Coating apparatus and method for coating a substrate - Patents.com

Abstract

The present invention includes a coating apparatus (50) and a method for coating a substrate (10). The coating apparatus comprises at least one holding device (20) for fixing the substrate, at least one stamping station (30), and at least one printing station (40) for applying one or more printing layers to at least one partial region of a first surface of the substrate and / or at least one partial region of one or more film elements (11) stamped on the substrate and / or at least one partial region of one or more additional printing layers (12) applied to the substrate, wherein the stamping station comprises one or more stamping units (31) for stamping one or more film elements onto at least one partial region of the first surface of the substrate and / or onto at least one partial region of one or more additional film elements stamped on the substrate and / or onto at least one partial region of one or more printing layers applied to the substrate.

Description

[Technical field]

[0001] The present invention relates to a coating apparatus and method for coating a substrate. [Background technology]

[0002] It is known to stamp or coat a transfer ply of a hot stamping film on a substrate for decoration. For example, as described in DE 10 2012109315 A1, such a stamping device has a holding device in which the workpiece to be stamped or coated is clamped as a stamping receiver. Furthermore, a stamping tool is provided which presses the hot stamping film against the surface of the workpiece to be decorated, whereby a stamping pressure is built up between the stamping receiver and the stamping tool. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] DE 102012109315 A1 Summary of the Invention [Problem to be solved by the invention]

[0004] It is an object of the present invention to provide a coating apparatus and method for coating substrates which improves the production of such substrates and reduces their production costs. [Means for solving the problem]

[0005] The present invention is achieved by a coating apparatus for coating a substrate, the coating apparatus having at least one holding device for fixing the substrate, at least one stamping station and at least one printing station for applying one or more printing layers to at least one partial region of a first surface of the substrate and / or to at least one partial region of one or more film elements stamped on the substrate and / or to at least one partial region of one or more further printing layers applied to the substrate, the stamping station having one or more stamping units for stamping one or more film elements onto at least one partial region of the first surface of the substrate and / or onto at least one partial region of one or more further film elements stamped on the substrate and / or onto at least one partial region of one or more printing layers applied to the substrate.

[0006] This object is further achieved by a method for coating a substrate, in particular by means of a coating device as described above, in which the method comprises, in particular in the following order: a) fixing a substrate to a holding device; b) stamping one or more film elements, in particular in a stamping station of a coating device, onto at least one partial area of ​​a first surface of the substrate and / or onto at least one partial area of ​​one or more further film elements stamped onto the substrate and / or onto at least one partial area of ​​one or more printing layers applied to the substrate, the substrate remaining in a holding device; c) applying one or more printing layers, in particular in a printing station of a coating device, to at least one partial area of ​​a first surface of the substrate and / or to at least one partial area of ​​one or more film elements stamped on the substrate and / or to at least one partial area of ​​one or more further printing layers applied to the substrate, the substrate remaining in a holding device; d) removing the coated substrate from the holding device.

[0007] The invention makes it possible to improve the possibilities for coating substrates and in particular to increase the functional and / or design diversity. By coating substrates fixed in a holding device with positive and / or non-positive locking by hot stamping and then printing, or in the reverse sequence by printing and then hot stamping, various coatings can be carried out which up to now have been carried out in completely separate operations, in particular with respect to time and space.

[0008] Advantageous embodiments of the invention are defined in the dependent claims.

[0009] The substrate is preferably rigid and in particular has at least one surface that is curved, flat and / or partially non-flat.

[0010] In particular, the substrate and / or the surface of the substrate, in particular the surface of the substrate to be coated, can be substantially flat, in particular two-dimensionally flat, or 2.5-dimensionally deformed, or three-dimensionally deformed.

[0011] The substrate preferably comprises a component, in particular a vehicle part, a housing part, a cockpit component and / or a body part, an injection moulded part, a 3D printed part and / or a component produced by cutting and / or non-cutting manufacturing methods.

[0012] Further, in particular, the method comprises the step of producing a substrate by injection molding and / or 3D printing and / or cutting and / or non-cutting manufacturing methods, In particular it is provided that said step is carried out before step a).

[0013] Advantageously, the substrate comprises a plastic material, including thermoplastics, in particular impact-resistant thermoplastics. Furthermore, the plastic material is in particular made of polyethylene (PE), polycarbonate (PC), polypropylene (PP), polystyrene (PS), polybutadiene, polynitrile, polyester, polyurethane, polymethacrylate, polyacrylate, polyamide, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), preferably acrylonitrile butadiene styrene (ABS), acrylonitrile styrene acrylate (ASA), ABS-PC, PET-PC, PBT-PC, PC-PBT and / or ASA-PC and / or copolymers or mixtures thereof. The plastic material can also contain inorganic or organic fillers, preferably SiO2, Al2O3, TiO2, clay minerals, silicates, zeolites, glass fibres, carbon fibres, glass beads, organic fibres or mixtures thereof. Here, fillers are in particular added to the plastic material in order to further increase the stability of the substrate. Furthermore, these fillers can reduce the proportion of polymeric material, which can reduce the production costs and / or the weight of the component. It is also possible for the plastic material to contain inorganic or organic auxiliary substances which in particular improve the processability of the plastic material.

[0014] The substrate material may include steel, copper, brass and / or other metallic materials and / or alloys. The substrate material may include glass and / or wood.

[0015] In particular, depending on the shape and material of the substrate, different holding devices are used, in particular adapted individually to the respective substrate, preferably adapted to fix the respective substrate in a positive-locking and / or non-positive-locking manner, the clamping force of the holding device being selected such that distortion and / or deformation of the substrate due to the clamping force is precluded.

[0016] The substrate preferably remains in the holding device with positive and / or non-positive locking during all method steps, which on the one hand ensures a correspondingly high stamping and printing quality also for further stamping and printing steps, and on the other hand ensures a particularly good alignment of the stamped further film elements or the applied further printing layers, whereby the product quality is also further significantly improved and waste is correspondingly reduced.

[0017] Alignment or registration or alignment accuracy or registration accuracy or position accuracy means in particular the accuracy of the position of two or more elements and / or layers relative to one another. The alignment (registration) accuracy is preferably within a certain tolerance range and is preferably as high as possible. At the same time, the alignment (registration) accuracy of several elements and / or layers relative to one another is a particularly important feature to increase the reliability of the process. Positionally accurate positioning (registration) is performed in particular by sensory, preferably optically detectable alignment marks or position markings. In particular, these alignment marks or position markings represent special separate elements or regions or layers or are themselves part of the elements or regions or layers to be positioned.

[0018] It is further preferably provided that during stamping, one or more of the one or more film elements are stamped in precise registration with respect to the one or more further film elements, in particular that one or more alignment marks of the one or more further film elements and / or optical features of the holding device are detected and used to control the stamp.

[0019] Furthermore, in particular, the holding device may be opened and / or closed mechanically and / or hydraulically and / or pneumatically and / or electrically and / or manually.

[0020] It is further possible that the method comprises a step of delivering and / or placing the substrate in a holding device, in particular said step being carried out before step a).

[0021] Delivery and / or positioning of the substrate is preferably performed by human hand, by a transport device connected to a holding device and / or fully automated, for example by a robot.

[0022] Preferably, the coating device has at least one movably mounted mould carrier, in particular a vertically or horizontally arranged rotating plate or sliding table, in particular a linear drive, on which at least one holding device is arranged, in particular the at least one holding device being movable by at least the mould carrier, in particular together with the fixed substrate, preferably between at least one stamping station and / or at least one printing station and / or at least one pre-treatment station and / or at least one inspection station and / or at least one cleaning station.

[0023] Furthermore, it is preferred that the coating apparatus has n stations, in particular at least one stamping station, at least one pretreatment station, at least one cleaning station and / or at least one printing station, and at least n holding devices can be arranged on at least one mould carrier.

[0024] It is also possible for the coating apparatus to have at least one adjustment device for moving the holding device and / or at least one holding device arranged on at least one common mold carrier between stations of the coating apparatus.

[0025] Here, preferably, the holding device or devices are attached to the at least one mould carrier, such that they can be moved together with the at least one mould carrier by means of the adjustment device.

[0026] Furthermore, in particular, the at least one adjusting device comprises at least one servo drive and / or at least one hydraulic drive and / or at least one pneumatic drive and / or at least one electric drive.

[0027] Further preferably, the adjustment device comprises one or more linear drives, in particular one or more high-precision linear drives, which in particular allow the at least one mould carrier to be moved in one, preferably two and more preferably three spatial directions, so that the individual work steps can be carried out positionally precisely and thus the production and product quality is improved.

[0028] In particular, the linear drive has a rotary drive that converts the rotary motion into a linear translational motion via a gear mechanism, in particular a shaft. The linear drive can also include a linear direct drive or a linear motor, which allows a linear translational propulsion directly, in particular via a magnetic field. The linear drive with a gear mechanism or a shaft has a positioning accuracy of less than or equal to + / -50 μm, preferably less than or equal to + / -30 μm. The linear direct drive or linear motor has a positioning accuracy of less than or equal to + / -10 μm, preferably less than or equal to + / -5 μm, which here means a high-precision linear drive. The high positioning (registration) accuracy of the high-precision linear drive can be achieved using an incremental or absolute direct measuring system on the linear drive. Here, the direct measuring system is directly coupled to the drive components of the linear drive and operates with reference to a measuring dial (with or without pre-calibration).

[0029] Furthermore, in particular, the coating apparatus has at least one process control device, which operates the conditioning device in such a way that in particular the one or more holding devices are cyclically delivered to two or more stations of the coating apparatus in a predefined sequence, in particular in the sequence stamping station-printing station, printing station-stamping station, pretreatment station-stamping station-printing station, stamping station-pretreatment station-printing station, pretreatment station-stamping station-pretreatment station-printing station. Advantageously, the process control device comprises one or more microprocessors, peripheral components for controlling the one or more stamping stations, the one or more printing stations, the one or more pretreatment stations, the one or more UV irradiation units (UV=electromagnetic radiation in the ultraviolet spectral range) and / or the one or more IR irradiation units (IR=electromagnetic radiation in the infrared spectral range), the one or more film supply units, as well as the at least one conditioning device, and corresponding software components.

[0030] In particular, it is possible here to send one or more holding devices to a station multiple times.

[0031] For example, steps b) and c) can be performed once or multiple times and / or in any desired order. The cycle time of steps b) and c) is in each case preferably from 1 to 300 seconds, more preferably from 5 to 120 seconds, and particularly preferably from 20 to 30 seconds.

[0032] Preferably, it is further possible to move at least one mold carrier, on which at least one holding device is arranged, in particular together with the fixed substrate, prior to step b) to a stamping position for carrying out step b) and / or prior to step c) to a printing position for carrying out step c).

[0033] It is further advantageous that the stamping station has at least one turret, which is preferably mounted rotatably about at least one axis and translatably movable along at least one axis, in particular the turret including one or more stamping die receivers for receiving one or more stamping dies. By arranging several stamping dies in one turret, it is possible to stamp various motifs with different stamping dies and at the same time ensure short cycle times.

[0034] It is particularly advantageous that one or more stamping dies are exchangeably mounted in one or more stamping die receivers of at least one turret, preferably each stamping die receiver having in each case a quick-change system for tool-free exchange of the stamping die, preferably the quick-change system having a dovetail bracket and / or a clamp lever for exchanging the stamping die.

[0035] Furthermore, the quick-change system may include a die-holding plate and / or a quick-release connector with thermal insulation, in particular at least one clamping lever and / or at least one dovetail bracket, and / or a direct heater integrated in the die-holding plate. The thermal insulation preferably ensures that heat formation during the stamping process is not transferred to other components of the coating apparatus. A further advantage is, in particular, that the set-up time of the coating apparatus is significantly reduced by the quick-change system.

[0036] Furthermore, it is preferably possible for the stamping die receiver or receivers and the stamping die or die to be coded, preferably by means of an RFID chip, which preferably provides the advantage that the coating device recognizes the inserted stamping die and that the process parameters specifically adapted thereto are provided from a database of a computing unit of the coating device.

[0037] Further, preferably, the stamping die or dies not mounted on the turret are temporarily mounted on a bracket of the coating apparatus for preheating. The heating range is preferably 0°C to 300°C, in particular 80°C to 250°C.

[0038] This preferably provides the advantage that when replacing the stamping die, the newly installed stamping die heats up more quickly and therefore the production process can be resumed sooner, thus reducing the downtime of the coating apparatus.

[0039] In particular, it is advantageous for the stamping die or dies to each have at least one direct heater for rapidly heating the stamping die, where the stamping die or dies in particular have a heating wire, preferably resulting in energy saving advantages.Preferably, the heating range of the stamping die or dies is 0°C to 300°C, in particular 80°C to 250°C.

[0040] Preferably, the stamping die or dies comprise a material or combination of materials selected from steel, silicone, plastic, aluminum, copper, brass and / or magnesium.

[0041] Furthermore, the stamping station has at least one film supply unit, which comprises two or more film spindles for winding and unwinding two or more film webs, which are preferably arranged parallel and adjacent to each other and can preferably be slid in and out between the stamping die and the substrate. Here, in particular, two or more film webs having different structures, colors, surface finishes, etc. can be used, resulting in a wide variety of designs and functions of the coated substrate. Furthermore, the frequency of changing the film web between the individual stamping steps can be reduced, which in particular provides the advantage of reduced set-up times.

[0042] It is furthermore preferably possible that at least one film supply unit has at least one splicing aid and / or that two or more film spindles can be removed, in particular for changing the film. By splicing aid is meant in particular an apparatus for splicing film webs, in particular by means of an adhesive tape. Furthermore, preferably, the splicing aid comprises a vacuum unit which generates a vacuum, in particular in the area of ​​the splice, so that the adhesive bonding of two or more film webs can be performed without air pockets. In particular, a removable film spindle allows for an easy and fast exchange of the film web.

[0043] Furthermore, the film supply unit may in particular comprise at least one double and / or multiple winder and unwinder, by means of which two and / or more film webs are wound and unwound. Preferably, the film supply unit further comprises at least one height-adjustable deflection roller, at least one brake drive and / or at least one motorized swivel roller for releasing tension in the film. Furthermore, the film supply unit may comprise at least one servo drive for driving the film spindle or spindles. Furthermore, the film supply unit may comprise at least one adjustable pressure roller.

[0044] Further, the coating apparatus may have at least one film control unit that inspects two or more film webs for cracks in the film, film edges and / or film stock, preferably by means of at least one sensor and / or two or more servo motors arranged on two or more film spindles.

[0045] In particular, the sensor is an optical sensor, e.g. a camera. Such an inspection is preferably performed using image processing methods, which can send a signal to the machine setter when a defect is detected, so that the machine setter can correct it.

[0046] With regard to the printing stations, in particular the at least one printing station comprises a digital printing station and / or an inkjet printing station and / or a pad printing station and / or an inkjet printing station.Furthermore, it is further preferred that the at least one printing station comprises at least one printing unit, in particular having at least one print head.

[0047] In this case, in particular, at least one printing unit has at least one linear drive, in particular at least one high-precision linear drive, which makes it possible to move the at least one printing unit in one spatial direction, preferably in two spatial directions, and more preferably in three spatial directions.

[0048] Furthermore, it is preferred that at least one print head of at least one printing unit has at least one linear drive, in particular at least one high-precision linear drive, which makes it possible to move the at least one print head in one spatial direction, preferably in two spatial directions, and more preferably in three spatial directions.

[0049] In the method, it is especially possible that the application of the printing layer or layers is carried out by digital printing and / or inkjet printing and / or inkjet printing and / or pad printing.

[0050] In particular, at least one print head applies one or more print layers. Furthermore, it is possible that the one or more print layers contain one or more materials selected in particular from print inks, in particular print inks with colors from the CMYK and / or RGB color models and / or spot colors, and / or transparent print inks, in particular clear varnishes and / or protective varnishes (ClearCoat), and / or adhesives, in particular low-temperature adhesives and / or UV adhesives, and / or varnishes. The CMYK color model in particular consists of the colors C=Cyan; M=Magenta; Y=Yellow; K=Black, and the RGB color model consists of the colors R=Red; G=Green; B=Blue. The spot colors can for example come from the PANTONE® color system. In particular, each print head provides one color. Any desired color is generated by additive or subtractive overlay and / or mixing of the individual color components, which can preferably be applied as one or more print layers.

[0051] Likewise, in this method, in particular, the application of the one or more printing layers in step c) is carried out by one or more print heads containing printing inks, in particular printing inks having colours from the CMYK and / or RGB colour model and / or spot colours, and / or transparent printing inks, in particular clear varnishes and / or protective varnishes (ClearCoat), and / or adhesives, in particular low-temperature adhesives and / or UV adhesives and / or varnishes, which preferably result in being applied as a printing layer to at least one partial area of ​​the first surface of the substrate and / or to at least one partial area of ​​the one or more film elements stamped on the substrate and / or to at least one partial area of ​​one or more further printing layers applied to the substrate.

[0052] It is further provided that the printed layer or layers applied to the substrate may be partially cured and / or fully cured.

[0053] It is furthermore particularly provided that the coating apparatus comprises at least one UV irradiation unit for UV pre-curing, in particular pinning, of one or more of the one or more printed layers and / or at least one UV irradiation unit for full curing of one or more of the one or more printed layers, the UV irradiation unit preferably comprising a UV-emitting light source emitting light in the wavelength range of 385 nm to 405 nm. In particular, the one or more printed layers to be cured comprise one or more materials selected from UV adhesives, low-temperature adhesives, adhesives, varnishes and / or inks.

[0054] The UV pre-curing, especially the pinning, works at a relatively low power of the UV irradiation unit, for example the power consumption of the corresponding UV LED is 1 Watt to 5 Watts. The UV irradiation unit for the full curing works at a relatively high power of the UV irradiation unit, for example the power consumption of the corresponding UV LED is 10 Watt to 50 Watts.

[0055] It is further possible for the at least one UV irradiation unit to comprise at least one linear drive, in particular at least one high-precision linear drive, which enables the at least one UV irradiation unit to move in one spatial direction, preferably in two spatial directions, more preferably in three spatial directions.

[0056] The method preferably comprises a step of UV irradiation with UV light, preferably a UV LED, in particular pinning, for pre-curing one or more of the printed layers, in particular UV adhesives, low-temperature adhesives, glues, varnishes and / or inks, in particular wherein the irradiation is carried out with light in the wavelength range of 385 nm to 405 nm, in particular which step is carried out in step c).

[0057] The method particularly preferably further comprises a step of UV irradiation with UV light, preferably a UV LED, for complete curing of one or more of the printed layers, preferably UV glues, low-temperature glues, adhesives, varnishes and / or inks, in particular where the irradiation is carried out with light in the wavelength range from 385 nm to 405 nm, in particular which step is carried out in step c).

[0058] In addition to the at least one stamping station and the at least one printing station, in particular at least one pretreatment station is also provided, in particular the coating device has at least one pretreatment station for pretreating partial areas of the surface of the substrate, the film element or elements stamped on the substrate and / or the printing layer or layers applied to the substrate with one or more treatment methods, in particular selected from treatment with gases, flame treatment, plasma treatment, fluorination, irradiation, cleaning, surface activation, coating, ionization.

[0059] It is furthermore particularly provided that the method comprises a step of pretreating at least one partial region of the first surface of the substrate and / or at least one partial region of the one or more film elements stamped on the substrate and / or at least one partial region of the one or more printing layers applied to the substrate using one or more treatment methods, in particular selected from treatment with gas, flame treatment, plasma treatment, fluorination, irradiation, cleaning, surface activation, coating, ionization, in particular said step being carried out one or more times before step b) and / or before step c).

[0060] It is particularly advantageous here that the pretreatment is "close" in time to both the stamping and printing processes, so that the pretreated surface is particularly "accessible" to the treatment methods carried out, and due to the closeness in time, alterations are largely avoided. Thus, the effectiveness of the pretreatment is significantly improved, for example improving the adhesive properties between the substrate and the film element(s) and / or the printing layer(s).

[0061] In particular, ionization allows the electrostatic charge to be reduced, so that the stamping of one or more film elements can be designed more efficiently. In particular, a relatively long distance effect of about 500 mm is achieved by transporting the ions using motorized ventilator elements, so that no special vertical distance adjustments are necessary. The function of the ionization is invisible to the operator, so that in the event of a unit failure, the control system is informed by the integrated monitoring function.

[0062] The coating apparatus preferably has at least one inspection station for optically inspecting at least one partial area of ​​the surface of the substrate, one or more film elements stamped on the substrate and / or one or more printing layers applied to the substrate by means of an optical sensor, in particular a camera.

[0063] Furthermore, in particular prior to step b) and / or step c), an optical inspection of at least one partial area of ​​the surface of the substrate and / or of at least one partial area of ​​one or more film elements stamped on the substrate and / or of at least one partial area of ​​one or more printing layers applied to the substrate is carried out by means of an optical sensor, in particular a camera.

[0064] Such optical inspection, preferably carried out here using image processing methods, can be used to optimize process parameters, for example by being integrated into a corresponding control loop, thereby further reducing the reject rate. Furthermore, this optical inspection can also be used for quality assurance. This optical inspection can be carried out multiple times at different points during the process, for example after the stamping process, and / or after pretreatment, and / or after the printing process, and / or after a cleaning process, and / or after removing the coated substrate from the holding device, and / or after further processing methods.

[0065] It is further possible for the coating apparatus to have at least one cleaning station for cleaning, in particular, at least one surface of the substrate and / or the one or more film elements stamped on the substrate and / or the one or more printed layers applied to the substrate, using a brush and / or compressed air and / or suction and / or CO2 snow blast and / or adhesive tape, in particular using a pad cleaning tape and / or a roll cleaning tape.

[0066] In particular, the method comprises a step of cleaning, in particular with a brush and / or compressed air and / or suction and / or CO2 snow blast and / or adhesive tape, in particular with a pad cleaning tape and / or a roll cleaning tape, in particular carried out before and / or after step b) and / or before and / or after step c).

[0067] Through this process, for example, waste products of the stamping process are removed from the exposed surface. In this case, the cleaning process is preferably carried out while the substrate is still located in the holding device. This preferably ensures that the substrate is securely fixed during the cleaning process, so that cleaning methods that require a stable fixation of the product to be cleaned can also be used.

[0068] Preferably, the coating device has at least one flow box for reducing and / or preventing dust, preferably at least one ventilator, in particular by which filtered ambient or room air can be blown into the working space with positive pressure. In the method, preferably before and / or during and / or after step b) and / or step c), the ingress of dust into the working space can be reduced, in particular prevented, by positive air pressure. This has the advantage that dust particles or other particles do not enter the working space from the outside, so that no dust inclusions are formed, for example during stamping or printing.

[0069] Here, the working space can preferably be sealed against the environment and particularly preferably closed off from the environment. Furthermore, it is particularly provided that the working space comprises a space in which at least one stamping station, at least one printing station, at least one pre-treatment station, at least one cleaning station and / or at least one inspection station are arranged.

[0070] It is also possible that the method comprises the steps of flooding, overspraying and / or spray coating the coated substrate and / or preferably laminating a sensor, in particular a contact and / or proximity sensitive sensor, on the back side of the coated substrate, in particular the coated substrate, which steps are in particular carried out in one or more further machines after step d).

[0071] In particular, by combining the coated substrate with touch and / or proximity sensitive sensors, individual items of programming can be made visible through corresponding decorations on the surface that match the corporate identity. Such sensors can be touch sensors that act resistively or capacitively.

[0072] Preferably, the stamping of the film element or elements in step b) is carried out by roll-on stamping and / or partial roll-on stamping and / or vertical stamping. Furthermore, it is also possible to use corresponding stamping methods for this, which are especially optimized for three-dimensionally formed surfaces, as described, for example, in DE 10 2012 109 315 A1.

[0073] Preferably, the stamping of the one or more film elements in step b) can be carried out by one or more stamping dies which apply the film or one or more sections of the film as a film element to at least one partial area of ​​the first surface of the substrate and / or to at least one partial area of ​​one or more further film elements stamped on the substrate and / or to at least one partial area of ​​one or more printing layers applied to the substrate.

[0074] Also in particular, the application of the film element or elements is carried out by means of stamping rollers, which are preferably adapted correspondingly to the shape of the substrate and / or allow or can be adapted in their guiding and their roll-on behavior to a corresponding following of the contour to the surface contour of the first surface of the substrate.

[0075] In particular, transfer films, such as hot stamping films or cold stamping films, but also lamination films come into consideration as films when step b) is carried out.

[0076] Particularly suitable for use herein is a transfer film comprising a carrier ply and a transfer ply removable from the carrier ply, where the carrier ply preferably consists of a plastic film, for example a PET film having a thickness of 5 μm to 250 μm, where the transfer ply preferably comprises one or more layers selected from one or more decorative layers, one or more functional layers, one or more protective layers, one or more adhesion promoting layers, one or more barrier layers, one or more conductive layers.

[0077] Furthermore, it is advantageous if one or more release layers are arranged between the carrier ply and the transfer ply to improve release properties. Such layers preferably contain wax and / or silicone and / or polymer.

[0078] If such a transfer film is designed as a hot stamping film, it preferably has a heat-activatable adhesive layer on the side of the transfer film facing away from the carrier ply, which can be activated in particular by the thermal energy of a stamping die and / or a stamping roller. The carrier film is then peeled off again together with the parts of the transfer ply that have not been acted upon by the stamping die and / or the stamping roller.

[0079] If such a transfer film is designed as a cold stamping film, a UV-curable adhesive layer is applied, in particular printed, for example by gravure printing and / or offset printing and / or flexographic printing and / or inkjet printing and / or pad printing to the side of the transfer film facing away from the substrate and / or carrier ply, and is activated and cured by UV radiation after the cold stamping film and the substrate are brought together. The carrier film is then peeled off again together with the parts of the transfer ply that were not joined to the adhesive layer.

[0080] It is further possible that the transfer ply of the transfer film further comprises openings, for example introduced by perforation or cutting or laser exposure, or that the transfer ply is provided in the form of a patch on the carrier ply. Such a transfer ply further preferably also comprises one or more further carrier films for stabilizing the transfer ply. This further provides the advantage that the "sensitive" functional and decorative layers receive additional protection from the thermal and mechanical stresses of the stamping process or subsequent process steps.

[0081] Preferably, a laminate film is used as the film in step b), and during stamping, at least one section of the laminate film, determined by the shape of the stamping die, is applied as a film element by activating an adhesive layer of the laminate film or an adhesive layer provided between the surface of the substrate and the laminate film.

[0082] The laminate film preferably does not have a "removable" carrier ply, i.e. the carrier ply and the further layer form a tightly bonded composite. The laminate film preferably has one or more of the following layers: decorative layer(s), functional layer(s), protective layer(s), carrier layer(s), adhesion promoting layer(s), carrier film(s), barrier layer(s), conductive layer(s).

[0083] Here, the laminated film preferably has openings, in particular introduced by perforation and / or cutting and / or laser exposure, or is already delivered to the stamping process during stamping, in particular in the form of tags, labels or similar individual elements which can be arranged on an auxiliary carrier.

[0084] The film element or elements applied by the stamping die or rollers preferably have a shape that can be largely predetermined by the design of the stamping die or rollers, the shape of the film or the transfer ply of the film, and / or by further measures as will be further described below. These film elements are determined in terms of their layer structure by the corresponding layer structure of the film used for stamping or the transfer ply of the film used for stamping. The film element or elements therefore preferably have one or more layers selected in each case from one or more decorative layers, one or more functional layers, one or more protective layers, one or more adhesion-promoting layers, one or more adhesive layers, one or more carrier layers, one or more carrier films.

[0085] In particular, the film element or elements and / or the further film element or elements in each case have at least one decorative layer and / or at least one functional layer, in particular a layer with electrical functionality, in particular one or more elements selected from touch sensors, antennas, electromagnetic shielding, non-conductivity, metal layers for preventing static electricity, displays, LEDs, electrical circuits, solar cells, at least one, in particular post-curable protective layer and / or at least one adhesion-promoting layer.

[0086] The decorative layer or layers preferably consist of one or a combination of the following decorative layers: a transparent, translucent or opaque varnish layer containing dyes and / or pigments, in particular organic / inorganic pigments, luminescent and / or fluorescent pigments and / or dyes, optically variable pigments, thermochromic pigments and / or dyes, metallic pigments, magnetically alignable pigments Volume hologram layer layers with optically active surface reliefs, in particular diffractive and / or refractive surface reliefs, holographic surface reliefs, surface reliefs including refractive structures, diffractive structures, in particular lens structures, microlens arrays, microprisms, micromirrors, matte structures, in particular isotropic matte structures and / or anisotropic matte structures, and / or combinations of any such structures Reflective layers, in particular metallic or dielectric reflective layers High or low refractive index layers, especially layers with a refractive index that differs from 1.5 by more than + / - 0.2 Liquid crystal layers, in particular cholesteric and / or nematic liquid crystal layers Thin film layers exhibiting optically variable color-changing effects, in particular three-layer structures including an absorber layer, a dielectric spacer layer and an optional reflector layer, or alternatively multiple alternating arrangements of high and low refractive index transparent layers.

[0087] These decorative layers can be applied one after the other and / or adjacent to one another in any desired order, where the individual decorative layers can be patterned over a portion of the surface in order to achieve a particularly desired graphic decoration. The decorative layers are preferably arranged in register.

[0088] The functional layer or layers preferably consist of one or a combination of the following mentioned functional layers: touch sensors, antennas, electromagnetic shielding, non-conductive, metal layers for preventing static charges, displays, LEDs, electric circuits, solar cells, layers with magnetic functionality, e.g. magnetic barcodes, layers with mechanical functionality, e.g. reinforcing or stiffening elements made of metals and / or plastics and / or woven and / or nonwoven fibre plies and / or fibrous additives and / or fibrous additional layers, layers with optical functionality, e.g. anti-reflective or reflective layers, layers with tactile functionality, e.g. soft-touch surface coatings.

[0089] A hot stamping film comprising a carrier ply and a transfer ply removable from the carrier ply can be used as a film in step b) and / or during step b) at least one section of the transfer ply determined by the shape of the stamping die can be applied as a film element by activating an adhesive layer of the transfer ply or an adhesive layer provided between the substrate and the transfer ply.

[0090] Furthermore, it is possible that a transfer film, in particular a cold stamping film, comprising a carrier ply and a transfer ply peelable from the carrier ply is used as a film in step b), in which an adhesive layer, in particular selected from a low-temperature adhesive and / or a UV adhesive, is applied, in particular by means of an inkjet printing head, to a partial area of ​​the transfer ply and / or to a first area of ​​the surface of the substrate but not to a second area, the transfer film is guided, in particular by means of a stamping die, towards the surface of the substrate, the adhesive layer is activated and the transfer film is peeled off again, so that a section of the transfer ply determined by the shape of the first area is applied as a film element.

[0091] The adhesive layer is preferably cured by high-energy electromagnetic radiation, for example by UV and / or IR and / or electron beam radiation. Curing can take place before and / or during and / or after application of the transfer ply to the adhesive layer in particular. If curing takes place before applying the transfer ply to the adhesive layer, the adhesive layer can be pre-cured, for example to increase (IR irradiation) or decrease (UV irradiation) the viscosity of the adhesive layer in the desired manner. If curing takes place during application of the transfer ply to the adhesive layer, curing can take place with the carrier ply still bonded to the transfer ply. If curing takes place after applying the transfer ply to the adhesive layer, curing can take place with the carrier ply already peeled off from the transfer ply and the transfer ply exposed from the upper surface of the substrate.

[0092] During the curing of the adhesive layer, further layers and / or partial areas of the substrate and / or one or more printed layers and / or one or more further printed layers can also be cured simultaneously, or one or more film elements and / or one or more further film elements can be post-cured by radiation acting on the substrate.

[0093] Furthermore, it is also possible to cure the printed layer(s) and / or the further printed layer(s) separately, reference being made here in particular to the abovementioned UV radiation.

[0094] Furthermore, in particular in the case of transparently formed substrates, it is provided to carry out the decoration or coating on both sides, so that a depth effect is formed through the spacing of the two decorations by the wall thickness of the substrate, for which the thickness of the substrate is preferably selected in such a way that the film element or elements on the one hand and the further film element or elements on the other hand are spaced apart from one another, so that an optical depth effect is generated by the interaction of the film element or elements with the further film element or elements.

[0095] If the substrate is made opaque for example, the double-sided decoration can provide different optical appearances of the substrate from different sides through the film element(s) and the further film element(s).

[0096] By using one or more film elements and one or more further film elements, a combination of a decorative film and a functional film can also be achieved, for example, one side of the substrate can be provided with decoration and the other side of the substrate can be provided with a functional element, such as a touch sensor or an antenna or a display.

[0097] For this purpose, it is particularly advantageous for the coating device to have a device for rotating the substrate. Furthermore, for this purpose, it is particularly advantageous for the adjustment device to have a further mould carrier for the rotated substrate, in particular since it is possible to form the rear side of the substrate differently from the front side of the substrate. Preferably, the rotation device can have, for example, a robot arm, which removes the substrate from one mould carrier, rotates the substrate accordingly and places or places the substrate in a rotated position in the further mould carrier.

[0098] During printing in step c), it is possible for at least one further partial area to be located inside at least one partial area of ​​the first surface of the substrate and / or at least one partial area of ​​the one or more film elements stamped on the substrate and / or at least one partial area of ​​the one or more further printing layers applied to the substrate, in which case printing is in particular carried out on the free surface of the substrate and / or on the one or more film elements stamped on the substrate and / or on the one or more further printing layers applied to the substrate.

[0099] However, it is also possible that the at least one further partial region is located only in the exposed first partial region of the surface of the substrate, in which case the printing is in particular carried out next to or adjacent to one or more film elements stamped onto the substrate and / or one or more further printing layers applied to the substrate.

[0100] It is further possible for the at least one further partial area to be both located inside at least one partial area to which the one or more film elements stamped on the substrate and / or the one or more further printing layers applied to the substrate are applied and located in an exposed first partial area of ​​the surface of the substrate, in which case the printing at least partially overlaps both the one or more film elements stamped on the substrate and / or the one or more further printing layers applied to the substrate and the exposed first partial area of ​​the surface of the substrate.

[0101] Further preferably, the application of the one or more printing layers is carried out in precise registration with respect to the one or more film elements stamped on the substrate and / or the one or more further printing layers applied on the substrate, for which purpose in particular one or more alignment marks or optical features of the one or more film elements stamped on the substrate and / or the one or more further printing layers applied on the substrate and / or the holding device are detected, for example by a camera, and used to control the application of the one or more printing layers.

[0102] The application of one or more printing layers in at least one further partial region preferably represents at least one decorative or visually recognizable design element, which may be, for example, a graphically designed contour, a figurative representation, an image, a motif, a symbol, a logo, a portrait, a pattern, a grid, alphanumeric characters, text, etc.

[0103] The present invention will now be described by way of example only with reference to a number of embodiments in the accompanying drawings, in which: FIG. [Brief description of the drawings]

[0104] [Figure 1a] A method for coating a substrate is provided. [Figure 1b] A method for coating a substrate is provided. [Figure 1c] A method for coating a substrate is provided. [Figure 1d] A method for coating a substrate is provided. [Figure 1e] A method for coating a substrate is provided. [Figure 1f] A method for coating a substrate is provided. [Figure 2a] FIG. 1 shows a schematic diagram of a coating apparatus for producing a coated substrate. [Figure 2b] FIG. 1 shows a schematic diagram of a coating apparatus for producing a coated substrate. [Diagram 3] 1 shows a schematic diagram of a coating apparatus for coating a substrate. [Figure 4a] A method for coating a substrate is provided. [Figure 4b] A method for coating a substrate is provided. [Figure 4c] A method for coating a substrate is provided. [Diagram 5] 1 shows a diagram of an exemplary coating apparatus. [Figure 6] 1 shows an exemplary diagram of a conditioning device and a mold carrier. [Figure 7]1 shows an exemplary diagram of a printing unit. [Figure 8] 1 shows an exemplary diagram of a UV irradiation unit. [Figure 9a] 1 shows an exemplary diagram of a substrate. [Figure 9b] 1 shows an exemplary view of a retention device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0105] A method for producing a coated substrate is described below with reference to Figures 1a to 1f.

[0106] 1a shows a holding device 20 to which the substrate 10 is fixed, preferably in a positive-locking and / or non-positive-locking manner. In particular, the holding device 20 can be opened and / or closed mechanically and / or hydraulically and / or pneumatically and / or electrically and / or manually. The positioning of the substrate 10 is preferably performed by human hand, by a transport device connected to the holding device 20 or fully automated, for example by a robot.

[0107] The substrate 10 is preferably rigid, and in particular has at least one surface that is curved, flat and / or partially uneven.

[0108] In particular, the substrate 10 and / or the surface of the substrate 10, in particular the surface of the substrate 10 to be coated, may be substantially flat, in particular two-dimensionally flat, or may be 2.5-dimensionally deformed, or may be three-dimensionally deformed.

[0109] More preferably, the substrate 10 comprises a component, in particular a vehicle part, a housing part, a cockpit component and / or a body part, an injection molded part, a 3D printed part and / or a component manufactured by cutting and / or non-cutting manufacturing methods.

[0110] In a next step, as shown in Fig. 1b, one or more film elements 11 are applied to at least one partial area of ​​a first surface of the substrate 10, in particular in a stamping station 30 of the coating device 50. In particular, the one or more film elements 11 are applied to at least one partial area of ​​the one or more further film elements 11 stamped on the substrate 10 and / or to at least one partial area of ​​the one or more printing layers 12 applied to the substrate 10. In particular, the substrate 10 remains in the holding device 20 during stamping.

[0111] The substrate 10, fixed in the holding device 20 and arranged in the stamping station 30, is shown in FIG. 1b. The stamping station 30 comprises a stamping unit 31. In this embodiment, the stamping unit 31 comprises a stamping die 32 and a film supply unit 36. The film supply unit 36 ​​comprises two film spindles 34. A film web 33 is wound on and unwound from the film spindles. To stamp the film element 11, the stamping die 32 is translated in the direction of the substrate 10, as indicated by the arrow. As a result of the input of stamping pressure and heat, the film element 11 is applied to the substrate 10. The resulting substrate 10 coated with the film element 11 is shown in FIG. 1c. Here, the substrate 10 is preferably still arranged fixedly in the holding device 20. However, one or more film elements 11 may also be stamped on the substrate 10.

[0112] The stamping station 30 preferably has at least one stamping unit 31 including one or more stamping dies 32. Furthermore, the coating apparatus 50 has at least one film supply unit 36 ​​including two or more film spindles 34 for winding and unwinding two or more film webs 33, which are preferably arranged adjacent to each other in parallel and preferably capable of being slid in and out between the stamping die 32 and the substrate 10.

[0113] In alternative design variations, it is possible that at least one film supply unit 36 ​​has at least one splicing aid and / or that two or more film spindles 34 can be removed, in particular for changing the film.

[0114] To stamp the film element(s) 11, the stamping die(s) 32 are preferably translated in the direction of the substrate 10 until the film element 11 comes into contact with the substrate 10. When contact occurs, a stamping pressure is then applied, in particular a predefined stamping pressure, and the film element 11 is stamped onto the substrate 10 by heat input. The stamping die(s) 32 can each comprise at least one direct heater for rapidly heating the stamping die 32. Furthermore, it is particularly provided that the heating range of the stamping die(s) 32 is between 0°C and 300°C, in particular between 80°C and 250°C.

[0115] It is further provided that the stamping of the film element or elements 11 in step b) is performed by roll-on stamping and / or partial roll-on stamping and / or vertical stamping.

[0116] In a preferred design variant, a hot stamping film comprising a carrier ply and a transfer ply removable from the carrier ply is used as film 33 in step b) and / or during step b) at least one section of the transfer ply determined by the shape of the stamping die 32 is applied as film element 11 by activating an adhesive layer of the transfer ply or an adhesive layer provided between the substrate 10 and the transfer ply.

[0117] Furthermore, a transfer film, in particular a cold stamping film, comprising a carrier ply and a transfer ply removable from the carrier ply, is preferably used as film 33 in step b). The transfer ply and / or the cold stamping film applied to the partial area of ​​the surface of the substrate 10 is preferably an adhesive layer, in particular selected from low-temperature adhesives and / or UV adhesives, applied by the inkjet print head 42 in particular in a first area but not in a second area. In particular, the transfer film is guided towards the surface of the substrate 10 by the stamping die 32, the adhesive layer is activated and the transfer film is peeled off again, so that the section of the transfer ply determined by the shape of the first area is applied as film element 11.

[0118] It is also possible that a laminate film is used as film 33 in step b) and that during stamping, at least one section of the laminate film determined by the shape of the stamping die 32 is applied as film element 11 by activating an adhesive layer of the laminate film or an adhesive layer provided between the surface of the substrate 10 and the laminate film.

[0119] The substrate 10 coated with the film element 11 and placed at the printing station 40 is shown in Figure 1d, where the substrate 10 still remains in the holding device 20. The printing station 40 comprises a printing unit 41 comprising two printing heads 42. It is further possible that the printing station 40 comprises at least one printing unit 41, which comprises one or more printing heads 42 by means of which one or more printing layers 12 are applied.

[0120] In a next step, the printing layer or layers 12 are applied to at least one partial area of ​​the film element or elements 11 stamped on the substrate 10, in particular in a printing station 40 of the coating device 50. In a further design variant, it is also provided that the printing layer or layers 12 are applied to at least one partial area of ​​the first surface of the substrate 10 and / or to at least one partial area of ​​one or more further printing layers 12 applied to the substrate 10. In particular, the substrate 10 remains in the holding device 20.

[0121] In particular, the application of the one or more printed layers 12 is carried out by digital printing and / or inkjet printing and / or inkjet printing and / or pad printing.

[0122] It is furthermore particularly provided that the application of the one or more printing layers 12 in step c) is carried out by means of one or more print heads (42) which contain printing inks, in particular printing inks having colours from the CMYK and / or RGB colour model and / or spot colours, and / or transparent printing inks, in particular clear varnishes and / or protective varnishes (Clear Coat), and / or adhesives, in particular low-temperature adhesives and / or UV adhesives and / or varnishes, which are preferably applied as printing layer 12 to at least one partial area of ​​the first surface of the substrate 10 and / or to at least one partial area of ​​the one or more film elements 11 stamped on the substrate 10 and / or to at least one partial area of ​​the one or more further printing layers 12 applied to the substrate 10.

[0123] The substrate 10 coated with the film element 11 and the print layer 12 is shown in FIG. 1e, where the substrate 10 is still fixed in the holding device 20 in a positive and / or non-positive locking manner.

[0124] The removal of the coated substrate 10 from the holding device 20 in a further step is shown in Figure 1f. This is indicated by the arrow. After removing the coated substrate 10, further processing steps can be carried out, which are preferably carried out in a separate machine.

[0125] It is also possible that the method comprises further steps, including flooding, overspraying and / or spray coating the coated substrate 10 and / or laminating a sensor, particularly a contact and / or proximity sensitive sensor, preferably on the back side of the coated substrate 10, particularly the coated substrate 10, particularly after removal of the coated substrate 10 from the holding device 20, carried out in one or more further machines.

[0126] FIG. 2a shows a schematic diagram of a coating apparatus 50, which is preferably implemented as a rotating plate and includes a mold carrier 21 which moves the holding device 20, not shown in this figure, together with the substrate 10 between the stamping station 30 and the printing station 40.

[0127] A schematic diagram of the coating device 50 is likewise shown in Fig. 2b. In a variant of this embodiment, the coating device 50 comprises a mould carrier 21, which includes a slide table and / or a linear unit 23 for moving the holding device 20 together with the substrate 10 fixed therein in a positive and / or non-positive locking manner between the stamping station 30 and the printing station 40.

[0128] Fig. 3 shows an embodiment of the coating apparatus 50 according to Fig. 2b, in which the mould carrier 21 comprises a slide table and / or a linear unit. In addition to the mould carrier 21, the coating apparatus 50 comprises an adjustment device 22, which translates the mould carrier 21 between the stamping station 30 and the printing station 40 as indicated by the double arrow. A holding device 20 is further arranged on the mould carrier 21, in which the substrate 10 is arranged fixedly, in particular in a positive-locking and / or non-positive-locking manner. Furthermore, the coating apparatus 50 comprises a process control device 60, which comprises one or more microprocessors, peripheral components for controlling the stamping station 30, the printing station 40 and the adjustment device 22, and corresponding software components.

[0129] Further, in particular, the coating apparatus 50 has at least one holding device 20 for fixing the substrate 10, at least one stamping station 30 and at least one printing station 40 for applying one or more printing layers 12 to at least one partial region of the first surface of the substrate 10 and / or to at least one partial region of one or more film elements 11 stamped on the substrate 10 and / or to at least one partial region of one or more further printing layers 12 applied to the substrate 10, the stamping station 30 having one or more stamping units 31 for stamping one or more film elements 11 onto at least one partial region of the first surface of the substrate 10 and / or to at least one partial region of one or more further film elements 11 stamped on the substrate 10 and / or to at least one partial region of one or more printing layers 12 applied to the substrate 10.

[0130] The stamping station 30 comprises at least one stamping unit 31 for stamping one or more film elements 11. The stamping unit 31 preferably comprises at least one turret 35 on which is mounted at least one stamping die 32. In a variant of the embodiment shown in FIG. 3, four stamping dies 32 are arranged on the turret 35.

[0131] The stamping station 30 may further comprise at least one turret 35, which is preferably mounted rotatably about at least one axis and translatably movable along at least one axis. In particular, the turret 35 comprises one or more stamping die receivers for receiving one or more stamping dies 32. The stamping dies 32 preferably have different shapes, so that different motifs can be stamped. The rotatable mounting of the turret 35 and the possibility of its translational movement are indicated by the illustrated arrows.

[0132] In particular, it is further provided that the stamping station 30 has at least one film supply unit 36, which comprises two or more film spindles 34 for winding and unwinding two or more film webs 33. It is in particular possible for the two or more film webs 33 to be arranged parallel and adjacent to one another, so that the two or more film webs 33 are slid in and out between the stamping die 32 and the substrate 10.

[0133] In a variant of this embodiment, the turret 35 together with the stamping die 32 translates towards the substrate 10, as in a lifting press. However, it is also possible to carry out the stamping of the film element or elements 11 by roll-on stamping and / or partial roll-on stamping.

[0134] One or more stamping dies 32 are replaceably mounted in one or more stamping die receivers of at least one turret 35, preferably each stamping die receiver having in each case a quick-change system for tool-free replacement of the stamping dies 32, preferably the quick-change system having a dovetail bracket and / or a clamp lever for replacing the stamping dies 32.

[0135] This has the advantage that the stamping die 32 can in particular be exchanged without tools, which significantly reduces the machine set-up times, in particular during maintenance or when changing over to another substrate 10 .

[0136] It is also possible for one or more stamping dies 32 that are not attached to the turret 35 to be temporarily attached to a bracket on the coating apparatus 50 for preheating purposes.

[0137] Additionally, the stamping die or dies 32 may comprise a material or combination of materials selected from steel, silicone, plastic, aluminum, copper, brass, and / or magnesium.

[0138] More particularly, the stamping die receiver(s) and the stamping die(s) 32 are encoded, preferably with an RFID chip.

[0139] Additionally, the at least one printing station 40 may include a digital printing station and / or an inkjet printing station and / or a pad printing station and / or an inkjet printing station.

[0140] Furthermore, the at least one printing station 40 may comprise at least one printing unit 41, in particular with at least one printing head 42. The one or more printing layers 12 are applied by the at least one printing head 42. In particular, each printing head 41 of the one or more printing heads 42 may be arranged to be separately translationally movable, preferably arranged to be movable in the z-direction, so that a constant processing distance from the surface of the substrate 10 can be maintained. The surface of the substrate 10 may have irregularities and / or roughness, which is why the control of the at least one printing head 41, in order to maintain the processing distance, is preferably performed by the process control device 60.

[0141] In particular, the one or more printing layers 12 comprise one or more materials in particular selected from printing inks, in particular printing inks having colours from the CMYK and / or RGB colour model and / or spot colours, and / or transparent printing inks, in particular clear varnishes and / or protective varnishes (Clear Coat), and / or adhesives, in particular low temperature adhesives and / or UV adhesives, and / or varnishes.

[0142] In a variant of an alternative embodiment, the coating apparatus 50 may have at least one pretreatment station 70 for pretreating partial areas of the surface of the substrate 10, one or more film elements 11 stamped on the substrate 10, and / or one or more printing layers 12 applied to the substrate 10, using one or more treatment methods selected in particular from treatment with gas, flame treatment, plasma treatment, fluorination, irradiation, cleaning, surface activation, coating, ionization.

[0143] It is further possible for the coating apparatus 50 to have at least one inspection station for optically inspecting at least one partial area of ​​the surface of the substrate 10, one or more film elements 11 stamped on the substrate 10, and / or one or more printing layers 12 applied to the substrate 10 by means of an optical sensor, in particular a camera.

[0144] Advantageously, the coating device 50 can comprise at least one cleaning station for cleaning at least one surface of the substrate 10, in particular by means of a brush and / or compressed air and / or suction.

[0145] Preferably, the coating apparatus 50 has at least one flow box for reducing and / or preventing dust, preferably at least one ventilator, in particular by which filtered ambient or room air can be blown into the working space at positive pressure.

[0146] Here, the working space can preferably be sealed against the environment and particularly preferably closed off from the environment. Furthermore, it is in particular provided that the working space comprises a space in which at least one stamping station 30, at least one printing station 40, at least one pre-treatment station 70, at least one cleaning station, at least one UV irradiation unit 80 and / or at least one inspection station are arranged.

[0147] In a further variant of the embodiment, the coating device 50 may have at least one UV irradiation unit 80 for UV pre-curing, in particular pinning, of one or more of the printing layers 12 and / or a UV irradiation unit 80 for full curing of one or more of the printing layers 12. The one or more printing layers 12 include a UV adhesive and / or a low-temperature adhesive and / or an adhesive and / or a varnish and / or an ink. The UV irradiation unit 80 preferably includes a UV radiation source emitting light preferably within a wavelength range of 385 nm to 405 nm.

[0148] It is further possible that the coating apparatus (50) comprises at least one film control unit which inspects the two or more film webs (33) for cracks in the film, film edges and / or film stock, preferably by means of at least one sensor and / or two or more servo motors arranged on two or more film spindles. In particular, the sensor is an optical sensor, e.g. a camera.

[0149] In a further design variant, it is possible for the coating apparatus 50 to have at least one movably mounted mould carrier 21, in particular a vertically or horizontally arranged rotating plate or slide table, in particular on which the at least one holding device 20 is arranged, whereby the at least one holding device 20, in particular together with the fixed substrate 10, can be moved between at least one stamping station 30 and / or at least one printing station 40 and / or at least one pre-treatment station 70 and / or at least one inspection station and / or at least one cleaning station.

[0150] In another embodiment, the coating apparatus 50 has n stations, in particular at least one stamping station 30, at least one pre-treatment station 70, at least one cleaning station and / or at least one printing station 40, and at least n holding devices 20 can be arranged on at least one mold carrier 21.

[0151] In particular, the coating apparatus 50 has at least one adjustment device 22 for moving the holding device 20 and / or at least one holding device 20 arranged on at least one common mold carrier 21 between stations of the coating apparatus 50.

[0152] In a further variant of the embodiment, the coating apparatus 50 has at least one process control device 60, which is capable of operating the adjustment device 22 so that one or more holding devices 20 are cyclically delivered to two or more stations of the coating apparatus 50 in a predetermined sequence, in particular in the sequence of stamping station 30-printing station 40, printing station 40-stamping station 30, pre-treatment station 70-stamping station 30-printing station 40, stamping station 30-pre-treatment station 70-printing station 40, pre-treatment station 70-stamping station 30-pre-treatment station 70-printing station 40.

[0153] In particular, a method for coating a substrate 10 using a coating device 50 is shown in FIG. 4a, in which the method comprises, in particular, the following steps: a) fixing the substrate 10 to a holding device 20; b) stamping one or more film elements 11 onto at least one partial area of ​​a first surface of the substrate 10 and / or onto at least one partial area of ​​one or more further film elements 11 stamped onto the substrate 10 and / or onto at least one partial area of ​​one or more printing layers 12 applied to the substrate 10, the substrate 10 remaining in a holding device 20; c) applying one or more printing layers 12 to at least one partial area of ​​a first surface of the substrate 10 and / or to at least one partial area of ​​one or more film elements 11 stamped on the substrate 10 and / or to at least one partial area of ​​one or more further printing layers 12 applied to the substrate 10, the substrate 10 remaining in the holding device 20; d) removing the coated substrate 10 from the holding device 20 is performed.

[0154] It is also possible for steps b) and c) to be performed once or multiple times and / or in any desired order, which is also illustrated in Figures 4b and 4c.

[0155] Particularly preferably, the cycle times of steps b) and c) each are between 1 second and 300 seconds, preferably between 5 seconds and 120 seconds, in particular between 20 seconds and 30 seconds.

[0156] Furthermore, the method may comprise a step of manufacturing the substrate (10) by injection molding and / or 3D printing and / or cutting and / or non-cutting manufacturing methods, which step may in particular be carried out before step a).

[0157] It is also possible that the method comprises a step of delivering and / or placing the substrate 10 in the holding device 20, which step is in particular carried out before step a).

[0158] It is furthermore particularly provided that the method comprises a step of UV irradiation, in particular pinning, with UV light, preferably UV LED, for pre-curing one or more of the one or more printed layers 12, in particular UV adhesives, low-temperature adhesives, glues, varnishes and / or inks, in particular wherein the irradiation is carried out in particular with light in the wavelength range of 385 nm to 405 nm, in particular which step is carried out in step c).

[0159] In an alternative variant, the method comprises a step of UV irradiation with UV light, preferably a UV LED, for complete curing of one or more of the one or more printed layers 12, preferably a UV adhesive, a low-temperature adhesive, an adhesive, a varnish and / or an ink, in particular where the irradiation is carried out with light in the wavelength range of 385 nm to 405 nm, in particular which step is carried out in step c).

[0160] 4b shows that first one or more printing layers 12 are applied to the substrate 10 according to step c), then step b) is carried out, resulting in stamping one or more film elements 11. Between the two steps b) and c), or in the reverse order, it is possible to pre-treat the substrate 10 in a pre-treatment station 70.

[0161] In particular, the method comprises a step of pretreating at least one partial area of ​​the first surface of the substrate 10 and / or at least one partial area of ​​one or more film elements 11 stamped on the substrate 10 and / or at least one partial area of ​​one or more printing layers 12 applied to the substrate 10 using one or more treatment methods selected in particular from treatment with gas, flame treatment, plasma treatment, fluorination, irradiation, cleaning, surface activation, ionization, coating, which in particular can be carried out one or more times before step b) and / or before step c).

[0162] In further design variants, in particular prior to step b and / or step c, optical inspection of at least one partial area of ​​the first surface of the substrate 10 and / or of at least one partial area of ​​one or more film elements 11 stamped on the substrate 10 and / or of at least one partial area of ​​one or more printing layers 12 applied to the substrate 10 is carried out by means of an optical sensor, in particular a camera.

[0163] In particular, the method comprises a step of cleaning, in particular with a brush and / or compressed air and / or suction and / or CO2 snow blast and / or adhesive tape, in particular with a pad cleaning tape and / or a roll cleaning tape, in particular carried out before and / or after step b) and / or before and / or after step c).

[0164] It is also possible that before and / or during and / or after step b) and / or step c), the ingress of dust into the working space is reduced, in particular prevented, by positive air pressure.

[0165] Furthermore, it is advantageous to move at least one mold carrier 21, on which at least one holding device 20 is arranged, in particular together with the fixed substrate 10, prior to step b) to a stamping position for carrying out step b) and / or prior to step c) to a printing position for carrying out step c).

[0166] It is also possible that the stamping of the one or more film elements 11 in step b is carried out by one or more stamping dies 32 which apply the film 33 or one or more sections of the film 33 as the film element 11 to at least one partial area of ​​the first surface of the substrate 10 and / or to at least one partial area of ​​one or more further film elements 11 stamped on the substrate 10 and / or to at least one partial area of ​​one or more printing layers 12 applied to the substrate 10.

[0167] Further, in step b), one or more of the one or more film elements 11 are stamped in precise alignment with respect to the one or more further film elements 11, in particular one or more alignment marks of the one or more further film elements 11 and / or of the optical features of the holding device 20 are detected and used to control the stamp.

[0168] It is also possible that the one or more film elements 11 and / or the one or more further film elements 11 in each case have at least one decorative layer and / or at least one functional layer, in particular a layer with electrical functionality, and in particular comprise one or more elements selected from touch sensors, antennas, electromagnetic shielding, non-conductivity, metal layers for preventing static electricity, displays, LEDs, electrical circuits, solar cells, at least one, in particular post-curable protective layer and / or at least one adhesion-promoting layer.

[0169] An exemplary diagram of a coating apparatus 50 is shown in FIG. 5. The coating apparatus 50 essentially comprises a stamping station 30 and a printing station 40. Furthermore, the coating apparatus includes a process control device 60, a UV irradiation unit 80, an adjustment device 22, and a mold carrier 21. The stamping station 30 further includes a turret 35 carrying one or more stamping dies 32, and a film supply unit 36. As indicated by a double arrow, the turret 35 is arranged to be movable in the z direction, and the film supply unit 36 ​​is arranged to be movable in the y direction by a linear drive device 23. The printing unit 41 and the UV irradiation unit 80 are also arranged to be movable by a linear drive device 23, and in particular arranged to be movable in the z direction, also indicated by a double arrow. In the following, the printing unit 41 and the UV irradiation unit 80 will be described in detail. Furthermore, in particular, the mold carrier 21 and the adjustment device 22 are also arranged to be movable by the linear drive device 23. They will also be described in detail.

[0170] Essentially, the mold carrier 21 can be moved in the y-direction between the stamping station 30, the printing station 40 and the UV irradiation unit, for which the adjustment device 22 is actuated by the process control device 60, so that the mold carrier 21 can be moved between the stamping position and the printing position. Furthermore, the mold carrier 21 is brought to the stamping position to stamp one or more film elements 11 and likewise to the printing position to apply one or more printing layers 12. The process control device 60 then controls the stamping and / or printing process. The individual decorations can be performed by the film supply unit 36, the turret 35 and the printing unit 41, which are movable via the linear drive 23.

[0171] 6 shows an exemplary diagram of the adjustment device 22 and the mould carrier 21. The mould carrier 21 is movable along the y-direction by means of a linear drive 23 arranged on the adjustment device 22. The mould carrier 21 itself has a further linear drive 23 which allows the mould carrier 21 to move in the x-direction. The direction of movement is indicated in particular by two double arrows.

[0172] An exemplary diagram of the printing unit 41 is shown in FIG. 7. In a variant of this embodiment, the printing unit 41 comprises four print heads 42. These can cover, for example, the color space of the CMYK color model. However, it is also possible to apply colors of the RGB color model, transparent printing inks, in particular clear varnishes and / or protective varnishes (ClearCoat), and / or adhesives, in particular low-temperature adhesives and / or UV adhesives, and / or varnishes by the print heads 42. In this exemplary variant, each of the four print heads 42 has a UV irradiation unit 80, in particular for pre-curing one or more of the printing layers 12. However, it is also possible that the UV irradiation unit 80 is implemented for fully curing one or more of the printing layers 12.

[0173] Furthermore, preferably, the printing unit 41 together with the four print heads 42 is movable in the x-direction by a linear drive 23, as indicated by the double arrow. In addition, each of the print heads 42 can have its own linear drive 23 for individually moving the print head 42 along the z-axis, as indicated by the double arrow. In this case, the arrangement of the linear drive 23 is not intended to have a limiting effect. Furthermore, the printing unit 41 and / or the print heads 42 can have further linear drives 23 that allow the printing unit 41 and / or the print heads 42 to move in further spatial directions.

[0174] An exemplary UV irradiation unit 80 is shown in Fig. 8. This is preferably a UV irradiation unit 80 for fully curing one or more of the one or more printed layers 12. However, the UV irradiation unit 80 can also be a UV irradiation unit 80 for pre-curing one or more of the one or more printed layers 12.

[0175] In this alternative design, the UV irradiation unit 80 comprises a linear drive 23, by means of which the UV irradiation unit 80 can be moved in the z-direction. However, it is also possible that the UV irradiation unit 80 comprises further linear drives 23, so that the UV irradiation unit 80 can be moved in further and / or other spatial directions.

[0176] In Fig. 9a, a substrate 10 is shown by way of example. The substrate 10 shown is a vehicle part, in particular a cockpit component. The geometry of the substrate 10 can have an individual shape, so that the substrate 10 has in particular a non-flat and / or curved surface.

[0177] Due to the various shapes of the substrate 10, a holding device 20 adapted to the substrate 10 is often necessary. Such an exemplary holding device 20 is shown in FIG. 9b. The holding device 20 preferably fixes the substrate 10 in a positive-locking and / or non-positive-locking manner, so that the substrate 10 is held positionally accurate during further processing. This provides in particular the advantage that further method steps can also be performed positionally accurate and / or with accurate alignment. Here, it is also possible that the holding device 20 preferably has position and / or alignment markings that are detected by a recognition unit, so that a positionally accurate stamping of the film element or elements 11 and / or application of the printing layer or layers 12 can then be effected. [Explanation of symbols]

[0178] 10 Base 11 Film Elements 12 printing layer 20 Holding device 21 Mold carrier 22 Adjustment device 23 Linear Drive Unit 30 Stamping Station 31 Stamping Unit 32 Stamping Die 33 Film / Film Web 34 Film Spindle 35 Turret 36 Film supply unit 40 Printing Station 41 Printing unit 42 Print Head 50 Coating Equipment 60 Process Control Equipment 70 Pre-treatment Station 80 UV irradiation units

Claims

1. A coating apparatus (50) for coating a substrate (10), comprising: The coating device (50) comprises: At least one holding device (20) for fixing said substrate (10); At least one stamping station (30); at least one printing station (40) for applying one or more printing layers (12) to at least one partial area of ​​a first surface of said substrate (10) and / or to at least one partial area of ​​one or more film elements (11) stamped on said substrate (10) and / or to at least one partial area of ​​one or more further printing layers (12) applied to said substrate (10); having the stamping station (30) comprises one or more stamping units (31) for stamping the one or more film elements (11) onto at least one partial area of ​​the first surface of the substrate (10) and / or onto at least one partial area of ​​one or more further film elements (11) stamped onto the substrate (10) and / or onto at least one partial area of ​​the one or more printing layers (12) applied to the substrate (10), The substrate (10) is a rigid body, stamping of the one or more film elements (11) is performed by one or more stamping dies (32) which apply a film (33) as the film element (11) or one or more sections of said film (33) to the at least one partial area of ​​the first surface of the substrate (10) and / or to the at least one partial area of ​​the one or more further film elements (11) stamped on the substrate (10) and / or to the at least one partial area of ​​the one or more printing layers (12) applied to the substrate (10); A coating apparatus (50) characterized in that a hot stamping film comprising a carrier ply and a transfer ply removable from the carrier ply is used as the film (33).

2. the coating device (50) comprises at least one inspection station for optically inspecting by means of an optical sensor at least one partial area of ​​the surface of the substrate (10), the one or more film elements (11) stamped on the substrate (10) and / or the one or more printing layers (12) applied to the substrate (10); and / or The coating apparatus (50) has at least one movably mounted mold carrier (21).

2. The coating apparatus according to claim 1 .

3. The coating apparatus (50) has n stations, At least n holding devices (20) are arranged on said at least one mold carrier (21), 3. The coating apparatus according to claim 2.

4. The stamping station (30) has at least one turret (35) that is rotatably mounted about at least one axis and is translationally movable along at least one axis; The turret (35) includes one or more stamping die receivers for receiving the one or more stamping dies (32).

4. The coating apparatus according to claim 1, wherein the coating apparatus is a coating apparatus for coating a substrate.

5. the one or more stamping die receivers and the one or more stamping dies (32) are encoded with an RFID chip; and / or the one or more stamping dies (32) each having at least one direct heater for rapidly heating the stamping die (32); and / or the one or more stamping dies (32) not attached to the turret (35) are temporarily attached to a bracket of the coating apparatus (50) for preheating; 5. The coating apparatus according to claim 4.

6. The stamping station (30) has at least one film supply unit (36); The film supply unit (36) includes two or more film spindles (34) for winding and unwinding two or more film webs (33); the two or more film webs (33) are arranged parallel and adjacent to one another and slid in and out between the stamping die (32) and the substrate (10); and / or the coating apparatus (50) having at least one film control unit that inspects the two or more film webs (33) for cracks in the film, film edges, and / or film stock by means of at least one sensor and / or two or more servo motors disposed on the two or more film spindles; 6. The coating apparatus according to claim 1, wherein the coating apparatus is a coating apparatus for coating a substrate.

7. said at least one printing station (40) comprising at least one printing unit (41) having at least one print head (42); and / or The at least one printing station (40) comprises a digital printing station and / or a pad printing station and / or an inkjet printing station; 7. The coating apparatus according to claim 1, wherein the coating apparatus is a coating apparatus for coating a substrate.

8. the coating device (50) has at least one adjustment device (22) for moving the holding device (20) and / or the at least one holding device (20) arranged on the at least one common mould carrier (21) between the stations of the coating device (50), 8. The coating apparatus according to claim 2, wherein the coating apparatus is a coating apparatus for coating a substrate.

9. A method of coating a substrate (10), comprising the steps of: a) fixing the substrate (10) to a holding device (20); b) stamping one or more film elements (11) onto at least one partial area of ​​a first surface of the substrate (10) and / or onto at least one partial area of ​​one or more further film elements (11) stamped onto the substrate (10) and / or onto at least one partial area of ​​one or more printing layers (12) applied to the substrate (10), the substrate (10) remaining in the holding device (20); c) applying said one or more printing layers (12) to at least one partial area of ​​said first surface of said substrate (10) and / or to at least one partial area of ​​said one or more film elements (11) stamped on said substrate (10) and / or to at least one partial area of ​​one or more further printing layers (12) applied to said substrate (10), said substrate (10) remaining in said holding device (20); d) removing the coated substrate (10) from the holding device (20); Including, The substrate (10) is a rigid body, stamping of the one or more film elements (11) in step b) is performed by one or more stamping dies (32) which apply a film (33) as the film element (11) or one or more sections of said film (33) to the at least one partial area of ​​the first surface of the substrate (10) and / or to the at least one partial area of ​​the one or more further film elements (11) stamped on the substrate (10) and / or to the at least one partial area of ​​the one or more printing layers (12) applied to the substrate (10), 4. The method according to claim 3, wherein in step b) a hot stamping film comprising a carrier ply and a transfer ply removable from the carrier ply is used as the film (33).

10. Steps b) and c) may be performed once or multiple times and / or in any order desired; and / or The cycle times of steps b) and c) are each between 1 second and 300 seconds; 10. The method of claim 9.

11. The application of said one or more printing layers (12) is carried out by digital printing and / or inkjet printing and / or pad printing; 11. The method according to claim 9 or 10.

12. Prior to step b) and / or step c), an optical inspection of the at least one partial area of ​​the first surface of the substrate (10) and / or of the at least one partial area of ​​the one or more film elements (11) stamped on the substrate (10) and / or of the at least one partial area of ​​the one or more printing layers (12) applied to the substrate (10) is performed by an optical sensor; and / or The method may include using a brush and / or compressed air and / or suction and / or CO ２ and / or cleaning with snow blasting and / or adhesive tape; Before and / or during and / or after step b) and / or step c), the ingress of dust into the working space is reduced by positive air pressure, The method according to any one of claims 9 to 11.

13. During step b), at least one section of the transfer ply defined by the shape of the stamping die (32) is applied as the film element (11) by activating an adhesive layer of the transfer ply or an adhesive layer provided between the substrate (10) and the transfer ply, or a transfer film comprising a carrier ply and a transfer ply peelable from the carrier ply is used as the film (33) in step b), and the adhesive layer is applied by an inkjet print head (42) to a portion of the transfer ply and / or to a first region of the surface of the substrate (10) but not to a second region; the transfer film is directed towards the surface of the substrate (10) by the stamping die (32), the adhesive layer is activated and the transfer film is peeled off again, so that a section of the transfer ply defined by the shape of the first region is applied as the film element (11), or a laminate film is used as the film (33) in step b), and during the stamping, at least one section of the laminate film defined by the shape of the stamping die (32) is applied as the film element (11) by activating an adhesive layer of the laminate film or an adhesive layer provided between the surface of the substrate (10) and the laminate film, The method according to any one of claims 9 to 12.

14. the one or more film elements (11) and / or the one or more further film elements (11) each have at least one decorative layer and / or at least one functional layer, The method according to any one of claims 9 to 13.

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