Methods for preparing coated particle foam molded parts

Abstract

The present invention relates to a more sustainable production of coated foam particle molded parts requiring less energy consumption, material consumption and resulting in less waste material generation. In particular the present invention relates to a process for preparing a coated particle foam molded part by using an in-mold coating composition in combination with foam particles comprising a coating. The in-mold coating composition allows to produce a pigmented coating layer during fusing of the foam particles comprising the coating while at the same time acting as a release agent facilitating removal of the produced coated foam particle molded part from the mold. The invention is further directed to a coated molded part produced by the inventive process, and the use of the inventive coated particle foam molded part in shoe soles, part of shoe soles, shoe intermediate soles shoe insoles, damping elements, cushioning elements, protective devices, underlays, grips, flooring, mattresses, sporting goods, bicycle saddles, and in automotive interiors and exteriors.

Description

METHODS FOR PREPARING COATED PARTICLE FOAM MOLDED PARTSThe present invention relates to a more sustainable production of coated foam particle molded parts requiring less energy consumption, material consumption and resulting in less waste material generation. In particular the present invention relates to a process for preparing a coated particle foam molded part by using an in-mold coating composition in combination with foam particles comprising a coating. The in-mold coating composition allows to produce a pigmented coating layer during fusing of the foam particles comprising the coating while at the same time acting as a release agent facilitating removal of the produced coated foam particle molded part from the mold. The invention is further directed to a coated molded part produced by the inventive process, and the use of the inventive coated particle foam molded part in shoe soles, part of shoe soles, shoe intermediate soles shoe insoles, damping elements, cushioning elements, protective devices, underlays, grips, flooring, mattresses, sporting goods, bicycle saddles, and in automotive interiors and exteriors.BACKGROUND OF THE INVENTIONA wide variety of different components or parts with variable layer thicknesses are nowadays mostly produced by means of molding processes, like molding and casting processes. A greatly used material in molding processes are particle foams. Composed of air bubbles entrapped in a continuous solid network, they combine the properties of the polymer with those of the foam to create an intriguing and complex material. Particle foams not only allow to use the wide range of interesting properties that the polymers offer, but also permit to profit from the advantageous properties of foams, including lightness, low density, compressibility and high surface-to-volume ratio.Particle foams are usually processed into molded parts by fusing the foam particles, gluing the foam particles or loosely embedding the foam particles in a binder system. Fusing of thermoplastic foam particles requires energy-intensive steam-chest molding processes to avoid damages occurring during the use of conventional heating presses, because the high temperatures on the molding tools, combined with the poor thermal conductivity of thermoplastic foam particles, lead to a foam-structure damaging temperature gradient during the molding process.Since superheated steam fusion has very high energy requirements, in recent years, there has been increasing search for alternatives. One alternative possibility to fuse the foam particles is to supply the required energy through an electromagnetic field. Using electromagnetic radiation or an electromagnetic field to provide the energy required for the molding process is describedin general in EP3698949 A1 and WO2017 / 125410 A1 for different foam particles. Especially in WO2017 / 125410 A1 it is shown that a foam molding with homogeneously fused foam particles can be achieved by using an electromagnetic field to apply the energy.However, fusing foam particles through an electromagnetic field requires a certain excitability of the particle foams regarding electromagnetic radiation which results from their specific dielectric properties. A low material specific excitability regarding electromagnetic radiation will lead to high cycle times and, therefore, result in inefficient molding processes. Another task is to control the molding process in such a way that, on the one hand, the surfaces of the foam particles weld together sufficiently but at the same time the foam structure of the particles does not collapse leading for example to an unfavorable density increase.A further approach is the coating of foam particles with a water-based binder which can be reactivated by suitable solvents or heat as described in WO / 2022 / 223438. This process has the advantage that the coating with the binder can result in a commercial product, so that an end user can simply use a solvent, e.g., water, or heat to prepare the shaped body. However, in order to enable the end user to make efficient use of already coated particles, the coated particles should be flowable, shelf-stable and non-sticky.The European patent application with application number EP22202204.8 relates to storage stable coated particles and shaped bodies comprising said coated particles as well as a process for the preparation for the preparation of storage-stable coated particles of a moldable thermoplastic particle foam comprising the steps of a1) bringing the particles into contact with an aqueous polyurethane dispersion, the polyurethane having a K-value according to DIN EN ISO 1628-1 2021 in the range from higher than 50 to lower than 100.Particle foam molded parts produced by the aforementioned processes and coated foam particles exhibit a characteristic swirl pattern or a mottled surface that can be attractive on durable outdoor, industrial or factory applications. However, the as-molded structural foam appearance may not be appropriate for all products. Particularly in the area of the production of footwear soles or in the area of the furniture industry, there is a sustained demand for particle foam molded parts having an attractive appearance. One way of providing such an attractive appearance is by post-treatment of the foam particle molded parts, for example by sanding and coating. Coatings can be applied for aesthetic purposes or to reduce or prevent damage of the particle foam molded part by environmental influences.Such processes, however, are inefficient, since they require a further process step after production of the foam particle molded part. Moreover, if an external release agent is used when producing the particle foam molded part, this external release agent has to be removed prior to applying further coating layers to ensure sufficient adhesion of the further coating layers on the surface of the particle foam molded part. This removal, however, requires costly and inconvenient cleaning processes. Further disadvantages associated with the use of external mold release agents include a frequent lack of compatibility between the release agent and the foam particles and / or between the release agent and the molding tool, leading to adhesion problems. When external release agents are used, there is an increase in the cost and complexity of the process and hence in the operating times. Furthermore, the use of external release agents leads frequently to shiny surfaces on the produced particle foam molded parts, this being unwanted especially in the footwear industry.Hence, there still remains a need for preparing coated foam particle molded parts comprising a coating on at least a part of their surface without requiring a separate coating step after production of the particle foam molded part using molding processes requiring less energy than superheated steam fusion processes.OBJECTIt was therefore an object of the present invention to remedy the disadvantages mentioned and to provide a process for the preparation of coated foam particle molded parts comprising on at least a part of the surface a coating which can be produced from a pigmented coating composition during the molding process. The process should allow energy efficient fusing of the foam particles while avoiding the use of additional external release agents to facilitate release of the coated foam particle molded parts. In particular, the pigmented coating composition should not only in the formation of a durable coating on the surface of the coated particle foam molded part but should, at the same time, allow damage-free removal of the coated particle foam molded part from the molding tool.TECHNICAL SOLUTIONThe objects described above are achieved by the subject matter claimed in the claims and also by the preferred embodiments of that subject matter that are described in the description hereinafter.A first subject matter of the present invention is therefore a process for preparing a coated particle foam molded part, wherein the coated particle foam molded part comprises at least onepigmented coating layer on at least a part of the surface of the particle foam molded part, the method comprising the steps of(A) application of at least one in-mold coating composition (C1) to at least a part of an inner surface of a closable, three dimensional mold (MO) having at least two mold parts which are movable relative to each other and which form a mold cavity including the inner surface,(B) drying the applied in-mold coating composition(s) (C1) to form coating film(s) (CF),(C) filling foam particles comprising a coating into the mold cavity, wherein the coating is obtained by mixing the foam particles with a composition (C2) comprising an aqueous polyurethane dispersion (PD) to produce the coating on the foam particles and drying the produced coating,(D) producing the coated particle foam molded part by at least partially curing the coating film(s) (CF) while fusing the foam particles comprising the coating by supplying energy, wherein the in-mold coating composition (C1) comprises:(a) at least one solvent,(b) at least one pigment,(c) at least one binder,(d) at least one crosslinking agent, and(e) at least one compound of the general formula (I)R1-(C=O)rO-(AO)s-R2(I) in which R1is a saturated or unsaturated, aliphatic hydrocarbon radical having 6 to 30 carbon atoms,R2is H,AO stands for one or more alkylene oxide radicals selected from the group consisting of ethylene oxide, propylene oxide and butylene oxide, r is 0 or 1, and s is 0 to 30.The above-specified process is hereinafter also referred to as process of the invention and accordingly is a subject of the present invention. Preferred embodiments of the process of the invention are apparent from the description hereinafter and also from the dependent claims.Surprisingly, it was found that the process according to the invention leads to coated foam particle molded comprising a coating layer on at least a part of the surface which exhibits a good appearance and good mechanical properties, such as high flexibility and good adhesion, and thus allows to provide aesthetically appealing particle foam molded parts without requiring post-coating processes to improve the appearance of the particle foam coated part. This allowsto reduce the amount of material and energy required for post-coating, hence allowing to produce the coated particle foam molded parts in a more sustainable way and reducing the environmental impact associated with the production of the coated particle foam molded parts. In addition, the in-mold coating composition not only produces the pigmented coating layer during the molding process but also acts as a release agent for the molded particle foam material to facilitate damage free removal of the coated particle foam molded part from the molding tool. This renders the use of additional (e.g. external) release agent compositions superfluous, hence allowing to reduce the material consumption and thus also the environmental impact associated with the inventive process. By using an aqueous in-mold coating composition within the inventive process, the environmental impact of said process can be further reduced as compared to processes using solvent-based coating compositions and processes requiring post-coating steps. Hence, the inventive process allows to produce coated particle foam molded parts in a more sustainable manner, e.g. allows to produce coated particle foam molded parts having a reduced environmental impact.The use of foam particles comprising the coating allows for processing into molded parts via thermo-pressing without negatively impacting the formation of a pigmented coating layer from the coating composition during thermo-pressing. This allows to achieve coated particle foam molded parts via thermo-pressing requiring reduced energy consumption as compared to high energy consuming steam molding while at the same time ensuring that the coating layer formed from the coating composition has a high adhesion to the surface of the particle foam molded component produced by fusing the foam particles comprising the coating (e.g. the coated foam particles).The surface coating of the foam particles moreover allows the use of foam particles of different sizes and chemistry (e.g., styrene polymer foam particles, polyurethane foam particles, polyamide foam particles, thermoplastic elastomer foam particles, polyolefine foam particles) as the fusing during thermo-pressing is achieved by the coating presence on the surface of the foam particles and not completely by the softening or melting of the wall of the foam particles. This has the advantage that also foam particles with a high melting or softening point can be used at a moderate temperature to produce a 3D coated foam particle molded part without the use of steam.A further subject of the present invention is a coated particle foam molded part prepared according to inventive process.Since no steam is used during the inventive process, the coated foam particle molded parts produced by the inventive process are not wet after demolding and, therefore time-consuming annealing to remove the moisture present after performing steam-based processes is eliminated.Yet a further subject of the present invention is a use of the inventive coated particle foam molded part in shoe soles, part of shoe soles, shoe intermediate soles shoe insoles, damping elements, cushioning elements, protective devices, underlays, grips, flooring, mattresses, sporting goods, bicycle saddles, and in automotive interiors and exteriors.DETAILED DESCRIPTIONInventive process:In accordance with the invention, the pigmented coating layer on at least a part of the surface of the particle foam molded part is achieved by applying an in-mold coating composition (C1) in step (A) on at least at part of an inner surface of the mold (MO) to form a coating film (CF) on such inner surface and curing the formed coating film (CF) while fusing the coated foam particles using energy, such as heat and pressure.The process according to the invention may be a manual process or an automatic process. A manual process is not linked to strict cycle times and may hence be associated with a significant variation in the cycle time of each process step during multiple repetitions of the process is present. In contrast, individual process steps are linked to strict cycle times in an automatic process. In other words, the cycle time for a process step is identical or does not vary significantly on multiple repetitions of the process. The manual process as well as the automated process may include automated process steps, such as automated application of the in-mold coating composition (C1), automated filling of the coated foam particles, automated opening and / or closing of the mold and / or automated removal of the coated foam particle mold part.Step (A):In step (A), an in-mold coating composition (C1) is applied to at least a part of an inner surface facing a mold cavity of a closable, three dimensional mold (MO) having at least two mold parts which are movable relative to each other and which form the mold cavity. The in-mold coating composition (C1) is therefore present on at least part of the surface of the mold parts which come in contact with the coated foam particles filled into the mold cavity in step (C).Mold:The 3D mold may have a three dimensional inner cavity which is formed by at least two mold parts that can be moved relative to each other to open and close the mold. The inner cavity of the mold therefore has three dimensions, i.e. a length, a width and a depth. The mold can have a single cavity or multiple cavities. In multiple cavity molds, each cavity can be identical and form the same geometry or can be unique and form multiple different geometries. The mold (MO) may be a metallic mold, a polymeric mold or a mold comprising metallic and polymeric mold parts. In an embodiment, the mold parts may be selected from metallic mold parts, preferably aluminum, steel, nickel or copper mold parts, very preferably aluminum and / or steel mold parts, and / or from polymeric mold parts.In-mold coating composition (C1):According to the invention, the coating composition (C1) is not only used to produce a pigmented coating layer on the surface of the particle foam molded part, but simultaneously acts as release agent facilitating demolding of the produced coated particle foam molded part. The pigmented coating layer produced by the in-mold coating composition (C1) during production of the coated particle foam molded part hence renders post-coating processes superfluous. Moreover, the release agent properties provided by the in-mold coating composition (C1) allows to avoid the additional use of external release agents on inner surfaces of the mold comprising a coating film produced by the in-mold coating composition (C1). Use of such external release agent may hamper the adhesion of coating layers to the fused particle foam molded part and therefore require additional cleaning steps before applying further coating materials in a post-coating process.The in-mold coating composition (C1) is applied to at least a part of the inner surface of the mold. The in-mold coating composition (C1) may be applied to all inner surfaces of the mold parts facing the mold cavity. The in-mold coating composition (C1) may be applied to specific areas of the inner surface. At least a first in-mold coating composition (C1a) may be applied to first part(s) of the inner surface and at least one further in-mold coating composition (C1n) (e.g. a different coating composition) may be applied to second or further part(s) of the inner surface. The in-mold coating compositions (C1a) and (C1n) may have different colors. The different colors may be achieved by using in-mold coating compositions (C1a) and (C1n) comprising a different pigment or pigment mixtures. Masking may be used to prevent undesired overspray of the further in-mold coating composition(s) (C1n) on parts of the inner surface comprising the applied first in-mold coating composition (C1a).In an embodiment, the in-mold coating composition (C1) has a viscosity of 10 to 60 s, more particularly of 20 to 30 s (DIN4 flow cup), measured according to DIN EN ISO 2431(March 2012). Low viscosity facilitates the application of the in-mold coating composition (C1) and therefore ensures sufficient wetting of the inner surface and production of a uniform pigmented coating layer on the fused particle foam molded part.In an embodiment, the in-mold coating composition (C1) has a solids content of 30 to 60 wt.%, preferably of 35 to 55 wt.%, more preferably of 40 to 50 wt.%, very preferably of 42 to 48 wt.%. The solids content can be determined according to ASTM D2369 (2015) at 110°C for 60 min on a 2 gram sample of the in-mold coating composition (C1).In an embodiment, the in-mold coating composition is a liquid in-mold coating composition. The at least one solvent may hence be present in amounts such that a liquid in-mold coating composition is obtained. Use of a liquid in-mold coating composition allows to apply the in-mold coating composition with commonly known pneumatic and / or electrostatic application equipment.In an embodiment, the in-mold composition (C1) is an aqueous in-mold coating composition. Aqueous coating compositions are coating compositions in which the principal constituent is water. The aqueous in-mold coating composition (C1) may contain a water fraction of at least 20 wt%, preferably at least 25 wt%, very preferably at least 30 wt%, based in each case on the total amount of the solvents present (i.e., water and organic solvents). Preferably in turn, the water fraction may be 50 to 100 wt%, more particularly 60 to 99 wt%, very preferably 85 to 95 wt%, based in each case on the total amount of the solvents present. Use of a water-based inmold coating composition (C1) allows to reduce the emissions, such as VOC emissions, generated during production of the coated particle foam molded part, hence resulting in an inventive process having a reduced environmental impact as well as in inventive coated particle foam molded parts having a reduced environmental impact.In another embodiment, the in-mold coating composition (C1) is a solvent-based coating composition. Solvent-based coating compositions are coating compositions in which the principal constituent is at least one organic solvent. Organic solvents constitute volatile constituents of the in-mold coating composition, and undergo complete or partial vaporization on drying or flashing, respectively. The solvent-based in-mold coating composition (C1) may contain a solvent fraction of at least 20 wt%, preferably at least 25 wt%, very preferably at least 30 wt%, based in each case on the total amount of the solvents present (i.e., water and organic solvents). Preferably in turn, the solvent fraction may be 50 to 100 wt%, more particularly 60 to 98 wt%, very preferably 85 to 95 wt%, based in each case on the total amount of the solvents present. Use of solvent-based in-mold coating compositions (C1) allows to reduce the dryingtime in process step (B), hence allowing shorter process cycle times of the inventive process. In addition, use of the solvent-based in-mold coating compositions (C1) allows to reduce the mold temperatures required for drying in step (B) resulting in a lower energy consumption of the inventive process and hence in a more sustainable production of the coated particle foam molded parts.In-mold coating composition (C1) - solvent:In an embodiment, the at least one solvent is selected from organic solvent(s), water, and mixtures thereof. The at least one solvent is preferably present in a total amount of 40 to 70 wt.%, more preferably 45 to 65 wt.%, and very preferably 50 to 60 wt.%, especially 52 to 58 wt.%, based in each case on the total weight of the in-mold coating composition (C1).Organic solvents may include aprotic organic solvents, such as polar aprotic organic solvents. The organic solvents may be chemically inert toward the remaining constituents of the in-mold coating composition (C1).The organic solvent(s) may be selected from ketones such as acetone, methyl ethyl ketone, cyclohexanone, methyl isobutyl ketone, methyl isoamyl ketone or diisobutyl ketone; esters such as ethyl acetate, n-butyl acetate, ethylene glycol diacetate, butyrolactone, diethyl carbonate, propylene carbonate, ethylene carbonate, 2-methoxypropyl acetate (MPA), and ethyl ethoxypropionate; amides such as N,N-dimethylformamide, N,N-dimethylacetamide, N-methylpyrrolidone, and N-ethylpyrrolidone; methylal, butylal, 1,3-dioxolane, glycerol formal; and, somewhat less preferably because they are nonpolar, hydrocarbons such as benzene, toluene, n-hexane, cyclohexane, and solvent naphtha. Especially preferred organic solvent(s) are selected from esters, such as n-butyl acetate and / or 1 -methoxypropyl acetate.In-mold coating composition (C1) - pigment:The pigment may be a color pigment and / or an effect pigment. The terms “coloring pigment” and “color pigment” are interchangeable, just like the terms “visual effect pigment” and “effect pigment”. A corresponding definition of pigments and further specifications thereof is regulated in DIN 55943 (date: October 2001). Effect pigments may refer to pigments which produce a decorative effect in coating finishes and may additionally, but not exclusively, produce a coloring effect. The effect pigments are notable in particular for a platelet-like construction.The use of pigments allows to achieve pigmented coating layers without negatively influencing the demoldability of the produced coated particle foam molded part and the adhesion of the obtained coating layer on the fused coated foam particles. Accordingly, it is possible to obtain aparticle foam molded part comprising coating layer(s) already having the desired color directly after production of the coated particle foam molded part. Hence, there is no need for the application of further coating materials to adjust the color of the particle foam molded part in a post-coating process such that the required number of production steps associated with the production of the coated particle foam molded parts can be reduced. This allows to reduce energy and material consumption as well as reduce waste material generation compared to processes including post-coating processes, hence resulting in a reduced environmental impact of the inventive production process. Accordingly, the produced coated particle foam molded part is also associated with a reduced environmental impact compared to coated particle foam molded part prepared by processes requiring post-coating process steps.The color pigment is preferably selected from the group of inorganic and / or organic color pigments and / or fillers.Particularly preferred organic color pigments are selected from the group of (i) monoazo pigments, such as C.l. Pigment Brown 25, C.l. Pigment Orange 5, 36 and 67, C.l. Pigment Orange 5, 36 and 67, C.l. Pigment Red 3, 48:2, 48:3, 48:4, 52:2, 63, 112 and 170, and C. I. Pigment Yellow 3, 74, 151 and 183; (ii) disazo pigments, such as C.l. Pigment Red 144, 166, 214 and 242, C.l. Pigment Red 144, 166, 214 and 242 and C.l. Pigment Yellow 83; (iii) anthraquinone pigments, such as C.l. Pigment Yellow 147 and 177 and C. I. Pigment Violet 31; (iv) benzimidazole pigments, such as C.l. Pigment Orange 64; (v) quinacridone pigments, such as C.l. Pigment Orange 48 and 49, C.l. Pigment Red 122, 202 and 206, and C.l. Pigment Violet 19; (vi) quinophthalone pigments, such as C.l. Pigment Yellow 138; (vii) diketopyrrolopyrrole pigments, such as C.l. Pigment Orange 71 and 73 and C.l. Pigment Red, 254, 255, 264 and 270; (viii) dioxazine pigments, such as C.l. Pigment Violet 23 and 37; (ix) indanthrone pigments, such as C.l. Pigment Blue 60; (x) isoindoline pigments, such as C.l. Pigment Yellow 139 and 185; (xi) isoindolinone pigments, such as C.l. Pigment Orange 61 and C.l. Pigment Yellow 109 and 110; (xii) metal complex pigments, such as C.l. Pigment Yellow 153; (xiii) perinone pigments, such as C.l. Pigment Orange 43; (xiv) perylene pigments, such as C.l. Pigment Black 32, C. I. Pigment Red 149, 178 and 179 and C.l. Pigment Violet 29; (xv) phthalocyanine pigments, such as C.l. Pigment Violet 29, C.l. Pigment Blue 15, 15:1 , 15:2, 15:3, 15:4, 15:6 and 16 and C. I. Pigment Green 7 and 36; (xvi) aniline black, such as C.l. Pigment Black 1; (xvii) azomethine pigments; and (xviii) mixtures thereof.Particularly preferred inorganic color pigments are selected from the group of (i) white pigments, such as titanium dioxide (C.l. Pigment White 6), zinc white, dye zinc oxide, zinc sulfide, lithopone; (ii) black pigments, such as iron oxide black (C.l. Pigment Black 11), iron-manganeseblack, spinel black (C.l. Pigment Black 27), carbon black (C.l. Pigment Black 7); (iii) colored pigments, such as ultramarine green, ultramarine blue, manganese blue, ultramarine violet, manganese violet, iron oxide red (C.l. Pigment Red 101), molybdate red (C.l. Pigment Red 104), ultramarine red, iron oxide brown, mixed brown, spinel and corundum phases (C.l. Pigment Brown 24, 29 and 31), iron oxide yellow (C.l. Pigment Yellow 42), bismuth vanadate (C.l. Pigment Yellow 184); and (iv) mixtures thereof.Examples of inorganic pigments commonly used as fillers include transparent silica, quartz flour, aluminum oxide, aluminum hydroxide, natural mica, natural and precipitated chalk and barium sulfate.The at least one pigment may be present in a total amount of 0.1 wt.% to 10 wt.%, based on the total weight of the in-mold coating composition (C1).In-mold coating composition (C1) - binder:The binder may denote physically and / or chemically curable polymers, examples being polyurethanes, polyesters, polyethers, polyureas, polyacrylates, polysiloxanes and / or copolymers of the stated polymers.In an embodiment, the at least one binder is selected from the group consisting of (i) poly(meth)acrylates, more particularly hydroxy-functional and / or carboxylate-functional and / or amine-functional poly(meth)acrylates, (ii) polyurethanes, more particularly hydroxy-functional and / or carboxylate-functional and / or amine-functional polyurethanes, (iii) polyesters, more particularly polyester polyols, (iv) polyethers, more particularly polyether polyols, (v) copolymers of the stated polymers, and (vi) mixtures thereof.Surprisingly, an excellent demolding as well as an excellent quality of the cured coating layer, especially an excellent adhesion, is achieved irrespective of the nature of the binder(s) contained in the in-mold coating compositions (C1). The in-mold coating compositions (C1) can therefore contain any crosslinkable binder or combination of crosslinkable binders which can be used in coating compositions, without adversely affecting the demoldability of the produced coated particle foam molded part or the outstanding properties of the pigmented coating layer produced from the in-mold coating composition (C1).Suitable binder(s) is / are selected from hydroxy-functional poly(meth)acrylates and / or polyester polyols, more particularly from a mixture of at least one hydroxy-functional poly(meth)acrylate and at least one polyester polyol. The use of such binder(s) may be preferred within solvent-based in-mold coating composition(s) (C1). The use of this mixture leads to pigmented coating layers which have a high flexibility and a high resistance toward environmental influences. Furthermore, the obtained coating layers can be adhesively bonded and / or coated with basecoat and / or clearcoat materials without costly and inconvenient aftertreatment.The hydroxy-functional poly(meth)acrylate may possess a hydroxyl number of 65 to 100 mg KOH / g solids, more preferably of 70 to 95 mg KOH / g solids, more particularly of 75 to 90 mg KOH / g solids or of 80 to 85 mg KOH / g solids. The hydroxyl number may be determined according to EN ISO 4629-2:2016.The hydroxy-functional poly(meth)acrylate may possess an acid number of less than 25 mg KOH / g solids, more preferably an acid number of 1 to 20 mg KOH / g solids, very preferably an acid number of 4 to 16 mg KOH / g solids, more particularly of 6 to 14 mg KOH / g solids or of 8 to 12 mg KOH / g solids. The acid number may be determined according to DIN EN ISO 2114:2002-06 (method A).The number-average molecular weight Mnand the weight-average molecular weight Mwmay be determined by means of gel permeation chromatography (GPC) using a polymethyl methacrylate standard (PMMA standard) (DIN 55672-1:2016-03). The number-average molecular weight Mnof the hydroxy-functional poly(meth)acrylate is preferably in a range from 4000 to 10 000 g / mol, more preferably 5000 to 9000 g / mol, very preferably 5500 to 8000 g / mol, more particularly 6000 to 7500 g / mol. The weight-average molecular weight Mwof the hydroxyfunctional poly(meth)acrylate is preferably in a range from 8000 to 30 000 g / mol, more preferably 10 000 to 25 000 g / mol, very preferably 12 000 to 22 000 g / mol, more particularly 14 000 to 20 000 g / mol.The polydispersity PD (= Mw / Mn) of the hydroxy-functional poly(meth)acrylate may be in the range from 2 to 3, more particularly from 2.2 to 2.8.The hydroxy-functional poly(meth)acrylate may possess a hydroxyl functionality of 5 to 15, more preferably of 6 to 14, more particularly of 8 to 12.The hydroxy-functional poly(meth)acrylate may be obtained by means of the polymerization reactions that are commonplace and familiar to a person of ordinary skill in the art using ethylenically unsaturated monomers, preferably monoethylenically unsaturated monomers. Initiators which may be used include peroxides, such as di-tert-butyl peroxide. The hydroxyfunctional poly(meth)acrylate may be obtained by reaction of(a1) at least one hydroxy-functional (meth)acrylic ester, more particularly (meth)acrylic ester of the formula HC=CRx-COO-Ry-OH, in which Rxis H or CH3 and Ryis an alkylene radical having 2 to 6, preferably 2 to 4, more preferably 2 or 3 carbon atoms,(a2) at least one carboxy-functional ethylenically unsaturated monomer, more particularly (meth)acrylic acid, and(a3) at least one hydroxyl-free and carboxyl-free ester of (meth)acrylic acid and / or at least one hydroxyl-free and carboxyl-free vinyl monomer, more particularly styrene.Examples of hydroxy-functional (meth)acrylic esters (a1) include hydroxyethyl methacrylate, hydroxyethyl acrylate, hydroxypropyl methacrylate, and hydroxypropyl acrylate, and with particular preference hydroxyethyl methacrylate and 2-hydroxypropyl methacrylate. The amount of hydroxy-functional (meth)acrylic esters (a1) used in preparing the hydroxy-functional poly(meth)acrylate may be calculated on the basis of the target range for the hydroxyl number, of 50 to 120 mg KOH / g.The hydroxy-functional poly(meth)acrylate preferably contains small quantities of carboxyl groups. These groups may be introduced into the poly(meth)acrylate during the polymerization reaction through the use of carboxy-functional monomers (a2), more preferably through the use of acrylic acid and / or methacrylic acid. These monomers (a2), especially (meth)acrylic acid, are present preferably in a total amount of 20 to 45 wt.%, more preferably of 25 to 40 wt.%, more particularly of 30 to 35 wt.%, based in each case on the total weight of all the monomers used in preparing the hydroxy-functional poly(meth)acrylate.Besides the hydroxy-functional (a1) and the carboxy-functional (a2) ethylenically unsaturated monomers, ethylenically unsaturated monomers (a3), more particularly monoethylenically unsaturated monomers (a3) being free both of hydroxyl and of carboxyl groups may be used. Suitable monomers (a3) include vinyl monomers, such as styrene. The vinyl monomer (a3), more particularly styrene, is present preferably in a total amount of 30 to 60 wt.%, more preferably of 35 to 55 wt.%, more particularly of 40 to 50 wt.%, based in each case on the total weight of all the monomers used in preparing the hydroxy-functional poly(meth)acrylate.The hydroxy-functional poly(meth)acrylate may be used in an organic solvent, preferably an aprotic solvent. A typical solvent for this purpose, for example, is n-butyl acetate, which may also be used when preparing the at least one hydroxy-functional poly(meth)acrylate. If the hydroxy-functional poly(meth)acrylate is used in a solvent, then the solvent is regarded as part of the at least one solvent of the in-mold coating composition (C1).The hydroxy-functional poly(meth)acrylate may be present in a total amount of 10 to 97 wt.%, preferably of 40 to 70 wt.%, more particularly of 40 to 50 wt.%, based in each case on the total weight of the solids content of all the binders present in the in-mold coating composition (C1).The polyester polyol may possess a hydroxyl number of 100 to 200 mg KOH / g, more preferably of 110 to 180 mg KOH / g, very preferably of 120 to 160 mg KOH / g, based in each case on the solids content.The acid number of the polyester polyol may be 0 to 9 mg KOH / g, more particularly 0.2 to 2 mg KOH / g, based in each case on the solids content. The hydroxyl number and acid number of the polyester polyol may be determined as described above.The number-average molecular weight of the polyester polyol may be in the range from 800 to 3,000 g / mol, more preferably 1,000 to 2,000 g / mol, more particularly from 1,000 to 1 ,600 g / mol. The number-average molecular weight may be determined as described above.The polyester polyol may be a branched polyester polyol.The polyester polyol may possess a hydroxyl functionality of 2.2 to 4, more preferably of 2.5 to 3.5, very preferably of 2.7 to 3.3.The polyester polyol may be present in a total amount of 40 wt.% to 97 wt.%, preferably of 40 to 70 wt.%, more particularly of 50 to 65 wt.%, based in each case on the total weight of the solids content of all the binders present in the in-mold coating composition (C1).Further suitable binders may be selected from aliphatic polyurethane(s) and / or hydroxyfunctional polyester-acrylate(s), more particularly from a mixture of aliphatic polyurethane(s) and hydroxy-functional polyester-acrylate(s). The use of such binder(s) may be preferred within aqueous in-mold coating composition(s) (C1). The use of a mixture of these binders may result in coating layers having a high flexibility and a high resistance toward environmental influences.The aliphatic polyurethane(s) may be based on polycarbonate diols and may comprise at least one group which can be converted into ionic groups (potentially ionic groups) and / or at least one nonionic group. This may facilitate dispersion of the aliphatic polyurethane(s) in an aqueous medium.The aliphatic polyurethane(s) may be prepared by reacting -OH groups of polycarbonate diols with (-NCO) groups of isocyanates to create a prepolymer that is poured and dispersed in water while a chain extension process takes place. Isocyanates useful for the preparation are typically aliphatic or cycloaliphatic diisocyanates or mixtures thereof. Examples include di-isocyanates such as for example l-isocyanate-3-isocyanate-methyl-3,5,5-trimethylcyclohexane (or isophoronediisocyanate), 4,4'-dicyclohexyl-methane-diisocyanate, hexamethylenediisocyanate, and mixtures thereof. Polycarbonate diols may be obtained for example by reacting carbonic acid derivatives, such as dialkyl carbonates, e.g. dimethyl carbonate, or phosgene, with diols. Suitable diols include ethylene glycol, 1,2- and 1,3-propanediol, 1,3- and 1,4-butanediol, 1,5- pentanediol, 1 ,6-hexanediol, cyclohexane dimethanol, diethylene glycol, dipropylene glycol, neopentylglycol and mixtures thereof.The aliphatic polyurethane(s) may not contain free / available -NCO groups. Aqueous polyurethane dispersions and methods for their preparation have been disclosed in for example WO 2011 / 124602 and WO 2018 / 172526.The aliphatic polyurethane(s) may be present in a total amount of 40 wt.% to 80 wt.%, preferably of 50 to 75 wt.%, more particularly of 60 to 70 wt.%, based in each case on the total weight of the solids content of all binders present in the in-mold coating composition (C1).Hydroxy-functional polyester-acrylate(s) may be prepared by reacting a polyester polyol with (meth)acrylic acid and / or hydroxyalkyl (meth)acrylates. The reaction may be performed in the presence of an acid catalyst. Hydroxy-functional polyester-acrylate(s) may be prepared by reacting a polyester polyol with (meth)acrylic acid and reacting the unsaturated groups with further unsaturated monomers The polyester polyol (e.g. hydroxyl groups containing polyester) may be produced according to standard processes by esterification of aliphatic, cycloaliphatic and aromatic di- and / or polyols. Examples of carboxylic acids include phthalic acid, isophthalic acid, terephthalic acid, tetrahydrophthalic acid, hexahydrophthalic acid, adipic acid, azelaic acid, sebacic acid, maleic acid, glutaric acid and longer-chain, aliphatic or cycloaliphatic dicarboxylic acids, such as dicarboxylic acids known as "dimer fatty acids". Examples of alcohols include ethylene glycol, propylene glycol-1,2 and -1,3, butanediols, pentanediols, neopentyl glycol, hexanediols, 2-methylpentanediol-1 ,5, 2-ethylbutanediol-1 ,4, dimethylol cyclohexane, glycerin, trimethylolethane, trimethylolpropane and trimethylolbutane, pentaerythritol, dipentaerythritol, polycaprolactone diols and tripols.The hydroxy-functional polyester-acrylate(s) may have OH numbers between 100 and 250 mg KOH / g solids, preferably between 130 and 170 mg KOH / g solids.The hydroxy-functional polyester-acrylate(s) may be present in a total amount of 15 wt.% to 60 wt.%, preferably of 25 to 45 wt.%, more particularly of 30 to 38 wt.%, based in each case on the total weight of the solids content of all binders present in the in-mold coating composition (C1).In an embodiment, the at least one binder is present in a total amount of 20 to 50 wt.% solids, preferably of 25 to 40 wt.% solids, more particularly of 25 to 35 wt.% solids, based in each case on the total weight of the in-mold coating composition (C1). If the binder is a dispersion or solution in a solvent, the above-recited total amounts are calculated using the solids content of the binder in each case. The total amounts represent the sum of the amounts of all binders present within the in-mold coating composition (C1). Hence, if a plurality of binders is present within the in-mold coating composition (C1), the total amount refers to the sum of the amounts of each of the binders being present within the in-mold coating composition (C1).In-mold coating composition (C1) - crosslinking agent:The in-mold coating composition (C1) further comprises at least one crosslinking agent. Said crosslinking agent comprises at least one reactive functional group which is able to undergo crosslinking reactions with complementary reactive functional groups present in the at least one binder. Since the at least one binder preferably contains reactive functional groups in the form of hydroxyl groups, preferred reactive functional groups which are able to undergo crosslinking reactions with such hydroxyl groups are isocyanate groups, amino groups or carbodiimide groups.In an embodiment, the crosslinking agent is selected from the group consisting of amino resins, polyisocyanates, blocked polyisocyanates, polycarbodiimides, photoinitiators, and mixtures thereof. Preferred crosslinking agents are unblocked polyisocyanates, i.e. polyisocyanates comprising at least two free isocyanate groups. Such polyisocyanates may have an NCO content of 10 to 50 % by weight, preferably 15 to 40 % by weight, very preferably 20 to 25 % by weight or 28 to 35 % by weight. The NCO content may be determined according to DIN EN ISO 11909:2007-05 or ASTM D 5155-2014.The polyisocyanates may comprise oligomers, preferably trimers or tetramers, of diisocyanates. The polyisocyanates may comprise iminooxadiazinediones, isocyanurates, allophanates and / or biurets of diisocyanates. The polyisocyanates may comprise aliphatic and / or cycloaliphatic, very preferably aliphatic, polyisocyanates. Examples of diisocyanates include hexamethylene diisocyanate, isophorone diisocyanate and / or methylene diphenyl diisocyanate.The hardness, flexibility, and elasticity of the pigmented coating layers may be influenced by the crosslinking agent. For example, use of polyisocyanates containing iminooxadiazinedione ring(s) leads to pigmented coating layers having a high hardness, thereby preventing structures of the fused particle foam from propagating through the surface of the coating layer(s) and allowing to achieve smooth surfaces. Use of polyisocyanates containing isocyanurate ring(s) may result in more flexible pigmented coating layers than pigmented coating layers obtained using polyisocyanates containing iminooxadiazinedione ring(s). The polyisocyanate may comprises at least one isocyanurate ring or at least one iminooxadiazinedione ring. The crosslinking agent may include a mixture of different polyisocyanates. For example, the crosslinking agent may include a mixture of a polyisocyanate comprising an isocyanurate ring and a polyisocyanate comprising an iminooxadiazinedione ring.In an embodiment, the at least one crosslinking agent is present in a total amount of 10 wt.% to 40 wt.%, preferably of 10 to 30 wt.%, more particularly of 15 to 25 wt.%, based in each case on the total weight of the in-mold coating composition (C1).In an embodiment, the molar ratio of the functional groups of the crosslinking agent, more particularly of the NCO groups, to the sum of the groups in the at least one binder that are reactive toward the functional groups of the crosslinking agent, more particularly hydroxyl groups, is 0.4:1 to 1:1, preferably 0.65:1 to 0.85:1, very preferably 0.7:1 to 0.8:1. Such molar ratio ensures that a sufficient crosslinking of the dried in-mold coating film under curing conditions is achieved, resulting in a high adhesion of the pigmented coating layer to the fused particle foam molded part.In-mold coating composition (C1) - compound(s) of general formula (I):The in-mold coating composition (C1) further comprises at least one compound of general formula (1). If r = 0 and s > 0, the compounds of the formula (I) are alkoxylated fatty alcohols, while the compounds of formula (I) are alkoxylated fatty acids, if r = 1 and s > 0.In an embodiment, R1in the general formula (I) is a saturated or unsaturated aliphatic hydrocarbon radical having 10 to 24 carbon atoms.In an embodiment, AO in the general formula (I) stands for one or more alkylene oxide radicals selected from the group consisting of ethylene oxide and propylene oxide. The radicals AO may be identical or different and within the s radicals may have a random, blockwise or gradient-like arrangement.In an embodiment, at least two different kinds of AO radicals are present and the ethylene oxide fraction in the entirety of the radicals AO is more than 50 mol%, preferably at least 70 mol%, very preferably at least 90 mol%, based on the total molar amounts of AO radicals. The AO radicals different from the ethylene oxide radicals may include propylene oxide radicals.In an embodiment, s is 0 or s is 6 to 20.Suitable compounds of general formula (I) include compounds in which residue R1is a saturated or unsaturated aliphatic hydrocarbon radical having 10 to 24 carbon atoms, AO stands for one or more alkylene oxide radicals selected from the group consisting of ethylene oxide and propylene oxide, r is 0 or 1, and s is 0 or 6 to 20.In an embodiment, the in-mold coating composition (C1) comprises a mixture of compounds of general formula (I), wherein the mixture includes at least one compound of formula (la) R1-O-(AO)S-H (la) and at least one compound of formula (lb)R1-(C=O)-OH (lb) in whichR1is a saturated or unsaturated, aliphatic hydrocarbon radical having 6 to 30 carbon atoms, preferably 12 to 22 carbon atoms,R1’ is a saturated or unsaturated, aliphatic hydrocarbon radical having 6 to 30 carbon atoms, preferably 12 to 22 carbon atoms,AO stands for one or more alkylene oxide radicals selected from the group consisting of ethylene oxide, propylene oxide and butylene oxide, preferably ethylene oxide and s is 2 to 28, preferably 6 to 20.The aforementioned mixture of compounds of formula (la) and (lb) results in a good demolding of the coated particle foam molded part without negatively influencing the high adhesion of the pigmented coating layer produced from the in-mold coating composition on the surface of the coated foam particles during fusing of the coated foam particles.In an embodiment, the at least one compound of the general formula (I) is present in a total amount of 0.1 to 10 wt.%, more preferably 0.5 to 5 wt.%, more particularly 1.5 to 4 wt.%, based in each case on the total weight of the in-mold coating composition (C1). If a mixture of compounds of the formula (I) are present, such as compounds of formula (la) and (lb), the total amount refers to the sum of the amount of each compound of general formula (I), e.g.compound of formula (la) and compound of formula (lb), present within the mixture. Hence, where more than one compound of general formula (I) is present within the in-mold coating composition (C1), the amounts indicated above are based on the total amount of all compounds which fall within general formula (I).In-mold coating composition (C1) - polyether-modified alkylpolysiloxane:The in-mold coating composition (C1), in particular the solvent-based in-mold coating composition, may further comprise at least one polyether-modified alkylpolysiloxane. Polyether- modified alkylpolysiloxanes may refer to alkylpolysiloxanes which are modified with at least one polyether group at the terminal ends and / or in the main chain. The polyether group(s) may be bonded directly and / or via an alkyl group to the silicon atom of the alkylpolysiloxane. The polyether group(s) are preferably bonded directly to the silicon atom of the alkylpolysiloxane. Preferred polyether group(s) include ethylene oxide, propylene oxide and butylene oxide groups. The use of such polyether-modified alkylpolysiloxane leads to reduced staining of the cured pigmented coating layer by environmental influences, such as dirt.The polyether-modified alkylpolysiloxane may comprise at least one structural unit (R7)2(OR6)SiOi / 2 and at least one structural unit (R7)2SiC>2 / 2, where R6is an ethylene oxide, propylene oxide, and butylene oxide group, more particularly a mixture of ethylene oxide and propylene oxide and butylene oxide groups, and R7is a C1-C10 alkyl group, more particularly a methyl group.The polyether-modified alkylpolysiloxane may have a molar ratio of siloxane to ethylene oxide groups to propylene oxide groups to butylene oxide groups of 6:21:15:1 to 67:22:16:1.The polyether-modified alkylpolysiloxane may have a molar ratio of the structural unit (R6)2(OR7)SiOi / 2 to the structural unit (R7)2SiC>2 / 2 of 1:10 to 1:15, more particularly of 1:10 to 1:13. R6and R7have the definitions listed above.The at least one polyether-modified alkylpolysiloxane may have a refractive index of 1.4 to 1.6, more preferably of 1.42 to 1.46, as determined according to DIN 51423-2:2010-02 at 23 °C.The at least one polyether-modified alkylpolysiloxane may have a viscosity of 300 to 1,500 mPa*s, more preferably 400 to 1,000 mPa*s, very preferably 500 to 900 mPa*s, as determined according to DIN 53015:2001-02 at 23 °C.The in-mold coating composition (C1) may comprise 0 to 6 % by weight, preferably 0.5 to 4 % by weight, very preferably 0.8 to 3 % by weight, based in each case on the total weight of the inmold coating composition (C1), of polyether-modified alkylpolysiloxanes, more particularly of the specific polyether-modified alkylpolysiloxanes listed above. The use of such polyether-modified alkylpolysiloxanes may improve the demolding properties of solvent-based in-mold coating compositions (C1) without negatively affecting the adhesion of the formed pigmented coating layer to the fused foam particles. Aqueous in-mold coating compositions (C1) preferably comprise 0 % by weight of such polyether-modified alkylpolysiloxanes since such compounds are not compatible with the aqueous medium of such in-mold coating compositions (C1).In-mold coating composition (C1) - polysiloxane of formula (II):In an embodiment, the in-mold coating composition (C1) comprises 0 % by weight, based on the total weight of the in-mold coating composition (C1), of at least one polysiloxane of general formula (II)R3-Si(R4)2-[O-Si(R4)(R5)]a-[O-Si(R4)2]b-O-Si(R4)2-R3(II), in whichR3and R4, in each case independently of one another, are a methyl group or a (HO-CH2)2- C(CH2-CH3)-CH2-O-(CH2)3-* radical, R5is a methyl group, a is 0 or 1 to 10, and b is 3 to 30.The *-symbol denotes the linking of the (HO-CH2)2-C(CH2-CH3)-CH2-O-(CH2)3- radical to the silicon atom, i.e. the (HO-CH2)2-C(CH2-CH3)-CH2-O-(CH2)3- is bonded via the *-symbol to the silicon atom.The radical R3in general formula (II) may be a (HO-CH2)2-C(CH2-CH3)-CH2-O-(CH2)3-* radical, the radicals R4and R5may each be a methyl group, a is 0, and b is 7 to 14.In-mold coating composition (C1) - crosslinking catalyst:In an embodiment, the in-mold coating composition (C1), preferably the solvent-based in-mold coating composition (C1), further comprises at least one crosslinking catalyst. The crosslinking catalyst serves primarily to catalyze the reaction between the functional groups of the crosslinking agent and the groups of the at least one binder that are reactive toward the functional groups of the crosslinking agent.The crosslinking catalyst may be selected from the group of the bismuth carboxylates and / or zinc carboxylates, preferably bismuth carboxylates of general formula (Illa) and / or zinc carboxylates of general formula (I I lb)Bi[OOC(CnH2n+1)]3 (Illa) Zn[OOC(CnH2n+1)]2 (Hlb) where n = 5 to 15, preferably n = 7 to 13, more particularly n = 8 to 11.The carboxylate radicals may include branched carboxylate radicals. Such branched carboxylate radicals may include a tertiary or quaternary carbon atom in the alpha-position to the carbon atom of the carboxylate group. Suitable bismuth carboxylates include bismuth trineodecanoate. Suitable zinc carboxylates include zinc neodecanoates.The bismuth carboxylates are preferably used in stabilized form in combination with the parent carboxylic acid of the carboxylate, HOOC(CnH2n+i), in which n possesses the definition indicated above. The free carboxylic acid is, for the purposes of this invention, regarded as an additive.The at least one crosslinking catalyst may be present in a total amount of O wt.% to 3.5 wt.%, preferably of 0.1 to 2 wt.%, very preferably of 0.4 to 1.5 wt.%, based in each case on the total weight of the in-mold coating composition (C1). The crosslinking catalyst may be used in solvent-based in-mold coating compositions (C1) in amounts of 0.1 to 2 wt.%, very preferably of 0.4 to 1.5 wt.%, to reduce curing times. Aqueous in-mold coating compositions (C1) preferably comprise 0 % by weight of the crosslinking catalyst since sufficient crosslinking can be achieved without the use of such catalyst.In-mold coating composition (C1) - additives:In an embodiment, the in-mold coating composition (C1) further comprises at least one additive selected from the group consisting of wetting agents and / or dispersants, viscosity modifier, coalescing agents, flow control agents, UV absorbers, and mixtures thereof.The at least one additive may be present in a total amount of 0 wt.% to 10 wt.%, based on the total weight of the in-mold coating composition (C1).In-mold coating composition (C1) - preparation:The in-mold coating composition (C1) may be configured as a multicomponent system (i.e. a kit- of-parts) comprising at least two separate components, i.e. at least one binder containing component (base varnish) and at least one crosslinker containing component (hardener) to avoid undesired reaction of the binder and crosslinker upon storage. The base varnish and thehardener may be mixed together before application to prepare the in-mold coating composition. The time remaining for application of the produced in-mold coating composition after mixing may be denoted as pot life and may define the time period the in-mold coating composition can be applied without negatively affecting the application equipment or the quality of the resulting pigmented coating layer.The base varnish may include all components of the in-mold coating composition (C1) except the crosslinking agent. The hardener may include the at least one crosslinking agent. The at least one crosslinking agent may be dissolved in a solvent, such as an organic solvent. The hardener may further include additives, such as coalescing agents.The kit-of-parts may comprise further components, for example a dilution component comprising at least one solvent and optionally at least one viscosity modifier to modify the viscosity of the in-mold coating composition (C1). The at least one solvent can be identical or different from the solvent in the base varnish and / or the hardener. If a different solvent is used, said solvent is preferably compatible with the solvent in the base varnish and / or the hardener to prevent undesired phase separation, agglomeration or precipitation upon mixing.To prepare the aqueous in-mold coating composition (C1), the base varnish and the hardener may be mixed in a weight ratio of 100:1 to 100:100, more preferably from 100:2 to 100:80, more particularly from 100:3 to 100:20. To prepare the solvent-based in-mold coating composition (C1), the base varnish and the hardener may be mixed in a weight ratio of 100:10 to 100:100, more preferably from 100:20 to 100:80, more particularly from 100:50 to 100:70. The use of the above-described mixing ratios ensures sufficient crosslinking of the respective in-mold coating composition (C1) during curing, resulting in a high adhesion of the cured pigmented coating layer formed on the surface of the fused foam particles as well as an excellent demoldability of the produced coated particle foam molded part.Mixing may take place manually, with the appropriate amount of the base varnish being introduced into a vessel, admixed with the corresponding quantity of the hardener and optionally further components. However, mixing of the two or more components may also be performed automatically by means of an automatic mixing system. Such an automatic mixing system may comprise a mixing unit, more particularly a static mixer, and at least two devices for supplying the base varnish and hardener, such as gear pumps and / or pressure valves. The static mixer may be a commercially available helical mixer, which is installed into the material supply line about 50 to 100 cm ahead of the atomizer. Preferably 12 to 18 mixing elements (for each element 1 cm in length, diameter 6 to 8 mm) may be used to obtain sufficient mixing of the twocomponents. In order to prevent clogging of the material supply line, it is preferred if the mixing unit is programmed so that not only the helical mixer but also the downstream hose line and the atomizer are flushed with the base varnish every 7 to 17 minutes. Where the composition is applied by means of robots, this flushing operation may take place when the robot head is in a pre-defined rest position. Depending on the length of the hose line, about 50 to 200 ml are discarded into a catch vessel. A preferred alternative to this procedure is the semi continuous conveying of the mixed in-mold coating composition (C1). If composition is forced out regularly (every 7 to 17 minutes, likewise into a catch vessel), it is possible to reduce the quantity of discard material to a minimum (about 10 to 50 ml). Furthermore, provision may be made for the hose line from the mixer to the atomizer, and also the atomizer, to be flushed. This flushing operation is preferred in particular after prolonged downtime of the system or at the end of a shift, to ensure a long lifetime of the equipment and continuous quality of the in-mold coating composition (C1).Mixing may be performed at temperatures of 15 to 70°C, more preferably 15 to 40°C, more particularly 20 to 30°C.In-mold coating composition (C1) - application:The in-mold coating composition (C1) can be applied using commonly known application gear for liquid coating compositions, for example spray guns, or by means of an application robot. In terms of economy, the use of application robots is preferred. The robots may be programmed for the geometry of the mold parts and may apply the in-mold coating composition (C1) pneumatically and autonomously to the inner surface of the mold parts.Nozzles used for application may have a diameter of 0.05 to 1.5 mm, preferably of 0.08 to 1 mm, more particularly of 0.1 to 0.8 mm.The mold cavity may have a surface temperature in step (A) of 20 to 100 °C, preferably of 40 to 80 °C, very preferably of 60 to 70 °C. Thus, the mold (MO) may be pre-heated before the application of the in-mold coating composition (C1) in step (A). Heating of the mold may be performed by supplying heat or by irradiation, for example IR radiation. In case the mold is preheated, said mold can be open or closed during the preheating. In case the mold is closed during preheating, the mold may be opened before applying the in-mold coating composition (C1).Step (B) :In step (B) of the inventive process, the applied in-mold coating composition (C1) may be dried. Drying may result in the formation of a coating film (CF) on the inner surface of the mold being in contact with the applied in-mold coating composition (C1). Drying of the applied in-mold coating composition (C1) may refer to the evaporation of solvents from the applied in-mold coating composition (C1). Drying may be performed at ambient temperature or by use of elevated temperatures. However, the drying does not result in a pigmented coating layer being ready for use, i.e. a cured pigmented coating layer, because the formed coating film (CF) is still soft or tacky after drying. Since the in-mold coating composition (C1) is still flowable directly after application and at the start of the drying process it can form a uniform, smooth coating film (CF) during the drying process.In an embodiment, the in-mold coating composition (C1) is dried in process step (B) for a period of 20 seconds to 60 minutes, preferably of 20 seconds to 25 minutes.In an embodiment, the in-mold coating composition (C1) is dried in process step (B) at a temperature of 20 to 120°C, more preferably 20 to 70°C or 20 to 100 °C. Solvent-based in-mold coating compositions (C1) may be dried at temperatures of 20 to 70°C. Aqueous in-mold coating compositions (C1) may be dried at temperatures of 20 to 100 °C.In an embodiment, the dry film thickness of the coating film (CF) formed in process step (B) is 20 to 120 pm, more particularly 25 to 100 pm.Step (C):In step (C) of the inventive process, foam particles comprising a coating (e.g. coated foam particles) are filled into the mold cavity. The coating may be obtained by mixing the foam particles with the composition (C2) comprising the aqueous polyurethane dispersion (PD) to produce a coating on the foam particles and drying the produced coating. The coating may be bound to the foam particle surface as patches, or a continuous shell-like layer, wherein the surface of the foam particles may be completely or partially covered with the coating. The coating may be in solid state at ambient conditions.Foam particles:Foam particles or also foam beads or foam granules in the sense of the present invention refers to a foam in the form of a lot of loose particles of the same chemical nature or of different chemical nature, the average length of the particles preferably being in the range of 1 to 20 mm. In the case of non-spherical, e.g., oval particles average length means the longest dimension bylength (determined by 3D evaluation of the granules, for example by means of dynamic image analysis with an optical measuring device named “PartAn 3D”, Microtrac).The single foam granules may have an average mass in the range of 0,1 to 50 mg, preferable in the range between 0,5 and 45 mg. The average mass means in this context the arithmetic mean based on a sample size of 10 different particles wherein each particle is weighted three times.The foam particles may have a bulk density of 20 g / l to 350 g / l, preferably 30 g / l to 250 g / l, more preferably 40 g / l to 200 g / l. The bulk density is measured analogously to DIN ISO 60:1999, wherein the determination of the above values in contrast to the standard, a vessel with 10 I volume is used instead of a vessel with 0,1 I volume, since especially for the foam particles with low density and large mass a measurement with only 0,1 I volume is too inaccurate.In an embodiment, the foam particles are selected from the group consisting of styrene polymer foam particles, polyurethane foam particles, polyamide foam particles, thermoplastic elastomer foam particles, polyolefine foam particles and mixtures thereof.In an embodiment, the foam particles are thermoplastic polyurethane foam particles. Thermoplastic polyurethane foam particles may be expanded foam particles and may belong to the group of particle foams, which are also referred to as foamed pellets (or bead foams, particle foam, expanded thermoplastic elastomer particles or expanded thermoplastic polyurethane beads). Particle foams and moldings (also referred to as molded article) made therefrom, based on thermoplastic polyurethanes or other thermoplastic elastomers, are known (for example WO 94 / 20568A1 , WO 2007 / 082838 A1 , WO2017 / 030835 A1, WO 2013 / 153190 A1, WO 2010 / 010010 A1 , WO 2019 / 202095, WO 2018 / 087362) and can be used in many ways.It is also possible to use mixtures of different coated foam particles in step (C). For example, the coated foam particles may comprise at least two different types of coated foam particles based on different polymers or different particle sizes. Two or more different types of coated foam particles may refer to a mixture of different lots of loose coated foam particles, wherein the lots differ in their chemical nature. In principle, all types of coated foam particles can be mixed regardless of their thermal properties such as melting point or glass transition. It is for example possible that the coated foam particles comprise a mixture of at least two thermoplastic coated foam particles selected from the group consisting of coated styrene polymer foam particles,coated polyamide foam particles, coated thermoplastic elastomer foam particles, coated polyolefin foam particles and mixtures thereof.Aqueous polyurethane dispersion (PD):Aqueous polyurethane dispersions (PD) may refer to dispersions of at least one polyurethane polymer within an aqueous medium. The aqueous medium may be made predominantly of water or else of a mixture made of predominantly water and of water-soluble organic solvents with boiling points, which are preferably below 150°C (1 bar). Particular preference is given to water as sole solvent within the aqueous medium. The aqueous polyurethane dispersion (PD) may include at least one polyurethane polymer. The aqueous polyurethane dispersion (PD) may include exactly one polyurethane polymer. In general, the aqueous polyurethane dispersion (PD) can be prepared by methods known in the art. Exemplary methods are described in WO 2021 / 249749 A1.The aqueous polyurethane dispersion (PD) may comprise at least one polyurethane (e.g polyurethane polymer) as polymeric binder dispersed in water, and optionally additives. Preferred additives may be selected from the group consisting of ionic surfactants, non-ionic surfactants, rheology modifiers (including thickeners), anti-blocking additives, other aqueous dispersions, cross-linkers, plasticizers, stabilizers against hydrolytic degradation, biocides, fillers and antifoam agents.Suitable polyurethanes are obtainable in principle through reaction of at least one polyisocyanate with at least one compound, which has at least two groups reactive toward isocyanate groups. Polyurethanes also encompass what are called polyurethane-polyureas, which as well as polyurethane groups also have urea groups as well.The at least one polyurethane may comprise in copolymerized form at least one polyisocyanate and at least one polyol. The aqueous polyurethane dispersion may comprise at least one polyurethane which comprises in copolymerized form at least one polyisocyanate and a diol component, of which a) 10 -100 mol%, based on the total amount of the diols, have a molecular weight of 500 to 5000 g / mol and b) 0 - 90 mol%, based on the total amount of the diols, have a molecular weight of 60 to less than 500 g / mol. Polymeric polyols are preferred. Suitable polymeric polyols are preferably selected from polyester diols, polyether diols, and mixtures thereof. The polymeric polyol preferably has a number-average molecular weight in the range from about 500 to 5000 g / mol.The at least one polyurethane is preferably synthesized to an extent of at least 40% by weight, more preferably at least 60% by weight, and very preferably at least 80% by weight, based on the total weight of the monomers used in preparing the polyurethane, of at least one diisocyanate and at least one polyether diol and / or polyester diol. Suitable further synthesis components to 100% by weight are, for example, polyisocyanates having at least three NCO groups, and compounds that are different from the polymeric polyols and have at least two groups reactive toward isocyanate groups. These include, for example, non-polymeric diols; diamines; polymers different from polymeric polyols and having at least two active hydrogen atoms per molecule; compounds which have two active hydrogen atoms and at least one ionogenic or ionic group per molecule; and mixtures thereof.The at least one polyurethane may have crystallinity. Preferred polyurethanes with crystallinity may be synthesized from:(i) at least one monomeric diisocyanate,(ii) at least one diol comprising a diol having a number-average molecular weight in the range from 500 to 5000 g / mol,(iii) at least one monomer, different from the monomers (i) and (ii), having at least one isocyanate group or at least one group reactive toward isocyanate groups, and additionally carrying at least one hydrophilic group or potentially hydrophilic group,(iv) optionally at least one further compound, different from the monomers (i) to (iii), having at least two reactive groups selected from alcoholic hydroxyl groups, primary or secondary amino groups or isocyanate groups, and(v) optionally at least one monofunctional compound, different from the monomers (i) to (iv), having a reactive group which is an alcoholic hydroxyl group, a primary or secondary amino group or an isocyanate group.Suitable monomeric diisocyanates (i) and diols (ii) are described in the EP patent application EP22202204.8.In order to make the polyurethanes dispersible in water they comprise as synthesis components monomers (iii), which carry at least one isocyanate group or at least one group reactive toward isocyanate groups and, furthermore, at least one hydrophilic group or a group which can be converted into a hydrophilic group. In the text below, the term “hydrophilic groups or potentially hydrophilic groups” is abbreviated to “(potentially) hydrophilic groups”. The (potentially) hydrophilic groups react with isocyanates at a substantially slower rate than do the functional groups of the monomers used to synthesize the polymer main chain. The fraction of the components having (potentially) hydrophilic groups among the total quantity of components (i)to (v) is generally such that the molar amount of the (potentially) hydrophilic groups, based on the amount by weight of all monomers (i) to (v), is from 30 to 1000, preferably 50 to 500, and more preferably 80 to 300 mmol / kg. The (potentially) hydrophilic groups can be nonionic or, preferably, (potentially) ionic hydrophilic groups.Particular suitable nonionic hydrophilic groups and ionic hydrophilic groups are described in the EP patent application EP22202204.8.The monomers (iv), which are different from the monomers (i) to (iii) and which may also be constituents of the polyurethane, may serve for crosslinking or chain extension. They may comprise nonphenolic alcohols with a functionality of more than 2, amines having 2 or more primary and / or secondary amino groups, and compounds which as well as one or more alcoholic hydroxyl groups carry one or more primary and / or secondary amino groups. Alcohols having a functionality of more than 2, which may be used in order to set a certain degree of branching or crosslinking, include for example trimethylolpropane, glycerol, or sugars. Other suitable compounds (d) are alpha, omega-diaminopolyethers, which are preparable by aminating polyalkylene oxides with ammonia. Compounds (d) are, for example, also isocyanates, which as well as free isocyanate groups carry further, masked isocyanate groups, e.g., uretdione groups or carbodiimide groups.Monomers (v), which are used optionally, are monoisocyanates, monoalcohols, and mono primary and -secondary amines. Their fraction is generally not more than 10 mol%, based on the total molar amount of the monomers. These monofunctional compounds customarily carry further functional groups such as olefinic groups or carbonyl groups and serve to introduce into the polyurethane functional groups, which facilitate the dispersing and / or the crosslinking or further polymer-analogous reaction of the polyurethane. Monomers suitable for this purpose include those such as isopropenyl-a,a’ -dimethylbenzyl isocyanate (TMI) and esters of acrylic or methacrylic acid such as hydroxyethyl acrylate or hydroxyethyl methacrylate.The at least one polyurethane present within the aqueous polyurethane dispersion (PD) and having at least a first glass transition temperature Tgiand a second glass transition temperature Tg2 may be prepared from(i) at least one organic diisocyanate, selected from diisocyanates of the formula X(NCO)2, where X is a noncyclic aliphatic hydrocarbon radical having 4 to 15 carbon atoms, a cycloaliphatic hydrocarbon radical having 6 to 15 carbon atoms, an aromatic hydrocarbon radical having 6 to 15 carbon atoms, or an araliphatic hydrocarbon radical having 7 to 15carbon atoms, wherein the amount of aromatic diisocyanates is less than 60 mol-%, based on the sum of all organic diisocyanates a);(ii) at least one dihydroxy compound having a molecular weight of 500 g / mol to 5000 g / mol and selected from the group consisting of polyesterdiols, polyetherols and polytetrahydrofuran;(iii) at least one dihydroxy compound selected from the group consisting of branched or unbranched acyclic diols having 2 to 8 C atoms, and cyclic diols having 3 to 8 C atoms, the at least dihydroxy compound having preferably a molecular weight from 62 g / mol to 200 g / mol.(iv) at least one compound having at least one group reactive toward isocyanate groups, and additionally carrying at least one ionic group or one group which can be converted into an ionic group, wherein the compounds c) preferably contain a group selected from carboxylate groups and sulfonate groups,(v) optionally further compounds different from a) to c).Preferred polyurethanes may be synthesized from:(i) at least one monomeric diisocyanate, the at least diols (ii) and (iii), (iv) at least one monomer, different from the monomers (i) to (iii), having at least one isocyanate group or at least one group reactive toward isocyanate groups, and additionally carrying at least one hydrophilic group or potentially hydrophilic group, (v) optionally at least one further compound, different from the monomers (i) to (iv), having at least two reactive groups selected from alcoholic hydroxyl groups, primary or secondary amino groups or isocyanate groups, and (vi) optionally at least one monofunctional compound, different from the monomers (i) to (v), having a reactive group which is an alcoholic hydroxyl group, a primary or secondary amino group or an isocyanate group.The at least one polyurethane may be an anionic polyurethane. Preferably, the aqueous polyurethane dispersion is an aqueous anionic polyurethane dispersion (e.g. an aqueous dispersion comprising at least one anionic polyurethane) made with low amount of aromatic diisocyanates or no aromatic diisocyanates, e.g. less than 60 mol%, based on the sum of all organic diisocyanates (i). The anionic groups of the at least one anionic polyurethane are preferably selected from carboxylate groups and sulfonate groups. The same applies to the polyurethane comprised in the at least partly coated particle and shaped body according to the present invention.Particular mention may be made as monomers (i) of diisocyanates X(NCO)2, where X is a noncyclic aliphatic hydrocarbon radical having 4 to 15 carbon atoms, a cycloaliphatic or aromatic hydrocarbon radical having 6 to 15 carbon atoms, or an araliphatic hydrocarbonradical having 7 to 15 carbon atoms. Examples of such diisocyanates include tetramethylene diisocyanate, hexamethylene diisocyanate (HDI), dodecamethylene diisocyanate, 1,4-diiso- cyanatocyclohexane, 1-isocyanato-3,5,5-trimethyl-3-isocyanatomethyl-cyclohexane (IPDI), 2,2- bis(4-isocyanatocyclohexyl)-propane, trimethylhexane diisocyanate, 1,4-diisocyanatobenzene, 2,4-diisocyanatotoluene, 2,6-diisocyanatotoluene (TDI), 4,4’-diisocyanato-diphenylmethane, 2,4’-diisocyanatodiphenylmethane, p-xylylene diisocyanate, tetramethylxylylene diisocyanate (TMXDI), the isomers of bis(4-isocyanatocyclohexyl)methane (HMDI) such as the trans / trans, the cis / cis, and the cis / trans isomers, and mixtures of these compounds. Diisocyanates of this kind are available commercially. With particular preference the diisocyanate is selected from the group consisting of hexamethylene diisocyanate, 1-isocyanato-3,5,5-trimethyl-3-isocyanato- methylcyclohexane, 2,6-diisocyanatotoluene, and tetramethylxylylene diisocyanate, or a mixture thereof. Particularly important mixtures of these isocyanates are the mixtures of the respective structural isomers of diisocyanatotoluene and diisocyanatodiphenylmethane; the mixture of 80 mol% 2,4-diisocyanatotoluene and 20 mol% 2,6-diisocyanatotoluene is particularly suitable. Also of particular advantage are the mixtures of aromatic isocyanates such as 2,4- diisocyanatotoluene and / or 2,6-diisocyanatotoluene with aliphatic or cycloaliphatic isocyanates such as hexa- methylene diisocyanate or IPDI, in which case the preferred molar mixing ratio of the aliphatic to the aromatic isocyanates is 1:9 to 9:1, more particularly 4:1 to 1 :4. It is also preferred that only aliphatic isocyanates are used.The diols (ii) may be polyester polyols, which are known, for example, from Ullmanns Enzyklopadie der technischen Chemie, 4thedition, volume 19, pp. 62 to 65. It is preferred to use polyester polyols which are obtained by reacting dihydric alcohols with dibasic carboxylic acids. Instead of the free polycarboxylic acids it is also possible to use the corresponding polycarboxylic anhydrides or corresponding polycarboxylic esters of lower alcohols or mixtures thereof to prepare the polyester polyols. The polycarboxylic acids can be aliphatic, cyclo aliphatic, araliphatic, aromatic or heterocyclic and can optionally be substituted, by halogen atoms for example, and / or unsaturated. Examples thereof include the following: suberic acid, azelaic acid, phthalic acid, isophthalic acid, phthalic anhydride, tetrahydrophthalic anhydride, hexahydrophthalic anhydride, tetrachlorophthalic anhydride, endomethylene tetrahydrophthalic anhydride, glutaric anhydride, maleic acid, maleic anhydride, fumaric acid, and dimeric fatty acids. Preferred dicarboxylic acids are those of the general formula HOOC-(CH2)y-COOH, where y is a number from 1 to 20, preferably an even number from 2 to 20, examples being succinic acid, adipic acid, sebacic acid, and dodecane dicarboxylic acid. Examples of suitable dihydric alcohols include ethylene glycol, propane-1,2- diol, propane-1, 3-diol, butane-1 , 3-diol, butene-1, 4-diol, butyne-1,4-diol, pentane-1, 5-diol, neopentyl glycol, bis(hydroxymethyl) cyclohexanes such as 1,4-bis(hydroxymethyl)cyclohexane, 2-methylpropane-1, 3-diol,methylpentanediols, and also diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycol, dipropylene glycol, polypropylene glycol, and dibutylene glycol and polybutylene glycols. To obtain crystallinity preferred alcohols are those of the general formula HO-(CH2)X-OH, where x is a number from 1 to 20, preferably an even number from 2 to 20. Examples of such alcohols are ethylene glycol, butane-1, 4-diol, hexane-1, 6-diol, octane-1, 8- diol, and dodecane-1,12-diol.The diols (ii) may also be polytetrahydrofuran. Suitable polytetrahydrofurans can be prepared by cationic polymerization of tetra hydrofuran in the presence of acidic catalysts, such as sulfuric acid or fluorosulfuric acid, for example. Preparation processes of this kind are known to the skilled person.The diols (ii) may also be polyether diols. Polyether diols are obtainable in particular by polymerizing ethylene oxide, propylene oxide, butylene oxide, tetrahydrofuran, styrene oxide or epichlorohydrin with itself, in the presence of BF3 for example, or by subjecting these compounds, optionally in a mixture or in succession, to addition reaction with starter components containing reactive hydrogen atoms, such as alcohols or amines, examples being water, ethylene glycol, propane-1, 2-diol, propane-1 , 3-diol, 2,2-bis(4-hydroxyphenyl)propane, and aniline. Particular preference is given to polyether diols with a molecular weight of 500 to 5000, and in particular 600 to 4500.The aqueous polyurethane dispersion may comprise at least one polyurethane with a K-value in the range from 40 to 100 determined according to DIN EN ISO 1628-1 2021. The K-value is a relative viscosity number, which is determined in analogy to or according to DIN EN ISO 1628-1 2021 at 25°C. It comprises the flow rate of a 1 weight-% strength solution of the polyurethane in DMF, relative to the flow rate of pure DMF, and characterizes the average molecular weight of the polyurethane.The aqueous polyurethane dispersion (PD) may have a solid content of at least 40 wt.-% based on the total weight of the dispersion (PD), more preferably in the range of from 45 wt.-% to 60 wt.-% based on the total weight of the dispersion (PD).The polyurethane present within the aqueous polyurethane dispersion (PD) may have a viscosity of less than 300 mPas at 23 °C, preferably less than 200 mPas at 23 °C, measured according to DIN EN ISO 3219-2:2021 at 23°C and a shear rate of 250 s-1.In an embodiment, the aqueous polyurethane dispersion (PD) has a glass transition temperature Tgmeasured according to DIN EN ISO 11357-2 2018 from -10°C to -80°C and a melting temperature Tmof in the range from 30°C to 100°C.The aqueous polyurethane dispersion (PD) may have a glass transition temperature Tgof below 0 °C, more preferably from -10 °C to -80 °C, even more preferably, from -20 °C to -75°C, even more preferably from -30 °C to -70 °C, even more preferably from -40 °C to -65 °C, even more preferably, from -45 °C to -60 °C. The glass transition temperature can be determined by differential scanning calorimetry according to DIN EN ISO 11357-2 (2014), as so-called midpoint temperature. The glass transition temperature of the aqueous polyurethane dispersion (PD) may correspond to the glass transition temperature obtained when evaluating the second heating curve (heating rate 20°C / min).The aqueous polyurethane dispersion (PD) may have at least a first glass transition temperature Tgiand a second glass transition temperature Tg2, wherein Tgiis below 0°C and Tg2 is higher than 25 °C. More preferably, Tg2 is higher than 40 °C, even more preferably higher than 50 °C, even more preferably higher than 60 °C. Typically, the at least one polyurethane polymer present within the aqueous polyurethane dispersion (PD) has a Tgifrom -10 °C to -60 °C and a Tg2from 60 °C to 90 °C. In an embodiment, the at least one polyurethane polymer present within the aqueous polyurethane dispersion (PD) has at least a first glass transition temperature and a second glass transition measured according to DIN EN ISO 11357-2 2018, wherein Tgiis below 0°C and Tg2 is higher than 25°C. Preferably, the at least one polyurethane polymer present within the aqueous polyurethane dispersion (PD) has exactly two Tg.The aqueous polyurethane dispersion (PD) may have a melting temperature Tmof in the range from 30 °C to 100 °C, preferably from 40 °C to 80 °C. Melting-points and enthalpy of fusion are determined according to DIN EN ISO 11357-3 (2018) (melting point = peak temperature) by heating with 20 K / min after cooling to -80°C; while enthalpy of fusion of the second run (Delta H2) is calculated from the area of second melting only. Tgand Tmof the aqueous polyurethane dispersion (PD) means that the aqueous polyurethane dispersion (PD) is dried and Tgand Tmvalues are determined from the resulting film.Preparation of foam particles comprising the coating (e.g. coated foam particles):In an embodiment, the composition (C2) comprising the aqueous polyurethane dispersion (PD) contains:(i) from 90 to 100% by weight of the aqueous polyurethane dispersion (PD) and(ii) from 0 to 10% by weight of additives,wherein the entirety of components (i) and (ii) provides 100% by weight.Mixing may include common methods for coating, like spray coating, e.g., as described in EP0009727A1. The foam particles may be spray coated keeping them in motion via blowing them with e.g., air or mixtures of different gases. The foam particles may be contacted with the composition (C2). This may include keeping the foam particles in motion while applying the composition (C2) by devices known to the person skilled in the art, such as for example kitchen mixer, cement mixer, conveyor belt, vibrating channel, or spray coating drum to obtain a sufficient surface coating.Drying may be achieved by all suitable methods are possible, like convective drying, contact drying, infrared drying and, also microwave technology.In an embodiment, the foam particles comprise the coating in an amount from 0.5% to 40% by weight based on the total weight of foam particles and the coating.Step (D):In step (D), the coating film (CF) formed in step (B) may be cured while simultaneously fusing the foam particles comprising the coating. Curing and fusing may be achieved by supplying energy. Curing of the coating film (CF) may refer to the conversion of such a film into a ready-to- use state, i.e. into a state in which the fused particle foam part provided with the respective pigmented coating layer can be transported, stored and used as intended. More particularly, the cured pigmented coating layer is no longer soft or tacky, but has been conditioned as a solid coating layer which does not undergo any further significant change in its properties, such as hardness or adhesion to the fused particle foam molded part, even under further exposure to curing conditions. Curing can be performed at higher temperatures and / or for longer times than used for drying of the applied in-mold coating composition (C1).In an embodiment, step (D) is carried out by steamless thermo-pressing. The thermo-pressing may be carried out at a temperature of from 80°C to 160°C, in particular of 100°C to 150°C.Further step(s):The inventive process may include further steps, such as one or more step(s) outlined in the following.The inventive process may include a step of opening the mold (MO) and removing the coated particle foam molded part. This may be accomplished by altering at least one part of the mold,in particular hydraulically, before the mold (MO) is opened. Furthermore, provision may be made requiring closure mechanisms for the closing of the mold (MO) to be opened before the mold (MO) is opened. Removing of the coated particle foam molded part may be performed using commonly used tools. Opening of the mold and / or removing of the coated particle foam molded part may be performed either manually or automatically.The coated particle foam molded part may be post-treated, for example by trimming and / or polishing and / or coating the obtained coated particle foam molded part. The coated particle foam molded part may be coated directly - without a sanding procedure, optionally after simple cleaning - with further coating materials such as, for example, with one or more basecoat materials and / or one or more clearcoat materials, to form one or more basecoat layers and / or one or more clearcoat layers, respectively. The coated particle foam molded part is preferably not coated with a primer or primer surfacer coating layer. Instead, a basecoat film or a topcoat film, more particularly a clearcoat film, may be applied directly to the coated particle foam molded part. The applied basecoat material(s) and / or clearcoat material(s) can be cured separately or jointly. As basecoat and topcoat, more particularly clearcoat, materials, all basecoat and clearcoat materials may be used that are conventionally employed in coating. Such basecoat and clearcoat materials are available, for example, from BASF Coatings GmbH.The inventive process may include a cleaning step after removal of the coated particle foam molded part. In said cleaning step, the mold (MO) may be cleaned, for example by manual or automatic cleaning. The mold (MO) may be cleaned by sandblasting or by use of organic solvents. This cleaning step ensures that the surface of the molding parts of the mold (MO) do not comprise unwanted contaminants and thus avoids lowering the adhesion of the pigmented aqueous coating composition to the surface of the molding parts and hence the demolding properties as well as the optical and mechanical properties of the coated particle foam molded part. Cleaning may be carried out after 20 to 100, more particularly 20 to 50, repetitions of the process steps (A) to (D). Cleaning of the mold (MO) after the production of 20 to 100 coated particle foam molded part permits an efficient process regime, since the mold (MO) does not have to be cleaned after being used only once. Furthermore, the amount of cleaning wastes is reduced.The process of the invention allows to produce a coating on the surface of fused particle foams during the fusing process coated foam particles, hence avoiding costly and inconvenient aftertreatment of particle foam molded parts to achieve a coating on said parts. The coating layer obtained on the particle foam molded parts by the use of the in-mold coating composition (C1) has a sufficient adhesion and can be crosslinked under conditions used for fusing thecoated foam particles. Moreover, the formed coating layer is highly elastic or flexible and also UV-resistant and nonshiny, hence resulting not only in damage-free demolding of the coated particle foam molded part but also in effective protection of the coated particle foam molded part produced with respect to environmental influences such as UV radiation, dirt or the like, directly after the production of the coated particle foam molded part. Because the in-mold coating composition (C1) used in the process of the invention at the same time has a release agent effect, this in-mold coating composition can be used both as a release agent and for producing the pigmented coating layer. Accordingly there is no need for the use of a separate external release agent on surfaces of the mold covered with the in-mold coating composition or resulting dried coting film, requiring costly and inconvenient removal of residues of said agent from the formed coated particle foam molded parts before aftertreatment of said material. Since only small residues of the in-mold coating composition (C1) remain in the mold (MO), the molds (MO) do not have to be cleaned before each application of the in-mold coating composition (C1). The use of coated foam particles in combination with the in-mold coating composition (01) allows to reduce the energy consumption, the material consumption and the waste generation associated with the production of the coated particle foam molded part. In addition, the use of an aqueous in-mold coating composition (01) allows to reduce VOC emissions resulting during drying and / or curing due to organic solvents present within the in-mold coating composition (01). Hence, the inventive process is associated with an improved environmental impact compared to processes using solvent-based in-mold coating compositions and / or the use of post-coating processes to produce coated particle foam molded parts.The invention is described in particular by the following embodiments:1. A process for preparing a coated particle foam molded part, wherein the coated particle foam molded part comprises at least one pigmented coating layer on at least a part of the surface of the particle foam molded part, the method comprising the steps of(A) application of at least one in-mold coating composition (C1) to at least a part of an inner surface of a closable, three dimensional mold (MO) having at least two mold parts which are movable relative to each other and which form a mold cavity including the inner surface,(B) drying the applied in-mold coating composition (C1) to form a coating film (CF),(C) filling foam particles comprising a coating into the mold cavity, wherein the coating obtained by mixing the foam particles with a composition (C2) comprising an aqueous polyurethane dispersion (PD) to produce the coating on the foam particles and drying the produced coating,(D) producing the coated particle foam molded part by at least partially curing the coating film (CF) while fusing the foam particles comprising the coating by supplying energy, wherein the in-mold coating composition (C1) comprises:(a) at least one solvent,(b) at least one pigment,(c) at least one binder,(d) at least one crosslinking agent, and(e) at least one compound of the general formula (I)R1-(C=O)rO-(AO)s-R2(I) in which R1is a saturated or unsaturated, aliphatic hydrocarbon radical having 6 to 30 carbon atoms, R2is H,AO stands for one or more alkylene oxide radicals selected from the group consisting of ethylene oxide, propylene oxide and butylene oxide, r is 0 or 1, and s is 0 to 30.2. The process according to embodiment 1, wherein the process is a manual process or an automatic process.3. The process according to embodiment 1 or 2, wherein the mold parts are selected from metallic mold parts, preferably aluminum, steel, nickel or copper mold parts, very preferably aluminum and / or steel mold parts, and / or from polymeric mold parts.4. The process according to any one of the preceding embodiments, wherein the in-mold coating composition (C1) has a viscosity of 10 to 60 s, more particularly of 20 to 30 s (DIN4 flow cup), measured according to DIN EN ISO 2431 (March 2012).5. The process according to any one of the preceding embodiments, wherein the in-mold coating composition has a solids content of 30 to 60 wt.%, preferably of 35 to 55 wt.%, more preferably of 40 to 50 wt.%, very preferably of 42 to 48 wt.%, measured according to ASTM D2369 (2015) (110°C, 60 min).6. The process according to any one of the preceding embodiments, wherein the in-mold composition (C1) is an aqueous in-mold coating composition or a solvent-based in-mold coating composition (C1).7. The process according to any one of the preceding embodiments, wherein the at least one solvent is preferably present in a total amount of 40 to 70 wt.%, more preferably 45 to 65 wt.%, and very preferably 50 to 60 wt.%, especially 52 to 58 wt.%, based in each case on the total weight of the in-mold coating composition (C1)..8. The process according to any one of the preceding embodiments, wherein the at least one pigment is selected from color pigment(s) and / or effect pigment(s).9. The process according to any one of the preceding embodiments, wherein the at least one pigment is present in a total amount of 0.1 wt.% to 10 wt.%, based on the total weight of the in-mold coating composition (C1).10. The process according to any one of the preceding embodiments, wherein the at least one binder is present in a total amount of 20 to 50 wt.% solids, preferably of 25 to 40 wt.% solids, more particularly of 25 to 35 wt.% solids, based in each case on the total weight of the in-mold coating composition (C1).11. The process according to any one of the preceding embodiments, wherein the at least one binder is selected from the group consisting of (i) poly(meth)acrylates, more particularly hydroxy-functional and / or carboxylate-functional and / or amine-functional poly(meth)acrylates, (ii) polyurethanes, more particularly hydroxy-functional and / or carboxylate-functional and / or amine-functional polyurethanes, (iii) polyesters, more particularly polyester polyols, (iv) polyethers, more particularly polyether polyols, (v) copolymers of the stated polymers, and (vi) mixtures thereof, preferably from aliphatic polyurethanes, and / or hydroxy-functional polyester-acrylates or from hydroxy-functional poly(meth)acrylates and / or polyester polyols.12. The process according to embodiment 11 , wherein the hydroxy-functional poly(meth)acrylate is present in a total amount of 10 wt.% to 97 wt.%, preferably of 40 to 70 wt.%, very preferably of 40 to 50 wt.%, based in each case on the total weight of the solids content of all binders present in the in-mold coating composition (C1).13. The process according to embodiment 11 or 12, wherein the polyester polyol is present in a total amount of 40 wt.% to 97 wt.%, preferably of 40 to 70 wt.%, more particularly of 50 to 65 wt.%, based in each case on the total weight of the solids content of all binders present in the in-mold coating composition (C1).14. The process according to any one of embodiments 11 to 13, wherein the aliphatic polyurethane is present in a total amount of 40 wt.% to 80 wt.%, preferably of 50 to 75 wt.%, more particularly of 60 to 70 wt.%, based in each case on the total weight of the solids content of all binders present in the in-mold coating composition (C1).15. The process according to any one of embodiments 11 to 14, wherein the hydroxyfunctional polyester-acrylate is present in a total amount of 15 wt.% to 60 wt.%, preferably of 25 to 45 wt.%, more particularly of 30 to 38 wt.%, based in each case on the total weight of the solids content of all binders present in the in-mold coating composition (C1).16. The process according to any one of the preceding embodiments, wherein the crosslinking agent is selected from the group consisting of amino resins, polyisocyanates, blocked polyisocyanates, polycarbodiimides, photoinitiators, and mixtures thereof, preferably from polyisocyanates.17. The process according to embodiment 17, wherein the polyisocyanate comprises at least one isocyanurate ring or at least one iminooxadiazinedione ring.18. The process according to any one of the preceding embodiments, wherein the at least one crosslinking agent is present in a total amount of 10 wt.% to 40 wt.%, preferably of 10 to 30 wt.%, more particularly of 15 to 25 wt.%, based in each case on the total weight of the in-mold coating composition (C1).19. The process according to any one of the preceding embodiments, wherein the molar ratio of the functional groups of the crosslinking agent, more particularly of the NCO groups, to the sum of the groups in the at least one binder that are reactive toward the functional groups of the crosslinking agent, more particularly hydroxyl groups, is 0.4:1 to 1:1, preferably 0.65:1 to 0.85:1, very preferably 0.7:1 to 0.8:1.20. The process according to any one of the preceding embodiments, wherein R1in the general formula (I) is a saturated or unsaturated aliphatic hydrocarbon radical having 10 to 24 carbon atoms.21. The process according to any one of the preceding embodiments, wherein AO in the general formula (I) stands for one or more alkylene oxide radicals selected from the group consisting of ethylene oxide and propylene oxide.22. The process according to any one of the preceding embodiments, wherein at least two different kinds of AO radicals are present and the ethylene oxide fraction in the entirety of the radicals AO is more than 50 mol%, preferably at least 70 mol%, very preferably at least 90 mol%, based on the total molar amounts of AO radicals.23. The process according to any one of the preceding embodiments, wherein s is 0 or s is 6 to 20.24. The process according to any one of the preceding embodiments, wherein the in-mold coating composition (C1) comprises a mixture of compounds of general formula (I), wherein the mixture includes at least one compound of formula (la)R1-O-(AO)S-H (la) and at least one compound of formula (lb)R1-(C=O)-OH (lb) in whichR1is a saturated or unsaturated, aliphatic hydrocarbon radical having 6 to 30 carbon atoms,R1’ is a saturated or unsaturated, aliphatic hydrocarbon radical having 6 to 30 carbon atoms,AO stands for one or more alkylene oxide radicals selected from the group consisting of ethylene oxide, propylene oxide and butylene oxide, and s is 2 to 28.25. The process according to any one of the preceding embodiments, wherein the at least one compound of the general formula (I) is present in a total amount of 0.1 to 10 wt.%, more preferably 0.5 to 5 wt.%, more particularly 1.5 to 4 wt.%, based in each case on the total weight of the in-mold coating composition (C1).26. The process according to any one of the preceding embodiments, wherein the in-mold coating composition (C1), in particular a solvent-based in-mold coating composition (C1), comprises at least one polyether-modified alkylpolysiloxane.27. The process according to embodiment 26, wherein the at least one polyether-modified alkylpolysiloxane comprises at least one structural unit (R7)2(OR6)SiOi / 2 and at least one structural unit (R7)2SiC>2 / 2, where R6is an ethylene oxide, propylene oxide, and butyleneoxide group, more particularly a mixture of ethylene oxide and propylene oxide and butylene oxide groups, and R7is a C1-C10 alkyl group, more particularly a methyl group.28. The process according to embodiment 26 or 27, wherein the polyether-modified alkylpolysiloxane has a molar ratio of the structural unit (R6)2(OR7)SiOi / 2to the structural unit (R7)2SiO2 / 2of 1 : 10 to 1 : 15, more particularly of 1 : 10 to 1 : 13.29. The process according to any one of embodiments 26 to 28, wherein the at least one polyether-modified alkylpolysiloxane is present in a total amount of 0 to 6 % by weight, preferably 0.5 to 4 % by weight, very preferably 0.8 to 3 % by weight, based in each case on the total weight of the in-mold coating composition (C1).30. The process according to any one of the preceding embodiments, wherein the in-mold coating composition (C1), comprises 0 % by weight, based on the total weight of the inmold coating composition (C1), of at least one polysiloxane of general formula (II)R3-Si(R4)2-[O-Si(R4)(R5)]a-[O-Si(R4)2]b-O-Si(R4)2-R3(II), in whichR3and R4, in each case independently of one another, are a methyl group or a (HO-CH2)2- C(CH2-CH3)-CH2-O-(CH2)3-* radical,R5is a methyl group, a is 0 or 1 to 10, and b is 3 to 30.31. The process according to any one of the preceding embodiments, wherein the in-mold coating composition (C1), in particular the solvent-based coating composition (C1), further comprises at least one crosslinking catalyst.32. The process according to embodiment 31 , wherein the crosslinking catalyst is selected from the group of the bismuth carboxylates and / or zinc carboxylates, preferably bismuth carboxylates of general formula (Illa) and / or zinc carboxylates of general formula (111 b)Bi[OOC(CnH2n+1)]3(Illa) Zn[OOC(CnH2n+1)]2(lllb) where n = 5 to 15, preferably n = 7 to 13, more particularly n = 8 to 11.33. The process according to embodiment 31 or 32, wherein the at least one crosslinking catalyst is present in a total amount of 0 wt.% to 3.5 wt.%, preferably of 0.1 to 2 wt.%, very preferably of 0.4 to 1 .5 wt.%, based in each case on the total weight of the in-mold coating composition (C1).34. The process according to any one of the preceding embodiments, wherein the in-mold coating composition (C1) further comprises at least one additive selected from the group consisting of wetting agents and / or dispersants, rheological assistants, flow control agents, UV absorbers, and mixtures thereof.35. The process according to embodiment 34, wherein the at least one additive is present in a total amount of O wt.% to 10 wt.%, based on the total weight of the in-mold coating composition (C1).36. The process according to any one of the preceding embodiments, wherein the in-mold coating composition (C1) is dried in process step (B) for a period of 20 seconds to 60 minutes, preferably of 20 seconds to 25 minutes.37. The process according to any one of the preceding embodiments, wherein the in-mold coating composition (C1) is dried in process step (B) at a temperature of 20 to 100°C, more preferably 20 to 70°C or of 20 to 100°C.38. The process according to any one of the preceding embodiments, wherein the dry film thickness of the coating film (CF) formed in process step (B) is 20 to 120 pm, more particularly 25 to 100 pm.39. The process according to any one of the preceding embodiments, wherein the foam particles are selected from the group consisting of styrene polymer foam particles, polyurethane foam particles, polyamide foam particles, thermoplastic elastomer foam particles, polyolefine foam particles and mixtures thereof.40. The process according to any one of the preceding embodiments, wherein the foam particles are thermoplastic polyurethane foam particles.41. The process according to any one of the preceding embodiments, wherein the aqueous polyurethane dispersion (PD) comprises at least one polyurethane with a K-value in the range from 40 to 100 determined according to DIN EN ISO 1628-1 2021.42. The process according to any of the preceding embodiments, wherein the aqueous polyurethane dispersion (PD) has a glass transition temperature Tgmeasured accordingto DIN EN ISO 11357-2 2018 from -10°C to -80°C and a melting temperature Tmof in the range from 30°C to 100°C determined according to DIN EN ISO 11357-3 (2018) by heating with 20 K / min after cooling to -80°C.43. The process according to any of the preceding embodiments, wherein the aqueous polyurethane dispersion (PD) has at least a first glass transition temperature and a second glass transition measured according to DIN EN ISO 11357-2 2018, wherein Tgiis below 0°C and Tg2is higher than 25°C.44. The process according to any of the preceding embodiments, wherein the composition (C2) comprising the aqueous polyurethane dispersion (PD) contains:(iii) from 90 to 100% by weight of the aqueous polyurethane dispersion (PD) and(iv) from 0 to 10% by weight of additives, wherein the entirety of components (i) and (ii) provides 100% by weight.45. The process according to any of the preceding embodiments, wherein the foam particles comprise the coating in an amount from 0.5% to 40% by weight based on the total weight of foam particles and the coating.46. The process according to any of the preceding embodiments, wherein step (D) is carried out by steamless thermo-pressing.47. The process of embodiment 46, wherein the thermo-pressing is carried out at a temperature of from 80°C to 160°C, in particular of 100°C to 150°C.48. A coated particle foam molded part prepared according to the process of any one of embodiments 1 to 47.49. Use of the coated particle foam molded part according to embodiment 48 in shoe soles, part of shoe soles, shoe intermediate soles shoe insoles, damping elements, cushioning elements, protective devices, underlays, grips, flooring, mattresses, sporting goods, bicycle saddles, and in automotive interiors and exteriors.EXAMPLESThe inventive and comparative examples below serve to illustrate the invention but should not be interpreted as imposing any restriction. Unless indicated otherwise, the amounts in parts are parts by weight, and the amounts in percent are percentages by weight, in each case.1. Methods of determination:1.1. DemoldabilityThe success of demoldability of the coated molded non-crosslinked polymer material from the three-dimensional mold is determined by removing the molded material from the mold and visually assessing the obtained molded material. If the coated molded non-crosslinked poylmer material could be fully demolded and no damage is detected visually, the demoldability is “OK”. If the molded non-crosslinked polymer material could not be demolded or the molded non- crosslinked polymer material was visually destroyed during demolding, the demoldability is rated “not OK”.1.2. OH numberThe OH number is determined according to DIN 53240-2:2007-11. The OH groups are reacted by acetylation with an excess of acetic anhydride. The excess acetic anhydride is subsequently split by addition of water to form acetic acid, and the entire acetic acid is back-titrated with ethanolic KOH. The OH number indicates the quantity of KOH in mg that is equivalent to the amount of acetic acid bound in the acetylation of 1 g of sample. The OH number is based on the solids content of the sample.1.3 ViscosityThe Viscosity is measured according to DIN EN ISO 3219-2:2021 at 23°C and a shear rate of 250 s’1.1.4 Thermal propertiesThe dispersions are dried in a mold at 40°C for 3 days and then at 23°C for 7 days. Thermal properties are measured by differential scanning calorimetry.Glass-transition temperature (as the midpoint temperature of the second heating curve at a heating rate of 20 K / min), melting-points and enthalpy of fusion are determined according to DIN ISO 11357 (2018) (melting point = peak temperature) by heating with 20 K / min after cooling to -80°C, while enthalpy of fusion of the second run (Delta H2) is calculated from the area of second melting only; a) from a film at its untreated state (drying see above) -> Tm1, Delta H1b) after heating the polyurethane films to 130 °C, cooling with 20 K / min to -80°C; reheating with 20k / min-> Tm2 delta H21.5 K-valueThe K-value was determined according to DIN EN ISO 1628-1:20212. Preparation of aqueous polyurethane dispersions (PD) for coating of foam particles2.1 Dispersion 1 (PD1)1039 g of a polyesterdiol from Adipic acid and Isophthalic acid (molar ratio of 1 :1) and 1,6 g Hexanediol (molecular weight 2000 g / mol), 104,6 g of Dimethylolpropionic acid (DMPA), 186.8 g Butanediol- 1,4 were reacted with 900 g isophorone diisocyanate (IPDI) in 530 g dry acetone in a pressurized reactor; starting at 50°C, increasing the temperature in 30 min to 90°C, then as 90°C is reached keeping the temperature constant for 8 h at 2.9 bar. After that, the obtained mixture was diluted with 1852 g acetone, cooled to 40°C and expanded to atmospheric pressure. The NCO-value was determined to 1.2%. Then 10.2 g of Isophoronediamine were added in a shot, followed by adding 81 g Diethylethanolamine (neutralization agent) within a period of 5 min. After 5 min stirring, the dispersion step was continued by adding 3567 g deionized water within a period of 37 min at 30°C, followed by an addition of 19.8 Diethylenetriamine stirred in 340 g deionized water within a period of 30 min. After that, the acetone was removed by vacuum distillation with the help of 0.23 g of defoamer (FoamStar PB 2724, BASF), resulting in Dispersion 1 with a solids content of 37.4%. The properties of the obtained dispersion 1 are shown in Table 1.Table 1: Properties of aqueous polyurethane dispersion 1 (PD1)2.2 Dispersion 2 (PD2)676 g of a polyesterdiol with a molecular weight of 2493 g / mol (based on adipic acid and 1,4- butanediol) were reacted with 0.11 g titaniumtetrabutylate, 40 g isophorone diisocyanate (IPDI,), 0.77 g NCO-terminated polycarbodiimid (Elastostab H02, BASF) at 60°C in 153 g dry acetone for 60 min. Then, 37.8 g 1 ,6-hexane diisocyanate (HDI) was added and the temperature raised to 74°C. The reaction was continued until the NCO-value has fallen below 1.25%. The mixture was diluted with 539 g acetone and cooled to 35-40°C. Then 22.4 g of aminoethylaminoethansulfonate sodium salt (50% aqueous solution) diluted with 22 g demineralized water was added within a period of 3 min, followed by adding 4.6 g isophorone diamine, diluted in 23 g demineralized water within a period of 3 min. Before dispergation, 38.7 g of a 20% aqueous solution of alkyl polyethylene glycol ether made from a linear, saturated C16C18 fatty alcohol with 18 moles of ethylene oxide, 20% active (e.g., Lutensol AT18 from BASF) was added. In the next step, the dispergation of the produced compound with 463 g demineralized water was carried out by using an anchor stirrer over a period of 15 min. Immediately after the water feed, additionally 4 g of N-(2- aminoethyl)-ethanolamine solved in 30 g water was added during the dispergation. During dispergation an additional amount of 200 g demineralized water was added.After the dispergation step, the acetone was removed by vacuum distillation with the help of two drops of defoamer (FoamStar PB 2724, BASF) and the solids content of the obtained semicrystalline dispersion adjusted to 50% by addition of controlled amount of water. The properties of the obtained dispersion are shown in Table 2.Table 2: Properties of aqueous polyurethane dispersion 2 (PD2)3. Preparation of foam particlesExperiments were carried out with thermoplastic polyurethane foam particles (E-TPLI) made according to W02013 / 153190 A1. The formulation of the thermoplastic polyurethanes (TPU) used as precursor material for the foam particles as well as the composition of the foam particles and their bulk density and particle weight are shown in Table 3, wherein Polytetrahydrofuran is abbreviated to PTHF and Diphenylmethylenediisocyanate is abbreviated to MDI, and Mndenotes the number average molecular weight.Table 3: Overview of precursor materials, composition of E-TPLI foam particles and properties of E-TPLI foam particles4. Preparation of foam particles comprising a coating (e.g. coated foam particles)To produce foam particles with a surface coating, the respective aqueous polyurethane dispersion (PD) was fed in a dispersion mixer (Vollrath dissolver) together with a defined amount of foam particles and mixed for 60 s at room temperature. Afterwards, the wetted foam particles were spread on Teflon foils and dried there at room temperature for about 10 minutes, keeping attention to isolate them from each other. Afterwards, the coated foam particles were collected. An overview of the used raw materials and the compositions is given in Table 4. The obtained coated foam particles are non-sticky, storage stable and can be collected without agglomeration.Table 4: Materials used to produce foam particles comprising a coating (% by weight is based on total amount of aqueous polyurethane dispersion and foam particles)In Table 4, the mass fraction of the dried coating is calculated from the mass fraction of the amount of the aqueous polyurethane dispersion (PD) applied to the foam particles and the solid content therein, e.g., 5 g aqueous polyurethane dispersion mixed with 95 g of foam particles means a weight fraction of 5% of aqueous polyurethane dispersion 2. Considering the solid content of 50% of the dispersion 2, a 2.5 % mass fraction of the dried coating is obtained.5. Preparation of in-mold coating compositions (C1)The in-mold coating compositions (C1) were prepared from the following base varnish and hardener compositions.5.1 Base varnish compositionsTable 5: Base varnish compositions (all amounts are stated in % by weight based on the total weight of the respective base varnish composition)1)hydroxyl-functional poly(meth)acrylate having a hydroxyl number of 82.5 mg KOH / g, an acid number of 10 mg KOH / g, Mnabout 6800 g / mol, Mwabout 17 000 g / mol (BASF SE),2)polyester polyol having a hydroxyl number of 115 mg KOH / g and a hydroxyl functionality of about 3.5 (Covestro),3)mixture of compounds of formula (la) with R1= mixture of saturated and unsaturated hydrocarbon radicals having 12 to 22 carbon atoms, AO = mixture of primarily ethylene oxide units and a few propylene oxide units, and R2= H (Mn» 650 g / mol); and compounds of formula (lb) with R1’ = unsaturated hydrocarbon radical having 21 carbon atoms (Munch Chemie International GmbH),4)hydroxy-modified polysiloxane (Siltec GmbH & Co. KG),5)bismuth neodecanoate in neodecanoic acid (Dura Chemicals),6)UV absorber, 2-(2H-benzotriazol-2-yl)-4, 6-bis (1-methyl-1-phenylethyl)phenol (BASF SE),7)light absorber blend based on a 2-hydroxyphenyl-s-triazine UV absorber and a basic HALS (BASF SE),8)Zinc neodecanoate (Dura Chemicals),9)the black color paste contains 84.9 wt.% of an acrylic resin prepared by polymerizing styrene, butylacrylate, hydroxyethyl methacrylate, methyl methacrylate and isodecyl methacrylate in the presence of di-tert-butyl peroxide, 6.2 wt.% Disperbyk 161 (Byk Chemie GmbH), 1.4 wt.% xylene, 1.9 wt.% carbon black (Monarch 1300, Cabot Corporation), 2.7 wt.% methylisobutylketone and 2.9 wt.% butylacetate10)anionic water-based dispersion of aliphatic polyurethane based on polycarbonate diols (Lehmann&Voss&Co.)11)water-dilutable, hydroxyl group-containing, polyester modified acrylic resin, OH number 140- 160 mg KOH / g solids (Synthopol Chemie Dr. rer. pol. Koch GmbH & Co. KG)12)the black color paste is prepared according to example 2.2, paragraph

[0240] of EP 4004125B15.2 Hardener compositionsTable 6: Hardener compositions (all amounts are stated in % by weight based on the total weight of the respective hardener composition)1)hexamethylene diisocyanate trimer of isocyanurate type with an NCO content of 11.0 wt.% (Covestro),2)hexamethylene diisocyanate trimer of the iminooxadiazinedione type with an NCO content of23.5 wt.% (Covestro),3)hydrophilic aliphatic polyisocyanate based on hexamethylene diisocyanate with an NCO content of 21 wt.% (Covestro),4)aliphatic polyisocyanate resin based on isophorone diisocyanate with an NCO content of 11 wt.% (Covestro),5)coalescing agent based on dicarboxylic acids-diisobutyl ester (BASF SE),5.3 Preparation of aqueous in-mold coating composition (C1-1)The aqueous in-mold coating composition (C1-1) was prepared by mixing 100 parts of base varnish BV2 with 4 parts of hardener 2.5.4 Preparation of solvent-based in-mold coating composition (C1-2)The solvent-based in-mold coating composition (C1-2) was prepared by mixing 100 parts of base varnish BV1 with 55 parts of hardener 1.6. Preparation of coated particle foam molded partsThe in-mold coating composition C1-1 is applied pneumatically (SATA Jet 4000 B HVLP with nozzle 1.0) onto an inner surface of a mold cavity of a 3D mold pre-heated to 90°C (3D mold dimensions 16.3 cm x 9.6 cm x 3.3 cm) and dried for 20 to 100 seconds. The in-mold coating composition C1-2 is applied pneumatically (SATA Jet 4000 B HVLP with nozzle 1.0) onto an inner surface of a mold cavity of a 3D mold pre-heated to 70°C (3D mold dimensions 16.3 cm x 9.6 cm x 3.3 cm) and dried for 20 to 100 seconds.For the composition C1-1 the mold temperature is increased to 120°C and afterwards the prepared foam particles as listed in Table 7 were filled into the mold cavity. The filled mold was covered with a mold lid, which allows a compression / compaction of 50%. Compression molding of the coated foam particles while simultaneously curing the respective in-mold coating composition was performed at a mold temperature of 120°C for 10 min for the composition C1- 1 , followed by a cooling time of 5 min before demolding the produced coated particle foam molded part from the mold. For the composition C1-2 the mold temperature is increased to 140C and afterwards the prepared foam particles as listed in Table 7 were filled into the mold cavity. The filled mold was covered with a mold lid, which allows a compression / compaction of 50%. Compression molding of the coated foam particles while simultaneously curing the respective in-mold coating composition was performed at a mold temperature of 140°C for 10 min for the composition C1-2, followed by a cooling time of 5 min before demolding the produced coated particle foam molded part from the mold. In contrast to steam chest molding, the obtained coated particle foam molded parts do not need to be stored or annealed, e.g., for drying purposes. Instead, the coated molded parts can be used directly for subsequent production processes.Table 7: Overview of prepared coated particle foam parts and determined characteristics.inventive1)Coated foam particles prepared as described in Table 47. ResultsThe coated particle foam parts produced in examples #1 to #3 were analyzed regarding tensile strength and elongation measured according to ASTM D 5035:2011, where instead of fabric strips (150 x 25.4 x 1.6) mm3e-TPU strips were used. Furthermore, the rebound was measured according to DIN 53512:2000-4 and the density of the obtained 3D parts measured according to DIN EN ISO 845:2009-10. The coated particle foam parts were furthermore analyzed withregard to homogeneity of color and demoldability. An overview of the obtained results for examples #1 to #6 produced as described in point 6. above is listed in Table 8 below.Table 8: Overview of test results for coated particle foam parts #1 to #41)determined by visual evaluation; rated as “OK” if a defect-free coating is achieved on the surface of the fused particle foam2)determined by visual evaluation; rated as “OK” If the coated particle foam molded part could be fully demolded and no damage is detected visually on the coated foam molded partThe results obtained for inventive coated particle foam molded parts #1 to #4 demonstrate that the use of the aqueous in-mold coating composition (C1-1) or solvent-based in-mold coating composition (C1-2) in combination with foam particles comprising a coating produced from a composition (C2) containing an aqueous polyurethane dispersion (PD) can be used to produce coated particle foam molded parts via a thermo-pressing process hence allowing to avoid the use of steam-chest molding requiring high amounts of energy and removal of the moisture from the molded parts. The produced parts have good mechanical properties which are not negatively influenced by the coating formed on the surface of the fused foam particles. The formed pigmented coating layer has a sufficient flexibility to allow bending of the produced parts without destroying the formed pigmented coating layer.In addition the inventive coated particle foam molded parts #1 to #4 show a uniform coating layer having a homogenous color, i.e. no coating defects as well as no color differences could be detected in the coating layer by visual inspection, and sufficiently high hiding power, i.e. the color of the underlying fused foam particles was no longer visible through the formed pigmented coating layer. Inventive coated particle foam molded parts #1 to #4 could be easily demolded from the mold and the demolded coated particle foam parts do not show any visual damages hence demonstrating that the in-mold coating compositions (C1-1) and (C1-2) do not only allow to provide a pigmented coating layer but simultaneously provide release agent properties, hence rendering the use of an external release agent superfluous.In summary, use of in-mold coating compositions (C1) in combination with foam particles comprising a coating prepared by mixing such foam particles with a composition (C2)comprising an aqueous polyurethane dispersion (PD) allows to obtain coated particle foam parts having good mechanical properties as well as good optical properties. This avoids the use of post-coating processes to achieve the desired appearance of particle foam molded parts, hence reducing the overall energy, material consumption and waste generation associated with the production of coated particle foam parts. Since the in-mold coating composition (C1) simultaneously provides release agent properties, the use of external release agents can be omitted, allowing to further reduce material consumption and avoiding cleaning processes to remove adhering external release agent after the molding process. The conditions present during thermo-pressing allow to sufficiently cure the coating film (CF) formed from the applied in-mold coating composition (C1), hence rendering additional curing processes superfluous and resulting in a high adhesion of the cured pigmented coating layer formed from the coating film (CF) on the fused particle foam formed from the coated foam particles due to the simultaneous curing and fusion. Overall, the use of in-mold coating compositions resulting in pigmented coating layer(s) having good optical and mechanical properties during production of particle foam molded parts allows to reduce the environmental impact associated with the inventive process by reducing the required energy, material consumption, waste generation, and required post-coating processes.

Claims

Claims1. A process for preparing a coated particle foam molded part, wherein the coated particle foam molded part comprises at least one pigmented coating layer on at least a part of the surface of the particle foam molded part, the method comprising the steps of(A) application of at least one in-mold coating composition (C1) to at least a part of an inner surface of a closable, three dimensional mold (MO) having at least two mold parts which are movable relative to each other and which form a mold cavity including the inner surface,(B) drying the applied in-mold coating composition(s) (C1) to form coating film(s) (CF),(C) filling foam particles comprising a coating into the mold cavity, wherein the coating is obtained by mixing the foam particles with a composition (C2) comprising an aqueous polyurethane dispersion (PD) to produce the coating on the foam particles and drying the produced coating,(D) producing the coated particle foam molded part by at least partially curing the coating film(s) (CF) while fusing the foam particles comprising the coating by supplying energy, wherein the in-mold coating composition (C1) comprises:(a) at least one solvent,(b) at least one pigment,(c) at least one binder,(d) at least one crosslinking agent, and(e) at least one compound of the general formula (I)R1-(C=O)rO-(AO)s-R2(I) in which R1is a saturated or unsaturated, aliphatic hydrocarbon radical having 6 to 30 carbon atoms,R2is H,AO stands for one or more alkylene oxide radicals selected from the group consisting of ethylene oxide, propylene oxide and butylene oxide, r is 0 or 1, and s is 0 to 30.

2. The process of claim 1, wherein R1in the general formula (I) is a saturated or unsaturated aliphatic hydrocarbon radical having 10 to 24 carbon atoms.

3. The process of claim 1 or 2, wherein at least two different kinds of AO radicals are present and the ethylene oxide fraction in the entirety of the radicals AO is more than 50 mol%,preferably at least 70 mol%, very preferably at least 90 mol%, based on the total molar amounts of AO radicals.

4. The process according to any one of the preceding claims, wherein s is 0 or s is 6 to 20.

5. The process according to any one of the preceding claims, wherein the in-mold coating composition (C1) comprises a mixture of compounds of general formula (I), wherein the mixture includes at least one compound of formula (la)R1-O-(AO)S-H (la) and at least one compound of formula (lb)R1-(C=O)-OH (lb) in whichR1is a saturated or unsaturated, aliphatic hydrocarbon radical having 6 to 30 carbon atoms,R1’ is a saturated or unsaturated, aliphatic hydrocarbon radical having 6 to 30 carbon atoms,AO stands for one or more alkylene oxide radicals selected from the group consisting of ethylene oxide, propylene oxide and butylene oxide, and s is 2 to 28.

6. The process according to any one of the preceding claims, wherein the at least one compound of the general formula (I) is present in a total amount of 0.1 to 10 wt.%, more preferably 0.5 to 5 wt.%, more particularly 1.5 to 4 wt.%, based in each case on the total weight of the in-mold coating composition (C1).

7. The process according to any one of the preceding claims, wherein the in-mold coating composition (C1) is an aqueous in-mold coating composition (C1) or a solvent-based inmold coating composition (C1).

8. The process according to any one of the preceding claims, wherein the foam particles are thermoplastic polyurethane foam particles.

9. The process according to any one of the preceding claims, wherein the at least one aqueous polyurethane dispersion (PD) comprises at least one polyurethane with a K- value in the range from 40 to 100 determined according to DIN EN ISO 1628-1 2021.

10. The process according to any of the preceding claims, wherein the aqueous polyurethane dispersion (PD) has at least a first glass transition temperature and a second glass transition measured according to DIN EN ISO 11357-2 2018, wherein Tgiis below 0°C and Tg2is higher than 25°C.

11. The process according to any of the preceding claims, wherein the foam particles comprise the coating in an amount from 0.5% to 40% by weight based on the total weight of foam particle and the coating.

12. The process according to any of the preceding claims, wherein step (D) is carried out by steamless thermo-pressing.

13. The process of claim 12, wherein the thermo-pressing is carried out at a temperature of from 80°C to 160°C, in particular of 100°C to 150°C.

14. A coated particle foam molded part prepared according to the process of any one of claims 1 to 12.

15. Use of the coated particle foam molded part according to claim 14 in shoe soles, part of shoe soles, shoe intermediate soles shoe insoles, damping elements, cushioning elements, protective devices, underlays, grips, flooring, mattresses, sporting goods, bicycle saddles, and in automotive interiors and exteriors.

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