Method for producing at least one component by means of an injection moulding device and injection moulding device for carrying out the method

Abstract

The invention relates to a method for producing at least one component (10) by means of an injection moulding device (12), comprising the steps A to U, and to an injection moulding device (12) for carrying out the method. The method for producing at least one component (10) by means of an injection moulding device (12), wherein the injection moulding device (12) comprises a tool (14) which has a first tool part (16) and a second tool part (18), wherein the first tool part (16) has a first mould region (100) and a second mould region (200), wherein the second mould part (18) has a third mould region (300) and a fourth mould region (400), wherein the second tool part (18) can be rotated into a first rotary position (20) and into a second rotary position (22), wherein the tool (14) can be brought from an open tool state into a closed tool state and can be brought from the closed tool state back into the open tool state, wherein the first mould region (100) and the third mould region (300) form a first cavity (1) in the closed tool state and the second mould region (200) and the fourth mould region (400) form a second cavity (2) in the closed tool state when the second tool part (18) is in the first rotary position (20), wherein the first mould region (100) and the fourth mould region (400) form a third cavity (3) in the closed tool state and the second mould region (200) and the third mould region (300) form a fourth cavity (4) in the closed tool state when the second tool part (18) is in the second rotary position (22), comprises the following steps: (A) bringing the tool (14) into the open state or leaving the tool (14) in the open state, (B) at least partially arranging at least one film (24, 25) in the second mould region (200) and / or the fourth mould region (400), (C) rotating the second tool part (18) into the first rotary position (20) or leaving the second tool part (18) in the first rotary position (20), (D) bringing the tool (14) into the closed state and injecting a first injection moulding material (26) into the second mould region (200) and / or fourth mould region (400) to form a first preform (30) of a component (10) to be produced where, with respect to the preform, the film (24) is connected to the first injection moulding material (26), (E) bringing the tool (14) into the open state and leaving the first preform (30) of the component (10) produced in step D in the fourth mould region (400), (F) rotating the second tool part (18) into the second rotary position (22), (G) bringing the tool (14) into the closed state, (H) injecting a second injection moulding material (27) or the second injection moulding material (27) into the third cavity (3) to form a second preform (32) of the component (10), (I) bringing the tool (14) into the open state and leaving the second preform (32) of the component (10) produced in step H in the first mould region (100), (J) rotating the second tool part (18) into the first rotary position (20), (K) if a further component (10) is to be produced, continuing the method with step L, otherwise continuing the method with step R, (L) at least partially arranging at least one further film (24, 25) in the second mould region (200) and / or the fourth mould region (400), (M) bringing the tool (14) into the closed state and injecting the first injection moulding material (26) into the second mould region (200) and / or fourth mould region (400) to form the first preform (30) of a further component (10) to be produced where, with respect to the preform, the film (24) is connected to the first injection-moulding material (26), (N) injecting a third injection moulding material (28) or the third injection moulding material (28) into the first cavity (1) to form the final form (36) of the component (10), (O) bringing the tool (14) into the open state, (P) removing the final form (36) of the component (10) formed in step N in the first cavity (1) from the tool (14) and leaving the first preform (30) of the further component (10) produced in step M in the fourth mould region (400), (Q) continuing the method with step F, (R) bringing the tool (10) into the closed state, (S) injecting a third injection moulding material (28) or the third injection moulding material (28) into the first cavity (1) to form the final form (36) of the component (10), (T) bringing the tool (14) into the open state, and (U) removing the final form (36) of the component (10) from the tool (14).

Description

[0001] Method for producing at least one component by means of an injection molding device and injection molding device for carrying out the method

[0002] Background of the invention

[0003] The present invention relates to a method for producing at least one component by means of an injection molding device and an injection molding device for carrying out this method.

[0004] It is known to produce multi-component components, which include a film, by injection molding, whereby the films are back- and / or over-molded with injection molding material.

[0005] The film can in particular be a film designed as a design film, which is intended as an outer film or as a film forming an outer layer of the respective multi-component component or article. In other applications, such a film, which is usually made of a plastic material, can also be intended to mechanically reinforce or protect the component. Components are also known in which the film is designed as a heating film which is connected to a respective plastic core of the component. In the injection molding production of such components, several injection molding materials are usually used to form the desired multi-component component.The respective injection molding process is very complex, especially if, depending on the application, more than two different injection molding materials have to be injected into the respective cavities of the respective injection molding tool to form the corresponding preforms right up to the respective final shape. For the injection molding production of such components or articles, it is known to use an injection molding tool with what is known as indexable insert technology, in which two interconnected tool halves can be rotated about a rotation axis to form the cavities of the respective preforms or final shape, in such a way that one of the two tool halves can be turned towards one of two other tool halves. In this way, by appropriate rotation, the cavities required for the production of the multi-component component can be formed by connecting the respective tool halves to form a closed tool.The use of this type of indexable insert technology is technically very complex and also costly. The equipment used is always a special machine in the form of an indexable insert machine, which requires a lot of space. This special machine requires two complete injection molding tools, which is very complex. Furthermore, such a special machine can only be used with other standard injection molding tools at additional expense. For this, the indexable insert must be removed or a "dummy tool" must be suspended in the respective parting line.

[0006] Underlying task

[0007] The present invention is therefore based on the object of specifying a method with which at least one multi-component component with at least one film can be produced with significantly less effort than the known solutions and of specifying an injection molding device for carrying out this method.

[0008] Inventive solution

[0009] This object is achieved according to the invention with a method having the features of claim 1 and with an injection molding device having the features of claim 9.

[0010] The method according to the invention is a method for producing at least one component or for producing at least one multi-component component with at least one film using an injection molding device. This injection molding device comprises a tool or an injection molding tool with a first tool part and a second tool part.

[0011] The first tool part or the first tool half of the tool has a first forming area and a second forming area.

[0012] The second tool part or the second tool half has a third mold area and a fourth mold area.

[0013] The second tool part is rotatable into a first rotational position and into a second rotational position, or the second tool part is rotatable into a first rotational position and into a second rotational position relative to the first tool part.

[0014] The tool can be transferred from an open tool state to a closed tool state and from the closed tool state back to the open tool state. The tool can be closed, as is known from injection molding devices, in particular by moving the first tool part towards the second tool part or by moving the second tool part towards the first tool part, or can be transferred from the open tool state to the closed tool state. Furthermore, the tool can be opened, as is known from injection molding devices, in particular by moving the first tool part away from the second tool part or by moving the second tool part away from the first tool part, or can be transferred back to the open tool state.It is also understood that the tool can be transferred from the open tool state to the closed tool state, in particular by moving the two tool parts towards each other, and can be transferred back from the closed tool state to the open tool state, in particular by moving the two tool parts away from each other.

[0015] The first mold area and the third mold area form a first cavity in the closed tool state, and the second mold area and the fourth mold area form a second cavity in the closed tool state when the second tool part is in the first rotational position. The first cavity and the second cavity - into which the injection molding materials intended to form the preforms and final shape of the component to be manufactured are to be injected - can therefore be formed by transferring the tool to the closed tool state with the second tool part already arranged in the first rotational position. The first rotational position is therefore the rotational position in which the formation of the first and second cavities is possible by closing the tool.

[0016] The first mold area and the fourth mold area form a third cavity in the closed tool state, and the second mold area and the third mold area form a fourth cavity in the closed tool state when the second tool part is in the second rotational position. The third cavity and the fourth cavity - into which the injection molding materials intended to form the preforms and final shape of the component to be manufactured are to be injected - can therefore be formed by transferring the tool to the closed tool state with the second tool part already arranged in the second rotational position. The second rotational position is therefore the rotational position in which the formation of the third and fourth cavities is possible by closing the tool.

[0017] The second tool part is rotatable into the first rotational position and the second rotational position. It is understood that the first and second rotational positions can be converted into one another by rotating through an angle of 180 degrees or by rotating through an angle of substantially 180 degrees. In other words: the second tool part is rotatable from the first rotational position to the second rotational position by rotating through an angle of 180 degrees or by rotating through an angle of substantially 180 degrees. Furthermore, the second tool part is rotatable from the second rotational position to the first rotational position by rotating through an angle of 180 degrees or by rotating through an angle of substantially 180 degrees. It is understood that the rotational distance between the first and second rotational positions is 180 degrees or substantially 180 degrees in order to provide for the formation of the first, second, third, and fourth cavities by the four mold regions as set forth above.(Potthast's note: This also clarifies my question at the time - without this restriction to 180 degrees, the process is probably not feasible.)

[0018] It is also understood that, to achieve the above-described rotatability, the second tool part can be rotated by at least 180 degrees about a rotational axis, with the second tool part preferably being rotatable by more than 180 degrees about this rotational axis. Particularly preferably, the second tool part can be rotated by 360 degrees about this rotational axis.

[0019] A particularly practical way to achieve the rotation of the second mold part around the rotation axis is to connect the second mold part to a rotating plate that can rotate 360 ​​degrees within the injection mold. In technical jargon, such a rotating plate is also called a turntable.

[0020] The above mold areas, two of which can each form one of the above cavities, can in particular be areas or formations or recesses or cutouts or elements or structures of the respective tool part which form part of the respective cavity into which the respective injection molding material is injected to form a corresponding preform or final shape of the component to be produced.

[0021] The method according to the invention is a method for producing at least one component using an injection molding device, or the method according to the invention is a method for producing at least one component using an injection molding device, three injection molding materials comprising a first injection molding material, a second injection molding material, and a third injection molding material, and at least one film. The method according to the invention comprises the following steps:

[0022] (A) transferring the tool (14) to the open state or leaving the tool (14) in the open state,

[0023] (B) at least partially arranging at least one film (24, 25) in the second forming area (200) and / or the fourth forming area (400),

[0024] (C) rotating the second tool part (18) into the first rotational position (20) or leaving the second tool part (18) in the first rotational position (20),

[0025] (D) transferring the tool (14) into the closed state and injecting a first injection-molding material (26) into the second molding area (200) and / or fourth molding area (400) to form a first preform (30) of a component (10) to be produced or a first preform (30) of the first component (10) to be produced, in which the film (24) is connected to the first injection-molding material (26),

[0026] (E) transferring the tool (14) into the open state and leaving the first preform (30) of the component (10) produced in step D in the fourth mold area (400),

[0027] (F) Rotating the second tool part (18) into the second rotational position (22),

[0028] (G) Transferring the tool (14) into the closed state,

[0029] (H) injecting a second injection molding material (27) or the second injection molding material (27) into the third cavity (3) to form a second preform (32) of the component (10),

[0030] (I) transferring the tool (14) into the open state and leaving the second preform (32) of the component (10) produced in step H in the first mold area (100),

[0031] (J) Turning the second tool part (18) into the first rotation position (20),

[0032] (K) if a further component (10) is to be produced, continue the process with step L, otherwise continue the process with step R,

[0033] (L) at least partially arranging at least one further film or at least one film (24, 25) in the second molding area (200) and / or the fourth molding area (400), (M) transferring the tool (14) into the closed state and injecting the first injection molding material (26) into the second molding area (200) and / or the fourth molding area (400) to form the first preform (30) of a further component (10) to be produced, in which the film (24) is connected to the first injection molding material (26),

[0034] (N) injecting a third injection molding material (28) or the third injection molding material (28) into the first cavity (1) to form the final shape (36) of the component (10),

[0035] (O) Transferring the tool (14) into the open state,

[0036] (P) removing the final shape (36) of the component (10) formed in step N in the first cavity (1) from the tool (14) and leaving the first preform (30) of the further component (10) produced in step M in the fourth mold area (400),

[0037] (Q) Continue the process with step F,

[0038] (R) Transferring the tool (10) into the closed state,

[0039] (S) injecting a third injection molding material or the third injection molding material into the first cavity (1) to form the final shape (36) of the component (10),

[0040] (T) transferring the tool (14) into the open state, and

[0041] (U) Removing the final shape (36) of the component (10) from the tool (14) or removing the final shape (36) of the component (10) formed in step S in the first cavity (1) from the tool (14).

[0042] In steps P and U, the final shape or the finished component, which is a multi-component component with at least one film, is removed.

[0043] A flow chart illustrating the sequence of the individual steps is shown in Fig. 3.

[0044] By performing the above steps, at least one component in the form of a multi-component component with at least one film, or at least one article in the form of a multi-component article with at least one film, can be manufactured with significantly less effort than with the known solutions, which involve the very complex use of indexable insert technology. In contrast to the known use of indexable insert technology, which, among other things, requires the very complex provision of two complete injection molding tools, a single injection molding tool with a significantly smaller footprint, corresponding to the footprint of a standard injection molding machine, is sufficient to carry out the method according to the invention.

[0045] The method according to the invention enables the production of one or more components. If only a single component is to be produced, which after completing the provided steps is a multi-component component with at least one film, the method according to step K provides for the method to be continued with step R or at step R. If several components are to be produced, the method according to step K provides for the method to be continued with step L or with step L. With the query in step K, the method can be brought to a conclusion after several final shapes or finished components have already been removed by continuing with step R and the associated formation of the final shape of a last component (step S) and removal of the last component (step U).

[0046] It is understood that naming the steps with the letters A to U does not necessarily imply a chronological order. For example, step C can also be performed before step B. However, step O, for example, must obviously be performed after step N, as this is technically impossible.

[0047] It is understood that the injection molding material to be injected in the corresponding steps (i.e., steps D, H, N, and S) is in a liquid state suitable for forming the respective preform or final shape during injection, which the person skilled in the art envisions for the respective component to be manufactured. The same applies to the temperatures and pressures of the injection molding materials, particularly during injection.

[0048] In step B, the at least one film is at least partially arranged in the second mold area and / or the fourth mold area, thereby preparing for step D, in which, among other things, the first injection molding material is injected into the second mold area and / or the fourth mold area to form the first preform. Depending on the application, the film can in particular also be arranged only partially in the second mold area and / or the fourth mold area, in particular if the film is to be fixed in the second mold area and / or the fourth mold area for back-injection with the plastic material, which can be done by clamping the film between the two tool parts when the tool is transferred into the closed state.This may in turn make it necessary to provide suitable edge regions for clamping, which, when clamped, are arranged outside the second molding region and / or the fourth molding region. However, partial arrangement is not mandatory. It is also conceivable to arrange the film entirely or completely in the second molding region and / or the fourth molding region. If it is necessary to fix the film locally when the film is completely arranged in the second molding region and / or the fourth molding region, this can also be done in a known manner by sucking the film onto the first and / or second tool part via provided suction channels.

[0049] In step L, at least one film or at least one further film is also at least partially arranged in the second forming area and / or the fourth forming area, wherein here too, the film can be partially or completely arranged in the second forming area and / or the fourth forming area, as already explained above for step B.

[0050] In steps D and M, the first preform of a component to be manufactured or of a further or next component to be manufactured is formed, in which the film is connected to the first injection molding material. It is understood that this connection of the film to the first injection molding material, brought about by the injection of the first injection molding material, can have one of numerous configurations that are possible by injection molding. For example, in the first preform, the film can be materially bonded to an outer surface of an injection-molded body made of the first injection molding material, which can be achieved by back-injection molding. Typical technical applications here are films in the form of so-called decorative films, which are bonded flatly to the injection-molded body made of the first injection molding material as an outer layer in the component to be manufactured or in the multi-component component to be manufactured. However, for exampleIt is also conceivable that the film, as a reinforcing film intended to increase mechanical strength, is at least partially enclosed or incorporated in the injection-molded body. This can be achieved in steps D and M by overmolding the film.

[0051] In steps D and M, the injection of the first injection molding material can take place, in particular, after the tool has been moved into the closed state. In this case, the injection takes place into the second cavity, which is in the closed tool state. In a particularly preferred embodiment of the method according to the invention, however, the injection of the first injection molding material for injection-compression molding the first preform of the component can take place in steps D and M while the tool is being moved into the closed state. In this way, injection-compression molding of the first preform can advantageously take place, whereby a uniformly building closing pressure can be achieved during the closing of the tool. By injection-compression molding, the first preform of the component can be manufactured very precisely, i.e. with only a very small deviation from the respective target shape, in particular even if the first preform is to be very large.

[0052] In a practical embodiment of the method according to the invention, in step B and / or in step L, a single film is at least partially arranged in the second molding region or the fourth molding region, wherein in step D and / or in step M the film is back-injected by injecting the first injection molding material into the fourth molding region or the second molding region. This practical embodiment can be used to produce multi-component components in which the film can be an outer layer of the component. The film can be, for example, a decorative film or a heating film, which is present on the respective component as an outer film.

[0053] In a further practical embodiment of the method according to the invention, in step B and / or in step L a first film is arranged in the second molding region and a second film is at least partially arranged in the fourth molding region, wherein in step D and / or in step M the first injection molding material is injected between the first film and the second film. This practical embodiment can also be used to produce multi-component components in which the two films can be outer layers of the component. Each of the two films can be, for example, a decorative film or a heating film, which is present on the respective component as an outer film.

[0054] Particularly preferably, the films in steps B and L can be identical films if several identical components are to be produced by means of the method according to the invention.

[0055] The at least one film in step B and / or the at least one film in step L can be a heating film or a decorative film or a reinforcement film or a structural film or generally a technical film. (Note from Potthast: if necessary, one could explain in more detail here which material the film is made of and, if necessary, also provide more details about the dimensions and technical properties of the film(s)) The first injection molding material is particularly preferably polycarbonate, the second injection molding material is a mixture of polycarbonate and ABS (abbreviation for acrylonitrile butadiene styrene) and the third injection molding material is polyurethane. Using this combination of injection molding materials, the following motor vehicle components in particular can be manufactured very precisely using the method according to the invention: bumpers, front panels, rear panels, side panels, BDHs, and headlights (Note from Potthast: If necessary,one could explain this in a little more detail, especially what is meant by BDH's and which components of the headlight are meant here).

[0056] The component that can be manufactured using the method according to the invention can, in particular, be a front panel for a motor vehicle, a rear panel for a motor vehicle, a side panel for a motor vehicle, or a bumper for a motor vehicle. (Potthast's note: Perhaps there are also German terms for "panels" here?)

[0057] The injection molding device according to the invention for carrying out the above method according to the invention comprises a tool with a first tool part and a second tool part, wherein the first tool part has a first molding area and a second molding area, wherein the second tool part has a third molding area and a fourth molding area, wherein the second tool part is rotatable into a first rotational position and into a second rotational position, wherein the tool can be transferred from an open tool state to a closed tool state and back from the closed tool state to the open tool state, wherein the first molding area and the third molding area form a first cavity in the closed tool state and the second molding area and the fourth molding area form a second cavity in the closed tool state when the second tool part is in the first rotational position,and wherein the first mold region and the fourth mold region form a third cavity in the closed mold state, and the second mold region and the third mold region form a fourth cavity in the closed mold state when the second mold part is in the second rotational position. Description of the Figures,

[0058] Exemplary embodiments of the invention are explained in more detail below with reference to the accompanying figures. The figures show:

[0059] Fig. 1 is a schematic representation of an injection molding device of the prior art,

[0060] Fig. 2A, 2B are schematic representations of a first embodiment of an injection molding device according to the invention,

[0061] Fig. 3 is a flow chart illustrating the sequence of the individual

[0062] Process steps of the process according to the invention,

[0063] Fig. 4 three partially sectioned schematic representations of the two tool parts of the injection molding device according to Fig. 2A and 2B,

[0064] Fig. 5 four partially sectioned schematic representations of the two tool parts of the injection molding device according to Fig. 2A and 2B to illustrate method steps of a first embodiment of the method according to the invention,

[0065] Fig. 6 shows three partially sectioned schematic representations of the two tool parts of the injection molding device according to Figs. 2A and 2B to illustrate process steps of the first embodiment of the process according to the invention,

[0066] Fig. 7 shows three partially sectioned schematic representations of the two tool parts of the injection molding device according to Fig. 2A and 2B to illustrate method steps of the first embodiment of the method according to the invention,

[0067] Fig. 8 shows three partially sectioned schematic representations of the two tool parts of the injection molding device according to Figs. 2A and 2B to illustrate method steps of the first embodiment of the method according to the invention,

[0068] Fig. 9 two partially sectioned schematic representations of the two tool parts of the injection molding device according to Fig. 2A and 2B to illustrate process steps of the first embodiment of the method according to the invention, Fig. 10 a very schematic representation of a second

[0069] Embodiment of an injection molding device according to the invention,

[0070] Fig. 11-18 are each very schematic plan views of the two tool parts of the injection molding device according to Fig. 10 together with very schematic representations to illustrate method steps of a second embodiment of the method according to the invention, and

[0071] Fig. 19 is a schematic diagram illustrating an alternative process step,

[0072] The prior art injection molding device 50, schematically illustrated in Fig. 1, with a reversible insert technology comprises two interconnected mold halves 46 or mold parts 46, which are rotatable about a vertical axis of rotation 51 by means of the molding regions 48 to form the cavities of the respective preforms or final molds, such that one of the two interconnected mold halves 46 can be turned toward one of two further mold halves 46 (left outer and right outer) by rotation. The prior art injection molding device 50 further comprises two injection units 40 and 44 and a PUR mixing head 42 for providing and injecting three different injection molding materials.

[0073] The injection molding device 12 according to the invention shown in Figs. 2A and 2B according to the first embodiment comprises a tool 14 with a first tool part 16 and a second tool part 18. Fig. 2B shows a schematic three-dimensional representation of the tool 14 with the tool parts 16 and 18.

[0074] The first tool part 16 has a first molding area 100 and a second molding area 200 (see Fig. 2B).

[0075] The second tool part 18 has a third mold area 300 and a fourth mold area 400.

[0076] The second tool part 18 can be rotated 360 degrees about a horizontal axis of rotation 19, so that the second tool part 18 can be rotated into a first rotational position 20 and into a second rotational position 22 (see also the illustrations in Fig. 4 for the rotational positions). The two rotational positions can be converted into one another by rotating through an angle of rotation of essentially 180 degrees, so that the third mold region 300 is arranged at the top in the first rotational position in Fig. 2B and the fourth mold region 400 is arranged at the bottom in the first rotational position 400. In the second rotational position, the third mold region 300 is arranged at the bottom in Fig. 2B and the fourth mold region 400 is arranged at the top in the second rotational position in Fig. 2B. The rotatability of the second tool part 18 about the rotation axis 19 is realized in that the second tool part 18 is connected to a rotatable plate 52 which is rotatable by 360 degrees in the injection molding device 12.In technical jargon, such a rotatable plate 52 is also called a turntable 52.

[0077] The injection molding device 12 also has two clamping plates 8 and 9, with the first tool part 16 being fixedly attached to the clamping plate 8. The rotary plate 52—to which the second tool part 18 is connected in a rotationally fixed manner—is mounted on the clamping plate 9 so that it can rotate 360 ​​degrees about the rotation axis 19.

[0078] The injection molding device 12 further comprises two injection units 40 and 44 and a PUR mixing head 42 for providing and injecting three different injection molding materials 26, 27 and 28, comprising polycarbonate 26 as the first injection molding material from the injection unit 40, a mixture of polycarbonate and ABS as the second injection molding material 27 from the injection unit 44 and PUR (abbreviation for polyurethane comprising polyol and polyisocyanate as the most important components) as the third injection molding material 28 from the mixing head 42.

[0079] As schematically illustrated in Fig. 2A by dashed arrows, the tool 14 can be transferred from an open tool state to a closed tool state and back from the closed tool state to the open tool state.

[0080] As can be seen from the middle illustration of Fig. 4 (Fig. 4 shows three partially sectioned schematic illustrations of the two tool parts 16 and 18 of the injection molding device 12 according to Figs. 2A and 2B), the first mold region 100 and the third mold region 300 form a first cavity 1 in the closed tool state and the second mold region 200 and the fourth mold region 400 form a second cavity 2 in the closed tool state when the second tool part 18 is in the first rotational position 20.

[0081] As can be seen from the lower illustration of Fig. 4, the first mold region 100 and the fourth mold region 400 form a third cavity 3 in the closed tool state and the second mold region 200 and the third mold region 300 form a fourth cavity 4 in the closed tool state when the second tool part 18 is in the second rotational position 22.

[0082] In Fig. 4, the upper illustration shows the open tool state.

[0083] 5 to 9, in conjunction with the flow chart or with the flow chart according to Fig. 3, illustrate individual method steps of the first exemplary embodiment of the method according to the invention for producing one or more multi-component components 10 with the final shape 36 comprising a film 24 in the form of a reinforcing film 24 (cf. also Fig. 8 and Fig. 9 below, shown only very schematically). This component 10 is a polygonal component 10 which has the reinforcing film 24, a base body 53 formed from the first injection molding material 26 (polycarbonate), a first outer layer 54 formed from the second injection molding material 27 (mixture of polycarbonate and ABS), and a second outer layer 55 formed from the third injection molding material 28 (PUR).

[0084] In the illustrations of Figs. 5 to 9, the respective injection channels 56 are illustrated in the form of dashed lines 56. Horizontal arrows illustrate the injection of the corresponding injection molding material.

[0085] The method according to the first embodiment comprises the following steps:

[0086] (A) transferring the tool (14) to the open state or leaving the tool (14) in the open state,

[0087] (B) Completely arranging the reinforcing film 24 in the fourth mold area 400,

[0088] (C) Rotating the second tool part 18 into the first rotational position 20 or leaving the second tool part 18 in the first rotational position 20,

[0089] (D) Transferring the tool 14 into the closed state and injecting the first injection molding material 26 into the second molding area 200 to form a first preform 30 of the first component 10 to be produced, in which the film 24 is bonded to the first injection molding material 26 in a planar manner, wherein the film 24 is back-injected during the injection of the first injection molding material 26, (E) Transferring the tool 14 into the open state and leaving the first preform 30 of the component 10 produced in step D in the fourth molding area 400,

[0090] (F) Turning the second tool part 18 into the second rotational position 22,

[0091] (G) Transferring the tool 14 into the closed state,

[0092] (H) Injecting the second injection molding material 28 into the third cavity 3 to form a second preform 32 of the component 10,

[0093] (I) Transferring the tool 14 into the open state and leaving the second preform 32 of the component 10 produced in step H in the first mold area 100,

[0094] (J) Turning the second tool part 18 into the first rotational position 20,

[0095] (K) if a further component 10 is to be produced, continue the process with step L, otherwise continue the process with step R,

[0096] (L) completely arranging a further reinforcing film 24 in the fourth mold area 400,

[0097] (M) Transferring the tool 14 into the closed state and injecting the first injection molding material 26 into the second mold area 200 to form the first preform 30 of the further or next component 10 to be produced, in which the film 24 is connected to the first injection molding material 26, wherein the film 24 is back-injected during the injection of the first injection molding material 26,

[0098] (N) Injecting the third injection molding material 28 into the first cavity 1 to form the final shape 36 of the component 10,

[0099] (O) Transferring the tool 14 into the open state,

[0100] (P) removing the final shape 36 of the component 10 formed in step N in the first cavity 1 from the tool 14 and leaving the first preform 30 of the further or next component 10 produced in step M in the fourth mold area 400,

[0101] (Q) Continue the process with step F, (R) Transfer the tool 10 into the closed state,

[0102] (S) Injecting the third injection molding material 28 into the first cavity 1 to form the final shape 36 of the component 10,

[0103] (T) Transferring the tool 14 into the open state, and

[0104] (U) Removing the final shape 36 of the component 10 from the tool 14.

[0105] In this first embodiment, the injection of the first injection molding material 26 for injection-compression molding the first preform 30 of the component 10 is performed in steps D and M while the tool 14 is being moved into the closed state. This is illustrated by the horizontal dashed lines in the corresponding illustrations in Fig. 5 (see second illustration from the top for step D) and Fig. 8 (see top illustration for step M).

[0106] In an alternative method, for forming an alternative first preform 30', it could also be provided to arrange a first reinforcing film 24' in the second molding region 200 and a second reinforcing film 24" in the fourth molding region 400 completely or entirely in step B and in step L, wherein in step D and in step M the first injection molding material 26 is injected between the first reinforcing film 24' and the second reinforcing film 24" during injection-compression molding. This is shown very schematically in Fig. 19, which illustrates the situation for step D. Fig. 19 also shows the alternative first preform 30' resulting from this injection-compression molding with the reinforcing films 24' and 24".

[0107] The second exemplary embodiment of an injection molding device 12 according to the invention according to Fig. 10 differs from the first exemplary embodiment according to Figs. 2A and 2B in that here the molding regions 100, 200, 300 and 400 are set up to form a component which is a film-reinforced, multi-component front panel for a motor vehicle or whose final shape to be produced is a film-reinforced, multi-component front panel for a motor vehicle. The molding regions 100, 200, 300 and 400 are shown only very schematically in dashed lines in Fig. 10. Furthermore, the injection molding device according to Fig. 10 is also dimensioned differently than the injection molding device according to Fig. 2A. With the injection molding device 12 according to Fig. 10, the front panel can be produced according to the second exemplary embodiment of the method according to the invention described below.The method steps of this second embodiment correspond - apart from the differently designed injection molding device 12 and the different design of the film provided in steps B and L - to the method steps of the above first embodiment.

[0108] The film 24 provided here is also a reinforcing film 24 which is intended for the mechanical reinforcement of the front panel.

[0109] The second embodiment of the method according to the invention is described below with reference to Figs. 11 to 18, which illustrate selected method steps. Figs. 11 to 18 each show, among other things, highly schematic plan views of the two tool parts 16 and 18 of the injection molding device 12 according to Fig. 10.

[0110] Thus, Fig. 11 illustrates the situation of step D in the closed mold state, specifically before the injection of the first injection molding material 26. The reinforcing foil 24 is completely arranged in the fourth mold area 400. (Note from Potthast: In Fig. 11 and in other figures, two straight vertical elements with circular ends can be seen. If necessary, one could briefly explain the purpose of these vertical elements here.)

[0111] Fig. 12 illustrates the situation after step D and before opening according to step E with the first preform 30 already present.

[0112] Fig. 13 illustrates the situation during the rotation according to step F into the second rotation position 22. Here, the tool 14 is in the open state and the first preform 30 has been left in the fourth mold area 400, as provided in step E.

[0113] Fig. 14 illustrates the situation after the injection of the second injection molding material 27 according to step H into the third cavity formed by the turning in step F and before the opening according to step I. The formed second preform 32 shown schematically in Fig. 14 has an edge region 58 formed by the injection of the second injection molding material 27 (mixture of PC and ABS).

[0114] Fig. 15 illustrates the rotation according to step J into the first rotational position 20. The second preform 32 was left in the first mold area 100, as provided in step I. If the query according to step K shows that a further or next component is to be produced, the method continues with step L; otherwise, the method continues with steps R, S and T and ends in step U with the removal of the final shape 36 or the finished component 10 from the tool 14.

[0115] Figure 16 illustrates the situation in step M with the mold closed and before injection. The further or next reinforcement film 24 is already completely arranged in the fourth mold area 400, as provided in step L.

[0116] Fig. 17 illustrates on the right the situation after step M and before step N with the second preform 32 and the first preform 30 and on the left the situation after step N with the final shape 36 and the first preform 30. The injection of the third injection molding material PUR in step N serves in particular for the further shaping of the edge region 58. The injection of the comparatively liquid PUR is also referred to in technical jargon as flooding.

[0117] Fig. 18 schematically illustrates step P with the removal of the final shape 36 or the finished component 10 from the tool 14. Thereafter, according to step Q, the process continues with step F.

[0118] List of reference symbols

[0119] 1 first cavity

[0120] 2 second cavity

[0121] 3 third cavity

[0122] 4 fourth cavity

[0123] 8 clamping plate

[0124] 9 Clamping plate

[0125] 10 components

[0126] 12 Injection molding device

[0127] 14 tools

[0128] 16 first tool part

[0129] 18 second tool part

[0130] 19 axis of rotation

[0131] 20 first turning position

[0132] 22 second rotation position

[0133] 24 foil 24' foil

[0134] 24” film

[0135] 26 first injection molding material

[0136] 27 second injection molding material

[0137] 28 third injection molding material

[0138] 30 first preform

[0139] 30' alternative first preform

[0140] 32 second preform

[0141] 36 Final shape

[0142] 40 Injection unit PC

[0143] 42 Mixing head PUR

[0144] 44 Injection unit PC / ABS

[0145] 46 tool part St.dT

[0146] 48 Form area St.dT

[0147] 50 injection molding devices St.dT

[0148] 51 axis of rotation

[0149] 52 turntables

[0150] 53 base bodies

[0151] 54 first outer layer

[0152] 55 second outer layer

[0153] 56 injection channel

[0154] 58 Marginal area

[0155] 100 first form area

[0156] 200 second mold area

[0157] 300 third form area

[0158] 400 fourth form area

Claims

Patent claims 1. A method for producing at least one component (10) by means of an injection molding device (12), wherein the injection molding device (12) has a tool (14) with a first tool part (16) and a second tool part (18), wherein the first tool part (16) has a first molding area (100) and a second molding area (200), wherein the second tool part (18) has a third molding area (300) and a fourth molding area (400), wherein the second tool part (18) is rotatable into a first rotational position (20) and into a second rotational position (22), wherein the tool (14) can be transferred from an open tool state to a closed tool state and can be transferred back from the closed tool state to the open tool state,wherein the first mold region (100) and the third mold region (300) form a first cavity (1) in the closed tool state and the second mold region (200) and the fourth mold region (400) form a second cavity (2) in the closed tool state when the second tool part (18) is in the first rotational position (20), wherein the first mold region (100) and the fourth mold region (400) form a third cavity (3) in the closed tool state and the second mold region (200) and the third mold region (300) form a fourth cavity (4) in the closed tool state when the second tool part (18) is in the second rotational position (22), the method comprising the following steps: (A) transferring the tool (14) to the open state or leaving the tool (14) in the open state, (B) at least partially arranging at least one film (24, 25) in the second forming region (200) and / or the fourth forming region (400), (C) rotating the second tool part (18) into the first rotational position (20) or leaving the second tool part (18) in the first rotational position (20), (D) transferring the tool (14) into the closed state and injecting a first injection-molding material (26) into the second molding area (200) and / or fourth molding area (400) to form a first preform (30) of a component (10) to be produced, in which the film (24) is connected to the first injection-molding material (26), (E) transferring the tool (14) into the open state and leaving the first preform (30) of the component (10) produced in step D in the fourth mold area (400), (F) Rotating the second tool part (18) into the second rotational position (22), (G) Transferring the tool (14) into the closed state, (H) injecting a second injection molding material (27) or the second injection molding material (27) into the third cavity (3) to form a second preform (32) of the component (10), (I) transferring the tool (14) into the open state and leaving the second preform (32) of the component (10) produced in step H in the first mold area (100), (J) Turning the second tool part (18) into the first rotation position (20), (K) if a further component (10) is to be produced, continue the process with step L, otherwise continue the process with step R, (L) at least partially arranging at least one further film (24, 25) in the second forming area (200) and / or the fourth forming area (400), (M) transferring the tool (14) into the closed state and injecting the first injection-molding material (26) into the second molding area (200) and / or fourth molding area (400) to form the first preform (30) of a further component (10) to be produced, in which the film (24) is connected to the first injection-molding material (26), (N) injecting a third injection molding material (28) or the third injection molding material (28) into the first cavity (1) to form the final shape (36) of the component (10), (O) Transferring the tool (14) into the open state, (P) removing the final shape (36) of the component (10) formed in step N in the first cavity (1) from the tool (14) and leaving the first preform (30) of the further component (10) produced in step M in the fourth mold area (400), (Q) Continue the process with step F, (R) Transferring the tool (10) into the closed state, (S) injecting a third injection molding material (28) or the third injection molding material (28) into the first cavity (1) to form the final shape (36) of the component (10), (T) transferring the tool (14) into the open state, and (U) Removing the final shape (36) of the component (10) from the tool (14).

2. Method according to claim 1, characterized in that in steps D and M the injection of the first injection molding material (26) for injection-compression molding of the first Preform (30) of the component (10) is carried out during the transfer of the tool (14) into the closed state.

3. Method according to claim 1 or 2, characterized in that in step B and / or in step L a single film (24) is at least partially arranged in the second molding area (200) or the fourth molding area (400), wherein in step D and / or in step M the film (24) is back-injected by injecting the first injection molding material (26) into the fourth molding area (400) or the second molding area (200).

4. The method according to claim 1 or 2, characterized in that in step B and / or in step L a first film (24') is at least partially arranged in the second molding area (200) and a second film (24") is at least partially arranged in the fourth molding area (400), wherein in step D and / or in step M the first injection molding material (26) is injected between the first film (24') and the second film (24").

5. Method according to one of the preceding claims, characterized in that the films (24, 25) in steps B and L are identical films (24, 25).

6. Method according to one of the preceding claims, characterized in that the at least one film (24, 25) in step B and / or the at least one film (24, 25) in step L is a heating film or a decorative film or a reinforcing film.

7. Method according to one of the preceding claims, characterized in that the first injection molding material (26) is polycarbonate, that the second injection molding material (27) is a mixture of polycarbonate and ABS, and that the third injection molding material (28) is polyurethane.

8. Method according to one of the preceding claims, characterized in that the component (10) is a front panel for a motor vehicle or a rear panel for a motor vehicle or a side panel for a motor vehicle or a bumper for a motor vehicle.Injection molding device (12) for carrying out a method according to one of claims 1 to 8, comprising a tool (14) with a first tool part (16) and a second tool part (18), wherein the first tool part (16) has a first molding area (100) and a second molding area (200), wherein the second tool part (18) has a third molding area (300) and a fourth molding area (400), wherein the second tool part (18) is rotatable into a first rotational position (20) and into a second rotational position (22), wherein the tool (14) is transferable from an open tool state to a closed tool state and from the closed tool state back to the open tool state,wherein the first mold region (100) and the third mold region (300) form a first cavity (1) in the closed tool state, and the second mold region (200) and the fourth mold region (400) form a second cavity (2) in the closed tool state when the second tool part (18) is in the first rotational position (20), and wherein the first mold region (100) and the fourth mold region (400) form a third cavity (3) in the closed tool state, and the second mold region (200) and the third mold region (300) form a fourth cavity (4) in the closed tool state when the second tool part (18) is in the second rotational position (22).

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