Transfer film, plastic injection molded product, and method for manufacturing the same

Abstract

The present invention relates to a method for producing a transfer film 1, in particular an IMD transfer film 1, which comprises the steps of: a) providing a carrier ply 3, b) providing a transfer ply 2 comprising a decorative ply 21, the transfer ply 2 being disposed or arranged on the carrier ply 3, and c) applying one or more shaping elements 40 to the carrier ply 3, the one or more shaping elements 40 having a three-dimensional shape and being applied in precise registration with the decorative ply 21. The present invention further relates to a method for coating a plastic injection-molded article with a transfer film, the transfer film, and the plastic injection-molded article.

Description

Technical Field

[0001] The present invention relates to a transfer film, a plastic injection molded article, and a method for manufacturing the same.

Background Art

[0002] It is known to place a decorative film in an injection mold and back-inject it with a plastic compound in the IMD method. During back-injection molding, the decorative film has a shape complementary to the injection mold. After back-injection molding, the carrier ply is peeled off from the decorative film. It is further known here to introduce a surface structure onto the thus-exposed surface. However, in order to change the shape to be manufactured, it is necessary to change the injection mold, and the surface structure is not accurately aligned with the decoration of the decorative film.

Summary of the Invention

Problems to be Solved by the Invention

[0003] Therefore, an object of the present invention is to identify a transfer film having improved properties, particularly improved decorative and / or functional properties, a plastic injection molded article coated with the transfer film, and an improved method for manufacturing the same.

Means for Solving the Problems

[0004] This object is achieved by a method for manufacturing a transfer film, particularly an IMD transfer film (IMD = In-Mold Decoration). In this method, a) preparing a carrier ply; b) preparing a transfer ply provided with a decorative ply, the transfer ply being placed or to be placed on the carrier ply; c) Applying one or more forming elements to a carrier ply, wherein the one or more forming elements have a three-dimensional shape and are precisely aligned and applied to the decorative ply, the steps are performed in a predetermined order.

[0005] This objective is further achieved by a transfer film, particularly an IMD transfer film. The transfer film is preferably manufactured by a method according to the present invention. The transfer film has a carrier ply and a transfer ply comprising a decorative ply, the transfer ply being placed on the carrier ply. The transfer film further comprises one or more forming elements, the one or more forming elements being applied to the carrier ply and applied in a manner that is precisely aligned with respect to the decorative ply.

[0006] This objective is further achieved by a method for producing plastic injection molded articles coated with a transfer film, particularly an IMD transfer film. Here, the transfer film is preferably produced by a transfer film and / or a method according to the present invention for producing a transfer film according to the present invention. Methods for manufacturing plastic injection molded products are: x1) A step of preparing a transfer film, wherein the transfer film has a carrier ply and a transfer ply comprising a decorative ply, and the transfer ply is placed on or positioned on the carrier ply. x2) A step of preparing one or more forming elements on a carrier ply, wherein one or more forming elements have a three-dimensional shape and are precisely aligned and applied to or applied to a decorative ply, x3) ​​The process includes, in particular, the steps of back-injecting a transfer film with an injection molding compound, thereby introducing a molded body of one or more forming elements into the transfer ply, precisely aligned with the decorative ply, by the action of the injection molding compound on the transfer film.

[0007] Therefore, the manufacturing method for plastic injection molded products is, in particular, the IMD injection molding method.

[0008] This objective is further achieved by plastic injection molded articles. Plastic injection molded articles are manufactured by methods according to the present invention for manufacturing plastic injection molded articles in particular. Plastic injection molded articles consist of an injection molding compound and a transfer ply of a transfer film, particularly an IMD transfer film, back-injected with the injection molding compound. The transfer film is manufactured by methods according to the present invention for manufacturing transfer films and / or transfer films according to the present invention. The transfer ply comprises a decorative ply and has a three-dimensional molded body, the molded body being introduced with precise registration to the decorative ply.

[0009] The three-dimensional shaped molded body is therefore not limited to the shape of the mold half of an injection molding machine. The molded body is preferably a molded body that is additionally introduced to the shape of a transfer ply produced by a mold half in which the carrier ply and / or one or more forming elements are stationary during back injection molding of a transfer film using an injection molding compound.

[0010] This makes it possible to generate tactile elements and / or tactile elements and / or depth effects on the surface of a plastic injection molded product. Tactile elements and / or tactile elements and / or depth effects can be manufactured with precision for both decorative elements and / or backlight masks and / or functional components of a plastic injection molded product, such as backlights and / or touch sensors. Here, it is possible to ensure that the transmitted illumination properties of the plastic injection molded product are not impaired. In particular, it becomes possible to prepare tactile and / or tactile elements and / or depth effects on a plastic injection molded product, and their precisely registered placement on decorative plies and optionally mask layers and / or functional components ensures improved operation and / or perception during use of the plastic injection molded product.

[0011] Furthermore, it becomes possible to reduce the need to manufacture new molds for different surface structures and / or to supplement the shape prepared by the mold with further three-dimensional shapes, particularly for individualization. In addition, transfer films, and therefore coated plastic injection molded parts, can be manufactured cost-effectively in small batch sizes. When the shape prepared by the mold is supplemented with three-dimensional shapes, the advantage of being able to configure the positioning of the transfer film in the injection molding machine more efficiently can also be achieved. Depending on the application, for example, deviations in the relative position between the decorative ply and the mold of the injection molding machine from the target position can be ignored to at least some extent. Since the molding of three-dimensional shapes is always precisely registered and positioned relative to the decorative ply by the precisely registered application of one or more forming elements to the decorative ply, the precise impression of the arrangement of different components of the plastic injection molded part is maintained. Here, all functional parts can also be precisely registered and positioned relative to the three-dimensional molded body, simultaneously with the decorative ply and optionally the mask layer, and as a result, the functional parts can function and operate precisely.

[0012] The advantageous design of the present invention is described in the dependent claims.

[0013] Registered, or precisely registered, or precisely registered, or registration accuracy, or registration accuracy refers to the positional accuracy of two or more layers relative to each other. Registration accuracy is bringing the registration tolerance within a predetermined tolerance, which is as small as possible. At the same time, the registration accuracy of several elements and / or layers relative to each other is an important feature for increasing the reliability of the process. Positionally accurate positioning can be achieved in particular by sensors, preferably optically detectable registration marks or registration marks. These registration marks or registration marks either represent a specific individual element or area or layer, or are themselves part of the element or area or layer to be positioned.

[0014] Layers and / or plies mean substantially two-dimensional structures that are formed or patterned over the entire surface, and are preferably single-layer or multi-layer in themselves.

[0015] A tactile element refers specifically to an element that can be perceived through touch. A tactile element refers specifically to an element that can be perceived through touch.

[0016] Functional components are components that have electrical, and especially electronic, functions. Functional components preferably mean components that enable interaction with the user through information input and / or information output.

[0017] During step b), the preparation step may include applying a transfer ply comprising at least a decorative ply to the carrier ply. One or more forming elements are preferably applied partially to the carrier ply and / or to the partial region with a greater thickness than other partial regions. The application of the layer to the carrier ply can be done in particular directly to the carrier ply or indirectly through one or more further layers.

[0018] A region, particularly a subregion, is defined when viewed perpendicular to the plane and / or main surface of the transfer film or each layer, and preferably comprises all portions of the transfer film and / or plastic injection molded product that overlap this plane and / or main surface.

[0019] The transfer ply is applied to or can be applied to the first surface of the carrier ply, and one or more forming elements are applied to or can be applied to the second surface of the carrier ply opposite to the first surface.

[0020] In an advantageous embodiment of the plastic injection molded article and / or its manufacturing method, the molded body is arranged and / or disposed so as not to impair the transmissive illumination characteristics of the transfer ply, particularly the decorative ply and / or the mask layer, and / or the injection molding compound. Not impairing means that the molded body is arranged so as not to substantially affect the radiation passing through the visible region of the transfer ply, particularly the wavelength of the light passing through the visible region of the transfer ply, particularly the color and / or scattering and / or brightness and / or luminance. For example, the transfer ply, particularly the protective layer of the transfer ply, can be made to transmit uniformly in the visible region, particularly when the transfer ply already has the molded body.

[0021] Preferably, when the molded body does not overlap the visible region or when the molded body overlaps the visible region, it is ensured that the transfer ply, particularly the protective layer of the transfer ply, has substantially no change in layer thickness in the visible region. This can be achieved, for example, when the visible region is overlapped across the entire surface by the molded body.

[0022] For this purpose, it is further possible for one or more forming elements to have a constant layer thickness, at least in the visible region.

[0023] In other words, this means that the transmissive illumination characteristics are not impaired or are not significantly impaired. Transmissive illumination characteristics mean, for example, particularly light scattering and / or luminous intensity and / or light color and / or wavelength and / or luminance and / or emission angle.

[0024] Back injection molding of the transfer film having the injection molding compound is preferably carried out at a temperature of the injection molding compound in the range of 200°C to 300°C. The injection molding compound preferably comprises or particularly consists of ABS, ASA, PA, PP, PC, PMMA, SAN, TPO or a mixture of two or more of these materials.

[0025] Before the back injection molding of the transfer film, the transfer film is preferably placed on the mold half in an injection molding machine, particularly between two mold halves, and the mold halves are closed before the back injection molding. By the back injection molding of the transfer film using an injection molding compound, the transfer film is particularly pressed against the mold half and forms a shape complementary to the mold half. The molded body of the plastic injection molded article is formed or particularly formed by one or more forming elements. Thereafter, one or more forming elements and / or carrier ply can be removed from the plastic injection molded article, particularly in the completed plastic injection molded article.

[0026] The three-dimensional shape of the forming element and / or the molded body particularly means that the dimensions in three spatial directions substantially contribute to the design of one or more forming elements or the molded body. Due to the three-dimensional shape, at least one surface of the transfer ply, in particular, is curved or curved in such a way in addition to the curvature provided by the mold half of the injection molding machine.

[0027] One or more forming elements preferably form or comprise one or more motifs and / or are introduced into the transfer film, particularly for the formation of one or more motifs, particularly for the molded body in a plastic injection molded article. In particular, the outer contour of the radiation of one or more forming elements and / or the molded body onto a plane can follow the outer contour of a two-dimensional motif. The three-dimensional shape can comprise a two-dimensional motif, and it is preferable for the two-dimensional motif to be provided with a three-dimensional structure since, for example, a height in the third spatial direction is provided. The height of the two-dimensional motif is, for example, the thickness or height of the forming element and / or the height of the molded body. The three-dimensional shape can be a motif that can only be depicted by a three-dimensional structure. The motif is, for example, selected from figurative representations, images, symbols, logos, emblems, portraits, patterns, alphanumeric characters, particularly 3D lettering, or a combination thereof, where, preferably, it can be a positive image and / or a negative image. Thus, the motif can provide for a depth effect and / or a tactile and / or haptic element.

[0028] During back injection molding of the transfer film having the injection molding compound of step x3), recessed regions are generated in the transfer ply, which are preferably formed by molding and include a positive image of one or more forming elements. Alternatively, during back injection molding of the transfer film having the injection molding compound of step x3), raised regions including a negative image of one or more forming elements may also be formed in the transfer ply. Thus, by the raised regions and / or recessed regions and / or molding, one or more motifs complementary to one or more motifs of one or more forming elements may be formed. Raised regions are areas in the transfer film where no forming elements are present and / or areas where the transfer ply is deformed in the direction of the carrier ply during back injection molding with the injection molding compound. Recessed regions are areas in the transfer film where forming elements are present and / or areas where the transfer ply does not move or moves substantially in the direction of the carrier ply during back injection molding with the injection molding compound. The raised and / or recessed regions may be continuous regions, or alternatively or additionally, comprise one or more separate subregions. The transfer ply is preferably positioned at least on the boundary line between regions having one or more forming elements and regions without forming elements, when viewed perpendicular to the plane of the transfer film. For example, by the action of pressure and / or heat on the transfer film, the transfer ply can be precisely aligned with the decorative ply and deformed to create raised and recessed regions in particular.

[0029] One or more first layers of one or more forming elements may contain or consist of digital printing ink, preferably inkjet printing ink, preferably UV inkjet printing ink. In particular, in the method for producing the transfer film of step c), one or more first layers of one or more forming elements are applied using a digital printing method, preferably an inkjet printing method, preferably a UV inkjet printing method.

[0030] One or more layers of one or more forming elements can be crosslinked or crosslinked by means of radiation, preferably UV radiation.

[0031] Digital printing methods enable particularly small batch sizes, especially single batch sizes. Furthermore, digital printing methods, particularly UV inkjet printing methods, improve registration tolerances.

[0032] In a digital printing method, one or more layers are preferably printed with one or more printing inks selected from CMYK inks (CMYK = cyan, magenta, yellow, black) or spot colors, such as white or metallic inks.

[0033] In particular in step c), it is also possible that one or more layers of one or more forming elements are applied or are applied by means of gravure printing and / or flexographic printing and / or screen printing. Thus, one or more layers of one or more forming elements of the transfer film may comprise gravure printing ink and / or flexographic printing ink and / or screen printing ink.

[0034] In particular, one or more forming elements can be single-layer or multi-layer. Preferably, two or more layers of one or more forming elements are applied and / or applied in step c) to the transfer film so as to overlap each other, and / or one or more forming elements are applied at least partially by 3D printing. This makes it possible, for example, to increase the height of one or more forming elements starting from a carrier ply. Furthermore, multiple layers of one or more forming elements may be applied or applied by the same printing method, and / or multiple layers may be applied or applied by different printing methods. 3D printing can mean, for example, selective laser sintering (SLS), fused deposition modeling (FDM), and / or stereolithography (SLA).

[0035] In particular, at least two different printing methods can be used for coating one or more forming elements. Preferably, one or more first layers of one or more forming elements can be applied by a printing method other than a digital printing method, such as a screen printing method. Large, undifferentiated surface areas of one or more forming elements are applied in particular using this method. At least one layer of one or more forming elements that is applied last in step c) can be further applied using a digital printing method, preferably an inkjet printing method, preferably a UV inkjet printing method. In particular, at least one layer of one or more forming elements that form the outer surface of the transfer film contains or consists of digital printing ink, preferably an inkjet printing ink, preferably a UV inkjet printing ink. Spatial separation of the application of different layers can be achieved here, for example, in step c). Preferably, individualization in the form of small surface areas can be done, for example, particularly before and / or after transportation, storage, and especially immediately before and / or at the time of manufacture of the plastic injection molded article.

[0036] Furthermore, by varying the heights of one or more forming elements, it is possible to manufacture or produce plastic injection molded articles having varying heights. This is preferably achieved by the number of overlapping printing ink and / or forming element layers, individual ink droplet sizes, UV curing parameters, applied weight of individual printing inks, and / or combinations thereof, particularly through the use of appropriate settings in the digital printing method. Thus, a transfer film may include one or more forming elements of varying heights, and / or a plastic injection molded article may include a molded article having varying heights and / or depths, particularly including partial regions of raised areas having varying heights and / or partial regions of recessed areas having varying heights.

[0037] The layer thickness of one or more forming elements applied by digital printing is preferably in the range of 0.5 μm to 50 μm, and particularly in the range of 1 μm to 25 μm.

[0038] At least one of the forming elements of one or more forming elements printed by digital printing may further have a layer thickness of 1 μm to 200 μm. In particular, the layer thickness of at least one of the forming elements of one or more forming elements is in the range of 1 μm to 200 μm. Here, some, preferably all, of the layers of at least one forming element are applied by means of digital printing and particularly overlap.

[0039] The layers of one or more forming elements printed by gravure printing may have a thickness in the range of 1 μm to 25 μm, and / or the layers of one or more forming elements printed by screen printing may have a thickness in the range of 1 μm to 100 μm.

[0040] In the method for manufacturing plastic injection molded articles, the height of the molded article is preferably in the range of 1 μm to 200 μm.

[0041] The method comprises a step of irradiating one or more forming elements, in particular by UV irradiation, and further comprising a step of performing one or more irradiation steps, preferably after and / or during step c), in particular before at least one layer of the one or more forming elements is applied so as to overlap with at least one other layer of two or more layers of the one or more forming elements. Irradiation during step c), in particular before at least one layer of the one or more forming elements is applied so as to overlap with at least one other layer of two or more layers of the one or more forming elements, is advantageous because the viscosity of the underlying layer increases thereafter, resulting in, firstly, that this layer does not flow, and secondly, that subsequent layers can be obtained as a more stable substrate. For example, curing in between can be considered so that the overlapping layers do not move, thereby, for example, a higher height-to-width ratio can be achieved.

[0042] One or more forming elements are preferably formed from or formed from polyacrylates and / or polymethacrylates, polyurethanes, particularly polyester polyols, polyether polyols, polycarbonate polyols, and polyacrylate polyols, and / or combinations of these polymers, polyesters, polyethers, polyolefins, epoxy resins, and / or derivatives thereof. These formulations are particularly capable of both uncrosslinked and further crosslinked, and are preferably crosslinked with isocyanates, carbodiimides, melamines and / or aziridines and / or derivatives of the compounds listed.

[0043] One or more forming elements can be constructed from radiation-curable acrylates and / or methacrylates, particularly those comprising polyacrylic acrylates, polyurethane acrylates, polyester acrylates, polycarbonate acrylates and / or polyether acrylates and / or copolymers thereof. The radiation-curable formulation, in particular the radiation-curable acrylates and / or methacrylates, are here preferably oligomers. Oligomers are molecules having monomer numbers in the range of 2 to 100.

[0044] One or more forming elements preferably include and / or are generated therefrom, in addition to the polyacrylates mentioned above, further UV-curable acrylate monomers and / or methacrylate monomers. Depending on the embodiment, these monomers particularly include one or more acrylate groups and / or preferably further side groups, for example, the following: alkyl, aryl, cycloalkyl, cycloalkylaryl, alkoxyalkyl, alkoxyaryl, thionyl, thionylaryl, cyclothionyl, cyclothionylaryl, alkoxythionyl, cycloalkoxythionyl, alkoxycyclothionyl, cycloalkoxycyclothionyl, alkoxythionyl allyl, cycloalkoxythionyl allyl, alkoxycyclothionyl allyl and / or cycloalkoxycyclothionyl allila groups. This allows for the optimization of three-dimensional network formation during radiation curing and the setting of specific varnish properties, such as viscosity.

[0045] By selecting monomers or combinations thereof, it is possible to control one or more forming elements in a manner that targets specific further properties, such as surface hardness or residual tack (commonly referred to as "adhesion").

[0046] One or more forming elements may consist of a radiation-curable double-cured varnish, particularly in the sense of the above combination. The double-cured varnish may consist of different polymers or oligomers having unsaturated acrylate groups and / or methacrylate groups. These functional groups can be radically crosslinked with each other during the radiation curing stage. For thermal pre-crosslinking in the first stage, at least two or more alcohol groups are also preferably used in the case of these polymers or oligomers. These alcohol groups can be crosslinked with polyfunctional isocyanates or melamine-formaldehyde resins in particular. Preferably, as unsaturated oligomers or polymers, various UV raw materials such as epoxy acrylates, polyether acrylates, polyester acrylates, and especially polyacrylic acrylates are considered. In particular, blocked and / or unblocked representatives based on TDI (toluene-2,4-diisocyanate), HDI (hexamethylene diisocyanate), or IPDI (isophorone diisocyanate) are used as isocyanates. Melamine crosslinking agents can come from the group consisting of fully etherified, imino, and / or benzoguanamines.

[0047] In a preferred embodiment, one or more forming elements are constructed or formed as a color layer, for example, for better readability in subsequent positioning, particularly for accurate registration of components to be coated later. Here, the color layer may consist of or be composed of colorants and / or pigments, in particular optically variable pigments and / or metallic pigments. One or more forming elements may also include or be comprised of fillers, such as HDK (fine particle silica), in particular for optimization of rheological properties.

[0048] One or more forming elements are provided with or comprise a release agent to improve the characteristics of delamination, particularly from the injection mold, and especially from the mold half in contact with the one or more forming elements in step x3). The release agent is preferably a silicone. In particular, for better integration in the three-dimensional network of one or more forming elements, these silicones may comprise side chains having radiation-curable groups in part. These groups are formed or preferably formed from a class of radiation-curable acrylates and / or methacrylates consisting of acrylic acrylates, urethane acrylates, ester acrylates, carbonate acrylates and / or ether acrylates and / or copolymers listed. Each of these groups, as with the silicone itself, may, in turn, particularly have terminal groups that contribute to thermal crosslinking in one or more forming elements. These terminal groups may, in particular, be alcohol groups, polyfunctional isocyanates or melamine-formaldehyde resins. As isocyanates, both blocked and unblocked representatives based on TDI (TDI = toluene-2,4-diisocyanate), HDI (HDI = hexamethylene diisocyanate), or IPDI (IPDI = isophorone diisocyanate) are preferably used. Melamine crosslinking agents are selected from the group consisting of fully etherified, imino, and / or benzoguanamine in particular. Silicones may further have side chain groups that do not particularly contribute to crosslinking but nevertheless influence the relevant silicone properties in a targeted manner. These side chains can be selected, for example, from one or more of the following material classes: alkyl, aryl, cycloalkyl, cycloalkylaryl, alkoxyalkyl, alkoxyaryl, thionyl, thionylaryl, cyclothionyl, cyclothionylaryl, alkoxythionyl, cycloalkoxythionyl, alkoxycyclothionyl, cycloalkoxycyclothionyl, alkoxythionylally, cycloalkoxythionylally, alkoxycrosionyl, or cycloalkoxycrosionyl groups.

[0049] One or more forming elements preferably include a so-called UV initiator for initiating radiation curing, especially if it is UV radiation curing. The UV initiator is preferably selected from the class of α-alkoxy, α-hydroxy, or α-aminoaryl ketones and / or the class of acylphosphine oxides. Acylphosphine oxides are preferably used in combination with UV inkjet printing of one or more forming elements, in particular, due to their particularly suitable absorption properties in the UV-LED range.

[0050] In particular, to improve specific and typical varnish properties such as wettability, mobility, and foam formation, one or more forming elements may contain additives. To incorporate these additives into a three-dimensional network, these additives typically include radiation-curable groups, thermally crosslinkable groups, or a combination thereof.

[0051] In particular, to minimize chain termination during radiation curing due to the reaction of formed radicals with oxygen molecules in the air and / or to reduce the movement of radical chains on the surface of the forming elements, tertiary amines and / or acrylate amines, especially so-called amine synergists, are preferably added to one or more forming elements. In particular, in order to incorporate these additives into a three-dimensional network, they preferably also include radiation-curable groups, thermally crosslinkable groups, or a combination thereof as part thereof.

[0052] The raised and / or recessed regions may have a minimum line width and / or minimum dot size in the range of 0.025 mm to 0.1 mm. Minimum line width specifically refers to the minimum width of the region. Minimum dot size specifically refers to the minimum diameter of a region having a circular area.

[0053] The recessed area may further have a minimum line width and / or minimum dot size greater than 0.025 mm, preferably for producing a positive image of one or more forming elements, particularly for cases where one or more forming elements are applied or applied by digital printing.

[0054] The raised region may further have a minimum line width and / or minimum dot size of 0.040 mm or more, preferably for the production of a negative image of one or more forming elements, and especially for cases where one or more forming elements are applied or applied by digital printing.

[0055] The recessed area may further have a minimum line width and / or minimum dot size greater than 0.075 mm, preferably for the production of a negative image of one or more forming elements, particularly for cases where one or more forming elements are applied or applied by gravure printing.

[0056] The raised region may further have a minimum line width and / or minimum dot size greater than 0.12 mm, preferably for the production of a negative image of one or more forming elements, and especially for cases where one or more forming elements are applied or applied by gravure printing.

[0057] The recessed area may further have a minimum line width and / or minimum dot size greater than 0.10 mm, preferably for the production of a negative image of one or more forming elements, and especially for cases where one or more forming elements are applied or applied by screen printing.

[0058] The raised region may further have a minimum line width and / or minimum dot size greater than 0.15 mm, preferably for the production of a negative image of one or more forming elements, and especially for cases where one or more forming elements are applied or applied by screen printing.

[0059] Therefore, for example, in the case of a manufactured tactile surface area of ​​approximately 0.5 cm × 0.01 cm, it can be confirmed that there is no tangible difference and / or difference that can be felt with the fingertips between positive and negative forming elements. Positive forming elements refer to isolated forming elements that, when viewed in cross-section, form recessed areas in the carrier ply after back injection molding. Negative forming elements refer to one or more surface forming elements that, when viewed in cross-section, form raised areas in the carrier ply after back injection molding.

[0060] In particular, one or more forming elements have higher dimensional stability than carrier plies and / or transfer plies, and preferably more than at least one layer of transfer plies. High dimensional stability means high resistance to deformation during back injection molding of the transfer film, especially the injection-molded compound.

[0061] One or more forming elements are mechanically stable and / or have mechanical stability, particularly in the case of back injection molding with an injection molding compound, preferably in the IMD injection molding process, preferably in step x3). Mechanical stability here means the stability of one or more forming elements against loads acting particularly through the injection molding compound, especially during back injection molding of a transfer film having an injection molding compound. In other words, one or more forming elements are preferably sufficiently rigid to withstand the high pressures generated, especially during back injection molding, and create a sufficiently strong connection to the carrier film. For this purpose, one or more forming elements preferably have a glass transition temperature above 200°C. Furthermore, one or more forming elements can have substantially constant compressive strength up to a temperature of 200°C. In particular, deformation of the transfer ply when the transfer film is exposed to pressure and / or heat, especially deformation when the transfer film is back injection molded with an injection molding compound, is thus guaranteed. Furthermore, high sharpness of the edges of the molded body is particularly possible.

[0062] When comparing the height of one or more forming elements of a transfer film containing an injection molding compound before and after back injection molding, it is conceivable to judge mechanical stability based on the difference in height. The height of one or more forming elements of a transfer film containing an injection molding compound after back injection molding corresponds to the height of the plastic injection molded product at the time of molding.

[0063] The molded article preferably has a height in the range of 90% to 100% of the height of one or more forming elements of the transfer film before back injection molding with the injection molding compound. The temperature generated in the injection mold during back injection molding, particularly the temperature of the injection molding compound, may or may be in the range of 150°C to 500°C, particularly in the range of 200°C to 300°C. The pressure generated in the injection mold during back injection molding, particularly the internal pressure of the injection mold, may be in the range of 300 bar to 1000 bar, particularly in the range of 400 bar to 800 bar.

[0064] The height of the molded article is preferably determined based on the height difference between the outer surface of the carrier ply in a recessed area and the adjacent outer surface of the carrier ply in a raised area, particularly in plastic injection molded articles. The outer surface is preferably the exposed surface after delamination of the carrier ply. The height of one or more forming elements is measured in particular before back injection molding of the transfer film. Measurement of the height of the molded article and / or the height of one or more forming elements and / or line width and / or dot size is performed in particular by scanning electron microscopy (SEM).

[0065] For example, if the carrier ply has a layer thickness of 50 μm and is preferably made of PET, it is particularly possible that after back injection molding of the injection molding compound, the molded body has a height of 90% of the height of one or more forming elements before back injection molding of the transfer film by the injection molding compound. It is also possible that after back injection molding of the injection molding compound, the molded body has a height of 100% of the height of one or more molded elements before back injection molding of the transfer film by the injection molding compound, and this is particularly possible if the carrier ply has a layer thickness of 75 μm and is preferably made of PET. Particularly preferably, if the layer thickness of the carrier ply made of PET is at least 75 μm, the height of one or more forming elements is maintained or is the same as before back injection molding of the transfer film by the injection molding compound, as it is after back injection molding.

[0066] It has been advantageously shown that the thickness of the carrier ply does not affect edge sharpness, and as a result, one or more forming elements do not need to have a rough structure in relation to edge sharpness. Edge sharpness represents the "sharpness," precision, or accuracy with which the fabricated structure penetrates or appears through the carrier film.

[0067] In particular, the decorative ply has one or more decorative elements. The decorative ply and / or one or more decorative elements preferably comprises one or more color layers, particularly one or more color varnish layers, one or more reflective layers, particularly one or more metal layers and / or one or more HRI layers (HRI = high refractive index), one or more optically active and / or optically variable structures, particularly one or more optically active relief structures, preferably one or more diffractive structures and / or holographic and / or refractive structures and / or matte structures. One or more layers and / or one or more decorative elements of the decorative ply are applied or preferably applied in a method for manufacturing a transfer film. One or more layers and / or one or more decorative elements of the decorative ply may be present over the entire surface in each case, or partially in each case. One or more layers and / or one or more decorative elements of the decorative ply may overlap in the surface area in each case, and / or may be adjacent to each other in the surface area. The adjacent arrangement may be present at a relative distance from each other, or may be directly adjacent without relative distance from each other.

[0068] Preferably, one or more forming elements are positioned in the transfer film or in step c) with precise registration to the decorative ply in at least two different directions. The two different directions are positioned particularly orthogonal to each other and / or extend in a plane parallel to the main surface of the carrier ply. For example, in a method for manufacturing a transfer film, it is possible here to apply one or more forming elements with precise registration to the decorative ply in both the continuous direction of the carrier ply and in a direction transverse to the continuous direction of the carrier ply, particularly to separate decorative elements of the decorative ply, e.g., separate motifs. It is particularly possible that at least one of the one or more forming elements is positioned, or can be positioned, with precise registration to at least one of the decorative elements of the one or more decorative elements, in each case, and at least one decorative element preferably forms a separate motif. The separate motif is particularly not an endless motif and / or has a visible boundary in two different directions in the transfer film and / or plastic injection molded article. One or more forming elements and one or more decorative elements may, in each case, overlap in a surface area and / or be adjacent to one another in a surface area. Adjacent arrangements may be located at relative distances from each other or directly adjacent without relative distance.

[0069] The registration tolerance between one or more forming elements and the decorative ply is preferably in the range of 0.05 mm to 1.0 mm, and more preferably in the range of 0.05 mm to 0.2 mm. The registration tolerance between one or more forming elements and the decorative ply is particularly about 1.0 mm, preferably about 0.2 mm. Therefore, the registration tolerance between the molded body and the decorative ply is preferably in the range of 0.05 mm to 1.0 mm, more preferably in the range of 0.05 mm to 0.2 mm, and / or can be up to 1.0 mm, preferably up to 0.2 mm.

[0070] Registration tolerances in the range of 0.05 mm to 0.2 mm are particularly achievable when one or more forming elements are applied by a digital printing method, preferably an inkjet printing method, preferably a UV inkjet printing method. When one or more forming elements are applied by means of screen printing, registration tolerances in the range of 0.2 mm to 1.0 mm are particularly possible. Registration tolerances are preferably achieved between one or more forming elements of one or more forming elements and one or more assigned decorative elements of one or more decorative elements, in each case.

[0071] Prior to the application of one or more forming elements to the carrier ply in step c), the positions of the decorative ply, particularly the positions of one or more decorative elements assigned to one or more forming elements, are preferably detected by at least one sensor. Then, during the application to the carrier ply in step c), the one or more forming elements are preferably aligned, depending on the positions of the decorative ply, particularly the positions of one or more decorative elements assigned to one or more forming elements.

[0072] The transfer ply has, in particular, a masking region and / or a visible region. The method preferably comprises a step of preparing and / or manufacturing the masking region and / or a visible region in the transfer ply, particularly before and / or after step c). The visible region in the transfer ply is preferably generated in or after step b1), and / or the transfer ply of the transfer film already has a visible region in step b1).

[0073] The visible area preferably has a transmittance particularly higher than that of the masking area, and preferably at least 10% and / or within the range of 10% to 100% higher than that of the masking area. The visible area preferably has a transmittance of 50% or more, particularly 75% or more. The masking area preferably has a transmittance of less than 50%, particularly less than 20%, and preferably less than 5%. Here, transmittance is particularly related to electromagnetic waves, and preferably has wavelengths visible to the human eye.

[0074] In possible embodiments, in the visible region, the transfer ply is particularly transparent to light visible to the human eye. In the masking region, the transfer ply is particularly opaque to light visible to the human eye. Opaque means having a transmittance of 0% to 10% in particular. Transparent means having a transmittance of 10% to 100% in particular.

[0075] The masking region is formed or created by a mask layer, which reduces the transmittance of the transfer ply in the masking region. In particular, the mask layer can be used as a backlight mask when the plastic injection molded product has one or more lights, especially one or more LEDs and / or one or more displays.

[0076] The mask layer is formed by one or more layers, or consists of one or more layers selected from the following: one or more color layers, particularly one or more color varnish layers, one or more reflective layers, particularly one or more metal layers and / or one or more HRI layers (HRI = high refractive index), one or more optically active structures and / or optically tunable structures, particularly one or more optically active relief structures, preferably one or more diffraction structures, holograms, refractive structures or matte structures.

[0077] Preferably, at least one of the reflective layers is located on the relief structure, particularly directly on the relief structure and / or located on the relief structure at least partially or entirely.

[0078] Furthermore, one or more color layers may be dyed, undyed, differently dyed, transparent, and / or opaque, respectively. Further transparent layers may be placed between the color layers. One or more color layers preferably comprise one or more binders, colorants, and / or pigments, in particular optically variable pigments and / or metallic pigments. One or more color layers may further comprise one or more polymethyl methacrylate (=PMMA) based varnishes. One or more reflective layers are preferably opaque and / or transparent. Furthermore, one or more reflective layers may be coated or applied to the entire surface or partially. The HRI layer is particularly a layer having a high refractive index, preferably a refractive index higher than 1.5. One or more HRI layers consist of, or preferably comprise, one or more of the following materials: Examples of materials include Zns, SiO2, TiO2, and / or ZrO2, and / or similar. One or more metallic layers consist of, or preferably comprise, one or more of aluminum, chromium, indium, copper, and / or alloys thereof. Furthermore, one or more reflective layers may have multiple different properties among those described above.

[0079] The above characteristics can be exhibited, in particular, by one or more layers of the mask layer and / or one or more layers of the decorative ply and / or one or more decorative elements. Furthermore, the mask layer and / or decorative ply may be single-layer or multi-layer.

[0080] The mask layer is applied or is applied by means of digital printing, particularly inkjet printing, preferably UV inkjet printing, gravure printing and / or screen printing. The mask layer has a thickness in the range of 1 μm to 100 μm. A mask layer thickness in the range of 1 μm to 50 μm is possible, especially when the mask layer is applied by digital printing, preferably inkjet printing, preferably UV inkjet printing. A mask layer thickness in the range of 1 μm to 30 μm is possible, preferably when the mask layer is applied by means of gravure printing. A mask layer thickness in the range of 5 μm to 100 μm is preferably possible when the mask layer is applied by means of screen printing.

[0081] Furthermore, before and / or after step x3), a step is performed in b2) to generate a visible area in the transfer ply, wherein the visible area is positioned or placed in registration with respect to one or more forming elements, molded bodies and / or decorative plies, the mask layer is partially removed in the visible area and / or the transmittance of the transfer ply is increased in the visible area. Here, the mask layer is preferably deposited first, after processing the mask layer, in the area in which the visible area is to be formed. In particular, the visible area is produced here using a laser. Particularly preferably, after step x3) is performed, in particular the transfer film is back-injection molded with an injection molding compound and after the injection molding compound has cured, the visible area is generated by a laser.

[0082] One or more forming elements, visible areas and / or masking areas, particularly the mask layer, are advantageously positioned or arranged in a transfer film that is precisely registered to one another. In this method, one or more forming elements, visible areas and / or masking areas, particularly the mask layer, are positioned in a precisely registered to one another, particularly during step c) and / or step b1).

[0083] The registration tolerance between one or more forming elements and the visible area and / or masking area, particularly between one or more forming elements and the mask layer, is preferably in the range of 0.05 mm to 1.00 mm, and more preferably in the range of 0.05 mm to 0.2 mm. The registration tolerance between one or more forming elements and the visible area and / or masking area, particularly between one or more forming elements and the mask layer, is particularly about 1.0 mm, preferably about 0.2 mm. Therefore, in particular, the registration tolerance between the molded body and the visible area and / or masking area, particularly between the molded body and the mask layer, is preferably in the range of 0.05 mm to 1.0 mm, more preferably in the range of 0.05 mm to 0.2 mm, and / or can be about 1.0 mm, and more preferably about 0.2 mm.

[0084] Registration tolerances in the range of 0.05 mm to 0.2 mm are particularly achievable when one or more forming elements are applied by a digital printing method, preferably an inkjet printing method, and preferably a UV inkjet printing method. When forming elements are applied by screen printing, registration tolerances in the range of 0.2 mm to 1.0 mm are particularly possible.

[0085] The registration tolerance between the decorative ply and the visible area and / or masking area, particularly between the decorative ply and the mask layer, is preferably in the range of 0.1 mm to 0.4 mm and / or about 0.4 mm. A registration tolerance in the range of 0.1 mm to 0.4 mm is achieved particularly when the mask layer is applied or applied by a gravure printing method, preferably inline. Here, the mask layer is applied inline, particularly by step c). The application of the decorative ply may further be performed inline, by the application of the mask layer, particularly by step c).

[0086] The method steps performed "inline" are, in particular, carried out directly, one after the other, or simultaneously. Here, the carrier ply is preferably unwound from a roll and is not wound up or temporarily stored between steps. The application of decorative ply, mask layer, separation layer, protective layer, and / or primer may also be carried out inline.

[0087] In particular, plastic injection molded products can have a visible area and / or masking area that is aligned with the molded body and decorative ply, especially formed by a mask layer. Therefore, for example, the visible area can be illuminated with a backlight, enabling interaction by further functional parts such as touch sensors, which can be carried out particularly easily, intuitively, or accurately.

[0088] The registration tolerance between one or more forming elements and / or decorative plies and / or visible areas and / or masking areas, particularly mask layers, can be in the range of 0.15 mm to 0.6 mm at most. Thus, the registration tolerance between the molded body and / or decorative plies and / or visible areas and / or masking areas, particularly mask layers, can be in the range of 0.15 mm to 0.6 mm at most. Here, the registration tolerance in particular represents the maximum deviation from the target value of the relative positions of up to two of the listed components.

[0089] The visible area is particularly formed by or consists of one or more voids and / or openings in the mask layer. Furthermore, the visible area may be positioned to coincide with one or more forming elements in at least a partial area, and / or the masking area may not overlap with one or more forming elements. For example, the visible area may be formed by or consists of one or more voids and / or openings in an opaque layer, and the opaque layer may, for example, form the masking area or a part thereof and / or the mask layer. In particular, in a plastic injection molded article or a method for manufacturing the same, the visible area may be formed by or consists of one or more voids and / or openings in the mask layer and / or the masking area may not overlap with the molded article. Here, it is envisioned that one or more voids and / or openings are at least partially filled with the transfer ply. In particular, during the back injection molding of the transfer film with the injection molding compound in step x3), it is envisioned that the transfer ply deforms so that one or more openings and / or voids are at least partially filled with the transfer ply. In particular, this can improve the sharpness of the edges of the molded body and the registration accuracy.

[0090] Here, "coincidence" means that, preferably, when viewed perpendicularly to a plane, preferably the transfer film, and preferably the viewing area, the boundaries of one or more forming elements and viewing areas overlap with each other.

[0091] The transfer ply comprises, or may further comprise, at least one first protective layer for the formation of the outer surface of the transfer ply, particularly facing the carrier ply. Here, the first protective layer may be provided over at least partially and / or the entire surface of the transfer ply. The protective layer is, in particular, a protective varnish layer. The protective layer preferably has a thickness in the range of 2 μm to 10 μm.

[0092] The at least one first protective layer preferably comprises at least one binder selected from the group consisting of polyurethane resin, polyurethane dispersion, acrylic resin, methacrylic resin, phenolic resin, epoxy resin, polyurea, melamine resin, aminoplast, polyester resin, alkyd resin, polyamide resin, vinyl ester resin and mixtures thereof, preferably polyurethane resin, polyurethane dispersion, phenolic resin, epoxy resin, polyurea, melamine resin, aminoplast, polyester resin, alkyd resin, polyamide resin and mixtures thereof.

[0093] In particular, at least one first protective layer that is not yet fully cured preferably comprises at least one binder having free isocyanate groups and / or free groups that react with isocyanate groups, preferably amino groups and / or hydroxyl groups, and / or analogs thereof that are capped in the respective cases.

[0094] A suitable binder is preferably selected from the group consisting of polyurethane resins, polyurethane dispersions, phenolic resins, epoxy resins, polyureas, melamine resins, aminoplasts, polyester resins, alkyd resins, polyamide resins, and mixtures thereof, and more preferably from the group consisting of polyurethane resins, polyurethane dispersions, phenolic resins, polyureas, melamine resins, aminoplasts, polyester resins, alkyd resins, polyamide resins, and mixtures thereof.

[0095] More preferably, the at least one first protective layer, particularly in a state that is not yet fully cured, comprises at least one binder having free isocyanate groups and / or free groups that react with isocyanate groups, preferably amino groups and / or hydroxyl groups and / or their corresponding cap-like analogues, in each case at a rate of at least 15% by weight, preferably 20% to 90% by weight, relative to the total weight of the layer.

[0096] More preferably, at least one binder contained in at least one first protective layer that is not yet fully cured does not have free ethylenically unsaturated groups. In a preferred embodiment, at least one first protective layer that is not yet fully cured comprises or consists of at least one aqueous uncrosslinked or crosslinked polyurethane dispersion having free groups that react with isocyanate groups, more preferably amino groups and / or hydroxyl groups, or at least one uncrosslinked or crosslinked polyurethane resin having isocyanate groups and / or their capped analogs or groups that react with isocyanate groups, more preferably amino groups and / or hydroxyl groups and / or their capped analogs in each case.

[0097] In particular, the protective varnish layer may consist of or be formed from a PMMA-based varnish. Furthermore, the protective varnish layer may comprise or consist of a radiation-curable double-cured varnish. The double-cured varnish is thermally pre-crosslinked or is thermally pre-crosslinked in particular during and / or after application in liquid form in a first step. Furthermore, the double-cured varnish is radically post-crosslinked or is radically post-crosslinked, particularly via high-energy radiation, preferably ultraviolet radiation, in a second step after processing the transfer film, particularly after back-injection molding of the transfer film with an injection molding compound and / or preferably after molding in step x3). This type of double-cured varnish may consist of different polymers or oligomers having unsaturated acrylate groups or methacrylate groups. These functional groups are radically crosslinked or are radically crosslinked with each other in the second step. For thermal pre-crosslinking in the first step, at least two or more alcohol groups are preferably present in these polymers or oligomers. These alcohol groups can be crosslinked with polyfunctional isocyanates or melamine-formaldehyde resins. Preferably, as unsaturated oligomers or polymers, UV raw materials such as epoxy acrylates, polyether acrylates, polyester acrylates and / or acrylic acrylates can be used. As isocyanates, block-type and / or non-block-type representatives based on TDI (toluene-2,4-diisocyanate), HDI (hexamethylene diisocyanate), or IPDI (isophorone diisocyanate) are preferably used. In particular, melamine crosslinking agents comprising or comprising completely etherified and / or imino-type and / or benzoguanamine can be used. The first protective layer can also be formed as a protective varnish consisting of a non-UV crosslinkable PMMA (polymethyl methacrylate) based varnish.

[0098] The first protective layer is applied or is applied by means of gravure printing and / or slot casting, particularly in the form of a protective varnish layer, which is applied to a carrier ply.

[0099] The carrier ply comprises or consists of one of the following materials or a combination of the following materials. Examples of materials include polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), polycarbonate (PC), or biaxially oriented polypropylene (BOPP). The carrier ply has a layer thickness in the range of 12 μm to 100 μm, preferably in the range of 50 μm to 75 μm. A sufficiently thick carrier ply ensures that the transfer film is not damaged, particularly during back injection molding with an injection molding compound, by preventing, for example, the edges of one or more forming elements from strongly pressing through the carrier ply.

[0100] In particular, the carrier ply has a breaking elongation in the range of 110% to 135%. Elongation is, in particular, the quotient of the length of the carrier ply in the stretching direction to the corresponding length of the carrier ply in the unstretched state. Elongation specifically refers to the average elasticity. The carrier ply may further have a tensile strength in the range of 15 kpsi to 50 kpsi, preferably in the range of 27 kpsi to 31 kpsi and / or an elastic modulus in the range of 100 kpsi to 1000 kpsi, preferably in the range of 300 kpsi to 700 kpsi.

[0101] The carrier ply may be uncoated. The carrier ply may have a coating on at least one of its main surfaces, particularly the surface facing the transfer ply, or both of its main surfaces. The coating is formed or made of a polymer in particular. This makes it possible, for example, for a surface of the carrier ply provided with one or more forming elements and / or provided for the application of one or more forming elements to have a coating, in particular to ensure sufficient adhesion of one or more forming elements to the carrier ply. The coating may further serve to protect the transfer ply during transport or back injection molding. The coating of the carrier ply preferably has a layer thickness in the range of 0.2 μm to 5 μm, preferably in the range of 1 μm to 3 μm. The coating of the carrier ply may be formed from one or more of the following components, and may comprise or consist of one or more of the following components: Components include polyacrylates, polymethacrylates, polyurethanes, particularly polyester polyols, polyether polyols, polycarbonate polyols and / or polyacrylate polyols, polyesters, polyethers, polyolefins, epoxy resins and / or derivatives of the listed components.

[0102] The carrier ply coating is crosslinkable or can be crosslinked by the following components in particular: isocyanates, carbodiimides, melamines, aziridines, and / or derivatives of the listed components. The carrier ply coating is preferably radiation-curable. In particular, the coating is radiation-cured or will be radiation-cured. The coating preferably comprises a double-cured varnish. For double-cured varnishes, please refer in particular to the above description.

[0103] Furthermore, the transfer film preferably comprises or comprises a primer layer, particularly to form the outer surface of the transfer ply opposite the carrier ply. The primer layer is particularly an adhesive layer and / or an adhesion promoter layer, and preferably comprises or comprises one or more of the following substances: Examples of substances include PMMA, PVC, polyester, polyurethane, chlorinated polyolefin, polypropylene, epoxy resin, polyurethane polyol combined with inactivated isocyanate, and inorganic fillers. The primer layer particularly has a layer thickness in the range of 1 μm to 50 μm. The primer layer may further be applied or coated by means of inkjet printing, gravure printing, screen printing and / or slot casting.

[0104] The transfer film may also preferably have a separation layer between the carrier ply and the transfer ply. The carrier ply is preferably peelable from the transfer ply by the separation layer.

[0105] In particular, decorative plies can be indirectly positioned on carrier plies, and one or more layers, such as a separation layer, can be placed between the carrier plies and the decorative plies.

[0106] The separation layer preferably has a thickness in the range of 0.1 μm to 50 μm. The separation layer may include one or more wax systems, particularly selected from one or more of the following waxes: carnauba wax, beeswax, montanate ester, polyethylene wax, polypropylene wax, and / or polytetrafluoroethylene wax (polytetrafluoroethylene = PTFE). The separation layer may further include one or more layers of melamine formaldehyde resin crosslinked varnish and / or surface-active substances, particularly silicone.

[0107] The separation layer is preferably applied to or by a carrier ply, preferably by gravure printing and / or slot casting.

[0108] A method for manufacturing a plastic injection molded article may include the step of separating the carrier ply from the transfer ply using a separation layer and / or a separation layer. In a plastic injection molded article, the transfer ply is preferably peeled off from the carrier ply. Therefore, the plastic injection molded article may not contain one or more forming elements of the carrier ply and transfer film.

[0109] Furthermore, the plastic injection-molded article is provided with one or more functional components during or after the back injection molding of the transfer film by the injection molding compound. Here, the one or more functional components are located or positioned on the side of the injection molding compound opposite to the transfer ply.

[0110] One or more functional components preferably include at least one of the following: one or more sensors, in particular one or more touch sensors; one or more lights, in particular one or more displays; one or more LEDs; one or more conductive components; one or more printed circuit boards; and / or a combination thereof.

[0111] With one or more lights, the backlight is incorporated, for example, into a plastic injection molded product. For this purpose, the backlight can be prepared as a separate component consisting of one or more LEDs on a printed circuit board, where one or more LEDs are connected to the printed circuit board, preferably via solder connections. In particular, one or more lights in the form of LEDs, preferably the backlight, are positioned or located preferably directly behind and / or within the viewing area so as to be precisely registered and overlapping the viewing area.

[0112] The plastic injection molded article may further include one or more diffusion layers and / or one or more light guide layers. One or more lights, particularly in the form of LEDs, preferably in the form of backlights, are incorporated into or incorporated into the plastic injection molded article by means of bonding, screwing, ultrasonic welding, soldering, clamping, heat scribing, infrared welding, etc.

[0113] One or more lights, preferably one or more LEDs, are placed in the plastic injection molded article, particularly before the back injection molding of the transfer film in step x3), preferably on the side of the transfer ply opposite to the carrier ply and / or connected to the transfer ply, optionally via the injection molding compound, during the back injection molding. One or more lights, preferably one or more LEDs, may be introduced into or and / or connected to the injection molding compound, particularly after the back injection molding with the plastic compound in step x3).

[0114] One or more sensors, in particular touch sensors, may be placed on or within the transfer film before the transfer film is back-injected with the injection molding compound. Furthermore, one or more sensors, in particular one or more touch sensors, are preferably placed on or positioned on the side of the transfer ply opposite to the carrier ply before the back-injection molding of the transfer film in step x3), and may be connected to or attached to the transfer ply during back-injection molding, optionally via the injection molding compound.

[0115] At least one of the one or more sensors, in particular at least one touch sensor, may preferably not be integrated into the plastic injection molded article as part of and / or as part of the transfer film. This at least one sensor, in particular the touch sensor, may then be further applied to a surface of the injection molded compound, preferably on the opposite side of the transfer ply. Here, the at least one sensor may preferably be bonded or adhered over a wide area of ​​any opening region formed by the shape of the component by the injection molded compound.

[0116] After back injection molding with the plastic compound in step x3), one or more touch sensors may be introduced into the plastic injection molded product, and moreover, they may be connected to and / or fixed to the injection molding compound.

[0117] Furthermore, one or more sensors, in particular one or more touch sensors, can be introduced by bonding, lamination, in-mold labeling (IML), and / or functional foil bonding (FFB).

[0118] During lamination, one or more sensors, preferably touch sensors, are attached to the injection-molded compound, particularly manually and / or mechanically, after the injection-molded compound has cured. For this purpose, an adhesive layer, preferably a transparent adhesive layer, more preferably OCA (OCA = optically transparent adhesive = optically high-quality double-sided adhesive tape and / or adhesive film), is placed on one or more sides of the sensors.

[0119] In the case of IML (In-Mold Labeling), one or more sensors, particularly touch sensors, are suitably positioned between the mold halves of the injection molding machine, preferably manually and / or mechanically, for example by a robot, before the injection of the injection molding compound. A primer, which ensures adhesion to the injection molding compound, is placed on or pre-placed on the back surface of one or more sensors, preferably touch sensors. By the injection of the injection molding material, one or more sensors, particularly touch sensors, are now connected to the injection molding material. Furthermore, it is possible to back-injection mold a transfer film simultaneously with the injection of the injection molding compound. It is possible to decorate the front surface of the plastic injection molded product with a transfer film and simultaneously apply one or more sensors, particularly touch sensors, to the back surface of the plastic injection molded product.

[0120] In the case of FFB (Functional Foil Bonding), one or more sensors (9), particularly touch sensors, are preferably stamped onto the plastic injection molded product at high temperature and pressure by a vertical stamping machine or roll-off machine. For this purpose, one or more sensors, particularly touch sensors, preferably have a primer on the back to ensure adhesion to the plastic injection molded product.

[0121] One or more functional components and one or more forming elements, molded articles, decorative plies, viewing areas and / or masking areas, preferably mask layers, are preferably registered or regulated with respect to each other. The registration tolerance between one or more functional components and one or more forming elements, molded articles, decorative plies, viewing areas and / or masking areas, particularly mask layers, may further be about 0.3 mm, particularly about 0.2 mm. Here, one or more functional components are particularly one or more sensors, preferably one or more touch sensors and / or one or more illuminations, particularly one or more LEDs and / or one or more displays. Even more preferably, the registration tolerance between the molded article and one or more functional components, particularly one or more sensors, preferably touch sensors and / or one or more illuminations, preferably displays and / or LEDs, is at most 0.3 mm, particularly using IML and / or lamination. More preferably, the registration tolerance between the decorative ply and one or more functional components, in particular one or more sensors, preferably touch sensors and / or one or more lights, preferably displays and / or LEDs, is at most 0.2 mm, especially with the use of force feedback.

[0122] In order to carry out step c) and / or in step c), the position in which one or more forming elements are applied to the carrier ply is set depending on the position of one or more registration marks. For this purpose, one or more registration marks are detected in particular by at least one sensor, and the position of one or more layers of the carrier ply and / or related decorative ply, in particular one or more decorative elements, a visible area, a masking area, in particular a mask layer, a first protective layer and / or a primer layer is detected by one or more registration marks.

[0123] For one or more layers of the decorative ply, in particular all layers, in particular one or more decorative elements, a visible area, a masking area, in particular the mask layer, the first protective layer and / or primer layer, corresponding registration marks assigned to each layer are preferably applied or generated during the application of each layer. Such registration marks are, for example, cross-shaped, circular and / or triangular. The registration marks are preferably applied in each case to at least one outer and / or one edge of the transfer film so that they can be read, in particular by at least one sensor. At least a portion of one or more motifs of the decorative ply and / or mask layer can also be used as registration marks. In particular, in a subsequent step, one or more forming elements and preferably associated registration marks are applied to the face of the carrier ply opposite to the transfer ply.

[0124] While providing one or more functional components to a plastic injection molded product, the position of one or more functional components may be aligned with or matched with the assigned registration marks of one or more layers of a decorative ply, in particular one or more decorative elements, a visible area, a masking area, in particular a mask layer, a first protective layer, a primer layer and / or one or more forming elements.

[0125] In particular, when one or more touch sensors are applied, printed and / or sprayed sensor outlines are used. The printed and / or sprayed sensor outlines are markings printed and / or sprayed on the respective transfer film or present in the injection molded product due to the mold design. The printed and / or sprayed sensor outlines are preferably positioned or aligned with one or more registration marks of one or more forming elements, decorative plies, viewing areas and / or masking areas, particularly the mask layer. Each touch sensor is connected to the plastic injection molded product and its components in a registerable manner, preferably by the printed and / or sprayed sensor outlines, particularly by the corresponding mold design and registration marks.

[0126] A method for manufacturing a plastic injection molded article may further include the step of at least partially immersing the transfer ply and / or injection molding compound with a polyurethane-containing composition and / or polyurea-containing composition, particularly after the separation of the carrier ply in step x4), in order to form at least one second protective layer. Thus, on the outer surface, preferably on the transfer ply, the plastic injection molded article may have at least one second protective layer formed of a polyurethane-containing composition and / or polyurea-containing composition.

[0127] Here, at least the molded body and / or the regions constituting the molded body and / or the motifs formed by the molded body are flooded, or preferably flooded. In particular, the plastic injection molded body is tactilely visible but tactilely smooth to the touch. The combination of the molded body and polyurethane flooding and / or polyurea flooding makes it possible to impart a specific optical depth effect to the plastic injection molded product at this location.

[0128] At least one first protective layer and at least one second protective layer are advantageously matched to each other. In relation to polyurethane flooding and / or polyurea flooding, and particularly in relation to IMD methods, a distinction is made between flooding and open flooding. Here, polyurethane flooding and / or polyurea flooding are carried out particularly in relation to IMD methods and therefore preferably in a closed system.

[0129] Flooding with a polyurethane-containing composition is preferably performed during or immediately after step x3) in relation to back injection molding of the transfer ply with an injection molding compound, and therefore preferably in a closed system, particularly with the mold half of the injection molding machine closed. Preferably fluid polyurethane reaction mixtures used in polyurethane-containing compositions preferably consist of polyurethane precursors (2C PUR system, PUR = polyurethane) and / or mixtures thereof, which preferably also have free reactive groups, preferably isocyanate groups or groups that react with isocyanate groups, preferably polyol groups and / or corresponding capped reactive groups in the range of 30°C to 180°C.

[0130] During the curing, preferably complete curing, of at least one first protective layer and / or at least one second protective layer particularly applied thereto of the transfer ply, free isocyanate groups contained in, for example, the at least one first protective layer of the transfer ply can react with free groups that react with isocyanate groups of a preferably fluid two-component polyurethane-containing composition used to produce the at least one second protective layer. In each case, the adhesion of the at least one second protective layer to the at least one first protective layer of the transfer ply is thereby preferably significantly improved after curing.

[0131] In particular, the above-described reaction mixture containing at least one fluid polyurethane can be applied to at least one first protective layer of a transfer ply, preferably as a composition comprising a polyurethane precursor (2C PUR system), and especially as a mixture of at least one of the above compounds having two or more isocyanate groups and at least one of the above compounds having two or more groups reactive with isocyanate groups. Preferably, the at least one compound having two or more isocyanate groups or the at least one compound having two or more groups reactive with isocyanate groups can be used in molar excess. More preferably, one preferably fluid polyurethane-containing reaction mixture used to produce at least one second protective layer is anhydrous.

[0132] When a two-component polyurethane system is used, the polyurethane precursors, preferably the polyol-containing component and the polyisocyanate-containing component, are preferably stored separately and combined in the mixing head only when particularly necessary. The reaction heat 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.

[0133] Flooding with a polyurethane-containing composition can also be carried out in relation to open flooding. In open flooding, the surface tension of the solvent-free or solvent-containing, preferably fluid, polyurethane-containing reaction mixture used to produce at least one second protective layer is particularly utilized in the outer edge region of the component to be flooded. In particular, here, at least one second protective layer is preferably immersed without having a shape that gives the component, especially the plastic injection molded product, a mold contour. Curing is preferably carried out by properly storing the immersed plastic injection molded product at a temperature in the range of 20°C to 100°C for a period of preferably 2 seconds to 60 seconds.

[0134] In particular, the preferably fluid polyurea reaction mixture used in the polyurea-containing composition preferably consists of a polyurea precursor (2CPUA system, PUA = polyurea) and / or a mixture thereof, which preferably also have free reactive groups, preferably isocyanate groups or groups that react with isocyanate groups, preferably (poly)amine groups and / or, in each case, corresponding capped reactive groups that release the corresponding reactive groups again at temperatures in the range of 30°C to 180°C. During the curing of at least one first protective layer, preferably fully cured, for example, free isocyanate groups contained in at least one first protective layer can react with free groups that react with isocyanate groups of the preferably fluid two-component polyurea-containing composition used to produce at least one second protective layer. In each case, the adhesion of the at least one second protective layer to at least one first protective layer of the transfer ply is thereby preferably significantly improved after curing.

[0135] The above-described preferably fluid polyurea-containing reaction mixture can be applied to at least one first protective layer of a transfer ply, particularly as a composition containing a polyurea precursor (2C PUA system), and more preferably as a mixture of at least one of the above compounds having two or more isocyanate groups and at least one of the above compounds having two or more groups reactive with isocyanate groups, in molar excess, at least one compound having two or more isocyanate groups and at least two compounds having two or more groups reactive with isocyanate groups can be used.

[0136] More preferably, one preferably fluid polyurea-containing reaction mixture used to produce at least one second protective layer is anhydrous. When a two-component polyurea system is used, the polyurea precursors, preferably the (poly)amine-containing component and / or the polyisocyanate-containing component, are preferably stored separately and combined in the mixing head only when necessary. The reaction heat formed during the reaction of the polyurea precursors results in heating to a temperature of preferably 60°C to 180°C, preferably 80°C to 120°C.

[0137] The present invention will be described below illustratively with reference to several embodiments using the accompanying drawings. [Brief explanation of the drawing]

[0138] [Figure 1] Figure 1 schematically shows the method for manufacturing a transfer film. [Figure 2] Figure 2 schematically shows the manufacturing method of a plastic injection molded product. [Figure 3a] Figure 3a schematically shows the transfer film and the plastic injection molded product. [Figure 3b] Figure 3b schematically shows the transfer film and the plastic injection molded product. [Figure 3c] Figure 3c schematically shows the transfer film and the plastic injection molded product. [Figure 4a] Figure 4a schematically shows the transfer film and the plastic injection molded product. [Figure 4b] Figure 4b schematically shows the transfer film and the plastic injection molded product. [Figure 4c] Figure 4c schematically shows the transfer film and the plastic injection molded product. [Figure 5a] Figure 5a schematically shows the transfer film and the plastic injection molded product. [Figure 5b] Figure 5b schematically shows the transfer film and the plastic injection molded product. [Figure 5c] Figure 5c schematically shows the transfer film and the plastic injection molded product. [Figure 6a] Figure 6a schematically shows the transfer film and the plastic injection molded product. [Figure 6b] Figure 6b schematically shows the transfer film and the plastic injection molded product. [Figure 6c] Figure 6c schematically shows the transfer film and the plastic injection molded product. [Figure 7a] Figure 7a schematically shows the transfer film and the plastic injection molded product. [Figure 7b] Figure 7b schematically shows the transfer film and the plastic injection molded product. [Figure 7c] Figure 7c schematically shows the transfer film and the plastic injection molded product. [Figure 8] Figure 8 schematically shows a plastic injection molded product. [Figure 9] Figure 9 schematically shows the transfer film. [Figure 10a] Figure 10a schematically shows the positive forming elements before and after back injection molding. [Figure 10b] Figure 10b schematically shows the positive forming elements before and after back injection molding. [Figure 11a] Figure 11a schematically shows the negative forming elements before and after back injection molding. [Figure 11b] Figure 11b schematically shows the negative forming elements before and after back injection molding. [Modes for carrying out the invention]

[0139] Figure 1 schematically shows a method for manufacturing a transfer film. This transfer film is in particular an IMD transfer film. In this method, the following steps are performed in a predetermined order: a) preparing a carrier ply 101; b) preparing a transfer ply 102 consisting of decorative plies, wherein the transfer ply is placed on or positioned on the carrier ply; and c) applying one or more forming elements 103 to the carrier ply, wherein the one or more forming elements have a three-dimensional shape and are applied in a manner that is precisely aligned with the decorative ply.

[0140] Figure 2 schematically illustrates a method for manufacturing a plastic injection molded article coated with a transfer film. The transfer film is in particular an IMD transfer film. Here, the transfer film may be a transfer film as described in other figures and / or may be manufactured in the manner described therein. A method for manufacturing a plastic injection molded article comprises, in a predetermined order, at least x1) a step of preparing a transfer film 201, wherein the transfer film has a carrier ply and a transfer ply comprising a decorative ply, and the transfer ply is placed on or positioned on the carrier ply; x2) a step of preparing one or more forming elements 202 on the carrier ply, wherein one or more forming elements have a molded body and are applied or applied in a manner precisely aligned with the decorative ply; and x3) a step of back-injection molding the transfer film 203 with an injection molding compound, wherein the action of the injection molding compound on the transfer film causes a three-dimensional molded body of one or more forming elements to be introduced into the transfer ply in a manner aligned with the decorative ply.

[0141] Figure 3a schematically shows the transfer film 1. The transfer film 1 is in particular an IMD transfer film. The transfer film 1 is preferably manufactured as described in relation to Figure 1, for example. The transfer film 1 has a carrier ply 3 and a transfer ply 2, the transfer ply 2 comprises a decorative ply 21 and is positioned on the carrier ply 3, and the transfer film 1 further has a forming element 40, the forming element 40 is positioned on the carrier ply3 It is applied on top and aligned with the decorative ply 21. It is also possible to arrange multiple forming elements 40 on the carrier ply 3.

[0142] During the back injection molding 203 of the transfer film 1 with the injection molding compound, one or more forming elements 40 remain stationary relative to the mold half of the injection molding machine. The injection molding compound can adhere to the exposed surface of the transfer film 1, particularly the primer, on the surface of the transfer film 1 opposite to the one or more forming elements 40. After the back injection molding 203, a plastic injection molded article 10 can be obtained, as shown as an example in Figure 3b or Figure 3c.

[0143] Figure 3b schematically shows a plastic injection molded article 10. The plastic injection molded article 10 is manufactured as described, for example, in relation to one of Figures 1, 2, and 3a. The plastic injection molded article 10 comprises an injection molding compound 5 and a transfer ply 2 of a transfer film 1 back-injection molded with the injection molding compound 5. The transfer film 1 is in particular an IMD transfer film and is preferably manufactured as described in relation to Figure 1 and / or Figure 3a and / or as described in relation to Figure 1 and / or Figure 3a. 2 It has a three-dimensional molded body 41 equipped with decorative plies 21. Here, the molded body 41 is introduced with precise registration relative to the decorative plies 21.

[0144] For example, the visualization of regions such as regions 71, 72, 81, and 82 is performed particularly on the main surface of each layer or transfer film 1, preferably from right to left or vice versa in Figure 3. Preferably, when viewed perpendicularly on the plane and / or main surface of the transfer film 1 or each layer, the region, particularly the partial region, preferably comprises all parts of the transfer film 1 and / or plastic injection molded product 10 that overlap this plane and / or main surface.

[0145] The molded body 41 of the plastic injection molded article is formed by, or specifically formed by, one or more forming elements 40. Therefore, the molded body 41 forms a shape complementary to the three-dimensional shape of, in particular, one or more forming elements 40. As shown as an example in Figures 3b and 3c, one or more forming elements 40 can preferably be removed from the plastic injection molded article 10 together with the carrier ply 3. Furthermore, it is assumed that at least the carrier ply 3 and optionally one or more forming elements 40 and / or their residues are still adhering to the plastic injection molded article 10. This ensures that the surface of the plastic injection molded article 10 is protected, particularly during, for example, transportation and / or storage.

[0146] In areas where no forming elements are placed, during the back injection molding 203 of the transfer film by the injection molding compound 5 in step x3), the carrier ply 3 is pressed against the mold half in at least the area, thereby Decoration A molded body 41 of one or more forming elements 40 is formed in the ply 21, and in particular, the molded body 41 enables tactile and / or depth effects.

[0147] One or more forming elements 40 have a three-dimensional shape, in particular, compared with the carrier ply 3 and the transfer ply 2, so that both the height and other spatial dimensions of the forming elements 40 contribute significantly to the design of the forming elements 40, and in particular, the height of the molded body 41 of the plastic injection molded product 10 depends on the design of the forming elements 40. The three-dimensional shape comprises, for example, a two-dimensional motif, and the two-dimensional motif is provided or preferably provided with a spatial structure, for example, by increasing the thickness or height of the two-dimensional motif in a particularly desired manner along the horizontal direction.

[0148] The carrier ply 3 is preferably a PET carrier ply. For further possible materials and optional coatings of the carrier ply 3, please refer in particular to the description above. The carrier ply 3 may have a layer thickness of, for example, 75 μm, which is particularly the case for use in the automotive sector. Alternatively, the carrier ply 3 may have a layer thickness of 50 μm, for example for the manufacture of laptop sleeves. The carrier ply 3 may particularly have a break elongation in the range of 110% to 135%. The degree of elongation is, in particular, the quotient of the length of the carrier ply in the elongation direction to the corresponding length of the carrier ply in the un-elongated state. The degree of elongation particularly means the average stretchability. For example, the carrier ply may particularly have an average stretchability of 25%. Here, the direction of the average stretchability is, in particular, based on the X direction and / or the Y direction. Here, the X direction is preferably shown along the horizontal direction, for example in Figure 3a, and / or the Y direction is shown along the vertical direction, for example in Figure 3a, so that the X direction is shown along the vertical direction, for example in Figure 3a. The carrier ply may have a tensile strength in the range of 15 kpsi to 50 kpsi, preferably in the range of 27 kpsi to 31 kpsi, and / or an elastic modulus in the range of 100 kpsi to 1000 kpsi, preferably in the range of 300 kpsi to 700 kpsi.

[0149] During step b), the preparation step may further include the application of the transfer ply, which comprises at least the decorative ply 21, to the carrier ply 3. One or more forming elements 40 are preferably applied partially to the carrier ply 3, and it is also possible that one or more forming elements 40 are applied to the partial region with a greater thickness than other partial regions. The application of one or more forming elements 40 to the carrier ply 3 may be done directly to the carrier ply 3 or indirectly through one or more further layers. The height or thickness is measured, for example, in Figure 3b, in particular, along the horizontal line.

[0150] Preferably, the transfer ply 2 is first applied to the carrier ply 3, and then one or more forming elements 40 are applied in a manner that is precisely aligned with the carrier ply 3, at least with respect to the decorative ply 21, and especially with respect to the side of the carrier ply 3 opposite to the transfer ply 2.

[0151] One or more first layers of one or more forming elements 40 contain or consist of digital printing ink. The digital printing ink is preferably an inkjet printing ink, and more preferably a UV inkjet printing ink. In particular, in the method for manufacturing the transfer film 1, in step c), one or more first layers of one or more forming elements 40 are applied using a digital printing method, preferably an inkjet printing method, and more preferably a UV inkjet printing method. One or more layers of one or more forming elements can be crosslinked or crosslinked, particularly by radiation, preferably UV radiation. The digital printing method makes it possible to achieve small batch sizes, particularly single batch sizes. Furthermore, the digital printing method, particularly the UV inkjet printing method, improves registration tolerances. In the digital printing method, preferably one or more layers are printed with one or more printing inks selected from CMYK inks (CMYK = cyan, magenta, yellow, black).

[0152] Furthermore, in particular in step c), one or more layers of one or more forming elements 40 may be applied or may be applied by gravure printing and / or screen printing means. Thus, one or more layers of one or more forming elements 40 of the transfer film may consist of gravure printing ink and / or screen printing ink.

[0153] In particular, one or more forming elements 40 can be single-layer or multi-layer. In step c) and / or in the transfer film 1, two or more layers of one or more forming elements 40 are preferably applied overlapping each other, and / or one or more forming elements 40 are at least partially applied by means of 3D printing. Furthermore, some layers of one or more forming elements 40 are applied or applied by the same printing method, and / or some layers are applied or applied by different printing methods.

[0154] In particular, at least two different printing methods can be used for the application of one or more forming elements 40. Preferably, one or more first layers of one or more forming elements 40 can be applied by a printing method other than a digital printing method, for example, a screen printing method. Large, undifferentiated surface areas of one or more forming elements are applied in particular using this method. At least one layer of one or more forming elements 40 that is applied last in step c) can be applied using a digital printing method, preferably an inkjet printing method, preferably a UV inkjet printing method. In particular, at least one layer of one or more forming elements 40 that forms the outer surface of the transfer film 1 comprises or consists of a digital printing ink, preferably an inkjet printing ink, preferably a UV inkjet printing ink. Spatial separation of the application of different layers can be achieved here, for example, in step c). Preferably, individualization in the form of small surface areas is possible here, for example, particularly before and / or after transportation and storage, and particularly immediately before and / or at the time of manufacture of the plastic injection molded article 10.

[0155] Furthermore, by varying the heights of one or more forming elements 40, it is possible to produce or manufacture molded bodies 41 with varying heights in the plastic injection molded article 10. This is preferably achieved by the number of overlapping printing ink and / or forming element layers, individual ink droplet size, UV curing parameters, applied weight of individual printing inks, and / or combinations thereof, particularly by using appropriate settings in the digital printing method. Thus, the transfer film 1 may have one or more forming elements 40 of varying heights and / or the plastic injection molded article 10 may have molded bodies 41 with varying heights and / or depths, particularly including partial regions of raised areas 82 with varying heights and / or partial regions of recessed areas 81 with varying heights.

[0156] The layer thickness of one or more forming elements 40 applied by digital printing is preferably in the range of 0.5 μm to 50 μm, and particularly in the range of 1 μm to 25 μm.

[0157] It is further possible that at least one of the forming elements 40 printed by digital printing has a layer thickness of 1 μm to 200 μm. In particular, the layer thickness of at least one of the forming elements 40 is in the range of 1 μm to 200 μm. Here, some, preferably all, layers of at least one forming element are applied by means of digital printing and overlap in particular.

[0158] The layers of one or more forming elements 40 printed by gravure printing may have a layer thickness in the range of 1 μm to 25 μm, and / or the layers of one or more forming elements 40 printed by screen printing may have a layer thickness in the range of 1 μm to 100 μm.

[0159] The method comprises the step of irradiating one or more forming elements 40 in particular by UV irradiation, and one or more irradiation steps are performed, which preferably include steps performed after and / or during step c), in particular before at least one layer of one or more forming elements is applied in overlap with at least one other layer of two or more layers of one or more forming elements. The overlapping layers are cured in between so as not to move, for example, and it is conceivable that a higher height-to-width ratio can be achieved therein.

[0160] For details regarding the composition of one or more forming elements 40, please refer specifically to the description above.

[0161] In particular, during the back injection molding of the transfer film 1 with the injection molding compound 5 in step x3), a recessed region 81 is generated in the transfer ply 2, which is preferably formed by the molded body 41. Thus, the recessed region 81 includes, in particular, a positive image of one or more forming elements 40. During the back injection molding of the transfer film 1 with the injection molding compound 5 in step x3), a raised region 82 is further possible to be formed in the transfer ply 2, which therefore includes, in particular, a negative image of one or more forming elements 40. The raised region 82 and / or the recessed region 81 can be a continuous region, or alternatively or additionally, composed of one or more separate subregions. Thus, the raised region 82, the recessed region 81 and / or the molded body 41 can form one or more motifs, which are particularly complementary to one or more motifs of one or more forming elements 40. The raised region 82 is provided in particular when no forming elements 40 are present on the transfer film 1 and / or when the carrier ply 3 deforms in the direction of the carrier ply 3 during back injection molding with the injection molding compound 5. The recessed region 81 is provided in particular when one or more forming elements 40 are present on the transfer film 1 and / or when the transfer ply 2 does not move or does not substantially move in the direction of the carrier ply 3 during back injection molding with the injection molding compound 5.

[0162] In particular, when one or more forming elements 40 are applied or applied by UV digital printing, the raised areas 82 and / or recessed areas 81 can have a minimum line width and / or minimum dot size in the range of 0.025 mm to 0.1 mm. For example, if the recessed area 81 has a circular footprint and the cross section is at its center, in Figures 3b and 3c, the dot size is the distance from the dashed line marking from the top to the bottom of the area 81. If the recessed area 81 is a line and extends in the line of sight direction in Figures 3b and 3c, the line width is preferably the distance from the dashed line marking from the top to the bottom of the area 81 in the shown cross-sectional plane.

[0163] In particular, when one or more forming elements 40 are applied by digital printing, the recessed area 81 may have a minimum line width and / or minimum dot size greater than 0.025 mm, and / or the raised area 82 may have a minimum line width and / or minimum dot size greater than 0.040 mm. Furthermore, when one or more forming elements 40 are applied by gravure printing, the recessed area 81 may have a minimum line width and / or minimum dot size greater than 0.075 mm, and / or the raised area 82 may have a minimum line width and / or minimum dot size greater than 0.12 mm. In particular, when one or more forming elements 40 are applied by screen printing, the recessed area 81 may have a minimum line width and / or minimum dot size of 0.10 mm or more, and / or the raised area 82 may have a minimum line width and / or minimum dot size of 0.15 mm or more.

[0164] For example, in the case of a generated tactile surface area of ​​approximately 0.5 cm × 0.01 cm, therefore, no tangible difference and / or difference that can be felt with a fingertip is discernible between the positive forming element 40 and the negative forming element 40. A positive forming element 40 refers to an isolated forming element 40 that, when viewed in cross-section, generates a recessed region 81 within the carrier ply 3 after back injection molding. Such positive forming elements 40 are shown in Figures 10a and 10b. Here, Figure 10a shows the positive forming element 40 before back injection molding, and Figure 10b shows the positive forming element 40 after back injection molding. A negative forming element 40 refers to one or more full-surface forming elements that, when viewed in cross-section, generate a raised region 82 of the carrier ply 3 after back injection molding. Such negative forming elements 40 are shown in Figures 11a and 11b. Here, Figure 11a shows the negative forming element before back injection molding, and Figure 11b shows the negative forming element after back injection molding. As shown in Figures 10b and 11b, after back injection molding, the forming element 40 is preferably coplanar or substantially coplanar with the surface of the carrier ply, and as a result, no tangible difference and / or difference that can be felt with a fingertip can be detected between the positive and negative forming elements 40.

[0165] In particular, one or more forming elements 40 have higher dimensional stability than the carrier ply 3 and / or the transfer ply 2, preferably more than at least one layer of the transfer ply 2. High dimensional stability means, in particular, high resistance to deformation of the transfer film 1 during back injection molding 203 by the injection molding compound 5.

[0166] It is preferable that one or more forming elements 40 are mechanically stable and / or have mechanical stability, especially in the case of back injection molding with the injection molding compound 5, preferably in the IMD injection molding process, and therefore especially in step x3). Mechanical stability here means, in particular, the stability of one or more forming elements 40 against loads acting through the injection molding compound 5, especially the stability during back injection molding 203 of the transfer film 1 using the injection molding compound 5. In other words, it is preferable that one or more forming elements 40 are sufficiently hard and carrier to withstand the high pressure generated, especially during back injection molding 203. ply To create a sufficiently strong connection with 3. For this purpose, one or more forming elements 40 preferably have a glass transition temperature above 200°C. It is further possible that one or more forming elements 40 have substantially constant compressive strength up to a temperature of 200°C. Especially when the transfer film 1 is exposed to pressure and / or heat, the transfer ply 2 The deformation, particularly the deformation when the transfer film 1 is back-injection molded with the injection molding compound, is thus guaranteed, and in particular, the high sharpness of the edges of the molded body 41 is possible.

[0167] When comparing the heights of one or more forming elements 40 before and after back injection molding 203 of the transfer film 1 with injection molding compound 5, it is conceivable to determine the mechanical stability by referring to the difference in height. The height of one or more forming elements 40 after back injection molding 203 of the transfer film 1 with injection molding compound 5 corresponds to the height of the molded body 41 of the plastic injection molded product 10.

[0168] The molded body 41 preferably has a height in the range of 90% to 100% of the height of one or more forming elements 40 of the transfer film 1 prior to back injection molding 203 with the injection molding compound 5. The temperature generated in the injection mold during back injection molding, particularly the temperature of the injection molding compound, is or can be in the range of 150°C to 500°C, particularly in the range of 200°C to 300°C. The pressure generated in the injection mold during back injection molding, particularly the internal pressure of the injection mold, is or can be in the range of 300 bar to 1000 bar, particularly in the range of 400 bar to 800 bar.

[0169] For example, if the carrier ply 3 has a layer thickness of 50 μm and is preferably made of PET, the molded body 41 after back injection molding 203 of the injection-molded compound 5 can have a height of 90% of the height of one or more forming elements 40 before back injection molding 203 of the injection-molded compound 5. Alternatively, the molded body 41 after back injection molding of the injection-molded compound can have a height of 100% of the height of one or more forming elements 40 before back injection molding of the transfer film 1 by the injection-molded compound 5, especially if the carrier ply 3 has a layer thickness of 75 μm and is preferably made of PET. In particular, if the layer thickness of the carrier ply 3, preferably made of PET, is at least 75 μm, the height of one or more forming elements 40 is maintained before back injection molding 203 of the transfer film 1 by the injection-molded compound 5, or is just higher than after back injection molding.

[0170] The height of the molded body 41 is preferably determined based on the difference in height between the outer surface of the transfer ply 2 in the recessed region 81 and the adjacent outer surface of the transfer ply 2 in the raised region 82 on the plastic injection-molded product 10. The height of one or more forming elements 40 is measured in particular before the back injection molding 203 of the transfer film 1. The height of the molded body 41, and / or the height of one or more forming elements 40, and / or the line width and / or dot size are measured in particular by a scanning electron microscope (SEM).

[0171] In the method for manufacturing the plastic injection molded product 10, the height of the molded body 41 of the plastic injection molded product 10 that is particularly achieved is preferably in the range of 1 μm to 200 μm.

[0172] Preferably, one or more forming elements 40 are positioned in the transfer film 1 or in step c) to be registered with respect to the decorative ply 21 in at least two different directions. In Figures 3a, 3b and 3c, one direction is shown, for example, along the viewing direction, and the other direction is shown along the vertical line. In a method for manufacturing the transfer film 1, it is possible, for example, to apply one or more forming elements 40 to the decorative ply 21 in a precisely registered manner both in the continuous direction of the carrier ply 3 and in a direction transverse to the continuous direction of the carrier ply 3, in particular to apply them in a precisely registered manner to separate decorative elements of the decorative ply 21, for example, separate motifs. It is particularly possible that at least one of the one or more forming elements 40 is positioned or positioned to be registered with respect to at least one of the one or more decorative elements, in each case, and at least one decorative element preferably forms an individual motif. The individual motif is not an endless motif and / or has a visible boundary in two different directions in the transfer film 1 and / or the plastic injection molded article 10. Therefore, the molded body 41 or at least a portion of the molded body 41 is positioned or can be positioned in a manner that is alignable with at least one decorative element of one or more decorative elements.

[0173] The registration tolerance between one or more forming elements 40 and the decorative ply is preferably in the range of 0.05 mm to 1.0 mm, and more preferably in the range of 0.05 mm to 0.2 mm. The registration tolerance between one or more forming elements 40 and the decorative ply 21 is particularly about 1.0 mm, preferably about 0.2 mm. Therefore, the registration tolerance between the molded body 41 and the decorative ply 21 is preferably in the range of 0.05 mm to 1.0 mm, more preferably in the range of 0.05 mm to 0.2 mm, and / or can be up to 1.0 mm, preferably up to 0.2 mm.

[0174] A registration tolerance in the range of 0.05 mm to 0.2 mm is particularly achievable when one or more forming elements 40 are applied by a digital printing method, preferably inkjet printing, and preferably UV inkjet printing. When one or more forming elements 40 are applied by screen printing, a registration tolerance in the range of 0.2 mm to 1.0 mm is particularly achievable.

[0175] Figure 3c shows the plastic injection molded product 10 shown in Figure 3b, except that the plastic injection molded product 10 further has a functional component 6. The functional component 6 is preferably a molded body 41 It is positioned with proper alignment relative to the decorative ply 21.

[0176] The transfer film 1 and / or the plastic injection molded article 10 may further have a viewing area 71 and / or a masking area 72. The viewing area 71 is provided to allow for the placement of further components that are visible at least occasionally through the transfer ply 2, particularly on the side of the plastic injection molded article 10 on the side of the injection molding compound 5 opposite the transfer ply 2, and the masking area 72 is provided so that further components placed on the side of the plastic injection molded article 10 on the side of the injection molding compound 5 opposite the transfer ply 2 are hidden in the masking area so as not to be seen through the transfer ply 2. For this purpose, the method preferably includes step b1) transfer ply 2The process includes the step of preparing and / or manufacturing a masking area 72 and / or a visibility area 71.

[0177] The visible area 71 preferably has a transmittance particularly higher than that of the masking area 72, and preferably has a transmittance at least 10% and / or in the range of 10% to 100% higher than that of the masking area. The visible area 71 preferably has a transmittance of 50% or more, particularly 75% or more. The masking area preferably has a transmittance of less than 50%, particularly less than 20%, and preferably less than 5%. The transmittance is particularly related to electromagnetic waves, and preferably has wavelengths visible to the human eye. In the visible area, the transfer plan 2 Preferably, it is transparent to light visible to the human eye. In the masking region 72, the transfer primer 2 It is opaque, especially to light visible to the human eye.

[0178] Furthermore, in or after step b1), the visible area 71 is a transfer plan 2 It is also possible to generate it, especially in the mask layer.

[0179] As shown in Figure 3c as an example, the plastic injection molded article 10 is equipped with one or more functional components 6, in particular, during or after the back injection molding 203 of the transfer film 1 by the injection molding compound 5. Here, one or more functional components 6 are located or positioned on the side of the injection molding compound 5 opposite to the transfer ply 2. The one or more functional components preferably have at least one of the following components: one or more sensors, in particular one or more touch sensors, one or more lights, in particular one or more displays, one or more LEDs, one or more light guide components, one or more printed circuit boards and / or combinations thereof.

[0180] The backlight is incorporated into the plastic injection molded product 10 by one or more lights. The backlight consists of one or more LEDs on a printed circuit board for this purpose. It is possible to prepare these as individual components, and one or more LEDs are preferably connected to a printed circuit board via solder connections. One or more illuminations, preferably in the form of LEDs, preferably backlights, are preferably positioned or arranged directly behind the viewing area 71 and / or overlapping the viewing area 71 in a manner specifically aligned with the viewing area 71. The plastic injection molded article 10 may further include one or more diffusion layers and / or one or more light guide layers. One or more illuminations, particularly in the form of LEDs, preferably in the form of backlights, are preferably integrated or integrated into the plastic injection molded article by bonding, screwing, ultrasonic welding, soldering, clamping, heat riveting, or infrared welding.

[0181] One or more lights, preferably one or more LEDs, are preferably positioned in the plastic injection molded article 10 or, in particular, before the back injection molding 203 of the transfer film 1 in step x3) on the side of the transfer ply 2 opposite to the carrier ply 3 and / or connected to the transfer ply 2 during the back injection molding 203, and optionally connected to the transfer ply 2 via the injection molding compound 5. One or more lights, preferably one or more LEDs, may further be introduced into or introduced into and / or connected to the injection molding compound in the plastic injection molded article, in particular, after the back injection molding of the plastic compound in step x3).

[0182] Before the transfer film 1 is back-injection molded with the injection molding compound 5, one or more sensors, in particular touch sensors, may be placed on or within the transfer film 1. Furthermore, one or more sensors, in particular touch sensors, may be placed or positioned on the side of the transfer ply 2 opposite to the carrier ply 3 before the back-injection molding 203 of the transfer film 1 in step x3), and optionally into the transfer ply 2 via the injection molding compound 5 during the back-injection molding 203. 2 It is connected or can be connected.

[0183] At least one of the one or more sensors, in particular at least one touch sensor, may preferably not be part of the transfer film 1 and / or not be integrated into the plastic injection molded product 10 as part of the transfer film 1. This at least one sensor, in particular the touch sensor, may then preferably be applied to the side of the injection molded compound 5 opposite to the transfer ply 2. Here, the at least one sensor may preferably be bonded or adhered to a wide area of ​​any opening region formed by the shape of the component by the injection molded compound 5.

[0184] After back injection molding 203 with the injection molding compound 5 in step x3), one or more touch sensors may be introduced into the plastic injection molded product 10, and in particular, they may be connected to and / or fixed to the injection molding compound 5.

[0185] Furthermore, one or more sensors, in particular one or more touch sensors, can be introduced by means of adhesion, lamination, in-mold labeling (IML), and / or functional foil bonding (FFB). For lamination, IML, and FFB methods, please refer specifically to the above description.

[0186] One or more functional components 6 are preferably mounted to the molded body 41 and the decorative ply 21 with precise alignment.

[0187] Figure 4a schematically shows a top view of a plastic injection molded article 10 coated with transfer film 1 and / or transfer ply 2 of transfer film 1. Figures 4b and 4c schematically show a cross-section of the transfer film 1 or the plastic injection molded article 10 along the cross-sectional line AA shown in Figure 4a. Here, the transfer film 1 is particularly capable of being the transfer film 1 described in relation to Figure 3 and / or being manufactured as described in relation to Figure 1 or Figure 3. Here, the plastic injection molded article 10 is further capable of being the plastic injection molded article 10 described in relation to Figure 2 and / or being manufactured as described in relation to Figure 2 or Figure 3. Here, the transfer ply 2 further comprises a primer layer 23, a mask layer 22, and a protective layer 24, similar to the separation layer 8.

[0188] In particular, the separation layer 8, protective layer 24, decorative ply 21, mask layer 22, and primer layer 23 are applied in a predetermined order on the carrier ply 3 to obtain a transfer film 1 as shown in Figure 4b. In a subsequent step, the plastic injection molded article 10 can be manufactured by back injection molding 203 of the transfer film 1.

[0189] As shown in Figure 4b, the primer layer 23 forms the outer surface of the transfer ply 2, particularly the side opposite the carrier ply 3. As shown in Figure 4c, in the plastic injection molded product 10, the primer layer 23 forms the outer surface of the transfer ply 2 facing the injection molding compound 5. The primer layer 23 is, in particular, an adhesive layer and / or an adhesion promoter layer. For the material of the primer layer 23, please refer specifically to the description above.

[0190] A protective layer 24 is further disposed on the surface of the transfer ply 2 facing the carrier ply 3. As shown in Figure 4b, and especially as seen in Figure 4c, the protective layer 24 preferably forms the surface of the transfer ply 2 facing the carrier ply 3 of the transfer film 1 or the exposed surface of the transfer ply 2 after the carrier ply 3 has been peeled off. Here, the protective layer 24 can be provided at least partially and / or entirely on the transfer ply. The protective layer 24 is, in particular, a protective varnish layer. The protective layer preferably has a thickness in the range of 1 μm to 50 μm. For the composition of the protective layer 24, please refer to the above description, in particular, regarding the composition of the first protective layer. The protective layer 24 is, in particular, in the form of a protective varnish layer, preferably applied to the carrier ply 3 and any separation layer 8, and is applied or applied by gravure printing and / or slot casting.

[0191] In Figure 4a, the visible area 71 and the recessed area 81 are depicted in the shape of, for example, a telephone symbol, and preferably comprise all portions of the transfer film 1 or plastic injection molded product 10 that overlap the telephone symbol. Here, the minimum line width is preferably the minimum distance between two opposing points on the boundary line of the recessed area 81, particularly the telephone symbol.

[0192] By precise registration and placement between one or more forming elements 40 and the mask layer 22, the molded body 41, particularly in the shape of the recessed region 81, can be precisely registered and positioned with respect to the mask layer 22 and / or particularly in the visible region 71, particularly with respect to the telephone symbol. For example, if one or more forming elements 40 are in the mask region 72 Alternatively, it is conceivable that the raised area 82 is positioned in a manner that aligns with the visible area 71.

[0193] In the example shown here, the transmittance of the transfer ply 2, particularly in the visible wavelength region, is reduced via the mask layer 22, and as a result, the transfer ply 2 A visible area 71 and a masking area 72 are obtained. The mask layer 22 is preferably a carrier ply 3It is positioned on the side of the decorative ply 21 opposite to and / or on the side of the decorative ply 21 facing the injection molding compound 5. In particular, the mask layer 22 can be used as a backlight mask when the plastic injection molded product 10 includes a functional component 6, as shown as an example in Figure 3c, the functional component 6 consists of one or more lights, in particular one or more LEDs and / or one or more displays.

[0194] The mask layer 22 is preferably applied by digital printing methods, particularly inkjet printing, preferably UV inkjet printing, gravure printing, and / or screen printing. The mask layer has a thickness in the range of 1 μm to 100 μm. A mask layer thickness in the range of 1 μm to 50 μm is possible, especially when the mask layer is applied by digital printing methods, preferably inkjet printing, and preferably UV inkjet printing. A mask layer thickness in the range of 1 μm to 30 μm is preferably possible when the mask layer 22 is applied by gravure printing. A mask layer thickness in the range of 5 μm to 100 μm is preferably possible when the mask layer 22 is applied by screen printing.

[0195] For further details regarding the characteristics of the mask layer, please refer specifically to the description above.

[0196] In an advantageous embodiment of the plastic injection molded article 10 and / or the method for manufacturing the same, the molded article 41 is arranged and / or particularly arranged so as not to impair the transmitted illumination properties of the transfer ply 3, in particular the decorative ply 21 and / or the mask layer 22, and the injection molding compound 5.

[0197] For example, the molded body 41 substantially does not affect the wavelength of radiation transmitted through the visible area 71 of the transfer ply 3, particularly the color and / or scattering, especially the wavelength of light transmitted through the visible area 71 of the transfer ply 3 that is visible to the human eye. In particular, the protective layer 24 of the transfer ply 3, especially the transfer ply 4, can be made to transmit uniformly in the visible area 71. For example, as shown in Figure 4c, the molded body 41 preferably does not constitute any change in layer thickness in the visible area 71. This can be achieved, for example, when the visible area 71 is overlapped over its entire surface by the molded body 41, especially by the recessed area 81. One or more forming elements 49 of the transfer film 1 preferably have a constant layer thickness at least in the visible area 71 for this purpose.

[0198] Advantageously, one or more forming elements 40 and the visible area 71 and / or masking area 72, particularly the mask layer 22, are positioned or arranged in a manner that is precisely registered to one another in the manufacturing method of the transfer film 1, particularly during step c) and / or step b1), and in the manufacturing method of the plastic injection molded article 10, in the transfer film 1 and in the plastic injection molded article 10. In the manufacturing method of the plastic injection molded article 10 and / or in the plastic injection molded article 10, the molded body 41 and the visible area 71 and / or masking area 72, particularly the mask layer 22, are positioned or arranged in a manner that is also precisely registered to one another.

[0199] The registration tolerance between one or more forming elements 40 and the viewing area 71 and / or masking area 72, particularly between one or more forming elements 40 and the mask layer 22, is preferably in the range of 0.05 mm to 1.0 mm, and more preferably in the range of 0.05 mm to 0.2 mm. The registration tolerance between one or more forming elements 40 and the viewing area 71 and / or masking area 72, particularly between one or more forming elements 40 and the mask layer 22, is particularly about 1.0 mm, preferably about 0.2 mm. A registration tolerance in the range of 0.05 mm to 0.2 mm can be achieved, for example, when one or more forming elements 40 are applied by a digital printing method, preferably an inkjet printing method, and more preferably a UV inkjet printing method. When one or more forming elements 40 are applied by means of screen printing, a registration tolerance in the range of 0.2 mm to 1.0 mm is particularly possible.

[0200] In particular, since the molded body 41 is formed by the forming element 40, the above-mentioned limits of the registration tolerance also apply to the registration tolerance between the molded body 41 and the mask layer 22 in the plastic injection molded product 10 and during its manufacturing process.

[0201] The registration tolerance between the decorative ply 21 and the visible area 71 and / or masking area 72, and particularly between the decorative ply 21 and the mask layer 22, is preferably in the range of 0.1 mm to 0.4 mm and / or about 0.4 mm. A registration tolerance in the range of 0.1 mm to 0.4 mm is achieved, in particular, when the mask layer 22 is applied or applied by a gravure printing method, preferably inline.

[0202] Here, it is particularly ensured that the plastic injection-molded product 10 has a visible area 71 and / or masking area 72 that are precisely aligned with the molded body 41 and decorative ply 21 formed by the mask layer 22. Thus, for example, the visible area 71 can be illuminated with a backlight, enabling interaction by further functional components such as touch sensors, which can be advantageously carried out particularly easily, intuitively and / or accurately. In particular, the optical appearance is also particularly impressive.

[0203] The registration tolerance between one or more forming elements 40 and / or decorative plies 21 and / or visible areas 71 and / or masking areas 72, particularly the mask layer 22, can further be in the range of 0.15 mm to 0.6 mm at most. Here, the maximum registration tolerance in particular represents the maximum deviation from the target value of the relative positions of two of the listed components between the forming elements and the decorative plies 21, for example. In particular, since the molded body 41 is formed by the forming elements 40, the limit of the registration tolerance also applies to the registration tolerance between the molded body 41 and the decorative plies 21 and / or visible areas and / or masking areas, particularly the mask layer 22, in the plastic injection molded product 10.

[0204] The plastic injection molded product 10 may have one or more functional components 6, as described in relation to Figure 3c, or may be provided such that the functional components 6 are applied in a later process.

[0205] One or more functional components 6 are preferably mounted or attached in a manner that allows for precise registration with respect to one or more forming elements 40, a molded body 41, a decorative ply 21, a mask layer 22, and / or a viewing area 71. Here, the registration tolerance between one or more functional components 6, the molded body 41, the decorative ply 21, the viewing area 71, and / or the mask layer 22 can be about 0.3 mm, and particularly about 0.2 mm. Here, one or more functional components 6 consist, for example, at least one touch sensor, which is positioned to be registrable with respect to the molded body 41 and deviates by a maximum of 0.2 mm from the target position relative to the positions of the decorative ply 21 and the molded body 41 during the process.

[0206] Furthermore, before and / or after step x3), it is conceivable that step b2) is performed, in which a visible area 71 is generated on the transfer ply 2, wherein the visible area 71 is positioned or placed in a manner that is precisely registered with respect to one or more forming elements 40, the molded body 41 and / or the decorative ply 21, and the mask layer 22 is partially removed in the visible area 71 and / or the transmittance of the transfer ply 2 is increased in the visible area 71. Here, the mask layer 22 is preferably first formed in the area where the visible area 71 is to be formed after processing the mask layer 22. In particular, here the visible area 71 is generated by a laser. It is further conceivable that after step x3) is performed, in particular the transfer film 1 is back-injection molded with injection molding compound 5, and after the injection molding compound 5 has cured, the visible area 71 is generated by a laser.

[0207] The visible area 71 is formed or can be formed by one or more voids and / or openings, particularly in the mask layer 22. The visible area 71 is positioned to coincide with one or more forming elements 40 in at least a partial area, and / or the masking area 72 may further not overlap with one or more forming elements 40. For example, the visible area 71 may be formed or can be formed by one or more voids and / or openings in an opaque layer, the opaque layer forming, for example, the masking area 72 or a part thereof and / or the mask layer 22. Here, in addition to voids and / or openings, the visible area 71 preferably comprises a further layer, such as at least a decorative ply 21.

[0208] In particular, in the plastic injection molded article 10 or the method for manufacturing the same, especially in the mask layer 22, the visible area 71 is formed or can be formed by one or more voids and / or openings. Here, the visible area 71 is positioned to coincide with the recessed area 81 of the molded body 41 and / or the transfer ply 3 in at least a partial area, and / or the masking area 72 does not overlap with the molded body 41. In particular, during the back injection molding 203 of the transfer film 1 by the injection molding compound 5 in step x3), the transfer ply 2 is deformed so that one or more openings and / or voids are at least partially filled by the transfer ply 2, which can improve the sharpness of the edges of the molded body 41 and the registration accuracy.

[0209] For the mask layer 22 and / or decorative ply 21, preferably, corresponding registration marks are applied or applied during the application of each layer of the mask layer 22 and / or decorative ply 21. Such registration marks are, for example, cross-shaped, circular and / or triangular. The registration marks are preferably applied to at least one outer and / or one edge of the transfer film 1 in each case, so that they can be read, in particular by at least one sensor. At least a portion of one or more motifs of the decorative ply 21 and / or mask layer 22 can also be used as registration marks. Particularly in the subsequent steps, one or more forming elements 40 and preferably registration marks associated with one or more forming elements 40 are applied to the carrier ply 3 on the opposite side of the transfer ply 2. In order to carry out and / or in step c), the position where, for example, one or more forming elements 40 are applied to the carrier ply 3 is set depending on the position of the registration marks assigned to the decorative ply 21 and mask layer 22.

[0210] While the plastic injection molded product 10 comprises one or more functional components 6, the position of one or more functional components 6 may be aligned or positioned with respect to the assigned registration marks of one or more layers of the decorative ply 21, the mask layer 22 and / or one or more forming elements 40.

[0211] In particular, for the application of one or more touch sensors, printed and / or sprayed sensor outlines are used. The printed and / or sprayed sensor outlines are markings printed and / or sprayed on each touch sensor. The printed and / or sprayed sensor outlines are preferably positioned or aligned with one or more registration marks assigned to one or more forming elements 40, decorative ply 21, viewing area 71 and / or masking area 72, and especially the mask layer 22. In particular due to the corresponding mold design and registration marks, each touch sensor is precisely registered and connected to the plastic injection molded product 10 and its components, preferably by the printed and / or sprayed sensor outlines.

[0212] The transfer film 1 has an optional separation layer 8 between the carrier ply 3 and the transfer ply 2. Here, the transfer ply 2 is peelable from the carrier ply 3, particularly by the separation layer 8. In Figure 4c, the carrier ply 3 is separated from the transfer ply 2 by the forming element 40. The separation layer 8 preferably has a layer thickness in the range of 1 μm to 5 μm. For the material of the separation layer 8, please refer in particular to the description above.

[0213] The separation layer 8 is preferably applied to or applied to the carrier ply by means of gravure printing and / or slot casting. A method for manufacturing a plastic injection molded article 10 may further comprise the step of separating the carrier ply 3 from the transfer ply 2 by and / or using the separation layer 8.

[0214] Figures 5a, 5b, and 5c show the transfer film, the plastic injection molded article, and the method described in relation to Figures 4a, 4b, and 4c, except that the decorative elements 210 are further included in the decorative ply 21. Here, they form the letters "Phone," as shown as an example. Here, each decorative element 210, in particular each letter, can be precisely registered and positioned with respect to the forming element 40 and the visible area 71, or to the corresponding masking area 72 and the mask layer 22.

[0215] For this purpose, for example, prior to the application of one or more forming elements 40 to the carrier ply in step c), the positions of one or more decorative elements 210 to be assigned to the one or more forming elements 40 are detected by at least one sensor. Here, the decorative elements 210 themselves may be used as registration marks. For further characteristics of the decorative ply 21 and the decorative elements 210, please refer in particular to the above description.

[0216] Figures 6a, 6b, and 6c show the transfer film 1, the plastic injection molded article 10, and the method described, in particular in relation to Figures 4a, 4b, and 4c, except that one or more forming elements 40 are not positioned to coincide with or overlap the viewing area 71. Thus, here, for example, the recessed area 81 is not positioned in the viewing area 71. With respect to the decorative ply 21, and especially with respect to the viewing area 71, precisely registered placement of the forming elements 40 is provided here. Precisely controllable and operable operating elements can thereby be integrated by items of, for example, tactile and visual information. For this purpose, the plastic injection molded article may include functional components 6, such as lighting and / or touch sensors, positioned to be registered with respect to the molded article 41.

[0217] Figures 7a, 7b, and 7c show the transfer film, the plastic injection molded article, and the method described, in particular in relation to Figures 4a, 4b, and 4c, but Figure 7c further shows the protective layer 25.

[0218] For this purpose, the method for manufacturing the plastic injection molded article 10 includes, particularly after the separation of the carrier ply 3 from the transfer ply 2 in step x4), the step of at least partially immersing the transfer ply 2 and / or the injection molding compound 5 with a polyurethane-containing composition and / or a polyurea-containing composition in order to form at least one second protective layer 25. Thus, on the outer surface, preferably on the transfer ply 2, the plastic injection molded article 10 can have at least one second protective layer 25 formed of a polyurethane-containing composition and / or a polyurea-containing composition.

[0219] Here, it is preferable that at least the molded body 41, the motif formed by the molded body 41, and / or the region constituting the molded body 41 are flooded or appear to be flooded. In particular, the plastic injection molded product 10 is visually tactile, but is tactilely smooth to the touch. By combining the molded body 41 with polyurethane flooding or polyurea flooding, it is possible here to impart a specific optical depth effect to the plastic injection molded product 10 at this location. For example, signs of wear caused by abrasion can also be particularly reduced.

[0220] Beneficiently, protective layer 24 and protective layer 25 are identical to each other. With regard to the composition of protective layers 24 and 25, refer in particular to the above description relating to at least one first protective layer and at least one second protective layer.

[0221] Figure 8 shows a plastic injection molded article 10 as described in relation to one of Figures 3, 4, 5 and / or 6. Here, the plastic injection molded article 10 has a sensor 9, for example, which is a touch sensor. Here, the sensor 9 is positioned on the injection molded compound 5 on the opposite side of the transfer ply 2, and here the plastic injection molded article 10 further comprises a printed circuit board 11 having an exemplary LED 12 connected to the sensor 9 via a light seal 13. The sensor 9 is preferably in direct contact with the surrounding components, preferably the injection molded compound 5. In a preferred design variation, it is specified that another layer is provided between the sensor 9 and the injection molded compound 5 to improve the light seal. It is also possible that at least one adhesive layer, at least one diffuser layer and / or at least one light guide layer are provided between the sensor 9 and the injection molded compound 5.

[0222] The LED 12 is positioned in a location that is precisely aligned with the viewing area 71, the decorative ply 21, and the molded body 41.

[0223] Furthermore, a protective layer 25, such as the one described in relation to Figure 7c, may be partially or entirely placed on the protective layer 24.

[0224] Figure 9 shows further schematic design variations of a transfer film 1, particularly an IMD transfer film 1, having a carrier ply 3 and a transfer ply 2 consisting of a decorative ply 21, the transfer ply 2 being placed on the carrier ply 3 and consisting of one or more forming elements 40, the one or more forming elements 40 being applied to the carrier ply 3 and precisely registered with respect to the decorative ply 21. Preferably, a separation layer 8 is placed between the carrier ply 3 and the transfer ply 2, and the transfer ply 2 may also have a separation layer 8. In this embodiment, in addition to the decorative ply 21, the transfer ply 2 has another protective layer placed between the decorative ply 21 and the separation layer 8, and a mask layer 22 and primer placed below the decorative ply. layerIt has 23. Here, the mask layer 22 is provided in the masking region 72 and not in the visible region 71. In addition, one or more forming elements are provided in the raised region 82 and not in the recessed region 81. [Explanation of Symbols]

[0225] 1 Transfer film 11 Printed circuit boards 12 LED 13 Light-up stickers 2 Transfer Ply 21 Decorative Ply 210 Decorative elements 22 Mask Layers 23 Primer layer 24 Protective layer 25 Protective layer 3. Carrier plan 40 Formative elements 41 Molded body 5. Injection molding compound 6 Functional parts 71. Visibility Area 72 Mask area 8 separation layer 81 Recessed area 82 Raised area 9 sensors

Claims

1. A method for manufacturing a transfer film, a) Steps to prepare a career plan, b) A step of preparing a transfer ply having a decorative ply, wherein the transfer ply is placed on or positioned on the carrier ply, c) A step of applying one or more forming elements to the carrier ply, wherein the one or more forming elements have a three-dimensional shape and are applied in a manner that is precisely registered to the decorative ply, wherein at least one of the printing processes is performed, wherein one or more layers of the one or more forming elements are applied by gravure printing and / or flexographic printing and / or screen printing means, one or more first layers of the one or more forming elements are applied using a digital printing method, the last layer of the one or more forming elements applied in step c) is applied using a digital printing method, and the one or more forming elements are applied by 3D printing means. b1) A step of preparing and / or manufacturing one or more forming elements and a mask area that does not overlap with a visible area, which is arranged to coincide with one or more forming elements in at least a portion of the transfer ply, and applying and / or manufacturing a registration mark called a registration mark of the preceding step, wherein the preceding step is performed before the subsequent step, The registration marks corresponding to the registration marks of the previous step, assigned to each of the one or more layers of the decorative ply, the viewing area and / or the mask area, are applied and / or manufactured to one or more layers of the decorative ply, the viewing area and / or the mask area, so that in the subsequent step, the registration marks referred to as the registration marks of the subsequent step, associated with the one or more forming elements, are applied to the surface of the carrier ply opposite to the transfer ply. In the visible area, the transfer ply is transparent to light visible to the human eye and has a transmittance of 75%, and in the mask area, the transfer ply is opaque to light visible to the human eye, where opaque means having a transmittance of 0% to 10%. The one or more forming elements have a certain layer thickness in at least the visible area. The method is characterized in that the registration tolerance between the one or more forming elements and the decorative ply is in the range of 0.05 mm to 1.0 mm.

2. The method according to claim 1, The transfer ply is applied to the first surface of the carrier ply, and the one or more forming elements are applied to the second surface of the carrier ply opposite to the first surface, and in step c), one or more first layers of the one or more forming elements are applied using a digital printing method and / or The layer of one or more forming elements that is applied last in step c) is applied using a digital printing method and / or In step c), two or more layers of the one or more forming elements are applied so as to overlap each other, and / or the one or more forming elements are applied by means of 3D printing. A method characterized in that the registration tolerance between the one or more forming elements and the decorative ply is in the range of 0.05 mm to 1.0 mm.

3. A method according to claim 1 or 2, The method is characterized in that the decorative ply has one or more decorative elements, which are applied by one or more layers selected from one or more color layers, one or more reflective layers, one or more optically active and / or optically variable structures, and / or holograms and / or refractive structures and / or matte structures.

4. A method according to claim 1 to 3, The method further comprises b1) preparing and / or manufacturing a masking area and / or a visible area in the transfer ply, In or after step b1), the visible area is manufactured in the transfer ply, the visible area has a higher transmittance than the masking area, and / or the masking area is formed by a mask layer, and / or the visible area is formed by one or more voids and / or openings, and / or The method is characterized in that the visible area is arranged to coincide with one or more forming elements in at least a partial area, and / or the masking area is arranged not to overlap with one or more forming elements.

5. A method according to one of claims 1 to 4, During step c) and / or step b1), the one or more forming elements and the viewing area and / or masking area are positioned in a manner that is precisely aligned with respect to each other and / or The registration tolerance between the decorative ply and the visible area and / or the masking area is in the range of 0.1 mm to 0.4 mm, and / or A method characterized in that the registration tolerance between one or more forming elements and / or the decorative ply and / or the visible area and / or the masking area is in the range of 0.15 mm to 0.6 mm at most.

6. A method according to one of claims 1 to 5, The carrier ply is characterized in that it has a coating on at least one of its main surfaces.

7. A method according to one of claims 1 to 6, A method characterized in that, for the formation of the outer surface of the transfer ply (2) opposite to the carrier ply (3), the transfer film is provided with a primer layer, and the carrier ply is separable from the transfer ply.

8. A method according to one of claims 1 to 7, A method characterized in that, in step c), the position in which the one or more forming elements are applied to the carrier ply is set depending on the position of one or more registration marks, the position of the one or more registration marks is detected by at least one sensor, and the one or more registration marks mark the position of one or more layers of the decorative ply, the visibility area, the masking area and / or primer in each case with respect to the carrier ply and / or each other.

9. A method for producing a plastic injection molded article coated with a transfer film manufactured according to one of claims 1 to 8, x1) A step of preparing a transfer film, wherein the transfer film has a carrier ply and a transfer ply having a decorative ply, and the transfer ply is placed on or positioned on the carrier ply, x2) A step of preparing one or more forming elements on the carrier ply, wherein the one or more forming elements have a three-dimensional shape and are precisely registered and applied to or applied to the decorative ply, x3) ​​A method characterized by comprising the step of back-injecting the transfer film with an injection molding compound, wherein the three-dimensional molded bodies of one or more forming elements are precisely aligned with the decorative ply and introduced in the transfer ply by the action of the injection molding compound on the transfer film.

10. The method according to claim 9, A method characterized in that, during the back injection molding of the transfer film with the injection molding compound in step x3), recessed regions formed by the molded body are generated in the transfer ply, and / or, during the back injection molding of the transfer film with the injection molding compound in step x3), raised regions are generated in the transfer ply.

11. The method according to claim 9 or 10, Before and / or after step x3), b2) a step of generating a visible area in the transfer ply, wherein the visible area is positioned so as to be precisely registered with respect to one or more forming elements, the molded body and / or the decorative ply, The method is characterized in that the registration tolerance between the one or more forming elements and the viewing area is in the range of 0.05 mm to 0.2 mm.

12. A method according to one of claims 9 to 11, A method characterized in that, during or after back injection molding of the transfer film with the injection molding compound, the plastic injection molded product comprises one or more functional components positioned on the side of the injection molding compound opposite to the transfer ply.

13. A transfer film (1) manufactured according to one of claims 1 to 8, A transfer film comprising a carrier ply and a transfer ply having a decorative ply, wherein the transfer ply is disposed on the carrier ply and comprises one or more forming elements, the one or more forming elements being applied to the carrier ply and precisely aligned with respect to the decorative ply.

14. A transfer film according to claim 13, The transfer ply is positioned on the first surface of the carrier ply, and the one or more forming elements are positioned on the second surface of the carrier ply opposite to the first surface. The one or more forming elements are transfer films comprising a release agent for improving the peelability from injection molding dies.

15. A transfer film according to claim 13 or 14, The transfer ply has a masking area and / or a visible area, and / or The masking region is formed by the mask layer that reduces the transmittance of the transfer ply in the masking region, and / or The one or more forming elements and the viewing area and / or the masking area are positioned so as to be precisely aligned with each other and / or The viewing area is formed by one or more voids and / or openings, and / or The viewing area is positioned to coincide with one or more forming elements in at least a portion of the area, and / or The masking region is arranged so as not to overlap with one or more forming elements. A transfer film characterized in that the registration tolerance between the one or more forming elements and the visible area and / or the mask area is in the range of 0.05 mm to 0.2 mm.

Images