Molded part with front and back PUR layer and method for its manufacture

Abstract

The invention relates to a molded part (100) comprising - an injection-molded base body (110) with a front (111) and a back (112) made of a translucent plastic material; - a front transparent PUR layer (120) applied to the front (111) of the base body (110); - a rear colored PUR layer (130) applied to the back (112) of the base body (110). The invention further relates to a method for manufacturing such a molded part (100).

Description

[0001] The invention relates to a molded part intended in particular as a decorative component for a motor vehicle. The invention further relates to a comparatively simple method for producing such a molded part.

[0002] DE 10 2015 101 013 A1 describes a molded part designed, in particular, as a decorative part and / or trim part for a vehicle interior. The molded part comprises a decorative layer formed by a plastic film, on the rear side of which a carrier is arranged, in particular injection-molded. The plastic film is preferably transparent or translucent and has, at least on one side, an opaque printed layer with at least one recess for light transmission. The plastic film is coated on the front side with a transparent or translucent protective and / or optical layer, which consists, for example, of polyurethane (PUR). The protective and / or optical layer is applied, in particular, by spray painting, injection molding, or RIM technology.

[0003] Based on this, the object of the invention is to provide a molded part that has a particularly high-quality appearance and is comparatively easy to produce.

[0004] This object is achieved by the molded part according to the invention having the features of patent claim 1. The independent patent claim also extends the invention to a method for producing such a molded part. Advantageous developments and refinements of the invention are evident for both subject matters of the invention from the dependent patent claims, the following description of the invention (this expressly includes features described optionally and by way of example), and the figure.

[0005] The molded part according to the invention comprises or has: - an injection-molded base body with a front side, which also forms the visible side of the molded part, and a back side, wherein the base body is formed from a translucent plastic material; - a front transparent PUR (polyurethane) layer applied to the front of the base body; - a rear colored PUR layer (polyurethane layer) applied to the back of the base body.

[0006] The molded part according to the invention has a spatial shape defined by the base body. The base body is preferably designed as a flat base body and preferably has a thickness of 2.5 mm to 4.0 mm, which refers to the thickness between the front and back sides. The front side can be flat or curved, in particular even multiply curved.

[0007] The injection-molded base body is made of a translucent, i.e., transparent, especially clear, or at least translucent, plastic material. The base body is preferably made of a (translucent) thermoplastic material, e.g., polycarbonate (PC). Due to its injection-molded base body, the molded part according to the invention can also be referred to as an injection-molded component.

[0008] The front PUR layer applied to the front side of the base body is transparent, meaning that it is clear or, if appropriate, tinted, in particular only slightly tinted. The rear PUR layer applied to the back of the base body is colored, in particular such that it is opaque or impermeable to light. Preferably, the front PUR layer and the rear PUR layer are each applied to the base body over the entire surface or at least substantially over the entire surface, whereby the rear PUR layer can also have recesses (see below). The front PUR layer can have a layer thickness of 0.3 mm to 1.0 mm. The rear PUR layer can have a layer thickness of 0.3 mm to 0.8 mm. Equivalently, polyurea (PUA) can also be used for both the front layer and the rear layer instead of polyurethane (PUR).

[0009] The molded part according to the invention can be manufactured comparatively easily and cost-effectively, as explained in more detail below. In particular, painting and / or printing processes for applying a coating or paint layer are not required.

[0010] Preferably, the front transparent PUR layer and the rear colored PUR layer are joined together along a seam line, in particular a circumferential seam line, i.e., a seam line running around the base body, in a material-to-material and preferably also sealed manner, i.e., moisture- and dirt-tight. In particular, the front transparent PUR layer and the rear colored PUR layer tightly enclose the base body, i.e., the base body is completely surrounded or encapsulated by PUR. This, in particular, improves weather resistance.

[0011] Indentations can be arranged on the back of the base body, which particularly refers to recesses molded into the base body (towards the front). The recesses can form a pattern, lettering, a logo, or the like. In principle, only one recess can be provided, forming, for example, a line or lettering. The recesses create a particularly high-quality, under-glass 3D effect.

[0012] The rear colored PUR layer can be thinner or applied in the recesses, meaning that the rear PUR layer has a thinner layer or a reduced layer thickness, particularly from 0.1 mm to 0.2 mm, in the recesses. The rear colored PUR layer can also be recessed in the recesses, meaning that no PUR layer is formed or applied in the recesses. The local thinning or recess enables particularly high-quality backlighting of the molded part at the recesses, whereby the local thinning enables a so-called no-show effect.

[0013] The molded part according to the invention is, in particular, a decorative component for a motor vehicle, which can be either an interior component or an exterior component. An interior component is, for example, a decorative panel. An exterior component is, for example, a radiator grille-like front panel.

[0014] The manufacturing process according to the invention comprises the following steps: - manufacturing or producing the base body by injection moulding a translucent plastic material, whereby any recesses provided on the rear side can also be produced; - Flooding the front of the base body with a transparent PUR, creating the front transparent PUR layer; - Flooding the back of the base body with a colored PUR, creating the rear colored PUR layer, if necessary with local thinning or recesses in the recesses.

[0015] When flooding the front side, a circumferential PUR edge (made of the transparent PUR) is preferably created. During the subsequent flooding of the back side, the colored PUR can bond firmly with the transparent PUR along this edge, forming a circumferential and, in particular, tight connecting seam. The flooding of the front side and the flooding of the back side can also be carried out in reverse order, although the above-mentioned order is preferred. The method according to the invention is also suitable for series production, in particular when using a 3-component injection mold (see below). The PUR materials used (or alternatively PUA materials) are preferably very fluid and, in particular, have a reaction or curing time of less than one second, thus enabling short cycle times.

[0016] The method according to the invention or the above-mentioned steps are preferably carried out in a 3-component injection mold (three-component injection mold), which in particular has a front slide and a rear slide. The method according to the invention can then also comprise the following steps: - Providing the 3-component injection mold (as a preliminary first step); and - Removing the manufactured and appropriately designed molded part from the 3-component injection mold (as the final step).

[0017] The 3-component injection mold can be equipped with interchangeable inserts (so-called interchangeable inserts) that allow for the production of different versions of molded parts. The inserts can be exchanged relatively quickly and easily for a change of version.

[0018] Within the scope of the invention, both the features described above and those explained below are applicable not only in the respective combination of features specified, but also in other combinations of features or in isolation. This also applies to the features shown in the figure.

[0019] The invention is explained in more detail below in a non-limiting manner with reference to a figure. The features shown in the figure and / or explained below may, even independently of specific combinations of features, be general features of the invention and further develop the invention accordingly. Fig. 1 shows a molded part according to the invention in a schematic (not to scale) sectional view

[0020] The molded part 100 has an injection-molded, flat base body 110 made of a translucent plastic material. The base body 110 is formed with a front side 111 and a back side 112. Recesses 113 are arranged in the back side 112. A front transparent PUR layer 120 is applied to the front side 111 of the base body 110. A rear colored PUR layer 130 is applied to the back side 112 of the base body 110. In the recesses 113, the rear PUR layer 130 is thinner or, if necessary, also recessed. The front PUR layer 120 and the rear PUR layer 130 are firmly and tightly bonded to one another along a circumferential seam line 140.

[0021] Further embodiments and variants of the molded part 100 are described above. A manufacturing method for the molded part 100 is also explained above. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2015 101 013 A1

[0002]

Claims

[1] Molded part (100), comprising - an injection-molded base body (110) having a front side (111) and a back side (112) formed from a translucent plastic material; - a front transparent PUR layer (120) applied to the front side (111) of the base body (110); - a rear colored PUR layer (130) applied to the back (112) of the base body (110). [2] Molded part (100) according to claim 1, characterized by that the front transparent PUR layer (120) and the rear colored PUR layer (130) tightly enclose the base body (110). [3] Moulded part (100) according to one of the preceding claims, characterized by that recesses (113) are arranged on the back (112) of the base body (110). [4] Molded part (100) according to claim 3, characterized by that the rear colored PUR layer (130) is thinner in the recesses (113). [5] Moulded part (100) according to one of the preceding claims, characterized by that the base body (110) is made of polycarbonate. [6] Moulded part (100) according to one of the preceding claims, characterized by that the base body (110) has a thickness between 2.5 mm and 4.0 mm. [7] Moulded part (100) according to one of the preceding claims 1 to 6, characterized by that this molded part (100) is an interior component for a motor vehicle. [8] Moulded part (100) according to one of the preceding claims 1 to 6, characterized by that this molded part (100) is an exterior component for a motor vehicle. [9] A method for producing a molded part (100) according to any one of claims 1 to 8, comprising the steps: - producing the base body (110) by injection molding; - flooding the front side (111) of the base body (110) with a transparent PUR; - Flooding the back (112) of the base body (110) with a colored PUR. [10] Method according to claim 9, characterized by that the steps are carried out in a 3-component injection mold.

Images