Plastic articles and methods for manufacturing a plastic article

Abstract

The invention relates to a plastic article (1) with at least one heating wire (2). The plastic article (1) has several carrier film segments (31, 32, 33, 34, 35) and at least one joint (10, 11, 12, 13, 14) formed by separating two carrier film segments (31, 32, 33, 34, 35) and the at least one heating wire (2), or alternatively or additionally by a further wire (20, 21, 22, 23, 24), such that the at least two carrier film segments (31, 32, 33, 34, 35) are arranged to rotate relative to each other and / or rotate at the at least one joint (10, 11, 12, 13). The invention also relates to a method for manufacturing a plastic article (1).

Description

[0001] The invention relates to a plastic article and a method for producing a plastic article.

[0002] To provide a heating function in plastic articles, it is known to glue heating foils or to back-inject heating foils in a cavity with a plastic injection molding compound. For example, WO 2020114851 A1 discloses back-injecting a heating foil with plastic to obtain a vehicle interior trim part with a heating surface. However, this approach is disadvantageous in that the heating foil is subjected to high mechanical stresses during the injection molding process, and the resulting injection-molded bodies—depending on their geometric design—are limited, reject rates can be increased, and the susceptibility to defects can be increased. In particular, this also impairs the options for designing the heating function.The main causes are high degrees of deformation during injection molding and / or pre-forming. This can, for example, damage the heating foil because the tensile / elongation behavior of copper wires and thermoplastics differs significantly, so that deformation of the back-injected and / or pre-formed plastic can be accompanied by tearing of the wires arranged on it. Furthermore, pre-forming as an additional process step increases the manufacturing effort. In addition, a three-dimensionally pre-formed component is more difficult to handle. This has a particularly negative impact on process reliability, transport, and logistics, since components (which are no longer flat and possibly less flexible) are difficult to stack and cannot be prepared for further processing using simple means and measures.

[0003] It is therefore an object of the invention to provide an improved plastic article, in particular with regard to its formability and durability as well as handling during processing as well as with regard to the design possibilities and reliability of the final product, and to provide an improved method for producing a plastic article.

[0004] The object is achieved by a plastic article according to claim 1 and by a method for producing a plastic article according to claim 27.

[0005] The object is achieved by a plastic article. The plastic article can in particular be an insert element for back-injection in an injection molding process or an injection-molded body. The plastic article has at least one heating wire. Furthermore, the plastic article has at least two carrier film segments. The plastic article has at least one joint which connects the at least two carrier film segments to one another. The at least one joint is formed by at least one separation which partially or completely separates the at least two carrier film segments from one another. The at least one joint is further formed by a) the at least one heating wire and / or b) at least one additional wire.

[0006] In other words, the at least one joint is particularly formed by one or more wires selected from the at least one heating wire and the at least one further wire. The at least one joint is designed such that the at least two carrier film segments are arranged on the at least one joint so as to be rotatable and / or rotated relative to one another.

[0007] The object is further achieved by a method for producing a plastic article. The method is used to produce, in particular, the plastic article according to the invention. The method comprises the following steps, in particular with the specified sequence of several or all of the following steps: Providing and / or producing at least two carrier film segments;

[0008] Applying at least one heating wire to the at least two carrier film segments and optionally applying at least one further wire to the at least two carrier film segments.

[0009] The method is carried out in such a way that the plastic article has at least one joint which connects the at least two carrier film segments to one another and is formed by at least one separation which partially or completely separates the at least two carrier film segments from one another. In addition, the joint is formed by a) at least one heating wire and / or b) at least one additional wire.

[0010] In other words, the at least one joint is formed in particular by one or more wires selected from the at least one heating wire and the at least one further wire. The at least one joint is formed such that the at least two carrier film segments are or will be arranged on the at least one joint so as to be rotatable and / or rotated relative to one another.

[0011] In other words, the method comprises in particular the following steps, preferably with the specified order of several or all of the following steps: Providing and / or producing at least two carrier film segments; applying at least one heating wire to the at least two carrier film segments. The method is carried out in such a way that the plastic article has at least one joint which connects the at least two carrier film segments to one another and is formed by at least one separation which partially or completely separates the at least two carrier film segments from one another, and by a) at least one heating wire and / or b) at least one further wire which is applied by the following step: applying the at least one further wire to the at least two carrier film segments.

[0012] The at least one joint is designed in such a way that the at least two carrier film segments are or are arranged so as to be rotatable and / or rotated relative to one another on the at least one joint.

[0013] Advantageously, the at least one joint ensures during processing of the plastic article (for example during its further processing into an injection-molded body) that at points where carrier film segments virtually abut each other, a corresponding deflection and / or buckling and / or bending of the carrier film segments together with the at least one heating wire and / or the at least one further wire is possible. The preferably slightly flexible and expediently thin wire structures of the at least one heating wire and / or the at least one further wire can serve like a hinge as connecting elements for the carrier film segments each connected by a joint. The at least one joint can advantageously achieve mobility of the carrier film segments relative to one another while simultaneously reducing the load on the at least one heating wire.This is particularly true since there is no adhesion between the at least one heating wire and the at least two carrier film segments in a movement area within the at least one joint.

[0014] In particular, it is possible to reduce stresses on the at least one heating wire, such as tensile stresses, compression, and / or shear stresses that occur during transport or processing of the plastic article. Without a joint, such stresses can occur in particular when the at least one heating wire is fixed to a carrier film in an area with a relatively high degree of deformation and would thus be forced to follow any deformation of the carrier film throughout. The at least one joint can then advantageously be arranged at the source of such stresses, i.e., at locations with a high degree of deformation, so that the generation of the stresses is reduced or avoided.

[0015] Alternatively or additionally, it is possible to arrange at least one joint in such a way that it interrupts the accumulation and / or transfer of such loads across other parts of the plastic article. This allows higher degrees of deformation to be achieved in the finished component, or even reduces the reject rate and susceptibility to defects even at lower degrees of deformation. Advantageously, the at least one joint and the at least two carrier film segments can be optimized, for example, depending on the degrees of deformation present in the finished component (e.g., in the injection-molded body as a result of an injection molding process).

[0016] The at least one additional wire can also increase the stability of the entire plastic article during handling, processing and use of the finished product and reduce the load on the at least one heating wire. If the at least one additional wire is present, for example, next to the at least one heating wire in the at least one joint, it is possible to relieve the load on the at least one heating wire when the corresponding carrier film segments rotate or when the at least two carrier film segments are arranged differently spatially around the joint. At the same time, any impairment of the heating function by the at least one additional wire can be avoided or kept within limits, since the additional wire is expediently decoupled from the at least one heating wire.

[0017] A further advantage is that handling and the manufacturing process, in particular, can be carried out more safely and simply. The plastic article can, for example, be transported and prepared as a flat component (prior to an injection molding process or other further processing involving deformation of the plastic article). It is then possible to easily shape the plastic article into three-dimensionally preformed components using previously provided folding / bending / deflection contours of the carrier film segments, which are designed in particular as flat film components, i.e., in particular without high pressures or temperatures. These components can then be inserted, for example, into an injection molding cavity and back-injected.

[0018] By means of the present invention, it can thus be advantageously achieved that the plastic article has an increased deformability during further processing and handling with improved stability and durability in the final product and that there are increased design possibilities, in particular with regard to achievable degrees of deformation.

[0019] Further advantageous embodiments of the invention are described in the subclaims.

[0020] A joint is to be understood in particular as a point, preferably in a plan view of the plastic article and / or perpendicular to a plane spanned by the plastic article, preferably straight or partially curved, between two carrier film segments, preferably lying close to one another or also spaced apart, at which point a relative position of the two carrier film segments connected via the joint can be changed or is or will be changed, in particular at least by means of rotation, preferably in that the at least one heating wire and / or the further wire is or will be bendable or bent at this point. This point in particular specifies an axis of rotation about which the rotation and / or deflection of the carrier film segments takes place or is set.During processing of the plastic article, a joint preferably represents a crease and / or bending edge and / or folding edge of the plastic article, at which two carrier film segments are at least partially or completely separated from one another and are arranged so as to be movable, preferably rotatable, at least via the at least one heating wire and / or the further wire. The plastic article, in particular the at least one heating wire, is preferably more bendable or more bent at the at least one joint than in regions without a joint, in particular than in regions without a joint which directly border on an area with the at least one joint. If the plastic article is or will be further processed into an injection-molded article, there is preferably a bend in the at least one heating wire and / or the further wire at the at least one joint, which bend is fixed by means of a plastic injection-mold compound.

[0021] The term “rotatable against one another and / or rotated against one another” is to be understood in particular as meaning that the at least two carrier film segments have a variable angle to one another, in particular one that can be changed without destroying the at least one heating wire, and / or that a fixed angle unequal to 0°, preferably greater than 0°, of the at least two carrier film segments, in particular of a plastic article further processed into an injection-molded body, is or will be set to one another, in particular without destroying the at least one heating wire, and thus the at least two carrier film segments preferably have different spatial arrangements and / or different spatial orientations and / or in particular are or will be spatially deflectable and / or spatially deflected against one another.

[0022] The variable angle and / or the fixed angle is present in particular at one or more points on an axis of rotation extending along the at least one separation or is adjustable there or is set there. The variable angle and / or the fixed angle is preferably spanned between two lines, each of which runs parallel to a main surface of the respective carrier film segment and / or each of which runs on a main surface of the respective carrier film segment. Main surfaces of a carrier film segment are in particular the two opposite surfaces of a carrier film segment with the largest surface area. It is in particular possible for the axis of rotation to be present between two main surfaces and / or to comprise a point of contact between two main surfaces, wherein these two main surfaces are present on a side of the at least two carrier film segments which has the at least one heating wire and / or the at least one further wire.Positive angle values ​​are specified below, particularly for this case. It is also possible for the axis of rotation to be located between two main surfaces and / or to have a point of contact between two main surfaces, with these two main surfaces being located on a side of the at least two carrier film segments opposite the side with the at least one heating wire and / or with the at least one additional wire. Negative angle values ​​are specified below, particularly for this case.

[0023] Negative angle values ​​can be achieved in particular if there is a lateral distance between the at least two carrier film segments, for example in the form of one or more recesses. A maximum angle of -180° can be achieved, for example, if this lateral distance between the carrier film segments is greater than π * D / 2. An angle of -90° can be achieved, for example, if this lateral distance between the carrier film segments is greater than π * D / 4. Here, D stands for the diameter of an arc of a circle to which the at least one heating wire and / or the at least one further wire in the at least one joint is (in particular approximately) bendable or is or will be bent. In this case, D = 2d preferably applies, where d is the respective thickness of the at least two carrier film segments.

[0024] The variable, in particular non-destructively variable, angle is preferably in a range from 0° to +180°, preferably from 0° to +90°, more preferably from +5° to +90°, in particular when the axis of rotation lies on the side with the at least one heating wire and / or the at least one further wire of the at least two carrier film segments. The variable, in particular non-destructively variable, angle is preferably in a range from -180° to +180°, preferably from -90° to +90°, in particular when the axis of rotation lies on the side opposite the side with the at least one heating wire and / or the at least one further wire of the at least two carrier film segments.

[0025] The fixed angle is the desired set angle between the at least two carrier film segments, which is to be fixed and / or is fixed or is fixed by means of injection molding by the first and / or second carrier component. The desired set angle is preferably not equal to 0°, more preferably greater than +5°, if the rotation axis lies on the side with the at least one heating wire and / or the at least one further wire of the at least two carrier film segments, or more preferably less than -5°, if the rotation axis lies on the side opposite the side with the at least one heating wire and / or the at least one further wire of the at least two carrier film segments. This fixed angle is after injection molding, iePreferably, if the at least two carrier film segments are mechanically reinforced, in particular by the first and / or second carrier components, the angle can be elastically adjusted relative to the originally desired angle, preferably within a range of -10° to +10°, preferably from -5° to +5°. This is advantageous, for example, to allow for adaptation to tolerances in an installation or assembly situation.

[0026] The variable and / or fixed angle is or will be set and / or changed in particular by a deformation, preferably a bending, of the at least one heating wire and / or the at least one further wire in the at least one joint. If carrier film material is optionally present between the carrier film segments connected via the joint, a deformation, preferably a bending, of this carrier film material can also take place. It is also possible for the at least one joint to be designed such that, in particular in addition to the variable angle and / or the fixed angle, a distance between the at least two carrier film segments from one another can be or is or will be set in one or more spatial directions, preferably of a Cartesian coordinate system. This distance is preferably comparatively small.

[0027] For a top view, a view of a visible side can be used, in particular. The visible side is, in particular, a side that is visible during normal use of a finished component, in particular the injection-molded body. The visible side can be understood, in particular, as the side facing the viewer of the plastic article during its intended use. The top view can preferably be a view of an orthogonal projection with the largest surface area of ​​the plastic article and / or the at least two carrier film segments.

[0028] It is possible that the at least one heating wire is or will not be applied to all carrier film segments, but in particular at least to one or at least two carrier film segments of the at least two carrier film segments. Alternatively or additionally, it is possible that the at least one further wire is or will not be applied to all carrier film segments, for example, but to two or more carrier film segments of the at least two carrier film segments.

[0029] A separation is to be understood in particular as an area or partial area, in particular between the at least two carrier film segments, in which there is no direct local material cohesion of the respective carrier film segments, for example in that the separation is formed by a cut or a recess. A regional separation can, for example, comprise one or more partially present recesses and / or one or more partially present cuts. In a regional separation, the partial areas without direct local material cohesion are preferably designed such that a crease edge and / or bending edge and / or a folding edge is or will be formed by the separation.

[0030] The at least one additional wire is or will be applied in particular decoupled from the at least one heating wire. In other words, the at least one additional wire is or will be applied preferably galvanically isolated from the at least one heating wire.

[0031] A layer or ply is preferably understood to mean a substantially planar structure, which itself can be single-layered or multi-layered. The at least two carrier film segments are, in particular, each carrier layer.

[0032] A region is understood, in particular, to be an area that has a surface that, when viewed perpendicularly, is spanned across a surface, preferably a main surface, of the plastic article, a layer and / or a ply, in particular of the at least two carrier film segments and / or of the at least one heating wire and / or of the at least one further wire, as its base area and extends in the direction of the perpendicular view. A main surface has, in particular, the largest surface area of ​​the surfaces of the plastic article, a layer and / or a ply, in particular of the at least two carrier film segments.

[0033] The at least one separation is or will preferably be formed by separating surfaces that are present opposite one another in the at least two carrier film segments. The separating surfaces are preferably present at least partially or completely without any direct local material cohesion of the respective carrier film segments. The separating surfaces therefore preferably separate the at least two carrier films partially or completely. In particular, the separating surfaces abut one another at a boundary between the at least two carrier film segments. It is possible for the at least one separation to be formed by one or more recesses that are present at least partially or over the entire surface between the at least two carrier film segments.A recess can be provided during production by removing carrier film material and / or by providing the at least two carrier film segments in the region of a recess without carrier film material, in particular by applying them to an application surface.

[0034] Alternatively or additionally, it is possible for the at least one separation to be formed in a continuous carrier film, in particular by one or more cuts and / or cutouts in this carrier film. Carrier film segments that are each connected to one another via a joint, i.e. in particular the at least two carrier film segments, can be in direct contact with their separating surfaces and / or have separating surfaces that are spaced apart from one another, in particular wherein the spacing is, for example, in a range from 0 µm to π * d µm (π = Pi, number of pi), where d corresponds to the respective thickness of the at least two carrier film segments, preferably, in the case of different thicknesses, in particular to the respective greater thickness or the respective smaller thickness. The spacing can be understood in particular as the width of the cutouts.For example, it is possible for the carrier film segments with the respective separating surfaces to have a thickness d, and for the distance to be in a range from 0 times d to 0.6 * π times d. Preferably, the distance is less than or equal to πd / 2. This ensures, in particular, that a large angle of a maximum of approximately 90° can be set between the respective carrier film segments, with the distance between the carrier film segments being so small that the respective joint is still sufficiently stable.

[0035] It is preferred that the at least two carrier film segments comprise at least one heating segment. The plastic article preferably comprises a heating region in which the at least one heating segment is arranged. In the heating region, the plastic article, in particular the at least one heating wire, is preferably configured to provide the heating function, preferably of the plastic article further processed into an injection-molded body.

[0036] It is possible for the plastic article, particularly in the heating area, to have at least one decorative layer, which is preferably applied to one or more of the at least two carrier film segments. The at least one decorative film comprises, for example, one or more color layers, in particular color lacquer layers.

[0037] It is also possible for the at least two carrier film segments to have at least one supply line segment. The at least one supply line segment is preferably enclosed by a contacting element. The at least one supply line segment is or will preferably be connected to the at least one heating segment via a first joint of the at least one joint.

[0038] Advantageously, the at least one supply line segment protrudes from an edge of the heating segment and preferably has smaller cross-sectional dimensions than the heating segment forming the edge.

[0039] A joint on or in the supply line segment is particularly advantageous if the at least one heating wire is very delicate, for example, with a thickness and / or diameter of 70 µm. The tensile strength of the heating wire is relatively low. For example, the Elektrisola extra high tension wire (XHTW) can be used (company: Elektrisola Dr. Gerd Schildbach GmbH & Co. KG, headquarter: Reichshof, Germany). The tensile strength of the at least one heating wire is approximately 390 N / mm. 2 , preferably measured according to IEC 60851-1 2021 (issue date: 2021-06-16 (16.06.2021)), especially at 20°C. If the at least one heating wire with a diameter of 70 µm is considered, its cross-sectional area can be estimated at approximately 0.004 m 2 which in turn corresponds to the specified tensile strength value of 390 N / mm 2to a force of 1.5 N until the at least one heating wire breaks or changes its mechanical properties. In particular, to enable electrical contact with the plastic article, deformations are often performed on or in the contacting element. Such deformations can be caused, for example, by tool surfaces with corresponding tool bending radii. Without the at least one joint, tensile forces as well as compression forces in the contacting element can be so great due to the tool bending radii that the at least one heating wire would be compressed and / or separated.If the at least one heating wire is anchored in at least one of the at least two carrier film segments, for example due to ultrasound technology, the freedom of movement is particularly impaired, for example due to restricted relative movement of the carrier film material and the heating wire, which increases the risk of compression and / or separation of the heating wire. In this case, the at least one joint, in particular a heating wire area where there is no adhesion to the carrier film segments, is particularly advantageous.

[0040] In particular, improved flexibility of the contacting element during further processing can be achieved, while simultaneously improving stability by reducing the stress on the at least one heating wire. This also increases the design possibilities, e.g., of a finished injection-molded body.

[0041] With regard to the design of the contacting element, particular reference is made to the explanations below.

[0042] The supply line segment has in particular two or more supply line carrier film sub-segments, which are or will be connected to one another preferably via one or more second joints of the at least one joint.

[0043] The at least one heating segment has in particular two or more heating carrier foil sub-segments, which are or will be connected to one another preferably via one or more third joints of the at least one joint.

[0044] It is possible for the at least two carrier film segments to have at least one branch segment which is or will be connected via a fourth joint of the at least one joint to one or more carrier film segments of the at least two carrier film segments, in particular the at least one heating segment and / or the at least one supply line segment.

[0045] The at least one branch segment preferably has a smaller width than the carrier film segment connected to the branch segment via the one or more fourth joints, in particular the heating segment and / or supply line segment. The width of the branch segment is preferably less than 0.5 times the heating segment and / or supply line segment, preferably less than 0.2 times the heating segment and / or supply line segment, more preferably less than 0.1 times the heating segment and / or supply line segment. The at least one branch segment can be provided with or without the at least one heating wire and / or with or without the at least one further wire and / or with or without a decorative layer. This allows particularly complex shapes to be provided with a heating function and / or a decorative function.

[0046] It is possible for two or more joints, in particular the first, second, third and / or fourth joint, to have separations running parallel to one another. Alternatively or additionally, it is possible for two or more joints, in particular the first, second, third and / or fourth joint, to have separations that run rotated by an angle to one another, for example rotated by an angle in a range from 0° to 180°, preferably from more than 0° to 180°, preferably of 90°. The angle can be measured in particular in a plan view and / or a view perpendicular to a plane spanned by the plastic article.

[0047] Preferably, the at least one heating segment has a joint with a separation that rotates relative to a separation of a joint in the supply segment. Thus, the contacting element can preferably be guided away from the heating segment particularly easily, in particular by bending the plastic article, and contacted.

[0048] Terms such as "first," "second," "third," and "fourth" are used solely for differentiation. However, a "fourth joint," for example, does not necessarily presuppose a "third joint."

[0049] The above designs with joints between or in heating segments, supply segments and / or branch segments can achieve the advantages of improved flexibility in the further processing of the plastic article as well as stability and increased design options in the finished injection-molded body.

[0050] Preferably, the at least one heating wire and / or the at least one further wire is or will be arranged in the at least one joint so as to overlap the at least one separation, in particular with one or more recesses and / or one or more cuts. This overlap can, in particular, increase the degrees of freedom of the at least one heating wire and / or the at least one further wire in the at least one joint and thus, in particular, reduce stresses during deformation of the plastic article.

[0051] Preferably, the at least one heating wire and / or the at least one further wire is or will be applied in at least one joint region comprising the at least one joint. In a preferred embodiment of the method and / or the plastic article, the at least one heating wire and / or the at least one further wire are or will be applied to the at least two carrier film segments in the joint region using a mold, wherein the mold is characterized by an increased areal density on the carrier film segments and in particular in the at least one joint.The areal density is particularly based on the coverage of a first area of ​​the at least two carrier film segments with the at least one heating wire and / or the additional wire in the joint region compared to the coverage of an adjacent area of ​​the at least two carrier film segments and / or an area that does not overlap with the first area with the at least one heating wire and optionally with the additional wire, in particular outside the joint region. Preferably, the first area and / or the adjacent area and / or the area that does not overlap with the first area has a contiguous area of ​​at least 500 mm. 2 , preferably at least 2000 mm 2 , more preferably of at least 50000 mm 2Preferably, the diameter of the at least one heating wire is the same in the regions used for comparison. The first surface can, for example, be located entirely within the joint region and / or be congruent therewith. The first surface can, in particular, be formed by two partial surfaces, each of which is located on one of two carrier film segments connected by a joint, preferably in a plan view of the plastic article.

[0052] In the joint region and / or on the first surface, the at least one heating wire and / or the at least one further wire has a sequence of multiple tracks, preferably of at least three tracks. The sequence is particularly arranged along a direction that preferably follows the at least one separation, preferably the at least one separation of a respective joint. More preferably, the direction runs parallel to and / or on one separation surface or both separation surfaces.

[0053] The tracks are connected to one another in particular by curves and / or corners, which are preferably also formed by the at least one heating wire and / or the additional wire. The at least one heating wire and / or the additional wire preferably has at least one turning point and / or at least one turning line in the tracks or at least in several tracks thereof. A turning line is to be understood in particular as a line which merges into a curvature on one side which differs in sign from a curvature on the other side. For example, the at least one heating wire and / or the at least one additional wire is meander-shaped in the joint region.It is also possible for the at least one heating wire and / or the at least one further wire in the joint region to have one or more of the following shapes: meandering, spiral, loop-shaped, pseudo-chaotic shapes, chaotic shapes, random structures, pseudo-random structures, single- and / or multi-layer shapes, alternating arrangement of different shapes, fractal shapes, flower-shaped, or combinations of the aforementioned shapes. Such shapes can, in particular, achieve corresponding advantages of successive paths, especially with an increased areal density.

[0054] It is preferred that at least two adjacent tracks or all adjacent tracks each have a spacing in a range of 0 mm to 12 mm, preferably from 0.02 mm to 12 mm, preferably from 0.02 mm to 1 mm. The spacing of the tracks is preferably measured between the outer surfaces of the respective tracks. "Adjacent to one another" means, in particular, without any intervening tracks.

[0055] By means of the above-described configurations of the at least one heating wire and / or at least one further wire, such as a meander-shaped or similar configuration in the joint area, a high mechanical stability of the joints can be achieved, depending on the requirements.

[0056] It is preferred that the at least one joint contains three or more tracks formed by the at least one heating wire and / or the at least one further wire. In particular, in order to connect and / or connectably design the at least one heating wire to a negative pole and a positive pole via the supply line segment, usually only two tracks of the at least one heating wire are provided or necessary. However, at least one further track present in the joint can advantageously reinforce the joint or reduce the load on the at least one heating wire in the joint, thus improving mechanical stability. In particular, if the at least one joint has the at least one further wire, it is also possible for the at least one heating wire to form only two tracks of the at least one joint, in particular the first, second, third and / or fourth joint.In this case, the at least one heating wire can run in a straight line within this joint and, in some areas, across this joint. Thus, the at least one heating wire, particularly in the joint area, can be optimized for its heating function and contacting capability with little or no influence on the heating function of the plastic article, with the at least one additional wire advantageously providing reinforcement in the joint areas.

[0057] In this context, it may be advantageous if the thicknesses of the at least one heating wire and the at least one additional wire differ in such a way that the at least one additional wire is advantageously thicker than the at least one heating wire, whereby in particular additional mechanical stability can be achieved in the at least one joint region.

[0058] Alternatively or additionally, it is also possible for only a single additional wire and / or only the at least one heating wire to be provided for each of one or more joints of the at least one joint, and / or for a single additional wire to form multiple paths present in multiple joints of the at least one joint. Advantageously, a high degree of mechanical reinforcement can thus be achieved in a single process step, and / or multiple joints can be reinforced in a single process step.

[0059] In particular, one or more tracks of the at least one heating wire and / or the at least one further wire each extend over two or more joints of the at least one joint. This advantageously eliminates the need for process steps to reinforce multiple joints while increasing stability.

[0060] It is possible for two or more of the carrier film segments to be encompassed by a continuous carrier film. In this case, at least one joint, in particular the first joint, preferably has one or more subregions of the carrier film. The subregions in particular connect two carrier film segments of the at least two carrier film segments, in particular the at least one heating segment and the at least one supply line segment, to one another. In one or more joints, the subregions are preferably located at the edge of carrier film segments connected to one another via a respective joint. This can, for example, reduce the risk of unintentional twisting of the carrier film segments and resulting damage to the heating wire.It is preferred that the at least one heating wire and / or the at least one further wire does not overlap with the one or more partial regions or does not overlap with the one or more partial regions in some regions. It is also possible for the at least one joint, in particular the first, second, third and / or fourth joint, to have a plurality of cutouts. In other words, it is possible for the separation of a respective joint, in particular the first, second, third and / or fourth joint, to be formed by a cutout which, for example, has the partial regions of the carrier film at the edge, or by a plurality of successive cutouts. If a plurality of successive cutouts are present, these are spaced from one another in particular by one or more of the partial regions of the carrier film.

[0061] It is possible for the at least one joint to comprise a further carrier layer which connects the at least two carrier film segments to one another at least in regions.

[0062] It is possible that, particularly when viewed perpendicular to a plane spanned by the plastic article, preferably in plan view, the at least one separation of the at least one joint runs in a straight line. However, it is also conceivable that the at least one separation runs in a curved manner, at least in some regions.

[0063] In a preferred embodiment of the plastic article and / or the method, the at least one further wire is or will be designed to have a material and / or a cross-section that is identical to the at least one heating wire. Advantageously, the at least one further wire can thus be applied using the same sonotrode and / or the same mouthpiece of the sonotrode and in particular in the same operation as the application of the at least one heating wire. However, it is alternatively or additionally possible for the at least one wire to have a material and / or a cross-section that is different from the at least one heating wire. Advantageously, the further wire can thus be designed to be optimized with regard to its function in the respective joint, with no or only a minor influence on the heating function of the plastic article.

[0064] It is possible for the at least one joint to have one or more conductive layers, in particular one or more conductive lacquer layers. Preferably, the at least one joint has a plurality of conductive lacquer layers, each of which is separate from one another and is each assigned to one or more tracks of the at least one heating wire. The one or more conductive lacquer layers are or will be formed, preferably in the contacting element, in particular by two partial layers, which are expediently each arranged over partial zones of the at least one heating wire, in particular such that, together with the at least one heating wire, they form a conductor track that can preferably be contacted in the contacting element.

[0065] It is possible that the one or more conductive layers or at least one conductive layer thereof are or will be applied between one or more carrier film segments of the at least two carrier film segments and the at least one heating wire and / or that the one or more conductive layers or at least one conductive layer thereof are or will be applied on a side of the at least one heating wire which faces away from one or more carrier film segments of the at least two carrier film segments.

[0066] A conductive ink layer is advantageous in particular if the at least one heating wire, preferably in the joint region, comprises an increased areal density, for example meandering wire structures or similar wire structures. In particular, this prevents the joint region with the meandering or similar wire structures from heating up too much and consequently the heat being dissipated during a current flow, for example during operation of the finished injection-molded body. It is advantageous if the at least one heating wire is not insulated or partially insulated, in particular is not insulated at least in an area with the conductive ink layer and / or in the joint region. This makes it possible in particular to reduce the electrical resistance of the wire structures in this area in parallel.

[0067] With regard to the design of the one or more conductive ink layers, particular reference is made to the explanations below.

[0068] The method for producing the plastic article preferably comprises the following step, in particular before providing and / or producing the at least two carrier film segments: Providing an application surface and applying the at least two carrier film segments to the application surface. Preferably, the at least two carrier film segments are fixed to the application surface, in particular by means of suction and / or by means of recesses in the application surface, which are expediently configured according to the shape and positioning of the carrier film segments. The application surface can be formed, for example, by an application plate. The application plate is in particular a plate made of or comprising one or more of the following materials: plastic(s), steel, stainless steel, aluminum, copper, stone, wood, composite materials, layered materials, filled materials, glass.

[0069] It is possible for one or more of the carrier film segments, in particular all of the carrier film segments, to be applied separately without material cohesion, in particular to the application surface. It is particularly conceivable for two or more of the carrier film segments, preferably all of the carrier film segments, to be applied with a spatial separation from one another, in particular wherein the spatial separation forms one or more recesses, in particular the recesses forming at least one separation. Alternatively or additionally, it is possible for one carrier film and / or two or more of the carrier film segments to be applied in a coherent form as one carrier film to the application surface. Subsequently, the carrier film is preferably separated into the at least two carrier film segments, in particular by means of an at least regional or complete separation.The separation can be effected in particular by introducing one or more cutouts and / or one or more through-holes into the carrier film such that the one or more cutouts and / or through-holes form the at least one separation of the respective carrier film segments, preferably by creating a spatial separation of the respective carrier film segments at least in some regions. Alternatively or additionally, it is also possible for one or more sub-regions of the carrier film to be created and / or retained between two or more of the at least two carrier film segments such that the at least one joint, in particular the first joint, has the one or more sub-regions of the carrier film, wherein the sub-regions connect two carrier film segments, in particular the heating segment and the supply line segment, to one another.

[0070] It is possible for the at least two carrier film segments to each have the same thickness, for example to provide the same stability during handling.

[0071] It is also possible for the at least two carrier film segments to each have different thicknesses, for example to provide different levels of stability during handling.

[0072] It is also possible for the at least two carrier film segments to each comprise the same or different materials and / or the same or different layer composites. The materials can be unfilled or filled.

[0073] Filled is understood in particular to mean a layer, in particular a carrier film layer, in which inorganic substances are present alongside a polymer matrix (i.e. in particular an adhesive matrix and / or a binder). Such inorganic substances can in particular be pigments and / or particles of different sizes and shapes and consist, for example, of metal, metal alloys, metal oxides or combinations thereof. The pigments and / or particles can have diameters in the micrometer range or even in the nanometer range (nanoparticles). The diameter of the pigments and / or particles can be smaller or larger than the layer thickness of the respective layer. The pigments and / or particles can be contained in the respective layer as a mixture of different substances and / or different sizes.

[0074] It is also possible for the at least two carrier film segments to each have identical and / or different structures. For example, one carrier film segment may be a flat and smooth carrier, while another carrier film segment may be a carrier with a surface structure. The surface structure may, for example, be a woven or nonwoven fabric structure.

[0075] The plastic article is preferably an injection-molded body. The plastic article has, in particular, on a first side, a carrier component made of a plastic injection-molding compound and / or on a second side, a second carrier component made of a plastic injection-molding compound. The second side is preferably opposite the first side. It is possible for the at least two carrier film segments, including the at least one heating wire and / or the at least one further wire, to be back-injected on a first side with a first carrier component made of a plastic injection-molding compound and / or on a second side with a second carrier component made of a plastic injection-molding compound.For back-injection molding of the first side and / or the second side, the at least two carrier film segments together with the at least one heating wire and / or the at least one further wire are arranged in particular on a wall with a preferably curved shape in a cavity of an injection molding tool and are preferably subsequently back-injected to obtain the first and / or second carrier component.The plastic injection molding compound of the first carrier component and / or the second carrier component overlaps the at least one joint, preferably one or more or all joints thereof, and / or the at least one heating wire and / or the at least one further wire of the at least one joint, preferably one or more or all joints, at least partially or completely, in particular such that the at least one heating wire and / or the further wire of the at least one joint, preferably one or more or all joints, is embedded in the plastic injection molding compound of the first carrier component and / or the second carrier component.

[0076] In particular, during arrangement on the wall and / or during back-injection molding, a deformation of the at least one heating wire and / or the at least one further wire of the at least one joint, preferably all joints, takes place according to the preferably curved shape of the wall of the cavity of the injection molding tool. The deformation preferably comprises at least one rotation of the at least two carrier film segments relative to one another. It is expedient for the at least two carrier film segments to be rotated relative to one another before or during the back-injection molding of the first side and / or the second side.It is possible for the at least two carrier film segments, together with the at least one heating wire and optionally the at least one further wire, to be fixed by means of the first carrier component and / or the second carrier component and / or to be more strongly curved, at least in some regions, in one or more regions having the at least one joint, in particular in the at least one joint region, than in one or more regions without the at least one joint, which regions are preferably directly adjacent to the one or more regions having the joint. Therefore, rotation of the at least two carrier film segments relative to one another is preferably carried out.The rotation can be effected directly by pressure exerted by the plastic injection molding compound of the first carrier component or the second carrier component on the at least two carrier film segments, such that the carrier film segments are preferably rotated and optionally deformed according to the curved shape of the cavity wall. In addition, one or more holding means (for example by means of vacuum suction using vacuum bars) can be provided to hold the respective carrier film segments in a specific position. Alternatively or additionally, the at least two carrier film segments can be introduced manually and / or automatically into the cavity and preferably pre-positioned according to the curved shape, in particular before the cavity is closed. In particular, it is also possible to guide the contacting element, in particular the at least one supply line segment, out of the closed cavity via a gap.

[0077] It is advantageous, for example, that the at least one heating wire can be embedded in the plastic injection molding compound in the injection-molded body, so that, in particular, mechanical protection can be provided in the at least one joint area. This advantageously allows for high flexibility in processing the plastic article while simultaneously maintaining high stability in the finished component.

[0078] It is possible for the first carrier component to be or to be arranged on a visible side of the plastic article and / or for the second carrier component to be or to be arranged on a rear side of the plastic article. The first carrier component arranged on the visible side forms or will form, for example, a lens, preferably of a headlight. The first and / or second carrier component can alternatively or additionally form a cover element, in particular of a headlight, or be enclosed by a cover element. The second carrier component arranged on the rear side forms or will form, for example, a contact surface or a holder for a radiation source and / or for installing the plastic article. The first carrier component arranged on the visible side can also form an outer side of a sensor, in particular a radar sensor.

[0079] The at least two carrier film segments have, in particular, a rear side and a front side, preferably wherein the visible side of the film body can be formed, is formed, or is formed at least on the front side and / or the rear side of the plastic article can be formed, is formed, or is formed on the rear side of the at least two carrier film segments. The at least one heating wire is or is preferably applied to a front side or the rear side of the at least two carrier film segments.

[0080] The at least one decorative layer is or will preferably be applied to the at least two carrier film segments. The at least one decorative layer is or will preferably be applied to a front side and / or the back side of the carrier film and / or the at least two carrier film segments. It is also possible for the at least one decorative layer to comprise a plurality of decorative layers, in particular wherein one or more decorative layers are or will be arranged on the front side and / or one or more decorative layers are or will be arranged on the back side. The at least one heating wire is preferably applied to one side of the at least two carrier film segments with or without a decorative layer. In particular, the at least one heating wire forms only one layer and / or only a preferably coherent heating wire structure and / or is arranged on only one side, for example only the front side or the back side of the plastic article.

[0081] It is possible that one or more decorative layers of the at least one decorative layer are or will be applied by means of one or more of the following processes: hot stamping, cold stamping, gravure printing, screen printing, inkjet printing, flexographic printing, digital printing, offset printing.

[0082] One or more of the at least one decorative layer are in particular selected from one or more of the following layers or layer structures: decorative layer with a continuous pattern, decorative layer with a single image, partial decorative layer, full-surface decorative layer, decorative layer on only one side, in particular the back or the front of the first carrier film, decorative layer on both sides, in particular the back and the front of the first carrier film, decorative layer comprising or consisting of metal, decorative layer with one or more preferably partial surface reliefs, decorative layer with a full-surface surface relief, reflective layer, in particular metal layer or HRI layer (HRI = High Refractive Index), replication layer, colored varnish layer, in particular colored varnish layer in full tone and / or colored varnish layer in half tone, preferably colored varnish layer with a printing screen.

[0083] The plastic article is in particular a preferably flexible film composite and / or a substantially flat structure. It is also possible for the plastic article to be a rigid component, preferably an injection-molded body. A rigid component in particular has a fixed shape and can expediently be elastic, e.g. to enable adaptation to tolerances in an installation or assembly situation. In particular, it is possible for the plastic article to be a rigid component, which is therefore preferably an injection-molded body, in particular via a connection to further carrier components, such as an injection-mold compound, preferably the first and / or second carrier component. Furthermore, it is possible to feed the plastic article as an insert element into an injection-mold process and expediently to back-inject it, whereby the plastic article is obtainable in the form of the injection-molded body.In particular, the plastic article, preferably in the form of an injection-molded body, is to be understood as a vehicle part, more preferably a headlight, a vehicle interior trim or a vehicle exterior trim, for example a cover for one or more radiation sources, preferably measuring devices, such as in particular radar devices, and / or lighting devices, such as in particular headlights, preferably LED headlights, preferably for a vehicle. The plastic article is in particular permeable, at least in some regions, preferably outside the at least one heating wire, to certain wavelengths, preferably at least for wavelengths in a range from 1 GHz to 150 GHz for radar applications and / or in a range from 350 THz to 850 THz for visible light. Permeable here preferably means having a transmittance, in particular for these wavelengths, of 5% to 100%, preferably of 15% to 85%.In particular, a surface of the plastic article can be heated by means of the at least one heating wire. The plastic article can form a cover and / or have additional layers and / or one or more radiation sources, preferably a measuring device, in particular a radar device, and / or a lighting device, in particular LED headlights. It is also possible for the plastic article to be, for example, a trim part of a household article, a sanitary article, a piece of furniture and / or white goods. A plastic article produced according to the method according to the invention can be used in a variety of areas. The produced plastic article can, for example, be used in or as one of the following parts: a vehicle part, a household article, a sanitary article, a piece of furniture, white goods.

[0084] It is possible for the plastic article to be provided with a contacting element. It is possible for the plastic article to have a contacting region. The contacting region is preferably present in the contacting element. The plastic article preferably has one or more contacting means and / or is connectable to the one or more contacting means, in particular in the contacting region, or is connected and / or can be electrically contacted via such means. The one or more contacting means and / or the contacting region provide in particular an interface for integrating the at least one heating wire into a power grid, for example into an on-board power grid, preferably of a vehicle. Typical electrical voltages in a power grid for integrating the at least one heating wire range up to a maximum of 100V.Typical electrical currents in a power grid for integrating the at least one heating wire range up to a maximum of 60A. Typical electrical powers in a power grid for integrating the at least one heating wire range up to a maximum of 1500W. Therefore, the plastic article is preferably usable and / or used in a system with a power grid with a maximum voltage of 100V and / or a maximum current of 60A and / or a maximum power of 1500W.

[0085] It is possible for at least one contact pad, which is preferably a multi-layer electrically conductive adhesive strip, and / or at least one bridge element for electrically contacting the at least one heating wire to be present or provided in the contacting region. The at least one bridge element is in particular electrically conductive. In particular, the at least one bridge element is or will be electrically conductively connected to the at least one heating wire in a connecting region and provided in a connection region, wherein the bridge element directly adjoins the at least one heating wire and / or partially overlaps the at least one heating wire and extends beyond the at least one heating wire.The at least one bridge element has in particular a connection surface via which the at least one heating wire is or will be contacted in an electrically conductive manner by means of the one or more contacting means and / or can be contacted.

[0086] The one or more contacting means can be or become connected, in particular, mechanically or materially, to the contacting area and / or the contact pad and / or the at least one bridge element in the connection area. The one or more contacting means, in particular, provide or form an interface for integration into the power grid, preferably the vehicle electrical system.For example, the one or more electrical contacting means comprise at least one contact socket, preferably with an insertion opening, and / or at least one plug contact which is electrically contacted with the contacting region and / or the contact pad and / or with the at least one bridge element in the connection region and which can be contacted in particular in the insertion opening, and / or one or more fastening means, in particular for holding a plug, which preferably serves to contact the plug contact to establish a connection to an on-board electrical system, and / or for holding the contacting element. It is possible that the one or more contacting means are or will be applied first to the rigid component, in particular the injection-molded body.The one or more contacting means can be or become mechanically and / or electrically conductively connected to the connection area, in particular by means of mechanical holders, such as positive and / or non-positive connections, and / or by means of material-to-material connections, such as adhesive connections and / or one or more further solder layers.

[0087] The contacting element is or will preferably be designed to be freely accessible at least in some regions, preferably designed to be freely accessible in the plastic article which is an injection-molded body or is further processed into an injection-molded body. In particular, the at least one heating wire can be electrically contacted by means of the contacting element. It is also possible for the at least one heating wire to be and / or to be contacted by means of contact points, in particular by means of soldering points, i.e. for it to be and / or to be connected in particular to an energy source and preferably to a control unit. It is possible for the contact points to be produced after the at least one heating wire has been applied and / or before the application surface has been removed from the plastic article. Preferably, a soldering station is guided automatically, in particular by means of a robot arm, to produce the soldering points.

[0088] The contacting element is or will be designed in particular such that it is suitable for electrically contacting the at least one heating wire. During the production of the plastic article in the form of an injection-molded body, the contacting element remains free of injection-molding compound, in particular free of the first and second carrier components, or is exposed therefrom, in particular at least in one contacting area.

[0089] It is possible for the contacting element to be or be formed with at least one end, in particular two ends, of the at least one heating wire and / or at least one end of the at least one heating wire provided with a contact reinforcement, in particular two ends of the at least one heating wire, which are preferably each provided with a contact reinforcement. Such contact reinforcements advantageously provide both an enlarged contact surface and mechanical reinforcement in the contacting region. Alternatively or additionally, it is possible for the contacting element to be or be formed with one or more of the following layers: at least one electrically conductive layer, in particular comprising or consisting of one or more materials selected individually or in combination from Cu, Ag, Au, Zn, at least one electrically insulating layer, at least one adhesion promoter layer, at least one anti-adhesion layer.The contacting element can be glued or bonded, in particular by means of electrically conductive adhesive, preferably at least to the at least one heating wire.

[0090] Within the contacting region, the contacting element comprises, in particular, at least one carrier film segment of the at least two carrier film segments, preferably the at least one supply line segment, as well as the at least one heating wire and optionally the at least one further wire. Via this at least one carrier film segment, in particular the supply line segment, the at least one heating wire can thus be led out, in particular, from the injection-molded body, for example from the injection-molded body provided with the first and / or second carrier component. Optionally, it is possible for the contacting element to have at least one decorative layer in some regions or over its entire surface.

[0091] The contacting element preferably has one or more joints of the at least one joint and / or is preferably connected to the at least one heating segment via one or more joints of the at least one joint.

[0092] The contacting area of ​​the plastic article, in particular the contacting element, can be formed, for example, by an area that is inaccessible to the first and / or second carrier component during the back-injection molding of the first side and / or the second side of the at least two carrier film segments, for example, by means of a corresponding cavity of an injection molding tool. Alternatively or additionally, it is also possible to leave a region of the plastic article free while retaining the contacting area, for example, by grinding, milling, drilling, cutting, punching, etching, chemical removal, and / or laser ablation.

[0093] It is possible for the plastic article to be a film, preferably an IMD film (IMD = In-Mold Decoration) or an IML (IML = In-Mold Label), or to be enclosed by a film, preferably an IMD film or an IML. It is particularly possible for an IMD process to be used to produce the plastic article in the form of an injection-molded body, or for the process for producing the plastic article to comprise an IMD process. Preferably, during the back-injection molding of the first side of the at least two carrier film segments, which are provided with the at least one heating wire and optionally with the at least one decorative layer, the plastic injection molding compound is or will be bonded to these and thus preferably decorated using an IMD process. It is also possible for the process for producing the plastic article to comprise an IML process (IML process = In-Mold Labeling process).In this case, the at least two carrier film segments, which are provided with the at least one heating wire and optionally the at least one decorative layer, are or will be obtained by a separation process, preferably punching, whereby in particular an IML is formed.

[0094] It is possible for the at least one heating wire to have or be applied with an electrically non-conductive insulation, in particular an insulating varnish layer, surrounding the at least one heating wire. The insulation preferably surrounds the at least one heating wire at least partially or completely around its circumference.

[0095] It is possible for the at least one heating wire, in particular at least in the connection region, to be exposed by an energy input during a process for electrically conductively connecting the at least one heating wire to the at least one bridge element. Preferably, the electrically non-conductive insulation surrounding the at least one heating wire, preferably an electrically non-conductive insulating varnish layer, is removed from the at least one heating wire at least in part. Alternatively, it is possible for the at least one heating wire to already be exposed when the at least two carrier film segments are or will be provided with the at least one heating wire, in particular in order to advantageously provide a thickness of the contacting region in this region that is reduced by the thickness of the insulation.

[0096] It is thus possible for the insulation, preferably the insulation layer, to be removed immediately before and / or during an electrically conductive connection of the at least one heating wire and the at least one bridge element. The removal of the insulation, preferably the insulation lacquer layer, is understood in particular to mean that the insulation, preferably the insulation lacquer layer, becomes flowable, preferably melted, and preferably is displaced at least in regions, and / or is destroyed as a result of the energy input. In this context, destruction means in particular that the chemical structures of the insulation are changed as a result of the energy input in such a way that there is no longer any electrical insulating effect and thus electrical contact with the heating wire is possible. The energy input is in particular a thermal energy input and / or results in a thermal energy input.Preferably, the energy input is introduced by means of ultrasound and / or by means of a laser and / or by means of a heated solder, which in particular forms a conductive layer. Preferably, the process for generating the energy input, e.g., ultrasound generation or laser radiation or introducing energy by applying a heated solder, is continued and / or operated in such a way that, immediately after the insulation is removed, the electrically conductive connection of the at least one heating wire and the bridge element is established by means of this process. It is conceivable that the amount of energy input remains the same or changes during this process.

[0097] It is preferred that the at least one heating wire is applied to the at least two carrier film segments without insulation, preferably without an insulating lacquer layer. It is also possible for the at least one heating wire to be or to be provided only partially with insulation, preferably an insulating lacquer layer, and / or for the at least one heating wire to be or to be not provided with insulation, preferably an insulating lacquer layer, in a region preferably associated with the connecting region and / or the contacting region, before the at least one heating wire is applied to the at least two carrier film segments. It is also possible for the at least one heating wire to be or to be applied completely uninsulated to the at least two carrier film segments. It is advantageously possible for the method for producing the plastic article not to comprise removing any insulation, preferably an insulating lacquer layer.Advantageously, material and time resources of a separate exposure step can be saved by using an already exposed heating wire or a heating wire that can be exposed by the energy input of the electrically conductive connection.

[0098] The insulation, preferably an insulating lacquer layer, preferably comprises or consists of at least one coating matrix. The coating matrix particularly comprises or consists of one or more of the following materials: base polymers based on polyester (PE), THEIC-modified polyester (PE), polyesterimides (PEI), polyamideimides, modified polyamideimides (PAI), polyimides (PI), modified polyimides, polyamides (PA), modified polyamides, polyurethanes (PU), modified polyurethanes and polyvinyl formal (PVF), butyral, epoxy, or combinations of the aforementioned materials.For example, it is possible for a solder used to connect the at least one heating wire to the bridge element and / or the one or more contacting means to be selected such that it is hot enough or is applied hot enough to melt the coating matrix and in particular to simultaneously provide contact, wherein the coating matrix is ​​locally incorporated into a matrix of the solder or is destroyed by it. In this context, destruction means in particular that as a result of the energy input, the chemical structures of the insulation are changed in such a way that there is no longer any electrical insulating effect and thus electrical contact with the heating wire is possible. It is also possible for the energy input to be carried out by means of ultrasound or a laser, so that the insulation, preferably the insulating lacquer layer, is melted and in particular is connected to the carrier layer.Insulation, preferably an insulating varnish layer, can also contribute to improving the overall bond.

[0099] It is possible for the at least one heating wire and / or the at least one further wire to be connected to the at least two carrier film segments under the action of ultrasound. It is preferred for the at least two carrier film segments to be provided with the at least one heating wire and / or the at least one further wire by penetrating the at least one heating wire and / or the at least one further wire into the at least two carrier film segments using ultrasound. Preferably, the at least one heating wire and / or the at least one further wire is guided through a sonotrode or guided to a sonotrode.The sonotrode vibrates and / or oscillates, in particular, at a frequency in a range from 20 kHz to 150 kHz, preferably from 50 kHz to 100 kHz, for example at 70 kHz, with lower ultrasonic frequencies typically associated with a higher amplitude and higher ultrasonic frequencies with a lower amplitude. Preferably, the at least one heating wire and / or the at least one further wire are attached, preferably successively attached, to a surface of the at least two carrier film segments by means of the sonotrode, in particular by means of a mouthpiece of the sonotrode, and are introduced, preferably successively introduced, into the surface of the at least two carrier film segments.This is achieved in particular by the surface of the at least two carrier film segments and / or an insulation, preferably an insulating lacquer layer, and / or at least one sheath layer, in particular at least one baked enamel layer, of the at least one heating wire and / or of the at least one further wire being melted locally at the location of the sonotrode, in particular the mouthpiece, as a result of the ultrasound, and preferably the surface of the at least two carrier film segments being connected to the at least one heating wire and / or the at least one further wire and / or its insulation, preferably an insulating lacquer layer, and / or its at least one sheath layer. At the same time, the sonotrode is preferably moved in accordance with the final shape of the at least one heating wire and / or the at least one further wire.In this context, but also independently thereof, an embodiment may be advantageous in which the at least one heating wire and / or the at least one further wire is or will be arranged in a curved, preferably loop-shaped and / or meandering manner in some regions in the plastic article, in particular outside the connection region, and / or is or will be arranged in a curved, preferably loop-shaped and / or meandering manner in some regions on a flat or curved surface of the at least two carrier film segments. In particular, the at least one heating wire and / or the at least one further wire in the plastic article, preferably outside the connection region, i.e. in a Cartesian coordinate system, has a curvature in all three spatial directions. The sonotrode is expediently movable and / or rotatable in one or more spatial directions.The sonotrode is preferably moved by a robot arm, preferably automatically, and / or is movable by means of the robot arm. Alternatively or additionally, it is possible for the at least two carrier film segments to be arranged on a table during the production of the plastic article, which is movable and / or rotatable in one or more spatial directions. A particular advantage is that complex surfaces can be reliably and efficiently provided with the at least one heating wire and / or the at least one additional wire.

[0100] Furthermore, a feed device for applying the at least one heating wire and / or the at least one further wire together with the sonotrode and a supply unit, in particular a supply roll, for providing the at least one heating wire and / or the at least one further wire can be provided, wherein the supply unit is preferably arranged and / or moved movably together with the sonotrode. The at least one heating wire and / or the at least one further wire is expediently guided from the supply unit to the sonotrode and / or through the sonotrode, for example by unwinding from the supply roll. After the at least one heating wire and / or the at least one further wire has been applied by means of the sonotrode, it is particularly possible to carry out the following step: severing, in particular automatically severing, the at least one heating wire and / or the at least one further wire.After separation, the feed device and / or the sonotrode are preferably removed from the at least two carrier film segments with the at least one heating wire. The separation can in particular also take place between the application of the at least one heating wire and the at least one further wire, preferably if these are formed from the same wire. This makes it possible to achieve a simple structure and a simple method for applying the wires with different functions. It is also conceivable to use several feed devices, for example to apply differently designed wires of the at least one heating wire and the at least one further wire.

[0101] It is possible for the at least one heating wire, in particular in the heating region, in particular when viewed perpendicular to a plane spanned by the plastic article, to have one or more of the following shapes: spiral path, loop-shaped path, jagged paths, meander-shaped path, oscillating paths with constant or changing amplitude, U-shaped paths, straight paths, which are preferably connected by curved paths, wherein, for example, each or every second curved path has the same sign of the curvature, merging, preferably straight, paths, which are preferably connected by corner points.

[0102] Conveniently, the at least one heating wire overlaps at least partially with a radiation region, wherein the radiation region is or will be provided in particular to be irradiated with electromagnetic radiation from a radiation source encompassed by the plastic article or connected or connectable to the plastic article. The radiation from the radiation source can be at least partially reflected, for example, by a reflective layer before irradiation.

[0103] The radiation area can also be configured to be larger than the area actually irradiated. In particular, the radiation area can be present over the entire surface or part of the surface of the plastic article when viewed perpendicular to a plane spanned by the plastic article and / or the at least two carrier film segments, or when viewed from a visible side of the plastic article in the form of a preferably rigid component, which is in particular an injection-molded body.

[0104] Preferably, the plastic article is or will be connected to a radiation source, in particular a measuring device, preferably a radar device, for example for distance measurement, and / or a light source, for example for forming a headlight and / or for forming backlighting of the at least one decorative layer, particularly in addition to a headlight function. Advantageously, despite the at least one decorative layer and the at least one heating wire, an overall sufficient transparency of the plastic article can be achieved.The influence of the heating wire and / or the at least one further wire on measured values ​​of a measuring device optionally provided with the plastic article is preferably negligible and / or can be taken into account, for example, by adapting the processing of measured data using training data and / or in the design of the heating windings and the surface area of ​​the heating wires to provide the heating, taking into account the required electrical resistances of the heating wires. In particular, this achieves that the heater is designed such that the heating output in the component is so high that the areas through which the radiation passes are ice-free or can be defrosted, and is also designed in particular such that the transmission of the respective radiation is maximized or its absorption is minimized.

[0105] It is possible for the at least one heating wire, particularly when viewed from above onto the plastic article and / or perpendicular to one of the plastic article and / or the at least two carrier film segments, to occupy an area in a range from 0.1% to 50%, preferably in a range from 1% to 10%, particularly preferably in a range from 1% to 5%, wherein the occupied area is in particular the surface area of ​​the area of ​​the heating region overlapping with the at least one heating wire, in particular of the at least two carrier film segments, divided by the total area of ​​the heating region, in particular of the at least two carrier film segments, preferably in a plan view. Such a surface coverage can advantageously provide a particularly strong heat output.It is also advantageously possible for the at least one heating wire, particularly in the injection-molded body, to be designed to be visually visible, allowing it to be easily integrated into a design, for example. In this context, the surface coverage of the heating wire across the surface of the plastic article can preferably be inhomogeneous rather than homogeneous, which allows for the formation of regions with both higher and lower heating outputs.

[0106] It is also possible that several heating wires with one or more features that are described for the at least one heating wire are or will be provided or that the at least one heating wire and / or the at least one further wire is a multi-core heating cable.

[0107] The plastic article preferably has, in particular in the heating area, a length and / or width in a range of 3 cm to 350 cm and / or an area in a range of 5 cm 2 up to 60000 cm 2 , in particular when viewed perpendicular to a plane spanned by the plastic article, preferably in plan view. The plastic article preferably has a thickness in a range of 0.1 cm to 10 cm, preferably in a range of 0.2 cm to 5 cm. The plastic article in the form of a preferably rigid component, which is in particular an injection-molded body, preferably has, in particular in the heating region, a length and / or width in a range of 3 cm to 350 cm and / or an area, in particular an area of ​​a visible side, in a range of 5 cm 2 up to 60000 cm 2, in particular when viewed perpendicular to a plane spanned by the plastic article, preferably in plan view. The plastic article, in the form of a preferably rigid component, which is in particular an injection-molded body, preferably has a thickness in a range of 0.1 cm to 10 cm, preferably in a range of 0.2 cm to 5 cm.

[0108] In particular, it is possible that the plastic article, especially in the heating area, has the following exemplary properties: Width of 100 cm, Length of 100 cm, Area 10000 cm 2 , Distance, preferably minimum distance, between opposite, in particular parallel, conductor tracks of the at least one heating wire: 0.5 cm Number of opposite, in particular parallel, conductor tracks of the at least one heating wire: 200, preferably 10000 cm 2 Distance of at least one heating wire from opposite ends of the layer composite: 1 cm. Length of at least one heating wire: 19600 cm, Diameter of at least one heating wire: 100 µm, Occupied area, especially in the heating area: 196 cm 2 (= length of at least one heating wire x diameter of at least one heating wire).

[0109] Area coverage of the at least one heating wire: 1.96% (= percentage share that the area of ​​the at least one heating wire occupies in relation to the total area, in particular in the heating area).

[0110] The total area can therefore preferably be determined, particularly in the heating area, based on the product of the width and the length of the plastic article and / or the at least two carrier film segments.

[0111] The at least one heating wire and / or the at least one additional wire and / or the tracks are or will preferably be applied with a diameter in a range from 20 µm to 350 µm, preferably from 75 µm to 120 µm. The at least one additional wire can also be applied, at least in some regions, with a larger and / or smaller diameter than the at least one heating wire. The dimensions can be measured, in particular, in a plan view of the plastic article.

[0112] The at least one heating wire and / or the at least one further wire comprises, in particular, a metal and / or a metal alloy. The at least one heating wire and / or the at least one further wire is, in particular, a copper wire. It is possible for the at least one heating wire and / or the at least one further wire to comprise one or more of the following chemical elements: Al, Cu, Ag, Au, C and / or an alloy thereof. The at least one heating wire and / or the at least one further wire more preferably comprises or consists of one or more of the following materials: NiCr15Fe, Cu, CuNi30Mn, CuMn12Ni, constantan, alloy 30Mn 70Cu, X10CrAlSi13. It is also possible to use other materials for the at least one heating wire, provided that they have, in particular, sufficient conductivity and thermal output.

[0113] Preferably, in particular at an ambient temperature of 20°C, the specific resistance of the material of the at least one heating wire is more than 0.3 Ω mm 2 / m and / or the electrical conductivity is less than 3 S / m or m / Ω mm 2 .

[0114] The at least two carrier film segments and / or the carrier film are or are each formed, in particular, by a carrier layer. Such a carrier layer is preferably single-layer or multi-layered. The carrier layer preferably comprises or consists of one or more of the following materials: polyolefin-based (PE), polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS), polyethylene terephthalate (PET), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), coextrudates, triextrudates, multiextrudates. It is possible for the carrier layer to comprise cellophane and / or be coated therewith. It is also possible for the carrier layer to be made from a biopolymer basis. The carrier layer can be a coated carrier, a fabric carrier, a multilayer composite, and / or a filled carrier.In particular, the carrier layer has a layer thickness in a range from 20 µm to 5000 µm, preferably from 50 µm to 800 µm. The carrier layer preferably has one or more of the following properties: smooth, rough, structured, partially structured, vapor-deposited on one side, partially vapor-deposited on one side, partially vapor-deposited on both sides, perforated, partially coated, colored, transparent, fully coated, microstructured, locally variable in thickness.

[0115] Preferably, one or more or all of the at least two carrier film segments, particularly in the heating region, are transparent, more preferably crystal-clear, preferably for wavelengths of light visible to the human eye. The layer thickness of the carrier film segment, particularly of the at least one carrier film comprising or consisting of PC, is in particular in a range from 50 µm to 2000 µm, preferably 375 µm.

[0116] The at least one heating wire is or will preferably be introduced directly into such a carrier layer and / or into an adhesive layer provided by such a carrier layer.

[0117] The conductive ink layer is or will preferably be made from a conductive ink. The conductive ink is in particular a silver conductive ink or conductive silver, a copper conductive ink or a graphite conductive ink. In particular, the conductive ink is a paint based on and / or comprising one or more of the following components: silver particles, copper particles, graphite particles, nanotubes, gold particles, aluminum particles, particles made of alloys of the aforementioned metals, metal particle combinations, nanoparticles. The conductive ink preferably comprises, in particular as a binder, a single-component paint or a multi-component paint, preferably solvent-based or water-based, or a synthetic resin, preferably a single-component or two-component, or multi-component synthetic resin. Synthetic resins are also preferably suitable as a conductive adhesive, i.e. in particular for forming an adhesive surface of the conductive ink layer.

[0118] The conductive ink layer is preferably single-layer or multi-layer. It is possible for the conductive ink layer to comprise multiple layers, which in particular differ in composition. Alternatively or additionally, it is possible for the conductive ink layer to be a reactive ink, a spray ink, and / or a printing ink and / or to be applied as such. It is also possible for the conductive ink layer to be or be designed as a layered composite, preferably in conjunction with one or more vapor-deposited metal layers or transparent oxide layers.

[0119] The conductive layer, in particular the conductive lacquer layer, preferably has a thickness in a range of 2 µm to 100 µm, preferably in a range of 10 µm to 25 µm.

[0120] It is also possible for the conductive layer to comprise a conductive paste system which is constructed in particular in multiple layers with individual layers each having a thickness of 5 µm to 100 µm, preferably each having a thickness in the range of 10 µm to 30 µm, and / or can be constructed from one or more conductive materials, in particular selected from Cu, Au, Ag, C, Zn, Al, which are then optionally coated in one or more layers with one or more pure conductive materials, in particular selected from Cu, Au, Ag, Zn, Al, in an additional second step via a galvanic process.

[0121] It is preferably possible for the at least one joint to have one or more conductive layers, in particular one or more conductive lacquer layers, which are or are completely and / or partially galvanically reinforced and are thereby coated in particular in one or more layers with one or more (preferably pure) conductive materials, preferably selected from Cu, Au, Ag, Zn, Al.

[0122] 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.

[0123] The invention will be explained below using several exemplary embodiments with the aid of the accompanying drawings. The exemplary embodiments shown are therefore not to be understood as limiting. Fig. 1 and Fig. 2 show schematic representations of a plastic article. Fig. 3 shows schematic representations of a process for producing a plastic article. Fig. Figures 4 to 11 show schematic representations of plastic articles. Fig. 12 to 22 show schematic representations of sections of a plastic article with a joint.

[0124] Fig. 1 shows schematically a top view and schematically a side view of an exemplary plastic article 1. The plastic article 1 can in particular be provided with the Fig. 3 have been or will be manufactured using the methods illustrated.

[0125] The example based on the Fig. The plastic article 1 illustrated in Figure 1 comprises the heating wire 2 as well as the carrier film segments 31, 32 and 33. The carrier film segments 31 and 32 are completely separated from each other, for example, by the separation 101. The carrier film segments 32 and 33 are completely separated from each other, for example, by the separation 102. The carrier film segments 31 and 32 and in particular also the carrier film segments 32 and 33 thus each have opposing separation surfaces. Such separation surfaces are particularly suitable for Fig. 12 and Fig. 17 with the separating surfaces 1011 and 1012. It is also conceivable that the separation 101 and / or the separation 102 is present only in certain regions. In the case of a separation in certain regions, this particularly forms a crease and / or bending edge in the respective carrier film material. Due to the separation 101, there is no direct local material cohesion between the carrier film segments 31 and 32, at least in certain regions or completely. Due to the separation 102, there is no direct local material cohesion between the carrier film segments 32 and 33, at least in certain regions or completely.

[0126] The one based on the Fig. 1 has at least the joint 10. The joint 10 connects the carrier film segments 31 and 32 to each other and is formed by the separation 101 of the carrier film segments 31 and 32 and by the heating wire 2. The carrier film segments 31 and 32 are arranged on the joint 10 so as to be rotatable relative to each other, as is the case, for example, by one of the Fig. 2 and 12 to 22. In particular, when the plastic article 1 is or will be further processed into an injection-molded body, the carrier film segments 31 and 32 are or will be arranged on the joint 10 in a manner rotating relative to one another. In addition, the Fig. 1 illustrates the optional joint 11, which connects the carrier film segments 32 and 33. The joint 11 is designed such that the carrier film segments 32 and 33 are arranged to be rotatable relative to one another, as is particularly the case with one of the Fig. 2 and 12 to 22, or are arranged in a rotated manner, preferably when it is a plastic article further processed into an injection-molded body. It is also conceivable that further carrier film segments are present, which are connected to one of the carrier film segments 31, 32 and 33 via further joints with further separations. The joint 11 or further optional joints can be designed as is the case, for example, for the joint 10 by one of the Fig. 2 and 12 to 22.

[0127] The separations 101 and / or 102 can each have separating surfaces that directly adjoin one another, at least in some areas. It is also conceivable that a separation, such as the separation 101 and / or 102 or a separation of a joint (not shown), is or will be formed by one or more recesses that are present at least in some areas or over the entire surface between each two carrier film segments. In particular, joints can be or will be formed by means of recesses, as is the case for the joint 10 by means of one of the Fig. 18 to 22. The spacing of the parting surfaces can thus advantageously be designed according to the intended angle in the injection-molded body.

[0128] The carrier foil segment 31, as shown by Fig. 1, is in particular a heating segment arranged in the heating region 1000. Therein, the heating wire 2 expediently has a shape by means of which a heating surface is or can be provided. The heating surface is, in particular, a heatable surface of the injection-molded body in the plastic article 1 further processed into an injection-molded body. This surface of the injection-molded body can thus be freed of ice and snow and / or brought to a defined temperature.

[0129] To contact the heating wire 2, the plastic article 1 preferably also has the contacting element 5, via which the heating wire 2 present on the heating segment can be contacted. The contacting element 5 here comprises, for example, the carrier film segments 32 and 33, which thus form, in particular, two supply line carrier film sub-segments of a supply line segment. The supply line segment with the carrier film segments 32 and 33 is connected via the first joint 10 to the carrier film segment 31, which is a heating segment. The supply line segment, which comprises the carrier film segments 32 and 33, expediently protrudes from an edge of the carrier film segment 31 and has smaller cross-sectional dimensions than the carrier film segment 31. This enables easy contacting of the heating wire 2. Optionally, the contacting points 200, which are, for example, solder points, are provided for easier contacting.The joint 11 also enables a well-deformable or deformed structure of the contacting element 5 while at the same time ensuring high mechanical stability of the heating wire 2.

[0130] Joints on or in the supply line segment, such as joints 10 and 11, are particularly advantageous when the at least one heating wire is very delicate, for example, with a thickness and / or diameter of 70 µm. The tensile strength of the heating wire is relatively low. For example, Elektrisola extra high tension wire (XHTW) can be used. The tensile strength of the at least one heating wire is approximately 390 N / mm. 2 , preferably measured according to IEC 60851-1 2021 (issue date: 2021-06-16 (16.06.2021)), especially at 20°C. If the at least one heating wire with a diameter of 70 µm is considered, its cross-sectional area can be estimated at approximately 0.004 m 2which in turn corresponds to the specified tensile strength value of 390 N / mm 2to a force of 1.5 N until at least one heating wire breaks or changes its mechanical properties. In particular, to enable electrical contact with the plastic article 1, deformations are usually carried out on or in the contacting element 5. Such deformations can be caused, for example, by tool surfaces with corresponding tool bending radii. Without a joint, tensile and compressive forces in the contacting element 5 can be so great due to the tool bending radii that the heating wire 2 would be compressed and / or separated. If the heating wire 2 is anchored in the carrier film segments 31, 32 and 33, for example due to ultrasound technology, the freedom of movement is particularly impaired, for example due to a restricted relative movement of the carrier film material and the heating wire 2, which increases the risk of compression and / or separation of the heating wire 2.Joints 10 and 11 can now be arranged in such a way that freedom of movement is increased and thus the aforementioned risk is minimized.

[0131] Alternatively or in addition to the carrier film segments 32 and / or 33, it is conceivable for the plastic article 1 to have a carrier film segment (not shown) that is a branch segment connected to the heating segment and / or the supply line segment via a joint (not shown), wherein the branch segment has a smaller width than the heating segment and / or supply line segment connected to the branch segment via the joint (not shown). This allows, in particular, "outlets" to be provided in the injection-molded body, which provide additional functions, such as an additional heating surface and / or decoration.

[0132] The carrier film segments 31, 32, and / or 33 are preferably single-layer or multi-layer. Preferably, the carrier film segments 31, 32, and / or 33 comprise or consist of one or more of the following materials: polyolefin-based (PE), polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS), polyethylene terephthalate (PET), polycarbonate (PC), acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), coextrudates, triextrudates, and multiextrudates. It is possible for the carrier film segments 31, 32, and / or 33 to comprise cellophane and / or be coated therewith. It is also possible for the carrier film segments 31, 32, and / or 33 to be made from a biopolymer base. The carrier film segments 31, 32 and / or 33 may be one or more coated carriers, fabric carriers, multilayer composites and / or filled carriers.In particular, the carrier film segments 31, 32, and / or 33 have a layer thickness in a range from 20 µm to 5000 µm, preferably from 50 µm to 800 µm. The carrier film segments 31, 32, and / or 33 preferably have one or more of the following properties: smooth, rough, structured, partially structured, vapor-deposited on one side, partially vapor-deposited on one side, partially vapor-deposited on both sides, perforated, partially coated, colored, transparent, fully coated, microstructured, locally varying thicknesses.

[0133] The carrier film segments 31, 32 and / or 33 can preferably also be of different thicknesses and / or consist of different materials.

[0134] As through Fig. 1, it is preferred that in the joint 10, the heating wire 2 overlaps with the separation 101 and / or the separation 102. Preferably, the heating wire 2 overlaps with the separating surfaces of the joints 10 and / or 11. The heating wire 2 is in particular meander-shaped in a region overlapping the joint 10 and the joint 11. Other shapes are also conceivable. However, it is preferred that the heating wire 2 has a sequence of several paths in a region, such as the joint region 100, which overlaps at least one joint, which are preferably connected to one another by curves. In the Fig. In the joint region 100 illustrated in Figure 1, the heating wire 2 is applied with an increased areal density compared to adjacent regions. It is preferred that in the at least one joint, such as the joint 10 and / or 11, there are three or more tracks formed by the heating wire 2 and / or the at least one further wire. In the example of Fig. 1, joint 10 has six tracks, and joint 11 also has six tracks. Thus, the joints can advantageously be reinforced, or the load on at least one heating wire in the joint can be reduced, thus improving mechanical stability. If the tracks of heating wire 2 extend over several joints, such as joints 10 and 11, process steps can advantageously be eliminated to reinforce the joints while increasing stability.

[0135] It is also possible that only one of the joints 10 and 11 is or will be provided. For example, it is possible for the plastic article 1 not to have the joint 11, in particular in that the carrier film segments 32 and 33 are not separated from one another, but instead there is a continuous carrier film segment. For example, it is also conceivable for the plastic article 1 not to have the joint 10, in particular in that the carrier film segments 31 and 32 are not separated from one another, but instead there is a continuous carrier film segment. In this case, the plastic article has the joint 11, which connects the continuous carrier film segment to the carrier film segment 33, which is in particular a supply line segment.

[0136] The plastic article 1 is particularly usable in an injection molding process as an insert element or is used therein, in particular wherein the plastic article is inserted into a cavity during the injection molding process, for example, and is back-injected with a plastic injection molding compound, in particular back-injected on one side or both sides. In this way, in particular the first and / or second carrier component can be formed or can be formed. It is therefore particularly possible that the plastic article 1, as shown by Fig. 1 is further processed into an injection-molded body or is exhibited by an injection-molded body.

[0137] The contacting element 5 is particularly suitable for contacting by means of one or more electrical contacting means. The one or more contacting means can, for example, be or become connected to the contact points 200 and thus provide or form an interface, such as a contact socket, for integration into a vehicle electrical system. It is also conceivable that the contacting element 5 is or becomes plugged into a contact socket, which, for example, forms the interface to the vehicle electrical system. As also shown by Fig. As illustrated in Figure 1, it is possible for the heating wire 2 to have one end and another end in the contacting element 5. Thus, one end can be assigned to a negative pole and the other end to a positive pole.

[0138] The heating wire 2 is, in particular, a copper wire. It is also possible for the heating wire 2 to comprise one or more of the following chemical elements: Al, Cu, Ag, Au, C, and / or an alloy thereof. Furthermore, it is possible for the heating wire 2 to be a multilayer system, for example, with insulation. The heating wire 2 preferably has a diameter of 70 µm.

[0139] Fig. Figure 2 schematically shows a side view of a plastic article 1 with carrier film segments 31, 32, and 33 rotated relative to one another. Two of the carrier film segments 31, 32, and 33 are rotated relative to one another via one of the joints 10 and 11. In a plastic article 1 that has not yet been further processed into a rigid component, such as an injection-molded body, the carrier film segments 31, 32, and 33 are preferably correspondingly rotatable. In a plastic article 1 that has been further processed into a rigid component, such as an injection-molded body, the carrier film segments are preferably correspondingly rotated and fixed. In particular, the Fig. Figures 12 to 22 further illustrate possible designs of a joint.

[0140] Fig. 3 illustrates an exemplary method for producing a plastic article 1 using the Fig. 3a to Fig. 3f illustrated steps.

[0141] To produce the plastic article 1, it is possible that the following step is carried out first, which is particularly characterized by the Fig. 3a to Fig. 3d:

[0142] Providing the carrier film segments 31, 32 and 33. This step is particularly Fig. 3d. Alternatively or additionally, it is possible that the following step is carried out in the method: producing the carrier film segments 31, 32 and 33. This step is particularly Fig. 3a to Fig. 3d. Preferably, the method comprises the following step: Providing an application surface 6 and applying the carrier film segments 31, 32, and 33 to the application surface 6. Preferably, the application surface 6 is provided by an application plate 60. The application plate 60 is made, for example, of materials selected individually or in combination from: plastic(s), steel, stainless steel, aluminum, copper, stone, wood, glass, composite materials, layered materials, and filled materials.

[0143] After the application surface 6 has been prepared, the carrier film segment 31 is first applied, as shown by Fig. 3b, then the carrier film segment 32, as shown by Fig. 3c, and then the carrier film segment 33, as shown by Fig. 3d. It is preferably possible for the carrier film segments 31, 32, and 33 to be applied separately to the application surface 6 without any material cohesion.

[0144] The carrier film segments 31 and 32 are preferably fixed to the application surface 6, for example, by suction. Alternatively or additionally, the application surface 6 may have recesses (not shown here), which are expediently configured according to the shape and positioning of the carrier film segments 31 and 32, in order to achieve, in particular, reliable positional tolerance as well as fast and effective further processing.

[0145] Subsequently, the heating wire 2 is applied to the carrier film segments 31, 32 and 33 and in particular at least partially inserted into them. The following step takes place: Application of the heating wire 2 to the carrier film segments 31, 32 and 33. This step takes place in such a way that the plastic article 1 has the joint 10, which connects the carrier film segments 31 and 32 to one another and is formed by the preferably full-surface separation 101 of the carrier film segments 31 and 32 and by the heating wire 2, in such a way that the carrier film segments 31 and 32 are arranged on the joint 10 so as to be rotatable relative to one another, as is particularly the case by Fig. 2. In addition, the step in this example is optionally carried out in such a way that the plastic article 1 has the joint 11, which connects the carrier film segments 32 and 33 to one another and is formed by the preferably full-surface separation 102 of the carrier film segments 32 and 33 and by the heating wire 2 in such a way that the carrier film segments 32 and 33 are arranged at the joint 11 so as to be rotatable relative to one another, as is particularly the case by Fig. 2. It is also possible, particularly during further processing into an injection-molded body and / or in a plastic article 1 further processed into an injection-molded body, that the carrier film segments 31 and 32 are or will be arranged in a rotated manner at the joint 10 and / or the carrier film segments 32 and 33 are or will be arranged in a rotated manner at the joint 11. It is also conceivable that the separations or one or more of the separations of the at least one separation are only introduced in certain regions, as is the case, for example, for Fig. 11 is described.

[0146] The shape of the heating wire 2, illustrated by way of example as a meandering shape with multiple paths traversing the separations of the joints 10 and 11, can achieve advantages both with regard to machine procurement costs and with regard to process costs (setup costs), especially since, for example, in an ultrasound application, the same sonotrode can be used for all wires of the joints 10 and 11. Therefore, it is preferred that the joints 10 and 11 be formed by the same wire of the at least one heating wire or the at least one further wire.

[0147] The procedure, which is Fig. 3, also includes the optional step, which is Fig. 3f illustrates: generating contact points 200 on the heating wire 2, in particular at two ends of the heating wire 2 in the contacting element 5.

[0148] The procedure, which is Fig. 3, also includes the optional step of detaching the plastic article 1 from the application surface 6 and removing the plastic article 1 and the application surface 6 from each other. In particular, the Fig. 1 described plastic articles 1 can be obtained.

[0149] After the Fig. 3, it is possible for the plastic article 1 to be further processed into an injection-molded body. In one possible embodiment, the plastic article 1 is therefore an injection-molded body. The plastic article 1 has, in particular, on a first side, a carrier component made of a plastic injection-molding compound and / or on a second side, a second carrier component made of a plastic injection-molding compound, wherein the second side is preferably opposite the first side. The first side is preferably the side of the carrier film segments 31, 32 and 33 provided with the heating wire 2. The second side is preferably the side of the carrier film segments 31, 32 and 33 which does not have the heating wire 2. It is possible for the carrier film segments 31, 32 and 33 together with the heating wire 2 and / or the at least one further wire, as is exemplified by the wires 20, 21, 22, 23, 24, 25 and / or 26 of one of the Fig. 5 to 11, are back-injected on the first side with a first carrier component made of a plastic injection molding compound and / or on the second side with a second carrier component made of a plastic injection molding compound. For back-injection of the first side and / or the second side, the at least two carrier film segments together with the heating wire 2 and optionally the at least one further wire are arranged on a wall with a preferably curved shape in a cavity of an injection mold and preferably then back-injected to obtain the first and / or second carrier component. In particular, during arrangement on the wall and / or during back-injection, the heating wire 2 and optionally the at least one further wire of the at least one joint, such as the joints 10 and 11, are deformed according to the preferably curved shape of the wall.

[0150] The plastic injection molding compound of the first carrier component and / or the second carrier component overlaps the at least one joint, for example the joints 10 and 11 and the heating wire 2 and optionally the at least one further wire of the at least one joint, for example the joints 10 and 11, at least partially or completely, in particular in such a way that the heating wire 2 and optionally the at least one further wire of the at least one joint, such as the joints 10 and 11, is embedded in the plastic injection molding compound of the first carrier component and / or the second carrier component.

[0151] It is therefore expedient for the carrier film segments 31, 32, and 33 to be rotated relative to one another before or during the back-injection molding of the first side and / or the second side. It is possible for the carrier film segments 31, 32, and 33, together with the heating wire 2 and optionally the at least one additional wire, to be fixed by means of the first carrier component and / or the second carrier component, or to be fixed in the finished component, and to be more strongly curved in the joint region 100, at least in some areas, than in one or more areas without the joints 10 and 11.

[0152] The heating wire 2 is preferably applied to the carrier film segments 31, 32, and 33 by means of ultrasound. For this purpose, a feed device can be used, for example, which has a sonotrode and a supply unit, in particular a supply roll, for providing the heating wire 2. The supply unit is preferably moved together with the sonotrode. The heating wire 2 is expediently guided from the supply unit to the sonotrode and / or through the sonotrode, for example by unwinding it from the supply roll. After the heating wire 2 has been applied by means of the sonotrode, it is particularly possible to carry out the following step: separating, in particular automatically separating, the heating wire 2. After separation, the feed device is preferably removed from the carrier film segments 31, 32, and 33 with the heating wire 2.It is also conceivable that at least one additional wire is applied after the separation. This can advantageously be applied to reinforce the at least one joint. Regarding possible designs of the sonotrode and the use of ultrasound to provide the carrier layer with the heating wire, reference is made in particular to the above explanations. It is preferred that the sonotrode vibrates and / or oscillates, for example, at 70 kHz.

[0153] Preferably, the heating wire 2 is or will be applied to the carrier film segments 31, 32, 33 in a connecting region or completely uninsulated. However, the thermal energy input by applying the contact points 200, in particular in the form of a solder layer, can also be utilized if the heating wire 2 is or will be provided or applied to the carrier layer 3 in the connecting region with an insulating lacquer layer. In this case, the insulating lacquer layer and the solder layer are preferably designed and the method is carried out in such a way that the thermal energy input through the solder layer exposes the heating wire 2 from the insulating lacquer layer and thus, in particular, creates an electrically conductive connection between the heating wire 2 and the contact point 200.It is also possible to provide, instead of the contact points 200 or in addition thereto, an electrically conductive bridge element which has several layers and provides a connection surface in order to enable improved contacting and design freedom of the heating wire 2 in the contacting element 5.

[0154] Fig. 4 shows how the Fig. 1, except that the plastic article 1 additionally has a conductive layer, which is a conductive lacquer layer 4. The conductive lacquer layer 4 is, in particular, a conductive paste system, which can be multi-layered and / or constructed from different materials. Regarding the design of a conductive lacquer layer, reference is made in particular to the above explanations.

[0155] It is also possible for the conductive layer to comprise a conductive paste system which is constructed in particular in multiple layers with individual layers each having a thickness of 5 µm to 100 µm, preferably each having a thickness in the range of 10 µm to 30 µm, and / or can be constructed from different conductive materials such as Cu, Au, Ag, C, Zn, Al, which are then or will be coated in one or more layers with pure conductive materials such as Cu, Au, Ag, Zn, Al in an additional second step using a galvanic process.

[0156] The conductive lacquer layer 4 is formed in particular by two partial layers, which are expediently arranged over partial zones of the heating wire 2, in particular so that they form a conductor track together with the heating wire 2, which can be contacted in the contacting element 5.

[0157] The conductive ink layer 4 is present here in particular in some areas of the contacting element 5 and in some areas of the heating segment. Fig. 4, it is possible for the conductive lacquer layer 4 to be present in the joint region 100 and preferably to extend beyond the joint region 100.

[0158] The conductive ink layer 4 is arranged here, for example, between the carrier foil segments 31, 32, and 33 and the heating wire 2. Alternatively or additionally, a conductive ink layer is possible that is applied to a side of the heating wire 2 that faces away from the carrier foil segments 31, 32, and 33.

[0159] The conductive ink layer 4 preferably has a thickness in a range of 2 µm to 100 µm, preferably in a range of 10 µm to 25 µm.

[0160] A conductive ink layer is particularly advantageous when the heating wire 2 comprises meandering wire structures or similar wire structures. In particular, it can prevent an area with the meandering or similar wire structures from heating up excessively, which would then dissipate the heat during a current flow. In this context, it is advantageous if the heating wire 2 is not insulated or is correspondingly partially insulated at least in the area of ​​the conductive ink layer, in order to thereby simultaneously reduce the electrical resistance of the wire structures in this area.

[0161] Fig. 5 illustrates how the Fig. 1, except that the heating wire 2 is preferably straight and / or in particular only with two tracks, one in the joint 10 and one in the joint 11, and that the plastic article 1 additionally comprises the wire 20. The method for producing the plastic article 1 therefore comprises the additional optional step of applying the further wire 20 to the carrier film segments 31, 32, and 33.

[0162] The wire 20 has a sequence of several tracks which are connected to each other by curves, such that several tracks overlap with the joint 10 and with the joint 11. As shown by Fig. As further illustrated in Figure 5, it is also possible for a single additional wire 20 to form multiple paths present in multiple joints, namely joints 10 and 11 here. The additional wire 20 has, for example, the same diameter and the same material as the heating wire 2. Thus, for example, both the heating wire 2 and the additional wire 20 can be applied in the joints 10 and 11 using a single feed device. However, it is also conceivable for the additional wire 20 to have a different diameter and / or be made of a different material.

[0163] The heating wire 2 thus has only two tracks per joint 10 and 11 and can be designed in a straight line. This minimally affects its heating function. In the example of the Fig. 5, the heating wire 2 is not provided in a meandering shape in the contacting element 5, but instead, decoupled long structures of the additional wire 20 are provided. The additional wire 20 thus has the function of connecting the carrier film segments 31, 32, and 33 and allowing bending accordingly. Advantageously, the influence of the additional wire 20 on the heating function is particularly minimal. It is also conceivable for the heating wire 2 to have a different shape in the contacting element 5, which is adapted, for example, according to the desired heating function and / or according to the contacting requirements for integration into a power grid.

[0164] In a preferred embodiment of the plastic article 1 and / or the method, the wire 20 is or will be designed to have a material and / or a cross-section identical to that of the heating wire 2. Advantageously, the at least one further wire 20 can thus be applied using the same sonotrode and / or the same mouthpiece of the sonotrode and in particular in the same operation as the application of the heating wire 2. However, it is alternatively or additionally possible for the wire 20 to have a different material and / or a different cross-section than the heating wire 2. Advantageously, the further wire can thus be designed to be optimized with regard to its function in the respective joint, with no or only a minor influence on the heating function of the plastic article.

[0165] Fig. 6 shows a particularly how based on the Fig. 5, except that the wire 20 is present only in the joint 10 and another wire 21 is present in the joint 11. Fig. 6 illustrates in particular how, based on the Fig. 1, except that the heating wire 2 is preferably straight and / or in particular only with two tracks, one in the joint 10 and one in the joint 11, and that the plastic article 1 additionally has the wire 20 and the wire 21. The wires 20 and 21 each have a sequence of several tracks, which are connected to one another by curves, such that several tracks overlap with the joint 10 and with the joint 11. Thus, the areal density of the further wires 20 and 21 in the joint regions 100 is increased. In particular, the heating wire 2 is not provided in a meandering shape, and instead two decoupled short wire structures are applied, which have the function of connecting the carrier film segments 31, 32 and 33 and accordingly allow bending.

[0166] Fig. 7 shows how the Fig. 6, except that instead of a heating segment in the form of the carrier film segment 31, there is a heating segment comprising the carrier film segments 31 and 34, which are connected to one another by the joint 12. The joint 12 is formed in particular by a complete separation of at least one of the carrier film segments 31 and 34 and the heating wire 2.

[0167] In other words, here, in particular, a main heating surface is segmented into two halves to provide improved flexibility. In this example, these two halves are preferably connected only via heating wire 2.

[0168] Fig. 8 shows how the Fig. 7, except that the joint 12 is additionally formed by the additional wires 22, 23, and 24. The connection of the carrier film segments 31 and 34 is thus effected in particular via the heating wire 2 as well as via additional wires 22, 23, and 25 decoupled from the heating wire 2.

[0169] Fig. 9 shows how the Fig. 6, except that instead of a heating segment in the form of the carrier film segment 31, a heating segment comprises the carrier film segments 31, 34 and 35, wherein the carrier film segments 31 and 34 are connected to one another by the joint 13 and the carrier film segments 34 and 35 are connected to one another by the joint 14. The separation 104 of the joint 13 and the separation 105 of the joint 14 rotate by an angle compared to the separations 101 and 102 of the joints 10 and 11, respectively, here for example by 90°.

[0170] Thus, in particular, bending / bending in a 90% direction to the bending direction of the carrier foil segments 32 and 33 in the contacting element 5 is permitted.

[0171] In this example, the connection of the carrier film segments 31, 34 and 35 by means of the joints 13 and 14 is carried out in particular only by the heating wire 2.

[0172] Fig. 10 shows how the Fig. 9, except that the joint 13 is additionally formed by the further wire 25 and the joint 14 is additionally formed by the further wire 26. The connection of the carrier film segments 31, 34, and 35 by means of the joints 13 and 14 is thus achieved in this example in particular by the heating wire 2 and wire structures decoupled from the heating wire 2, namely the wires 25 and 26.

[0173] Fig. 11 shows how the Fig. 10, except that the separations which are present between two of the carrier film segments 31 to 35 are only present in certain regions.

[0174] The connection of carrier film segments 31 to 35 is thus effected in particular via the heating wire 2, via further wires 20, 21, 25 and 26 decoupled from the heating wire 2, and also via preferably narrow lateral carrier connection structures in the partial regions 30.

[0175] The carrier film segments 31 to 35 are thus separated from the continuous carrier film 3. The at least one separation is formed in particular by one or more cuts and / or recesses in the carrier film 3. The at least one separation is preferably designed in such a way that it provides a crease and / or bending edge of the plastic article. The plastic article thus comprises the joints 10, 11, 13, and 14, each of which is additionally formed by two of the partial regions 30 of the carrier film 3.

[0176] The heating wire 2 and the other wires 20, 21, 25 and 26 can, as exemplified by Fig. 11, are not arranged overlapping with the sub-areas 30.

[0177] It is also conceivable that at least one of the joints 10, 11, 13 and 14 comprises a further carrier layer which connects the respective carrier film segments to one another.

[0178] As one of the Fig. 7 to 11, it is possible for the plastic article 1 to have a heating segment comprising two or more heating carrier film sub-segments, such as the carrier film segments 31, 34, and 35, which are connected to one another via one or more second joints, such as the joints 12, 13, and 14. It is also possible for the contacting element 5 to be provided, for example, without the joints 10 and 11.

[0179] Fig. 12 schematically illustrates a side view of a section of a plastic article 1 with the joint 10, as illustrated in one of the previously described figures.

[0180] Fig. Figure 12a shows a state in which there is no rotation of the carrier foil segments 31 and 32 relative to each other. The joint 10 is designed in such a way that a rotation around the point P1 is possible, as shown by the Fig. 12b and Fig. 12c is further illustrated. Fig. 12c is an enlarged view of the section with the joint 10. The point P1 thus represents in particular an axis of rotation about which the carrier film segments 31 and 32 are rotatable, or is encompassed by such an axis of rotation. In this case, the separating surfaces 1011 and 1012 move away from one another, starting from a state without rotation. In other words, the carrier film segments 1011 and 1012 are preferably only rotatable in one direction, starting from a state without rotation. The carrier film segments 31 and 32 here have, for example, the thickness d. The at least one separation 101 of the carrier film segments 31 and 32 is present in particular from the point P1 to the point P2 along the thickness d of the carrier film segments 31 and 32. The at least one separation 101 of the carrier film segments 31 and 32 is designed such that the carrier film segments 31 and 32 touch the separation surfaces 1011 and 1012 when there is no rotation.The separating surfaces 1011 and 1012 are thus in particular directly adjacent to one another. For this purpose, it is possible, for example, to apply the carrier foil segments 1011 and 1012 to the application surface 6 before applying the heating wire 2 and optionally the additional wires in such a way that the carrier foils touch each other, preferably at the end faces.

[0181] Fig. 13 now illustrates a rotation of the carrier foil segments 31 and 32, as these lead to Fig. 12 are described against each other.

[0182] Fig. 13b is an enlarged view of the section with the joint 10 of the Fig. 13a. As an example, a rotation through an angle of 22.5° is illustrated here. As can be seen particularly from the Fig. 13, the angle is measured in particular between two lines, each extending along a main surface of the carrier film segments 31 and 32 having the heating wire 2. It is advantageously possible to insert the plastic article 1 into a cavity of an injection molding device with such a rotation and to back-inject it from the side with the heating wire 2 or the side opposite the heating wire 2 and thus further process it into an injection-molded body. In particular, a rotation in a range from 0° to 180° is possible, preferably in a range from 0° to 90°, more preferably from 70° to 90°. In this context, a rotation of 180° would correspond to folding the carrier film segment 32 onto the carrier film segment 31.

[0183] Is the Fig. If the plastic article 1 illustrated in Figure 13 is fixed at an angle of 22.5° in the injection-molded body, it is possible, for example, for a deviation of 10°, preferably 5°, to be achieved through elastic deformation. In other words, a change in the fixed angle to a value between 12.5° and 32.5°, preferably between 17.5° and 27.5°, is possible through elastic deformation. This can be advantageously useful in an installation situation to enable adaptability to tolerances.

[0184] Fig. 14 illustrates a rotation, such as this Fig. 13, by an angle of, for example, 45°. In a plastic article in the form of an injection-molded body in which this angle is fixed, a change in the fixed angle to a value of 35° to 55°, preferably 40° to 50°, is possible, particularly through elastic deformation.

[0185] Fig. 15 illustrates a rotation, such as this Fig. 13 is described by an angle of, for example, 67.5°. In a plastic article in the form of an injection-molded body in which this angle is fixed, a change in the fixed angle to a value of, for example, 57.5° to 77.5°, preferably 62.5° to 72.5°, is possible, particularly through elastic deformation.

[0186] Fig. 16 illustrates a rotation, such as this Fig. 13, by an angle of, for example, 90°. In a plastic article in the form of an injection-molded body in which this angle is fixed, a change in the fixed angle to a value of 80° to 100°, preferably 85° to 95°, is possible, particularly through elastic deformation.

[0187] Fig. 17 schematically illustrates a side view of a section of a plastic article 1 with the joint 10, as this is particularly illustrated by one of the Fig. 1 to 11.

[0188] Fig. Figure 17a shows a state in which there is no rotation of the carrier foil segments 31 and 32 relative to each other. The joint 10 is designed in such a way that a rotation around the point P2 is possible, as shown by the Fig. 17b and Fig. 17c is further illustrated. Fig. 17c is an enlarged view of the section with the joint 10. The point P2 thus represents in particular an axis of rotation about which the carrier film segments 31 and 32 are rotatable, or is encompassed by such an axis of rotation. The separating surfaces 1011 and 1012 are or will be arranged at a distance from one another. The at least one separation 101 of the carrier film segments 31 and 32 is thus designed in particular such that the carrier film segments 31 and 32 do not touch the separating surfaces 1011 and 1012 when there is no rotation. Thus, both a rotation is possible in which the separating surfaces 1011 and 1012 move towards one another starting from a state without rotation and a rotation is possible in which the separating surfaces 1011 and 1012 move away from one another starting from a state without rotation.In other words, the carrier film segments 1011 and 1012 are preferably rotatable in multiple directions starting from a non-rotating state. In addition to rotation, a displacement of the carrier film segments 31 and 32 is also possible.

[0189] The carrier film segments 31 and 32 here have, for example, the thickness d. The at least one separation 101 of the carrier film segments 31 and 32 is present in particular from the point P1 to the point P2 along the thickness d of the carrier film segments 31 and 32. In this case, the at least one separation 101 is formed in particular by a recess which has, for example, a width of d / 2. For this purpose, it is possible, for example, to apply the carrier film segments 1011 and 1012 to the application surface 6 separately at a distance from one another before the heating wire 2 and optionally the further wires are applied, or to apply a continuous carrier film to the application surface 6 and to remove areas with the distance before or after the heating wire 2 and optionally the further wires are / have been applied.

[0190] Fig. 18 now illustrates a rotation of the carrier foil segments 31 and 32, as these lead to Fig. 17, against each other.

[0191] Fig. 18b is an enlarged view of the section with the joint 10 of the Fig. 18a. As an example, a rotation through an angle of approximately 28.65° around the point P2 is illustrated here. Such an angle is particularly achievable when the distance between the carrier foil segments is d / 2, i.e., half the thickness of the carrier foil segments. As shown by Fig. 18, the angle is measured in particular between two lines which each extend along a main surface of the carrier film segments 31 and 32, wherein the main surface does not have the heating wire 2 or is opposite the main surface with the heating wire 2.

[0192] It is advantageously possible to insert the plastic article 1 into a cavity of an injection molding device with such a rotation and to back-inject it from the side with the heating wire 2 or the side opposite the heating wire 2 and thus to further process it into an injection-molded body.

[0193] Preferably, the rotation is in a range from 0° to 90°, more preferably from 70° to 90°, in particular if it is ensured that the necessary spacing of the film segments is provided, such as for the joint 10 of one of the Fig. 17 to 22. Expressed in the negative angle value, for example, a variable and / or fixed angle is possible, in particular in a range from 0° to -90°, preferably from -70° to -90°.

[0194] It is preferred that two or more of the carrier film segments, in particular all carrier film segments, are applied with a spatial separation from one another, in particular wherein the spatial separation forms one or more recesses. It is also conceivable that two or more of the carrier film segments are applied in connected form as one carrier film to the application surface and then a separation into the at least two carrier film segments takes place. The separation can take place in particular by one or more recesses being introduced into the carrier film such that the one or more recesses form the at least one separation of the respective carrier film segments, preferably by a spatial separation of the respective carrier film segments being created at least in some regions.

[0195] Fig. 19 shows a section of a plastic article 1 with the joint 10, as this can be seen in particular from the Fig. 17 and to Fig. 18, except that the distance between the carrier film segments 31 and 32 corresponds to the thickness d of the carrier film segments 31 and 32.

[0196] Fig. 20 now illustrates a rotation of the carrier foil segments 31 and 32, as these Fig. 19, against each other. Fig. Figure 20b shows an enlarged view of the area with the joint 10 of the Fig. 20a. As illustrated by this example, a rotation around the point P2 of approximately 57° is possible.

[0197] Fig. 21 shows a section of a plastic article 1 with the joint 10, as this can be seen in particular from the Fig. 17 and to Fig. 18, except that the distance between the carrier film segments 31 and 32 corresponds to half the thickness d of the carrier film segments 31 and 32 multiplied by π, i.e., π * d / 2. This corresponds to a quarter of the circumference of a circle having a radius equal to the thickness of the carrier film segments.

[0198] Fig. 22 now illustrates a rotation of the carrier foil segments 31 and 32, as these Fig. 21, against each other. Fig. 22b shows an enlarged view of the area with the joint 10 of the Fig. 22a. As illustrated by this example, a rotation of 90° around point P2 is possible. In a plastic article in the form of an injection-molded body in which this angle is fixed, a change in the fixed angle to an angle of 80° to 100°, preferably 85° to 95°, is possible, particularly through elastic deformation.

[0199] The spacings of carrier foil segments 31 and 32 are examples. Depending on the application, other spacings for carrier foil segments 31 and 32 can of course also be selected.

[0200] However, the closer the carrier film segments, such as the carrier film segments 31 and 32, are to one another in a joint, the smaller the angle at which (starting from a state without rotation of the carrier film segments relative to one another) the carrier film segments can be rotated relative to one another in such a way that opposing separating surfaces of the carrier film segments move towards one another and possibly collide with one another.

[0201] Advantageously, at least one joint, such as joint 10 and / or further joints, can thus be optimized according to the degree of deformation during further processing of the plastic article and in the final product.

[0202] The illustrations for the illustration of the plastic article 1 based on the Fig. 1 to 22 are, in particular, merely schematic and not to scale, particularly with regard to depicted dimensions, such as the thickness of the carrier film segments, the at least one heating wire, the at least one further wire, their spacing, or the depth to which the at least one heating wire and / or the at least one further wire are sunk into the at least two carrier film segments. An example of such dimensions may be, in particular, as follows: Width, especially diameter, of the heating wire 2: 70 µm Width, in particular diameter, of the further wire 20 and / or the further wires 21, 22, 23 and / or 24: 120 µm Distance between successive paths of the heating wire 2 and optionally the further wires 21, 22, 23 and / or 24 in a joint, such as joint 10, 11, 12, 13 and / or 14: 2000 µm Distance in the heating region and / or on a heating segment, such as the carrier film segment 31, 34 and / or 35, in a direction of successive paths of the heating wire 2: 0.5 cm. The distance is present in particular at least outside the at least one joint region 100 and optionally also within the at least one joint region 100. Thickness of the at least two carrier film segments, such as the carrier film segments 31, 32, 33, 34, and / or 35: 500 µm The plastic article 1 can, in particular in the heating area, preferably in plan view, for example, have a length and a width of 100 cm and an area of ​​10000 cm 2 In other words, such a length, width and / or area can be exhibited by the totality of all heating segments.

[0203] The at least one heating wire and / or the further wire can partially or completely sink or be sunk into the at least two carrier film segments, for example with a penetration depth in a range of 20% to 100%, in particular 50% to 80%, of its thickness, in particular width and / or its diameter.

[0204] Carrier film segments connected to each other via a joint can be in direct contact with their separating surfaces or can have separating surfaces spaced apart, in particular, where the spacing is, for example, in a range from 0 µm to π * d µm (π = pi, pi number). An example value for such a spacing is 900 µm for a material thickness of 500 µm.

[0205] The joints shown as examples have at least one separation that is straight in plan view. However, it is also conceivable that the at least one separation is curved in plan view, at least in some areas.

[0206] Of course, the listed design variants can be combined with each other as desired and do not represent any limitations. The above-mentioned material characteristics can be used equivalently in a process, or the process characteristics listed can be used in the product. List of reference symbols 1 plastic item 10, 11, 12, 13, 14 joints 100 joint area 101, 102, 103, 104, 105 Separations 1011, 1012 Separation surfaces 2 heating wires 20, 21, 22, 23, 24 more wires 200 contact points 3 Carrier film 30 sub-areas 31, 32, 33, 34, 35 carrier film segments 4 conductive ink layer 5 Contacting element 6 Application interface 60 application plate d Carrier film segment thickness P1, P2 points 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] WO 2020114851 A1

[0002]

Claims

[1] Plastic article (1), in particular in the form of an insert element for back-injection in an injection molding process or an injection-molded body, comprising at least one heating wire (2) and at least two carrier film segments (31, 32, 33, 34, 35), wherein the plastic article (1) has at least one joint (10, 11, 12, 13, 14) which connects the at least two carrier film segments (31, 32, 33, 34, 35) to one another and is formed by at least one separation (101, 102, 103, 104, 105) which partially or completely separates the at least two carrier film segments (31, 32, 33, 34, 35) from each other, and a) the at least one heating wire (2) and / or b) at least one further wire (20, 21, 22, 23, 24), such that the at least two carrier film segments (31, 32, 33, 34, 35) are arranged rotatable and / or rotated relative to one another on the at least one joint (10, 11, 12, 13). [2] Plastic article (1) according to one of the preceding claims characterized by that the at least one separation (101, 102, 103, 104, 105) is formed by separating surfaces (1011, 1012) which are present opposite one another in the at least two carrier film segments (31, 32, 33, 34, 35), preferably without direct local material cohesion, and which separate at least two carrier films (31, 32, 33, 34, 35) in regions or completely and / or is formed by one or more recesses which are present at least in regions or over the entire surface between the at least two carrier film segments (31, 32, 33, 34, 35). [3] Plastic article (1) according to one of the preceding claims characterized by that the at least two carrier film segments (31, 32, 33, 34, 35) have separating surfaces (1011, 1012) with a distance of less than or equal to π d from one another, wherein d corresponds to the respective thickness of the at least two carrier film segments (31, 32, 33, 34, 35). [4] Plastic article (1) according to one of the preceding claims characterized by that the at least two carrier film segments (31, 32, 33, 34, 35) each have the same thickness and / or that the at least two carrier film segments (31, 32, 33, 34, 35) each have the same materials and / or layer composites. [5] Plastic article (1) according to one of the preceding claims characterized by that the at least two carrier film segments (31, 32, 33, 34, 35) each have different thicknesses and / or that the at least two carrier film segments (31, 32, 33, 34, 35) each have different materials and / or different layer composites. [6] Plastic article (1) according to one of the preceding claims, characterized by that the at least two carrier film segments have at least one heating segment (31, 34, 35). [7] Plastic article (1) according to one of the preceding claims, characterized byin that the at least two carrier film segments have at least one supply line segment (32, 33), wherein the at least one supply line segment (32, 33) is encompassed by a contacting element (5) and is connected to the heating segment (31, 34, 35) via a first joint (10) of the at least one joint. [8] Plastic article () according to one of the preceding claims characterized by that the at least one supply line segment has two or more supply line carrier film sub-segments (32, 33) which are connected to one another via one or more second joints (11) of the at least one joint. [9] Plastic article (1) according to one of the preceding claims characterized by that the at least one heating segment has two or more heating carrier film sub-segments (31, 34, 35) which are connected to one another via one or more third joints (12, 13, 14) of the at least one joint. [10] Plastic article (1) according to one of the preceding claims characterized by that the at least two carrier film segments have at least one branch segment which is connected to the at least one heating segment and / or the at least one supply line segment via a fourth joint of the at least one joint, wherein the at least one branch segment has a smaller width than the heating segment and / or supply line segment connected to the branch segment via the one or more fourth joints. [11] Plastic article (1) according to one of the preceding claims characterized by that in the at least one joint (10, 11, 12, 13) the at least one heating wire (2) and / or the at least one further wire (20) overlaps with the at least one separation. [12] Plastic article (1) according to one of the preceding claims, characterized byin that the at least one heating wire (2) and / or the at least one further wire (20, 21, 22, 23, 24) in at least one joint region (200) comprising the at least one joint (10, 11, 12, 13) is applied to the at least two carrier film segments (31, 32, 33, 34, 35) in a shape which is characterized by an increased areal density on the carrier film segments (31, 32, 33, 34, 35). [13] Plastic article (1) according to one of the preceding claims, characterized by in that the at least one heating wire (2) and / or the at least one further wire (20, 21, 22, 23, 24) has a sequence of several tracks, preferably of at least three tracks, in at least one joint region (200) which comprises the at least one joint (10, 11, 12, 13) in a direction which follows the at least one separation (101, 102, 103, 104, 105). [14] Plastic article (1) according to one of the preceding claims characterized bythat in the at least one joint (10, 11, 12, 13) there are three or more tracks which are formed by the at least one heating wire (2) and / or the at least one further wire (20). [15] Plastic article (1) according to one of the preceding claims characterized by that one track or several tracks each extend over two or more joints of the at least one joint (10, 11, 12, 13). [16] Plastic article (1) according to one of the preceding claims characterized by in that two or more of the carrier film segments (31, 32, 33, 34, 35) are encompassed by a continuous carrier film (3) and at least one joint (10, 11, 12, 13), in particular the first joint, has one or more partial regions (30) of the carrier film (3), wherein the partial regions (30) connect the at least two carrier film segments (31, 32, 33, 34, 35), in particular the heating segment and the supply line segment, to one another. [17] Plastic article (1) according to one of the preceding claims characterized by that at least one joint comprising the partial regions (30) connects two carrier film segments to one another, wherein the partial regions (30) are present at least at one edge on these two carrier film segments. [18] Plastic article (1) according to one of the preceding claims characterized by that the at least one joint comprises a further carrier layer which connects the at least two carrier film segments to one another at least in regions. [19] Plastic article (1) according to one of the preceding claims characterized by that the at least one heating wire (2) and / or the at least one further wire (20) does not overlap with the one or more partial regions (30). [20] Plastic article (1) according to one of the preceding claims, characterized bythat the at least one further wire has a material and / or a cross-section identical to the at least one heating wire. [21] Plastic article (1) according to one of the preceding claims, characterized by that the at least one further wire has a different material and / or different cross-section from the at least one heating wire. [22] Plastic article (1) according to one of the preceding claims, characterized by that the at least one joint has one or more conductive layers, in particular one or more conductive lacquer layers (4). [23] Plastic article (1) according to one of the preceding claims, characterized by that the at least one joint has one or more conductive layers, in particular one or more conductive lacquer layers (4), which are completely and / or partially galvanically reinforced. [24] Plastic article (1) according to one of the preceding claims, characterized bythat the plastic article has on a first side a carrier component made of a plastic injection molding compound and / or on a second side a second carrier component made of a plastic injection molding compound, wherein the second side is preferably opposite the first side. [25] Plastic article (1) according to one of the preceding claims, characterized by that the plastic injection molding compound of the first carrier component and / or the second carrier component overlaps the at least one joint and / or the at least one heating wire and / or the at least one further wire of the at least one joint at least partially or completely. [26] Plastic article (1) according to one of the preceding claims, characterized bythat the at least two carrier film segments together with the at least one heating wire and optionally the at least one further wire are fixed by means of the first carrier component and / or the second carrier component and / or in at least one joint region (200) which comprises the at least one joint, are at least partially more curved than in one or more regions without the at least one joint, which are preferably directly adjacent to the joint region (200). [27] Method for producing a plastic article (1), in particular according to one of the preceding claims, comprising the following steps, in particular with the specified order of several or all of the following steps: - Providing and / or producing at least two carrier film segments (31, 32, 33, 34, 35); - applying at least one heating wire (2) to the at least two carrier film segments (31, 32, 33, 34, 35) and optionally applying at least one further wire (20, 21, 22, 23, 24) to the at least two carrier film segments, such that the plastic article (1) has at least one joint (10, 11, 12, 13, 14) which connects the at least two carrier film segments (31, 32, 33, 34, 35) to one another and is formed by at least one separation (101, 102, 103, 104, 105) which partially or completely separates the at least two carrier film segments from one another, and by a) the at least one heating wire (2) and / or b) the at least one further wire (20, 21, 22, 23, 24), such that the at least two carrier film segments (31, 32, 33, 34, 35) are or will be arranged rotatable and / or rotated relative to one another on the at least one joint (10, 11, 12, 13, 14). [28] Method according to one of the preceding claims, characterized by that the procedure includes the following step: Providing an application surface (6) and applying the at least two carrier film segments (31, 32, 33, 34, 35) to the application surface (6). [29] Method according to one of the preceding claims, characterized by that one or more of the at least two carrier film segments (31, 32, 33, 34, 35), in particular all carrier film segments, are applied separately without material cohesion, in particular are applied to the application surface (6). [30] Method according to one of the preceding claims, characterized by that two or more of the at least two carrier film segments (31, 32, 33, 34, 35), in particular all carrier film segments, are applied with a spatial separation from one another. [31] Method according to one of the preceding claims, characterized bythat two or more of the at least two carrier film segments (31, 32, 33, 34, 35) are applied in a connected form as a carrier film (3) to the application surface (6) and then the carrier film (3) is separated into the at least two carrier film segments (31, 32, 33, 34, 35). [32] Method according to one of the preceding claims, characterized by that the at least two carrier film segments (31, 32, 33, 34, 35) together with the at least one heating wire (2) and / or the at least one further wire (20, 21, 22, 23, 24) are back-injected on a first side with a first carrier component made of a plastic injection-molding compound and / or on a second side with a second carrier component made of a plastic injection-molding compound, wherein the second side is preferably opposite the first side. [33] Method according to one of the preceding claims, characterized bythat the plastic injection molding compound of the first carrier component and / or the second carrier component overlaps the at least one joint (10, 11, 12, 13, 14), preferably all joints, and / or the at least one heating wire (2) and / or the at least one further wire (20, 21, 22, 23, 24) of the at least one joint (10, 11, 12, 13, 14), preferably all joints, at least in regions or completely. [34] Method according to one of the preceding claims, characterized byin that for the back-injection molding of the first side and / or the second side, the at least two carrier film segments (31, 32, 33, 34, 35) together with the at least one heating wire (2) and / or the at least one further wire (20, 21, 22, 23, 24) are arranged on a wall with a preferably curved shape in a cavity of an injection molding tool and are then back-injected to obtain the first and / or second carrier component, wherein during the arrangement on the wall and / or during the back-injection molding, a deformation of the at least one heating wire (2) and / or the at least one further wire (20, 21, 22, 23, 24) of the at least one joint (10, 11, 12, 13, 14), preferably of all joints, takes place in accordance with the preferably curved shape of the wall. [35] Method according to one of the preceding claims, characterized bythat before or during the back-injection of the first side and / or the second side, the at least two carrier film segments (31, 32, 33, 34, 35) are rotated against each other.

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