Article, method of producing same and use of same

Abstract

The invention relates to a method for producing an article (1), the method comprising at least one of steps A1) or A2) or A3): providing a base element (9) bearing a transfer ply (3) and / or a print layer, with the protective varnish layer (8) and / or the print layer at least regionally being not yet fully cured or being thermoplastic; and with the method, further to at least one of steps A1) or A2) or A3), comprising the following steps: e) forming at least one first region (5) and at least one second region (6) by embossing in the protective varnish layer (8) and / or print layer, with the at least one first region (5) having a relief structure; f) optionally curing the at least regionally not yet fully cured protective varnish layer (8) and / or print layer, with the protective varnish layer (8) and / or print layer at least regionally curing fully; g) obtaining an article (1). The invention further relates to an article produced by the method, with the article (1) comprising a base element (9) and a protective varnish layer (8) and / or print layer, with the protective varnish layer (8) and / or print layer at least regionally being fully cured or thermoplastic, with the protective varnish layer (8) and / or print layer having at least one first region (5) and at least one second region (6), with the at least one first region (5) having a relief structure arranged therein.

Description

[0001] LEONHARD KURZ Foundation & Co. KG, Schwabacher Str. 482, 90763 Fürth

[0002] Method of manufacturing an article, an article and use of the article

[0003] The invention relates to a method for producing an article as well as to an article and the use of the article.

[0004] Films are used to decorate the surfaces of articles. Such decorated articles are used, for example, in automotive engineering for interior components such as door trim, instrument panel trim, and center console trim; in the entertainment electronics sector for decorative trim on televisions; and in the electronics and telecommunications sector for housing shells of portable devices, such as mobile phones or laptops, or other cover elements, trim elements, or control elements, for example, in household appliances.

[0005] To produce these items, it is common practice to back-inject IMD transfer films (IMD = In-Mold Decoration) with a plastic compound in an injection mold. To ensure the durability of items manufactured in this way, IMD transfer films often have protective lacquer layers, which form the outer surface of the items after a carrier layer of the IMD transfer film is removed.

[0006] The surface decoration of articles using insert molding technology is also known. This is a combined process of hot stamping or cold stamping, vacuum forming and injection molding, whereby a transfer film is first applied to a substrate using hot stamping or cold stamping. After the carrier film of the transfer film has been removed, this substrate is deformed three-dimensionally or 2.5-dimensionally, in particular by deep drawing, and then the substrate is back-injected with a plastic mass. After deforming, in particular deep drawing, it has previously been provided for the decorated substrate, in particular its outer layers such as protective lacquer layers, to be cured directly. This curing takes place, for example, using high-energy radiation, for example UV radiation, and preferably takes place by irradiation on the decorated side of the substrate.Curing can be achieved alternatively or additionally by thermal curing and / or alternatively or additionally by reactive curing within the respective layers and / or between adjacent layers. Curing is preferably followed by back-injection with the plastic compound.

[0007] The surface decoration of articles using wet painting is also known. This involves the application of liquid paints or inks using well-known processes such as spray painting, screen printing, inkjet printing, pad printing, or similar. Prior to this wet painting, the article may already have a coating, at least in some areas, selected individually or in combination from wet painting, transfer coating using hot stamping, transfer coating using cold stamping, transfer coating using the IMD process, coating using insert molding, lamination, coextrusion, or labeling.

[0008] While it is also known to provide articles with surface structuring that covers the entire surface, for example, with matte transfer films, if it is desired to provide surface structuring only in specific areas, it is necessary to use transfer films that have been provided with a specific area-by-area post-structuring before being made available for an article's manufacturing process. However, this leads to challenges during the subsequent manufacture of the article, particularly if it is desired to align the specific area-by-area surface structuring with motifs, color backgrounds, or other decorative elements of the transfer film and / or with functional areas such as operating areas and displays, or with specific areas of the 3D geometry of the decorated part.Furthermore, transfer films that allow for partial post-structuring of the surface usually have insufficient resistance to mechanical or chemical stress due to this very structuring capability. However, if the surface is required to be very robust, post-processing of the surface is complex and cost-intensive due to its nature, and there is a risk that a molding will be carried out, at least partially, but will not meet all optical requirements. For example, the result of post-processing of an already fully cured and / or cross-linked lacquer layer by embossing can appear inhomogeneous and spotty. Furthermore, the robustness of a lacquer layer usually also results in brittleness or low extensibility, which limits the formability of the lacquer layer and thus its use in IMD and in-mold processes.

[0009] Thus, it is not known how to provide cost-effective and efficient surfaces that only have a surface structure in certain areas, whereby the surface is on the one hand very resistant to external influences, such as UV radiation, hand creams, solvents, abrasion or scratches, and on the other hand a flexible surface design and the production of three-dimensional or 2.5-dimensional articles is possible.

[0010] It is now an object of the invention to provide an improved method for producing an article and to provide an improved article, as well as its use.

[0011] The object is achieved by a method for producing an article, in particular according to one of claims 1 to 31, wherein the method comprises at least one of steps A1) or A2) or A3), wherein step A1) comprises the following steps: a1) providing a transfer film, wherein the transfer film has a carrier layer and a transfer layer, wherein the carrier layer is removable from the transfer layer, wherein the carrier layer comprises a carrier layer, wherein the transfer layer comprises a protective lacquer layer, wherein the protective lacquer layer is at least partially not yet fully cured or is thermoplastic and wherein the protective lacquer layer is arranged such that it is in contact with the carrier layer; b1) arranging the transfer film, in particular the transfer layer, in an injection mold; c1) back-injecting the transfer film, in particular the transfer layer, with a plastic mass, wherein the plastic mass forms a base body;d) Detaching the carrier layer from the transfer layer; wherein step A2) comprises the following steps: a2) Providing an insert, wherein the insert has a substrate and a transfer layer and / or a printing layer arranged on the substrate, wherein the transfer layer comprises a protective lacquer layer; b2) Arranging the insert in an injection mold; c2) Back-molding the insert with a plastic compound, wherein the plastic compound forms a base body;wherein step A3) comprises the following steps: a3) providing a transfer film, wherein the transfer film has a carrier layer and a transfer layer, wherein the carrier layer is removable from the transfer layer, wherein the carrier layer comprises a carrier layer, wherein the transfer layer comprises a protective lacquer layer and wherein the protective lacquer layer is arranged such that it is in contact with the carrier layer, and providing a base body separate from the transfer film, which is produced in particular by injection molding; k3) arranging the transfer film, in particular the transfer layer, on a surface of the base body and hot stamping the transfer film onto the surface of the base body; d) detaching the carrier layer from the transfer layer;wherein the protective lacquer layer and / or the printing layer in steps A1) or A2) or A3) is at least partially not yet fully cured or is thermoplastic, and wherein the method comprises the following steps in addition to at least one of steps A1) or A2) or A3): e) forming at least one first region and at least one second region by embossing in the protective lacquer layer and / or in the printing layer, wherein the at least one first region has a relief structure; f) optionally curing the at least partially not yet fully cured protective lacquer layer and / or printing layer, wherein the protective lacquer layer cures completely at least partially;g) Obtaining an article, wherein the article comprises a base body and a protective lacquer layer and / or printing layer which is cured or thermoplastic at least in some regions, wherein the protective lacquer layer and / or printing layer has at least one first region and at least one second region, wherein a relief structure is arranged in the at least one first region;

[0012] The object is further achieved by an article, preferably according to claim 32, wherein the article has a base body and a protective lacquer layer and / or a printing layer, wherein the protective lacquer layer and / or the printing layer is at least partially completely cured or thermoplastic, wherein the protective lacquer layer and / or the printing layer has at least a first region and at least one second region, wherein a relief structure is arranged in the at least one first region, and wherein the article was produced according to one of claims 1 to 31.

[0013] Furthermore, the object is achieved, in particular by claim 33, by the use of the article according to claim 32 or produced by a method according to one of claims 1 to 31, alone or in combination, as a display window, touch field, panel, bezel, cladding, cover, functional element, electronic article and housing part or outer part, in particular of white goods and / or of household appliances and / or of automotive interior areas and / or of automotive exterior areas.

[0014] In this case, a region is understood to mean, in particular, a defined area of ​​a layer, film or ply which, when viewed perpendicular to a plane formed by the transfer film, in particular by the transfer ply, the protective lacquer layer, the printing layer, the base body and / or the substrate. For example, the at least one protective lacquer layer and / or the printing layer of the resulting article has at least a first region and at least a second region, wherein each of the two or more regions occupies a defined area when viewed perpendicular to a plane formed by the protective lacquer layer and / or printing layer, in particular in all layers arranged in the protective lacquer layer and / or printing layer and in all layers arranged above and / or below the protective lacquer layer and / or printing layer, in particular in all layers of the transfer ply.

[0015] In the present case, forming at least one region is understood to mean, in particular, the manipulation of a layer, a ply, or a lacquer, for example, the protective lacquer layer and / or print layer, wherein the surface structure of the original layer, ply, or lacquer, for example, the protective lacquer layer and / or print layer, subsequently differs from the surface structure, in particular the relief structure, of the manipulated region. The regions are formed, in particular, in the layer, ply, or lacquer, for example, in the protective lacquer layer and / or print layer, wherein, in particular, the surface structure of the layer, ply, or lacquer is more structured in the manipulated region.Thus, it may be the case that before the formation of the at least one region, no surface structure, in particular no relief structure, is present in the layer, ply, or lacquer, for example in the protective lacquer layer and / or print layer, and after formation, a surface structure, in particular a relief structure, is formed in the at least one manipulated region. It is thus possible for the at least two formed regions to differ optically. This difference is perceptible in particular to the human eye and / or measurable by a sensor. The regions are preferably formed by embossing.

[0016] A layer, in particular the protective lacquer layer and / or printing layer, is preferably referred to as not yet fully cured if its hardness and / or durability does not yet have a specified minimum value. The specified minimum value of the hardness and / or durability is preferably a function of the final intended use of the layer, for example, as a protective lacquer layer and / or printing layer. Consequently, a layer is referred to as "fully cured" within the meaning of the present invention if its hardness and / or durability has a specified minimum value.

[0017] It is possible that the above-mentioned minimum values ​​are defined such that a layer is considered not yet fully cured within the meaning of the present invention if no more than 95% of the polymer components of the layer capable of crosslinking exhibit crosslinking. Consequently, a layer is considered fully cured within the meaning of the present invention if more than 95% of the polymer components of the layer capable of crosslinking exhibit crosslinking. A fully cured layer exists when complete (> 95%) crosslinking of its polymer components has occurred.

[0018] This process makes it possible to emboss transfer foils after an injection molding process, applying a relief structure only in certain areas. This offers several advantages. For example, during the production of an article, no foil needs to be provided that already has a relief structure in certain areas. This also eliminates the risk of an unintentional offset of the relief structure in certain areas to decorative or functional elements.

[0019] The present invention makes it possible to provide articles that have a surface resistant to mechanical and chemical influences and are nevertheless structured with a relief structure in certain areas. This can be achieved by only allowing the partially structured layer to acquire its intended strength during the process. This also makes it possible to produce three-dimensional or 2.5-dimensionally shaped articles, since the transfer film exhibits sufficient flexibility during the forming process. However, it is also possible for the transfer film to undergo no or only very slight forming and to be applied to a flat (2D, two-dimensional) area.

[0020] Furthermore, the use of various and interchangeable embossing tools or carriers allows for a comprehensive master structure to create customized layouts for the items. This means that even small batches or even individual pieces are associated with significantly lower additional costs than if specifically pre-structured transfer foils had to be produced. Furthermore, layout changes can also be made at short notice.

[0021] This means that no transfer films need to be disposed of unused if their layout is no longer up to date. Another major advantage over the current state of the art is that the re-structuring has no or only insignificant impact on any backlit structures and / or motifs in the article and / or in the transfer film. The re-structuring only influences the local transparency to a minor extent. The scattering effect introduced by the relief structure is therefore so small that it is negligible in transmitted light. This makes it possible to emboss diffractive optical structures that are designed for illumination in transmission. If the article is provided with backlighting, additional optical effects, such as anti-glare effects, can be achieved by the relief structures only being introduced in certain areas.

[0022] Further advantageous embodiments of the invention are described in the subclaims.

[0023] Steps A1), A2), and A3) describe, in particular, equivalent alternatives for obtaining and / or providing a base body on which a transfer layer and / or a printing layer is arranged, wherein the protective lacquer layer and / or the printing layer is not yet fully cured, at least in some regions, or is thermoplastic. Step A1) comprises at least steps a1), b1), c1), and d). Step A2) comprises at least steps a2), b2), and c2). Step A3) comprises at least steps a3), k3), and d).

[0024] In particular, steps e), f) and g) describe how an article is obtained from the base body, preferably after steps A1) and / or A2) and / or A3), on which a transfer layer and / or a print layer is arranged. The article comprises a base body and a protective lacquer layer and / or a print layer, wherein the protective lacquer layer and / or the print layer is cured or thermoplastic at least in some regions, and wherein the protective lacquer layer and / or the print layer has at least a first region and at least a second region, wherein a relief structure is arranged in the at least one first region. Step a) is understood to mean steps a1), a2) and / or a3). Furthermore, step b) is understood to mean steps b1) and / or b2). Furthermore, step c) is understood to mean step c1) and / or step c2).

[0025] Step a) is preferably the first step of the method and is carried out in particular before steps b) to g). In step a), it is possible for the transfer film to be provided as a roll. Furthermore, it is possible for the transfer film to be provided as a hot stamping film or as an IMD film. Furthermore, it is possible for an insert to be provided. The article is preferably produced using an IMD process or an insert molding process. It is also possible for the article to be produced using an injection molding process with a downstream hot stamping process, wherein the transfer layer is arranged on a base body in the hot stamping process. In particular, in step a3), in addition to the transfer film, a base body is provided which can preferably be designed like the base body described for step c).

[0026] A transfer film or insert provided in step a) may have a transfer layer that has a multi-layer structure.

[0027] It is possible for a provided insert to have a multi-layer transfer layer and / or a multi-layer printing layer. The printing layer is preferably arranged partially or over the entire surface of the insert. The printing layer is designed in particular as a screen printing layer, a gravure printing layer, an inkjet printing layer, or a combination thereof. The insert preferably has a gravure printing layer and a screen printing layer. It is possible for the layers of the printing layer to at least partially overlap. It is possible for the insert to have a transfer layer that is partially printed with one or more printing layers.

[0028] The transfer layer preferably has a layer thickness selected from a range of 0.1 pm to 100 pm, preferably from 0.5 pm to 75 pm, more preferably from 1 pm to 50 pm.

[0029] The protective lacquer layer and / or the print layer protects the finished article, particularly against external influences such as UV radiation, mechanical influences such as scratches, or chemical influences such as creams or solvents. The protective lacquer layer and / or print layer thus exhibits particularly high resistance to mechanical and chemical stress, especially compared to the underlying layers, the base body, and / or the optional substrate.

[0030] The protective lacquer layer preferably has a layer thickness selected from a range of 1 μm to 15 μm, preferably from 2 μm to 8 μm, more preferably from 2 μm to 5 μm. With such a layer thickness of the protective lacquer layer, it is possible for the protective lacquer layer to have the required resistance in the finished article.

[0031] Furthermore, the protective lacquer layer has a transmittance of at least 70%, preferably at least 85%, for the wavelength range perceivable by the human eye, preferably in the range from 400 nm to 700 nm. The above transmittances mean that the protective lacquer layer is transparent. This allows any underlying decoration, decorative element, or base body to be clearly visible.

[0032] In particular, the protective lacquer layer is not yet fully cured, at least in some areas. Preferably, the protective lacquer layer is precured chemically and / or by irradiation, preferably UV irradiation, at least in some areas, and / or is still fully curable, at least in some areas, by irradiation, preferably UV irradiation. For this purpose, the protective lacquer layer comprises at least one UV-crosslinkable polymer. A UV-crosslinkable polymer within the meaning of the invention preferably has at least one, preferably two or more, ethylenically unsaturated double bond(s).

[0033] Preferably, the term "ethylenically unsaturated double bond" means a mono-, di-, or trisubstituted C=C double bond that is not incorporated into an aromatic electron system. Preferably, an ethylenically unsaturated double bond is not conjugated with other double bonds.

[0034] The partially not yet cured protective lacquer layer is preferably

[0035] Based, alone or in combination, on at least one UV-crosslinkable or at least one chemically crosslinkable polymer. Furthermore, the protective lacquer layer can be made of a thermoplastic polymer.

[0036] It is possible for the protective lacquer layer to further comprise at least one chemically crosslinkable polymer, which is more preferably selected from the group consisting of isocyanate group-containing polymers, melamine-containing polymers, hydroxyl group-containing polymers and mixtures thereof.

[0037] The protective lacquer layer preferably comprises at least one chemically crosslinkable polymer combination which comprises or is a polymer and / or copolymer having at least one, preferably two or more, isocyanate group(s) and at least one polymer and / or copolymer having at least one, preferably two or more, hydroxyl group(s) and / or at least one melamine resin and at least one polymer and / or copolymer having at least one, preferably two or more, hydroxyl group(s).

[0038] It is further possible for the at least one UV-crosslinkable polymer of the protective lacquer layer to further comprise, independently of one another, at least one chemically crosslinkable functional group, wherein the chemically crosslinkable functional group is preferably selected from hydroxyl group, isocyanate group, melamine group, epoxy group and combinations thereof.

[0039] Preferably, the at least one UV-crosslinkable polymer further comprises at least one hydroxyl group.

[0040] Suitable UV-crosslinkable hydroxyl group-containing polymers are known from the prior art and include, for example, at least one diacrylate monomer, aliphatic polyetherurethane diacrylate, aliphatic polyesterurethane diacrylate, aromatic polyetherurethane diacrylate, aromatic polyesterurethane diacrylate, polyester diacrylate, polyether diacrylate, epoxy diacrylate, acrylated acrylic diacrylate, polyacrylate monomer, aliphatic polyetherurethane polyacrylate, aliphatic polyesterurethane polyacrylate, aromatic polyetherurethane polyacrylate, aromatic polyesterurethane polyacrylate, polyester polyacrylate, polyether polyacrylate, epoxy polyacrylate, acrylated acrylic polyacrylate or mixtures thereof and / or at least one hydroxy monoacrylate, hydroxy diacrylate, hydroxy polyacrylate, hydroxy-functionalized aliphatic polyetherurethane monoacrylate, hydroxy-functionalized aliphatic polyesterurethane monoacrylate, hydroxy-functionalized aromatic polyetherurethane monoacrylate,hydroxy-functionalized aromatic polyester urethane monoacrylate, hydroxy-functionalized polyester monoacrylate, hydroxy-functionalized polyether monoacrylate, hydroxy-functionalized epoxy monoacrylate, hydroxy-functionalized acrylated acrylic monoacrylate, hydroxy-functionalized aliphatic polyether urethane diacrylate, hydroxy-functionalized aliphatic polyester urethane diacrylate, hydroxy-functionalized aromatic polyether urethane diacrylate, hydroxy-functionalized aromatic polyester urethane diacrylate, hydroxy-functionalized polyester diacrylate, hydroxy-functionalized polyether diacrylate, hydroxy-functionalized epoxy diacrylate, hydroxy-functionalized acrylated acrylic diacrylate, hydroxy-functionalized aliphatic polyether urethane polyacrylate, hydroxy-functionalized aliphatic polyester urethane polyacrylate, hydroxy-functionalized aromatic polyether urethane polyacrylate, hydroxy-functionalized aromatic polyester urethane polyacrylate,hydroxy-functionalized polyester polyacrylate, hydroxy-functionalized polyether polyacrylate, hydroxy-functionalized epoxy polyacrylate, hydroxy-functionalized acrylated acrylate or mixtures thereof.

[0041] Particularly suitable melamine resins are those which are obtainable by reacting melamine with aldehydes and which can optionally be partially or completely modified.

[0042] Formaldehyde, acetaldehyde, isobutyraldehyde and glyoxal are particularly suitable as aldehydes.

[0043] Melamine-formaldehyde resins are preferably reaction products of the reaction of melamine with aldehydes, for example the above-mentioned aldehydes, especially formaldehyde. The resulting methylol groups are preferably modified by etherification with mono- or polyhydric alcohols. Furthermore, it is possible for the protective lacquer layer to comprise precured systems and / or hybrid systems. In particular, it is possible for the protective lacquer layer to comprise at least one UV-curable component made of UV-curable monomers and / or UV-curable oligomers or mixtures thereof and further comprise at least one binder selected from the group consisting of polyurethanes, polyacrylates, polymethacrylates, polyester resins, polycarbonates, phenolic resins, epoxy resins, polyureas, melamine resins, preferably polymethyl methacrylate (PMMA), polyester, polycarbonate (PC), and mixtures thereof.

[0044] It is further possible for the protective coating layer to preferably comprise at least one polyisocyanate. The term polyisocyanate preferably describes an organic compound having two or more isocyanate groups, including triisocyanates and isocyanates with higher functionality. In certain embodiments, the at least one polyisocyanate is selected from the group consisting of diisocyanate monomer, diisocyanate oligomer, diisocyanate-terminated prepolymer, diisocyanate-terminated polymer, polyisocyanate monomer, polyisocyanate oligomer, polyisocyanate-terminated prepolymer, polyisocyanate-terminated polymer, polyisocyanate-terminated polymer, and mixtures thereof.

[0045] More preferably, the at least one polyisocyanate comprises or is at least one diisocyanate-containing component, which preferably contains at least one diisocyanate-containing polyurethane oligomer, diisocyanate-containing polyurea oligomer, prepolymers thereof, polymer thereof or mixtures thereof.

[0046] In certain embodiments, the at least one polyisocyanate comprises or is at least one diisocyanate-containing component, which is preferably selected from the group consisting of hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), methylene diphenyl diisocyanate (MDI), toluene diisocyanate (TDI), phenylene diisocyanate, naphthalene diisocyanate, diphenylsulfone diisocyanate, ethylene diisocyanate, propylene diisocyanate, dimers of these diisocyanates, trimers of these diisocyanates, triphenylmethane triisocyanate, polyphenylmethane polyisocyanate (polymeric MDI), and mixtures thereof. The protective lacquer layer is or preferably comprises a dual-cure system, preferably based, for example, on a hydroxyl-containing polyacrylic acrylate crosslinked with melamine resin. A dual-cure system can in particular be cured in two curing steps based on a combination of chemical crosslinking and curing of UV-crosslinkable polymers.

[0047] In particular, it is possible for the protective lacquer layer to be produced based on a physically drying and chemically and / or UV-crosslinkable system. The protective lacquer layer of the transfer film, preferably the transfer layer, is preferably cured during the process for producing the article by chemically crosslinking and / or crosslinking the protective lacquer layer.

[0048] The protective coating layer can preferably comprise additives, for example, selected alone or in combination from pigments, initiators, crosslinkers, or catalysts. In particular, the initiators are photoinitiators. This makes it possible to initiate, assist, and / or control the curing of the protective coating layer.

[0049] It is possible for the protective lacquer layer of the transfer film, preferably the transfer layer, to be based on a thermoplastic polymer and / or a thermoplastic resin. It is therefore possible for the protective lacquer layer to preferably not be chemically crosslinkable or crosslinkable and / or not be crosslinkable or crosslinkable by UV radiation. The thermoplastic polymer and / or the thermoplastic resin can, for example, be selected alone or in combination from the group of polyurethanes, polyacrylates, polymethacrylates, polyester resins, polycarbonates, styrene-butadiene copolymers, preferably alone or in combination from the group of polymethyl methacrylate (PMMA), polyester, polycarbonate (PC), polycarbonate / acrylonitrile butadiene styrene (ABS / PC).

[0050] In a preferred embodiment, the protective lacquer layer is formed as a printing layer, in particular as a screen printing layer, as a gravure printing layer, as an inkjet printing layer, or as a combination thereof. The protective lacquer layer preferably has a transmittance of a maximum of 30%, preferably a maximum of 15%, for the wavelength range perceivable by the human eye, preferably for the range from 400 nm to 700 nm. The above transmittances mean that the protective lacquer layer is not transparent. This makes it possible for the protective lacquer layer to be perceived as a decoration and / or decorative element, preferably for the protective lacquer layer to form a decoration and / or decorative element.

[0051] It is possible for the protective lacquer layer to be arranged partially or over the entire surface of the transfer layer; preferably, the protective lacquer layer is arranged over the entire surface of the transfer layer. It is possible for the protective lacquer layer to be formed in multiple layers, in particular with the layers of the protective lacquer layer at least partially overlapping. This is particularly advantageous when the protective lacquer layer is formed as a printed layer, as this allows for the creation of interesting designs.

[0052] It is possible for a printing layer, in particular a further printing layer and / or the above-described printing layer of the insert, to be arranged on the protective lacquer layer, in particular wherein the printing layer has not yet fully cured, at least in some regions. This printing layer, in particular this further printing layer and / or the above-described printing layer of the insert, is and / or will preferably be arranged partially or over the entire surface of the protective lacquer layer. Furthermore, this printing layer, in particular this further printing layer and / or the above-described printing layer of the insert, is designed in particular as a screen printing layer, as a gravure printing layer, as an inkjet printing layer or as a combination thereof, preferably as a screen printing layer.

[0053] The transfer layer has in particular at least one decorative layer containing at least one decorative element, preferably on the side of the protective lacquer layer facing away from the carrier layer.

[0054] Furthermore, the at least one decorative element containing the at least one decorative layer is preferably selected from the group consisting of transparent and / or colored lacquer layers, in particular comprising one or more dyes and / or pigments, replication layers with a molded optically active surface structure, reflection layers, in particular opaque reflection layers, transparent reflection layers, metallic reflection layers or dielectric reflection layers, optically variable layers, optically active layers, interference multilayer systems, volume hologram layers, liquid crystal layers, in particular cholesteric liquid crystal layers, and combinations thereof.

[0055] Alternatively or additionally, it is possible for the transfer layer to have at least one functional layer containing at least one functional element on the side of the protective lacquer layer facing away from the carrier layer. In this case, it is possible for at least one functional layer to be arranged overlapping and / or adjacent to at least one decorative layer. It is also possible for at least one functional layer to be arranged between at least two decorative layers or to be arranged on a side of the functional layer of at least one decorative layer facing toward and / or away from the protective lacquer layer.

[0056] The at least one functional element is in particular selected from the group consisting of at least one electronic element, in particular conductor track, contact element, LED, sensor, in particular touch sensor, temperature sensor, pressure sensor, antenna, in particular RFID element, memory, processor, operating element, display, capacitance, resistor, microfluidic element and combinations thereof.

[0057] For example, the functional layer can be designed, alone or in combination, as electrically conductive layers, antenna layers, electrode layers, magnetic layers, magnetic storage layers or barrier layers.

[0058] Preferably, the at least one decorative element is arranged in at least one decorative layer and / or the at least one functional element is arranged in at least one functional layer, each of which independently comprises a UV-crosslinked lacquer or chemically crosslinked lacquer or a thermoplastically deformable layer and each of which independently is unpigmented, pigmented, or colored. It is also conceivable for the protective lacquer layer to at least partially preferably comprise at least one decorative element and / or one functional element, or for example, none of them.

[0059] A bonding agent layer is preferably arranged between the protective lacquer layer and the at least one decorative element and / or the at least one functional element. The bonding agent layer may comprise or consist of at least one acrylic resin. Furthermore, the bonding agent layer may preferably have a layer thickness selected from a range of 0.1 μm to 10 μm.

[0060] It is also possible for the transfer layer to have at least one lacquer layer, preferably with a layer thickness selected from a range of 0.5 μm to 10 μm, which forms a surface of the transfer layer facing away from the carrier layer. This lacquer layer preferably serves to bond it to the base body or the plastic compound.

[0061] Preferably, the at least one lacquer layer comprises or consists of at least one adhesive selected from the group consisting of physically curing adhesives, chemically curing adhesives, pressure-sensitive adhesives, or mixtures thereof. Furthermore, it is possible for the at least one lacquer layer to be a primer layer and / or for a primer layer to be arranged instead of the at least one lacquer layer and / or for a primer layer to be arranged on the side of the at least one lacquer layer facing away from the protective lacquer layer, in particular wherein the primer layer comprises or consists of PVC copolymers and PMMA (PVC=polyvinyl chloride, PMMA=polymethyl methacrylate).

[0062] Furthermore, the transfer layer can have at least one or more of the following layers, each selected individually or in combination from: at least one colored lacquer layer, at least one metal layer, at least one oxide layer, at least one barrier layer, at least one acceptance layer, at least one second protective lacquer layer, at least one laser protective lacquer layer. The layers can each be arranged over the entire surface or partially in the transfer layer. The carrier layer of the transfer film is provided with a carrier layer which preferably comprises, alone or in combination, polyethylene terephthalate (PET), glycol-modified polyethylene terephthalate (PETG), polypropylene (PP), polycarbonate (PC), polyimide (PI) or polyamide (PA), and / or blends or copolymers thereof. The carrier layer, preferably the carrier layer, preferably has a layer thickness selected from the range from 10 μm to 100 μm, preferably from 10 μm to 50 μm.

[0063] It is possible for the carrier layer to have at least one release layer, which is preferably arranged between the carrier layer and the protective lacquer layer. The layer thickness of the release layer is in particular selected from a range of 0.1 nm to 100 nm. The release layer preferably comprises or consists of at least one wax, for example a polyethylene wax. The release layer preferably has a melting temperature selected from a range of 80 °C to 100 °C. The carrier layer is preferably arranged on the protective lacquer layer with an adhesive force in a range of 2 cN to 50 cN, preferably in a range of 5 cN to 35 cN, or this force must be overcome when peeling off the carrier layer.

[0064] “In contact with the carrier layer” means, with regard to the protective lacquer layer, that the protective lacquer layer is in direct contact with the carrier layer of the carrier layer if no release layer is provided or, if a release layer is provided, that the protective lacquer layer is in contact with the release layer of the carrier layer.

[0065] It is also conceivable that the transfer film is arranged on a substrate before step b) and in particular before step d), is formed, preferably pre-formed and / or deep-drawn, and / or trimmed. It is particularly advantageous if the protective lacquer layer is not yet cured, at least in some areas, since it then exhibits significantly greater extensibility.

[0066] In other words, it is possible that the method further comprises at least one of the following steps h), i) and j): h) arranging the transfer film on a substrate; i) forming the transfer film and / or the substrate into a desired shape; and j) trimming the transfer film and / or the substrate along a defined contour line

[0067] In particular, it is possible for steps h), i), and j) to be carried out after step a), preferably after step a1). Preferably, step h) is carried out before step d). Preferably, steps i) and j) are carried out after step d) and preferably before step b).

[0068] It may also be expedient to perform steps h), i), and j) before step d). This offers the advantage that the protective coating layer is still protected by the carrier layer during back-injection, especially if only minimal forming is performed in step i).

[0069] Steps h), i) and j) are carried out in particular in an insert molding process, wherein the transfer film arranged on the substrate corresponds to an insert or can be used as an insert. It is possible for the insert to be used as and / or correspond to the insert provided in step a2). In other words, the insert provided in step a2) can be obtained after step i). For this purpose, the insert can be placed into an injection mold in a subsequent process step, in particular step b), and can be back-injected there, preferably in step c).

[0070] In particular, the transfer film is applied to a substrate by embossing, in particular hot stamping or cold stamping. Preferably, the transfer film is applied by applying heat and / or pressure and / or UV radiation.

[0071] In particular, the substrate is selected, alone or in combination, from polycarbonate (PC), polycarbonate / acrylonitrile butadiene styrene (ABS / PC), polypropylene (PP), thermoplastic polyurethane (TPU), polymethyl methacrylate (PMMA), or blends and / or coextrudates thereof. In particular, the forming can be carried out, alone or in combination, by deep drawing or vacuum forming. Preferably, the forming takes place by applying heat and / or pressure.

[0072] In particular, trimming can be carried out, alone or in combination, by means of water jet cutting, laser cutting or punching.

[0073] In step b), the transfer layer is placed in an injection mold and, in step c), back-injected with a plastic compound. Step b) is preferably performed after step a) or after step j), and in particular before step c). Step c) is preferably performed before step d) and / or after step b). In particular, step c) can be performed once or several times, in particular using the same or different plastic compounds.

[0074] Conveniently, the injection mold has and / or predetermines the shape of the surface of the article. It is possible to obtain an article that is a rigid body. It is preferably possible for the surface of the article, especially with the protective lacquer layer, to be curved and / or bent.

[0075] Preferably, during the back-injection molding of the transfer layer, in particular in step e), the transfer layer or optionally the substrate is at least partially covered with the plastic compound on at least one surface of the transfer layer of the transfer film facing away from the carrier layer. For this purpose, the transfer film is arranged in the injection mold, and the injection mold is filled with at least the plastic compound. Furthermore, it is possible for the injection mold to be formed by two tool halves, in particular which are open before step b) and closed before step c), preferably during which the injection mold is formed.

[0076] The base body is formed from the plastic compound and comprises the plastic compound. The plastic compound preferably comprises thermoplastic, selected individually or in combination from polycarbonate (PC), polyethylene terephthalate (PET), polypropylene (PP), polymethyl methacrylate (PMMA), polyethylene naphthalate (PEN), polyamide (PA), acrylonitrile-butadiene-styrene copolymer (ABS), ABS / PC, PC / ABS, and thermoplastic polyurethane (TPU). The base body can be formed in a single or multi-layer configuration.

[0077] Furthermore, it is possible for the base body to have a transmission of at least 45%, preferably at least 70%, for the wavelength range perceivable by the human eye, preferably the range from 400 nm to 700 nm. This allows displays or light sources, for example, to be perceived through the base body. This offers the advantage that a manufactured article can be backlit.

[0078] Advantageously, after the plastic compound has cooled or after the base body has been formed, the base body and the transfer film are demolded. In particular, the transfer film and / or optionally the substrate are bonded to the base body after step c). The transfer layer and / or the substrate can no longer be removed from the base body without damaging it.

[0079] The carrier layer is detached from the transfer layer in step d). Preferably, step d) is performed before step e). In particular, step d) can be performed before step f) and before step g). Furthermore, step d) is preferably performed after step c). It is possible for step d) to be performed after step k3).

[0080] When removing the carrier layer, any release layer present may remain on the carrier layer or on the transfer layer. It is also possible that the release layer separates, so that after the carrier layer is removed, remnants of the release layer are present on the carrier layer and on the transfer layer.

[0081] It is furthermore possible for the back-injection molding of the transfer layer in step c) and the detachment of the carrier layer in step d) to be carried out with a spatial separation. In this case, it is possible for the transfer layer connected to the base body to be temporarily stored and / or transported. In particular at a different production location, it is then possible to individualize the article by forming the at least one first and / or second region. In step k3) of step A3), the transfer film, in particular the transfer layer, is arranged on a surface of the base body. Furthermore, the transfer film, preferably the transfer layer, is connected to the surface of the base body by hot stamping. The transfer layer can preferably no longer be removed from the base body without causing damage. Furthermore, it is possible for the transfer layer to be and / or is arranged partially or over the entire surface of the base body.

[0082] In step e), at least one first region and at least one second region are arranged in the protective lacquer layer and / or the printed layer. This is done by means of an embossing process, for example, hot stamping, in particular roll stamping or stroke stamping, preferably by contacting the protective lacquer layer and / or the printed layer with an embossing tool. For example, the embossing tool can have a master structure on the surface that is contacted with the protective lacquer layer and / or the printed layer.

[0083] The master structure on the surface of the embossing tool can be introduced, for example, by laser processing and / or by etching processes and / or by means of other known surface processing processes.

[0084] In a further embodiment, it is possible for a carrier comprising a master structure to be arranged at least in some regions between an embossing tool and the transfer layer and / or for a carrier comprising a master structure to be arranged at least in some regions between an embossing tool and the printing layer. In other words, it is possible for the embossing tool to have a carrier comprising a master structure at least in some regions. In this case, the embossing tool preferably has no master structure and / or is smooth and preferably only defines the embossing surface with a contour as the outer contour and possibly defines the embossing surface with one or more recesses within the outer contour as the inner contour. It is therefore possible for the embossing tool to define the outer contour and preferably the inner contour of the embossing surface.

[0085] Alternatively, the embossing tool can have an additional master structure in addition to the master structure of the carrier, in which case the master structure of the embossing tool and the master structure of the carrier overlap in the protective lacquer layer and / or in the print layer, particularly in the at least one first region. The master structure of the embossing tool and the carrier are preferably different. For example, the master structure on the embossing tool has a different size dimension than the master structure on the carrier.

[0086] For example, the embossing tool provides a coarse structure in the millimeter to micrometer range and the master structure on the carrier as a fine structure in the micrometer to nanometer range is superimposed on it, whereby a combination structure of coarse structure and fine structure is molded in the protective lacquer layer and / or in the printing layer.

[0087] By contacting the embossing tool with the protective lacquer layer and / or with the printing layer and / or the carrier arranged therebetween, the master structure of the embossing tool or of the carrier is at least partially molded in the protective lacquer layer and / or in the printing layer, wherein a relief structure complementary to the master structure is imaged in the protective lacquer layer and / or in the printing layer, in particular in the at least one first region.

[0088] In particular, the protective lacquer layer and / or the printing layer is only contacted with the embossing tool or the carrier in certain regions, preferably only where at least a first region is arranged in the protective lacquer layer and / or in the printing layer.

[0089] It is also possible for the embossing tool and / or the carrier to be designed such that the embossing tool and / or the carrier only has a master structure in certain regions, wherein the protective lacquer layer and / or the printing layer is contacted with the embossing tool and / or the carrier such that the master structure contacts the protective lacquer layer and / or the printing layer where at least a first region is arranged in the protective lacquer layer and / or in the printing layer. Alternatively or additionally, the regions of the protective lacquer layer and / or the printing layer in which the at least one second region is arranged can be covered with a mask, in particular a removable one, for example a removable polymer film. Step e) is preferably carried out using an embossing tool.For example, at least one embossing roller or at least one embossing wheel or at least one embossing die and / or at least one carrier comprising a master structure can be used as the embossing tool.

[0090] The embossing tool preferably has, on the surface that comes into contact with the protective lacquer layer and / or print layer, for example, its outer circumference, a coating made of an elastomer with a layer thickness selected from a range of 3 mm to 20 mm, preferably from 5 mm to 15 mm. The elastomer is preferably silicone rubber. The elastomer preferably has a hardness selected from the range of 30 Shore A to 95 Shore A, preferably from 60 Shore A to 90 Shore A. Advantageously, the optical properties of the relief structure of the at least one first region can be influenced by the different Shore hardnesses.

[0091] Alternatively, it is also possible for the embossing tool to have a surface made of metal, in particular selected from the group of brass, copper, steel or titanium.

[0092] The embossing wheel preferably has a bevel on its circumference at each of its outer edges, wherein in particular the coating made of an elastomer has a bevel on its circumference at each of its outer edges. The bevel preferably has an angle to the surface normal of the circumference of the embossing wheel of between 15° and 75°, more preferably between 25° and 65°. With such a bevel, particularly clean edges of the embossing can be achieved. This means that the transition between the first region and the adjacent second region is, to the naked human eye, largely smooth, largely straight, and largely without disturbing artifacts, in particular smooth, straight, and largely without disturbing artifacts.

[0093] Preferably, the formation of the at least one first region and second region takes place at an embossing temperature, i.e., the temperature of the embossing tool, selected from a range of 125°C to 250°C. The above temperature range ensures a clear expression of the relief structure without the carrier or the layers of the transfer layer being damaged by the temperature.

[0094] Furthermore, the embossing speed, i.e. the feed speed, is a value selected from a range of 1 m / min to 5 m / min.

[0095] The embossing pressure, in particular in stroke embossing, is preferably selected from a range of 0.1 kN to 25 kN, preferably from 0.2 kN to 20 kN, particularly preferably from 0.3 kN to 15 kN.

[0096] The embossing time, in particular in stroke embossing, is preferably selected from the range from 0.3 s to 2.5 s, preferably from 0.5 s to 2.0 s, particularly preferably from 1.0 s to 1.5 s, wherein the embossing time is preferably adapted to the layer thickness of the carrier.

[0097] Furthermore, it is also possible that the embossing pressure, especially during roll embossing, is preferably selected from a range of 10 kg / cm 2 up to 50 kg / cm 2 , preferably 15 kg / cm 2 up to 30 kg / cm 2 , particularly preferably 20 kg / cm 2 up to 25 kg / cm 2 , becomes.

[0098] To determine the embossing pressure for roll-on embossing, an embossing wheel or embossing roller is moved down onto a substrate, for example the transfer layer, while in an upright position. The resulting contact area is then measured. This is caused by the squeezing of the coating, for example the silicone rubber, by the embossing wheel or embossing roller. The contact area is influenced by the hardness of the coating and the applied embossing pressure. Theoretically, for very hard materials, the contact area corresponds only to a line of contact between the embossing wheel or embossing roller and the substrate. The resulting contact area is then called the "print image". For an embossing wheel or embossing roller with 80 Shore A, a preferred print image is a 20 mm to 25 mm wide strip. For 60 Shore A, a preferred print image is a 30 mm to 55 mm wide strip.Depending on the width of the embossing wheel or roller and the resulting surface area, a force can be specified with which the embossing wheel or roller is pressed onto the substrate. The applied embossing pressure can thus be conveniently specified, especially for roll-on embossing, as a function of the contact area. If the contact area and embossing pressure are known, these can also be converted into an embossing pressure using the unit Newton.

[0099] For example, if the embossing wheel or embossing roller is 100 mm wide and the contact surface is 25 mm wide, the resulting area is 100 mm x 25 mm = 25 cm 2 . With a target value of 25 kg / cm 2 and a contact area of ​​25 cm 2 This results in an embossing pressure of 625 N. The width of the embossing wheel is measured at its outermost circumference.

[0100] For example, a good result in a stamping process, especially in stroke stamping, is achieved with the combination of a stamping temperature of 190 °C, a stamping time of 1.5 s and a stamping pressure of 15 kN.

[0101] In an embossing process, especially by means of roll embossing, a good result is achieved, for example, with the combination of an embossing temperature of 185°C, an embossing speed of 2 m / min, an embossing pressure of 20 kg / cm 2 up to 25 kg / cm 2 and when using an embossing roller with a hardness of 80 Shore A.

[0102] The master structure has, in particular, a structure depth selected from a range of 0.1 pm to 15 pm, preferably from 0.1 pm to 10 pm, particularly preferably from 0.1 pm to 5 pm. In particular, the master structure has an average structure spacing selected from the range of 0.05 pm to 1000 pm, preferably from 0.1 pm to 100 pm, particularly preferably from 0.1 pm to 50 pm.

[0103] The complementary relief structure can, in particular, have a smaller structural depth than the master structure. In particular, the complementary relief structure has a structural depth that preferably corresponds to 20% to 99% of the structural depth of the master structure, particularly preferably 40% to 95% of the structural depth of the master structure.

[0104] Structure depth is defined as the distance between the maxima of the elevation of the master structure and the minima of the depressions, viewed perpendicular to the plane spanned by the support containing the master structure. Structure pitch is defined as the distance between two adjacent minima of the depressions, viewed perpendicular to the plane spanned by the support containing the master structure.

[0105] The master structure or the complementary relief structure can, alone or in combination, comprise a regular one-dimensional lattice, a regular two-dimensional lattice, a random structural component, or a pseudo-random structural component. In particular, the complementary relief structure can exhibit optical and / or functional effects.

[0106] Random relief structures can be created, for example, using substrates with an incorporated surface roughness or particles. For example, with a matte or brushed substrate, or with a substrate comprising a master structure layer into which particles are incorporated. This creates, in particular, a rather undefined and rounded profile shape.

[0107] Pseudo-random relief structure is a relief structure that appears to be a random relief structure when viewed locally, but is preferably reproduced at regular intervals and is therefore not recognizable as a random structure.

[0108] A preferred one-dimensional or two-dimensional grating is a non-random relief structure, preferably featuring precise and geometrically formed profile shapes such as rectangular profiles, sinusoidal profiles, sawtooth profiles, hemispherical profiles, or blaze structures. Furthermore, a one-dimensional or two-dimensional grating can feature binary profiles or profiles with stepped profile depths or with a constant profile depth.

[0109] It is advantageous if the master structure is designed such that the complementary relief structure comprises a microstructure, in particular a microstructure whose dimensions are below the resolution limit of the human unaided eye. The resolution limit of the human unaided eye is preferably structures with dimensions of at least 300 pm. Furthermore, the master structure can be designed such that the complementary relief structure comprises a macrostructure, in particular a macrostructure whose dimensions are above the resolution limit of the human unaided eye.

[0110] Furthermore, the master structure can be designed such that the complementary relief structure is formed as a microstructure whose dimensions are below the resolution limit of the unaided human eye, and additionally as a macrostructure visible to the unaided human eye. A macrostructure can be present next to a microstructure and / or be superimposed by a microstructure.

[0111] Advantageously, a microstructure can have an optical effect that simulates the presence of a macrostructure.

[0112] The master structure can be designed such that the complementary relief structure is formed as a matte structure, a diffractive structure, and / or a refractive structure, and / or a macrostructure. Furthermore, several of the aforementioned structures can be present side by side and / or superimposed.

[0113] Diffractive structures are structures that create optical effects based on the diffraction of light, such as diffraction gratings or holograms. These can be classic 2D / 3D or 3D holograms, which allow the representation of three-dimensional information based on a surface structure. Locally, the profile of a holographically generated hologram, such as a Fourier hologram, can be considered approximately periodic, with typical line counts in the range of 300 lines / mm to

[0114] 3000 lines / mm and typical structure depths in the range of 50 nm to 1000 nm. For achromatic effects, however, very coarse grating structures with line counts in the range of 10 lines / mm to 300 lines / mm and structure depths in the range of 0.5 pm to 10 pm can also be used. A computer-generated hologram, such as the so-called kinoform, can create the impression of a stochastic surface relief and exhibit an asymmetric diffraction effect. A typical structure depth is half or a multiple of the wavelength of the incident light and depends on whether the kinoform is intended to exert its effect in transmission or reflection.

[0115] The matte structure is a diffractive structure with a stochastic progression, so that incident light is scattered randomly. On a microscopic scale, matte structures have fine relief structure elements that determine the scattering power and can be described using statistical parameters. Examples of these parameters are the average spacing of the relief structure elements in the x- and / or y-direction of the plane spanned by the transfer film, the mean roughness Ra, and the correlation length Ic. Preferred matte structures have an average spacing in the range from 300 nm to 5000 nm and a mean roughness Ra in the range from 20 nm to 2000 nm, preferably from 50 nm to 500 nm. The correlation length Ic is preferably in the range from 200 nm to 50,000 nm, more preferably from 500 nm to 10,000 nm.

[0116] Refractive structures are structures that create optical effects based on the refraction and / or reflection of light, such as microlenses or micromirrors. Such microlenses or micromirrors are not used individually, but rather are preferably arranged next to one another in a regular or pseudorandom grid or pixel array.

[0117] Optically variable effects based on the aforementioned structures can be realized, for example, by varying one or more structural parameters, for example by varying the grating period, the average structural spacing, the tilt angle of the micromirrors, the structural depth and / or the azimuth angle.

[0118] Preferably, the carrier comprising the master structure is used for a small number of embossings in the same surface area of ​​the carrier, in particular selected from a range of 1 to 20, preferably 1 to 10. If a carrier is used for too many embossings, accumulated contaminants will have a negative effect on the embossing.

[0119] The advantage of using a carrier, which is replaced regularly, is that contamination of the master structure that accumulates during embossing does not build up on the carrier, but that after a defined maximum number of embossings in the same surface area of ​​the carrier, a new surface area of ​​the carrier with unused structure is immediately available.

[0120] The new surface area will then be cleaner, for example, and the master structure will have the intended depth. This ensures consistently high-quality embossing.

[0121] When using an embossing tool without a carrier, it should be noted that dirt can accumulate over time or the surface, such as the elastomer surface coating, can harden over time. This can also lead to a deterioration in the quality of the relief structure incorporated into the protective lacquer layer, making it necessary to replace the embossing tool, which is more costly than replacing a carrier.

[0122] In particular, it is advantageous that at least 20%, preferably at least 40%, more preferably at least 50%, even more preferably at least 70%, of the relief shape or surface structure of the master structure, in particular the structure depth of the master structure, is and / or is formed into the protective lacquer layer and / or printing layer. As a result, the intended relief structure exhibits the desired optical properties in the finished article.

[0123] It is possible to provide and / or obtain a base body having a surface that is or will be facing the transfer film and / or optionally the substrate, and wherein at least one bevel, preferably a chamfer, is arranged on this surface. The at least one bevel, preferably a chamfer, is arranged on at least one outer edge of the base body.

[0124] The bevel preferably has an angle to the surface normal of the

[0125] The plane formed on the surface of the base body is selected from the range of 15° to 75°, more preferably from 25° to 65°. Preferably, the base body has a bevel, preferably a chamfer, on opposite edges.

[0126] When arranging the transfer layer and / or printing layer on the base body, the transfer layer and / or printing layer preferably assumes the contour of the base body. It is possible for the first region to be and / or be formed on the bevel and on the plane formed by the surface of the base body, in particular to be and / or be formed continuously.

[0127] It is possible for the embossing tool, especially the embossing wheel, to be height-adjustable. The height adjustment of the embossing tool can be achieved using one or more servo motors or via pneumatic control. This offers the advantage that the same embossing pressure is applied across the entire surface. This makes it possible to create a uniformly executed and interrupted first area.

[0128] Advantageously, the carrier comprising the master structure is supplied in particular as a roll and can thus be transported further as a carrier web. This allows for particularly rapid changes to the surface area of ​​the carrier used for embossing. It is also possible to provide and use a carrier comprising the master structure in the form of sheet material or as a plate. This, too, can be easily replaced and customized as required. The carrier preferably consists of or comprises a polymer, for example PET. The carrier preferably has a layer thickness selected from a range of 5 μm to 500 μm, more preferably 20 μm to 50 μm.

[0129] Alternatively, the carrier may consist of or comprise metal, for example brass, copper, steel or titanium.

[0130] Preferably, the master structure was incorporated into the carrier during its manufacture, particularly during extrusion. This offers the advantage that the structure is resistant to the temperatures during the embossing step. For example, step e) can comprise at least one or more of the following substeps:

[0131] - Arranging and aligning the transfer foil, preferably the transfer layer, and the base body according to the embossing tool or the carrier;

[0132] - Heating the embossing tool to embossing temperature

[0133] Contacting the master structure of the embossing tool or the carrier with the transfer layer, in particular the protective lacquer layer, in particular in the at least one first region;

[0134] Moving or rotating the embossing tool or the carrier.

[0135] Preferably, step e) is performed after steps A1) and / or A2) and / or after A3). Preferably, step e) is performed after step d) and in particular before step f). Step e) can also be performed multiple times, in particular with different or identical embossing tools or carriers comprising the same or different master structure.

[0136] In particular, in step e), the at least one first region is formed such that the transfer layer has a relief structure in the at least one first region, wherein the relief structure is preferably complementary to the master structure of the embossing tool and / or the carrier used. Preferably, the at least one second region has no structure and is perceived as smooth and flat. In particular, the at least one first region differs optically or functionally from the at least one second region, in particular by its degree of gloss or transmittance.

[0137] Preferably, the at least one first region is formed only in regions of the protective lacquer layer and / or print layer when viewed perpendicular to a plane spanned by the protective lacquer layer and / or print layer. Preferably, the protective lacquer layer and / or print layer has the at least one first region only in regions.

[0138] The at least one first region preferably consists of one or more contiguous and / or separate regions, in particular when viewed perpendicular to the plane spanned by the protective lacquer layer and / or print layer. For example, the at least one first region can completely surround the at least one second region and / or the at least one first region can be completely surrounded by the at least one second region. The at least one first region and the at least one second region are arranged next to one another and do not overlap, in particular when viewed perpendicular to the plane spanned by the protective lacquer layer and / or print layer.

[0139] In particular, the design or shape of the at least one first area is selected individually or in combination from: motif, letter, number, symbol, geometric figure, visually recognizable design element, pattern, logo, codes and conductor track.

[0140] In particular, the at least one first region is formed in register with a layer or element, preferably a decorative element and / or functional element, of the transfer layer and / or the base body in the protective lacquer layer and / or in the print layer. For this purpose, the protective lacquer layer and / or the print layer can, for example, be masked, such that the relief structure is formed only in the unmasked at least one first region.

[0141] Accurate registration refers to the positioning accuracy of two or more layers, elements, areas and / or layers relative to one another. The registration accuracy should be within a specified tolerance and as small as possible. At the same time, the registration accuracy of several layers, elements, areas and / or layers relative to one another is an important feature for increasing process reliability and / or product quality, as well as protection against counterfeiting. Accurate positioning can be achieved in particular using sensory, preferably optically detectable, register marks. These register marks can either represent special separate layers, elements, areas and / or layers or can themselves be part of the layers, elements, areas and / or layers to be positioned.

[0142] Furthermore, it is possible for the protective lacquer layer of the transfer film and / or the printing layer and / or the article to have a transmission of at least 45%, preferably of at least 70%, for the wavelength range perceivable by the human eye, preferably for the range from 400 nm to 700 nm, in the at least one first region and / or in the at least one second region. This allows, for example, displays or light sources to be perceived in the at least one first region and / or in the at least one second region. This offers the advantage that a manufactured article can be backlit.

[0143] The at least one first region of the printing layer and / or the insert and / or the transfer film, in particular the protective lacquer layer or the article, can have a gloss value selected from a range of 1 Gil to 59 Gil, preferably from 5 Gil to 30 Gil, or can be designed in such a way.

[0144] The at least one second region of the print layer and / or the insert and / or the transfer film, which preferably has no relief structure, in particular of the protective lacquer layer or of the article, can have a gloss value selected from a range of 31 Gil to 98 Gil, preferably from 60 Gil to 90 Gil.

[0145] This advantageously allows gloss values ​​to be adjusted such that the at least one first region and the at least one second region are visually perceptibly different from one another. In particular, this also allows for very matte surfaces due to corresponding structures, which are not possible with other coatings, especially known structured protective coatings.

[0146] The gloss values ​​are measured at a measuring angle of 60° using the "micro-gloss" measuring device from Byk-Gardener GmbH, Geretsried. During gloss measurement, a precisely defined, directed light beam is directed at a paint surface, such as the protective lacquer layer of the transfer film and / or the article, at a 60° angle. A reflectometer positioned opposite measures the amount of light reflected at a 60° angle (gloss angle). The gloss is preferably calibrated to 100 GU (gloss units) (= 100%) using a standard. The highest achievable gloss value is therefore preferably 100 GU. The gloss value is preferably specified in percent (%). Therefore, it is expedient if the unit of the gloss value is percent (%) in this case. The measured gloss value is therefore preferably a value from a range of 0% to 100%.The gloss units are in particular percentage values ​​and the gloss units are in particular percentage values.

[0147] It is possible that the method for producing the article expediently further comprises the optional following step, which is carried out in particular after step e) and before step g): f) curing the protective lacquer layer and / or print layer which is at least partially not yet completely cured, wherein the protective lacquer layer and / or print layer cures completely at least partially.

[0148] Preferably, all curable components of the article are fully cured in step f). Thus, the protective coating after step f) exhibits high chemical and mechanical resistance in all areas.

[0149] In particular, in step f), the complete curing of the protective lacquer layer and / or printing layer is carried out by means of high-energy electromagnetic radiation, in particular UV radiation, and / or by means of high-energy particle radiation, in particular electron radiation, and / or is carried out by curing, preferably at a temperature in a range of 25 °C to 180 °C, the protective lacquer layer and / or printing layer.

[0150] The irradiation is preferably carried out using high-energy electromagnetic radiation and / or high-energy particle radiation. The electromagnetic radiation is preferably UV radiation, in particular from a wavelength range of 100 nm to 390 nm, preferably from 200 nm to 380 nm, particularly preferably from 200 nm to 300 nm. The particle radiation is preferably electron radiation.

[0151] For complete curing in step f), the protective lacquer layer and / or printing layer is exposed to an irradiance selected from the range of 500 mW / cm 2 up to 700 mW / cm 2 irradiated. The UV dose is preferably selected from the range of 2000 mJ / cm 2 up to 3500 mJ / cm 2 . The irradiation preferably takes place over a period of time selected from the range of 1 s to 10 s, preferably from 2 s to 6 s.

[0152] The possibility of carrying out step f) and / or the not yet fully cured protective lacquer layer and / or print layer results in a number of advantages. The not yet fully cured transfer film, preferably transfer layer, is therefore particularly more deformable than a transfer film, preferably transfer layer, with fully cured layers. This ensures, especially when creating curves, that the corresponding layers can stretch without cracking or other adverse effects occurring. Once deformation, in particular of the transfer film, preferably transfer layer, has taken place, for example in an injection mold or during deep drawing, the protective lacquer layer and / or print layer can subsequently be cured to achieve its final hardness and durability.

[0153] In step g), the article produced by the process is obtained, which comprises the transfer layer, in particular the protective lacquer layer, and / or printing layer, and the base body, and optionally the substrate. Thus, step g) is particularly the last step of the process according to the invention and is preferably carried out after step e).

[0154] The article preferably has the protective lacquer layer and / or print layer as an outermost surface. Preferably, no further layers are applied to the protective lacquer layer and / or print layer, thereby advantageously ensuring a high resistance of the outermost surface, particularly compared to the base body and / or optionally the substrate.

[0155] The article preferably comprises at least one decorative layer containing at least one decorative element, in particular in the transfer layer of the transfer film and / or the insert, and / or at least one functional layer containing at least one functional element, in particular in the transfer layer of the transfer film and / or the insert. An article produced according to the method according to the invention can be used in a variety of areas. The produced article can be used, for example, alone or in combination, as a display window, touch field, panel, bezel, cladding, cover, functional element, electronic article and housing part or exterior part, in particular of white goods and / or household appliances and / or automotive interior areas and / or automotive exterior areas.

[0156] It is also possible for the process steps to be performed once or multiple times. In particular, process steps can be repeated. A preferred process comprises at least the following steps a), e), and g), optionally a), e), f), and g), wherein, in particular, further steps can be inserted between these steps.

[0157] For an IMD process, the process comprises in particular at least the following steps in the order a1), b1), c1), d), e), g), optionally a1), b1), c1), d), e), f), g).

[0158] For an insert molding process, the process in particular comprises at least the following steps in the order a2), b2, c2), e), g), optionally a2), b2, c2), e), f), g). Alternatively, the process for an insert molding process in particular comprises at least the following steps in the order a1), h), d), b1), c1), e), g), optionally a1), h), d), b1), c1), e), f), g). It is possible for an insert molding process to comprise at least the steps in the order a1), h), d), i), j), b1), c1), e), g), optionally a1), h), d), i), j), b1), c1), e), f), g).

[0159] For an injection molding process with downstream hot stamping processes, the process comprises in particular at least the following steps in the order a3), k3), d), e), g), optionally a3), k3), d), e), f), g).

[0160] In particular, if the method for producing an article is an IMD method, it can comprise at least the following steps once or several times: a1) providing a transfer film, wherein the transfer film has a carrier layer and a transfer layer, wherein the carrier layer is removable from the transfer layer, wherein the carrier layer comprises a carrier layer, wherein the transfer layer comprises a protective lacquer layer, wherein the protective lacquer layer is at least partially not yet fully cured or is thermoplastic, and wherein the protective lacquer layer is arranged such that it is in contact with the carrier layer; b1) arranging the transfer film, in particular the transfer layer, in an injection mold; c1) back-molding the transfer film, in particular the transfer layer, with a plastic compound, wherein the plastic compound forms a base body; d) detaching the carrier layer from the transfer layer;e) forming at least one first region and at least one second region by embossing in the protective lacquer layer, wherein the at least one first region has a relief structure; f) optionally curing the protective lacquer layer which is at least partially not yet fully cured, wherein the protective lacquer layer cures completely at least partially; g) obtaining an article, wherein the article comprises a base body and a protective lacquer layer which is at least partially cured or thermoplastic, wherein the protective lacquer layer has at least one first region and at least one second region, wherein a relief structure is arranged in the at least one first region.

[0161] In particular, if the method for producing an article is an insert molding method, it can comprise at least the following steps once or several times: a2) providing an insert, wherein the insert has a substrate and a transfer layer and / or a print layer arranged on the substrate, wherein the transfer layer comprises a protective lacquer layer, wherein the protective lacquer layer and / or the print layer is at least partially not yet fully cured or is thermoplastic; b2) arranging the insert in an injection mold; c2) back-molding the insert with a plastic compound, wherein the plastic compound forms a base body; e) forming at least one first region and at least one second region by embossing in the protective lacquer layer and / or in the print layer, wherein the at least one first region has a relief structure;f) optionally curing the protective lacquer layer which is at least partially not yet fully cured, wherein the protective lacquer layer and / or the print layer fully cures at least partially; g) obtaining an article, wherein the article comprises a base body and a protective lacquer layer and / or a print layer which is at least partially cured or thermoplastic, wherein the protective lacquer layer and / or a print layer has at least a first region and at least one second region, wherein a relief structure is arranged in the at least one first region;

[0162] In particular, if the method for producing an article is an injection molding process with subsequent hot stamping, it can comprise at least the following steps once or several times: a3) providing a transfer film, wherein the transfer film has a carrier layer and a transfer layer, wherein the carrier layer is removable from the transfer layer, wherein the carrier layer comprises a carrier layer, wherein the transfer layer comprises a protective lacquer layer and wherein the protective lacquer layer is arranged such that it is in contact with the carrier layer, wherein the protective lacquer layer is at least partially not yet fully cured or is thermoplastic, and providing a base body separate from the transfer film, which is produced in particular by injection molding; k3) arranging the transfer film, in particular the transfer layer, on a surface of the base body and hot stamping the transfer film onto the surface of the base body;d) Detaching the carrier layer from the transfer layer; e) Forming at least one first region and at least one second region by embossing in the protective lacquer layer, wherein the at least one first region has a relief structure; f) Optionally curing the protective lacquer layer which is at least partially not yet fully cured, wherein the protective lacquer layer fully cures at least partially; g) Obtaining an article, wherein the article comprises a base body and a protective lacquer layer which is at least partially cured or thermoplastic, wherein the protective lacquer layer has at least one first region and at least one second region, wherein a relief structure is arranged in the at least one first region.

[0163] Of course, the above-mentioned material characteristics can also be applied equivalently in a process or the above-mentioned process characteristics can be applied in the product.

[0164] The invention is explained below using several exemplary embodiments with the aid of the accompanying drawings. The exemplary embodiments shown are therefore not to be understood as limiting.

[0165] Fig. 1 shows a schematic representation of a transfer film suitable for the process.

[0166] Fig. 2 shows a schematic side view of a through the

[0167] procedure obtained article.

[0168] Fig. 3a shows a schematic plan view of an intermediate product obtained by the process.

[0169] Fig. 3b to 3e show schematic plan views of a through the

[0170] Articles obtained through the procedure.

[0171] Fig. 1 shows a schematic transfer film 2 which is suitable for the inventive method and can be provided in step a), preferably in step a1) and / or step a3).

[0172] This transfer film 2 comprises, in particular, a transfer layer 3 and a carrier layer 4, wherein the transfer layer 3 is detachable from the carrier layer 4. The transfer layer 3 can be single-layered or multi-layered. The transfer layer 3 shown in Fig. 1 is single-layered in this example and has a protective lacquer layer 8, which is preferably not yet fully cured, at least in some areas, or is made of a thermoplastic.

[0173] In step a), it is possible for the transfer film 2 to be provided as a roll. Furthermore, the transfer film 2 can be provided as a hot stamping film or as an IMD film. The article 1 is preferably manufactured using an IMD process or an insert molding process.

[0174] Alternatively, it is possible to already provide an insert after step a2). In a further alternative after step a3), it is possible for a base body 9 to be provided separately. It is possible for a provided insert to have a multi-layer transfer layer and / or a multi-layer printing layer. The printing layer is preferably arranged partially or over the entire surface of the insert. The printing layer is designed in particular as a screen printing layer, as a gravure printing layer, as an inkjet printing layer or as a combination thereof. The insert preferably has a gravure printing layer and a screen printing layer. It is possible for the layers of the printing layer to at least partially overlap. It is possible for the insert to have a transfer layer that is partially printed with one or more printing layers.

[0175] Preferably, the transfer layer 3 of the provided transfer film 2 has a layer thickness selected from a range of 0.1 pm to 100 pm, preferably from 0.5 pm to 75 pm, more preferably from 1 pm to 50 pm.

[0176] The protective lacquer layer 8 protects the resulting article 1, in particular, against external influences such as UV radiation, mechanical influences, for example, scratches, or chemical influences, for example, creams or solvents. The protective lacquer layer 8 thus exhibits particularly high resistance to mechanical and chemical stress, particularly compared to the underlying layers and / or base body 9. The protective lacquer layer 8 preferably has a layer thickness selected from a range of 1 μm to 15 μm, preferably from 2 μm to 8 μm, more preferably from 2 μm to 5 μm.

[0177] Furthermore, the protective lacquer layer 8 has in particular a transmission of at least 70%, preferably of at least 85%, for the wavelength range perceivable by the human eye, preferably for the range from 400 nm to 700 nm.

[0178] In particular, the protective lacquer layer 8 is not yet fully cured, at least in some areas. Preferably, the protective lacquer layer 8 is precured chemically and / or by irradiation, preferably UV irradiation, at least in some areas, and / or can still be fully cured, at least in some areas, by irradiation, preferably UV irradiation. For this purpose, the protective lacquer layer 8 comprises at least one UV-crosslinkable polymer. A UV-crosslinkable polymer within the meaning of the invention preferably has at least one, preferably two or more, ethylenically unsaturated double bond(s).

[0179] The partially uncured protective lacquer layer 8 is preferably based, alone or in combination, on at least one UV-crosslinkable or at least one chemically crosslinkable polymer. Furthermore, the protective lacquer layer 8 can be made of a thermoplastic polymer.

[0180] In a preferred embodiment, the protective lacquer layer 8 is formed as a printing layer, in particular as a screen-printed layer 8, as a gravure printing layer, as an inkjet printing layer, or as a combination thereof. The protective lacquer layer 8 preferably has a transmission of a maximum of 30%, preferably a maximum of 15%, for the wavelength range perceivable by the human eye, preferably for the range from 400 nm to 700 nm.

[0181] Preferably, the protective lacquer layer is arranged over the entire surface of the transfer layer 3. Alternatively, in an embodiment not shown here, it is possible for the protective lacquer layer 8 to be arranged partially in the transfer layer 3. It is possible for the protective lacquer layer 8 to be formed in multiple layers, in particular with the layers of the protective lacquer layer 8 at least partially overlapping.

[0182] In a further embodiment not shown here, it is possible for a printing layer to be and / or be arranged on the protective lacquer layer 8, in particular wherein the printing layer is not yet fully cured, at least in some regions. This printing layer is and / or is preferably arranged partially or over the entire surface of the protective lacquer layer. Furthermore, this printing layer, in particular a further printing layer, is designed in particular as a screen printing layer, as a gravure printing layer, as an inkjet printing layer, or as a combination thereof, preferably as a screen printing layer.

[0183] The transfer layer 3 has in particular at least one decorative layer containing at least one decorative element 11, preferably on the side of the protective lacquer layer 8 facing away from the carrier layer 4.

[0184] Furthermore, the at least one decorative element 11 containing the at least one decorative layer is preferably selected from the group consisting of transparent and / or colored lacquer layers, in particular comprising one or more dyes and / or pigments, replication layers with a molded optically active surface structure, reflection layers, in particular opaque reflection layers, transparent reflection layers, metallic reflection layers or dielectric reflection layers, optically variable layers, optically active layers, interference multilayer systems, volume hologram layers, liquid crystal layers, in particular cholesteric liquid crystal layers, and combinations thereof.

[0185] Alternatively or additionally, it is possible for the transfer layer 3 to have at least one functional layer containing at least one functional element 10 on the side of the protective lacquer layer facing away from the carrier layer. In this case, it is possible for at least one functional layer to be arranged overlapping and / or adjacent to at least one decorative layer. It is also possible for at least one functional layer to be arranged between at least two decorative layers, or for at least one decorative layer to be arranged on a side of a functional layer facing toward and / or away from the protective lacquer layer 8.

[0186] The at least one functional element 10 is in particular selected from the group consisting of at least one electronic element, in particular conductor track, contact element, LED, sensor, in particular touch sensor, temperature sensor, pressure sensor, antenna, in particular RFID element, memory, operating element, display, processor, capacitance, resistor, microfluidic element and combinations thereof.

[0187] For example, the functional layer can be designed, alone or in combination, as electrically conductive layers, antenna layers, electrode layers, magnetic layers, magnetic storage layers or barrier layers.

[0188] Preferably, the at least one decorative element 11 is arranged in at least one decorative layer and / or the at least one functional element 10 is arranged in at least one functional layer, each of which independently comprises a UV-crosslinked lacquer or a chemically crosslinked lacquer or a thermoplastically deformable layer and each of which independently is unpigmented or pigmented or colored.

[0189] It is also conceivable that the protective lacquer layer 8 at least partially preferably comprises at least one decorative element 11 and / or one functional element 10 or, for example, none of them.

[0190] A bonding agent layer is preferably arranged between the protective lacquer layer 8 and the at least one decorative element 11 and / or the at least one functional element 10. The bonding agent layer may comprise or consist of at least one acrylic resin. Furthermore, the bonding agent layer may preferably have a layer thickness in a range of 0.1 μm to 10 μm.

[0191] It is also possible for the transfer layer 3 to have at least one lacquer layer, preferably with a layer thickness selected from a range of 0.5 μm to 10 μm, which forms a surface of the transfer layer 3 facing away from the carrier layer 4. This lacquer layer preferably serves to connect to the base body 9 or the plastic mass. Preferably, the at least one lacquer layer comprises or consists of at least one adhesive selected from the group consisting of physically curing adhesives, chemically curing adhesives, pressure-sensitive adhesives, or mixtures thereof. Furthermore, it is possible for the at least one lacquer layer to be a primer layer and / or for a primer layer to be arranged instead of the at least one lacquer layer and / or for a primer layer to be arranged on the side of the at least one lacquer layer facing away from the protective lacquer layer 8, in particular wherein the primer layer comprises or consists of PVC copolymers and PMMA.

[0192] Furthermore, the transfer layer 3 can comprise at least one or more of the following layers, each selected individually or in combination from: at least one color lacquer layer, at least one metal layer, at least one oxide layer, at least one barrier layer, at least one acceptance layer, at least one second protective lacquer layer, at least one replication layer, and at least one laser protective lacquer layer. The layers can each be arranged over the entire surface or partially in the transfer layer 3.

[0193] The carrier layer 7 of the transfer film 2 is provided with a carrier layer 4, which preferably consists of or comprises, alone or in combination, polyethylene terephthalate (PET), glycol-modified polyethylene terephthalate (PETG), polypropylene (PP), polycarbonate (PC), polyimide (PI) or polyamide (PA) and / or blends or copolymers thereof. The carrier layer, preferably the carrier layer, preferably has a layer thickness selected from a range of 10 μm to 100 μm, preferably 10 μm to 50 μm.

[0194] It is possible for the carrier layer 4 to have at least one release layer, which is preferably arranged between the carrier layer 7 and the protective lacquer layer 8. The layer thickness of the release layer is in particular in a range from 0.1 nm to 100 nm. The release layer preferably comprises or consists of at least one wax, for example a polyethylene wax. The release layer preferably has a melting temperature in a range from 80 °C to 100 °C. The carrier layer 4 is preferably arranged on the protective lacquer layer 8 with an adhesive force in a range from 2 cN to 50 cN, preferably in a range from 5 cN to 35 cN, or this force must be overcome when peeling off the carrier layer 4.

[0195] After the transfer film 2 has been provided in step a), preferably step a1), the next step in the method according to the invention takes place, for example step b), in that transfer layer 3 is arranged in an injection mold.

[0196] However, it is also conceivable that the transfer film 2 is arranged on a substrate before step b) and in particular before step d), is formed, preferably pre-formed and / or deep-drawn and / or trimmed. In this case, it is particularly advantageous if the protective lacquer layer 8 is not yet cured, at least in some areas, since it then exhibits significantly greater extensibility.

[0197] In other words, it is possible for the method to further comprise at least one of the following steps h), i) and j): h) arranging the transfer film 2 on a substrate; i) forming the transfer film 2 and / or the substrate into a desired shape by applying heat and pressure; and j) trimming the transfer film 2 and / or the substrate along a defined contour line.

[0198] In particular, it is possible for steps h), i), and j) to be carried out after step a), preferably step a1). Preferably, step h) is carried out after step d). Preferably, steps i) and j) are carried out after step d) and preferably before step b). It may also be expedient to carry out steps i) and j) before step d), especially if only minor forming is carried out in step i).

[0199] In particular, the transfer film 2 is arranged on a substrate by embossing, in particular hot stamping or cold stamping. Preferably, the transfer film 2 is arranged by applying heat and / or pressure and / or irradiation with UV radiation. In particular, the substrate is selected, alone or in combination, from polycarbonate (PC), polycarbonate / acrylonitrile butadiene styrene (ABS / PC), polypropylene (PP), thermoplastic polyurethane (TPU), polymethyl methacrylate (PMMA), or blends and / or coextrudates thereof.

[0200] In particular, the forming can be carried out, alone or in combination, by deep drawing or vacuum forming. Preferably, the forming is carried out by applying heat and / or pressure. In particular, the trimming can be carried out, alone or in combination, by waterjet cutting, laser cutting, or punching.

[0201] In step b), the transfer layer 3 is arranged in an injection mold and, in step c), back-injected with a plastic compound. Step b) is preferably performed after step a) or after step j), and in particular before step c). Step c) is preferably performed before step d) and / or after step b). In particular, step c) can be performed once or several times, in particular using the same or different plastic compounds.

[0202] Conveniently, the injection mold has and / or predetermines the shape of the surface of the article 1. It is possible to obtain an article 1 that is a rigid body. It is preferably possible for the surface of the article 1, particularly with the protective lacquer layer, to be curved and / or bent.

[0203] Preferably, during the back-injection molding of the transfer layer 3, in particular in step c), the transfer layer 3 or optionally the substrate is covered at least partially with the plastic compound on at least one surface of the transfer layer 3 of the transfer film 2 facing away from the carrier layer 4. For this purpose, the transfer film 2 is arranged in the injection mold, and the injection mold is filled with at least the plastic compound. Furthermore, it is possible for the injection mold to be formed by two tool halves, in particular which are opened before step b) and closed before step c), preferably during which the injection mold is formed. The base body 9 is formed from the plastic compound and comprises the plastic compound.The plastic compound preferably comprises thermoplastic, selected individually or in combination from polycarbonate (PC), polyethylene terephthalate (PET), polypropylene (PP), polymethyl methacrylate (PMMA), polyethylene naphthalate (PEN), polyamide (PA), acrylonitrile-butadiene-styrene copolymer (ABS), ABS / PC, PC / ABS, and thermoplastic polyurethane (TPU). The base body 9 can be formed in a single layer or in multiple layers.

[0204] Furthermore, it is possible for the base body 9 to have a transmission of at least 45%, preferably at least 70%, for the wavelength range perceivable by the human eye, preferably for the range from 400 nm to 700 nm. This allows, for example, displays or light sources to be perceived through the base body 9.

[0205] Advantageously, after the plastic compound has cooled or after the base body 9 has been formed, the base body 9 and the transfer film 2 are demolded. In particular, the transfer film 2 and / or optionally the substrate are bonded to the base body 9 after step c). The transfer layer and / or the substrate can no longer be removed from the base body without causing damage.

[0206] In an alternative embodiment, step k3) is performed instead of step c). Here, the transfer film 2, in particular the transfer layer 3, is arranged on a surface of the base body 9 provided in step a3). Furthermore, the transfer film 2, preferably the transfer layer 3, is bonded to the surface of the base body 9 by hot stamping. The transfer layer 3 can preferably no longer be removed from the base body 9 without causing damage. Furthermore, it is possible for the transfer layer 3 to be arranged partially or over the entire surface of the base body 9.

[0207] The carrier layer is detached from the transfer layer in step d). Preferably, step d) is carried out before step e). In particular, step d) can be carried out before step f) and before step g). Furthermore, step d) is preferably carried out after step c). It is possible for step d) to be carried out after step k3). When the carrier layer 4 is removed, any release layer present can remain on the carrier layer 4 or on the transfer layer 3. Furthermore, it is also possible for the release layer to separate, so that after the carrier layer 4 has been removed, residues of the release layer are arranged on the carrier layer 4 and on the transfer layer 3.

[0208] It is further possible for the back-injection molding of the transfer layer 3 in step c) and the detachment of the carrier layer 4 in step d) to be carried out with a spatial separation. In this case, it is possible for the transfer layer 3 connected to the base body 9 to be temporarily stored and / or transported. In particular, at another production location, it is then possible to individualize the article 1 by forming the at least one first region 5 and the at least one second region 6.

[0209] In step e), at least one first region 5 and at least one second region 6 are formed in the protective lacquer layer 8 and / or printed layer. This is done by means of an embossing process, for example, hot stamping, in particular roll stamping or stroke stamping, preferably by contacting the protective lacquer layer 8 and / or printed layer with an embossing tool 13. The embossing tool 13 can have a master structure on the surface that is contacted with the protective lacquer layer 8 and / or printed layer.

[0210] The master structure on the surface of the embossing tool 13 can be introduced, for example, by laser processing and / or by etching processes and / or by means of other known surface processing processes.

[0211] In a further embodiment, it is possible for a carrier comprising a master structure to be arranged at least in regions between an embossing tool 13 and the transfer layer 3 and / or for a carrier comprising a master structure to be arranged at least in regions between an embossing tool 13 and the printing layer. In other words, it is possible for the embossing tool 13 to have a carrier comprising a master structure at least in regions. In this case, the embossing tool 13 preferably has no master structure and / or is smooth and preferably only defines the embossing surface with a contour as the outer contour and possibly defines the embossing surface with one or more recesses within the outer contour as the inner contour.

[0212] Alternatively, the embossing tool 13 can have an additional master structure in addition to the master structure of the carrier, wherein the master structure of the embossing tool 13 and the master structure of the carrier then overlap in the protective lacquer layer and / or in the print layer, in particular in the at least one first region. The master structure of the embossing tool 13 and the carrier are preferably different. For example, the master structure on the embossing tool 13 has a different size dimension than the master structure on the carrier. For example, the embossing tool 13 specifies a coarse structure in the millimeter to micrometer range, and the master structure on the carrier as a fine structure in the micrometer to nanometer range is superimposed thereon, wherein a combination structure of coarse structure and fine structure is molded in the protective lacquer layer and / or in the print layer.

[0213] By contacting the embossing tool 13 with the protective lacquer layer 8 and / or with the printing layer and / or the carrier arranged therebetween, the master structure of the embossing tool 13 or of the carrier is at least partially molded in the protective lacquer layer 8 and / or printing layer, wherein a relief structure complementary to the master structure is formed in the protective lacquer layer 8 and / or in the printing layer, in particular in the at least one first region 5.

[0214] In particular, the protective lacquer layer 8 and / or printing layer is only partially contacted with the embossing tool 13 or the carrier, preferably only where at least a first region 5 is to be arranged in the protective lacquer layer 8 and / or in the printing layer.

[0215] It is also possible for the embossing tool 13 and / or the carrier to be designed such that the embossing tool 13 and / or the carrier only has a master structure in certain regions, wherein the protective lacquer layer 8 and / or the printing layer is contacted with the embossing tool 13 and / or the carrier such that the master structure contacts the protective lacquer layer 8 and / or the printing layer where at least a first region 5 is formed in the protective lacquer layer 8 and / or in the printing layer. Alternatively or additionally, the regions of the protective lacquer layer 8 and / or in the printing layer in which the at least one second region 6 is formed can be covered with a mask, in particular a removable mask, for example a removable polymer film.

[0216] Step e) is preferably carried out using an embossing tool 13. As embossing tool 13, for example, at least one embossing roller or at least one embossing wheel or at least one embossing stamp and / or at least one carrier comprising a master structure can be used.

[0217] The embossing tool 13 preferably has, on the surface that is in contact with the protective lacquer layer 8 and / or printing layer, for example, its outer circumference, a coating made of an elastomer with a layer thickness selected from a range of 3 mm to 20 mm, preferably from 5 mm to 15 mm. The elastomer is preferably silicone rubber. The elastomer preferably has a hardness selected from the range of 30 Shore A to 95 Shore A, preferably from 60 Shore A to 90 Shore A. Advantageously, the optical properties of the relief structure of the at least one first region 5 can be influenced by the different Shore hardnesses.

[0218] Alternatively, it is also possible for the embossing tool 13 to have a surface made of metal, in particular selected from the group of brass, copper, steel or titanium.

[0219] The embossing wheel preferably has a bevel on its circumference at each of its outer edges, wherein in particular the coating made of an elastomer has a bevel on its circumference at each of its outer edges. The bevel preferably has an angle to the surface normal of the circumference of the embossing wheel of between 15° and 75°, more preferably between 25° and 65°. With such a bevel, particularly clean edges of the embossing can be achieved. This means that the transition between the first region 5 and the adjacent second region 6 is, to the naked human eye, largely smooth, largely straight, and largely without disturbing artifacts, in particular smooth, straight, and largely without disturbing artifacts. The formation of the at least one first region 5 and the at least one second region 6 preferably takes place at an embossing temperature, i.e. the temperature of the embossing tool 13, selected from a range of 125°C to 250°C.

[0220] Furthermore, the embossing speed, i.e. the feed speed, is a value selected from a range of 1 m / min to 5 m / min.

[0221] The embossing pressure, in particular in stroke embossing, is preferably selected from a range of 0.1 kN to 25 kN, preferably from 0.2 kN to 20 kN, particularly preferably from 0.3 kN to 15 kN.

[0222] The embossing time, in particular in stroke embossing, is preferably selected from the range of 0.3 s to 2.5 s; preferably from 0.5 s to 2.0 s, particularly preferably from 1.0 s to 1.5 s. In particular, the embossing time is preferably adapted to the layer thickness of the carrier.

[0223] Furthermore, it is also possible that the embossing pressure, especially during roll embossing, is preferably selected from a range of 10 kg / cm 2 up to 50 kg / cm 2 , preferably 15 kg / cm 2 up to 30 kg / cm 2 , particularly preferably 20 kg / cm 2 up to 25 kg / cm 2 , is.

[0224] For example, a good result in a stamping process, especially in stroke stamping, is achieved with the combination of a stamping temperature of 190 °C, a stamping time of 1.5 s and a stamping pressure of 15 kN.

[0225] In an embossing process, especially by means of roll embossing, a good result is achieved, for example, with the combination of an embossing temperature of 185°C, an embossing speed of 2 m / min, an embossing pressure of 20 kg / cm 2 up to 25 kg / cm 2 and when using an embossing roller with a hardness of 80 Shore A.

[0226] The master structure has, in particular, a structure depth selected from a range of 0.1 pm to 15 pm, preferably from 0.1 pm to 10 pm, particularly preferably from 0.1 pm to 5 pm. In particular, the master structure has an average structure spacing selected from the range of 0.05 pm to 1000 pm, preferably from 0.1 pm to 100 pm, particularly preferably from 0.1 pm to 50 pm.

[0227] The complementary relief structure can, in particular, have a smaller structural depth than the master structure. In particular, the complementary relief structure has a structural depth that preferably corresponds to 20% to 99% of the structural depth of the master structure, particularly preferably 40% to 95% of the structural depth of the master structure.

[0228] The master structure or the complementary relief structure can, alone or in combination, comprise a regular one-dimensional lattice, a regular two-dimensional lattice, a random structural component, or a pseudo-random structural component. In particular, the complementary relief structure can exhibit optical and / or functional effects.

[0229] A preferred one-dimensional or two-dimensional grating is a non-random relief structure, preferably featuring precise and geometrically formed profile shapes such as rectangular profiles, sinusoidal profiles, sawtooth profiles, hemispherical profiles, or blaze structures. Furthermore, a one-dimensional or two-dimensional grating can feature binary profiles or profiles with stepped profile depths or with a constant profile depth.

[0230] It is advantageous if the master structure is designed such that the complementary relief structure comprises a microstructure, in particular a microstructure whose dimensions are below the resolution limit of the human unaided eye. The resolution limit of the human unaided eye is preferably at structures with dimensions of at least 300 pm.

[0231] Furthermore, the master structure can be designed such that the complementary relief structure comprises a macrostructure, in particular a macrostructure whose dimensions lie above the resolution limit of the human unaided eye. Furthermore, the master structure can be designed such that the complementary relief structure is formed as a microstructure whose dimensions lie below the resolution limit of the human unaided eye and additionally as a macrostructure that is visible to the human unaided eye. A macrostructure can be present next to a microstructure and / or be superimposed by a microstructure.

[0232] Advantageously, a microstructure can have an optical effect that simulates the presence of a macrostructure.

[0233] The master structure can be designed such that the complementary relief structure is formed as a matte structure, a diffractive structure, and / or a refractive structure, and / or a macrostructure. Furthermore, several of the aforementioned structures can be present side by side and / or superimposed.

[0234] Optically variable effects based on the aforementioned structures can be realized, for example, by varying one or more structural parameters, for example by varying the grating period, the average structural spacing, the tilt angle of the micromirrors, the structural depth and / or the azimuth angle.

[0235] Preferably, the carrier comprising the master structure is used only for a small number of embossings in the same surface area of ​​the carrier, in particular selected from a range of 1 to 20 times, preferably from 1 to 10 times.

[0236] In particular, it is advantageous that at least 20%, preferably at least 40%, more preferably at least 50%, even more preferably at least 70%, of the relief shape or surface structure of the master structure, in particular the structure depth of the master structure, is and / or is formed into the protective lacquer layer 8 and / or printing layer. As a result, the intended relief structure has the desired optical properties in the finished article.

[0237] Advantageously, the carrier comprising the master structure is supplied in particular as a roll and can thus be transported further as a carrier web. This allows for a particularly rapid change of the surface area of ​​the carrier used for embossing. It is also possible to provide and use a carrier comprising the master structure in the form of sheet material or as a plate. The carrier preferably consists of or comprises a polymer, for example, PET. The carrier preferably has a layer thickness selected from a range of 5 μm to 500 μm, preferably from 20 μm to 50 μm.

[0238] Alternatively, the carrier may consist of or comprise metal, for example brass, copper, steel or titanium.

[0239] For example, step e) may comprise at least one or more of the following substeps:

[0240] - Arranging and aligning the transfer film 2, preferably transfer layer 3, and the base body 9 according to the embossing tool 13 or the carrier;

[0241] - Heating the embossing tool 13 to embossing temperature

[0242] Contacting the master structure of the embossing tool 13 or the carrier with the transfer layer 3, in particular the protective lacquer layer 8, in particular in the at least one first region 5;

[0243] Moving or rotating the embossing tool 13 or the carrier.

[0244] Preferably, step e) is performed after step d) and in particular before step f). Step e) can also be performed multiple times, in particular with different or identical embossing tools 13 or carriers comprising identical or different master structures.

[0245] In particular, in step e), the at least one first region 5 is formed such that the transfer layer 3 has a relief structure in the at least one first region 5, wherein the relief structure is preferably complementary to the master structure of the embossing tool 13 and / or the carrier used. Preferably, the at least one second region 6 has no structure and is perceived as smooth and flat. In particular, the at least one first region 5 differs optically or functionally from the at least one second region, in particular by its degree of gloss or transmittance. Preferably, the at least one first region 5 is formed only in regions in the protective lacquer layer 8 and / or printing layer when viewed perpendicular to a plane spanned by the protective lacquer layer 8 and / or printing layer. Preferably, the protective lacquer layer 8 and / or printing layer has the at least one first region 5 only in regions.

[0246] The at least one first region 5 preferably consists of one or more contiguous and / or separate regions, in particular when viewed perpendicular to the plane spanned by the protective lacquer layer 8 and / or printing layer. For example, the at least one first region 5 can completely surround the at least one second region 6 and / or the at least one first region 5 can be completely surrounded by the at least one second region 6. The at least one first region 5 and the at least one second region 6 are arranged next to one another and do not overlap, in particular when viewed perpendicular to the plane spanned by the protective lacquer layer 8 and / or printing layer.

[0247] In particular, the design or shape of the at least one first region 5 is selected individually or in combination from: motif, letter, number, symbol, geometric figure, visually recognizable design element, pattern, logo, codes and conductor track.

[0248] In particular, the at least one first region 5 is arranged in register with a layer or an element of the transfer layer 3 and / or the base body 9 in the protective lacquer layer 8 and / or print layer, in particular in register with a decorative element 11 and / or functional element 10 arranged in the transfer layer 3 and / or base body 9. For this purpose, for example, the protective lacquer layer 8 and / or print layer can be masked such that the relief structure is formed only in the unmasked at least one first region 5.

[0249] Furthermore, it is possible that in the at least one first region 5 and / or in the at least one second region 6, the protective lacquer layer 8 and / or print layer of the transfer film 2 and / or of the article 1 has a transmission of at least 45%, preferably of at least 70%, for the wavelength range perceivable by the human eye, preferably for the range from 400 nm to 700 nm.

[0250] The at least one first region 5 of the printing layer, the insert and / or the transfer film 2, in particular the protective lacquer layer 8 or the article 1, can have a gloss value selected from a range of 1 Gil to 59 Gil, preferably from 5 Gil to 30 Gil, or can be designed in such a way.

[0251] The at least one second region 6 of the printing layer, the insert and / or the transfer film 2, which preferably has no relief structure, in particular of the protective lacquer layer 8 or of the article 1, can have a gloss value selected from a range of 31 Gil to 98 Gil, preferably from 60 Gil to 90 Gil.

[0252] It is possible that the method for producing article 1 expediently further comprises the optional following step, which is carried out in particular after step e) and before step g): f) curing the protective lacquer layer 8 and / or printing layer which is at least partially not yet completely cured, wherein the protective lacquer layer 8 and / or printing layer cures completely at least partially.

[0253] Preferably, all curable components of article 1 are fully cured in step f). Thus, the protective lacquer layer and / or printing layer after step f) exhibits high chemical and mechanical resistance in all areas.

[0254] In particular, in step f), the complete curing of the protective lacquer layer 8 and / or printing layer is carried out by means of high-energy electromagnetic radiation, in particular UV irradiation, and / or by means of high-energy particle radiation, in particular electron radiation, and / or is carried out by means of curing, preferably at a temperature in a range of 25 °C to 180 °C, of ​​the protective lacquer layer 8 and / or printing layer.

[0255] The irradiation is preferably carried out using high-energy electromagnetic radiation and / or high-energy particle radiation. The electromagnetic radiation is preferably UV radiation, in particular from a wavelength range of 100 nm to 390 nm, preferably from 200 nm to 380 nm, particularly preferably from 200 nm to 300 nm. The particle radiation is preferably electron radiation.

[0256] For complete curing in step f), the protective lacquer layer 8 and / or printing layer is exposed to an irradiance selected from the range of 500 mW / cm 2 up to 700 mW / cm 2 irradiated. The UV dose is preferably selected from the range of 2000 mJ / cm 2 up to 3500 mJ / cm 2 . The irradiation preferably takes place over a period of time selected from the range of 1 s to 10 s, preferably from 2 s to 6 s.

[0257] In step g), the article 1 produced by the process is obtained. Thus, step g) is in particular the last step of the process according to the invention and is preferably carried out after one of the steps e) or one of the further optional steps.

[0258] Fig. 2 shows a schematic representation of the layer structure of an exemplary article 1. The article 1 has at least one protective lacquer layer 8 and / or print layer of the transfer layer 3 of a transfer film 2 provided in step a) of the method, for example a transfer film according to Fig. 1.

[0259] Alternatively, the article 1 comprises the insert provided according to step a2), wherein the insert comprises a substrate and a transfer layer 3 and / or a printing layer arranged on the substrate, and wherein the transfer layer 3 comprises a protective lacquer layer 8.

[0260] The protective lacquer layer 8 and / or print layer is preferably cured or thermoplastic at least in some regions and represents the surface of an article 1 facing a viewer. The article 1 further comprises a base body 9, which is formed in step c) by back-injecting the transfer layer 3 with a plastic compound. In an alternative embodiment, the base body 9 is provided in step a2). The base body 9 is arranged on the side of the transfer layer 3 or insert facing away from a viewer. Furthermore, the protective lacquer layer 8 and / or print layer of the article 1 comprises at least one first region 5 and at least one second region 6, which were formed in the protective lacquer layer 8 and / or print layer in step e) of the method. A relief structure is formed in the at least one first region 5.

[0261] The article 1 can further preferably have at least one decorative layer containing at least one decorative element 11, in particular in the transfer layer 3 of the transfer film 2 or the insert, and / or at least one functional layer containing at least one functional element 10, in particular in the transfer layer 3 of the transfer film 2 or the insert.

[0262] An article 1 produced by the method according to the invention can be used in a variety of fields. The produced article 1 can be used, for example, alone or in combination, as a display window, touch panel, panel, bezel, trim, cover, functional element, electronic article, and housing part or exterior part, in particular for white goods and / or household appliances and / or automotive interiors and / or automotive exteriors.

[0263] When carrying out the process according to the invention, it is possible to perform the process steps once or several times. In particular, process steps can be repeated. A preferred process comprises at least the following steps a), e), and g), preferably a), e), f), and g), wherein further steps can be inserted, in particular, between these steps.

[0264] For an IMD process, the process comprises in particular at least the following steps in the order a1), b1), c1), d), e), g), optionally a1), b1), c1), d), e), f), g).

[0265] For an insert molding process, the process in particular comprises at least the following steps in the order a2), b2, c2), e), g), optionally a2), b2, c2), e), f), g). Alternatively, the process for an insert molding process in particular comprises at least the following steps in the order a1), h), d), b1), c1), e), g), optionally a1), h), d), b1), c1), e), f), g). It is possible for an insert molding process to comprise at least the steps in the order a1), h), d), i), j), b1), c1), e), g), optionally a1), h), d), i), j), b1), c1), e), f), g).

[0266] For an injection molding process with downstream hot stamping processes, the process comprises in particular at least the following steps in the order a3), k3), d), e), g), optionally a3), k3), d), e), f), g).

[0267] Fig. 3a shows a schematic intermediate product of the manufacturing process of an article 1, wherein the intermediate product is viewed perpendicular to the plane spanned by the protective lacquer layer 8. Thus, the surface of the protective lacquer layer 8 faces the observer, which is preferably not yet fully cured, at least in some areas.

[0268] Fig. 3a shows the intermediate product at a point in time during a process, wherein step e), i.e., the formation of at least a first region 5 and a second region 6, has not yet been performed. Preferably, the intermediate product comprises a base body 9. In other words, step c) or step k3) of the process has already been performed. The intermediate product comprises, for example, a transfer layer 3 according to Fig. 1 and / or can have a layer structure as described above for article 1 according to Fig. 2. Furthermore, the intermediate product can comprise the insert.

[0269] In this exemplary embodiment, a transfer layer 3 was provided for producing the intermediate product. On the left side, the transfer layer 3 has a decorative element 11 in the form of two dashed circles and, in the upper left corner, a decorative element 11 in the form of a circle with a broken line through it. Three further decorative elements 11 in the form of circles with a broken line through them are arranged on the right edge of the article 1. Furthermore, functional elements 10 are arranged in the transfer layer 3 or the base body 9, preferably in precise register with the aforementioned decorative elements 11. The functional elements 10 can, for example, be designed as an operating element. On the right side, a further functional element 10 in the form of a display is arranged. The display can either be arranged beneath a transparent protective lacquer layer 8 or arranged instead of the protective lacquer layer 8.If step e) of the method is now carried out, at least a first region 5 and at least a second region 6 are formed, wherein the at least one first region 5 has a relief structure. Figs. 3b to 3d show different articles 1 as they can be produced from the further processing of the intermediate product according to Fig. 2 by the inventive method. In particular, this is intended to demonstrate the flexible layout design by the inventive method. What all articles 1 have in common is that they have at least a first region 5 and at least one second region 6, wherein the at least one first region 5 has a relief structure, for example a matting. For the article according to Fig. 3e, a slightly modified intermediate product is used which differs from the intermediate product according to Fig. 3a in that it does not have a design element 11 in the form of a dashed circle, but is otherwise designed identically.

[0270] The embodiments for an article 1 according to Fig. 3b to 3e are, for example, a control panel of a household appliance, which is preferably decorated with an IMD film with a high gloss, preferably with a gloss level selected from the range of 85 Gil to 95 Gil. In the at least one second region 6, in which no relief structure is depicted and / or in which the display window is arranged, the protective lacquer layer is thus still high gloss. Expediently, at least the protective lacquer layer 8 and / or the base body 9 of the resulting article 1 is transparent. The at least one first region 5 is preferably perceived as matt due to the introduced relief structure, preferably with a gloss level selected from the range of 1 Gil to 30 Gil. The entire protective lacquer layer 8 has high chemical and mechanical resistance.

[0271] In the embodiment of article 1 according to Fig. 3b, the surface of the article is divided into at least a first region 5 and at least one second region 6, independently of decorative elements 11. This results in an operating region on the left-hand side and a display region on the right-hand side. The operating region is encompassed by the at least one first region 5, and the display region is encompassed by the at least one second region 6. In article 1 according to Fig. 3c, only a single decorative element 10 or functional element 11 of transfer layer 3 is optically set off from the at least one second region 6 by the introduction of a relief structure into at least one first region 5, preferably in precise register.

[0272] The article 1 according to Fig. 3d is comparable to the article according to Fig. 3c, but all design elements 11 of the transfer layer 3 are provided with at least one corresponding first region 5. The first regions 5 are preferably arranged in precise register with the design element 11 and are completely surrounded by at least one second region 6.

[0273] A further design variant for an article 1 is shown in Fig. 3e. This article 1 has, analogously to the articles according to Figs. 3a to 3d, design elements 11 and functional elements 10, for example, operating elements and a display, arranged in the transfer film 3. However, a circular first region 5 is arranged such that it is not precisely registered with a design element 11, but only with a functional element 10. Through such a design, a functional element 10 of the article 1 can be visually highlighted and made recognizable to a viewer without a corresponding decorative element 11 having to be present in the transfer layer 3.In addition, it is possible, in the region in which the functional element 10 is arranged in the form of a display, to arrange at least one further first region 5 by means of a further step e), which has a further relief structure that differs from the first at least one first region 5. For example, the relief structure can provide an "anti-glare" effect to improve the readability of the display.

[0274] A further design variant for an article 1 is shown in Figs. 4a and 4b. This article 1 has, analogous to the articles according to Figs. 3a to 3d, design elements 11 and functional elements 10, for example operating elements and a display, arranged in the transfer film 3. However, the article 1 has a bevel on two opposite sides, which in the example shown is approximately 15° to the other (horizontal, flat) surface of the article 1. The boundary between the bevel and the other surface of the article 1 is shown as a dashed line. The first region 5 is provided both on the flat surface of the article 1 and on the bevels 12 such that the first region 5 is arranged uninterrupted between the opposite outer edges of the article 1. Fig. 4c shows a side view of the article 1 according to Fig. 4a and4b is shown to illustrate by way of example how the first region 5 is arranged using the embossing tool 13. The embossing tool 13, here an embossing wheel, is designed to be height-adjustable according to the article contour, with deeper bevels 12 and a higher flat surface, so that approximately the same embossing pressure can be exerted on all areas of the article 1 to create a uniformly executed and uninterrupted first region 5. The height adjustment can be carried out using one or more servo motors or via pneumatic control. Fig. 4c schematically shows the position of the embossing tool 13 or its axis of rotation when embossing the flat surface of the article 1, as well as a possible position of the embossing tool 13' or its axis of rotation when embossing the deeper bevel 12, depending on the contour of the article 1.

[0275] Of course, the listed versions can be combined with each other as desired and do not represent any limitations.

[0276] List of reference symbols

[0277] 1 article

[0278] 2 Transfer film 3 Transfer layer

[0279] 4 carrier layers

[0280] 5 First area

[0281] 6 Second area

[0282] 7 Carrier layer 8 Protective lacquer layer

[0283] 9 Basic body

[0284] 10 Functional element

[0285] 11 decorative element

[0286] 12 Bevel 13, 13' Embossing tool

Claims

LEONHARD KURZ & Co. KG, Schwabacher Str. 482, DE - 90763 Fürth Patent claims 1. Method for manufacturing an article (1), wherein the method comprises at least one of steps A1) or A2) or A3), wherein step A1) comprises the following steps: a1) providing a transfer film (2), wherein the transfer film (2) has a carrier layer (4) and a transfer layer (3), wherein the carrier layer (4) is peelable from the transfer layer (3), wherein the carrier layer (4) comprises a carrier layer (7), wherein the transfer layer (3) comprises a protective lacquer layer (8), and wherein the protective lacquer layer (8) is arranged such that it is in contact with the carrier layer (4); b1) arranging the transfer film (2), in particular the transfer layer (3), in an injection mold; c1) back-injecting the transfer film (2), in particular the transfer layer (2), with a plastic compound, wherein the plastic compound forms a base body (9); d) separating the carrier layer (4) from the transfer layer (3);wherein step A2) comprises the following steps: a2) providing an insert, wherein the insert has a substrate and on the substrate an arranged transfer layer (3) and / or an arranged printing layer, wherein the transfer layer (3) comprises a protective coating layer (8); b2) arranging the insert in an injection mold; c2) back-injecting the insert with a plastic compound, wherein the plastic compound forms a base body (9); wherein step A3) comprises the following steps: a3) providing a transfer film (2), wherein the transfer film (2) has a carrier layer (4) and a transfer layer (3), wherein the carrier layer (4) is peelable from the transfer layer (3), wherein the carrier layer (4) comprises a carrier layer (7), and wherein the transfer layer (3) comprises a; protective coating layer (8) and wherein the protective coating layer (8) is arranged such that it is in contact with the carrier layer (4) and the transfer film (2) is separately provided by a base body (9), which is produced in particular by injection molding; k3) arranging the transfer film (2), in particular the transfer layer (3), on a surface of the base body (9) and hot stamping the transfer film (2) onto the surface of the base body (9); d) separating the carrier layer (4) from the transfer layer (3);wherein the protective coating layer (8) and / or the printing layer is at least partially uncured or thermoplastic in steps A1) or A2) or A3), and wherein the method, in addition to at least one of steps A1) or A2) or A3), comprises the following steps: e) forming at least one first area (5) and at least one second area (6) by embossing in the protective coating layer (8) and / or in the printing layer, wherein the at least one first area (5) has a relief structure; f) optionally curing the protective coating layer (8) and / or printing layer, which is at least partially uncured, wherein the protective coating layer (8) is at least partially fully cured;(g) Obtaining an article (1), wherein the article (1) comprises a base body (9) and a protective lacquer layer (8) and / or printing layer, which is at least partially cured or thermoplastic, wherein the protective lacquer layer (8) and / or printing layer has at least a first region (5) and at least a second region (6), wherein a relief structure is arranged in the at least one first region (5). The method according to claim 1, characterized in that the method further comprises at least one of the following steps: (h), (i), and (j): (h) Arranging the transfer film (2) on a substrate; (i) Forming the transfer film (2) and / or the substrate into a desired shape; and; j) Trimming the transfer film (2) and / or the substrate along a defined contour line.

3. Method according to one of the preceding claims, characterized in that in step f) the complete curing of the protective coating layer (8) and / or printing layer is carried out by means of high-energy electromagnetic radiation, in particular UV irradiation, and / or by means of high-energy particle radiation, in particular electron radiation, and / or by means of curing, preferably at a temperature in a range of 25 °C to 180 °C, of ​​the protective coating layer (8) and / or printing layer.

4. Method according to one of the preceding claims, characterized in that step f) is performed with an irradiance selected from the range of 500 mW / cm². 2 up to 700 mW / cm² 2 is carried out, and / or that the UV dose is preferably selected from the range of 2000 mJ / cm² 2 up to 3500 mJ / cm² 2and / or that the irradiation takes place over a period of time selected from the range of 1 s to 10 s, in particular from 2 s to 6 s.

5. Method according to one of the preceding claims, characterized in that the transfer layer (3) is provided such that the protective coating layer (8) which is not yet fully cured in certain areas comprises at least one UV-curable and / or at least chemically crosslinkable polymer.

6. Method according to claim 5, characterized in that the at least one chemically crosslinkable polymer is selected from the group consisting of isocyanate group-containing polymers, melamine-containing polymers, hydroxyl group-containing polymers and mixtures thereof.

7. Method according to claim 5 or 6, characterized in that the at least one chemically crosslinkable polymer comprises a polymer combination comprising or consisting of a polymer and / or copolymer with at least one isocyanate group and at least one polymer and / or copolymer with at least one hydroxyl group and / or at least one melamine resin and at least one polymer and / or copolymer with at least one hydroxyl group. A method according to claims 5 to 7, characterized in that the at least one UV-crosslinkable polymer comprises at least one chemically crosslinkable functional group, wherein the chemically crosslinkable functional group is preferably selected from a hydroxyl group, an isocyanate group, a melamine group, an epoxy group, and combinations thereof.Method according to one of the preceding claims, characterized in that the transfer film (2), preferably transfer layer (3), provided in step a), preferably step a1), a2) and / or a3), comprises at least one decorative layer containing at least one decorative element (11) and / or at least one functional layer containing at least one functional element (10).Method according to claim 9, characterized in that the at least one decorative element (11) comprising the at least one decorative layer is selected from the group consisting of transparent and / or colored lacquer layers, in particular comprising one or more dyes and / or pigments, replica layers with a molded optically active surface structure, reflective layers, in particular opaque reflective layers, transparent reflective layers, metallic reflective layers or dielectric reflective layers, optically variable layers, optically active layers, interference multilayer systems, volume hologram layers, liquid crystal layers, in particular cholesteric liquid crystal layers, and combinations thereof.

11. Method according to claim 9, characterized in that the at least one functional element (10) is selected from the group consisting of at least one electronic element, in particular conductor track, contact element, LED, sensor, in particular touch sensor, temperature sensor, pressure sensor, antenna, in particular RFID element, memory, display, control element, processor, capacitor, resistor, microfluidic element and combinations thereof.

12. Method according to one of the preceding claims, characterized in that an adhesion promoter layer is arranged between the protective lacquer layer (8) and the at least one decorative element (11) and / or the at least one functional element (10), preferably wherein the adhesion promoter layer comprises or consists of at least one acrylic resin, and preferably wherein the adhesion promoter layer preferably has a layer thickness selected from a range of 0.1 pm to 10 pm.

13. Method according to one of the preceding claims, characterized in that the transfer layer (3) has at least one lacquer layer, preferably with a layer thickness selected from a range of 0.5 pm to 10 pm, which forms a surface of the transfer layer (3) facing away from the carrier layer (4), in particular wherein the at least one lacquer layer consists of or comprises at least one adhesive selected from the group consisting of physically curing adhesives, chemically curing adhesives, pressure-sensitive adhesives or mixtures thereof.

14. Method according to one of the preceding claims, characterized in that the carrier layer (4) has at least one release layer, which is preferably arranged between the carrier layer (7) and the protective lacquer layer (8), wherein the release layer preferably comprises at least one wax or consisting of, and wherein the release layer is a preferred It has a melting temperature in the range of 80 °C to 100 °C.

15. Method according to one of the preceding claims, characterized in that step e) is carried out by means of hot stamping, in particular roll stamping or stroke stamping, wherein step e) comprises the use of a stamping tool (13), in particular wherein the stamping tool (13) is selected alone or in combination from at least one stamping roller, at least one stamping wheel, at least one stamping die, at least one carrier comprising a master structure.

16. Method according to claim 15, characterized in that a carrier comprising a master structure is arranged at least partially between the embossing tool (13) and the transfer layer (3) and / or between the embossing tool (13) and the printing layer, in particular wherein the embossing tool (13) does not have a master structure and / or is smooth.

17. Method according to claim 15, characterized in that the embossing tool (13) has a master structure.

18. Method according to claims 15 to 17, characterized in that the protective lacquer layer (8) and / or the printing layer is contacted with the embossing tool (13).

19. Method according to one of claims 15 to 18, characterized in that the embossing tool (13) has no master structure and / or is smooth.

20. Method according to any one of claims 16 to 19, characterized in that, by contacting the embossing tool (13) with the protective varnish layer (8) and / or with the printing layer or the intermediate carrier, the master structure of the embossing tool (13) or of the carrier is at least partially molded in the protective varnish layer (8) and / or in the printing layer, wherein a relief structure complementary to the master structure is formed in the protective varnish layer (8) and / or in the printing layer, in particular in the at least one first area (5).

21. Method according to claims 16 to 20, characterized in that the master structure or the complementary relief structure is selected alone or in combination from a regular one-dimensional, a regular two-dimensional grid, a random structural component, and a pseudo-random structural component.

22. Method according to claims 16 to 21, characterized in that the master structure has a structure depth selected from a range of 0.1 pm to 15 pm, preferably from 0.1 pm to 10 pm, particularly preferably from 0.1 pm to 5 pm, and / or that the master structure has a mean structure spacing selected from a range of 0.05 pm to 1000 pm, preferably from 0.1 pm to 100 pm, particularly preferably from 0.1 pm to 50 pm.

23. Method according to claims 15 to 22, characterized in that the complementary relief structure has a lower structural depth than the master structure, in particular wherein the complementary relief structure has a structural depth that preferably corresponds to 20% to 99% of the structural depth of the master structure, and more preferably to 40% to 95% of the structural depth of the master structure.

24. Method according to any one of claims 16 to 23, characterized in that the carrier comprises or consists of a polymer, preferably PET, and preferably has a layer thickness selected from a range of 5 pm to 500 pm, preferably from 20 pm to 50 pm.

25. Method according to one of claims 16 to 24, characterized in that the protective varnish layer (8) and / or the printing layer is only partially contacted with the embossing tool (13) or the carrier, preferably only where at least a first area (5) is arranged in the protective varnish layer (8) and / or the printing layer.

26. Method according to one of claims 16 to 25, characterized in that the embossing tool (13) and / or the carrier is designed such that the embossing tool (13) and / or the carrier only has the master structure in certain areas, wherein the protective varnish layer (8) and / or the printing layer is contacted with the embossing tool (13) and / or the carrier such that the master structure contacts the protective varnish layer (8) and / or the printing layer where at least a first area (5) is arranged in the protective varnish layer (8) and / or in the printing layer.

27. Method according to one of claims 16 to 26, characterized in that the carrier comprising the master structure is used for a small number of embossings in the same surface area of ​​the carrier, in particular selected from a range of 1 to 20 embossings, preferably from 1 to 10 embossings.

28. Method according to one of the preceding claims, characterized in that the formation of the at least one first region (5) and the at least one second region (6) at an embossing temperature selected from the The temperature range is from 125 °C to 250 °C, and / or the embossing speed is a value selected from the range of 1 m / min to 5 m / min.

29. Method according to one of the preceding claims, characterized in that an embossing pressure in step e), particularly in the case of stroke embossing, is selected from a range of 0.1 kN to 25 kN, preferably from 0.2 kN to 20 kN, particularly preferably from 0.3 kN to 15 kN, and / or that an embossing pressure, particularly in the case of roll embossing, is selected from a range of 10 kg / cm² 2 up to 50 kg / cm² 2 , preferably 15 kg / cm² 2 up to 30 kg / cm² 2 , especially preferred at 20 kg / cm² 2 up to 25 kg / cm² 2 .

30. Method according to one of the preceding claims, characterized in that the at least one first area (5) is formed in register-accurate form to a layer or element, in particular a functional element and / or a decorative element, of the transfer layer (3) and / or of the base body (9) in the protective varnish layer (8) and / or in the printing layer.

31. Method according to one of the preceding claims, characterized in that the at least one first area (5) of the printing layer and / or the insert and / or the transfer foil (2) is designed such that it has a gloss value in a range of 1 Gil to 59 Gil, preferably from 5 Gil to 30 Gil.

32. Article (1), wherein the article (1) comprises a base body (9) and a protective coating layer (8) and / or a printing layer, wherein the protective coating layer (8) and / or the printing layer is at least partially fully cured or thermoplastic, wherein the protective coating layer (8) and / or the printing layer comprises at least a first region (5) and at least a second region (6), wherein a relief structure is arranged in the at least one first region (5), and wherein the article (1) was manufactured according to any one of claims 1 to 31. Use of the article according to claim 32 or manufactured according to a method according to any one of claims 1 to 31, alone or in combination, as a display window, touch field, panel, bezel, cladding, cover, functional element, electronic article and housing part or outer part, in particular of white goods and / or household appliances and / or automotive interior areas and / or automotive exterior areas.

Images