Component having a layer construction, method for producing the component, and injection mould for producing the component

Abstract

The invention relates to a component, in particular a component having a polyurethane layer, to a method for producing the component, and to an injection mould for producing the component and / or carrying out the method. In order to be able to manufacture the component simply and to ensure broad use of the component, according to the invention the component has a layer construction, in particular a layer construction having at least three layers. The layer construction comprises a decorative ply (1) having at least one decorative layer. A first layer (3) of a first material, in particular a thermoplastic, is arranged on the decorative ply (1). A second layer (4) of a second material, in particular polyurethane, is arranged on the first layer (3). The first layer (3) has a peripheral edge. The first layer (3) comprises at least one holding element or is connected to at least one holding element, and the holding element extends along the edge of the first layer (3).

Description

[0001] >

[0002] Component having a layer structure, method for producing the component and injection molding tool for producing the component

[0003] The invention relates to a component having a layer structure, a method for producing the component and an injection molding tool for producing the component and / or an injection molding tool for carrying out the method for producing the component.

[0004] Components having a layered structure are known in the state of the art as injection-molded articles.

[0005] For example, DE 10221482 C1 discloses a device for producing a molded part from a curing injection-molding material, which is decorated during injection molding using the IMD process (IMD = In-Mold Decoration) with an embossed foil comprising a carrier film and a decorative layer that can be detached from the carrier layer. The embossed foil is inserted into an open injection mold, with the decorative layer of the embossed foil facing an upper mold part. The injection mold is closed, and liquid injection-molding material is injected through an injection channel into the cavity of the injection mold, with the embossed foil adhering to the visible side of the molded part. The embossed foil, with its decorative layer, bonds with the injection-molding material, which is removed from the injection mold after curing. After the carrier film is removed from the decorative layer, the decorated molded part is finished.Such decorated injection-molded articles are used in particular for automotive interior parts such as door strips, strips in instrument panels, gear lever covers and center console covers, for automotive exterior parts such as door sill protection strips and covers on A, B and C pillars, in the audio and video sector for decorative strips on the housings of radio and television sets, and in the telecommunications sector for housing shells of mobile devices such as cell phones or navigation devices.

[0006] Insert molding (IM) is a process that combines hot stamping, vacuum forming or deep drawing, and casting, particularly injection molding. Compared to the IMD process, insert molding offers the possibility of more pronounced deformation of the foil. This is advantageous when, for example, highly profiled and shaped parts are required. First, a vacuum-formable, thin stamping foil is hot-stamped or cold-stamped onto a carrier, e.g., an ABS foil (thickness approximately between 200 μm and 750 μm, ABS = acrylonitrile butadiene styrene). This carrier, coated with the decorative layer of the stamping foil, is vacuum-formed under heat. The vacuum-formed layers of stamping foil and carrier form the so-called "insert" and are cut or punched to precise contours. The insert is positioned in an injection mold, the mold is filled with plastic (the insert is back-injected), then the decorated injection-molded article is removed from the injection mold.

[0007] The flooding of objects, for example injection-molded articles, using polyurethane (PU) is also known from the prior art. For this purpose, for example, an object to be coated is positioned in a tool that has two tool halves. A first tool half accommodates the object to be coated and a second tool half forms a slightly larger cavity than the object to be coated. PU is introduced into this space and the object to be coated is flooded with PU. Two-component PU systems (2K-PU) are also known, which cure within a short time, in particular a few seconds, after the components have been mixed and / or immediately during and / or after flooding (with the tool halves still closed). When the tool opens, the PU is already sufficiently hard.

[0008] The international patent application WO 2019 / 034361 A2 discloses a component manufactured by injection molding with a thermoplastic material, in which a surface protection is additionally applied to the film coating by flooding with polyurethane.

[0009] The production of this well-known component requires two separate manufacturing units. This makes production relatively complex, time-consuming, and expensive.

[0010] Furthermore, according to the state of the art, the film, and thus also the decorative layer and / or the decorative layer, is encapsulated between the injection-molded material and the overflow material, i.e., between the thermoplastic and the polyurethane. Such an arrangement severely limits the possibilities for X-ray inspection and subsequent processing of the decorative layer.

[0011] The invention is based on the object of eliminating the disadvantages of the prior art. In particular, it is intended to provide a versatile and adaptable component, a simple and inexpensive method for producing a component, and a device for producing the component or a device for carrying out the method for producing the component. Preferably, the component should be produced with at least one polyurethane layer. Preferably, the component should be easily producible by injection molding. In particular, an injection molding tool should be provided for this purpose. In particular, series production of the component in high quantities should be enabled.

[0012] According to the invention, this object is achieved by a component according to the subject matter of claim 1, by a method according to the subject matter of claim 13, and by an injection molding tool according to the subject matter of claim 23. Advantageous embodiments of the invention are specified in the dependent claims.

[0013] According to the invention, a component is created which has a layered structure, in particular a layered structure with at least three layers. The layered structure or the component comprises at least one decorative layer, wherein the decorative layer comprises at least one decorative layer. A first layer made of a first material is arranged on the decorative layer. The first layer is preferably arranged directly on the decorative layer.

[0014] The decorative layer or the decorative layer can preferably have a plurality of layers, individually, multiple times or in combination selected from: primer layer, adhesive layer, adhesion promoter layer, color layer, colored varnish layer, masking layer, spacer layer, light guide layer, functional layer, in particular optical functional layer, metal layer, reflection layer, HRI layer (HRI = High Refractive Index), replication layer with optically active and / or optically variable structures, in particular optically active relief structures, preferably diffractive structures and / or holograms and / or refractive structures and / or matte structures. The one or more layers of the decorative layer are or are preferably applied during the process for producing the decorative layer. The one or more layers of the decorative layer can each be present over the entire surface or partially.The one or more layers of the decorative layer can overlap in certain areas and / or be adjacent to one another in certain areas. The adjacent arrangements can be spaced apart from one another or directly adjacent to one another without any space relative to one another.

[0015] In particular, the decorative layer may comprise a primer layer and / or an adhesive layer. The primer layer and / or adhesive layer is preferably arranged directly on one of the at least one decorative layer. Preferably, the primer layer and / or the

[0016] The adhesive layer is bonded to the first layer. In this case, the first layer is arranged directly on the primer layer and / or adhesive layer. The first layer is preferably formed from at least one thermoplastic.

[0017] A second layer made of a second material is arranged on the first layer. The second layer can be arranged directly on the first layer. Alternatively, at least one further layer, in particular a further decorative layer and / or a further decorative layer comprising a further decorative layer, can be arranged between the first layer and the second layer. The second layer is preferably made of polyurethane. The second layer can also be referred to as a protective layer.

[0018] The further decorative layer or the further decorative layer can preferably have a plurality of layers, selected individually, multiple times or in combination from: primer layer, adhesive layer, adhesion promoter layer, color layer, colored varnish layer, functional layer, in particular optical functional layer, metal layer, reflection layer, HRI layer (HRI = High Refractive Index), replication layer with optically active and / or optically variable structures, in particular optically active relief structures, preferably diffractive structures and / or holograms and / or refractive structures and / or matt structures. The one or more layers of the further decorative layer are or are preferably applied during the process for producing the further decorative layer. The one or more layers of the further decorative layer can each be present over the entire surface or partially.The one or more layers of the additional decorative layer can overlap in certain areas and / or be adjacent to one another in certain areas. The adjacent arrangements can be spaced apart from one another or directly adjacent to one another without any space relative to one another.

[0019] The first layer has a circumferential edge, preferably a closed circumferential edge. The first layer comprises at least one holding element or is connected to at least one holding element, in particular connected in one piece. The holding element is preferably formed from the first material. The holding element extends along the edge of the first layer. The holding element can extend partially along the edge of the first layer. Alternatively, the holding element can extend completely along the edge of the first layer. Due to the formation of the holding element, the first layer can also be referred to as a carrier layer. The wall thickness or thickness of the first layer can be dimensioned such that the component achieves a predetermined mechanical stability. The mechanical stability can have flexural rigidity or torsional strength.

[0020] The holding element preferably extends at least in a direction perpendicular to the layer structure. The holding element therefore preferably extends substantially in a plane in which the areal extent of the first layer also lies. The holding element particularly preferably extends substantially in a direction perpendicular to the layer structure. The holding element particularly preferably extends exclusively in planes in which the areal extent of the first layer also lies. Alternatively, the holding element can also extend partially in the direction of the layer structure. It is therefore also possible for the holding element to partially leave the plane in which the areal extent of the first layer also lies.

[0021] The holding element is preferably designed such that the component is firmly held and / or fixed by an interaction of the holding element with at least one holding arm of a holding device. The holding element is in particular designed such that the component is firmly held and / or fixed by the engagement of at least one holding arm of a holding device into the holding element. The engagement of the holding arm can take place directly on the circumferential edge of the first layer. In this case, it is particularly possible for the holding arm to engage in a region of the first layer that is located on the inside with respect to the circumferential edge. Such a region can in particular be formed by an indentation. This will be discussed in more detail below.

[0022] Alternatively, the holding element can comprise a molded portion extending from the peripheral edge of the first layer and / or a projection on the peripheral edge of the first layer. In this case, the interaction with the holding arm takes place in a region of the first layer that is outer with respect to the peripheral edge. The interaction can be realized by the holding arm engaging in the holding element and / or by the holding element engaging in the holding arm. The molded portion and / or the projection can therefore also have an indentation. Such a molded portion or such a projection can in particular be formed by a tab. This will be discussed in more detail below.

[0023] Advantageously, the component is held or fixed in two opposite directions by the retaining element, particularly by tension and compression. In one embodiment, the retaining element can fix the component in an injection molding tool. This is particularly useful to enable simple production even when changing cavity halves or mold parts. Due to the advantageous compression and tension fixation of the component by the retaining element, cavity halves or mold parts can be changed on both sides of the component without negatively impacting production.

[0024] The retaining element can be used to fix the finished component to another part, for example, by riveting or gluing. Alternatively, the retaining element can also be removed after the component has been manufactured. For example, by separating it, preferably by cutting and / or breaking it off. The retaining element can preferably have corresponding predetermined breaking points. Alternatively or additionally, the retaining element can be removed by milling.

[0025] Even if these terms are used in the singular in the explanations regarding the holding element and / or holding arm, the person skilled in the art will understand that the features mentioned can equally apply to all holding elements and / or holding arms if multiple holding elements and / or multiple holding arms are present. Similarly, when explanations regarding the holding element and / or holding arm are used in the plural, the person skilled in the art will understand that the features mentioned can equally apply if only one holding element and / or one holding arm is present.

[0026] An advantage of the invention is that the decorative layer comprising at least one decorative layer, the first layer and optionally further decorative layers and / or further application layers are protected by the overlying, outer second and / or third layer, which is preferably made of polyurethane, as a protective layer. This enables additional effects, such as the creation of an increased optical depth effect. Advantageously, the decorative layer comprising at least one decorative layer is only coated on one side with the further layer structure. In particular, the decorative layer comprising at least one decorative layer is not encapsulated on both sides. Therefore, the decorative layer comprising at least one decorative layer is advantageously accessible for further processing. In particular, the layer structure according to the invention enables direct laser processing of the decorative layer orThis makes it possible to create a decorative layer without having to laser through an injection-molded material. Laser processing allows, in particular, one or more layers of the decorative layer to be specifically removed, in particular ablated, and / or one or more layers of the decorative layer to be specifically modified. Such a modification includes, for example, bleaching and / or a color change of one or more layers of the decorative layer.

[0027] Furthermore, there are diverse possibilities for structural integration. Structures, in particular relief structures, can be provided, for example, in one cavity half of the injection mold. Such a structure can, for example, be imaged or molded onto the second and / or third layer, i.e. in particular onto the protective layer made of polyurethane, in particular as a relief structure corresponding to the relief structure of the injection mold, so that the structure is visible on the front side of the finished component. Furthermore, such a structure can be imaged or molded onto the first layer so that the structure is visible on the back side of the finished component. It should be emphasized that when the structure is incorporated on the back, the decorative layer or decorative layer also images or molds the structure very well.In particular, one or more microstructures and / or nanostructures can be provided as relief structures, preferably one or more diffractive structures and / or holograms and / or refractive structures and / or matte structures. Furthermore, rear-side structures, which are also reproduced by the decorative layer or an IMD film encompassing it, are excellently visible as a design element. The provision of rear-side structures can also be done by laser. By laser processing, in particular one or more layers of the decorative layer can be specifically removed, in particular ablated, and thereby in particular a visually visible two-dimensional structuring and / or a surface relief can be created. Furthermore, further application can be carried out by hot stamping and / or cold stamping and / or digital printing and / or functional foil bonding (FFB).

[0028] Functional Foil Bonding (FFB) is a process in which a flexible, essentially self-supporting label is applied to a flat and / or 2.5D-formed component. The label can have functional properties, such as electrical and / or electronic functional layers, for example, for a touch-sensitive sensor function, an antenna function, or a heating function. The label can also have optical functional layers, such as anti-reflective layers, reflective layers, diffusion layers, or polarization layers. Alternatively or additionally, the label can have decorative layers.To apply the label, a radiation-curing adhesive is applied to the component surface and / or the label, which is then cured, for example, using UV radiation. Alternatively, the label and / or the component surface is coated with a hot-melt adhesive that is activated by elevated temperature during label application. After application, which is optionally accompanied by pressure, the adhesive cools down again, bonding the label to the component surface. The transferred label preferably remains completely on the component. The component can advantageously be used in automotive construction as a body part in the exterior, or as a functional and / or decorative part in the interior.In particular, it can be used in automotive interior parts such as door strips, strips in instrument panels, gear lever covers and center console covers, in automotive exterior parts such as door sill protection strips and covers on A, B and C pillars, in the audio and video sector for decorative strips on the housings of radio and television sets, and in the telecommunications sector for housing shells of mobile devices such as mobile phones or navigation devices.

[0029] Further advantageous embodiments of the invention are described in the subclaims.

[0030] According to an advantageous embodiment of the invention, the first material is formed by an injection-molded material, in particular by at least one thermoplastic, or by polyurethane.

[0031] According to a further advantageous embodiment of the invention, the second material is a flooding material, in particular polyurethane.

[0032] Polyurethane is not thermoplastic, but a reaction product with an initially very low viscosity. Therefore, polyurethane can mold geometries and / or structures, in particular complex geometries and / or structures. The component according to the invention, in particular the second layer of the component according to the invention, can therefore have geometries and / or structures, in particular complex geometries and / or structures. These geometries and / or structures can, for example, comprise abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, peaks and / or arches. Preferably, the component, in particular the second layer of the component, can have particularly thick walls and / or abrupt changes in wall thickness. Compared to the injection molding process with thermoplastic materials, very little and / or very few geometric distortions and / or sink marks and / or cavities arise when flooding with polyurethane.The components according to the invention therefore advantageously have a high optical quality.

[0033] The first material is preferably transparent, in particular a transparent thermoplastic or transparent polyurethane.

[0034] The second material is preferably transparent, in particular transparent polyurethane.

[0035] It is also conceivable for the first material and / or the second material to be translucent or opaque and / or colored. The first material and the second material can have different transmittances.

[0036] In the present application, a film, layer, ply, or material with a transmittance greater than 70% is preferably referred to as transparent. With a transmittance between 50% and 70%, the film, layer, ply, or material is preferably referred to as translucent. With a transmittance of less than 50%, the film, layer, ply, or material is preferably referred to as opaque. The percentage values ​​(% values) mentioned relate in particular to a transmittance in the wavelength range perceivable by the human eye. The wavelength range perceivable by the human eye is preferably assumed to be the wavelength range from 380 nm to 780 nm.

[0037] According to a further advantageous embodiment of the invention, a third layer made of a third material is arranged on the second layer. The third layer is preferably arranged directly on the second layer. The third material is preferably a flooding material, in particular polyurethane. The third material is preferably transparent, in particular transparent polyurethane.

[0038] According to a further advantageous embodiment of the invention, the second layer and the third layer are each formed from a flooding material, in particular from polyurethane. In this embodiment, the second and the third material are therefore each a flooding material, in particular polyurethane. Preferably, the second material is translucent or opaque and / or colored. Preferably, the third material is transparent. Preferably, the second layer forms geometries and / or structures, in particular complicated geometries and / or structures. These geometries and / or structures can, for example, comprise abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, points and / or arches. In particular, the second layer can have particularly thick walls and / or abrupt changes in wall thickness.The third layer is preferably arranged directly on the second layer. The third layer preferably covers the geometries and / or structures formed by the second layer. The third layer preferably has a smooth, free surface or a free surface structured in a different way than the second layer. The third layer therefore preferably forms a protective layer on the second layer. Advantageously, the geometries and / or structures formed by the second layer are protected from contamination and / or damage by the third layer and remain visible through it. It can be provided that several layers of the third layer are provided to smooth the structures of the second layer. According to a further advantageous embodiment of the invention, the holding element for holding the component is designed in an injection molding tool.The component can thus be fixed in the injection molding tool.

[0039] According to a further advantageous embodiment of the invention, the retaining element is designed as an outwardly projecting tab. In this case, the retaining element is formed from the first material. Alternatively or additionally, the retaining element is designed as an indentation in the first material. The indentation can be provided in an area located inward relative to the circumferential edge of the first layer. In particular, the retaining element can be designed as a tab having an indentation.

[0040] According to a further advantageous embodiment of the invention, the indentation is designed to engage a holding device of an injection molding tool. For this purpose, the holding device can comprise a movable holding arm. The indentation can be designed to receive one end of the movable holding arm. In particular, the indentation is designed for the positive engagement of the holding device of an injection molding tool. Preferably, the end of the holding arm is held in a positive-locking manner. In particular, the indentation is designed to complement the contour of the tip of the holding arm.

[0041] The holding element and the holding device remain firmly connected to each other, in particular when an external force acts in a direction perpendicular to the first layer.

[0042] According to a further advantageous embodiment of the invention, the decorative layer is a layer of an IMD film or a label to be transferred. Alternatively, the decorative layer is a component of an insert film. The IMD film preferably has a decorative layer and a carrier layer, whereby the decorative layer can comprise multiple decorative layers. The carrier layer is preferably removed at the end of the process for manufacturing the component. Therefore, the finished component preferably does not include the carrier layer of the IMD film.

[0043] As an alternative to an IMD film, an insert film can be used. An insert film comprises a decorative layer and a carrier layer. Unlike an IMD film, the carrier layer remains in the layered structure with an insert film. Therefore, the finished component manufactured with an insert film preferably also includes the carrier layer.

[0044] The carrier layer of an IMD film and / or insert film can comprise at least one carrier layer. The carrier layer can preferably have several layers, individually, multiple layers, or in combination, selected from: PET carrier and / or release layer and / or thermoplastic carrier.

[0045] The one or more layers of the carrier layer can each be present over the entire surface or partially. The one or more layers of the carrier layer can each overlap in certain areas and / or be adjacent to one another in certain areas. The adjacent arrangements can be spaced apart from one another or directly adjacent to one another without any space relative to one another.

[0046] According to a further advantageous embodiment of the invention, a further decorative layer and / or a further decorative layer comprising at least one further decorative layer is arranged between the first layer and the second layer. The further decorative layer and / or the further decorative layer can be applied to the first layer by hot stamping and / or cold stamping and / or digital printing and / or functional foil bonding (FFB). The further decorative layer and / or the further decorative layer is therefore preferably arranged between the first layer made of thermoplastic and the second layer made of polyurethane.

[0047] The further decorative layer or the further decorative layer can preferably have a plurality of layers, selected individually, multiple times or in combination from: primer layer, adhesive layer, adhesion promoter layer, color layer, colored varnish layer, functional layer, in particular optical functional layer, metal layer, reflection layer, HRI layer (HRI = High Refractive Index), replication layer with optically active and / or optically variable structures, in particular optically active relief structures, preferably diffractive structures and / or holograms and / or refractive structures and / or matt structures. The one or more layers of the further decorative layer are or are preferably applied during the process for producing the further decorative layer. The one or more layers of the further decorative layer can each be present over the entire surface or partially.The one or more layers of the further decorative layer or the further decorative layer can each overlap in certain areas and / or be adjacent to one another in certain areas. The adjacent arrangements can be spaced apart from one another or directly adjacent to one another without any space relative to one another.

[0048] Advantageously, the decorative layer and the further decorative layer or the further decorative layer complement one another in the formation of a design, in particular in conjunction with transillumination technologies. The one or more layers of the decorative layer and / or the decorative layer and / or the further decorative layer can each overlap in some areas and / or be adjacent to one another in some areas. The adjacent arrangement can be spaced apart from one another or directly adjacent to one another without any space relative to one another. According to a further advantageous embodiment of the invention, the first layer comprises precisely one holding element. The holding element is preferably configured to run all the way around the component. Particularly preferably, the holding element is configured to run completely around the component. In this case, the holding element extends completely around the edge surrounding the first layer.

[0049] Alternatively, the first layer can comprise a plurality of retaining elements. In particular, an even or odd number of retaining elements can be provided. Preferably, between 2 and 20 retaining elements are provided, particularly preferably between 2 and 16 retaining elements, and further preferably between 2 and 12 retaining elements.

[0050] According to a further advantageous embodiment of the invention, the first layer comprises two, three, four, five, six, eight, ten, or twelve retaining elements. The retaining elements are preferably arranged spaced apart from one another along the edge of the first layer. The retaining elements are preferably equally spaced from one another. However, the spacing of the retaining elements can also vary. The retaining elements are preferably arranged symmetrically to one another. The retaining elements can preferably be arranged in pairs. A pair can be arranged opposite one another, in particular symmetrically and / or diametrically opposite one another.

[0051] For example, the edge of the first layer forms a rectangle, in particular a square. In this case, the first layer can comprise two holding elements, which are arranged on two opposite sections of the edge, i.e. on two opposite sides of the rectangle or square. As a further example, in this case the first layer can comprise four holding elements. In this case, a holding element can be arranged on each section of the edge, i.e. on each side of the rectangle or square, so that two holding elements are arranged opposite one another in pairs. The holding elements are preferably each arranged in the middle of the respective side of the rectangle or square.

[0052] In another example, the edge of the first layer forms a triangle, in particular an equilateral triangle. In this case, the first layer can comprise three retaining elements. A retaining element can be arranged at each section of the edge, i.e., at each side of the triangle or equilateral triangle. Preferably, the retaining elements are each arranged in the center of the respective side of the triangle or equilateral triangle.

[0053] In another example, the edge of the first layer forms a hexagon, in particular an equilateral hexagon. In this case, the first layer can comprise six retaining elements. A retaining element can be arranged at each section of the edge, i.e., at each side of the hexagon or equilateral hexagon, so that two retaining elements are arranged opposite one another in pairs. The retaining elements are preferably arranged in the center of the respective side of the hexagon or equilateral hexagon.

[0054] According to a further advantageous embodiment of the invention, the first layer has a wall thickness of 0.5 mm to 10 mm. Preferably, the first layer has a wall thickness of 1 mm to 5 mm. Particularly preferably, the first layer has a wall thickness of 1.5 mm to 3 mm. The first layer preferably has a flat and / or smooth surface facing the second layer.

[0055] For the purposes of this application, the wall thickness of a layer can also be referred to as the "layer thickness" of the layer or as the "layer thickness" or "thickness" of the layer. The wall thickness extends in the direction of the layer structure of the component.

[0056] According to a further advantageous embodiment of the invention, the second layer has a wall thickness of 0.2 mm to 50 mm. In particular, the second layer has a wall thickness of 0.2 mm to 30 mm. Preferably, the second layer has a wall thickness of 0.3 mm to 15 mm. Preferably, the second layer has a wall thickness of 0.5 mm to 5 mm. Particularly preferably, the second layer has a wall thickness of 0.8 mm to 3 mm. Preferably, only individual structures have the full wall thickness.

[0057] The second layer preferably forms geometries and / or structures, in particular complex geometries and / or structures. These geometries and / or structures can, for example, comprise abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, points, and / or arches. In particular, the second layer can have particularly thick walls and / or abrupt wall thickness changes.

[0058] In particular, by means of laser processing and / or mechanical processing and / or by means of tool structures, it is possible to produce exposed relief structures in the second layer, which is preferably made of polyurethane, with a minimum line thickness and / or a minimum laserable dot diameter of 5 pm to 150 pm, preferably 10 pm to 100 pm. This allows the finest details, in particular for motifs and / or alphanumeric information, to be produced. It is also possible to combine such fine structures with coarser, macroscopic structures, either in a laterally adjacent combination or as an overlay of a coarse structure with a fine structure.This can be achieved in particular by combining several processing steps, for example to produce coarse structures with dimensions of the individual structural elements of 0.5 mm to 50 mm in combination with laser processing and / or mechanical processing adjacent thereto and / or superimposed thereon with a minimum line thickness and / or a minimum laserable spot diameter of 5 pm to 150 pm, preferably from 10 pm to 100 pm. However, it is also possible for coarse structures and fine structures to be present together as a tool structure and thus molded in the second layer, which is preferably made of polyurethane. The depth of the relief structures can be between 0.001 mm and the maximum wall thickness of the second layer, which is preferably made of polyurethane, in particular between 0.001 mm and 50 mm, preferably between 0.001 mm and 30 mm, preferably between 0.001 mm and 15 mm.

[0059] Advantageously, components according to the invention can have a wide range of wall thicknesses. In particular, components according to the invention can have particularly thin and / or particularly thick wall thicknesses. Advantageously, components according to the invention can have both particularly thin and particularly thick wall thicknesses. Such wall thicknesses are very difficult or impossible to achieve using an injection molding process with thermoplastic materials alone.

[0060] According to a further advantageous embodiment of the invention, the third layer has a wall thickness of 0.2 mm to 50 mm. In particular, the third layer has a wall thickness of 0.2 mm to 30 mm. Preferably, the third layer has a wall thickness of 0.3 mm to 15 mm. Preferably, the third layer has a wall thickness of 0.5 mm to 5 mm. Particularly preferably, the third layer has a wall thickness of 0.8 mm to 3 mm. In this case, the third layer is arranged in particular complementary to the second layer. This means that the structures formed in the second layer are preferably compensated by the third layer. Preferably, the third layer has a flat and / or smooth surface facing away from the second layer.

[0061] According to the invention, the method for producing a component having a layer structure, in particular a layer structure with at least two layers, preferably for producing the component according to the invention, comprises the following steps, in particular in the following order: a) Providing an injection molding tool comprising a holding device and a first and second cavity half, b) Inserting a film comprising a decorative layer with at least one decorative layer into the first cavity half, c) Closing the injection molding tool by inserting the second cavity half into the first cavity half, so that a first cavity is formed adjacent to the film, d) Coating the film with a first material to form a first layer by introducing the first material into the first cavity, wherein the first layer is formed with at least one holding element in such a way,that the holding device is arranged in a form-fitting manner with respect to the holding element, e) removing the second cavity half, wherein the film coated with the first layer remains in the first cavity half by holding the holding element by the holding device.

[0062] The holding device is preferably movable and / or comprises movable components, in particular a movable clamping frame and / or at least one movable holding arm.

[0063] After the film has been introduced into the first cavity half in step b) and / or before the injection molding tool is closed in step c), the holding device, in particular the clamping frame, is preferably moved against the film. The movement preferably occurs in a direction perpendicular to a plane formed by the film. The film is thereby preferably pressed against the first cavity half. The film is preferably fixed between the holding device, in particular between the clamping frame, and the first cavity half. See also step I) below.

[0064] In step d), the first material is preferably formed by at least one thermoplastic. Coating the film can therefore also be referred to as back-injection molding of the film. Alternatively, the first material can be polyurethane.

[0065] The coating or back-injection of the film in step d) preferably takes place on the back of the film, in particular on a primer layer formed by the film. The primer layer is preferably designed as an adhesive layer for bonding to the thermoplastic of the first layer. The film is preferably an IMD film or insert film.

[0066] The coating or back-injection of the film with the first material to form the first layer preferably takes place directly on the film in step d).

[0067] During coating or back-injection molding of the film in step d), the first layer with the at least one holding element is preferably formed such that the holding device is positively connected to the holding element. Preferably, a holding arm formed by the holding device is arranged in a positively locking manner with the holding element and / or is positively connected to the holding element. In particular, the first layer can be formed as a carrier layer. The wall thickness or thickness of the first layer can be dimensioned such that the component achieves a predetermined mechanical stability. The mechanical stability can have flexural rigidity or torsional strength.

[0068] According to an advantageous embodiment of the invention, the injection molding tool comprises a third cavity half. The method additionally comprises the following steps, which are preferably carried out after step e), in particular in the following order: f) closing the injection molding tool by inserting the third cavity half into the first cavity half, so that a second cavity is created; g) coating the film coated with the first layer with a second material to form a second layer by introducing, in particular injecting, the second material into the second cavity.

[0069] The cavity half can be changed from the second to the third cavity half using, for example, a turntable, sliding table, and / or indexable insert technology. The change to the third cavity half can also be done manually.

[0070] The second cavity created in step f) preferably lies directly adjacent to the first layer. Alternatively, a further decorative layer and / or a further decorative layer comprising at least one further decorative layer can be applied to the side of the first layer facing away from the film (see step k) below). In this case, the second cavity preferably lies directly adjacent to the further decorative layer and / or the further decorative layer.

[0071] The coating or flooding with the second material to form the second layer is carried out in step g) preferably on the surface of the first layer facing away from the film, preferably directly on the first layer.

[0072] Alternatively, a further decorative layer and / or a further decorative layer comprising at least one further decorative layer can be applied to the side of the first layer facing away from the film (see step k) below). In this case, the coating or flooding with the second material to form the second layer in step g) preferably takes place directly on the surface of the further decorative layer and / or the further decorative layer facing away from the first layer. The surface of the further decorative layer and / or the further decorative layer facing away from the first layer preferably forms a primer layer. The primer layer is preferably designed as an adhesive layer and / or adhesion promoter layer for bonding to the polyurethane of the second layer.

[0073] Furthermore, it is possible for the additional decorative layer and / or the additional decorative layer comprising at least one additional decorative layer to be applied only in regions on the side of the first layer facing away from the film. In this case, the coating or flooding with the second material to form the second layer in step g) preferably takes place in regions directly on the first layer and in regions directly on the surface of the additional decorative layer and / or the additional decorative layer facing away from the first layer.

[0074] In the present application, the term "region" is understood in particular to mean a defined area of ​​a layer or film or ply in the plane formed by the respective layer and / or film and / or ply. For example, the first layer can have at least a first region and at least one second region, wherein each of the two or more regions occupies a defined area in the plane formed by the first layer. The respective layers, films or plies preferably extend parallel to one another. In particular, the first layer preferably extends parallel to the further decorative layer and / or the further decorative ply.

[0075] In the present application, the term “regionally” is preferably understood in the same way as described above for the term “region”.

[0076] By completing step g), the component is preferably manufactured.

[0077] In step g), the second material is preferably polyurethane. Coating the film coated with the first layer can therefore also be referred to as flooding the first layer with polyurethane.

[0078] Particularly preferably, the second material in step g) is a mixture, in particular a polyurethane-forming mixture. Thus, the mixture is preferably introduced, in particular injected, into the second cavity.

[0079] Preferably, the film coated with the first layer is coated with the mixture in step g). The first layer can be directly flooded and / or poured over with the mixture. Alternatively, the surface of the further decorative layer and / or the further decorative ply facing away from the first layer can be directly flooded and / or poured over with the mixture. Furthermore, it is possible for the first layer to be partially flooded and / or poured over with the mixture and / or for the surface of the further decorative layer and / or the further decorative ply facing away from the first layer to be partially flooded and / or poured over with the mixture.

[0080] Preferably, in step g), the first layer is flooded and / or poured over its entire surface by the mixture, directly or indirectly. The term "flooding" within the meaning of the present application can mean overflooding, underflooding, flooding, and / or flooding around it. Different orientations of the resulting component in the closed mold halves are therefore possible. In this case, the first layer and / or the further decorative layer and / or the further decorative ply are each covered by the mixture, at least in some areas, on their surface facing away from the film. For linguistic simplification, the term "flooding" is used in particular in this application. The above-mentioned meanings can be interpreted as meanings.

[0081] In this application, the second layer formed from polyurethane is also referred to as the polyurethane layer.

[0082] The application of the polyurethane layer to the first layer and / or the further decorative layer and / or the further decorative layer is preferably carried out in step g) by at least partially flooding and / or pouring over the first layer and / or the further decorative layer and / or the further decorative layer, in each case on its surface facing away from the film, with at least one solvent-containing, preferably flowable, polyurethane-containing composition and subsequent curing.

[0083] The term “flowable polyurethane-containing composition” is preferably understood to mean a polyurethane-containing composition which preferably has a dynamic viscosity in a range from 2 mPas to 1500 mPas, preferably from 10 mPas to 1000 mPas, more preferably from 10 mPas to 500 mPas, at a temperature of 25°C, preferably determined according to the method described in DIN EN ISO 3219:1994-10, for example using a HAAKE Viscotester® VT550, more preferably using a cylinder measuring device NV and a measuring cup NV.The at least one solvent-containing, preferably flowable, polyurethane-containing composition preferably has free, reactive groups, preferably free isocyanate groups or free groups reactive towards isocyanate groups, and / or corresponding capped, reactive groups which release the corresponding reactive group again at a temperature in a range from 30°C to 180°C.

[0084] As already explained above, a further decorative layer and / or further decorative ply can be applied to the first layer. The further decorative layer and / or further decorative ply preferably has a primer layer on the surface facing away from the first layer for bonding with the polyurethane of the second layer. The primer layer is preferably a primer layer, in particular an adhesion promoter layer, that is not yet fully cured at least in some areas.During the curing, preferably complete curing, of the primer layer, which is at least partially not yet completely cured, and / or the polyurethane layer applied thereon, free isocyanate groups contained in the primer layer can, for example, react with free groups reactive towards isocyanate groups of the solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer.

[0085] As a result, the adhesion of the polyurethane layer to the primer layer after curing according to the process according to the invention, preferably according to step q) (see below), is preferably significantly improved.

[0086] More preferably, the at least one solvent-containing, preferably flowable, polyurethane-containing composition is selected from the group consisting of polyurethane-containing dispersions, polyurethane-containing resins, polyurethane solutions, compositions of polyurethane precursors (2K-PLIR systems) and mixtures thereof, which preferably also have free, reactive groups, preferably isocyanate groups or groups reactive towards isocyanate groups and / or in each case corresponding capped, reactive groups which release the corresponding reactive group again at a temperature in a range from 30°C to 180°C.

[0087] For example, the at least one solvent-containing, preferably flowable, polyurethane-containing composition as described above can be applied to the primer layer as compositions of polyurethane precursors (2K-PLIR systems), in particular as a mixture of at least one of the aforementioned compounds having two or more isocyanate groups and at least one of the aforementioned compounds having two or more groups reactive towards isocyanate groups, wherein preferably either the at least one compound having two or more isocyanate groups or the at least one compound having two or more groups reactive towards isocyanate groups is used in molar excess.

[0088] For example, polyurethane-containing dispersions, polyurethane-containing resins, and / or polyurethane solutions comprise the aforementioned prepolymers with free groups reactive toward isocyanate groups, which may be crosslinked or uncrosslinked, the aforementioned prepolymers with capped groups reactive toward isocyanate groups, which may be crosslinked or uncrosslinked, or mixtures thereof, and / or the aforementioned isocyanate prepolymers, which may be crosslinked or uncrosslinked, the aforementioned capped isocyanate prepolymers, which may be crosslinked or uncrosslinked, or mixtures thereof. More preferably, the at least one solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer comprises at least one organic solvent, for example ethyl acetate, 2-butanone, acetone, toluene, xylenes, or mixtures thereof.

[0089] Further preferably, at least one solvent-containing, preferably flowable, polyurethane-containing composition comprising the aforementioned isocyanate prepolymers used to produce the polyurethane layer is anhydrous. The aforementioned capped isocyanate prepolymers, however, can be present as an aqueous dispersion.

[0090] More preferably, a polyurethane layer used to produce the polyurethane layer comprises at least one solvent-containing, preferably flowable, polyurethane-containing composition which comprises the aforementioned prepolymers with free groups reactive towards isocyanate groups, which may be crosslinked or uncrosslinked, the aforementioned prepolymers with capped groups reactive towards isocyanate groups, which may be crosslinked or uncrosslinked, or mixtures thereof, water and / or at least one organic solvent, for example ethyl acetate, 2-butanone, acetone, toluene, xylenes or mixtures thereof.

[0091] When using 2-component PU systems, the polyurethane precursors, for example, polyol-containing and isocyanate-containing components, are preferably stored separately and only brought together in the mixing head when required. The heat of reaction generated during the reaction of the polyurethane precursors preferably results in heating to a temperature of 60°C to 180°C, preferably 80°C to 120°C. The surfaces or walls of the cavity halves can also preferably have a temperature in the range of 40°C to 160°C, preferably 80°C to 120°C.

[0092] The introduction, in particular injection, of the at least one solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer is preferably carried out via a mixing head, preferably at a pressure of less than 10 bar.

[0093] A first curing phase can be initiated by applying heat to the injection molding tool, for example at a temperature of 60°C to 160°C, preferably for a period of 60 s to 600 s.

[0094] After removal from the injection mold, the component is preferably stored for approximately 24 hours before further use for residual curing.

[0095] During the curing, preferably complete curing, of the primer layer, which is at least partially not yet completely cured, and the polyurethane layer applied thereon, free isocyanate groups contained in the primer layer can, for example, react with free groups reactive towards isocyanate groups of the solvent-containing, preferably flowable, polyurethane-containing composition used to produce the polyurethane layer.

[0096] Preferably, a layer is referred to as “cured” in the sense of the present invention when the polymer components capable of crosslinking, preferably binders, for example free isocyanate groups and / or free isocyanate-reactive

[0097] Groups of the respective layer have more than 95% networking.

[0098] Preferably, before and / or during and / or after the application of the polyurethane layer in step g) and / or in step o), the polyurethane layer can be modified and / or structured, preferably by inserting / placing particles onto the primer layer and / or by using tool structures during the application in step g) and / or in step o) and / or by subsequently processing the polyurethane layer by means of process steps selected individually or in combination from laser processing, overprinting, hot stamping, cold stamping, blind stamping, mechanical processing.

[0099] In particular, by means of laser processing and / or mechanical processing and / or the use of tool structures, it is possible to create exposed relief structures in the polyurethane layer with a minimum line width and / or a minimum laserable dot diameter of 5 pm to 150 pm, preferably 10 pm to 100 pm. This allows the finest details, particularly for motifs and / or alphanumeric information, to be produced. It is also possible to combine such fine structures with coarser, macroscopic structures, either in a laterally adjacent combination or as an overlay of a coarse structure with a fine structure.This can be achieved in particular by combining several of the above-mentioned process steps, for example to produce coarse structures with dimensions of the individual structural elements of 0.5 mm to 50 mm in combination with laser processing and / or mechanical processing adjacent thereto and / or superimposed thereon with a minimum line thickness and / or a minimum laserable spot diameter of 5 pm to 150 pm, preferably from 10 pm to 100 pm. However, it is also possible for coarse structures and fine structures to be present together as a tool structure and thus molded into the polyurethane layer. The depth of the relief structures can be between 1 pm and the maximum wall thickness of the polyurethane layer, in particular between 0.001 mm and 50 mm, preferably between 0.001 mm and 30 mm, more preferably between 0.001 mm and 15 mm.

[0100] Preferably, a modification of the polyurethane layer and / or the primer layer can take place in register with design features and / or motifs already present in the decorative layer and / or in the decorative layer and / or in the further decorative layer and / or in the further decorative layer. For example, a surface structure can be arranged in register with a wood grain, in particular of the decorative layer and / or decorative layer and / or further decorative layer and / or further decorative layer, and / or a tactilely and / or visually perceptible structure can be arranged in register with a motif, in particular of the decorative layer and / or decorative layer and / or further decorative layer and / or further decorative layer.The structures mentioned can, for example, be produced by process steps individually or multiple times or in combination selected from the use of tool structures during the application in step g) and / or o), laser processing, overprinting, overembossing, mechanical processing.

[0101] 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.

[0102] A polyurethane layer produced by the process according to the invention preferably has transparent or reduced light-transmitting properties.

[0103] In step g) and / or in an additional step preceding step g), a polyurethane-forming mixture is preferably provided at a mixing head of the injection molding tool. For this purpose, components of the polyurethane-forming mixture are preferably mixed together at the mixing head. The mixture thus provided is preferably flowable. The mixture can be a solvent-containing and polyurethane-containing composition. The components preferably comprise at least one polyol and one isocyanate.

[0104] The mixture provided is formed in particular from a polyol and an isocyanate and preferably contains further chemical additives.

[0105] In other words, the polyurethane-forming mixture can be a solvent-containing and polyurethane-containing composition and in particular comprise several components, individually or in combination selected from polyol, isocyanate, catalyst, release agent, additive.

[0106] Preferably, a chemical reaction starts when the mixture is provided. The chemical reaction is preferably an exothermic reaction. Furthermore, the chemical reaction is preferably a crosslinking reaction, in which molecular polymer chains are preferably formed. Crosslinks preferably form between the polymer chains. Polyurethane is preferably formed during the crosslinking reaction. Preferably, the additional step takes place immediately before step g), i.e., the components forming the mixture are mixed together immediately before injection into the closed cavity halves.

[0107] In particular, the chemical reaction begins by mixing the two polyurethane-forming components, polyol and isocyanate. Preferably, a crosslinking reaction occurs, forming the molecular polymer chains. The crosslinking reaction is preferably exothermic. Preferably, the polyol and isocyanate components remain separate before the mixing process and are only combined immediately before injection into the closed cavity halves according to step g). This can prevent a premature chemical reaction. This advantageously allows the rheological flow properties of the mixture to be maintained for injection into the closed cavity halves in step g).

[0108] The mixture is preferably thin-bodied when injected into the closed cavity halves in step g). The viscosity at the start of injection into the closed cavity halves is preferably in a range between 100 mPas and 300 mPas, preferably 120 mPas and 200 mPas, at a mixture temperature of 40°C to 100°C, preferably at a mixture temperature of 50°C to 75°C, particularly preferably at a mixture temperature of 60°C to 70°C.

[0109] Preferably, the viscosity of the mixture and / or the resulting polyurethane layer increases as the chemical crosslinking reaction progresses until the end of the chemical reaction. Preferably, the mixture and / or the resulting polyurethane layer cures as the chemical crosslinking reaction progresses. Preferably, a fully cured polyurethane layer is formed at the end of the chemical reaction. The provided mixture preferably comprises reactive groups. More preferably, the provided mixture comprises at least two reactive groups, preferably three or more reactive groups.

[0110] Preferably, the respective components of the mixture each have at least two reactive groups, preferably three or more reactive groups. In particular, the polyol preferably has at least two reactive groups, preferably three or more reactive groups.

[0111] Furthermore, the isocyanate preferably has at least two reactive groups, preferably three or more reactive groups.

[0112] The reactive groups may preferably be free reactive groups and / or capped reactive groups which release the corresponding reactive group at a temperature in the range of 30°C to 180°C.

[0113] The presence of three or more reactive groups preferably enables the formation of cross-links to form the polyurethane layer.

[0114] The term “curing” or “hardening” preferably refers to the transition from a liquid or plastically deformable state to a solid state of a substance or mixture of substances under standard conditions (temperature: 25°C, pressure: 1013 mbar).

[0115] The curing or hardening process can preferably be carried out by cooling, i.e., by reducing the temperature below the freezing point and / or below the glass transition temperature of a substance or mixture of substances, and / or by physical drying, i.e., by removing at least one liquid constituent, for example, a solvent, and / or by chemical reaction, for example, by chain polymerization, polyaddition, and / or polycondensation. The term "polymeric component and / or precursor thereof" preferably refers to a substance or mixture of substances that comprises at least one, preferably organic, polymer and / or at least one precursor thereof.

[0116] The term "polymer" preferably refers to a substance composed of preferably at least 10 structural units, so-called constitutional repeating units, which may be identical or different from one another and which form at least one organic polymer through chemical reaction, preferably chain polymerization, polyaddition, and / or polycondensation. A constitutional repeating unit (CRU) is preferably the smallest repeating group of atoms within a polymer.

[0117] A polymer within the meaning of the invention can be unbranched or branched.

[0118] The term “precursor of a polymeric component” preferably refers to monomers or monomer mixtures as well as oligomers and mixtures thereof, which can each combine to form the corresponding unbranched or branched polymer, preferably by chemical reaction, more preferably chain polymerization, polyaddition and / or polycondensation.

[0119] The term “reactive functional group” is preferably understood to mean a functional group which can participate in the formation of the corresponding unbranched or branched polymer by chemical reaction, more preferably chain polymerization, polyaddition and / or polycondensation.

[0120] Monomers or monomer mixtures within the meaning of the invention are preferably low-molecular-weight, reactive molecules or mixtures of reactive molecules that can each combine to form the corresponding unbranched or branched polymer by chemical reaction, more preferably chain polymerization, polyaddition, and / or polycondensation, thereby forming a constitutional repeating unit of the polymer. A reactive molecule, for example, a monomer, oligomer, and optionally a polymer, preferably has at least one reactive functional group.

[0121] The term “oligomer” is preferably understood to mean a substance which is composed of preferably 2 to 9 constitutional repeating units which may be the same or different from one another and which may combine to form an unbranched or branched polymer, preferably by chemical reaction, more preferably chain polymerization, polyaddition and / or polycondensation.

[0122] The term “cured polymeric component” preferably refers to a polymeric substance or a mixture of polymeric substances which has a solid state under standard conditions (temperature: 25°C, pressure: 1013 mbar) and is preferably not plastically deformable.

[0123] According to a further advantageous embodiment of the invention, the third cavity half forms a negative for the second layer, which is preferably made of polyurethane. The cavity half preferably has mold cavity regions of different thicknesses to form different wall thicknesses of the second layer.

[0124] Preferably, the cavity half has at least one first mold cavity region for producing the first wall thickness of the second layer and at least one second mold cavity region for producing the second wall thickness of the second layer. The first wall thickness can differ from the second wall thickness, in particular, by 5% to 75%, preferably by 10% to 50%.

[0125] According to a further advantageous embodiment of the invention, the method additionally comprises the following steps, which are preferably carried out after step g), in particular in the following order: h) removing the third cavity half or removing the first cavity half, wherein the component remains in the holding device by the holding element being held by the holding device, i) releasing the holding element by the holding device, j) demoulding the component.

[0126] The film coated with the first and second layers is already referred to as a component here.

[0127] Preferably, when removing the third cavity half in step h), the component remains in the first cavity half.

[0128] Preferably, an adhesive force of the polyurethane (PUR) of the second layer to the third cavity half is smaller than an adhesive force of the thermoplastic of the first layer to the first cavity half.

[0129] Adhesion PUR to third cavity half < Adhesion thermoplastic to first cavity half

[0130] Particularly preferably, the adhesive force of the holding element and / or the holding elements on the holding arm and / or on the holding arms is greater than the adhesive force of the second layer, preferably made of polyurethane, on the third cavity half. As a result, the component preferably remains with the holding device in the first cavity half. Preferably, the film continues to be pressed against the first cavity half by the holding device, in particular by the clamping frame.

[0131] If the first cavity half is removed in step h), the component preferably remains in the third cavity half.

[0132] Preferably, the holding element is released in step i) by retracting the movable holding arm from the holding element. The movable holding arm is preferably designed as a piston. The holding device preferably comprises a plurality of holding arms. The component can have one or more holding elements. The holding arms are preferably each moved out of the holding element or each moved out of the corresponding holding element.

[0133] The holding arms, preferably designed as pistons, can be retracted along their axis within the holding device. The direction of movement of the holding arms preferably forms a demolding angle relative to a layering plane of the layered structure. The demolding angle is preferably 1° to 89°, particularly preferably 1° to 60°. Retracting the holding arms overcomes the positive locking between the respective holding arm and the holding element and / or the corresponding holding element.

[0134] After the holding arms have retracted, the clamping frame is preferably released from the film. To do this, the clamping frame is preferably moved. The clamping frame is preferably moved in the direction of the layer buildup.

[0135] Any vacuum that may exist between the film and the first cavity half is preferably flushed with ambient air. This allows the component to be removed from the injection mold. Furthermore, it is possible to produce multiple components in parallel using turntable technology, cube technology, and / or indexable insert technology.

[0136] Polyurethane is not thermoplastic, but a reaction product with an initially very low viscosity. Therefore, polyurethane can mold geometries and / or structures, in particular complex geometries and / or structures. The process according to the invention is therefore advantageously particularly flexible in terms of special geometric specifications. Components with geometries and / or structures, in particular complex geometries and / or structures, can be produced. These geometries and / or structures can, for example, comprise abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, peaks and / or arches. In particular, the components can have particularly thick walls and / or abrupt changes in wall thickness. Compared to the injection molding process with thermoplastic materials, very little and / or very few geometric distortions and / or sink marks and / or cavities arise.The components according to the invention therefore advantageously have a high optical quality.

[0137] Preferably, before and / or during and / or after the application of the second layer, which is preferably made of polyurethane, in step g), the second layer can be modified and / or structured, preferably by inserting / placing particles onto the first layer and / or by using tool structures on the third cavity half used in step f) and / or by subsequently processing the second layer by means of process steps selected individually or in combination from laser processing, overprinting, hot stamping, cold stamping, blind stamping, mechanical processing.

[0138] In particular by means of laser processing and / or mechanical

[0139] By processing and / or using tool structures, it is possible to create exposed relief structures in the second layer, which is preferably made of polyurethane, with a minimum line width and / or a minimum laserable dot diameter of 5 pm to 150 pm, preferably 10 pm to 100 pm. This allows the finest details, particularly for motifs and / or alphanumeric information, to be produced. It is also possible to combine such fine structures with coarser, macroscopic structures, either in a laterally adjacent combination or as an overlay of a coarse structure with a fine structure.This can be achieved in particular by combining several of the above-mentioned process steps, for example to produce coarse structures with dimensions of the individual structural elements of 0.5 mm to 50 mm in combination with laser processing and / or mechanical processing adjacent thereto and / or superimposed thereon with a minimum line thickness and / or a minimum laserable spot diameter of 5 pm to 150 pm, preferably from 10 pm to 100 pm. However, it is also possible for coarse structures and fine structures to be present together as a tool structure and thus molded in the second layer, which is preferably made of polyurethane. The depth of the relief structures can be between 1 pm and the maximum wall thickness of the second layer, which is preferably made of polyurethane, in particular between 0.001 mm and 50 mm, preferably between 0.001 mm and 30 mm, preferably between 0.001 mm and 15 mm.

[0140] According to a further advantageous embodiment of the invention, the method additionally comprises the following step, which is preferably carried out between step e) and step f): k) Applying a further decorative layer and / or a further decorative layer comprising at least one further decorative layer to the side of the first layer facing away from the film. The further decorative layer and / or the further decorative layer can be applied to the first layer by hot stamping and / or cold stamping and / or digital printing and / or functional foil bonding (FFB). The further decorative layer and / or the further decorative layer is preferably applied to the first layer made of thermoplastic and, in step g), flooded with polyurethane to form the second layer.

[0141] Furthermore, it is possible that the further decorative layer and / or the further decorative layer comprising at least one further decorative layer is applied only in regions on the side of the first layer facing away from the film.

[0142] Advantageously, the decorative layer and the further decorative layer or the further decorative layer complement each other in the formation of a design, particularly in conjunction with transillumination technologies.

[0143] According to a further advantageous embodiment of the invention, the film is introduced in step b) with its carrier side adjacent to the first cavity half.

[0144] According to a further advantageous embodiment of the invention, the film is an IMD film. The IMD film is fed into the first cavity half in step b) as film roll material or inserted into the first cavity half as a label. Alternatively, the film can be an insert film. In this case, the insert film is inserted into the first cavity half in step b).

[0145] According to a further advantageous embodiment of the invention, the method additionally comprises the following step, which is preferably carried out after step b):

[0146] I) Pressing the film comprising the decorative layer against the first cavity half by means of the holding device, in particular by means of a clamping frame formed by the holding device. Step I) is preferably carried out before the injection molding tool from step c) is closed. Preferably, the holding device, in particular the clamping frame, is moved against the film. The movement preferably occurs in a direction perpendicular to a plane formed by the film. The film is thereby preferably pressed against the first cavity half. The film is preferably fixed by the holding device, in particular by the clamping frame.

[0147] According to a further advantageous embodiment of the invention, the method additionally comprises the following step, which is preferably carried out after step b) and / or after step I): m) evacuating the first cavity half so that a vacuum is created between the film comprising the decorative layer and the first cavity half.

[0148] Preferably, step m) is carried out immediately after step b) and / or immediately after step 1). Alternatively, step m) can be carried out during step c) or immediately after step c).

[0149] Preferably, the vacuum between the film comprising the decorative layer and the first cavity half is also maintained during steps c) to g). If the third cavity half is removed in step h), the vacuum between the film comprising the decorative layer and the first cavity half is preferably also maintained during step h).

[0150] By evacuating the first cavity half, the film and / or the resulting component are advantageously held stably in the first cavity half. Furthermore, by evacuating the first cavity half, air pockets or cavities in the first layer in step d) and / or in the second layer in step g) are advantageously prevented. This ensures high component quality.

[0151] According to a further advantageous embodiment of the invention, the first material is formed by an injection-molded material, in particular by at least one thermoplastic, or by polyurethane.

[0152] According to a further advantageous embodiment of the invention, the second material is a flooding material, in particular polyurethane.

[0153] Polyurethane is not thermoplastic, but rather a reaction product with an initially very low viscosity. Therefore, polyurethane can mold geometries and / or structures, especially complex geometries and / or structures. The component according to the invention, in particular the second layer of the component according to the invention, can therefore have geometries and / or structures, especially complex geometries and / or structures. These geometries and / or structures can, for example, include abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, peaks, and / or arches.

[0154] In particular, the component, especially the second layer of the component, can have particularly thick walls and / or abrupt wall thickness changes. Compared to injection molding with thermoplastic materials, very little and / or very few geometric distortions and / or sink marks and / or cavities occur. The components according to the invention therefore advantageously have a high optical quality.

[0155] The first material is preferably transparent, in particular a transparent thermoplastic or transparent polyurethane. The second material is preferably transparent, in particular transparent polyurethane.

[0156] It is also conceivable for the first material and / or the second material to be translucent or opaque and / or colored. The first material and the second material can have different transmittances.

[0157] In the present application, a film, layer, or ply with a transmittance greater than 70% is preferably referred to as transparent. With a transmittance between 50% and 70%, the film, layer, or ply is preferably referred to as translucent. With a transmittance of less than 50%, the film, layer, or ply is preferably referred to as opaque. The percentage values ​​(% values) mentioned relate in particular to a transmittance in the wavelength range perceivable by the human eye. The wavelength range perceivable by the human eye is preferably assumed to be the wavelength range from 380 nm to 780 nm.

[0158] According to an advantageous embodiment of the invention, the injection molding tool comprises a fourth cavity half. The method additionally comprises the following steps, which are preferably carried out between the removal of the third cavity half in step h) and step i), in particular in the following order: n) closing the injection molding tool by inserting the fourth cavity half into the first cavity half, so that a third cavity is created, o) coating the second layer with a third material to form a third layer by introducing, in particular injecting, the third material into the third cavity, p) removing the fourth cavity half or removing the first cavity half, wherein the component remains in the holding device by the holding element being held by the holding device.

[0159] The third material is preferably a flooding material, in particular polyurethane. Coating the second layer can therefore also be referred to as flooding the first layer with polyurethane. The third material is preferably transparent, in particular transparent polyurethane.

[0160] The cavity half can be changed from the third to the fourth cavity half using, for example, a turntable, sliding table, and / or indexable insert technology. The change to the fourth cavity half can also be done manually.

[0161] The third cavity created in step n) is preferably located directly adjacent to the second layer.

[0162] The coating or flooding with the third material to form the third layer is carried out in step o) preferably on the surface of the second layer facing away from the film, preferably directly on the second layer.

[0163] By completing step o), the manufacture of the component is preferably achieved.

[0164] The film coated with the first, second and third layers is already referred to here as a component.

[0165] Preferably, during removal of the fourth cavity half in step p), the component with the holding device remains in the first cavity half. Preferably, the adhesive force of the polyurethane (PUR) of the third layer to the fourth cavity half is smaller than the adhesive force of the thermoplastic of the first layer to the first cavity half.

[0166] Adhesion PUR to fourth cavity half < Adhesion thermoplastic to first cavity half

[0167] Particularly preferably, the adhesive force of the holding element and / or the holding elements on the holding arm and / or on the holding arms is greater than the adhesive force of the third layer, preferably made of polyurethane, on the fourth cavity half. As a result, the component preferably remains with the holding device in the first cavity half. Preferably, the film continues to be pressed against the first cavity half by the holding device, in particular by the clamping frame.

[0168] If the first cavity half is removed in step p), the component preferably remains in the fourth cavity half.

[0169] According to a further advantageous embodiment of the invention, the second layer and the third layer are each formed from a flooding material, in particular from polyurethane. In this embodiment, the second and the third material are therefore each a flooding material, in particular polyurethane. Preferably, the second material is translucent or opaque and / or colored. Preferably, the third material is transparent. Preferably, the second layer forms geometries and / or structures, in particular complicated geometries and / or structures. These geometries and / or structures can, for example, comprise abrupt or continuous cross-sectional changes, in particular tapers, corners, edges, points and / or arches. In particular, the second layer can have particularly thick walls and / or abrupt changes in wall thickness.The third layer is preferably arranged directly on the second layer. The third layer preferably covers the geometries and / or structures formed by the second layer. The third layer preferably has a smooth, exposed surface or a free surface structured in a different way than the second layer. The third layer therefore preferably forms a protective layer on the second layer. Advantageously, the geometries and / or structures formed by the second layer are protected from contamination and / or damage by the third layer and remain visible.

[0170] Preferably, the vacuum between the film comprising the decorative layer and the first cavity half is also maintained during steps n) and o). If the fourth cavity half is removed in step p), the vacuum between the film comprising the decorative layer and the first cavity half is preferably also maintained during step p).

[0171] Particularly preferably, the third material in step o) is a mixture, in particular a polyurethane-forming mixture. To avoid repetition, reference is made to the explanations regarding the mixture forming the second material in step g). These explanations apply accordingly to the third material in step o). In particular, the term "polyurethane layer" can also apply to the third layer.

[0172] Advantageous embodiments of the invention are explained below, which can relate to step g) and / or step o). To simplify the language, uniform terms are used. The term “closed cavity halves” can be understood as the second cavity in relation to step g) and / or as the third cavity in relation to step o). The term “polyurethane layer” can be understood as the second layer in relation to step g) and / or as the third layer in relation to step o). According to a further advantageous embodiment of the invention, the mixture in step g) and / or in step o) is introduced, in particular injected, into the closed cavity halves at a filling pressure selected from a range of 70 bar to 140 bar, preferably from 80 bar to 100 bar. In step g), the mixture is preferably introduced, in particular injected, into the second cavity.In step o), the mixture is preferably introduced, in particular injected, into the third cavity.

[0173] According to a further advantageous embodiment of the invention, the polyurethane layer is formed in the closed cavity halves as a result of the introduction, in particular injection, of the mixture in step g) and / or in step o) at a temperature selected from a range of 40°C to 160°C, preferably from 60°C to 140°C, particularly preferably from 80°C to 120°C, and / or at a pressure selected from a range of 3 bar to 100 bar, preferably from 5 bar to 50 bar, particularly preferably from 8 bar to 30 bar.

[0174] Advantageously, lower temperatures are required to form the polyurethane layer than when using thermoplastic materials in the injection molding process.

[0175] Preferably, an exothermic reaction starts in the mixture when the polyurethane-forming mixture is made available at the mixing head. This exothermic reaction preferably heats the mixture introduced into the closed cavity halves in step g) and / or step o). Depending on the current temporal phase of the exothermic reaction, it is advantageous to temper the mixture, in particular to heat it up or cool it down, so that the exothermic reaction takes place at an approximately constant process temperature. At the start of the exothermic reaction, the mixture is therefore heated up or cooled down by the then prevailing mold temperature, which is higher than the mixture temperature.As the exothermic reaction progresses, with increasing thermal energy released, the largely constant mold temperature leads to a cooling of the mixture, which is heated by the reaction, because the mold temperature is then temporarily below the mixture temperature influenced by the exothermic reaction. The mold temperature remains largely constant during the exothermic reaction.

[0176] The cavity halves are preferably pre-tempered to a temperature selected from a range of 40°C to 160°C, preferably 60°C to 140°C, particularly preferably 80°C to 120°C, prior to introducing, in particular injecting, the mixture according to step g) and / or according to step o). The temperature of the mixture at the start of the chemical reaction and / or immediately after mixing the mixture and / or immediately upon injection into the closed cavity halves is preferably lower than the temperature of the cavity halves (mold temperature). Due to the low thermal conductivity of the polyurethane of approximately 0.020 W / Km to 0.040 W / Km, the mixture and / or the forming polyurethane layer preferably assumes the preset temperature of the cavity halves (mold temperature) over time and / or as the reaction progresses.

[0177] Preferably, the temperature difference for cooling the component formed in the closed cavity halves is between 0°C and 100°C, preferably between 0°C and 50°C, particularly preferably between 0°C and 30°C. The temperature difference for cooling the component formed in the closed cavity halves is thus advantageously much lower than when injection molding thermoplastic materials. Advantageously, lower pressures are required to form the polyurethane layer than when using thermoplastic materials in the injection molding process.

[0178] According to a further advantageous embodiment of the invention, the method additionally comprises the following step, which is preferably carried out after step g) and / or after step o): q) curing the mixture inside and / or outside the closed cavity halves to form the polyurethane layer.

[0179] The duration of the curing process within the closed cavity halves is preferably 10 seconds to 120 seconds, particularly preferably 20 seconds to 90 seconds, further preferably 30 seconds to 70 seconds.

[0180] This is in particular 2 to 10 times the pot life of the mixture, preferably 3 to 7 times the pot life of the mixture. Pot life is the processability or service life of the reactive mixture.

[0181] Preferably, the component is cooled in the closed cavity halves during the curing process. The duration of the curing process within the closed cavity halves can also be referred to as the cooling time. After the cooling time has ended, step h) is preferably carried out immediately. The cavity halves are opened. The cooling time depends on the degree of curing of the polyurethane and can vary as described above. The initially liquid polyurethane must have transformed into the solid state so that deformation is avoided after the cavity halves are opened. For this purpose, the temperature of the tool cavity, i.e. in particular of the cavity halves, preferably exceeds the ambient temperature by at least 5 K, preferably by 10 K.

[0182] T-tool cavity > T environment + 5 K

[0183] The duration of the curing process outside the closed cavity halves, in particular on a holding device with the shape of the component, is preferably 5 minutes to 90 minutes, particularly preferably 5 minutes to 45 minutes.

[0184] Preferably, the viscosity of the mixture and / or the forming polyurethane layer increases as the chemical crosslinking reaction progresses.

[0185] Preferably, the mixture and / or the resulting polyurethane layer cures as the chemical crosslinking reaction progresses. Preferably, a fully cured polyurethane layer is formed at the end of the chemical crosslinking reaction.

[0186] Preferably, the mixture is completely cured in step q) to form the polyurethane layer.

[0187] The curing according to step q) is preferably carried out at a temperature selected from a range of 20°C to 160°C, preferably from 20°C to 120°C.

[0188] In the case of the embodiment with a further decorative layer and / or further decorative layer applied to the first layer, the further decorative layer and / or further decorative layer has a primer layer, preferably a primer layer that is at least partially not yet fully cured, in particular an adhesion promoter layer, on the surface facing away from the first layer for bonding with the polyurethane of the second layer. The primer layer that is at least partially not yet fully cured is preferably cured, preferably fully cured, together with the mixture applied thereto and / or with the polyurethane layer applied thereto. In the process, crosslinks preferably form between the polyurethane layer and the primer layer. The polyurethane layer is preferably bonded to the primer layer in a material-to-material manner.

[0189] The composite of the first layer and / or the further decorative layer and / or the further decorative ply with the polyurethane layer is preferably dimensionally stable. Preferably, the polyurethane layer cannot be removed non-destructively from the first layer and / or the further decorative layer and / or the further decorative ply.

[0190] According to a further advantageous embodiment of the invention, the method additionally comprises the following step, which is preferably carried out after step i) and / or step j): r) Removing the carrier layer of the film.

[0191] This advantageous embodiment therefore preferably relates to the design of the film as an IMD film.

[0192] After performing step r), preferably only the decorative layer of the IMD film remains on the component.

[0193] A release layer of the IMD film can be arranged completely or partially on the decorative layer after removal of the carrier layer from the film and / or can be arranged completely or partially on the carrier layer.

[0194] According to a further advantageous embodiment of the invention, the film in step b) is provided as a roll and / or as a continuous film and / or as a sheet and / or is introduced into the cavity half by means of film feed device technology. In particular, an IMD film can preferably be provided as a roll and / or as a continuous film. An IMD film can also be provided as a sheet. In particular, an insert film can preferably be provided as a sheet. An insert film can also be provided as a roll and / or as a continuous film.

[0195] The process is preferably carried out as an IMD process (IMD = In-Mold Decoration). The film comprising the decorative layer is conveyed as a transfer film with a carrier layer and a decorative layer comprising the decorative layer, in particular as a roll, and is introduced into the first cavity half, in particular according to step b).

[0196] Compared to other decoration methods, such as wet coating, the lacquer transfer technology decoration process advantageously enables a significantly greater variety of designs. This allows for the creation of individual images, technical designs, tactile surfaces, and many other design variations.

[0197] According to a further advantageous embodiment of the invention, the method comprises the further following step or the step b), e), h), i), j) and / or step p) comprises the further following sub-step: s) cleaning the film and / or the component, preferably the first, second and / or third layer, in particular by means of at least one brush and / or a blower and / or a suction device.

[0198] According to a further advantageous embodiment of the invention, the method has the further following step or step j) comprises the further following sub-step: t) printing the component, preferably the second and / or third layer, in particular in at least a first and / or second region, preferably alone or in combination selected from inkjet printing, gravure printing, screen printing, planographic printing, letterpress printing, flexographic printing, pad printing.

[0199] According to a further advantageous embodiment of the invention, the method has the further following step or step b) comprises the further following sub-step: u) pretreatment of the film, preferably of the primer layer, in particular by means of a method alone or in combination selected from corona treatment, flame treatment, plasma treatment.

[0200] According to a further advantageous embodiment of the invention, the method comprises the further following step or step j) comprises the further following sub-step: v) cutting the component by means of punching or water jet cutting or laser cutting.

[0201] Cutting preferably refers to external cutting.

[0202] Preferably, the method may comprise the further following step or step j) may comprise the further following sub-step: w) dividing the component into individual panels, in particular in the case of roll goods having a plurality of panels or in the case of a sheet having a plurality of panels.

[0203] According to a further advantageous embodiment of the invention, the component obtained in step j) is selected from the group consisting of displays, touch fields, panels, bezels, and functional elements, in particular from the following areas: white goods, motor vehicles, aviation, ships, household appliances, telecommunications equipment, consumer goods, documents, security elements, labels, and / or electronic items. The aforementioned method steps and substeps are described serially (executing one after the other). The aforementioned method steps and substeps can also be performed at least partially in parallel, particularly for producing multiple components according to the invention. For this purpose, turntable technology and / or cube technology and / or indexable plate technology are preferably used.

[0204] It is also possible for the process steps and substeps to be performed once or multiple times. In particular, process steps and substeps can be repeated. The preferred sequence of process steps comprises at least the order of step a) - step b) - step c) - step d) - step e) - step f) - step g) - step h) - step i) - step j), whereby, in particular, further steps or substeps can be inserted between these steps.

[0205] An advantage of the invention is that the decorative layer comprising at least one decorative layer, the first layer, and optionally further decorative layers and / or further application layers, are protected by the overlying, outer second and / or third layer, preferably made of polyurethane, as a protective layer. This enables advantageous effects, such as the creation of an enhanced optical depth effect.

[0206] Advantageously, the decorative layer comprising at least one decorative layer is coated with the additional layer structure on only one side. In particular, the decorative layer comprising at least one decorative layer is not encapsulated on both sides. Therefore, the decorative layer comprising at least one decorative layer is advantageously accessible for further processing. In particular, the layer structure according to the invention enables direct laser processing of the decorative layer or layer without having to laser through an injection-molded material.

[0207] Furthermore, there are diverse possibilities for structural integration. In this case, structures can be provided, for example, in one cavity half of the injection mold. Such a structure can, for example, be mapped onto the second and / or third layer, i.e. in particular onto the protective layer made of polyurethane, so that the structure is visible on the front side of the finished component. Furthermore, such a structure can be mapped onto the first layer so that the structure is visible on the back side of the finished component. It should be emphasized that when the structure is incorporated on the back, the decorative layer or layer also maps the structure very well. The structures provided can be, for example, microstructures or nanostructures.

[0208] Furthermore, rear-side structures, which are reflected by the decorative layer or an IMD film surrounding it, are excellently visible as a design element. Rear-side structures can also be created using a laser. Further application can be achieved using hot stamping and / or cold stamping, digital printing, and / or functional foil bonding (FFB).

[0209] The decoration process using a transfer film, such as an IMD film, i.e. using lacquer transfer technology, enables a significantly greater design variety compared to other decoration processes such as wet painting, so that individual images, technical designs, haptic surfaces and many other design variants can be created. By decorating with transfer film, it is possible to dispense with one or more subsequent process steps after decoration, such as separate overprinting or lasering of lettering, symbols, etc. This in turn advantageously offers cost savings. A transfer film could incorporate all of these decorative elements, such as decorative printing, negative decorations such as lettering or symbols, etc., already in the layer structure of the transfer layer.

[0210] It is also possible to provide multiple decorative layers and / or decorative layers, creating front and back structures. The front and back structures can also be created using a laser. Furthermore, application can be achieved using hot stamping and / or cold stamping and / or digital printing and / or functional foil bonding (FFB).

[0211] By using transparent and / or translucent plastics, a component can be illuminated. This makes light integration possible for a correspondingly constructed component.

[0212] According to the invention, an injection molding tool is claimed, which comprises a holding device and a first, second, and third cavity half. The injection molding tool is claimed for carrying out a method for producing a component having a layer structure according to one of claims 1 to 12, and / or for carrying out a method according to one of claims 13 to 22. The holding device is designed to hold the at least one holding element formed on the first layer.

[0213] The holding device is preferably movable and / or comprises movable components, in particular a movable clamping frame and / or at least one movable holding arm.

[0214] Preferably, the injection mold additionally comprises a fourth cavity half. According to an advantageous embodiment of the invention, the holding device comprises a clamping frame. The clamping frame is designed to create a tight connection between the first cavity half and the film surrounding the decorative layer, so that a vacuum can be created between the film surrounding the decorative layer and the first cavity half.

[0215] The clamping frame is preferably hydraulically, mechanically, electromechanically, and / or pneumatically controllable. The clamping frame preferably presses the film encompassing the decorative layer against the first cavity half. The clamping frame preferably presses the film along a closed, circumferential line against the first cavity half. For this purpose, the clamping frame preferably has an annular shape. The annular shape can preferably be rectangular. The clamping frame preferably presses against a primer layer of the film, designed as an adhesive layer for bonding to the first layer.

[0216] According to a further advantageous embodiment of the invention, the clamping frame is designed in one part or in several parts, in particular in two parts.

[0217] According to a further advantageous embodiment of the invention, the holding device comprises at least one movable holding arm. The holding arm can be controlled hydraulically, mechanically, electromechanically, and / or pneumatically to move the holding arm away from the holding element and / or the first layer.

[0218] The movable holding arm is preferably designed as a piston. The holding device preferably comprises a plurality of holding arms. The holding arms, which are preferably designed as pistons, can be moved along their axis in the holding device. In particular, the holding arm or arms can be moved away from the holding element and / or from the first layer. In particular, the movable holding arm or arms can be connected to the clamping frame. Preferably, the movable holding arm or arms can be movably mounted in or on the clamping frame. In particular, the movable holding arm or arms can be driven to move out of the clamping frame in the direction of the holding element or into the clamping frame, i.e. away from the holding element.

[0219] The number of holding arms of the holding device and the number of holding elements provided on the first layer can be the same. However, multiple holding arms can also correspond to one holding element. The number, arrangement, and orientation of the holding arms depend particularly on the geometry and size of the component.

[0220] According to a further advantageous embodiment of the invention, the direction of movement of the holding arm to a layering plane of the layer structure forms a demoulding angle of 1° to 89°, preferably a demoulding angle of 1° to 60°.

[0221] The above-described method according to the invention can be carried out using an injection molding tool that has one or more features of the injection molding tool according to the invention. Preferably, the above-described method according to the invention is carried out using the injection molding tool according to the invention.

[0222] Of course, the above-mentioned material features can also be applied equivalently in a process, or the above-mentioned process features can be applied in a product. 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.

[0223] Fig. 1 shows schematic views of a first component according to the invention.

[0224] Fig. 2 shows schematic views of a second component according to the invention.

[0225] Fig. 3 shows a flow chart of an exemplary method according to the invention.

[0226] Fig. 4 shows views of the individual steps of the exemplary method according to the invention shown in Fig. 3 in the production of the first component according to the invention.

[0227] Fig. 5 shows views of the individual steps of the exemplary method according to the invention shown in Fig. 3 in the production of the second component according to the invention.

[0228] Fig. 6 shows various examples of structuring individual layers of a component according to the invention as well as of applying one or more further layers of a component according to the invention.

[0229] Fig. 7 shows a schematic structure of an (a) IMD film and a schematic structure of an (b) insert film, each for providing a further decorative layer arranged between a first layer (thermoplastic) and a second layer (PUR).

[0230] Fig. 8 shows a schematic structure of an (a) IMD film and a schematic structure of an (b) insert film, each for providing a decorative layer for coating with a first layer (thermoplastic).

[0231] Fig. 1 shows schematic views of a first component according to the invention. Fig. 1 (a) shows a schematic sectional view of the first component according to the invention. Fig. 1 (b) shows a schematic plan view of the first component according to the invention. The first component according to the invention has a layer structure. The layer structure is formed in this order by a decorative layer 1, a first layer 3, a further decorative layer 2 and a second layer 4. The first layer 3 is formed from a thermoplastic. The first layer 3 is therefore also referred to as a thermoplastic layer. The first layer 3 has, for example, a layer thickness of 2 mm. The second layer 4 is formed from polyurethane. The second layer 4 is therefore also referred to as a polyurethane layer. The second layer 4 has, for example, a layer thickness of 1 mm. In the present example, the decorative layer 1 is a layer of an IMD film to be transferred.The decorative layer 1 comprises, in this order, a protective layer, a decorative layer, and a primer layer. In the present example, the primer layer is designed as an adhesive layer for bonding to the thermoplastic of the first layer 3.

[0232] In a modification of the first component according to the invention, the further decorative layer 2 is omitted. In this case, the layer structure is formed in this order by a decorative layer 1, a first layer 3 and a second layer 4. The other features discussed here also apply in the same way to this modification of the first component according to the invention. In the present example, the first layer 3 forms two holding elements. The two holding elements are arranged symmetrically to one another on two opposite sides of the component. In the first component according to the invention, the holding elements are each designed as outwardly projecting tabs 5. The first layer 3 and the two tabs 5 are formed in one piece. The tabs 5, like the first layer 3, are made of thermoplastic. In the present example, the tabs 5 each have an indentation 6 at their outwardly projecting end.These indentations 6 each enable the engagement of a movable holding arm 11 of a holding device provided on an injection molding tool.

[0233] Fig. 1 (c) shows a detailed view as a schematic sectional view. In addition to the holding arm 11, the holding device comprises a clamping frame 10, which presses the film comprising the decorative layer 1, in the present example IMD film, against the first cavity half 7. The holding device can additionally have further holding arms 11, in the present example a further holding arm 11 (not shown in the detailed view). Each holding arm 11 is movably received along its axis in a bore in the clamping frame 10. The outer end of the holding arm 11 forms a projection, which engages positively in the indentation 6 provided on the tab 5. In this way, the holding device blocks movement of the component in both an upward and a downward direction. This means that the holding device blocks movement of the component in both directions perpendicular to the first layer 3.Furthermore, the two holding arms 11 of the holding device are arranged symmetrically to each other and opposite each other, corresponding to the holding elements of the component. Therefore, any lateral movement of the component, i.e., any movement in the layering plane, is also prevented by the two opposing holding arms 11. This advantageously enables the component to be held securely in the holding device. In the present example, the holding arm 11 is designed as a piston that is movable along its axis. The holding arm 11 thus enables the holding element, and thus the component, to be released by retracting from the recess 6. For this purpose, the holding arm 11 can be controlled electromechanically.

[0234] Fig. 2 shows schematic views of a second component according to the invention. Fig. 2 (a) shows a schematic sectional view of the second component according to the invention. Fig. 2 (b) shows a schematic plan view of the second component according to the invention. The second component according to the invention has a layered structure. The layered structure has the same sequence as in the first component according to the invention. Likewise, in a modification of the second component according to the invention, the additional decorative layer 2 can be omitted. To avoid repetition, reference is made to the explanations for the first component according to the invention, which apply identically here.

[0235] The first layer 3 also forms two holding elements in the second component according to the invention. The two holding elements are also provided symmetrically to one another on two opposite sides of the component. In contrast to the first component according to the invention, the holding elements in the second component according to the invention are designed without the outwardly projecting tabs. The holding elements are each designed as an indentation 6 in the first layer. The indentations each extend over a surface area over which the underlying decorative layer 1 also extends. In the present example, the additional decorative layer 2 lying above also extends over these surface areas. In the present example, the second layer 4 is set back compared to the underlying layers so that it does not cover the underlying layers in a surrounding edge area.In the present example, the second layer 4 does not extend beyond the surface area defined by the indentations. The surface area defined by the second layer 4 can also be flush with the surface area of ​​the first layer 2.

[0236] The indentations 6, in turn, each enable the engagement of a movable holding arm 11 of a holding device provided on an injection molding tool. Fig. 2 (c) shows a detailed view as a schematic sectional view. In addition to the holding arm 11, the holding device comprises a clamping frame 10, which presses the film comprising the decorative layer 1, in the present example IMD film, against the first cavity half 7. The holding device can additionally have further holding arms 11, in the present example a further holding arm 11 (not shown in the detailed view). Each holding arm 11 is movably received along its axis in a bore in the clamping frame 10. The outer end of the holding arm 11 forms a projection, which engages in a form-fitting manner in the indentation 6 provided in the first layer 3. In this way, the holding device blocks movement of the component in both an upward and a downward direction.This means that the holding device blocks movement of the component in both directions perpendicular to the first layer 3. Furthermore, the two holding arms 11 of the holding device are arranged symmetrically to one another and opposite one another, corresponding to the holding elements of the component. Therefore, lateral movement of the component, i.e. movement in the layering plane, is also prevented by the two opposing holding arms 11. This advantageously enables secure holding of the component in the holding device. In the present example, the holding arm 11 is designed as a piston which is movable along its axis. The holding arm 11 thus enables the holding element and thus the component to be released by moving back out of the indentation 6. For this purpose, the holding arm 11 can be controlled electromechanically. Fig. 3 shows a flow diagram for an exemplary method according to the invention.

[0237] Fig. 4 shows views of the individual steps of the exemplary inventive method shown in Fig. 3 in the production of the first component according to the invention. In this case, tabs 5 with indentations 6 are formed on the first layer 3.

[0238] Fig. 5 shows views of the individual steps of the exemplary inventive method shown in Fig. 3 in the production of the second inventive component. In this case, indentations 6 are formed in the first layer 3 without the provision of tabs.

[0239] The steps of the exemplary method according to the invention are explained together for Figures 3 to 5. The method is carried out using an injection molding tool. The injection molding tool comprises the holding device and a first cavity half 7, a second cavity half 8, and a third cavity half 9. The holding device has a clamping frame 10 and two symmetrically opposed holding arms 11 corresponding to the two recesses 6 to be produced.

[0240] The following steps are preferably carried out one after the other.

[0241] In a step S01, an IMD film is inserted into the first cavity half 7. The IMD film is inserted into the first cavity half 7 such that the carrier side of the IMD film rests against the first cavity half 7. The back side of the IMD film, which has the decorative layer 1, will subsequently face the injection molding material. After insertion, the IMD film is pressed firmly against the first cavity half 7 by a clamping frame 10. The clamping frame 10 has a ring-shaped configuration in plan view. The ring shape is rectangular. The clamping frame 10 presses the IMD foil firmly against the first cavity half 7 along a closed, circumferential line. In addition to pressing the IMD foil against the first cavity half 7 by the clamping frame 10, a vacuum is created between the IMD foil and the first cavity half 7, so that the IMD foil is pressed against the first cavity half

[0242] 7 is sucked in.

[0243] In a step S02, the injection molding tool is closed by inserting the second cavity half 8 into the first cavity half 7. This creates a first cavity on the back of the IMD film, which has the decorative layer 1. The first cavity is formed by the decorative layer 1, by the second cavity half

[0244] 8 and limited by the holding arms 11 provided in the clamping frame 10.

[0245] The clamping frame 10 and the holding arms 11 together form the holding device. Furthermore, the first cavity can be partially delimited by the first cavity half 7. The first cavity corresponds to the volume of the first layer 3 to be produced by back-injection molding. In the case of the first component according to the invention, the first cavity therefore also comprises the volume of the tabs 5 to be produced together with the first layer 3 (see Figure 4, step 2). Furthermore, in this case, the first cavity each has an indentation at the outer end of the volume of the tabs. The indentations are each formed by a projection provided at the end of the holding arm 11 projecting into the first cavity. In the case of the second component according to the invention, the first cavity has the indentations to be produced in the first layer 3 (see Figure 5, step 2).In this case too, the indentations are each formed by the projection provided at the end of the holding arm 11 projecting into the first cavity.

[0246] In a step S03, the IMD film is directly back-injected with a thermoplastic on its rear side, which has the decorative layer 1. The first cavity is filled with the thermoplastic. In the process, the first layer 3 is formed. In the case of the first component according to the invention, the two tabs 5 are also formed together with the first layer 3 (see Figure 4, step 3). In this case, the tabs 5 each have an indentation 6 at their outer end, corresponding to the indentations previously molded in the first cavity. The projection provided at the end of the respective holding arm 11 therefore engages in the corresponding indentation 6 in a form-fitting manner. In the case of the second component according to the invention, the two indentations 6 are formed in the first layer 3 corresponding to the indentations previously molded in the first cavity by the projections provided at the end of the holding arms 11 (see Figure 5, step 3).In this case too, the projection provided at the end of the respective holding arm 11 engages in a form-fitting manner in the corresponding recess 6.

[0247] In a step S04, the injection mold is opened after a cooling time of, for example, 60 seconds. For this purpose, the second cavity half 8 is removed. The holding elements are held by the holding arms 11 of the holding device. Likewise, the clamping frame 10 continues to press the IMD film against the first cavity half 7, and the vacuum between the IMD film and the first cavity half 7 is maintained. Therefore, the IMD film coated with the first layer 3 remains securely and dimensionally stable in the first cavity half 7 when the injection mold is opened.

[0248] In a step S05, the injection molding tool is closed by inserting the third cavity half 9 into the first cavity half 7. This creates a second cavity adjacent to the first layer 3. The second cavity is also delimited by the third cavity half 9. The second cavity corresponds to the volume of the second layer 4 to be produced by flooding with polyurethane.

[0249] Alternatively, in further embodiments, a further

[0250] A decorative layer and / or a further decorative layer 2 comprising at least one further decorative layer can be arranged on the first layer 3. When the injection mold is closed by inserting the third cavity half 9 into the first cavity half 7 (step S05), a second cavity is thus created adjacent to the first layer 3, the further decorative layer, and / or the further decorative layer. The second cavity is also delimited again by the third cavity half 9. The second cavity also corresponds to the volume of the second layer 4 to be produced by flooding with polyurethane.

[0251] The change of the cavity half from the second 8 to the third cavity half 9 can be carried out, for example, by means of turntable, sliding table and / or indexable plate technology.

[0252] In a step S06, the surface of the first layer 3 facing away from the IMD film is flooded with polyurethane. In the process, the second cavity is filled with the polyurethane. The second layer 4 is formed from polyurethane. With the completion of the second layer 4, the IMD film is coated with the first layer 3 and the second layer 4. The first layer 3 has the retaining elements described above. Thus, a component according to the invention has already been realized.

[0253] In the present example, the first layer 3 is directly flooded with polyurethane. In further embodiments, in which a further decorative layer and / or a further decorative layer comprising at least one further decorative layer is arranged on the first layer 3 (see alternative in step S05), the further decorative layer, the further decorative layer, and / or the first layer 3 are flooded with polyurethane in step S06.

[0254] In a step S07, the injection mold is opened after a cooling time of, for example, 60 seconds. For this purpose, the third cavity half 9 is removed. The holding elements continue to be held by the holding arms 11 of the holding device. In particular, the adhesive force of the holding elements on the holding arms 11 is greater than the adhesive force of the second layer 4 formed from polyurethane on the third cavity half 9. Furthermore, the clamping frame 10 continues to press the IMD film against the first cavity half 7, and the vacuum between the IMD film and the first cavity half 7 is maintained. Therefore, the component remains secure and dimensionally stable in the first cavity half 7 when the injection mold is opened.

[0255] In a step S08, the holding elements are released by the holding device. For this purpose, the holding arms 11 of the holding device are each moved out of the corresponding holding element. In the present example, the holding arms 11, designed as pistons, are retracted along their axis in the holding device. The direction of movement of the holding arms forms a demolding angle 12 of 30° with respect to the plane of the first layer 3. By retracting the holding arms 11, the form fit between the respective holding arm 11 and the corresponding holding element is overcome. After the holding arms 11 have retracted, the clamping frame 10 is released from the IMD film. In addition, the evacuation between the IMD film and the first cavity half 7 is ended. The component can thus be removed from the injection mold.

[0256] After step S08, a carrier layer and a release layer of the IMD film can be removed from the component in a further step not shown in the figures. Further explanations can be found in Fig. 8 (a) and the associated description.

[0257] In a further step (not shown), the two retaining elements configured as tabs 5 can be removed. The tabs 5 can be removed by cutting (e.g., with a knife) and / or by laser cutting.

[0258] Fig. 6 shows various examples of structuring individual layers of a component according to the invention. Fig. 6 also shows examples of applying one or more layers to produce a component according to the invention.

[0259] In a first example (Fig. 6 (a)), the decorative layer 1 has a surface structure. The surface structure can include or reinforce design elements. Furthermore, the surface structure can produce haptic and / or optical effects. The surface structure can, for example, include micro- or nanostructures.

[0260] The surface structure can already be provided on the decorative layer 1 of the IMD film to be inserted into the injection molding tool before carrying out the method according to the invention. The surface structure can be applied, in particular molded, onto the decorative layer 1 through the first cavity half 7. Furthermore, the surface structure can be provided on the decorative layer 1 in a further step after carrying out the method according to the invention and / or after applying the second layer 4 to the first layer 3. For this purpose, post-processing can be carried out, for example, by laser, embossing and / or milling. Furthermore, a first application 1' can be carried out by means of digital printing and / or hot stamping and / or cold stamping and / or functional foil bonding (FFB). Preferably, the first application 1' is applied to the decorative layer 1 by means of digital printing and / or hot stamping and / or cold stamping and / or functional foil bonding (FFB) (see also Fig.6 (f), 6 (g) and 6 (i)). The surface structure and / or the first application 1' can be provided on the decorative layer 1 by post-processing the back of the component after the application of the second layer 4 and the removal of the component from the first cavity half 7. Furthermore, it is possible for the surface structure and / or first application 1' to be provided on the decorative layer 1 after the application of the first layer 3 and before the application of the second layer 4.

[0261] In a second example (Fig. 6 (b)), the decorative layer 1 has a surface structure created through two processing steps. For example, the decorative layer 1 can already have its own surface structure before performing the method according to the invention. Additionally, a surface structure can be molded onto the decorative layer 1 through the first cavity half 7.

[0262] In a third example (Fig. 6 (c)), the second layer 4 formed from polyurethane has a surface structure. This surface structure can also include or reinforce design elements. Furthermore, this surface structure can produce haptic and / or optical effects. The surface structure can, for example, include micro- or nanostructures.

[0263] This surface structure can be molded onto the second layer 4 through the third cavity half 9. Furthermore, this surface structure can be produced in a further step after performing the method according to the invention on the second layer 4. For this purpose, post-processing can be carried out, for example, by laser, embossing, and / or milling.

[0264] In a fourth example (Fig. 6 (d)), both the decorative layer 1 and the second layer 4 formed from polyurethane have a surface structure. The possibilities outlined for the first to third examples again apply to the respective surface structure. In particular, the surface structure can be molded onto the decorative layer 1 through the first cavity half 7, and the surface structure can be molded onto the second layer 4 through the third cavity half 9.

[0265] In a fifth example (Fig. 6 (e)), a further decorative layer 2 is provided between the first layer 3 and the second layer 4. The further decorative layer 2 can have a surface structure and / or a second application 2' and / or be formed by a second application 2'.

[0266] The surface structure can incorporate or reinforce design elements. Furthermore, the surface structure can create optical effects. The surface structure can, for example, include micro- or nanostructures.

[0267] The surface structure on the further decorative layer 2 and / or the second application 2' is preferably provided after the application of the first layer 3 and before the application of the second layer 4. Processing can be carried out, for example, by laser, embossing, and / or milling. The second application 2' can be applied, in particular, by digital printing and / or hot stamping and / or cold stamping and / or functional foil bonding (FFB).

[0268] In a sixth example, both the decorative layer 1 and the further decorative layer 2 have a surface structure and / or a first 1' or second application 2'. The further decorative layer 2 can also be formed by the second application 2'. Fig. 6 (f) illustrates the presence of a first application 1'. The case in which the decorative layer 1 has a surface structure could be illustrated, starting from Fig. 6 (f), by replacing the layers 1 and 1' with the decorative layer 1 shown in Fig. 6 (a). For the respective surface structure or application, the possibilities shown for the first, second and fifth examples again arise. For example, the surface structure can be molded onto the decorative layer 1 through the first cavity half 7.

[0269] The first application 1' is preferably applied to the decorative layer 1 by means of digital printing and / or hot stamping and / or cold stamping and / or functional foil bonding (FFB). The second application 2' preferably forms the further decorative layer 2 and is preferably applied by means of digital printing and / or hot stamping and / or cold stamping and / or functional foil bonding (FFB). For example, both the first application 1' and the second application 2' are applied by means of digital printing.

[0270] Figures 6 (g) to 6 (i) show the structure of the corresponding components according to the invention in more detail than the previous Figures 6 (a) to 6 (f). Figures 6 (g) to 6 (i) do not represent completely new examples. Figure 6 (g) relates to the first example (Fig. 6 (a)) or to the second example (Fig. 6 (b)). Figure 6 (h) relates to the fifth example (Fig. 6 (e)). Figure 6 (i) relates to the sixth example (Fig. 6 (f)). In Figures 6 (g) to 6 (i), the illustration is intended to clarify that the decorative layer 1, the first application 1', the further decorative layer 2 and / or the second application 2' can be present over the entire surface or only in certain regions. A decorative layer 1, first application 1', further decorative layer 2 and / or second application 2' that is only present in some areas can be produced, for example, by embossing, digital printing and / or laser processing.Figures 6 (g) and 6 (i) each show examples in which a full-surface decorative layer 1 has a partially present first application 1'. In the example of Figure 6 (i), the further decorative layer 2 is also formed by a partially present second application 2'. For example, the partially present second application 2' is produced by embossing and the partially present first application 1' is produced by laser processing. In a further example, both the partially present second application 2' and the partially present first application T can be produced by digital printing. In Figure 6 (h) too, the further decorative layer 2 is formed by a partially present second application 2', whereas in Figure 6 (h) only one full-surface decorative layer 1 is present. It goes without saying for Figures 6 (a) to 6 (f) that the decorative layer 1 or 2 shownThe first application T shown or the further decorative layer 2 shown or the second application 2' shown can each be provided over the entire surface or only in certain areas. In addition, the decorative layer 1 or the further decorative layer 2 can each be constructed from one or more decorative layers.

[0271] Fig. 7 shows a schematic structure of (a) an IMD film 20 and a schematic structure of (b) an insert film 30, each for providing an additional decorative layer 2 arranged between a first layer 3 formed from a thermoplastic and a second layer 4 formed from polyurethane. The additional decorative layer 2 is visible in the finished component from the front, i.e., from a first surface. Therefore, the additional decorative layer 2 is also referred to as a "first surface decoration."

[0272] The following describes the layer structure of an IMD film 20 or insert film 30 used for the additional decorative layer 2. The sequence of the layers corresponds to the sequence in the layer structure of the resulting or finished component.

[0273] The IMD film 20 has a first primer layer 21. The first primer layer 21 is formed by an adhesive layer for bonding to the thermoplastic of the first layer 3 of the component. In the finished component, the first primer layer 21 lies directly adjacent to the first layer 3 formed from a thermoplastic. The first primer layer 21 is immediately followed by a decorative layer 22. The decorative layer 22 is immediately followed by a second primer layer 23. The second primer layer 23 is formed by an adhesive layer for bonding to the polyurethane of the second layer 4 of the component. In the finished component, the second primer layer 23 lies directly adjacent to the second layer 4 formed from polyurethane. The first primer layer 21, the decorative layer 22 and the second primer layer 23 together form the layer of the IMD film 20 to be transferred, which forms the decorative layer 2 in the finished component.In the structure of the IMD film 20, a release layer 24 immediately follows the second primer layer 23. The release layer 24 is immediately followed by a carrier layer 25. The carrier layer 25 is formed by a PET film. The release layer 24 and the carrier layer 25 are detached from the IMD film 20 before flooding with polyurethane (step S06).

[0274] The insert film 30 has a carrier layer 31. The carrier layer 31 is a thermoplastic film. In the finished component, the carrier layer 31 lies directly against the first layer 3 formed from a thermoplastic. The carrier layer 31 is immediately followed by a third primer layer 32. The third primer layer 32 is formed by an adhesive layer for connecting to the carrier layer 31 designed as a thermoplastic film. The third primer layer 32 is immediately followed by a decorative layer 33. The decorative layer 33 is immediately followed by a fourth primer layer 34. The fourth primer layer 34 is formed by an adhesive layer for connecting to the polyurethane of the second layer 4 of the component. In the finished component, the fourth primer layer 34 lies directly against the second layer 4 formed from polyurethane.

[0275] Fig. 8 shows a schematic structure of (a) an IMD film 40 and a schematic structure of (b) an insert film 50, each for providing a decorative layer 1 for coating with a first layer 3 formed from a thermoplastic. The decorative layer 1 is located at the rear of the finished component, i.e., on a second surface. Therefore, the decorative layer 1 is also referred to as a "second surface decoration."

[0276] The following describes the layer structure of an IMD film 40 or insert film 50 used for the decorative layer 1. The sequence of the layers corresponds to the sequence in the layer structure of the resulting or finished component.

[0277] The IMD film 40 has a carrier layer 41. The carrier layer 41 is formed by a PET film. In step S01, the IMD film 40 is inserted into the first cavity half 7 such that the carrier layer 41 of the IMD film 40 rests against the first cavity half 7. The carrier layer 41 is immediately followed by a release layer 42. The carrier layer 41 and the release layer 42 can be detached from the IMD film 40 after steps S01 to S08 have been carried out, i.e., after the component has been completed. In the structure of the IMD film 20, a protective layer 43 immediately follows the release layer 42. After the carrier layer 41 and release layer 42 have been detached, the protective layer 43 can form a surface of the finished component. The protective layer 43 is immediately followed by a decorative layer 44. The decorative layer 44 is immediately followed by a fifth primer layer 45.The fifth primer layer 45 is formed by an adhesive layer for bonding to the thermoplastic of the first layer 3 of the component. The fifth primer layer 45 is back-injected with thermoplastic in the process according to the invention and, in the finished component, lies directly against the first layer 3 formed from the thermoplastic. The protective layer 43, the decorative layer 44, and the fifth primer layer 45 together form the layer of the IMD film 40 to be transferred, which forms the decorative layer 1 in the finished component. The insert film 50 has a carrier layer 51. The carrier layer 51 is a thermoplastic film. The insert film 50 is inserted into the first cavity half 7 according to step S01 such that the carrier layer 51 rests against the first cavity half 7. The carrier layer 31 is immediately followed by a sixth primer layer 52.The sixth primer layer 52 is formed by an adhesive layer for bonding to the carrier layer 51, which is configured as a thermoplastic film. The sixth primer layer 52 is immediately followed by a decorative layer 53. The decorative layer 53 is immediately followed by a seventh primer layer 54. The seventh primer layer 54 is formed by an adhesive layer for bonding to the thermoplastic of the second layer 3 of the component. In the process according to the invention, the seventh primer layer 54 is back-injected with thermoplastic and, in the finished component, lies directly against the first layer 3 formed from the thermoplastic.

[0278] It is clear to the person skilled in the art that the above-mentioned embodiments of the devices, equipment, methods or method steps can be combined with one another as desired and do not represent any limitation, particularly in their design and combination.

[0279] List of reference symbols

[0280] 1 decorative layer

[0281] 1' first application

[0282] 2 additional decorative layers

[0283] 2' second application

[0284] 3 first layer

[0285] 4 second layer

[0286] 5 tab

[0287] 6 indentation

[0288] 7 first cavity half

[0289] 8 second cavity half

[0290] 9 third cavity half

[0291] 10 clamping frames

[0292] 11 Holding arm

[0293] 12 draft angles

[0294] 20 IMD foil

[0295] 21 first primer layer

[0296] 22 decorative layer

[0297] 23 second primer layer

[0298] 24 release layer

[0299] 25 Carrier layer

[0300] 30 insert foil

[0301] 31 Carrier layer

[0302] 32 third primer layer

[0303] 33 decorative layer

[0304] 34 fourth primer layer 40 IMD film

[0305] 41 Carrier layer 42 Release layer

[0306] 43 Protective layer

[0307] 44 decorative layer

[0308] 45 fifth primer layer 50 insert film

[0309] 51 Carrier layer

[0310] 52 sixth primer layer

[0311] 53 Decorative layer

[0312] 54 seventh primer layer

Claims

> Patent claims 1. Component having a layer structure, in particular a layer structure with at least three layers, characterized in that the layer structure comprises a decorative layer (1), wherein the decorative layer (1) comprises at least one decorative layer, that a first layer (3) made of a first material is arranged on the decorative layer (1), that a second layer (4) made of a second material is arranged on the first layer (3), and that the first layer (3) has a circumferential edge and comprises at least one holding element or is connected to at least one holding element, wherein the holding element extends along the edge of the first layer (3).

2. Component according to claim 1, characterized in that the first material is formed by an injection-molded material, in particular by at least one thermoplastic, or by polyurethane, and / or that the second material is a flooding material, in particular polyurethane.

3. Component according to claim 1 or 2, characterized in that a third layer made of a third material is arranged on the second layer (4), and that the third material is preferably a flooding material, in particular polyurethane.

4. Component according to one of the preceding claims, characterized in that the holding element is designed to hold the component in an injection molding tool.

5. Component according to one of the preceding claims, characterized in that the holding element is designed as an outwardly projecting tab (5), wherein the holding element is formed from the first material, and / or that the holding element is designed as an indentation (6) in the first material.

6. Component according to one of the preceding claims, characterized in that the indentation (6) is designed for engagement of a holding device of an injection molding tool, in particular that the indentation (6) is designed for positive engagement of a holding device of an injection molding tool.

7. Component according to one of the preceding claims, characterized in that the decorative layer (1) is a layer of an IMD film or a label to be transferred, or that the decorative layer (1) is a component of an insert film.

8. Component according to one of the preceding claims, characterized in that a further decorative layer and / or a further decorative layer (2) comprising at least one further decorative layer is arranged between the first layer (3) and the second layer (4).

9. Component according to one of the preceding claims, characterized in that the first layer (3) comprises exactly one holding element, wherein the holding element is preferably designed to run continuously around the component, wherein the holding element is particularly preferably designed to run completely around the component.

10. Component according to one of the preceding claims, characterized in that the first layer (3) comprises two, three, four, five, six, eight, ten or twelve holding elements. 11 . Component according to one of the preceding claims, characterized in that the first layer (3) has a wall thickness of 0.5 mm to 10 mm, that the first layer (3) preferably has a wall thickness of 1 mm to 5 mm, that the first layer (3) particularly preferably has a wall thickness of 1.5 mm to 3 mm.

12. Component according to one of the preceding claims, characterized in that the second layer (4) has a wall thickness of 0.2 mm to 50 mm, that the second layer (4) in particular has a wall thickness of 0.2 mm to 30 mm, that the second layer (4) preferably has a wall thickness of 0.3 mm to 15 mm, that the second layer (4) preferably has a Wall thickness of 0.5 mm to 5 mm, that the second layer (4) particularly preferably has a wall thickness of 0.8 mm to 3 mm.

13. A method for producing a component having a layer structure, in particular a layer structure with at least two layers, preferably a component according to one of claims 1 to 12, preferably an injection molding method, wherein the method comprises the following steps, in particular in the following order: a) Providing an injection molding tool comprising a holding device and a first (7) and second cavity half (8), b) Inserting a film comprising a decorative layer (1) with at least one decorative layer into the first cavity half (7), c) Closing the injection molding tool by inserting the second cavity half (8) into the first cavity half (7) so that a first cavity is formed adjacent to the film, d) Coating the film with a first material to form a first layer (3) by introducing the first material into the first cavity,wherein the first layer (3) is formed with at least one holding element such that the holding device is arranged in a form-fitting manner with respect to the holding element, e) removing the second cavity half (8), wherein the film coated with the first layer (3) remains in the first cavity half (7) by holding the holding element by the holding device.

14. The method according to claim 13, characterized in that the injection molding tool comprises a third cavity half (9), and that the method additionally comprises the following steps, which are preferably carried out after step e), in particular in the following order: f) closing the injection molding tool by inserting the third cavity half (9) into the first cavity half (7) so that a second cavity is created, g) coating the film coated with the first layer (3) with a second material to form a second layer (4) by introducing the second material into the second cavity.

15. The method according to claim 14, characterized in that the method additionally comprises the following steps, which are preferably carried out after step g), in particular in the following order: h) removing the third cavity half (9) or removing the first cavity half (7), wherein the component remains in the holding device by the holding element being held by the holding device, i) releasing the holding element by the holding device, j) demolding the component.

16. The method according to any one of claims 13 to 15, characterized in that the method additionally comprises the following step, which is preferably carried out between step e) and step f): k) applying a further decorative layer and / or a further decorative layer (2) comprising at least one further decorative layer on the side of the first layer (3) facing away from the film.

17. Method according to one of claims 13 to 16, characterized in that in step b) the film is introduced with its carrier side adjacent to the first cavity half (7).

18. The method according to any one of claims 13 to 17, characterized in that the film is an IMD film, wherein the IMD film is fed into the first cavity half (7) in step b) as film roll material or is inserted as a label, or that the film is an insert film and is inserted into the first cavity half (7) in step b).

19. Method according to one of claims 13 to 18, characterized in that the method additionally comprises the following step, which is preferably carried out after step b): l) pressing the film comprising the decorative layer (1) onto the first cavity half (7) by means of the holding device, in particular by means of a clamping frame (10) formed by the holding device.

20. The method according to any one of claims 13 to 19, characterized in that the method additionally comprises the following step, which is preferably carried out after step b) and / or after step I): m) evacuating the first cavity half (7) so that a vacuum is created between the film comprising the decorative layer (1) and the first cavity half (7).

21. Method according to one of claims 13 to 20, characterized in that the first material is formed by an injection-molded material, in particular by at least one thermoplastic, or by polyurethane, and / or that the second material is a flooding material, in particular polyurethane.

22. Method according to one of claims 13 to 21, characterized in that the injection molding tool comprises a fourth cavity half, and in that the method additionally comprises the following steps, which are preferably carried out between the removal of the third cavity half (9) in step h) and step i), in particular in the following order: n) closing the injection molding tool by inserting the fourth cavity half into the first cavity half (7) so that a third cavity is created, o) coating the second layer (4) with a third material to form a third layer by introducing the third material into the third cavity, p) removing the fourth cavity half or removing the first cavity half (7), the component remaining in the holding device by the holding element being held by the holding device.

23. Injection molding tool comprising a holding device and a first (7), second (8) and third cavity half (9) for carrying out a method for producing a component having a layer structure according to one of claims 1 to 12, and / or for carrying out a method according to one of claims 13 to 22, characterized in that the holding device is designed to hold the at least one holding element formed on the first layer (3).

24. Injection molding tool according to claim 23, characterized in that the holding device comprises a clamping frame (10), wherein the clamping frame (10) is designed to produce a tight connection of the first cavity half (7) with the film comprising the decorative layer (1), so that a vacuum can be created between the film comprising the decorative layer (1) and the first cavity half (7).

25. Injection molding tool according to claim 23 or 24, characterized in that the clamping frame (10) is designed in one part or in several parts.

26. Injection molding tool according to one of claims 23 to 25, characterized in that the holding device comprises at least one movable holding arm (11), wherein the holding arm is hydraulically, mechanically, electromechanically and / or pneumatically controllable in order to move the holding arm (11) away from the holding element and / or from the first layer (3).

27. Injection molding tool according to claim 26, characterized in that the direction of movement of the holding arm (11) forms a demolding angle (12) of 1° to 89° with respect to a layering plane of the layer structure, preferably a demolding angle (12) of 1° to 60°.

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