Method for producing at least one component by means of an injection molding device and injection molding device for carrying out the method

Abstract

The invention relates to a method for producing at least one component (10) by means of an injection molding device (12) with the steps A to U and an injection molding device (12) for carrying out the method.

Description

BACKGROUND OF THE INVENTIONThe present invention relates to a method for producing at least one component by means of an injection-molding device and to an injection-molding device for carrying out this method.It is known to produce multi-component components which, among other things, have a film by injection molding, wherein the films are for this purpose back-injected and / or over-injected with injection molding material.The film can be, in particular, a film designed as a design film, which is provided as an outer film or as a film, forming an outer layer, of the respective multicomponent component or article. In other applications, such a film, which is generally formed from a plastic material, can also be provided to mechanically reinforce or also to protect the component. Components are also known in which the film is designed as a heating film which is connected to a respective plastic core of the component. In the injection-molding production of such components, a plurality of injection-molding materials are generally used to form the desired multicomponent component. The injection molding process or the respective injection molding method is very complicated, in particular if, depending on the application, more than two different injection molding materials are to be injected into the respective cavities of the respective injection mold up to the respective final mold for forming corresponding preforms. It is known to use an injection molding tool with a so-called indexable insert technique for the injection molding production of such components or articles, in which two tool halves connected to one another are rotatable about an axis of rotation in order to form the cavities of the respective preforms or end mold, in such a way that in each case one of the two tool halves can be turned towards one of two further tool halves by rotation. Thus, by appropriate rotation, the cavities required for producing the multicomponent component can be formed by connecting the respective tool halves to form a closed tool. The use of such a turning plate technique is technically very complicated and also cost-intensive. The device to be used in each case is then always a special machine in the form of a indexable insert machine with a high space requirement. In this special machine, two complete injection molds are very expensively required. Furthermore, such a special machine can only be used with additional effort for other standard injection molding tools. For this purpose, the indexable insert must be removed or a "dummy tool" ("dummy tool") suspended in the respective parting plane.Underlying TaskThe object of the present invention is therefore to specify a method with which at least one multicomponent component with at least one film can be produced with substantially less outlay than the known solutions, and to specify an injection molding apparatus for carrying out this method.Solution according to the inventionThis object is achieved according to the invention by a method having the features of claim 1 and by an injection molding device having the features of claim 9.The method according to the invention is a method for producing at least one component or for producing at least one multicomponent component having at least one film by means of an injection molding device. This injection molding device has a tool or an injection molding tool with a first tool part and a second tool part.The first tool part or the first tool half of the tool has a first forming region and a second forming region.The second tool part or the second tool half has a third forming region and a fourth forming region.The second tool part is rotatable into a first rotational position and into a second rotational position, or the second tool part is rotatable relative to the first tool part into a first rotational position and into a second rotational position.The tool can be transferred from an open tool state to a closed tool state and can be transferred back from the closed tool state to the open tool state. As is known from injection molding apparatuses, the tool can be closed, in particular by moving the first tool part toward the second tool part or by moving the second tool part toward the first tool part, or can be transferred from the opened tool state into the closed tool state. Furthermore, as is known from injection molding apparatuses, the tool can be opened or transferred back into the opened tool state, in particular by moving the first tool part away from the second tool part or by moving the second tool part away from the first tool part. It is also understood that the tool can be transferred from the open tool state to the closed tool state, in particular by moving the two tool parts towards one another, and can be transferred from the closed tool state back to the open tool state, in particular by moving the two tool parts away from one another.The first mold region and the third mold region form a first cavity in the closed tool state and the second mold region and the fourth mold region form a second cavity in the closed tool state when the second tool part is in the first rotational position. The first cavity and the second cavity-into which injection molding materials respectively provided for the respective formation of the preforms or end shape of the component to be produced are to be injected-can thus be formed in that the tool is transferred into the closed tool state when the second tool part is arranged in the first rotational position. The first rotational position is thus the rotational position in which the formation of the first and the second cavity is possible by closing the tool.The first mold region and the fourth mold region form a third cavity in the closed tool state and the second mold region and the third mold region form a fourth cavity in the closed tool state when the second tool part is in the second rotational position. The third cavity and the fourth cavity-into which injection molding materials respectively provided for the respective formation of the preforms or end shape of the component to be produced are to be injected-can thus be formed in that the tool is transferred into the closed tool state when the second tool part is arranged in the second rotational position. The second rotational position is thus the rotational position in which the formation of the third and the fourth cavity is possible by closing the tool.The second tool part is rotatable into the first rotational position and the second rotational position. It is understood that the first and the second rotational position can be transformed into one another by rotating through an angle of 180 degrees or by rotating through an angle of substantially 180 degrees. In other words, the second tool part is rotatable from the first rotational position into the second rotational position by rotating by an angle of 180 degrees or by rotating by an angle of substantially 180 degrees. Furthermore, the second tool part is rotatable from the second rotational position into the first rotational position by rotating by an angle of 180 degrees or by rotating by an angle of substantially 180 degrees. It should be appreciated that the rotational distance between the first and second rotational positions is 180 degrees and substantially 180 degrees, respectively, to provide the formation of the first, second, third and fourth cavities by the four mold regions as set forth above. (Note potthast: this has also clarified my daily question-without this restriction to 180 degrees, the method is certainly not realizable.)It is also understood that the second tool part is rotatable about an axis of rotation by at least 180 degrees in order to form the above-described rotation capability, wherein the second tool part is preferably rotatable about this axis of rotation by more than 180 degrees. Particularly preferably, the second tool part is rotatable 360 degrees about this axis of rotation.In a particularly practical manner, the rotation of the second tool part about the axis of rotation can be realized in that the second tool part is connected in a rotationally fixed manner to a rotatable plate which is rotatable through 360 degrees in the injection molding tool. In the technical jargon, such a rotatable disk is also called a turntable.The above mold regions, of which two can form one of the above cavities in each case, can be in particular regions or formations or recesses or recesses or elements or structures of the respective tool part, which form part of the respective cavity into which the respective injection molding material is injected in order to form a corresponding preform or end shape of the component to be produced.The method according to the invention is a method for producing at least one component by means of an injection molding device, or the method according to the invention is a method for producing at least one component by means of an injection molding device, three injection molding materials comprising a first injection molding material, a second injection molding material and a third injection molding material and at least one film.The method according to the invention comprises the following steps: (A) transferring the tool (14) into the open state or leaving the tool (14) in the open state, (B) at least partially arranging at least one film (24, 25) in the second mould region (200) and / or the fourth mould region (400), (C) rotating the second tool part (18) into the first rotational position (20) or leaving the second tool part (18) in the first rotational position (20), (D) transferring the tool (14) into the closed state and injecting a first injection moulding material (26) into the second mould region (200) and / or the fourth mould region (400) for forming a first preform (30) of a component (10) to be produced or a first preform (30) of the first component (10) to be produced, respectively, in which the film (24) is connected to the first injection-molding material (26), (E) transferring the tool (14) into the open state and leaving the first preform (30) of the component (10) produced in step D in the fourth molding region (400), (F) rotating the second tool part (18) into the second rotational position (22), (G) transferring the tool (14) into the closed state, (H) injecting a second injection-molding material (27) or the second injection-molding material (27) into the third cavity (3) to form a second preform (32) of the component (10), (I) transferring the tool (14) into the open state and leaving the second preform (32) of the component (10) produced in step H in the first molding region (100), (J) rotating the second tool part (18) into the first rotational position (20), (K) if a further component (10) is to be produced, continuing the method to step L, otherwise continuing the method to step R, (L) at least partially arranging at least one further film or at least one film (24, 25) in the second molding region (200) and / or the fourth molding region (400), (M) transferring the tool (14) into the closed state and injecting the first injection molding material (26) into the second molding region (200) and / or the fourth molding region (400) in order to form the first preform (30) of a further component (10) to be produced, in which the film (24) is connected to the first injection molding material (26), (N) injecting a third injection molding material (28) or the third injection molding material (28) into the first cavity (1) to form the final mold (36) of the component (10), (O) transferring the tool (14) into the open state, (P) removing the final mold (36) of the component (10) formed in the first cavity (1) in step N from the tool (14) and leaving the first preform (30) of the further component (10) produced in step M in the fourth mold region (400), (Q) continuing the method with step F, (R) transferring the tool (10) into the closed state, (S) injecting a third injection molding material or the third injection molding material into the first cavity (1) to form the final mold (36) of the component (10), (T) transferring the tool (14) into the open state, and (U) removing the end shape (36) of the component (10) from the tool (14) or removing the end shape (36) of the component (10) formed in the first cavity (1) in step S from the tool (14).Steps P and U therefore result in the removal of the final form or of the finished component which is a multicomponent component having at least one film.A flow chart for illustrating the sequence of the individual steps is shown in FIG. 3.By carrying out the above steps, at least one component in the form of a multicomponent component having at least one film or at least one article in the form of a multicomponent article having at least one film can be produced with substantially less outlay in comparison with the known solutions-in which a indexable insert technique is used in a very complicated manner. In contrast to the known use of indexable insert technology, which makes it necessary, among other things, to provide two complete injection molds in a very complicated manner, a single injection mold with a significantly smaller space requirement, which corresponds to the space requirement of a standard injection molding machine, is sufficient for carrying out the method according to the invention.The method according to the invention enables the production of one or more components. If only a single component is to be produced which, after passing through the provided steps, is a multicomponent component with at least one film, the method according to the invention according to step K is intended to continue with step R or with step R. If a plurality of components are to be produced, provision is made according to step K for the method to be continued at step L or with step L. With the query at step K, the method can be completed after already completed removal of several end molds or finished components by continuing with step R and forming the end mold of a last component (step S) and removing the last component (step U) accompanying this.It is understood that by naming the steps with the letters A to U, a binding to a temporal sequence is not to be understood throughout. For example, step C may also be performed before step B. However, step O, for example, is obviously absolutely necessary to perform after step N in time, since this is not possible in a technically different manner.It is understood that the injection molding material to be injected in the corresponding steps (i.e., in steps D, H, N and S) is present during injection in a liquid state suitable for forming the respective preform or final mold, which the person skilled in the art provides for the component to be produced in each case. The same also applies to the temperatures and pressures of the injection molding materials, in particular during the injection.In step B, the at least one film is arranged at least partially in the second mold region and / or the fourth mold region, whereby step D is prepared, in which, among other things, the first injection molding material is injected into the second mold region and / or the fourth mold region to form the first preform. Depending on the application, the film can in particular also be arranged only partially in the second mold region and / or the fourth mold region, namely in particular when the film is to be fixed in the second mold region and / or the fourth mold region for injection molding with the plastic material, which can be carried out by the film being clamped between the two tool parts when the tool is transferred into the closed state. This may in turn make it necessary to provide suitable edge regions for clamping, which in the clamped state are arranged outside the second mold region and / or the fourth mold region. However, partial arrangement is not obligatory. It is also conceivable to arrange the film completely or entirely in the second forming region and / or the fourth forming region. If it is necessary to fix the film locally when the film is completely arranged in the second forming region and / or the fourth forming region, this can also be effected in a known manner by the film being sucked onto the first and / or second tool part via provided suction ducts.Also in step L, at least partial arrangement of at least one film or at least one further film in the second mold region and / or the fourth mold region takes place, wherein here too partial or complete arrangement of the film in the second mold region and / or the fourth mold region can be carried out, as already explained above for step B.Steps D and M each involve the formation of the first preform of a component to be produced or of a further or next component to be produced, in which the film is connected to the first injection-molding material. It is understood that this connection of the film to the first injection molding material effected by the injection of the first injection molding material can have one of numerous configurations that are possible by injection molding. Thus, in the case of the first preform, the film can be bonded to an outer surface of an injection-molded body made of the first injection-molding material in a materially integral manner, which can be achieved by injection molding behind it. Typical technical applications here are films in the form of so-called decorative films which, in the component to be produced or in the multicomponent component to be produced, are connected in a planar manner as an outer layer to the injected body made of the first injection-molding material. However, it is also conceivable, for example, for the film to be at least partially enclosed or accommodated in the injection-molded body as a reinforcing film-which is provided for increasing the mechanical strength. This can be done in steps D and M by injection molding around the film.In steps D and M, the injection of the first injection molding material can take place temporally in particular in each case after the transfer of the tool into the closed state. In this case, the injection therefore takes place into the second cavity, which is present in the closed tool state.In a particularly preferred embodiment of the method according to the invention, however, in steps D and M the injection of the first injection molding material for injection-embossing the first preform of the component can be carried out during the transfer of the tool into the closed state. Thus, an injection-stamping of the first preform can advantageously take place, whereby a uniformly built-up closing pressure can be realized during the closing of the tool. By injection-stamping, the first preform of the component can be produced very accurately, that is to say with only a very slight deviation from the respective desired shape, in particular even if the first preform is to be formed very large.In a practical embodiment of the method according to the invention, in step B and / or in step L a single film is at least partially arranged in the second mold region or the fourth mold region, wherein in step D and / or in step M the film is injection-molded by injecting the first injection molding material into the fourth mold region or the second mold region. With this practical embodiment, multicomponent components can be produced in which the film can be an outer layer of the component. The film can be, for example, a decorative film or a heating film which is present on the respective component as an outer film.In a further practical embodiment of the method according to the invention, in step B and / or in step L a first film is arranged at least partially in the second molding region and a second film is arranged at least partially in the fourth molding region, wherein in step D and / or in step M the first injection molding material is injected between the first film and the second film. With this practical embodiment too, multi-component components can be produced in which the two films can be outer layers of the component. Each of the two films can be, for example, a decorative film or a heating film which is present on the respective component as an outer film.Particularly preferably, the foils in steps B and L can be foils of identical construction, provided that a plurality of components of identical construction are to be produced by means of the method according to the invention.The at least one film in step B and / or the at least one film in step L can be a heating film or a decorative film or a reinforcing film or a structured film or generally a technical film. (Note Potthast: it would be possible here to further elaborate, where appropriate, on the material of which the film is composed, where appropriate, also to show more details of the dimensioning and the technical properties of the film(s))Particularly preferably, the first injection molding material is polycarbonate, the second injection molding material is a mixture of polycarbonate and ABS (abbreviation for acrylonitrile butadiene styrene) and the third injection molding material is polyurethane. By means of this combination of the injection-molded materials, in particular the following motor vehicle components can be produced very precisely by means of the method according to the invention: bumpers, front panels, rear panels, side panels, BDHs, and headlights (note potfast: this could optionally be carried out in even greater detail, in particular in greater detail, which is to be understood by BDHs and which components of the headlight are meant here)The component that can be produced by means of the method according to the invention can be, in particular, a front panel for a motor vehicle or a rear panel for a motor vehicle or a side panel for a motor vehicle or a bumper for a motor vehicle. (Note Potthast: There are also, if so, German language terms for the "panels"?)The injection molding device according to the invention for carrying out the above method according to the invention comprises a tool having a first tool part and a second tool part, wherein the first tool part has a first molding region and a second molding region, wherein the second tool part has a third molding region and a fourth molding region, wherein the second tool part is rotatable into a first rotational position and into a second rotational position, wherein the tool can be transferred from an open tool state into a closed tool state and can be transferred back from the closed tool state into the open tool state, wherein the first molding region and the third molding region form a first cavity in the closed tool state and the second molding region and the fourth molding region form a second cavity in the closed tool state when the second tool part is in the first rotational position, and wherein the first mold region and the fourth mold region form a third cavity in the closed tool state and the second mold region and the third mold region form a fourth cavity in the closed tool state when the second tool part is in the second rotational position.DESCRIPTION OF THE FIGURESExemplary embodiments of the invention are explained in more detail below with reference to the attached figures. In the figures, the following shows: FIG. 1 shows a schematic illustration of an injection molding device of the prior art, FIGS. 2A, 2B are schematic representations of a first exemplary embodiment of an injection molding device according to the invention, FIG. 3 shows a flow chart for illustrating the sequence of the individual method steps of the method according to the invention, FIG. 4 shows three schematic representations, partially in section, of the two tool parts of the injection molding device according to FIGS. 2A and 2B, FIG. 5 shows four schematic representations, partially in section, of the two tool parts of the injection molding device according to FIGS. 2A and 2B to illustrate method steps of a first exemplary embodiment of the method according to the invention, FIG. 6 shows three partially cut schematic representations of the two tool parts of the injection molding device according to FIGS. 2A and 2B to illustrate method steps of the first exemplary embodiment of the method according to the invention, FIG. 7 shows three partially cut schematic representations of the two tool parts of the injection molding device according to FIGS. 2A and 2B to illustrate method steps of the first exemplary embodiment of the method according to the invention, FIG. 8 shows three partially cut schematic representations of the two tool parts of the injection molding device according to FIGS. 2A and 2B to illustrate method steps of the first exemplary embodiment of the method according to the invention, FIG. 9 shows two schematic representations, partially in section, of the two tool parts of the injection molding device according to FIGS. 2A and 2B to illustrate method steps of the first exemplary embodiment of the method according to the invention, FIG. 10 shows a very schematic illustration of a second exemplary embodiment of an injection molding device according to the invention, FIGS. 11 to 18 are respectively very schematic plan views of the two tool parts of the injection molding device according to FIG. 10 together with respectively very schematic representations for illustrating method steps of a second exemplary embodiment of the method according to the invention, and FIG. 19 is a schematic illustration to illustrate an alternative method step,The injection molding device 50 of the prior art with a turning plate technique, schematically illustrated in FIG. 1, comprises two interconnected tool halves 46 or tool parts 46, which are rotatable about a vertical axis of rotation 51 by means of the mold regions 48 in order to form the cavities of the respective preforms or end mold, in such a way that in each case one of the two interconnected tool halves 46 can be turned towards one of two further tool halves 46 (outer left and outer right) by rotation. The injection molding apparatus 50 of the related art further includes two injection units 40 and 44 and a PUR mixing head 42 for providing and injecting three different injection molding materials.The injection molding device 12 according to the invention according to FIGS. 2A and 2B according to the first exemplary embodiment has a tool 14 with a first tool part 16 and a second tool part 18. FIG. 2B shows a schematic three-dimensional representation of the tool 14 with the tool parts 16 and 18.The first tool part 16 has a first molding region 100 and a second molding region 200 (cf. FIG. 2B ).The second tool part 18 has a third molding region 300 and a fourth molding region 400.The second tool part 18 is rotatable 360 degrees about a horizontal axis of rotation 19, so that the second tool part 18 is rotatable into a first rotational position 20 and into a second rotational position 22 (see also the representations of FIG. 4 for the rotational positions). The two rotational positions can be transferred into one another by a rotation through a rotational angle of substantially 180 degrees, so that the third mold region 300 is arranged at the top in FIG. 2B in the first rotational position and the fourth mold region 400 is arranged at the bottom in the first rotational position 400. In the second rotational position, the third mold region 300 is arranged at the bottom in FIG. 2B and the fourth mold region 400 is arranged at the top in the second rotational position in FIG. 2B. The ability of the second tool part 18 to rotate about the axis of rotation 19 is realized in that the second tool part 18 is connected in a rotationally fixed manner to a rotatable plate 52, which is rotatable through 360 degrees in the injection molding device 12. In the technical jargon, such a rotatable disk 52 is also called a turntable 52.The injection molding apparatus 12 also has two platens 8 and 9, the first die 16 being fixedly attached to the platen 8. The rotary plate 52-to which the second tool part 18 is connected in a rotationally fixed manner-is mounted on the clamping plate 9 such that it can rotate 360 degrees in order to form the rotation about the axis of rotation 19.The injection molding apparatus 12 further includes two injection units 40 and 44 and a PUR mixing head 42 for providing and injecting three different injection molding materials 26, 27 and 28 including polycarbonate 26 as a first injection molding material from the injection unit 40, a mixture of polycarbonate and ABS as a second injection molding material 27 from the injection unit 44, and PUR (abbreviation for polyurethane including polyol and polyisocyanate as major components) as a third injection molding material 28 from the mixing head 42.As schematically illustrated by dashed arrows in FIG. 2A, the tool 14 is transferable from an open tool state to a closed tool state and is transferable back from the closed tool state to the open tool state.As can be seen from the middle illustration of FIG. 4 (FIG. 4 shows three partially cut schematic illustrations of the two tool parts 16 and 18 of the injection molding device 12 according to FIGS. 2A and 2B ), the first mold region 100 and the third mold region 300 form a first cavity 1 in the closed tool state and the second mold region 200 and the fourth mold region 400 form a second cavity 2 in the closed tool state when the second tool part 18 is in the first rotational position 20.As can be seen from the lower illustration of FIG. 4, the first mold region 100 and the fourth mold region 400 form a third cavity 3 in the closed tool state and the second mold region 200 and the third mold region 300 form a fourth cavity 4 in the closed tool state when the second tool part 18 is in the second rotational position 22.In FIG. 4, the upper view illustrates the opened tool state.FIGS. 5 to 9 illustrate, in conjunction with the flow chart or with the flow chart according to FIG. 3, individual method steps of the first exemplary embodiment of the method according to the invention for producing one or more multicomponent components 10 having the final shape 36 comprising a film 24 in the form of a reinforcing film 24 (cf. also FIGS. 8 and 9 below, illustrated only very schematically). This component 10 is a polygonal component 10 which has the reinforcing film 24 a base body 53 formed from the first injection-molded material 26 (polycarbonate), a first outer layer 54 formed from the second injection-molded material 27 (mixture of polycarbonate and ABS), and a second outer layer 55 formed from the third injection-molded material 28 (PUR).In the representations of FIGS. 5 to 9, the respective injection ducts 56 are illustrated in the form of dashed lines 56. Horizontal arrows illustrate the injection of the corresponding injection molding material.The method according to the first exemplary embodiment comprises the following steps: (A) transferring the tool (14) into the open state or leaving the tool (14) in the open state, (B) completely arranging the reinforcing film 24 in the fourth molding region 400, (C) rotating the second molding part 18 into the first rotational position 20 or leaving the second molding part 18 in the first rotational position 20, (D) transferring the tool 14 into the closed state and injecting the first injection molding material 26 into the second molding region 200 to form a first preform 30 of the first component 10 to be produced, in which the film 24 is connected in a planar manner to the first injection molding material 26, wherein the film 24 is injection-molded behind during the injection of the first injection molding material 26, (E) transferring the tool 14 into the open state and leaving the first preform 30 of the component 10 produced in step D in the fourth molding region 400, (F) rotating the second tool part 18 into the second rotational position 22, (G) transferring the tool 14 into the closed state, (H) injecting the second injection molding material 28 into the third cavity 3 to form a second preform 32 of the component 10, (I) transferring the tool 14 into the open state and leaving the second preform 32 of the component 10 produced in step H in the first molding region 100, (J) rotating the second tool part 18 into the first rotational position 20, (K) if a further component 10 is to be produced, continuing the method to step L, Otherwise, the method continues with step R, (L) complete arrangement of a further reinforcing film 24 in the fourth mold region 400, (M) transfer of the tool 14 into the closed state and injection of the first injection molding material 26 into the second mold region 200 to form the first preform 30 of the further or next component 10 to be produced, in which the film 24 is connected to the first injection molding material 26, wherein the film 24 is injection-molded from behind during the injection of the first injection molding material 26, (N) injection of the third injection molding material 28 into the first cavity 1 to form the final mold 36 of the component 10, (O) transfer of the tool 14 into the open state, (P) removing the final mold 36 of the component 10 formed in the first cavity 1 in step N from the tool 14 and leaving the first preform 30 of the further or next component 10 produced in step M in the fourth mold region 400, (Q) continuing the method with step F, (R) transferring the tool 10 into the closed state, (S) injecting the third injection molding material 28 into the first cavity 1 to form the final mold 36 of the component 10, (T) transferring the tool 14 into the open state, and (U) removing the final mold 36 of the component 10 from the tool 14.In this first exemplary embodiment, in steps D and M, the injection of the first injection-molding material 26 for injection-embossing the first preform 30 of the component 10 is carried out during the transfer of the tool 14 into the closed state. In the corresponding representation of FIG. 5 (cf. second representation from above for step D) and FIG. 8 (cf. uppermost representation for step M), this is illustrated by the horizontal dashed-line file.In an alternative method, for forming an alternative first preform 30', provision could also be made, in step B and in step L, for a first reinforcing film 24' to be arranged completely or completely in the second mold region 200 and a second reinforcing film 24" to be arranged completely or completely in the fourth mold region 400, wherein in step D and in step M the first injection-molding material 26 is injected between the first reinforcing film 24' and the second reinforcing film 24" during injection-stamping. This is shown very schematically in Figure 19, which illustrates the situation for step D. FIG. 19 also shows the alternative first preform 30' resulting from this injection-stamping with the reinforcing films 24' and 24".The second exemplary embodiment of an injection molding device 12 according to the invention according to FIG. 10 differs from the first exemplary embodiment according to FIGS. 2A and 2B in that here the mold regions 100, 200, 300 and 400 are configured to form a component which is a multi-component front panel for a motor vehicle reinforced with a film or the final mold thereof to be produced is a multi-component front panel for a motor vehicle reinforced with a film. The shaped regions 100, 200, 300 and 400 are only shown very schematically in dashed lines in FIG. 10. In addition, the injection molding device according to FIG. 10 is also dimensioned differently from the injection molding device according to FIG. 2A. With the injection molding device 12 according to FIG. 10, the front panel can be produced according to the second exemplary embodiment of the method according to the invention described below. The method steps of this second embodiment.Apart from the differently configured injection molding device 12 and the different configuration of the film provided in steps B and L, the exemplary embodiment corresponds to the method steps of the above first exemplary embodiment. The film 24 provided here in each case is also a reinforcing film 24, which is provided for the mechanical reinforcement of the front panel.The second exemplary embodiment of the method according to the invention is described below with reference to FIGS. 11 to 18, which illustrate selected method steps. FIGS. 11 to 18 show, inter alia, very schematic plan views of the two tool parts 16 and 18 of the injection molding device 12 according to FIG. 10.Thus, FIG. 11 illustrates the situation of step D in the closed tool state, namely before the injection of the first injection-molded material 26. (Note Potthast: In FIG. 11 and also in further figures, two straight vertical elements with circular ends can be seen in each case. If necessary, one could briefly explain for which these vertical elements are provided).FIG. 12 illustrates the situation after step D and before the opening according to step E with the first preform 30 already present.FIG. 13 illustrates the situation during the rotation according to step F into the second rotational position 22, Here, the tool 14 is in the open state and the first preform 30 has been left in the fourth forming region 400, as provided in step E.FIG. 14 illustrates the situation after the injection of the second injection molding material 27 according to step H into the third cavity formed by the rotation in step F and before the opening according to step I. The formed second preform 32 schematically illustrated in FIG. 14 has a peripheral region 58 formed by the injection of the second injection molding material 27 (mixture of PC and ABS).FIG. 15 illustrates the turning according to step J into the first rotational position 20.If the query according to step K reveals that a further or next component is to be produced, the method is continued with step L; otherwise, the method is continued with steps R, S and T and is ended in step U with the removal of the final form 36 or the finished component 10 from the tool 14.FIG. 16 illustrates the situation of step M with the tool state closed and before injection. The further or next reinforcing film 24, as provided in step L, is already arranged here completely in the fourth forming region 400.FIG. 17 illustrates on the right the situation after step M and before step N with the second preform 32 and the first preform 30 and on the left the situation after step N with the final mold 36 and the first preform 30. the injection of the third injection-molding material PUR in step N serves in particular for the further shaping of the edge region 58.FIG. 18 schematically illustrates step P with the removal of the final mold 36 or of the finished component 10 from the tool 14.List of reference characters1 First cavity 2 Second cavity 3 Third cavity 4 Fourth cavity 8 Clamping plate 9 Clamping plate 10 Component 12 Injection molding device 14 Tool 16 First tool part 18 Second tool part 19 Axis of rotation 20 First rotational position 22 Second rotational position 24 Film 24' Film 24" Film 26 First injection molding material 27 Second injection molding material 28 Third injection molding material 30 First preform 30' Alternative first preform 32 Second preform 36 Final mold 40 Injection unit PC 42 Mixing head PUR 44 Injection unit PC / ABS 46 Tool part St.d.T. 48 Mold region St.d.T. 50 Injection molding device St.d.T. 51 Axis of rotation 52 Rotary plate 53 Base body 54 First outer layer 55 Second outer layer 56 Injection channel 58 Edge region 100 First mold region 200 Second mold region 300 Third mold region 400 fourth molding region

Claims

Method for producing at least one component (10) by means of an injection-molding device (12), wherein the injection-molding device (12) has a tool (14) having a first tool part (16) and a second tool part (18), wherein the first tool part (16) has a first molding region (100) and a second molding region (200), wherein the second tool part (18) has a third molding region (300) and a fourth molding region (400), wherein the second tool part (18) is rotatable into a first rotational position (20) and into a second rotational position (22), wherein the tool (14) can be transferred from an open tool state into a closed tool state and can be transferred back from the closed tool state into the open tool state, wherein the first mold region (100) and the third mold region (300) form a first cavity (1) in the closed tool state and the second mold region (200) and the fourth mold region (400) form a second cavity (2) in the closed tool state when the second tool part (18) is in the first rotational position (20), wherein the first mold region (100) and the fourth mold region (400) form a third cavity (3) in the closed tool state and the second mold region (200) and the third mold region (300) form a fourth cavity (4) in the closed tool state when the second tool part (18) is in the second rotational position (22), wherein the method comprises the following steps: (A) transferring the tool (14) into the open state or leaving the tool (14) in the open state, (B) at least partially arranging at least one film (24, 25) in the second mold region (200) and / or the fourth mold region (400), (C) rotating the second mold part (18) into the first rotational position (20) or leaving the second mold part (18) in the first rotational position (20), (D) transferring the mold (14) into the closed state and injecting a first injection molding material (26) into the second mold region (200) and / or the fourth mold region (400) to form a first preform (30) of a component (10) to be produced, in which the film (24) is connected to the first injection molding material (26), (E) transferring the mold (14) into the open state and leaving the first preform (30) of the component (10) produced in step D in the fourth mold region (400), (F) rotating the second tool part (18) into the second rotational position (22), (G) transferring the tool (14) into the closed state, (H) injecting a second injection molding material (27) or the second injection molding material (27) into the third cavity (3) to form a second preform (32) of the component (10), (I) transferring the tool (14) into the open state and leaving the second preform (32) of the component (10) produced in step H in the first molding region (100), (J) rotating the second tool part (18) into the first rotational position (20), (K) if a further component (10) is to be produced, continuing the method to step L, otherwise continuing the method to step R, (l) at least partially arranging at least one further film (24, 25) in the second molding region (200) and / or the fourth molding region (400), (M) transferring the tool (14) into the closed state and injecting the first injection molding material (26) into the second molding region (200) and / or the fourth molding region (400) to form the first preform (30) of a further component (10) to be produced, in which the film (24) is connected to the first injection molding material (26), (N) injecting a third injection molding material (28) or the third injection molding material (28) into the first cavity (1) to form the final mold (36) of the component (10), (O) transferring the tool (14) into the open state, (P) removing the final mold (36) of the component (10) formed in the first cavity (1) in step N from the tool (14) and leaving the first preform (30) of the further component (10) produced in step M in the fourth mold region (400), (Q) continuing the method with step F, (R) transferring the tool (10) into the closed state, (S) injecting a third injection molding material (28) or the third injection molding material (28) into the first cavity (1) to form the final mold (36) of the component (10), (T) transferring the tool (14) into the open state, and (U) removing the final mold (36) of the component (10) from the tool (14).Method according to Claim 1, characterized in that, in steps D and M, the injection of the first injection-moulding material (26) for injection-stamping the first preform (30) of the component (10) is carried out during the transfer of the tool (14) into the closed state.Method according to claim 1 or 2, characterised in that in step B and / or in step L a single film (24) is at least partially arranged in the second mould region (200) or the fourth mould region (400), wherein in step D and / or in step M the film (24) is injection-moulded by injection of the first injection-moulding material (26) into the fourth mould region (400) or the second mould region (200).Method according to Claim 1 or 2, characterized in that in step B and / or in step L a first film (24') is arranged at least partially in the second moulding region (200) and a second film (24") is arranged at least partially in the fourth moulding region (400), wherein in step D and / or in step M the first injection moulding material (26) is injected between the first film (24') and the second film (24").Method according to one of the preceding claims, characterized in that the films (24, 25) in steps B and L are identically constructed films (24, 25).Method according to one of the preceding claims, characterized in that the at least one film (24, 25) in step B and / or the at least one film (24, 25) in step L is a heating film or a decorative film or a reinforcing film.Method according to one of the preceding claims, characterized in that the first injection-moulding material (26) is polycarbonate, in that the second injection-moulding material (27) is a mixture of polycarbonate and ABS, and in that the third injection-moulding material (28) is polyurethane.Method according to one of the preceding claims, characterized in that the component (10) is a front panel for a motor vehicle or a rear panel for a motor vehicle or a side panel for a motor vehicle or a bumper for a motor vehicle.Injection molding device (12) for carrying out a method according to one of Claims 1 to 8, comprising a tool (14) having a first tool part (16) and a second tool part (18), wherein the first tool part (16) has a first molding region (100) and a second molding region (200), wherein the second tool part (18) has a third molding region (300) and a fourth molding region (400), wherein the second tool part (18) is rotatable into a first rotational position (20) and into a second rotational position (22), wherein the tool (14) can be transferred from an open tool state into a closed tool state and can be transferred back from the closed tool state into the open tool state, wherein the first mold region (100) and the third mold region (300) form a first cavity (1) in the closed tool state and the second mold region (200) and the fourth mold region (400) form a second cavity (2) in the closed tool state when the second tool part (18) is in the first rotational position (20), and wherein the first mold region (100) and the fourth mold region (400) form a third cavity (3) in the closed tool state and the second mold region (200) and the third mold region (300) form a fourth cavity (4) in the closed tool state when the second tool part (18) is in the second rotational position (22).

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