Method for producing a partially translucent exterior trim part for a vehicle having at least one masking layer

Abstract

The invention relates to a method for producing a partially translucent exterior trim part for a vehicle, said exterior trim part having at least one masking layer (1), wherein the masking layer (1) is applied to a thin-walled base component (2) at least partially defining the geometry of the exterior trim part, wherein the base component (2) has an outer side (A) that is visible in its intended use and a rear side opposite the outer side (A), wherein the base component (2) is primary formed in an injection molding tool (3) by means of an injection molding process, wherein the injection molding tool (3) has at least two mold halves (3a, 3b) that, in the closed state, form a cavity (4) defining the base component (2) between them, wherein the method comprises the following sequence of steps: primary forming of the base component (2) by introducing at least one plastic material (K) forming the base component (2) into the cavity (4),wherein the at least one plastic material comprises a transparent or translucent polymer material, in particular polycarbonate (PC), or polypropylene (PP) or polymethyl methacrylate (PMMA) or acrylonitrile-butadiene-styrene copolymer (ABS) or polycarbonate-acrylonitrile-butadiene-styrene copolymers (PC-ABS copolymers), solidifying the plastic material (K), partially or completely opening the tool halves (3a, 3b) so that at least a partial area (5) of the surface of the primary molded base component (2) becomes freely accessible, wherein the base component (2) is further fixed in position by at least one of the tool mold halves (3a) and / or by at least one ejector integrated in at least one of the tool mold halves (3a), applying the masking layer (1) to the partial area (5) of the base component (2) by means of a coating process, while the base component (2) remains in or on the tool mold half (3a) is fixed in position,Structuring or perforating or partially removing the masking layer (1) by means of high-energy laser radiation (L), while the base component remains fixed in position in or on the mold half (3a), complete demolding and removal of the base component (2) from the injection molding tool (3).

Description

The present invention relates to a method for producing a partially translucent exterior panel part for a vehicle, which exterior panel part has at least one masking layer, wherein the masking layer is applied to a thin-walled base component, which at least partially defines the geometry of the exterior panel part, wherein the base component has an outer side that is visible in the intended use and a rear side opposite the outer side, wherein the base component is primary-molded in an injection mold by means of an injection molding process, wherein the injection mold has at least two mold halves, which in the closed state form a cavity defining the base component between them.In methods known from the prior art, the application of the at least one masking layer to the base component takes place after the latter has been produced in an injection molding method. For this purpose, the basic component must be taken up again in painting racks and supplied to painting lines in additional method steps. A subsequent processing of the masking layer in order to make it partially translucent is generally also carried out in a further, separate processing station.These additional method steps are time-consuming and therefore cost-intensive.The invention therefore addresses the problem of specifying a method having the features described at the beginning which, compared with the prior art, enables the quicker and more cost-effective production of a component for a vehicle which has at least one masking layer.According to the invention, this object is achieved by the following process:Method for producing a partially translucent exterior cladding part for a vehicle, which has at least one masking layer, wherein the masking layer is applied to a thin-walled base component, which at least partially defines the geometry of the exterior cladding part, wherein the base component has an outer side visible in the intended use and a rear side opposite the outer side, wherein the base component is primary-formed in an injection mould by means of an injection moulding process, wherein the injection mould has at least two mould halves, which in the closed state form a cavity defining the base component between them, wherein the method has the following step sequence:molding the base component by inserting at least one plastic material forming the base component into the cavity, wherein the at least one plastic material comprises a transparent or translucent polymer material, in particular polycarbonate (PC), or polypropylene (PP) or polymethyl methacrylate (PMMA) or acrylonitrile butadiene styrene copolymer (ABS) or polycarbonate acrylonitrile butadiene styrene copolymers (PC-ABS copolymers),solidifying the plastic material,partially or completely opening the tool halves, so that at least a partial area of the surface of the primary-formed base component becomes freely accessible, wherein the base component is in this case further positionally fixed by at least one of the tool mold halves and / or by at least one ejector integrated in at least one of the tool mold halves,applying the masking layer to the partial region of the base component by means of a coating method, while the base component is still fixed in position in or on the mold half,structuring or perforating or partially removing the masking layer (1) by means of high-energy laser radiation (L), while the base component is still fixed in position in or on the tool mold half,complete demolding and removal of the base component (2) from the injection molding tool (3).The integration of the coating method and the processing of the masking layer by means of laser radiation within the process sequence of injection molding makes it possible to specify an efficient and more cost-effective production of an outer cladding part.The ink jet printer head can be moved over the portion of the base member during the application of the masking layer.The laser radiation can be directed over the masking layer by means of a reflection mirror. Alternatively, the laser radiation can be irradiated onto the masking layer by means of a laser radiation emitter, wherein the laser beam emitter is moved over the partial region of the base component (e.g. by means of a robot or a linear displacement unit). The laser beam emitter can be moved by means of a manipulator in front of the partial region of the basic component and can be moved there in all spatial directions.The coating method can comprise, for example, an inkjet printing method, wherein at least one liquid or pulverulent pigment ink or at least one liquid or pulverulent dye ink is applied to the partial region by means of an inkjet printer head, wherein the inkjet printer head is moved over the partial region of the base component during the application of the masking layer.As possible alternatives, the coating method can also comprise a film application method or a method for applying a lacquer layer, in particular a spray lacquer method or a pad printing method.Parallel to or after the step of applying the masking layer, a simultaneous or subsequent curing and / or solidification of the masking layer can be provided, wherein the curing and / or solidification takes place partially or completely, wherein the curing and / or solidification is enabled and / or accelerated in particular by an additional energy supply.It is possible in particular to use UV-curing lacquers (i.e. lacquers which cure by ultraviolet light) as a base for the lacquer layer or the liquid pigment ink or the liquid dye ink. In the case of using an ink jet printing method, at least one UV light source may then be coupled to the ink jet print head. Further preferably, in each direction of movement (in particular in the forward and rearward direction) of the inkjet print head, a UV light source arranged to run in the respective direction of movement is located on the inkjet print head.The masking layer may be formed by a plurality of individual layers or may be formed therein. This means that the masking layer can be constructed in particular from at least two or more individual layers.The masking layer may be applied in a plurality of adjacent tracks. The masking layer consequently does not necessarily have to be applied to the partial region of the base component in one pass, but can be applied, for example, in a plurality of tracks. The adjacent webs can also overlap in their edge regions.During the step of molding the base component, at least one further plastic material can be introduced into the cavity, which material forms the base component together with the at least one plastic material. The further plastic material can form, for example, a mounting or fastening or sealing element.After the step of applying the masking layer, the mold halves can be closed again around the base component provided with the masking layer and a sealing material, in particular a sealing material comprising polyurea or polyurethane, can subsequently be arranged on the masking layer and / or the base component. For this purpose, the tool mold halves are not completely closed, so that an intermediate space is formed between one of the tool mold halves and the base component, which is filled with the sealing material.After the step of applying the masking layer, one of the tool mold halves can be closed together with a replaceable tool mold half around the base component provided with the masking layer and a sealing material, in particular a sealing material comprising polyurea or polyurethane, can subsequently be arranged on the masking layer and / or the base component.During the step of molding the base component, at least one insert part arranged in the cavity can be back-injected, injection-molded or over-injected with the plastic material. The insert part can be a decorative film and / or a functional film. In the case of a functional film, the functional film can have at least one heating wire or at least one antenna wire or at least one electrical circuit or at least one light-emitting diode.The exterior panel may be, for example, a bumper panel or a grille panel or a fender panel or an A, B, C or D pillar panel or a spoiler exterior skin or a sill panel or a door exterior panel or a door flap exterior panel or a front mask.The exterior panel may form a component of a bumper cladding or a grille cladding or a fender cladding or an A, B, C or D pillar cladding or a spoiler exterior skin or a sill cladding or a door exterior cladding or a door flap exterior cladding or a front mask.A front mask is that part of a vehicle in place of which the grille has been located in combustion vehicles. In particular in electric vehicles, this front mask is no longer designed as an air inlet to the radiator (which is no longer present here), but rather is provided as a design element in the vehicle center.Furthermore, part of the invention is an exterior cladding part which is produced by the method described above.The invention is explained below with reference to drawings which merely represent exemplary embodiments. They show schematically: FIGS. 1 and 2 show method steps of the primary component being initially formed; FIG. 3 shows a method step of opening the tool halves and applying the masking layer; FIG. 4 shows a method step of structuring or perforating or partially removing the masking layer; FIG. 5 shows a method step of demolding the base component; FIG. 6 shows a partially translucent outer cladding part; FIGS. 7 and 8 show a variant of the method.In the figures, identical or functionally identical elements are provided with the same reference numerals.FIGS. 1 to 5 describe a method for producing a partially translucent exterior panel part for a vehicle, which exterior panel part has at least one masking layer.The masking layer 1 is applied to a thin-walled base component 2 which at least partially defines the geometry of the outer cladding part. The base component 2 has an outer side A that is visible in the intended use and a rear side opposite the outer side A (cf. FIG. 6 ).The base component 2 is primary-molded in an injection mold 3 by means of an injection molding process, wherein the injection mold 3 has at least two mold halves 3 a, 3 bwhich, in the closed state, form a cavity 4 defining the base component 2 between them (cf. FIG. 1 ).The method has the following step sequence:hydroformylation of the base component 2 by introducing at least one plastic material K forming the base component 2 into the cavity 4, wherein the at least one plastic material comprises a transparent or translucent polymer material, in particular polycarbonate (PC), or polypropylene (PP) or polymethyl methacrylate (PMMA) or acrylonitrile-butadiene-styrene copolymer (ABS) or polycarbonate-acrylonitrile-butadiene-styrene copolymers (PC-ABS copolymers), (cf. FIG. 2 ),solidifying the plastic material K cf. FIG. 2,partially or completely opening the tool halves 3 a, 3 b,so that at least a partial region 5 of the surface of the primary-formed basic component 2 becomes freely accessible, wherein the basic component 2 is in this case also fixed in position by at least one of the tool mold halves 3 aand / or by at least one ejector integrated in at least one of the tool mold halves 3 a(cf. FIG. 3 ),structuring or perforating or partially removing the masking layer 1 by means of high-energy laser radiation L, while the basic component is still fixed in position in or on the tool mold half 3 a(cf. FIG. 4 ),complete demolding and removal of the base component 2 from the injection molding tool 3 (cf. FIG. 5 ).The laser radiation L can be directed over the masking layer 1 by means of a reflection mirror. In the present exemplary embodiment, the laser radiation L is radiated onto the masking layer 1 by means of a laser radiation emitter 10, wherein the laser beam emitter 10 is moved over the partial region 5 of the basic component 2.The coating method, not shown in detail, can comprise an inkjet printing method, wherein at least one liquid or pulverulent pigment ink or at least one liquid or pulverulent dye ink is applied to the partial region 5 by means of an inkjet printer head, wherein the inkjet printer head is moved over the partial region 5 of the base component 2 during the application of the masking layer 1. Further coating methods can comprise, for example, a film application method or a method for applying a lacquer layer, in particular a spray lacquer method or a pad printing method.FIGS. 7 and 8 show, as a variant, that after the step of applying the ink layer 1, one of the tool mold halves 3 atogether with a replaceable tool mold half 7 is closed around the base component 2 provided with the laser-coated masking layer 1, and subsequently a sealing material 6, in particular a sealing material comprising polyurea or polyurethane, is arranged on the masking layer 1 and / or the base component 2.As a variant of the method, at least one further plastic material can be introduced into the cavity during the step of molding the base component 2, which plastic material forms the base component 2 together with the at least one plastic material.In the step of molding the base component 2, at least one insert part arranged in the cavity 4 can be back-injected, injection-molded or over-molded by the plastic material as a variant. The insert part can be a decorative film and / or a functional film. In the case of a functional film, the functional film can have at least one heating wire or at least one antenna wire or at least one electrical circuit or at least one light-emitting diode.The exterior panel is a bumper panel or a grille panel or a fender panel or an A, B, C or D pillar panel or a spoiler exterior skin or a sill panel or a door exterior panel or a door flap exterior panel or a front mask.The exterior panelling part can also form a component of a bumper cladding or a grille cladding or a fender cladding or an A, B, C or D pillar cladding or a spoiler outer skin or a sill cladding or a door outer cladding or a door flap outer cladding or a front mask.

Claims

Method for producing a partially translucent outer cladding part for a vehicle, which outer cladding part has at least one masking layer (1), wherein the masking layer (1) is applied to a thin-walled base component (2) at least partially defining the geometry of the outer cladding part, wherein the base component (2) has an outer side (A) visible in the intended use and a rear side opposite the outer side (A), wherein the base component (2) is primary-formed in an injection mould (3) by means of an injection moulding process, wherein the injection mould (3) has at least two mould halves (3a, 3b) which, in the closed state, form between them a cavity (4) defining the base component (2), characterized in that, the method having the following step sequence: - forming the base component (2) by introducing at least one plastic material (K) forming the base component (2) into the cavity (4), wherein the at least one plastic material comprises a transparent or translucent polymer material, in particular polycarbonate (PC), or polypropylene (PP) or polymethyl methacrylate (PMMA) or acrylonitrile-butadiene-styrene copolymer (ABS) or polycarbonate-acrylonitrile-butadiene-styrene copolymers (PC-ABS copolymers), - solidifying the plastic material (K), - partially or completely opening the mold halves (3a, 3b), so that at least one partial region (5) of the surface of the formed base component (2) becomes freely accessible, wherein the base component (2) is in this case also positionally fixed by at least one of the tool mold halves (3a) and / or by at least one ejector integrated in at least one of the tool mold halves (3a), - applying the masking layer (1) to the partial region (5) of the base component (2) by means of a coating method, while the base component (2) is still positionally fixed in or on the tool mold half (3a), - structuring or perforating or partially removing the masking layer (1) by means of high-energy laser radiation (L), while the base component is still positionally fixed in or on the tool mold half (3a), - completely removing the base component (2) from the injection mold (3).Method according to Claim 1, characterized in that the laser radiation (L) is directed via the masking layer (1) by means of a reflection mirror or in that the laser radiation (L) is radiated onto the masking layer (1) by means of a laser radiation emitter (10), wherein the laser beam emitter (10) is moved over the subregion (5) of the basic component (2).Method according to Claim 1 or 2, characterized in that the coating method comprises an inkjet printing method, wherein, in order to form the masking layer (1), at least one liquid or pulverulent pigment ink or at least one liquid or pulverulent dye ink is applied to the subarea (5) by means of an inkjet printer head, wherein the inkjet printer head is moved over the subarea (5) of the base component (2) during the application of the masking layer (1).Method according to claim 1 or 2, characterised in that the coating method comprises a film application method or a method for applying a lacquer layer, in particular a spray lacquer method or a pad printing method.Method according to one of the preceding claims, characterized in that during the step of moulding the base component (2) at least one further plastic material is introduced into the cavity, which material forms the base component (2) together with the at least one plastic material.Method according to one of the preceding claims, characterized in that after the step of structuring or perforating or partially removing the masking layer (1), the tool mould halves (3a, 3b) are closed again around the base component (2) and subsequently a sealing material (6) comprising sealing material (6), in particular polyurea or polyurethane, is arranged on the masking layer (1) and / or the base component (2), or in that after the step of applying the masking layer (1), one of the tool mould halves (3a) is closed together with a changing tool mould half (7) around the base component (2) provided with the masking layer (1) and subsequently a sealing material (6), in particular polyurea or polyurethane, comprising sealing material (6), on the masking layer (1) and / or the base component (2).Method according to one of the preceding claims, characterized in that, during the step of moulding the basic component (2), at least one insert part arranged in the cavity (4) is injection-moulded, injection-moulded or injection-moulded from the plastics material.Method according to claim 7, characterised in that the insert part is a decorative film and / or a functional film.Method according to Claim 8, characterized in that the functional film has at least one heating wire or at least one antenna wire or at least one electrical circuit or at least one light-emitting diode.Method according to one of the preceding claims, characterized in that the component is an outer cladding part of a vehicle, in particular a bumper cladding or a grille cladding or a fender cladding or an A, B, C or D pillar cladding or a spoiler outer skin or a sill cladding or an outer door cladding or an outer door flap cladding or a front mask, or forms a constituent part of a bumper cladding or a grille cladding or a fender cladding or an A, B, C or D pillar cladding or a spoiler outer skin or a sill cladding or an outer door cladding or an outer door flap cladding or a front mask.

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