METHOD FOR MANUFACTURING A COMPONENT AND DEVICE FOR MANUFACTURING A COMPONENT

Description

[0001] The invention relates to a method for manufacturing a component and a device for manufacturing a component.

[0002] It is known to manufacture plastic components using injection molding in an injection molding machine. Such plastic components are used, for example, in automotive manufacturing for interior parts such as door trim, instrument panel trim, and center console panels; in consumer electronics for decorative trim on televisions; in telecommunications for housings of portable devices such as mobile phones; and in the security sector.

[0003] The production of such plastic components using a manufacturing process known as "in-mold decoration" is described, for example, in document DE 10 2010 020 039 A1. In this process, a transfer film is used to produce a plastic component. This transfer film is fed from top to bottom through an injection mold and clamped between the mold halves when the mold is closed. During the injection of the molten metal, the pressure of the melt presses the transfer film against the wall of a cavity. After cooling, the polyester backing film of the transfer film is then peeled away from the component decorated with the transfer layer of the transfer film.

[0004] However, a disadvantage here is the sensitivity of the plastic component decorated in this way with regard to further transport and processing of this plastic component.

[0005] While it is known to apply a protective coating to plastic components to shield them from external influences, this is typically done in flood coating units, which are often located a considerable distance from the injection molding machine. To apply a protective coating to the plastic components produced in the injection molding machine, they must be transported in packaging that protects their delicate surface to a flood coating unit for the coating process. This elaborate and generally non-eco-friendly packaging is associated with significant costs and time expenditure.

[0006] DE 10 2010 019 625 A1 describes a method for producing a composite or hybrid structure.

[0007] EP 1 655 122 A1 describes a method for back injection, back pressing or flow embossing and a corresponding molding tool.

[0008] US 2007 / 0184273 A1 describes an overmolding of inserts.

[0009] DE 10 2018 113 194 A1 describes a method and a plant for the production of a decorative component, as well as a decorative component.

[0010] DE 10 2004 041 833 A1 describes a decorated injection-molded article, a method for producing a decorated injection-molded article and a transfer film for use in such a method.

[0011] It is therefore an object of the present invention to provide an improved method for manufacturing a component and an improved device for manufacturing a component.

[0012] The problem is solved by a method for manufacturing a component according to claim 1.

[0013] Furthermore, this problem is solved by a device for manufacturing a component according to claim 9.

[0014] Investigations have shown that it is possible to move the upper tool carrier with a first upper tool module of a first workstation within the device in such a way that a second upper tool module can be combined with a first lower tool module to form a second workstation. In this process, a component produced in a first manufacturing step in the first workstation can remain in the first lower tool module. For example, the first workstation can be configured as an injection molding station and the second workstation as a flood molding station. In this case, the part produced in the injection molding station remains in the first lower tool module, while the first workstation is disassembled by moving the upper tool carrier with the first upper tool module, and the second upper tool module is combined to form the second workstation.This significantly increases the utilization rate and thus the profitability of the workstations, ideally doubling it.

[0015] The invention now makes it possible to protect the environment and reduce process costs: studies have shown that the part produced in the first workstation does not need to be removed from the device and therefore does not need to be transported to another device. This also eliminates the economically and ecologically disadvantageous packaging of the parts for transport to the next device.

[0016] Preferably, at least one upper tool carrier of the at least one upper tool carrier can be moved relative to at least one lower tool carrier of the at least one lower tool carrier.

[0017] The term "method" here preferably refers to a change in the position and / or orientation of at least one element, preferably along at least one direction in space, particularly relative to a predetermined reference system, and / or relative to the position and / or orientation of at least one further element, preferably along at least one further direction and / or the at least one direction, in particular wherein the at least one element and / or the at least one further element are selected and / or combined from: upper tool carrier, lower tool carrier, upper tool module, lower tool module. For example, the element or elements can be translated and / or rotated, particularly about a point and / or axes or several points and / or axes in space.

[0018] The at least one upper and / or lower tool support can be, for example, a concrete floor, in particular a reinforced concrete floor, a metal structure, a crane, one or more robot arms and / or a combination thereof.

[0019] Advantageous embodiments of the invention are described in the dependent claims.

[0020] The first upper tool module of the at least two upper tool modules of the at least one upper tool carrier and the at least one first lower tool module of the at least one lower tool module of the at least one lower tool carrier are combined in the at least one predetermined position such that one or more workstations of the one or more workstations are formed as an injection molding station comprising an injection mold, wherein the injection mold has the first upper tool module and the first lower tool module, wherein the first upper tool module has a first upper mold half with at least one first upper mold cavity, and the first lower tool module has a first lower mold half with at least one first lower mold cavity.

[0021] The procedure further comprises the following steps, in particular in the following sequence: a) Closing the injection mold comprising the first upper mold half with the at least one first upper mold cavity, and the first lower mold half with the at least one first lower mold cavity, wherein at least one first injection cavity defined by the first upper mold cavity and the first lower mold cavity is formed; b) Injection molding at least one base body by introducing a first plastic material into the at least one first injection cavity; c) Opening the injection mold, wherein the at least one base body remains contour-following in the at least one first lower or first upper mold cavity and only at least a first partial area of ​​one or more surfaces of the at least one base body is exposed, wherein at least a second partial area of ​​the surface of the base body remains in the first upper or lower mold cavity.d) Demolding of the component comprising at least one base body from the first upper or lower tool cavity or tool mold half.

[0022] It is further possible that before step a) and / or d) the following additional step is carried out once or several times: a1) Inserting one or more insert elements into the at least one first injection molding cavity and / or onto at least one exposed first partial area of ​​the surface of the at least one base body, wherein the at least one base body remains contour-following in the at least one first upper or first lower mold cavity of the first upper or first lower mold half.

[0023] The terms "inserting" and / or "inserting" are preferably understood to mean the insertion of individual elements such as sheets, labels or the like, and / or the feeding of continuous elements such as webs, strips, threads or the like.

[0024] Preferably, in step d) the base body comprises one or more or all of the insert elements.

[0025] After step d), in particular between steps a) and b) and / or b) and c), the following further step is carried out once or several times: e) Application of at least a first cover layer made of a second plastic material by flooding onto at least a partial area of ​​the surface of the at least one base body.

[0026] It is advantageous to apply the first cover layer in such a way that the one or more insert elements are encapsulated between the at least one base body and the at least one first cover layer. This encapsulation makes it possible to protect the insert elements effectively from environmental influences or to achieve particularly advantageous optical and / or functional effects through the resulting interactions.

[0027] It is also possible that during the execution of step e) at least one basic body remains contour-following in the first upper or first lower tool cavity of the first upper or first lower tool mold half.

[0028] In carrying out step e), at least a second injection molding cavity is formed by means of one or more further upper mold halves of the at least two upper mold modules of the at least one upper mold carrier or one or more further lower mold halves of the at least one lower mold module of the at least one lower mold carrier by sealing the one or more further upper or lower mold halves against the at least one base body, the optional one or more insert elements or the first upper or lower mold half, and the second plastic material is introduced into the at least one second injection molding cavity.

[0029] In particular, the following step is performed once or multiple times between steps b), c) and / or d) and / or between steps d) and e): Pretreatment of at least one exposed first sub-area of ​​the surface of at least one base body, in particular by one or more processing methods and / or combinations of one or more processing methods selected from: gassing, flame treatment, plasma treatment, fluorination, irradiation, cleaning, surface activation, coating.

[0030] It is possible that between steps c), d) and / or e) at least an optical inspection of at least a partial area of ​​the surface of the at least one base body, the one or more insert elements, and / or the component is carried out by means of an optical sensor or several optical sensors, in particular one or more cameras.

[0031] It is also possible that after step c) or d) and / or between steps d) and e) and / or after step e) the following step is carried out: Cleaning, especially using brushes and / or compressed air and / or suction.

[0032] Furthermore, it is possible that one or more insert elements of the one or more insert elements in step a1) are used as a transfer foil, in particular a cold stamping foil, comprising a carrier layer and a transfer layer that can be removed from it, an adhesive layer is applied to the transfer layer and / or to at least a partial area of ​​the surface of the at least one base body, in particular by means of an inkjet printhead, in at least a first area, but is not applied in at least a second area, the transfer foil is guided against the one or more surfaces of the at least one base body by means of the stamping tool, the adhesive layer is activated and the transfer foil is then peeled off the transfer layer adhering to the base body, so that a section of the transfer layer determined by the shaping of the first area is applied as the one or more insert elements.

[0033] Furthermore, it is possible that one or more insert elements of the one or more insert elements in step a1) are used as a transfer foil, in particular a hot stamping foil, preferably comprising a carrier layer and / or a transfer layer removable from it with an adhesive layer, in particular wherein the transfer foil is pressed against the one or more surfaces of the at least one base body by means of a heated embossing tool, in particular wherein the adhesive layer and the release layer of the transfer foil are activated and in particular wherein the transfer foil is subsequently peeled off from the transfer layer adhering to the base body, in particular wherein a section of the transfer layer determined by the shaping of the embossing tool is applied as the one or more insert elements.

[0034] Furthermore, it is also possible that one or more of the following further steps and / or that at least a combination of one or more of the following one or more steps are carried out, in particular selected from: printing, in particular inkjet printing and / or pad printing, labeling, in particular affixing labels, applying and / or marking lasers, lasers, in particular ablation or material removal and / or blackening and / or color change, preferably of laser-sensitive layers or areas of the component and / or the base body, cold stamping, hot stamping, thermal transfer, preferably wherein these steps are carried out in particular before and / or after the demolding of the component and / or the at least one base body and / or the component comprising the at least one base body, preferably before and / or after step d), further preferably before and / or after the demolding station,and / or in particular before and / or after flooding, preferably before and / or after step e).

[0035] Preferably, when stamping one or more insert elements, especially when using a hot stamping foil, a section of a transfer layer determined by the shaping of the stamping tool is applied as an insert element by activating an adhesive layer of the transfer layer or an adhesive layer provided between the base body and the transfer layer.

[0036] Furthermore, it is advantageous, particularly when using a cold stamping foil, to apply an adhesive layer to the carrier layer and / or to a partial area of ​​the base body's surface in a third area, but not to apply it in a fourth area. Using an embossing tool, the transfer foil is then guided against the surface of the base body, the adhesive layer is activated, and the transfer foil is removed. In particular, a section of the transfer layer defined by the shape of the third area is applied to the base body as an insert element. The adhesive layer is preferably applied using a digital printing process, especially an inkjet printhead.

[0037] Furthermore, it is possible that further steps are carried out after demolding or after demolding the component and / or the at least one base body and / or the component comprising the at least one base body, wherein one or more of the further steps are preferably selected from: assembly with functional elements, in particular assembly with printed circuit boards and / or electronic components and / or mechanical components and / or fastening elements, coating, in particular coating with adhesive and / or with further, preferably different, functional layers, installation and / or attachment to and / or into further, in particular different, bodies and / or base bodies, preferably bodies of all kinds.

[0038] Preferably, before step a), one or more further insert elements are placed into the at least one first injection molding cavity, in particular into the first upper and / or first lower mold half, and in step b) are back-injected and / or overmolded with the first plastic material.

[0039] Preferably, in carrying out step a1), one or more insert elements of the one or more insert elements are inserted with register accuracy to one or more further insert elements of the one or more further insert elements and / or with register accuracy to the contour of the first upper and / or first lower tool cavity, in particular wherein one or more register marks or optical features of the one or more further insert elements and / or the first upper and / or first lower tool cavities or tool mold halves are detected and used to control the insertion.

[0040] Register, register accuracy, register alignment, or positional accuracy refers specifically to the positional accuracy of two or more elements and / or layers relative to each other. The register accuracy should preferably fall within a predefined tolerance and be as high as possible. At the same time, the register accuracy of multiple elements and / or layers relative to each other is a particularly important characteristic for increasing process reliability. Precise positioning is achieved, in particular, by means of sensory, preferably optically detectable, register marks or position markers. These register marks or position markers either represent specific separate elements, areas, or layers, or are themselves part of the elements, areas, or layers to be positioned.

[0041] Preferably, one or more insert elements of the one or more insert elements and / or one or more further insert elements of the one or more further insert elements are a laminating film preferably in a partial surface form, for example as a "label", or a so-called "insert" as a pre-formed partial element, in particular provided with decorative and / or functional elements, and / or an insert part, in particular as a functional reinforcing or stiffening element made of metal and / or plastic, and / or fiber composite material and / or plastic with fiber components, and / or a transfer film.

[0042] It is possible that, prior to step a), closing the injection mold, one or more insert elements and / or one or more further insert elements are placed into the at least one first injection mold cavity. For this purpose, the one or more insert elements and / or the one or more further insert elements are placed, preferably as individual elements, into the first lower and / or first upper mold half and / or fed in the form of a film web.

[0043] Furthermore, it is possible that a first group of one or more insert elements and / or one or more further insert elements of the one or more further insert elements are inserted into at least one upper tool mold half and / or tool cavity of the at least one upper tool mold half and / or tool cavity, in particular the first upper tool mold half and / or the first upper tool cavity, and / or that a second group of one or more insert elements and / or one or more further insert elements of the one or more further insert elements are inserted into at least one lower tool mold half and / or tool cavity of the at least one lower tool mold half and / or tool cavity, in particular the first lower tool mold half and / or the first lower tool cavity.

[0044] This makes it possible to achieve a "double-sided" decoration of at least one base body and / or component, or to apply the desired functional layers to both sides of the component. For example, the underside of at least one base body and / or component is formed by one or more insert elements and / or further insert elements of the first group of insert elements and / or further insert elements, while on the top side of at least one base body and / or component, one or more insert elements and / or further insert elements of the second group of insert elements and / or further insert elements form the top side of at least one base body and / or component.

[0045] The component and / or at least one base body can preferably be designed to be opaque, translucent, or transparent, in particular to provide different optical appearances of the component.

[0046] Preferably, the term "opaque" is understood to mean a transparency, particularly in the wavelength range visible to humans, of less than 50%, especially less than 20%, preferably less than 5%.

[0047] Preferably, the term "transparent" is understood to mean a transparency, particularly in the wavelength range visible to humans, of at least 50%, in particular of more than 50%, preferably of more than 75%.

[0048] If the component and / or at least one base body is, for example, transparent, the decoration on both sides can create an optical depth effect by spacing them apart using the wall thickness of the component and / or the base body. For this purpose, the thickness of the base body is preferably chosen such that the one or more insert elements and / or further insert elements of the first group of insert elements and / or further insert elements, on the one hand, and the one or more insert elements and / or further insert elements of the second group of insert elements and / or further insert elements, on the other hand, are spaced apart from each other in such a way that an optical depth effect is generated by the interaction of the one or more insert elements and / or further insert elements of the first and / or second group of insert elements and / or further insert elements.

[0049] If the component and / or at least one base body is, for example, opaque, the double-sided decoration can provide a different visual appearance of the component and / or at least one base body from different sides, or vice versa, by means of one or more insert elements and / or further insert elements of the first group of insert elements and / or further insert elements and / or by means of one or more insert elements and / or further insert elements of the second group of insert elements and / or further insert elements.

[0050] The use of one or more insert elements and / or further insert elements from the first group of insert elements and / or further insert elements and / or one or more insert elements and / or further insert elements from the second group of insert elements and / or further insert elements allows, in particular, a combination of decorative and functional films, or vice versa. For example, one side of the component and / or the at least one base body can be decorated, while the other side of the component and / or the at least one base body can have a functional element applied, such as a touch sensor and / or conductive traces and / or an antenna and / or a display.

[0051] The manufacturing process is preferably designed such that one or more first insert elements of the one or more insert elements and / or one or more first further insert elements of the one or more further insert elements, which are preferably more resistant to pressure and / or heat, are used than one or more second insert elements of the one or more insert elements and / or one or more second further insert elements of the one or more further insert elements, or vice versa, and the insert elements and / or further insert elements, which are in particular less resistant to pressure and / or heat than the one or more second insert elements and / or second further insert elements, are used, or vice versa.In this variant, it is possible that one or more third insert elements of the one or more insert elements and / or one or more third further insert elements of the one or more further insert elements are applied to the component and / or the at least one base body as one or more functional elements, and that one or more fourth insert elements of the one or more insert elements and / or one or more fourth further insert elements of the one or more further insert elements are applied to the component as one or more decorative elements, or vice versa.

[0052] Preferably, the manufacturing process is alternatively designed such that one or more fifth insert elements of the one or more insert elements and / or one or more fifth further insert elements of the one or more further insert elements are applied as one or more functional elements to the component and / or the at least one base body, and one or more sixth insert elements of the one or more insert elements and / or one or more sixth further insert elements of the one or more further insert elements are applied as one or more decorative elements to the component and / or the at least one base body, or vice versa.

[0053] It is possible that the first, second, third, fourth, fifth and / or sixth insert elements and / or further insert elements and / or the first and / or the second group of insert elements and / or further insert elements are identical or different from each other.

[0054] It is particularly advantageous that the method allows the one or more first, second, third, fourth, fifth and / or sixth insert elements and / or further insert elements and / or the first and / or the second group of insert elements and / or further insert elements to be arranged relative to each other with particularly high register accuracy.This is because, both during back-injection of the first, second, third, fourth, fifth and / or sixth insert elements and / or further insert elements and / or the first and / or the second group of insert elements and / or further insert elements, as well as during flooding and / or embossing of the first, second, third, fourth, fifth and / or sixth insert elements and / or further insert elements, the at least one base body and / or the component is defined by the at least one upper and / or lower tool cavity of the at least one upper and / or lower mold half, in particular by the first upper and / or lower tool cavity of the first upper and / or lower mold half, and therefore no further registration step is required in this respect.

[0055] In particular, the following step is carried out between steps d) and e) or after step e): f) Applying at least one second top layer to at least a partial area of ​​the surface of the at least one base body.

[0056] In particular, at least one second top layer consists of a third plastic material.

[0057] Preferably, particularly during step f), and especially during the insertion of the one or more insert elements, one or more insert elements are inserted and / or flooded with precise registration to one or more further insert elements. For this purpose, it is advantageous to detect one or more registration marks and / or optical features of the one or more further insert elements and / or the first upper and / or lower mold half and / or the first upper and / or lower mold cavity and to use these for controlling the insertion and / or flooding. Additionally, corresponding registration marks and / or optical features of the insert elements and / or further insert elements can be detected, which are used during the insertion and / or flooding of the one or more insert elements and / or further insert elements, as described above.

[0058] In particular, one or more insert elements of the one or more insert elements and / or one or more further insert elements of the one or more further insert elements are preferably back-injected and / or injection-molded and / or overmolded with the first, second and / or third plastic material in step b).

[0059] Furthermore, it is possible that the one or more insert elements and / or the one or more additional insert elements each have at least one decorative layer and / or at least one functional layer, in particular a layer with an electrical functionality, in particular comprising one or more elements selected from touch sensor, antenna, capacitor, coil, electromagnetic shielding, electrically non-conductive metallic layers, in particular to prevent electrostatic charging, display, LED, electrical circuit, solar cell, at least one protective layer, in particular post-curable, and / or at least one barrier layer and / or at least one adhesion promoter layer or adhesion promoter layer.

[0060] Preferably, at least one decorative layer of the at least one decorative layer consists of one or more or a combination of one or more decorative layers of the following decorative layers: Transparent, translucent, or opaque lacquer layer containing dyes and / or pigments, in particular organic / inorganic pigments, luminescent and / or fluorescent pigments and / or dyes, optically variable pigments, thermochromic pigments and / or dyes, metallic pigments, magnetically alignable pigments, volume hologram layer, layer with optically active surface relief, in particular a diffractive and / or refractive surface relief, a holographic surface relief, a surface relief containing refractive structures, diffractive structures, in particular lens structures, microlens arrangements, microprisms, micromirrors, matte structures, in particular isotropic and / or anisotropic matte structures and / or a combination of any such structures; reflective layers, in particular metallic or dielectric reflective layers;High-refractive-index or low-refractive-index layers, in particular with refractive indices that differ by more than + / - 0.2 from a refractive index of 1.5; liquid crystal layers, in particular cholesteric and / or nematic liquid crystal layers; thin-film layers exhibiting an optically variable color-changing effect, in particular comprising an absorber layer, a dielectric spacer layer and an optional reflective layer or alternatively comprising a multiple sequence of alternating high-refractive-index and low-refractive-index transparent layers.

[0061] It is possible for these decorative layers to be applied in any sequence, either on top of or next to each other. In particular, each individual decorative layer is partially designed in a patterned form, preferably to achieve a desired graphic decoration. The decorative layers are preferably arranged in register relative to each other.

[0062] At least one functional layer of the at least one functional layer preferably consists of one or more or a combination of one or more functional layers of the following functional layers: Layers with electrical functionality, in particular comprising one or more elements selected from: touch sensor, antenna, electromagnetic shielding, electrically non-conductive metallic layers to prevent electrostatic charging, display, LED (LED = Light Emitting Diode), electrical circuit, solar cell, layer with magnetic functionality, for example a magnetic barcode, layers with mechanical functionality, for example reinforcing or stiffening elements made of metal and / or plastic and / or woven and / or non-woven fiber layers and / or fibrous additives and / or fibrous additional layers, layers with optical functionality, for example anti-reflective or reflective layers, layers with tactile functionality, for example soft-touch surface coatings.

[0063] It is also possible that the first upper and / or first lower tool mold half is rotated and / or moved and / or repositioned between the execution of steps a1) and b), steps a) and b) and / or steps d) and e).

[0064] According to the invention, a second upper tool module of the at least two upper tool modules of the at least one upper tool carrier and the first lower tool module of the at least one lower tool module of the at least one second tool carrier are combined in the at least one predetermined position such that one or more workstations of the one or more workstations are designed as a flooding station comprising the second upper tool module and the first lower tool module, in particular wherein the second upper tool module is a first upper flooding half and / or the first lower tool module is the second tool mold half with the second tool cavity.

[0065] It is particularly advantageous to apply at least one second cover layer in such a way that the one or more insert elements are encapsulated between the at least one base body and the at least one second cover layer. This encapsulation makes it possible to protect the insert elements effectively from environmental influences or to achieve particularly advantageous optical and / or functional effects through the resulting interactions.

[0066] In particular, it is possible that the at least one first cover layer, preferably according to step e), is applied to at least a partial area of ​​the surface of the at least one base body, but no second cover layer, preferably according to step f), is applied to the at least a partial area of ​​the surface of the at least one base body or vice versa.

[0067] Preferably, the at least one first covering layer is applied, preferably according to step e), to one or more first partial areas of the surface of the at least one base body, and the at least one second covering layer is applied, preferably according to step f), to one or more second partial areas of the surface of the at least one base body, in particular wherein the at least one first covering layer in the first partial areas and the at least one second covering layer in the second partial areas are arranged in register to each other.

[0068] Furthermore, it is possible that the at least one first top layer and the at least one second top layer have different properties in the first sub-areas and second sub-areas, respectively, in particular where one or more of the properties or combinations of one or more properties are selected from: color, pattern, motif, relief structure, in particular diffractive relief structure, optical elements, in particular optically variable elements, gloss levels.

[0069] It is possible that in step f) the at least one second cover layer is applied by means of the flooding station in such a way that one or more insert elements of the one or more insert elements are at least partially encapsulated between the at least one base body and the at least one second cover layer, in particular wherein in step f) the at least one second cover layer is applied by means of the flooding station in such a way that the at least one second cover layer only partially or completely overlaps the one or more insert elements and / or the at least one first partial area of ​​the surface of the base body.

[0070] Preferably, in all these steps, at least one base body remains contour-following in the first lower mold cavity of the first lower mold half. This ensures, firstly, a correspondingly high injection molding and flooding quality for the subsequent injection molding and / or flooding steps, and secondly, particularly good registration of the applied one or more inserts and / or additional inserts, as well as the at least one first and / or second top layer. This significantly improves the registration of the applied inserts and / or additional inserts and / or first and / or second top layers, and thus the product quality, while correspondingly reducing scrap.

[0071] Furthermore, it is possible that the at least one first and / or second cover layer is applied in such a way that it only partially overlaps the one or more inlay elements and / or the at least one, in particular the first and / or second, sub-area of ​​the surface of the at least one base body. This partial overlap can also occur in register with the one or more inlay elements and / or the at least one, in particular the first and / or second, sub-areas of the surface of the at least one base body, in order to create functional and / or decorative elements in a register-enhancing manner through the at least one first and / or second cover layer, which interact with and / or complement the decorative elements and / or functions of the one or more inlay elements.

[0072] It is also possible for at least one first and / or second top layer to be applied in such a way that it completely overlaps one or more insert elements and / or at least one, in particular the first and / or second, sub-area of ​​the surface of at least one base body. This allows, for example, the creation of at least one correspondingly closed protective or decorative layer in the corresponding at least one, in particular the first and / or second, sub-area of ​​the surface of at least one base body and / or the component, which, for example, is intended to form the weather-exposed outer surface of at least one base body and / or the component.

[0073] Furthermore, it is possible that before and / or during and / or after the application of the at least one second cover layer in step c), in particular by means of the flooding station, the at least one second cover layer is modified and / or structured, preferably by inserting / placing particles onto at least a partial area of ​​the surface of the at least one base body and / or after step b) and / or by using tool structures during the application in step f) and / or by subsequent lasering, overprinting and / or embossing of the at least one second cover layer.

[0074] Flooding or pouring over at least a partial area of ​​the surface of the at least one base body and / or the component preferably allows the use of a large number of different solvent-containing, preferably flowable, polyurethane-containing compositions, which can be specifically tailored to the composition of the at least one first, second and / or third plastic material of the at least one base body and / or the component and / or to the properties to be fulfilled by the at least one first and / or second cover layer, for example with regard to optical properties, mechanical properties and / or chemical resistance.

[0075] It is possible that the application of at least one first and / or second cover layer to at least one partial area of ​​the surface of the at least one base body and / or the component, in particular according to step e) and / or f), preferably wherein the at least one partial area of ​​the surface of the at least one base body and / or the component is not yet fully cured at least in some areas, and in particular wherein the application of the at least one first and / or second cover layer to the at least one partial area of ​​the surface of the at least one base body and / or the component is carried out by at least partial flooding and / or pouring with at least one solvent-containing, preferably flowable, polyurethane-containing composition and subsequent curing, preferably at a temperature in the range of 25°C to 180°C.In particular, the at least one solvent-containing, preferably flowable, polyurethane-containing composition comprises at least one organic solvent, for example ethyl acetate, 2-butanone, acetone, toluene, xylenes or mixtures thereof.

[0076] Furthermore, it is possible that the application of at least one first and / or second cover layer to at least one partial area of ​​the surface of the at least one base body and / or the component takes place, in particular according to step e) and / or f), wherein the partial area of ​​the surface of the at least one base body and / or the component preferably consists of one or more elements from the group consisting of paper, plastic, wood, composite, glass, metal and combinations thereof.

[0077] In particular, it is possible to emboss one or more insert elements of the one or more insert elements and / or one or more further insert elements of the one or more insert elements and / or at least a partial area of ​​the surface of the at least one base body in a further step, which is carried out in particular between one of steps a) to d) or after step d), preferably by means of roll embossing, partial roll embossing or lift embossing. Furthermore, it is also possible to use appropriate embossing processes for this purpose.

[0078] The embossing of the one or more insert elements and / or one or more further insert elements is preferably carried out with an embossing tool or several embossing tools, which apply a film or one / or more sections of a film as insert elements and / or further insert elements to at least one exposed partial area or at least one, in particular first and / or second, preferably exposed, partial area of ​​the at least one, in particular first and / or second, partial area of ​​the surface of the at least one base body.The embossing tools are preferably embossing dies or embossing rollers, which may, in particular, be adapted to the shape of the at least one base body or whose guidance and rolling behavior enable or are adapted to a corresponding contour sequence with respect to the surface contour of, in particular, the first and / or second, sub-area of ​​the surface of the at least one base body. Such embossing dies and embossing rollers preferably each have an elastomeric base body or elastomeric layers, for example, made of silicone.

[0079] When carrying out step a1), the following are particularly suitable as insert elements and / or further insert elements: transfer foils, for example hot stamping foils or cold stamping foils, but also laminating foils.

[0080] Particularly suitable for this application are transfer films comprising a carrier layer and a removable transfer layer. The carrier layer preferably consists of a plastic film, for example, a PET film with a thickness between 10 µm and 250 µm. The transfer layer has one or more layers, preferably selected from: one or more decorative layers, one or more functional layers, one or more protective layers, one or more adhesion-promoting layers, one or more barrier layers, or one or more conductive layers.

[0081] Furthermore, it is advantageous if one or more release layers are arranged between the carrier layer and the transfer layer, which improve removability. Such layers preferably contain waxes and / or silicones and / or polymers.

[0082] If such a transfer foil is designed as an embossing foil, it preferably has a thermally activatable adhesive layer on the side of the transfer foil facing away from the carrier layer, which can be activated in particular by the thermal energy of the embossing tool.

[0083] Furthermore, it is also possible that the transfer layer of the transfer foil has cutouts created, for example, by die-cutting, cutting, or laser treatment, or that the transfer layer is provided in the form of patches on the carrier layer. Such transfer layers preferably also have one or more carrier films for stabilizing the transfer layer. This offers the further advantage that "sensitive" functional and decorative layers receive additional protection against the thermal and mechanical stresses of the embossing process and subsequent process steps.

[0084] Laminating films preferably do not have a "removable" carrier layer. Laminating films preferably have one or more of the following layers: one or more decorative layers, one or more functional layers, one or more protective and / or cover layers, one or more carrier layers, one or more adhesion promoter layers, one or more carrier films, one or more barrier layers, one or more conductive layers.

[0085] Preferably, the laminating films have recesses introduced in particular by punching and / or cutting and / or laser action, or are already introduced into the embossing process in the form of freestanding, in particular die-cut, individual elements on a carrier layer.

[0086] It is also possible that the first, second and / or third plastic material consists of a thermoplastic plastic material, a crosslinking-curing plastic material, in particular a two-component material (2K = two-component) and / or a thermally and / or radiation-curable material, and / or a mixture of such plastic materials and / or wherein the first, second and / or third plastic material is fully or partially cured, in particular by irradiation.

[0087] Particularly advantageous is the use of a two-component plastic material for the first, second, and / or third injection molding cavity. During injection, the two components are mixed in a mixing head, ensuring a mixture is delivered to the respective cavities. The reaction of this mixture takes place within the cavities and can continue even after the mold halves have been opened. Using such materials makes it possible to achieve a particularly hard and weather-resistant first and / or second top layer.

[0088] Furthermore, it is also possible that the first, second, and / or third plastic material is post-cured or cured in a later step or several later steps. Such post-curing or curing can be carried out, for example, by irradiation, in particular by actinic radiation, preferably UV irradiation, and / or electron beam curing.

[0089] It is particularly advantageous to repeat the step of applying at least one first and / or second cover layer made of the first, second, and / or third plastic material multiple times, especially by overmolding, flooding, and injection molding. In these successive steps, different first, second, and / or third plastic materials and / or different third mold halves can also be used, so that corresponding first and / or second cover layers differing in their shape and / or material are applied to one another. Furthermore, it is also possible to perform step a1), the insertion of one or more insert elements, one or more times after each application of the first and / or second cover layer.For example, after applying a first and / or second top layer, it is possible to repeat steps a1) and / or e) and / or f), then apply another top layer, possibly in a different shape and / or made of a different material, and then insert one or more inlay elements, and so on. This makes it possible to implement correspondingly complex decorative and / or functional features in the component and / or in at least one base body in a cost-effective manner.

[0090] Preferably, the first, second and / or third plastic material consists of polyurethane or polyurea and the first, second and / or third plastic material consists of a thermoplastic, in particular ABS, ASA, ABS-PC, PC-PBT and / or ASA-PC and / or the composition of the first, second and / or third plastic material is selected from the group consisting of polyurethane-containing dispersions, polyurethane-containing resins, polyurethane solutions, compositions of polyurethane precursors (2K-PUR systems) and mixtures thereof.

[0091] It is also possible that the first, second and / or third plastic material preferably consists of a thermoplastic, in particular an impact-resistant thermoplastic, polyethylene (PE), polycarbonate (PC), polypropylene (PP), polystyrene, polybutadiene, polynitriles, polyester, polyurethanes, polymethacrylates, polyacrylates, polyamides, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), preferably acrylonitrile butadiene styrene (ABS), acrylonitrile styrene acrylate (ASA), ABS-PC, PET-PC, PBT-PC, PC-PBT and / or ASA-PC and / or copolymers or mixtures thereof. The first, second and / or third plastic material preferably further contains inorganic or organic fillers, preferably SiO2, Al2O3, TiO2, clay minerals, silicates, zeolites, glass fibers, carbon fibers, glass beads, organic fibers or mixtures thereof.The fillers are added to the first, second, and / or third plastic material to further increase the stability of at least one base body and / or the component. In particular, these fillers reduce the proportion of polymeric materials, thereby lowering the manufacturing costs and / or the weight of at least one base body and / or the component.

[0092] Furthermore, it is also possible that the first, second and / or third plastic material is either the same or different.

[0093] Preferably, the thickness of the at least one first and / or second cover layer is selected from a range between 100 µm and 20000 µm, in particular 100 µm to 10000 µm, preferably between 200 µm and 5000 µm.

[0094] Preferably, the at least one first and / or second topcoat adheres to the at least one base body and / or the component, in particular to at least a partial area of ​​the at least one base body and / or the component, preferably after curing with an adhesion force determined according to the method described in DIN EN ISO 4624: 2016-08, preferably using a PosiTest® AT series adhesion tester from DeFelsko Corporation (Ogdensburg, NY, USA) with a 20 mm test probe, in the range of 2.5 MPa to 5 MPa, in particular from 2.5 MPa to 10 MPa. It is possible that the at least one first and / or second topcoat cannot be removed from the at least one base body and / or the component, in particular from at least a partial area of ​​the at least one base body and / or the component, without damage after curing.

[0095] Furthermore, it is also possible that step e) is performed multiple times with different first and / or second and / or third plastic materials and / or different additional upper and / or lower mold halves and / or additional upper and / or lower mold cavities.

[0096] In addition to carrying out the steps described above, it is further advantageous to perform one or more of the following steps, even multiple times, during the manufacture of the component and / or the at least one base body: Preferably, at least one partial area, in particular an exposed partial area, of the surface of the at least one base body and / or the one or more insert elements and / or further insert elements is pretreated. This pretreatment is preferably carried out between steps c) and d) and / or between step d) and the application of the at least one first and / or second top layer, in particular steps e) and / or f). If further flooding is carried out and / or a first and / or second top layer is applied multiple times, as described above, such pretreatment is preferably also carried out before these respective steps.

[0097] As a pretreatment, preferably one or more of the following processing methods are carried out: surface activation, in particular by gassing, flame treatment, plasma treatment, fluorination, irradiation, cleaning, coating.

[0098] A particular advantage here is that, due to the temporal proximity of the pretreatment to both the upstream injection molding process and the downstream flooding process, the pretreated surface is especially accessible for the machining processes carried out, and degradation is largely avoided due to this temporal proximity. This significantly increases the effectiveness of the pretreatment and, for example, improves the adhesion properties between the base body (at least one) and the one or more inserts and / or further inserts and / or the first and / or second top layer.

[0099] Preferably, an optical inspection of at least a portion of the surface of the at least one base body and / or the one or more inserts and / or further inserts and / or the component is carried out. This is done in particular by means of an optical sensor, for example a camera, for example comprising a CCD chip (CCD = "Charged Coupled Device") and / or a TES sensor (TES = "Transition Edge Sensor"). Such an optical inspection is preferably carried out using image processing methods and can, for example, be used to optimize process parameters, for example by integrating them into a corresponding control loop, in order to further reduce reject rates. Furthermore, this optical inspection can also be used for quality assurance.This optical inspection can take place multiple times at different points in the process, for example after the injection molding process and / or after the flooding process and / or after pretreatment and / or after the application of one or more insert elements and / or further insert elements and / or after further coating, flooding, overmolding and / or after a cleaning process and / or after the removal of the component from the first upper and / or lower mold cavity and / or from the upper and / or lower mold cavities.

[0100] Preferably, a cleaning process is carried out, particularly after steps a1) and / or e) and / or f), the application of one or more insert elements and / or further insert elements or the application of at least one first and / or second cover layer, and / or after step e) and / or f), in which the at least one first and / or the second cover layer is applied. This process, for example, cleans the exposed surface of waste products from the injection molding and / or flooding process. Preferably, the cleaning process is carried out while the at least one base body is still located in the first upper and / or lower mold half and / or the first upper and / or lower mold cavity.This ensures that at least one of the base components is securely fixed during cleaning, allowing the use of cleaning methods that require stable fixation of the product to be cleaned.

[0101] Preferably, cleaning is carried out using brushes and / or compressed air and / or suction.

[0102] Preferably, the first mold half is rotated and / or moved and / or moved between the execution of steps b) and a1) and / or a1) and e) and / or a1) and f), the injection molding of the at least one base body and the insertion of the one or more insert elements and / or further insert elements, in order to enable appropriate processing of the exposed surface of the at least one base body, for example by a flooding unit and / or an embossing unit and / or a printing unit and / or a laser unit.

[0103] However, it is also possible to leave the upper and / or lower tool mold halves, in particular the first upper and / or lower tool mold half, stationary and, for example, to move at least one insertion unit arranged on a robot arm, so that by means of this it is possible to insert one or more insertion elements and / or further insertion elements onto at least a partial area and / or the exposed surface of the at least one base body.

[0104] Preferably, during the execution of the further processing steps described above, the upper and / or lower tool mold halves, in particular the first upper and / or lower tool mold halves, are also moved and / or rotated in such a way that the at least one base body is preferably processed accordingly by a workstation assigned to the respective processing step.

[0105] Preferred embodiments of the device are described below.

[0106] It is advantageous that the device comprises several further workstations between which the upper and / or lower tool mold halves, in particular the first upper and / or lower tool mold half, are moved and / or transported, for example by shifting and / or rotating, in order to machine the at least one base body according to the specified procedure sequence in accordance with the machining steps described above.

[0107] It is possible that the at least one upper tool carrier has at least two upper tool modules that can be moved in at least one direction to at least one predetermined position, or that the at least one lower tool carrier has at least one lower tool module that can be moved in at least one direction to at least one predetermined position, or that the at least one upper tool carrier and the at least one lower tool carrier can be moved in at least one direction to at least one predetermined position.

[0108] Furthermore, it is possible that the at least one upper tool carrier has the at least two upper tool modules and / or that the at least one lower tool carrier has the at least one lower tool module arranged along a predetermined preferred direction and / or in a predetermined preferred plane, in particular wherein the at least one upper tool carrier and / or the at least one lower tool carrier is designed as a rotary table or sliding table, preferably arranged vertically or horizontally.

[0109] The method of at least one upper and / or lower tool module or tool mold half is preferably implemented by arranging the at least one upper and / or lower tool module and / or tool mold half so as to be movably mounted on the at least one upper and / or lower tool carrier and, in particular, being rigidly connected to it. This at least one upper and / or lower tool carrier is preferably a vertically or horizontally arranged rotary table or sliding table. Preferably, the at least one upper and / or lower tool module or tool mold half is mounted on this rotary table or sliding table.The rotary table and / or sliding table is further mounted in such a way that at least one upper and / or lower tool module and / or tool mold halves can be moved between the workstations, in particular between the injection molding station and the flooding station.

[0110] Preferably, the device comprises not just one first upper and / or one first lower tool module or mold half, but two or more upper and / or lower tool modules or mold halves arranged on at least one common upper and / or lower tool carrier of the at least one upper and / or lower tool carrier. This makes it possible to significantly increase the efficiency of the manufacturing processes as well as the utilization rate of the individual workstations. For example, if two upper and / or lower mold halves are arranged on one common upper and / or lower tool carrier of the at least one upper and / or lower tool carrier, a new base body can be injection molded in parallel in the first injection molding station while the flooding process is being carried out in the flooding station, thereby effectively doubling the utilization rate.

[0111] It is also possible that at least one upper tool module of the at least two upper tool modules of the at least one upper tool carrier and / or that at least one lower tool module of the at least one lower tool module of the at least one lower tool carrier is selected from: tool mold half, in particular tool mold half comprising a tool cavity, preferably a first tool mold half with a first tool cavity or a second tool mold half with a second tool cavity.

[0112] Preferably, one or more workstations are selected and / or combined from: injection molding station, flooding station, pretreatment station, flooding station, first further injection molding station, second further flooding station, cleaning station, demolding station.

[0113] In particular, at least one workstation of the one or more workstations is designed as an injection molding station comprising a first upper tool module of the at least two upper tool modules of the at least one upper tool carrier and a first lower tool module of the at least one lower tool module of the at least one lower tool carrier, in particular wherein the first upper tool module is a first upper tool mold half with a first upper tool cavity and / or the first lower tool module is a first and / or second lower tool mold half with a first and / or second lower tool cavity.

[0114] Preferably, the at least one injection molding station has at least one insertion unit, wherein the at least one insertion unit is for inserting one or more insertion elements and / or further insertion elements into the first upper and / or the first lower mold cavity of the first upper or first lower mold half.

[0115] It is also possible that the at least one injection molding station has a closing device for closing an injection mold, in particular comprising the first upper mold half with the first upper mold cavity and the first lower mold half with the first lower mold cavity forming at least one first injection cavity, and for opening the injection mold.

[0116] Furthermore, it is also possible that the at least one injection molding station has an injection unit for introducing at least one base body forming a first plastic material into the at least one injection molding cavity and / or for applying at least one first cover layer to at least one partial area of ​​the surface of the at least one base body, in particular wherein the at least one first cover layer consists of a second plastic material.

[0117] In particular, the at least one base body comprises one or more or all of the insert elements of the one or more insert elements.

[0118] It is possible that the at least one basic body is arranged contour-following in the first upper and / or first lower tool cavity of the first upper or first lower tool mold half of the first upper or first lower tool modules of the at least one upper or lower tool carrier and / or the at least one first injection molding cavity.

[0119] Preferably, at least one workstation of the one or more workstations is designed as a flooding station comprising a second upper tool module of the at least two upper tool modules of the at least one upper tool carrier and the first lower tool module of the at least one lower tool module of the at least one lower tool carrier, in particular wherein the second upper tool module is a first upper flooding half and / or the first lower tool module is the first lower tool mold half with the first lower tool cavity.

[0120] Preferably, the flooding station and / or the first upper half of the flooding is or includes a casting tool or a 2K tool.

[0121] It is possible that the at least one flooding station and / or the first upper flooding half has a flooding unit for applying at least a second top layer made of a second plastic material, in particular to at least a partial area of ​​the surface of the at least one base body, preferably by means of flooding and / or partial flooding.

[0122] In addition to at least one injection molding station and at least one flooding station, the device preferably further comprises one or more of the following workstations: At least one workstation, in particular at least one further injection molding station, for applying the at least one first and / or second top layer made of a second plastic material, in particular by injection molding, flooding and / or partial overmolding.The at least one further injection molding station preferably comprises a closing device for forming the second injection molding cavity and / or a further injection molding cavity by means of one or more upper and / or lower second and / or third mold halves, in particular by sealing the one or more upper and / or lower second and / or third mold halves against the at least one base body, the one or more insert elements, and / or the first upper and / or lower mold half. Furthermore, the at least one further injection molding station preferably comprises an injection unit for introducing the first, second, and / or third plastic material into the second injection molding cavity. Reference is made to the above descriptions in this regard.

[0123] Furthermore, it is possible that the device has at least one pretreatment station for pretreating at least a partial area of ​​the surface of the at least one base body, in particular by one or more processing methods selected from: gassing, flame treatment, plasma treatment, fluorination, irradiation, cleaning, surface activation, coating and / or combinations thereof.

[0124] It is also possible that the device includes at least one test station for the optical inspection of at least a partial area of ​​the surface of the at least one base body, which has one or more insert elements and / or the component, by means of an optical sensor, in particular by means of a camera. As already explained above, the inspection can be carried out in particular by means of optical sensors, especially a camera.

[0125] Furthermore, it is also possible that the device includes at least one cleaning station, in particular for cleaning at least a partial area of ​​the surface of the at least one base body and / or the component using brushes and / or compressed air and / or suction. Reference is also made to the above explanations regarding the cleaning step in this respect.

[0126] Preferably, the device has a demolding station for demolding the at least one base body and / or the component comprising the at least one base body. Furthermore, it is possible that the demolding station for demolding the component comprising the at least one base body, the one or more insert elements, and optionally the one or more further insert elements and / or the at least one first and / or second cover layer, in particular from the first upper and / or lower mold half. InThe demolding station can also be used to cool and harden the component before demolding.

[0127] It is possible that the device has a number n workstations, in particular one or more injection molding stations, one or more flooding stations, one or more pretreatment stations, one or more testing stations, one or more cleaning stations and one or more demolding stations, and that on the at least one upper tool carrier and / or on the at least one lower tool carrier, preferably at least n upper and / or lower tool modules, in particular comprising upper and / or lower tool mold halves and / or upper and / or lower flooding halves, are arranged.If the device includes, for example, an injection molding station, an embossing station, another injection molding station, and a demolding station, then at least four upper or lower mold halves are provided on the common upper or lower mold carrier, and four lower or upper mold halves are provided on the lower or upper mold carrier. The four processing steps performed by these four workstations, which can be combined from the four upper and four lower mold halves, can thus be carried out in parallel, thereby improving the utilization rate accordingly, in particular by a factor of four.

[0128] Furthermore, the device may have one or more workstations and / or one or more combinations of one or more workstations, preferably selected from: a printing station, in particular a printing station for inkjet printing and / or pad printing; a labeling station, in particular a labeling station for applying labels; a laser marking station, in particular a laser marking station for ablation or material removal and / or blackening and / or color change, preferably of laser-sensitive layers; a cold stamping station; a hot stamping station, preferably wherein these workstations, preferably for printing, labeling, laser marking, cold stamping, and / or hot stamping, are located before and / or after the demolding of the component and / or the at least one base body and / or the component comprising the at least one base body, in particular before and / or after step d), preferably before and / or after the demolding station.and / or before and / or after flooding, in particular before and / or after step e), preferably before and / or after the flooding station.

[0129] Preferably, the device comprises at least one positioning device for moving the at least two upper tool modules of the at least one upper tool carrier and / or the at least one lower tool module of the at least one lower tool carrier, particularly between the workstations of the device. This positioning device can be provided by a suitable servo drive and / or a hydraulic drive and / or a pneumatic drive. Preferably, this positioning device is controlled by a process control device, which cyclically moves the at least one upper and / or lower tool mold half in a predefined sequence between the two or more workstations of the device and supplies it to the respective workstations for machining.

[0130] Furthermore, it is possible that the device has a process control device which controls the positioning device in such a way that the at least two upper tool modules of the at least one upper tool carrier and / or the at least one lower tool module of the at least one lower tool carrier are cyclically or anticyclically supplied to two or more workstations of the device in a predefined sequence, in particular in a sequence: Injection molding station - Flooding station, Injection molding station - Flooding station - Demolding station, Injection molding station - Pretreatment station - Flooding station - Demolding station, Injection molding station - Flooding station - further injection molding station - Demolding station, Injection molding station - Pretreatment station - Flooding station - further injection molding station - Demolding station, Injection molding station - Pretreatment station - Flooding station - further injection molding station - Cleaning station - Demolding station, Injection molding station - Pretreatment station - Flooding station - further injection molding station - further pretreatment station - further flooding station - Cleaning station - Demolding station, Injection molding station - Pretreatment station - Flooding station - further injection molding station - further pretreatment station - further flooding station - Cleaning station - Testing station - Demolding station.

[0131] The invention will now be explained by way of example using several embodiments and the accompanying drawings. Fig. 1 shows a schematic representation of a method. Fig. 2 shows a schematic representation of a device. Fig. 3 shows a schematic representation of a device. Fig. 4 shows a schematic representation of a device. Fig. 5 shows a schematic representation of a device. Fig. 6 shows a schematic representation of a device. Fig. 7 shows a schematic cross-sectional view of a tool module.

[0132] Fig. 1 shows a method for manufacturing a component 1, wherein the following steps are carried out in the method, in particular in the following sequence: A Providing at least one upper tool carrier 2a and at least one lower tool carrier 2b, wherein the at least one upper tool carrier 2a has at least two upper tool modules 20a and the at least one lower tool carrier 2b has at least one lower tool module 20b, B Method of moving at least one upper tool carrier 2a and / or at least one lower tool carrier 2b in at least one direction to at least one predetermined position, C Combination of a first upper tool module 20aa of the at least two upper tool modules 20a of the at least one upper tool carrier 2a and a first lower tool module 20ba of the at least one first lower tool module 20b of the at least one lower tool carrier 2b in the at least one predetermined position such that one or more workstations 3 are used for The execution of at least one manufacturing step of component 1 must be trained. D Execution of at least one manufacturing step to form component 1.

[0133] The first upper tool module 20aa of the at least two upper tool modules 20a of the at least one upper tool carrier 2a and the at least one first lower tool module 20ba of the at least one lower tool module 20b of the at least one lower tool carrier 2b are combined in the at least one predetermined position such that one or more workstations of the one or more workstations 3 are formed as an injection molding station 3a comprising an injection mold 3aa, wherein the injection mold 3aa has the first upper tool module 20aa and the first lower tool module 20ba, wherein the first upper tool module 20aa has a first upper mold half 200aa, with at least one first upper mold cavity 2000aa, and the first lower tool module 20ba has a first lower mold half 200ba with at least one first lower mold cavity 2000ba.

[0134] The procedure further comprises the following steps, in particular in the following sequence: a Closing of the injection mold 3aa comprising the first upper mold half 200aa with the at least one first upper mold cavity 2000aa, and the first lower mold half 200ba with the at least one first lower mold cavity 2000ba, wherein at least one first injection mold cavity 2000 defined by the first upper mold cavity 2000aa and the first lower mold cavity 2000ba is formed, b Injection molding of at least one base body 4 by introducing a first plastic material 4a into the at least one first injection molding cavity 2000, c Opening the injection mold 3aa, wherein the at least one base body 4 remains contour-following in the at least one first lower or first upper mold cavity 2000aa, 2000ba and only at least a first partial area of ​​one or more surfaces of the at least one base body 4 is exposed, wherein at least a second partial area of ​​the surface of the base body 4, however, still remains in the first upper or lower mold cavity 2000aa, 2000ba, d Demolding of component 1, comprising at least one base body 4 from the first upper or lower tool cavity 2000aa, 2000ba or tool mold half 200aa, 200ba.

[0135] It is also possible that the following further step is carried out once or several times before step a and / or d: a1 Inserting one or more insert elements 5 into the at least one first injection molding cavity 2000 and / or onto at least one exposed first partial area of ​​the surface of the at least one base body 4, wherein the at least one base body 4 remains contour-following in the at least one first upper or first lower mold cavity 2000aa, 2000ba of the first upper or first lower mold half 200aa, 200ba.

[0136] Preferably, in step d, the base body 4 comprises one or more or all of the insert elements of the one or more insert elements 5, in particular wherein one or more insert elements of the one or more insert elements 5 are designed as foil elements, preferably a foil, as decorative elements and / or as functional elements.

[0137] After step d, in particular between steps a and b and / or b and c, the following further step is carried out once or several times: e Applying at least a first cover layer 6 made of a second plastic material 6a by flooding at least a partial area of ​​the surface of the at least one base body 4.

[0138] In particular, during the execution of step e, at least one basic body 4 remains contour-following in the first upper or first lower tool cavity 2000aa, 2000ba of the first upper or first lower tool mold half 200aa, 200ba.

[0139] In carrying out step e, at least a second injection molding cavity is formed by means of one or more further upper mold halves of the at least two upper mold modules 20a of the at least one upper mold carrier 2a or one or more further lower mold halves of the at least one lower mold module 20b of the at least one lower mold carrier 2b, by sealing the one or more further upper or lower mold halves against the base body 4, the optional one or more insert elements 5 or the first upper or lower mold half, and the second plastic material 6a is introduced into the at least one second injection molding cavity 2001.

[0140] Furthermore, it is possible that the following step is performed once or multiple times between steps b, c and / or d and / or between steps d and e or d: Pretreatment of at least one exposed first sub-area of ​​the surface of at least one base body 4, in particular by one or more processing methods and / or combinations of one or more processing methods selected from: gassing, flame treatment, plasma treatment, fluorination, irradiation, cleaning, surface activation, coating.

[0141] It is also possible that between steps c, d and / or e at least an optical inspection of at least a partial area of ​​the surface of the at least one base body 4, the one or more insert elements 5, and / or the component 1 is carried out by means of an optical sensor or several optical sensors, in particular one or more cameras.

[0142] Furthermore, it is also possible that after step c or d and / or between steps d and e and / or after step e, the following step is carried out: Cleaning, especially using brushes and / or compressed air and / or suction.

[0143] In particular, one or more insert elements of the one or more insert elements 5 in step a1 are used as a transfer foil, in particular a cold stamping foil, comprising a carrier layer and a transfer layer removable from it, onto which an adhesive layer is applied, in particular by means of an inkjet printhead, in at least a first area, but not in at least a second area, the transfer foil is guided against the one or more surfaces of the at least one base body 4 by means of the stamping tool, the adhesive layer is activated and the transfer foil is removed again, so that a section of the transfer layer determined by the shaping of the first area is applied as the one or more insert elements 5.

[0144] Preferably, before step a, one or more further insert elements 5 are placed into the at least one first injection molding cavity 2000, in particular into the first upper and / or first lower mold half 200aa, 200ba, and in step b are back-injected and / or overmolded with the first plastic material 4a.

[0145] It is possible that during the execution of step a1, one or more insert elements of the one or more insert elements 5 are inserted with register accuracy to one or more further insert elements of the one or more further insert elements, in particular wherein one or more register marks or optical features of the one or more further insert elements and / or the first upper and / or first lower tool cavities 2000aa, 2000ba or tool mold halves 200aa, 200ba are detected and used to control the insertion.

[0146] Furthermore, it is possible that the one or more insert elements 5 and / or the one or more further insert elements each have at least one decorative layer, at least one functional layer, in particular a layer with an electrical functionality, in particular comprising one or more elements selected from touch sensor, antenna, capacitor, coil, electromagnetic shielding, electrically non-conductive metallic layers, in particular to prevent electrostatic charging, display, LED, electrical circuit, solar cell, at least one protective layer, in particular post-curable, and / or at least one adhesion-promoting layer or adhesion-promoting layer.

[0147] Preferably, the first upper and / or first lower mold half 200aa, 200ba is rotated and / or moved and / or transported between the execution of steps a1 and b, steps a and b and / or steps d and e.

[0148] According to the invention, a second upper tool module 20ab of the at least two upper tool modules 20a of the at least one upper tool carrier 2a and the first lower tool module 20ba of the at least one lower tool module 20b of the at least one second tool carrier 2b are combined in the at least one predetermined position such that one or more workstations of the one or more workstations 3 are designed as a flooding station 3b comprising the second upper tool module 2ab and the first lower tool module 2ba, in particular wherein the second upper tool module 20ab is a second upper tool mold half 200ab with a first upper flooding half 2000ab and / or the first lower tool module 20ba is the first and / or second tool mold half 200ba with the first and / or second tool cavity 2000ba.

[0149] It is also possible that the following step is performed between steps d and e and / or after step e: f Applying at least one second top layer 6 to at least a partial area of ​​the surface of at least one base body 4.

[0150] Furthermore, it is also possible that in step f the at least one second cover layer 7 is applied by means of the flooding station 3b in such a way that one or more insert elements of the one or more insert elements 5 are at least partially encapsulated between the at least one base body 4 and the at least one second cover layer 7.

[0151] In particular, in step f, at least one second cover layer 7 is applied by means of the flooding station 3b in such a way that the at least one second cover layer 7 only partially or completely overlaps the one or more insert elements 5 and / or the at least one first partial area of ​​the surface of the base body 4.

[0152] It is also possible that before and / or during and / or after the application of the at least one second cover layer 7 in step c, in particular by means of the flooding station 3b, the at least one second cover layer 7 is modified and / or structured, preferably by inserting / placing particles onto at least a partial area of ​​the surface of the at least one base body 4 and / or after step b and / or by using tool structures during the application in step f and / or by subsequent laser cutting, overprinting and / or embossing of the at least one second cover layer 7.

[0153] Preferably, at least one second cover layer 7 consists of a third plastic material 7a.

[0154] It is possible that the first and / or second and / or third plastic material 4a, 6a, 7a consists of a thermoplastic plastic material, a crosslinking-curing plastic material, in particular a 2K material and / or two-component material and / or a thermally and / or radiation-curable material, and / or a mixture of such plastic materials and / or wherein the first and / or second and / or third plastic material 4a, 6a, 7a is fully or partially cured, in particular by irradiation.

[0155] Furthermore, it is possible that the first and / or second and / or third plastic material 4a, 6a, 7a consists of polyurethane or polyurea and that the first and / or second and / or third plastic material 4a, 6a, 7a consists of a thermoplastic, in particular ABS, ASA, ABS-PC, PC-PBT and / or ASA-PC and / or that the composition of the first and / or second and / or third plastic material 4a, 6a, 7a is selected from the group consisting of polyurethane-containing dispersions, polyurethane-containing resins, polyurethane solutions, compositions of polyurethane precursors, 2K-PUR systems and mixtures thereof.

[0156] Preferably, step e is performed multiple times with different first and / or second and / or third plastic materials 4a, 6a, 7a and / or different further upper and / or lower mold halves.

[0157] The Figure 2Figure 10 shows a device 10 for manufacturing a component 1, in particular for carrying out a method described above or one or more of the method steps A, B, C, D, a1, a, b, c, d, e and / or f, wherein the device has an upper tool carrier 2a and a lower tool carrier 2b, wherein the upper tool carrier 2a has two upper tool modules 20a and the lower tool carrier 2b has one lower tool module 20b, wherein the upper tool carrier 2a is movable in a first direction or opposite direction R1 and / or in a second direction or opposite direction R2 to at least one predetermined position, in particular wherein the lower tool carrier 2b is not movable.and wherein a first upper tool module 20aa of the two upper tool modules 20a of the upper tool carrier 2a and a first lower tool module 20ba of the one lower tool module 20b of the lower tool carrier 2b can be combined in the at least one predetermined position such that two workstations 3a, 3b, in particular for carrying out at least one manufacturing step of the component 1, are formed.

[0158] In particular, the first direction or opposite direction R1 and the second direction or opposite direction R2 are arranged perpendicular to each other.

[0159] The also shows Figure 2 further, that the injection molding station 3a has an insertion unit 3ab, wherein the insertion unit 3ab is for inserting and / or advancing one or more insertion elements 5 into the first upper mold half 200aa.

[0160] Furthermore, the upper tool carrier 2a, which has the two upper tool modules 20a, can be moved in the directions R1 and / or R2 to at least one predetermined position.

[0161] It is possible that the at least one upper tool carrier 2a has the at least two upper tool modules 20a and / or that the at least one lower tool carrier 2b has the lower tool module 20b arranged along a predetermined preferred direction and / or in a predetermined preferred plane, in particular wherein the upper tool carrier 2a is designed as a rotary table or sliding table, preferably arranged vertically or horizontally.

[0162] Furthermore, it is possible that at least one upper tool module of the two upper tool modules 20a of the upper tool carrier 2a and / or that the lower tool module of the lower tool module 20b of the lower tool carrier 2b is selected from: tool mold half, in particular tool mold half comprising a tool cavity, preferably a first tool mold half with a first tool cavity or a second tool mold half with a second tool cavity.

[0163] It is also possible that one or both of the two workstations 3a, 3b are selected and / or combined from: injection molding station, flooding station, pretreatment station, first further flooding station, further injection molding station, second further flooding station, cleaning station, demolding station.

[0164] The Figure 2further shows that a first workstation of the two workstations 3 is designed as an injection molding station 3a comprising a first upper tool module 20aa of the two upper tool modules 20a of the upper tool carrier 2a and a first lower tool module 20ba of the lower tool module 20b of the lower tool carrier 2b.

[0165] The also shows Figure 2 further, that a second workstation of the two workstations 3 is designed as a flooding station 3b comprising a second upper tool module 20ab of the two upper tool modules 20a of the upper tool carrier 2a and the first lower tool module 2ba of the lower tool module 20b of the lower tool carrier 2b, in particular wherein the second upper tool module 20ab is a second upper tool mold half 200ab and / or the first lower tool module 20ba is the first lower tool mold half 200ba.

[0166] It is possible that the flooding station 3b and / or the second upper mold half 200ab is or includes a casting tool or a 2K tool.

[0167] Furthermore, it is possible that the flooding station 3b and / or the second upper mold half 200ab has a flooding unit 3ba for applying at least a second cover layer 7 made of a second plastic material 7a, in particular to at least a partial area of ​​the surface of at least one base body 4, preferably by means of flooding and / or partial flooding.

[0168] The Figure 3 shows the in the Figure 2 The device shown 10, except that the upper tool carrier 2a is not movable and the lower tool carrier 2b is movable in a third direction or opposite direction R3 and / or in a fourth direction or opposite direction R4 to at least one predetermined position.

[0169] In particular, the third direction or opposite direction R3 and the fourth direction or opposite direction R4 are arranged perpendicular to each other. In the example shown here, the third direction or opposite direction R3 can also be a rotational movement about an axis of rotation parallel to direction R4.

[0170] It is also possible that the first tool carrier and the second tool carrier can each be moved in one or more of the directions R1, R2, R3 and / or R4 and / or rotated along the axes which are defined by these directions.

[0171] The Figure 4 shows the in the Figure 2 Device 10 shown, except that the upper tool carrier 2a is movable in a fifth direction or opposite direction R5 and / or in a sixth direction or opposite direction R6 and the lower tool carrier 2b is not movable into at least one predetermined position.

[0172] In particular, the fifth direction or opposite direction R5 and the sixth direction or opposite direction R6 are arranged perpendicular to each other.

[0173] Furthermore, the Figure 4 , that the first upper tool module 20aa is a first upper tool mold half 200aa with a first upper tool cavity 2000aa and the first lower tool module 20ba is a second lower tool mold half 200ba with a second lower tool cavity 2000ba.

[0174] The also shows Figure 4 further, that the injection molding station 3a has an insertion unit 3ab, wherein the insertion unit 3ab is for inserting and / or advancing one or more insertion elements 5 into the first upper mold cavity 2000aa of the first upper mold half 200aa.

[0175] It is possible that the at least one injection molding station 3a has a closing device 3ac for closing an injection mold 3aa, in particular comprising the first upper mold half 200aa with the first upper mold cavity 2000aa and the first lower mold half 200ba with the first lower mold cavity 2000ba forming at least one first injection cavity 2000, and for opening the injection mold 3aa.

[0176] The Figure 5 shows the in the Figure 4The device 10 shown is identical, except that the upper tool carrier 2a is movable in a seventh direction or opposite direction R7 and / or in an eighth direction or opposite direction R8, and the lower tool carrier 2b is movable in a ninth direction or opposite direction R9 to at least one predetermined position. In the example shown here, the ninth direction or opposite direction R9 can also be a rotational movement about an axis of rotation parallel to direction R7.

[0177] In particular, the seventh direction or opposite direction R7 and the eighth direction or opposite direction R8 are arranged perpendicular to each other, and the seventh and eighth directions or opposite directions R7 and R8 are arranged perpendicular or parallel to the ninth direction or opposite direction R9.

[0178] The Figure 6Figure 10 shows a device comprising an upper tool half 2a and a lower tool half 2b, which in particular have a rectangular, preferably square, more preferably circular, base. The upper tool carrier 2a further comprises four upper tool modules 20aa, 20ab, 20ac, 20ad. The lower tool carrier 2b comprises four lower tool modules 20ba, 20bb, 20bc, 20bd.

[0179] In this case, the upper tool carrier 2a is movable and / or displaceable along a tenth direction or opposite direction R10 and / or an eleventh direction or opposite direction R11, and is movable or rotatable along a first direction of rotation or opposite direction D1.

[0180] In particular, the tenth direction or counter-direction R8 and the eleventh direction or counter-direction R11 are arranged perpendicular to each other. Preferably, the axis of rotation defining the first direction of rotation or counter-direction D1 is perpendicular to the plane defined by the upper and / or lower tool carrier 2a, 2b.

[0181] The one in Figure 6The device 10 shown has four workstations in the arrangement shown, in particular spatial arrangement, of the upper tool carrier 2a comprising the four upper tool modules 20aa, 20ab, 20ac, 20ad and the lower tool carrier 2b comprising the four lower tool modules 20ba, 20bb, 20bc, 20bd. Here, the first workstation, as a first injection molding station 3a1, is a combination of the first upper tool module 20aa and the first lower tool module 20ba; the second workstation, as a first flooding station 3b1, is a combination of the second upper tool module 20ab and the second lower tool module 20bb; the third workstation, as a second injection molding station 3a2, is a combination of the third upper tool module 20ac and the third lower tool module 20bc; and the fourth workstation, as a second flooding station 3b2, is a combination of the fourth upper tool module 20ad and the fourth lower tool module 20bd.The four lower tool modules 20ba, 20bb, 20bc, 20bd each have a tool cavity 2000ba, 2000bb, 2000bc, 2000bd.

[0182] Rotating the upper tool carrier by 90° around the axis of rotation, particularly along the first direction of rotation or counter-direction D1, results in a further combination of four workstations. After four rotations of the upper tool carrier by 90° around the axis of rotation, particularly along the first direction of rotation or counter-direction D1, i.e., by 360°, the initial combination of the four workstations described above is obtained, comprising the first injection molding station 3a1, the first flooding station 3b1, the second injection molding station 3a2, and the second flooding station 3b2.

[0183] Alternatively or additionally, it is also possible for the lower tool carrier to be rotatable and / or movable around the same axis of rotation and / or other axes of rotation as the upper tool carrier.

[0184] Such a device 10 advantageously enables four machining steps, in particular along a cycle comprising four 90° rotations along the axis of rotation, in particular along the first direction of rotation or counter-direction of rotation D1, which are combinable from these four workstations from the four upper tool modules 20aa, 20ab, 20ac, 20ad and the four lower tool modules 20ba, 20bb, 20bc, 20bd, to be carried out in parallel, thereby improving the utilization rate accordingly, in particular by a factor of four.

[0185] Alternatively, two of the upper tool modules 20aa, 20ab or 20ac and 20ad may be missing, leaving two of the lower tool modules 20ba and 20bb or 20bc and 20bd free. These free lower tool modules, and any base bodies they may contain, can undergo further processing steps while injection molding and flooding processes take place in the other two workstations. For example, testing, cleaning, pretreatment, printing, and / or laser marking processes can be performed on the free tool modules and any base bodies they may contain. These processes preferably coincide with, or be shorter than, the cycle times of the injection molding and flooding processes.

[0186] Furthermore, it is possible that the injection molding stations 3a1, 3a2 each have an injection unit 3ad for introducing at least one base body 4 forming a first plastic material 4a into at least one first injection molding cavity 2000 and / or for applying at least one first cover layer 6 to at least a partial area of ​​the surface of the at least one base body 4, in particular wherein the at least one first cover layer 6 consists of a second plastic material 6a, wherein the at least one base body 4 comprises one or more or all of the insert elements 5.

[0187] Furthermore, it is possible that at least one basic body 4 is arranged contour-following in the lower tool cavity 2000ba, 2000bb, 2000bc, 2000bd, in particular the lower tool mold halves 200ba, 200bb, 200bc, 200bd, the lower tool modules 20ba, 20bb, 20bc, 20bd of the lower tool carrier 2b and / or the at least one first injection molding cavity 2000.

[0188] It is also possible that the one in the Figure 6 The flooding stations shown, 3b1 and 3b2, include a casting tool or a 2K tool.

[0189] Furthermore, it is possible that the flooding stations 3b1, 3b2 and / or the upper mold halves 20a, 20ad each have a flooding unit 3ba for applying at least a second cover layer 7 made of a second plastic material 7a, in particular to at least a partial area of ​​the surface of the at least one base body 4, preferably by means of flooding and / or partial flooding.

[0190] The Figure 7 This is shown, for example, in the Figure 6 Tool modules 20bb shown in a cross-section along the in the Figure 6 line AA shown and in particular perpendicular to the plane spanned by the base of the lower tool carrier 2b, wherein the tool module 20bb has a tool cavity 2000bb.

[0191] It has proven advantageous if the device 10 has one or more of the following workstations: Pretreatment station 3c for pretreating at least a partial area of ​​the surface of the at least one base body 4, in particular by one or more processing methods selected from: gassing, flame treatment, plasma treatment, fluorination, irradiation, cleaning, surface activation, coating and / or combinations thereof. Testing station 3d for optically testing at least a partial area of ​​the surface of the at least one base body 4, which has one or more insert elements 5 and / or the component 1, by means of an optical sensor, in particular by means of a camera. Cleaning station 3e, in particular for cleaning at least a partial area of ​​the surface of the at least one base body 4 and / or the component 1 by means of brushes and / or compressed air and / or suction. Demolding station 3f for demolding the at least one base body 4 and / or the component 1.in particular comprising the at least one base body 4, positioning device 10a for moving the at least two upper tool modules 20a of the at least one upper tool carrier 2a and / or the at least one lower tool module 20b of the at least one lower tool carrier 2b, in particular between the workstations 3 of the device, printing station, in particular printing station for inkjet printing and / or pad printing, labeling station, in particular labeling station for applying labels, laser marking station, in particular laser marking station for ablation and / or blackening and / or color change, preferably of laser-sensitive layers and / or areas of the base body and / or the component, cold stamping station, hot stamping station.

[0192] Furthermore, the device 10 may have one or more workstations and / or one or more combinations of one or more workstations, preferably selected from: a printing station, in particular a printing station for inkjet printing and / or pad printing; a labeling station, in particular a labeling station for applying labels; a laser marking station, in particular a laser marking station for ablation and / or blackening and / or color change, preferably of laser-sensitive layers and / or areas of the base body; a cold stamping station; a hot stamping station, preferably wherein these workstations, preferably for printing, labeling, laser marking, cold stamping, and / or hot stamping, are located before and / or after the demolding of the component and / or the at least one base body and / or the component comprising the at least one base body, in particular before and / or after step d), preferably before and / or after the demolding station.and / or before and / or after flooding, in particular before and / or after step e), preferably before and / or after the flooding station.

[0193] Furthermore, it is possible that one or more insert elements of the one or more insert elements in step a1) are used as a transfer foil, in particular a hot stamping foil, preferably comprising a carrier layer and / or a transfer layer removable from it with an adhesive layer, in particular wherein the transfer foil is pressed against the one or more surfaces of the at least one base body by means of a heated embossing tool, in particular wherein the adhesive layer and the release layer of the transfer foil are activated and in particular wherein the transfer foil is subsequently peeled off the transfer layer adhering to the base body, in particular wherein a section of the transfer layer determined by the shaping of the embossing tool is applied as the one or more insert elements.

[0194] Furthermore, it is also possible that one or more of the following further steps and / or that at least a combination of one or more of the following one or more steps are carried out, in particular selected from: printing, in particular inkjet printing and / or pad printing, labeling, in particular affixing labels, applying and / or marking lasers, lasers, in particular ablation or material removal and / or blackening and / or color change, preferably of laser-sensitive layers or areas of the component and / or the base body, cold stamping, hot stamping, thermal transfer, preferably wherein these steps are carried out in particular before and / or after the demolding of the component and / or the at least one base body and / or the component comprising the at least one base body, preferably before and / or after step d), further preferably before and / or after the demolding station,and / or in particular before and / or after flooding, preferably before and / or after step e).

[0195] Furthermore, it is possible that further steps are carried out after demolding or after demolding the component and / or the at least one base body and / or the component comprising the at least one base body, wherein one or more of the further steps are preferably selected from: assembly with functional elements, in particular assembly with printed circuit boards and / or electronic components and / or mechanical components and / or fastening elements, coating, in particular coating with adhesive and / or with further, preferably different, functional layers, installation and / or attachment to and / or into further, in particular different, bodies and / or base bodies, preferably bodies of all kinds.

[0196] It is also possible that the device 10 has a number n workstations, in particular one or more injection molding stations 3a, 3a1, 3a2, one or more flooding stations 3b, 3b1, 3b2, one or more pretreatment stations 3c, one or more testing stations 3d, one or more cleaning stations 3e and one or more demolding stations 3f, and that on the at least one upper tool carrier 2a and / or on the at least one lower tool carrier 2b, preferably at least n upper and / or lower tool modules 20a, 20b, in particular comprising upper and / or lower tool mold halves and / or upper and / or lower flooding halves, are arranged.

[0197] Furthermore, it is possible that the device 10 has a process control device 10b which controls the positioning device 10a such that the at least two upper tool modules 20a of the at least one upper tool carrier 2a and / or that the at least one lower tool module 20b of the at least one lower tool carrier 2b are cyclically or anticyclically supplied to two or more workstations 3 of the device 10 in a predefined sequence, in particular in a sequence: Injection molding station 3a - Flooding station 3b, Injection molding station 3a - Flooding station 3b - Demolding station 3f, Injection molding station 3a - Pretreatment station 3c - Flooding station 3b - Demolding station 3f, Injection molding station 3a - Flooding station 3b - further injection molding station - Demolding station 3f, Injection molding station 3a - Pretreatment station 3c - Flooding station 3b - further injection molding station - Demolding station 3f, Injection molding station 3a - Pretreatment station 3c - Flooding station 3b - further injection molding station - Cleaning station 3e - Demolding station 3f, Injection molding station 3a - Pretreatment station 3c - Flooding station 3b - further injection molding station - further pretreatment station - further flooding station - Cleaning station 3e - Demolding station 3fInjection molding station 3a - Pretreatment station 3c - Flooding station 3b - further injection molding station - further pretreatment station - further flooding station - cleaning station 3e - testing station 3d - demolding station 3f. , Reference symbol list:

[0198] 1 Component 10 Device 10a Positioning device 10b Process control device 2a Upper tool carrier 2b Lower tool carrier 20a Upper tool module 20b Lower tool module 20aa First upper tool module 20ab Second upper tool module 20ba First lower tool module 200aa First upper mold half 200ab Second upper mold half 200ba First lower mold half 2000 First injection cavity 2001 Second injection cavity 2000aa First upper mold cavity 2000ab First upper flood half 2000ba First lower mold cavity 3 Workstation 3a Injection molding station 3a1 First injection molding station 3a2 Second injection molding station 3aa Injection mold 3ab Insertion unit 3ac Clamping device 3ad Injection unit 3b Flooding station 3b1 First flooding station 3b2 Second flooding station 3c Pretreatment station 3d Testing station 3e Cleaning station 3f Demolding station 4 Base body 4a First plastic material 5 Insert element 6 First top layer 6a Second plastic material 7 Second top layer7a Third plastic material A Process step B Process step C Process step D Process step a1 Process step a Process step b Process step c Process step d Process step e Process step f Process step R1 Direction or opposite direction R2 Direction or opposite direction R3 Direction or opposite direction R4 Direction or opposite direction R5 Direction or opposite direction R6 Direction or opposite direction R7 Direction or opposite direction R8 Direction or opposite direction R9 Direction or opposite direction R10 Direction or opposite direction R11 Direction or opposite direction D1 Direction of rotation or opposite direction of rotation

Claims

1. Method for producing a component (1), wherein the following steps are carried out in the method: - providing at least one upper tool holder (2a) and at least one lower tool holder (2b), wherein the at least one upper tool holder (2a) has at least two upper tool modules (20a), and the at least one lower tool holder (2b) has at least one lower tool module (20b), - shifting the at least one upper tool holder (2a) and / or the at least one lower tool holder (2b) in at least one direction into at least one predetermined position, - combining a first upper tool module (20aa) of the at least two upper tool modules (20a) of the at least one upper tool holder (2a) and a first lower tool module (20ba) of the at least one first lower tool module (20b) of the at least one lower tool holder (2b) in the at least one predetermined position in such a way that one or more work stations (3) are formed for carrying out at least one production step of the component (1), - carrying out the at least one production step for forming the component (1), wherein the first upper tool module (20aa) of the at least two upper tool modules (20a) of the at least one upper tool holder (2a) and the at least one first lower tool module (20ba) of the at least one lower tool module (20b) of the at least one lower tool holder (2b) are combined in the at least one predetermined position in such a way that one or more work stations of the one or more work stations (3) are formed as an injection moulding station (3a) comprising an injection moulding tool (3aa), wherein the injection moulding tool (3aa) has the first upper tool module (20aa) and the first lower tool module (20ba), wherein the first upper tool module (20aa) has a first upper tool mould half (200aa) with at least one first upper tool cavity (2000aa), and the first lower tool module (20ba) has a first lower tool mould half (200ba) with at least one first lower tool cavity (2000ba), wherein the method comprises the following steps: a) closing the injection moulding tool (3aa) comprising the first upper tool mould half (200aa) with the at least one first upper tool cavity (2000aa), and the first lower tool mould half (200ba) with the at least one first lower tool cavity (2000ba), wherein at least one first injection moulding cavity (2000) determined by the first upper tool cavity (2000aa) and the first lower tool cavity (2000ba) is formed, b) injection moulding at least one base body (4) by introducing a first plastic material (4a) into the at least one first injection moulding cavity (2000), c) opening the injection moulding tool (3aa), wherein the at least one base body (4) remains following the contour in the at least one first lower or first upper tool cavity (2000aa, 2000ba), and only at least one first partial region of one or more surfaces of the at least one base body (4) is exposed, wherein at least one second partial region of the surface of the base body (4) still remains, however, in the first upper or lower tool cavity (2000aa, 2000ba), d) demoulding the component (1) comprising the at least one base body (4) from the first upper or lower tool cavity (2000aa, 2000ba) or tool mould half (200aa, 200ba), wherein a second upper tool module (20ab) of the at least two upper tool modules (20a) of the at least one upper tool holder (2a) and the first lower tool module (20ba) of the at least one lower tool module (20b) of the at least one second tool holder (2b) are combined in the at least one predetermined position in such a way that one or more work stations of the one or more work stations (3) is formed as a flood station (3b) comprising the second upper tool module (2ab) and the first lower tool module (2ba), wherein after step d) the following further step is carried out once or multiple times: e) applying at least one first covering layer (6) made of a second plastic material (6a) by means of flooding onto at least one partial region of the surface of the at least one base body (4), wherein, when carrying out step e), at least one second injection moulding cavity (2001) is formed by means of one or more further upper tool mould halves of the at least two upper tool modules (20a) of the at least one upper tool holder (2a), or one or more further lower tool halves of the at least one lower tool module (20b) of the at least one lower tool holder (2b) is formed by sealing the one or more further upper or lower further tool mould halves from the base body (4) or the first upper or lower further tool mould halves, and the second plastic material (6a) is introduced into the at least one second injection moulding cavity (2001).

2. Method according to claim 1, characterised in that before step a) and / or d), the following further step is carried out once or multiple times: a1) inserting one or more insertion elements (5) into the at least one first injection moulding cavity (2000) and / or onto at least one exposed first partial region of the at least one first exposed partial region of the surface of the at least one base body (4), wherein the at least one base body (4) remains following the contour in the at least one first upper or first lower tool cavity (2000aa, 2000ba) of the first upper or first lower tool mould half (200aa, 200ba), in particular wherein the base body (4) in step d) comprises one or more or all insertion elements of the one or more insertion elements (5).

3. Method according to claim 1, characterised in that, when carrying out step e), the at least one base body (4) remains following the contour in the first upper or first lower tool cavity (2000aa, 2000ba) of the first upper or first lower tool mould half (200aa, 200ba).

4. Method according to one of the preceding claims, characterised in that the following step is carried out once or several times between steps b), c) and / or d) and / or between steps d) and e): - pre-treating at least one exposed first partial region of the at least one exposed first partial region of the surface of the at least one base body (4), in particular by means of one or more processing methods and / or combinations of one or more processing methods, selected from: fumigation, flame treatment, plasma treatment, fluorination, irradiation, cleaning, surface activation, coating, and / or after step c) or d) and / or between steps d) and e) and / or after step e), the following step is carried out: - cleaning, in particular by means of brushes and / or pressurised air and / or suction.

5. Method according to one of the preceding claims, characterised in that, before step a), one or more further insertion elements (5) are introduced into the at least one first injection moulding cavity (2000), in particular into the first upper and / or first lower tool mould half (200aa, 200ba), and in step b) back-injected and / or over-moulded with the first plastic material (4), and / or, when carrying out step a1), one or more insertion elements of the one or more insertion elements (5) are inserted accurately according to register with one or more further insertion elements of the one or more further insertion elements, in particular wherein one or more register marks or optical features of the one or more further insertion elements and / or the first upper and / or first lower tool cavities (2000aa, 2000ba) or tool mould halves (200aa, 200ba) are detected and are used to control the insertion.

6. Method according to one of the preceding claims, characterised in that the following step is carried out between steps d) and e) or after step e): f) applying at least one second covering layer (7) to at least one partial region of the surface of the at least one base body (4).

7. Method according to claim 6, characterised in that, in step f), the at least one second covering layer (7) is applied by means of the flooding station (3b) in such a way that one or more insertion elements of the one of more insertion elements (5) are at least partially encapsulated between the at least one base body (4) and the at least one second covering layer (7), and / or in step f), the at least one second covering layer (7) is applied by means of the flooding station (3b) in such a way that the at least one second covering layer (7) overlaps only over part of the surface or completely with the one or more insertion elements (5) and / or the at least one first partial region of the surface of the base body (4).

8. Method according to one of claims 6 to 7, characterised in that the at least one second covering layer (7) consists of a third plastic material (7a), and / or the first and / or second and / or third plastic material (4a, 6a, 7a) consists of a thermoplastic plastic material, of a plastic material hardened by curing, in particular a 2K material and / or two-component material and / or of a material that can be cured thermally and / or of a material that can be cured by radiation, and / or of a mixture of such plastic materials, and / or wherein the first and / or second and / or third plastic material (4a, 6a, 7a), is cured completely or partially, in particular by irradiation, and / or the first and / or second and / or third plastic material (4a, 6a, 7a) consists of polyurethane or polyurea, and the first and / or second and / or third plastic material (4a, 6a, 7a) consists of a thermoplastic, in particular of ABS, ASAA, ABS-PC, PC-PBT and / or ASA-PC, and / or the composition of the first and / or second and / or third plastic material (4a, 6a, 7a) is selected from the group, which consists of polyurethane-containing dispersions, polyurethane-containing resins, polyurethane solutions, compositions of polyurethane precursors (2K-PUR systems) and mixtures thereof.

9. Device (10) for producing a component (1) for carrying out a method according to one of the preceding claims, characterised in that the device (10) has at least one upper tool holder (2a) and at least one lower tool holder (2b), wherein the at least one upper tool holder (2a) has at least two upper tool modules (20a), and the at least one lower tool holder (2b) has at least one lower tool module (20b), wherein the at least one upper tool holder (2a) and / or the at least one lower tool holder (2b) can be shifted in at least one direction into at least one predetermined position, and wherein a first upper tool module (20aa) of the at least two upper tool modules (20a) of the at least one upper tool holder (2a) and a first lower tool module (20ba) of the at least one lower tool module (20b) of the at least one lower tool holder (2b) can be combined in the at least one predetermined position in such a way that one or more work stations (3) are formed.

10. Device (10) according to claim 9, characterised in that the at least one upper tool holder (2a) having the at least two upper tool modules (20a) can be shifted in the at least one direction into at least one predetermined position, or the at least one lower tool holder (2b) having the at least one lower tool module (20b) can be shifted in the at least one direction into at least one predetermined position, or the at least one upper tool holder (2a) and the at least one lower tool holder (2b) can be shifted in the at least one direction into the at least one predetermined position, and / or the at least one upper tool holder (2a) having the at least two upper tool modules (20a) and / or the at least one lower tool holder (2b) having the at least one lower tool module (20b) is or are arranged in a predetermined preference direction and / or on a predetermined preference plane, in particular wherein the at least one upper tool holder (2a) and / or the at least one lower tool holder (2b) is or are formed as a preferably vertically or horizontally arranged rotary table or sliding table, and / or at least one upper tool module of the at least two upper tool modules (20a) of the at least one upper tool holder (2a) and / or at least one lower tool module of the at least one lower tool module (20b) of the at least one lower tool holder (2b) is or are selected from: tool mould half, in particular tool mould half comprising a tool cavity, preferably a first tool mould half with a first tool cavity or a second tool mould half with a second tool cavity, and / or one or more work stations of the one or more work stations (3) are selected and / or combined from: injection moulding station, flooding station, pre-treating station, first further flooding station, further injection moulding station, second further flooding station, cleaning station, demoulding station.

11. Device (10) according to one of claims 9 to 10, characterised in that at least one work station of the one or more work stations (3) is formed as an injection moulding station (3a) comprising a first upper tool module (20aa) of the at least two upper tool modules (20a) of the at least one upper tool holder (2a) and a first lower tool module (20ba) of the at least one lower tool module (20b) of the at least one lower tool holder (2b).

12. Device (10) according to claim 11, characterised in that the first upper tool module (20aa) is a first upper tool mould half (200aa) with a first upper tool cavity (2000aa), and / or the first lower tool module (20ba) is a first and / or second lower tool mould half (200ba) with a first and / or second lower tool cavity (2000ba), and / or the at least one injection moulding station (3a) has at least one insertion unit (3ab), wherein the at least one insertion unit (3ab) is for inserting one or more insertion elements (5) into the first upper and / or the first lower tool cavity (2000aa, 2000ba) of the first upper or first lower tool mould half (200aa, 200ba).

13. Device (10) according to one of claims 11 to 12, characterised in that the at least one injection moulding station (3a) has an injection unit (3ad) for introducing first plastic material (4a) forming at least one base body (4) into the at least one first injection moulding cavity (2000) and / or is for applying at least one first covering layer (6) to at least one partial region of the surface of the at least one base body (4), in particular wherein the at least one first covering layer (6) consists of a second plastic material (6a).

14. Device (10) according to claim 13, characterised in that the at least one base body (4) comprises one or more or all insertion elements of the one or more insertion elements (5), and / or the at least one base body (4) is arranged following the contour in the first upper and / or first lower tool cavity (2000aa, 2000ba) of the first upper or first lower tool mould half (200aa, 200ba) of the first upper or first lower tool modules (20aa, 20ba) of the at least one upper or lower tool holder (2a, 2b) and / or the at least one first injection moulding cavity (2000).

15. Device (10) according to one of claims 9 to 14, characterised in that at least one work station of the one or more work stations (3) is formed as a flooding station (3b) comprising a second upper tool module (20ab) of the at least two upper tool modules (20a) of the at least one upper tool holder (2a) and the first lower tool module (2ba) of the at least one lower tool module (20b) of the at least one lower tool holder (2b), in particular wherein the second upper tool module (20ab) is a second upper tool mould half (200ab) with a first upper flooding half (2000ab), and / or the first lower tool module (20ba) is the first lower tool mould half (200ba) with the first lower tool cavity (2000ba).

16. Device (10) according to claim 15, characterised in that the flooding station (3b) and / or the second upper tool mould half (200ab) is or comprises a mould tool or a 2K tool, and / or the at least one flooding station (3b) and / or the second upper tool mould half (200ab) has a flooding unit (3ba) for applying at least one second covering layer (7) made of a second plastic material (7a), in particular to at least one partial region of the surface of the at least one base body (4), preferably by means of flooding and / or partially flooding.

17. Device (10) according to one of preceding claims 9 to 16, characterised in that the device (10) has at least one pre-treatment station (3c) for pre-treating at least one partial region of the surface of the at least one base body (4), in particular by one or more processing methods selected from: fumigation, flame treatment, plasma treatment, fluorination, irradiation, cleaning, surface activation, coating and / or combination thereof, and / or the device (10) has at least one cleaning station (3e), in particular for cleaning at least one partial region of the surface of the at least one base body (4) and / or the components (1) by means of brushing and / or compressed air and / or suction, and / or the device (10) has a demoulding station (3f) for demoulding the at least one base body (4) and / or the component (1) comprising the at least one base body (4).