material is a flooding material, in particular polyurethane. [3] Component according to claim 1 or 2, characterized by , that a third layer made of a third material is arranged on the second layer (4), and that the third material is preferably a flooding material, in particular polyurethane. [4] Component according to one of the preceding claims, characterized by , that the holding element is designed to hold the component in an injection mold. [5] Component according to one of the preceding claims, characterized by , that the retaining element is designed as an outwardly projecting tab (5), wherein the retaining element is formed from the first material, and / or that the retaining element is designed as a recess (6) in the first material. [6] Component according to one of the preceding claims, characterized by, that the indentation (6) is designed to engage a holding device of an injection molding tool, in particular that the indentation (6) is designed to engage a holding device of an injection molding tool in a form-fitting manner. [7] Component according to one of the preceding claims, characterized by , that the decorative layer (1) is a layer of an IMD film or label to be transferred, or that the decorative layer (1) is part of an insert film. [8] Component according to one of the preceding claims, characterized by , that between the first layer (3) and the second layer (4) a further decorative layer and / or a further decorative layer (2) comprising at least one further decorative layer is arranged. [9] Component according to one of the preceding claims, characterized by, that the first layer (3) comprises exactly one retaining element, wherein the retaining element is preferably designed to extend around the component, and wherein the retaining element is particularly preferably designed to extend completely around the component. [10] Component according to any one of claims 1 to 8, characterized by that the first layer (3) comprises two, three, four, five, six, eight, ten or twelve retaining elements. [11] Component according to one of the preceding claims, characterized by , that the first layer (3) has a wall thickness of 0.5 mm to 10 mm, that the first layer (3) preferably has a wall thickness of 1 mm to 5 mm, that the first layer (3) particularly preferably has a wall thickness of 1.5 mm to 3 mm. [12] Component according to one of the preceding claims, characterized by, that the second layer (4) has a wall thickness of 0.2 mm to 50 mm, that the second layer (4) in particular has a wall thickness of 0.2 mm to 30 mm, that the second layer (4) preferably has a wall thickness of 0.3 mm to 15 mm, that the second layer (4) preferably has a wall thickness of 0.5 mm to 5 mm, that the second layer (4) particularly preferably has a wall thickness of 0.8 mm to 3 mm. [13] Method for manufacturing a component comprising a layer structure, in particular a layer structure with at least two layers, preferably a component according to one of claims 1 to 12, preferably an injection molding method, wherein the method comprises the following steps, in particular in the following order: a) Providing an injection mold comprising a holding device and a first (7) and second cavity half (8), b) Inserting a foil comprising a decorative layer (1) with at least one decorative layer into the first cavity half (7), c) Closing the injection mold by inserting the second cavity half (8) into the first cavity half (7), so that a first cavity is formed that is in contact with the film, d) Coating the film with a first material by forming a first layer (3) by introducing the first material into the first cavity, wherein the first layer (3) is formed with at least one retaining element such that the retaining device is arranged in a form-fitting manner with respect to the retaining element, e) Removal of the second cavity half (8), wherein the film coated with the first layer (3) remains in the first cavity half (7) by holding the retaining element through the holding device. [14] Method according to claim 13, characterized by, that the injection mold includes a third cavity half (9), and that the method additionally includes the following steps, which are preferably carried out after step e), in particular in the following order: f) Closing the injection mold by inserting the third cavity half (9) into the first cavity half (7), so that a second cavity is formed, g) Coating the foil coated with the first layer (3) with a second material to form a second layer (4) by introducing the second material into the second cavity. [15] Method according to claim 14, characterized by , that the method additionally comprises the following steps, which are preferably carried out after step g), in particular in the following order: h) Removal of the third cavity half (9) or removal of the first cavity half (7), wherein the component remains in the holding device by holding the holding element through the holding device, i) Release of the holding element by the holding device, j) Demolding of the component. [16] Method according to any one of claims 13 to 15, characterized by , that the procedure additionally includes the following step, which is preferably carried out between step e) and step f): k) Applying a further decorative layer and / or a further decorative layer comprising at least one further decorative layer (2) to the side of the first layer (3) facing away from the film. [17] Method according to any one of claims 13 to 16, characterized by , that in step b) the film is inserted with its carrier side against the first cavity half (7). [18] Method according to any one of claims 13 to 17, characterized by, that the film is an IMD film, wherein the IMD film is fed into the first cavity half (7) as film roll material in step b) or is used as a label, or that the film is an insert film and is inserted into the first cavity half (7) in step b). [19] Method according to any one of claims 13 to 18, characterized by , that the procedure additionally includes the following step, which is preferably carried out after step b): I) Pressing the foil comprising the decorative layer (1) against the first cavity half (7) by the holding device, in particular by a clamping frame (10) formed by the holding device. [20] Method according to any one of claims 13 to 19, characterized by , that the procedure additionally includes the following step, which is preferably carried out after step b) and / or after step I): m) Evacuating the first cavity half (7) so that a vacuum is created between the film encompassing the decorative layer (1) and the first cavity half (7). [21] Method according to any one of claims 13 to 20, characterized by that the first material is formed by an injection molding material, in particular by at least one thermoplastic, or by polyurethane, and / or that the second material is a flooding material, in particular polyurethane. [22] Method according to any one of claims 13 to 21, characterized by , that the injection mold includes a fourth cavity half, and that the method additionally includes the following steps, which are preferably carried out between the removal of the third cavity half (9) in step h) and step i), in particular in the following order: n) Closing the injection mold by inserting the fourth cavity half into the first cavity half (7), so that a third cavity is formed, o) Coating the second layer (4) with a third material to form a third layer by introducing the third material into the third cavity, p) Removal of the fourth cavity half or removal of the first cavity half (7), wherein the component remains in the holding device by holding the holding element through the holding device. [23] Injection mold comprising a holding device and a first (7), second (8) and third cavity half (9) for carrying out a method for producing a component having a layer structure according to one of claims 1 to 12, and / or for carrying out a method according to one of claims 13 to 22, characterized by, that the holding device is designed to hold the at least one holding element formed on the first layer (3). [24] Injection mold according to claim 23, characterized by , that the holding device comprises a clamping frame (10), wherein the clamping frame (10) is designed to create a tight connection between the first cavity half (7) and the film comprising the decorative layer (1), so that a vacuum can be created between the film comprising the decorative layer (1) and the first cavity half (7). [25] Injection mold according to claim 23 or 24, characterized by that the clamping frame (10) is made in one piece or in multiple parts. [26] Injection mold according to any one of claims 23 to 25, characterized by, that the holding device comprises at least one movable holding arm (11), wherein the holding arm can be controlled hydraulically, mechanically, electromechanically and / or pneumatically to move the holding arm (11) away from the holding element and / or from the first layer (3). [27] Injection mold according to claim 26, characterized by , that the direction of movement of the holding arm (11) to a layering plane of the layer structure forms a demolding angle (12) of 1° to 89°, preferably a demolding angle (12) of 1° to 60°.

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