Decorated moulded part and method for producing a decorated moulded part

Abstract

The invention relates to a decorated moulded part (10), wherein the moulded part (10) has a fibre mat (11) which has natural fibres and thermoplastic fibres, wherein in an upper boundary region (40) of the fibre mat (11) the natural fibres are decorated at least partially with a decorative layer (14) of a decorative web (12), and in a lower region (41) the thermoplastic fibres and a substrate (13) of the decorative web (12) are fused to form a composite.

Description

[0001] Decorated molded part and method for producing a decorated

[0002] molded part

[0003] The invention relates to a decorated molded part and a method for producing a decorated molded part.

[0004] It is known to three-dimensionally deform natural fiber polypropylene fiber mats, also known as NFPP mats, particularly by thermoplastic deep drawing or "thermoforming." This involves first preparing an NFPP mat tailored to the component to be manufactured, which is then pressed into a planar shape in a so-called calibration press under pressure and heat. This so-called calibration process melts the thermoplastic matrix of the polypropylene fibers, making the NFPP mat deformable. The calibrated NFPP mat is then inserted into a three-dimensional mold and subsequently "cold-pressed" so that the NFPP mat adapts to the shape of the mold. Upon cooling, the previously melted thermoplastic matrix solidifies again, producing a three-dimensional component.Previously known methods have the problem that only single-color components can be produced, with the color being essentially determined by the color of the polypropylene fibers and natural fibers present in the NFPP mat. There are already processes in which carpets or leather are laminated onto the NFPP mat, but this results in the loss of the fibers' feel and characteristic visual appearance. The invention is therefore based on the object of providing a process by which fiber mats, in particular NFPP mats, can be decorated in a variety of ways while, in particular, preserving the feel and characteristic visual appearance of the fiber mat.

[0005] The object is achieved by a decorated molded part, wherein the molded part has a fiber mat which has natural fibers and thermoplastic fibers, wherein in an upper boundary region of the fiber mat the natural fibers are at least partially decorated with a decorative layer of a decorative web and in a lower region the thermoplastic fibers and a substrate of the decorative web are fused to form a composite.

[0006] This object is further achieved by a method for producing a decorated molded part, wherein the molded part comprises a fiber mat which has natural fibers and thermoplastic fibers, wherein the method comprises the following steps, in particular in the following order: a) providing a decorative web, wherein the decorative web has a substrate and at least one decorative layer applied to the substrate; b) providing a fiber mat, wherein the fiber mat has natural fibers and thermoplastic fibers; c) inserting the fiber mat and the decorative web into a press, in particular into a calibration press, wherein the decorative web is arranged on the fiber mat such that the at least one decorative layer of the decorative web faces the fiber mat;d) pressing the fiber mat and the decorative sheet under thermal heating so that the substrate of the decorative sheet fuses with the thermoplastic fibers of the fiber mat and the decorative layer of the decorative sheet decorates the natural fibers arranged in an upper boundary region of the fiber mat to provide a decorated fiber mat; e) molding the decorated fiber mat in a mold to obtain a decorated molded part;

[0007] It has been shown that the method according to the invention for producing a decorated molded part and the decorated molded part according to the invention result in a molded part in which the feel of the fiber mat and its characteristic visual appearance are retained, and the molded part has a visually appealing decoration. Such molded parts can be used, for example, as cockpit panels in vehicle construction and, due to the visually appealing decoration, can now also be used as a replacement for conventional cockpit elements made of plastic.

[0008] Further advantageous embodiments of the invention are described in the subclaims.

[0009] The "visible side" refers to the side that is always visible to the observer after the decorated molding has been installed. This is usually the decorated side of the fiber mat or molding.

[0010] In this case, “back” or reverse side is understood to mean the side of the decorative sheet that faces the fiber mat when the decorative sheet is inserted into the press.

[0011] In this case, “front side” or front side is understood to mean the side of the decorative sheet that faces away from the fiber mat when the decorative sheet is inserted into the press.

[0012] The term “upper limit area” is understood to mean the area of ​​the fiber mat or molded part that extends from the visible side of the fiber mat or molded part in the direction of the side of the fiber mat or molded part opposite the visible side.

[0013] The "lower area" is understood to be the opposite area of ​​the upper limit area. This means that the lower area extends from the side facing away from the visible side toward the visible side and ends where the upper limit area ends. For example, if the upper limit area corresponds to 33% of the thickness of the fiber mat or molded part, then the lower area corresponds to 67% of the thickness of the fiber mat or molded part.

[0014] A transition zone may also develop between the upper and lower limits. In this transition zone, the natural fibers preferably exhibit only very light decoration, whereas in the upper limit, the decoration is ideally more pronounced.

[0015] “Registered” refers to the arrangement of one layer in relation to another layer or the structuring of a layer relative to another layer in a way that is accurate to register. Registered or register or accurate to register or register accuracy or register accuracy refers to the positional accuracy of two or more layers relative to one another. The register accuracy should be within a specified tolerance and as small as possible. At the same time, the register accuracy of several elements and / or layers in relation to one another is an important feature for increasing process reliability. Accurate positioning can be achieved in particular using sensory, preferably optically detectable, fiducials or register marks.These registration marks can either represent specific separate elements, regions, or layers, or they can themselves be part of the elements, regions, or layers to be positioned. "Degradable biopolymers" preferably refers to plastics that decompose under certain conditions, producing, in particular, carbon dioxide (CO2) or water (H2O) as the end product. For example, the degradable biopolymers can be made from thermoplastic starch, cellulose, and polylactide (PLA). Biopolymers are preferably made from renewable, particularly organic, raw materials, which include, in particular, starch- and cellulose-rich plants, such as corn, miscanthus, wood, or oilseeds.

[0016] It can preferably be provided that the fiber mat comprises essentially 50% natural fibers and 50% thermoplastic fibers, in particular that the fiber mat comprises at least 33% natural fibers and / or at least 33% thermoplastic fibers. In a preferred embodiment, it is provided that the fiber mat comprises half natural fibers and the other half thermoplastic fibers. Such a proportion of thermoplastic fibers ensures that the subsequent molded part has the necessary mechanical stability, in particular strength, for the predetermined intended use. This is preferably due to the fact that the thermoplastic fibers fuse to form a thermoplastic composite after pressing, and this composite hardens. The natural fibers, on the other hand, retain their original shape after pressing and thus ensure the characteristic feel and visual appearance of the fiber mat or molded part.

[0017] In particular, it is possible for the natural fiber to comprise a fiber type or mixture of fiber types selected from: hemp fiber, flax fiber, jute fiber, kenaf fiber, sisal fiber, or coconut fiber. Such fibers are widely used industrially and are characterized by good material properties. In particular, the natural fiber cannot melt under the influence of temperature, in particular in a temperature range up to 300°C, particularly preferably up to 220°C. Preferably, the natural fiber is a non-melting fiber. This ensures that even during or after pressing the fiber mat, which takes place under the influence of heat or temperature, the natural fibers retain their characteristic feel and shape.

[0018] Furthermore, it is also possible for the thermoplastic fiber to comprise a material or combination of materials selected from: polypropylene (PP), polyethylene (PE), polyolefins, polyethylene terephthalate (PET), biodegradable biopolymers, in particular polylactide (PLA). Polypropylene in particular is particularly well suited for fiber production and can also be easily recycled. This means, for example, that the thermoplastic fibers can be made from recycled polypropylene or other polymers. For polypropylene fibers, for example, the melting point is an important factor. The melting temperature of the thermoplastic fibers or the polypropylene fiber determines the temperature at which the subsequent pressing or calibration of the fiber mat takes place. For example, isotactic polypropylene fibers have a melting point in the range of approximately 150°C to 170°C, and atactic polypropylene fibers have a melting point of approximately120°C to 140°C. This means that when using atactic polypropylene fibers, the fiber mat can be pressed or calibrated at lower temperatures, making it more energy-efficient.

[0019] Calibration refers to the pre-compression of the fiber mat. The calibration process can be applied to the fiber mat alone, or it can be applied to the fiber mat together with the decorative sheet, i.e., in this case, calibration can be applied to the fiber mat and the decorative sheet simultaneously. Fiber mats that contain, in addition to natural fibers and polymer fibers, also a proportion of inorganic materials, preferably glass fibers and / or carbon fibers, are also conceivable. Such fibers or fiber mats further improve the mechanical stability and mechanical resilience of the fiber mat after processing.

[0020] The different fibers vary in their thickness and fiber length. The corresponding parameters for the different fiber types are shown in the table below:

[0021] Depending on the fibers used, a different haptic and / or visual appearance can be achieved, which is also tactilely and / or visually perceptible to the consumer in the decorated molded part. For example, the fiber mat can be designed to contain hemp fibers and polypropylene fibers. However, all fiber materials with a matrix are possible.

[0022] It is also possible to modify the feel of the decorated fiber mat and the resulting decorated molded part haptically and / or visually or in terms of appearance by inserting at least one textile or several textiles. Preferably, the decorated molded part comprises at least one textile or several textiles, in particular wherein the at least one textile or several textiles is / are arranged in the upper boundary region of the decorated molded part and / or is / are preferably encapsulated in the fused composite of thermoplastic fibers and the substrate of the decorative sheet.

[0023] It is preferably provided that in step c) at least one textile or a plurality of textiles are placed into the press, in particular so that the at least one textile or the plurality of textiles is / are arranged between the decorative web and the fiber mat. Preferably then, in step d), the decorative web, the fiber mat and the at least one textile or the plurality of textiles are pressed, in particular with thermal heating, so that the substrate of the decorative web fuses with the thermoplastic fibers of the fiber mat and the threads of the at least one textile or the plurality of textiles and the decorative layer of the decorative web at least partially decorates the threads of the at least one textile or the plurality of textiles and / or the natural fibers arranged in an upper boundary region of the fiber mat in order to provide a decorated fiber mat.The at least one textile or several textiles can change the feel and / or visual appearance of the decorated molded part. Appropriate textiles are selected depending on the desired haptic and / or visual effects.

[0024] Textiles are understood here to mean a textile flat or three-dimensional structure. The textiles are produced in particular by meshing or weaving thread systems or by needling or tufting fibers. The threads and / or the fibers in these textiles consist, for example, entirely of natural fibers such as cotton, linen, jute, flax, hemp, kenaf, sisal, coconut fibers, or combinations of these. Furthermore, hybrid fabrics, so-called composites, made from the aforementioned natural fibers in combination with chemical fibers or inorganic fibers such as glass fibers, carbon fibers, basalt fibers are also conceivable. The threads are preferably transferred into a textile by different stitching or weaving. Fibers are preferably transferred into a textile by means of nonwoven formation or tufting.

[0025] The textile is preferably manufactured either by knitting, weaving, or nonwoven fabrication. Each textile is distinguished by its own distinct properties and produces different appearances depending on its manufacturing method.

[0026] In principle, stitch formation occurs primarily by interlacing one loop with another loop of a thread. This preferably creates a connected stitch. In weaving, however, at least two thread systems (warp and weft threads) are crossed in a pattern, particularly at right angles. Depending on which warp threads are raised or lowered during weaving, a different distribution of weave points is created. This pattern of crossing is referred to as weave patterns.

[0027] Typical weaves for woven textiles are preferably produced using different weaving techniques, such as plain weave. Plain weaves are derived from cross-rib, lengthwise rib (collectively referred to as rib weaves), and Panama weaves.

[0028] Depending on the design, ribbed weaves create longitudinally or transversely ribbed surfaces. The appearance and profile of the fabric depend on the thread thickness of the warp or weft threads. Ribbed weaves preferably produce very strong, profiled, and directional longitudinal or transverse ribs, depending on the direction of the ribs. Panama weaves are also known as checkerboard weaves or nap weaves. These weaves make it possible to create a checkerboard-like appearance in the fabric. A Panama weave generally has the same number of weft and warp threads per centimeter.

[0029] A further derivative of plain weave and ribbed weave is called crepe weave. This weave type makes it particularly possible to create irregular structures in the fabric that do not follow a static pattern. The so-called false crepe weave is primarily used for this purpose.

[0030] Plain weave fabrics or woven textiles include honan silk, chiffon, voile, perkai, muslin, gingham, linen, canvas, batiste and cretonne.

[0031] In addition to the plain weaves and their derivatives, there are also the twill weave and satin weave, which can also be called a 5-shaft weave.

[0032] Twill weaves are preferably weaves in which the threads run diagonally, parallel, in lines. This stepped arrangement creates the weave points. This weave type is particularly common because, depending on the design, it allows for the creation of various patterns such as multi-ridge, pointed, or herringbone weaves. One example of this weave type is denim fabrics for jeans. Carbon fiber fabric looks are also created this way.

[0033] The satin weave produces two-sided fabrics. This is preferably achieved by having a predominance of warp threads on the upper side, thus creating very smooth surfaces like satin. Nonwovens are produced primarily by homogeneously mixing at least one fiber type, especially several different fiber types, in a mixing chamber. Following mixing, these fibers are conveyed to a combing machine, also called a carding machine, to form a nonwoven.

[0034] The combing machine is specifically designed to align the fibers horizontally. This creates so-called carded nonwovens, which are then stacked in several layers by a layerer to form a fiber pile.

[0035] The multi-layered fiber web is then mechanically bonded, preferably in a needle loom. This step is also known as needling. Needling is preferably carried out using needle boards located in the needle loom and equipped with a large number of needles. Each needle has a barb. The fiber web is conveyed over these needle boards, with the needles piercing the web up to 1,000 times per minute, roughly in the normal direction of the web. As the needle moves backward, the fibers are pulled upwards through the fiber web in the direction of the needle's backward movement. The result is that the fibers become entangled in the fiber web, which in turn compacts and strengthens the fiber web. This compaction and strengthening of the fiber web then turns the fiber web into the web.

[0036] A nonwoven fabric can be designed to consist of a top layer and a bottom layer. The top layer can visually form the visible side of the textile. These top layers and bottom layers are preferably manufactured separately and needled together in the needling step described above. This is done primarily to ensure high stability of the individual layers and to prevent threads from the bottom layer from being drawn into the top layer, which would unintentionally change its appearance.

[0037] It may be provided that the construction or composition of the top layer and bottom layer can be coordinated to adjust the dimensional stability and lying behavior of the fleece.

[0038] Preferably, the at least one textile or the plurality of textiles has a thickness in a range from 0.25 mm to 6 mm, preferably from 0.75 mm to 4 mm. Preferably, the thickness is measured between the outermost threads of the at least one textile or the plurality of textiles.

[0039] Furthermore, the at least one textile or the plurality of textiles preferably comprises one or more threads.

[0040] Preferably, the threads of the at least one textile or the plurality of textiles have a thickness in a range from 0.1 mm to 3 mm, preferably from 0.5 mm to 2 mm.

[0041] Preferably, the at least one textile or the plurality of textiles has a mesh size and / or a grammage.

[0042] A mesh size is preferably the clear distance between two adjacent warp threads or between two adjacent weft threads, measured from the two sides of the respective weft thread or warp thread facing each other and defining the edge of the clear distance. In particular, it is provided that the mesh size or the clear distance between the warp threads or weft threads, particularly in woven fabrics or meshes, form a mesh surface, wherein this mesh surface enables the thermoplastic substrate of the decorative sheet to fuse with the thermoplastic fibers of the fiber mat within this mesh surface, in particular wherein the thermoplastic can penetrate through this mesh surface. In other words, the mesh surface can also be referred to as the gap that forms between the threads forming the mesh.

[0043] The mesh area is preferably calculated from two lateral mesh sizes, preferably arranged orthogonally to each other, between two opposing threads. The two orthogonally arranged lateral mesh sizes are preferably approximately the same size within the usual textile manufacturing parameters. However, the two orthogonally arranged lateral mesh sizes can also be different sizes. The two mesh sizes can also be arranged non-orthogonally to each other.

[0044] The mesh size preferably ranges from 0.00 mm to 10 mm, preferably from 0.15 mm to 10 mm, and particularly preferably from 0.3 mm to 5 mm. If the mesh size between two opposing threads is 0.00 mm, then the two threads are preferably located directly next to each other. This means that no gap forms between the two opposing threads.

[0045] A grammage preferably describes a surface weight, which is specified in grams per square meter. Furthermore, the grammage can also be described as fabric weight, because the higher the grammage, the heavier the textile. It is possible that the grammage is in a range of 10 g / m 2 up to 800 g / m 2 preferably in a range of 50 g / m 2 up to 600 g / m 2 , particularly preferably in a range of 80 g / m 2 up to 300 g / m 2 .

[0046] It may also be possible for the thickness of the decorative sheet to be between 10% and 75%, particularly preferably between 20% and 75%, of the thickness of the at least one textile or the plurality of textiles.

[0047] It is preferably provided that one or more woven textiles are used to modify the surface or feel of the decorated molded part to be produced.

[0048] The fiber mat represents the starting point for the production of the decorated molded part. In the subsequent molded part, the thermoplastic fibers are preferably no longer visible as such, as they plasticize through thermal heating and later solidify into a solid composite with the natural fibers. In particular, it is intended that the thermoplastic composite comprises a proportion of at least 33 vol.%, in particular of at least 50 vol.%, of the total volume of the decorated molded part. Such a proportion of the thermoplastic composite gives the molded part the necessary structural integrity, which, as a carrier matrix, in conjunction with the fibers, forms a corresponding composite that generates the necessary mechanical stability, in particular strength, required for the predetermined intended use of the molded part.

[0049] Preferably, the fiber mat, in particular the uncalibrated fiber mat, has a thickness in the range of 2 mm to 25 mm, in particular 6 mm to 15 mm, in step b). Typically, the fiber mat is provided wound on a roll. Before inserting the fiber mat into a press in step c), it is preferably provided that the fiber mat is cut accordingly, so that a finished fiber mat is preferably provided.

[0050] It may be possible for the substrate of the decorative sheet to comprise polypropylene (PP) as its material. It may also be possible for the substrate of the decorative sheet to comprise a material or combination of materials selected from: polypropylene (PP), polyethylene (PE), polyolefins, polyethylene terephthalate (PET), biodegradable biopolymers, in particular polylactides (PLA). Furthermore, it is also possible to use the aforementioned materials of the substrate of the decorative sheet in combination with fillers made of organic and / or inorganic substances. For example, the fillers may be selected from: calcium carbonate, waste products from the wood industry, in particular in the form of granulated and / or powdered residues of bark or sawdust, cotton, paper particles, in particular paper dust. The proportion of these fillers or substances in the substrate of the decorative sheet is preferably between 1% and 80%, more preferably between 20% and 50%. Such fillers orSubstances ensure that the decorative sheet can be produced more cost-effectively and is also more sustainable.

[0051] It has been found to be particularly advantageous if the substrate of the decorative sheet comprises a similar or identical material to the thermoplastic fibers of the fiber mat. This allows a homogeneous composite of the plastic mass, comprising the molten thermoplastic fibers and the material of the substrate of the decorative sheet, to form during the subsequent pressing of the fiber mat. A plastic mass that is as homogeneous as possible ensures that a homogeneous composite is formed during subsequent cooling, which is particularly stable and break-resistant. In particular, it is envisaged that the following steps, particularly in the specified order, are carried out to prepare the decorative sheet in step a):

[0052] - Providing the substrate;

[0053] - Applying the decorative layer by printing and / or by transferring a transfer layer of a transfer film, in particular by hot stamping.

[0054] It is thus possible for the decorative layer to be formed from a combination of one or more printing layers and one or more transfer layers of a transfer film. It is also possible for the hot embossing to be arranged on one side of the substrate and the printing on the other side of the substrate. Alternatively, it is possible for the printing and hot embossing to be arranged on one side of the substrate. In particular, it is provided that the printing and hot embossing overlap and / or that the printing and hot embossing are arranged at a distance from one another. This makes it possible to realize a multitude of design variants. When the decorative layer is applied by printing, this is preferably done by means of a printing process, individually or in combination selected from: screen printing, gravure printing, digital printing, inkjet printing, laser printing. When a transfer layer of a transfer film is applied, the transfer layer of the transfer film preferably functions as the decorative layer.The transfer foil, in particular hot stamping foil, preferably comprises a carrier and a transfer layer that can be detached from the carrier by means of a release layer. This transfer layer can have at least one layer or a combination of several layers selected from: ink layer, metal layer, replication layer, protective lacquer layer, primer, adhesive layer, adhesion promoter layer, barrier layer, conductive layer, lacquer layer.

[0055] The application of the decorative layer can, for example, involve applying a transfer layer of a transfer film and subsequently overprinting the applied transfer layer on the substrate. For example, the transfer layer can comprise a metal layer, and the overprinting of the transfer layer can be carried out with one or more translucent ink layers.

[0056] It is particularly preferred that the decorative layer comprises, individually or in combination, one or more layers selected from the group: metal layer, opaque color layer, translucent color layer, translucent color layer, colorless translucent layer, colorless transparent layer.

[0057] Preferably, it may be possible for the transfer layer to be transferred at least partially or over the entire surface onto the substrate of the decorative web by means of a hot stamping stamp and / or by means of a hot stamping wheel.

[0058] It is preferably provided that the decorative layer of the decorative web has at least one layer or combinations of several layers selected from: color layer, metal layer, replication layer, protective lacquer layer, primer, adhesive layer, adhesion promoter layer, barrier layer, conductive layer, lacquer layer.

[0059] In particular, it is provided that the decorative layer is designed as one or more motifs. A motif can be, for example, a graphically represented outline, a figurative representation, an image, a visually recognizable design element, a symbol, a logo, a portrait, a pattern, a continuous pattern, an alphanumeric character, a code, a code pattern, a cryptographic pattern, a text, a color design, and the like. The motif can also be customized. In particular, it is provided that the decorated area forms one or more motifs.

[0060] It is preferred that the motif has a minimum line width and / or a minimum dot size and / or detail size that is larger than the mesh size of the at least one textile or the plurality of textiles.

[0061] Particularly preferably, the motif has a minimum line width and / or a minimum dot size and / or detail size corresponding to 1.5 times the mesh size, more preferably 2 times the mesh size. This has the advantage that, in designs in which one or more textiles are inserted, the motif is sufficiently recognizable through the fabric, particularly visually on the visible side of the decorated fiber mat or the decorated molded part. As a result, the line is also reproduced on the thread(s).

[0062] Furthermore, it can be provided that in step a), the decorative layer is applied to the front and / or back of the substrate. Advantageously, the decorative layer is applied to the back of the substrate. This allows for particularly effective decoration of the natural fibers. Surprisingly, it has been shown that when the decorative layer is applied to the back of the substrate, the decorative layer adheres extremely well to the fiber mat, particularly to the natural fibers of the fiber mat.

[0063] A carrier is preferably understood to mean a single-layer or multi-layer film, one or more layers of which comprise in particular the following materials or combinations: PET (polyethylene terephthalate), PP (polypropylene), PE (polyethylene), PEN (polyethylene naphthalate), PC (polycarbonate), PVC (polyvinyl chloride), Kapton (poly[N,N-(oxydiphenylene)pyromellitimide]) or other polyimides, PLA (polylactide), PMMA (polymethyl methacrylate) or ABS (acrylonitrile butadiene styrene).

[0064] The layer thickness of the carrier is in particular in a range from 1 pm to 500 pm, preferably from 6 pm to 100 pm, more preferably from 6 pm to 75 pm. The carrier may have been subjected to a surface treatment, for example by means of plasma and / or corona, on one or both sides.

[0065] The carrier itself can have an adhesion promoter layer. This adhesion promoter layer is applied during the carrier manufacturing process. The layer thickness of the adhesion promoter layer of a carrier supplied by the carrier supplier is preferably in the range of 0.1 μm to 5 μm. The primer materials listed below can be used as the adhesion promoter layer.

[0066] A primer or adhesion promoter layer increases the adhesion between two layers that would otherwise lack sufficient adhesion to each other. For example, this can be the adhesion of the replication layer to the carrier. The primer or adhesion promoter layer preferably comprises a material or combinations thereof selected from: polyester, polyacrylate, polymethacrylate, polyurethane, polystyrene, polybutyrate, nitrocellulose, polyvinyl chloride, ethylene-vinyl acetate, their copolymers, or similar polymers or mixtures thereof. The primer or adhesion promoter layer can be thermoplastic, chemically crosslinkable, UV-curable, a hybrid variant (thermoplastic and UV-curable or / or crosslinkable by other means), a cold-bonding primer, or a self-adhesive primer.

[0067] The primer or adhesion promoter layer preferably has a thickness in the range of 0.01 pm to 15 pm, preferably 0.1 pm to 5 pm. Inorganic materials such as metals, metal oxides, alloys, oxides, or silicates can also serve as adhesion promoters or be part of such a system.

[0068] The primer or adhesion promoter layer may also contain additives based on organic or inorganic substances that

[0069] Processing properties, for example, when applying a layer of transfer film, achieve a predetermined effect. The proportion of additives in the total coating of the primer or adhesion promoter layer is usually between 0% and 10%, preferably between 0% and 5%, more preferably between 0.01 and 3%.

[0070] Furthermore, fillers can also be part of the formulation of a primer or adhesion promoter layer. This preferably includes all other materials added to a system, especially a polymer-based system, such as silica, pigments, dyes, tracers, especially taggants, and / or similar materials. The proportion of fillers in the total coating of the primer or adhesion promoter layer is usually between 0% and 80%.

[0071] In addition, primers or adhesion promoter layers can be formulated so that they remain tacky or even liquid even after the solvent has evaporated and / or before full curing. This is particularly advantageous when two substrates are to be bonded together over a large area, as is typically the case in a laminating process.

[0072] The release layer ensures, in particular, that the transfer layer of the transfer foil, in particular hot stamping foil, which is applied as a decorative layer to the substrate of the decorative web, can be non-destructively separated from the carrier as transfer layers. The release layer preferably comprises a material or combination of materials selected from: waxes, polyethylene (PE), polypropylene (PP), cellulose derivatives, and / or poly(organo)siloxanes. The aforementioned waxes can be natural waxes, synthetic waxes, or combinations thereof. The aforementioned waxes include, for example, carnauba waxes. The aforementioned cellulose derivatives include, for example, cellulose acetate (CA), cellulose nitrate (CN), cellulose acetate butyrate (CAB), or mixtures thereof. The aforementioned poly(organo)siloxanes include, for example, silicone binders, polysiloxane binders, or mixtures thereof.The release layer preferably has a layer thickness in the range of 1 nm and 500 nm, in particular of 5 nm and 250 nm, preferably of 10 nm and 250 nm.

[0073] As already mentioned above, it is also possible for at least one decorative layer to be applied to the front side of the substrate of the decorative sheet. When applying the decorative layer to the front side, it is particularly intended that a protective lacquer layer is applied to the front side of the substrate in step a). This protective lacquer layer provides protection against mechanical or physical-chemical stress.

[0074] The protective coating layer is preferably a layer made of PMMA, PVC, melamine, and / or acrylates. The protective coating layer can also be made of a radiation-curing dual-cure coating. This dual-cure coating can be thermally pre-crosslinked in a first step during and / or after application in liquid form. Preferably, in a second step, particularly after processing the starting material or the multilayer body, the dual-cure coating is post-crosslinked radically, particularly via high-energy radiation, preferably UV radiation. Dual-cure coatings of this type can consist of various polymers or oligomers containing unsaturated acrylate or methacrylate groups. These functional groups can be radically crosslinked with one another, particularly in the second step.For thermal pre-crosslinking in the first step, it is advantageous that these polymers or oligomers also contain at least two or more alcohol groups. These alcohol groups can be crosslinked with multifunctional isocyanates or melamine-formaldehyde resins. Preferred unsaturated oligomers or polymers are various UV raw materials such as epoxy acrylates, polyether acrylates, polyester acrylates, and especially acrylate acrylates. Both blocked and unblocked versions based on TDI (TDI = toluene-2,4-diisocyanate), HDI (HDI = hexamethylene diisocyanate), or IPDI (IPDI = isophorone diisocyanate) can be used as the isocyanate. The melamine crosslinkers can be fully etherified versions, imino types, or benzoguanamine versions.

[0075] The protective lacquer layer preferably has a layer thickness in the range of 50 nm to 50 pm, preferably from 1 pm to 30 pm. The protective lacquer layer can be produced or applied by gravure printing, flexographic printing, screen printing, inkjet printing, or by means of a slot nozzle and / or by vapor deposition, in particular by means of physical vapor deposition (PVD), chemical vapor deposition (CVD), and / or sputtering.

[0076] Preferably, the protective lacquer layer can be transparent or colored.

[0077] A replication layer is preferably understood here to be a special, functional layer into which structures, preferably optically variable structures, are introduced and / or fixed, in particular by means of thermal replication and / or UV replication using a replication tool. In the case of a hybrid replication layer, this is replicated thermally, for example, and subsequently cured by means of radiation, for example by means of UV radiation and / or at least one electron beam. In the case of a UV-curing replication layer, this is replicated at room temperature and simultaneously cured by means of radiation, for example by means of UV radiation and / or at least one electron beam. For example, it is possible that the varnish becomes warm during UV replication.

[0078] It is possible that the replication layer has a layer thickness in the range of 0.1 pm to 30 pm, in particular in the range of 0.5 pm to 10 pm.

[0079] Preferably, the at least one primer is an adhesive that preferably increases or improves adhesion to other layers. For example, to the substrate to which the transfer layer is to be applied as a decorative layer.

[0080] The at least one primer used may preferably comprise one or more adhesives selected from: single-layer adhesive, multi-layer adhesive, water-based adhesive, solvent-based adhesive, solvent-free adhesive, radiation-curing adhesive, thermally activated adhesive, thermally curable adhesive or combinations thereof.

[0081] It is particularly provided that the at least one primer is applied by means of a printing process and / or by pouring and / or by means of a doctor blade. Furthermore, it is advantageous if the at least one primer is applied at least partially, preferably over the entire surface. The layer thickness of the individual adhesive layers within the primer is between 0.01 μm and 8.00 μm, preferably between 0.05 μm and 5.00 μm. In particular, it is provided that the adhesive layer or layers comprise at least one binder selected from: polyacrylates, polyurethanes, epoxies, polyesters, polyvinyl chlorides, rubber polymers, ethylene-acrylic acid copolymers, ethylene-vinyl acetates, polyvinyl acetates, styrene block copolymers, phenol-formaldehyde resin adhesives, melamines, alkenes, allyl ethers, vinyl acetate, alkyl vinyl ethers, conjugated dienes, styrene, acrylates and / or combinations thereof.

[0082] It is further preferably provided that the lacquer from which the adhesive layer is produced by an application process comprises at least one solvent selected from: water, aliphatic (petrol) hydrocarbons, cycloaliphatic hydrocarbons, terpene hydrocarbons, aromatic (benzene) hydrocarbons, chlorinated hydrocarbons, esters, ketones, alcohols, glycols, glycol ethers, glycol ether acetates and / or combinations thereof. This solvent or solvent mixture is largely removed again in the application process. It is also further possible that the at least one primer or the adhesive comprises at least one additive selected from: hardeners, crosslinkers, photoinitiators, fillers, stabilizers, inhibitors, corrosion inhibitors, additives such asFlow control additives, defoamers, deaerators, dispersing additives, wetting agents, lubricants, matting agents, rheology additives, pigments, anti-corrosive pigments, dyes, waxes, and / or combinations thereof. By appropriately selecting fillers or waxes, for example, the tackiness of at least one primer at room temperature can be reduced.

[0083] In particular, a thermally activatable adhesive and / or an adhesive comprising thermoplastic and / or UV-based raw materials has a solids content in the range of 10% to 100%, preferably 15% to 35%. This allows for high-quality application on the coating machine. It is also preferably provided that the adhesive has a non-sticky surface after drying, particularly at room temperature. It is also advantageous if the raw materials of the adhesive are selected such that the processing temperature during production of the multilayer body is always above the glass transition temperature and below the melting point of the adhesive.

[0084] A multi-layer adhesive layer offers the particular advantage of achieving excellent adhesion even between highly demanding surfaces. Furthermore, a multi-layer structure enables primer systems that can meet a wide range of chemical and physical resistance requirements. Chemical resistance refers to the adhesive layer's resistance to the effects of chemicals. The composition of the adhesive layers is preferably selected to ensure sufficient resistance to predefined chemicals. Furthermore, it is advantageous for multi-layer adhesives to provide interlayer adhesion between the individual layers. This is achieved by appropriately selecting the adhesive components.

[0085] In particular, it is provided that the at least one metal layer comprises a material or a combination of materials selected from: aluminum, indium, silver, chromium, copper, tin, gold, zinc or an alloy of the aforementioned metals.

[0086] Advantageously, it is provided that the layer thickness of the at least one metal layer is in a range from 3 nm to 300 nm, preferably in a range from 5 nm to 100 nm.

[0087] It may also be possible for the metal layer to be applied to a replication layer in which optically variable structures are molded to generate optically variable effects. This allows, for example, color-shift effects to be realized.

[0088] Furthermore, the decorative layer can be provided with a full-surface metal mirror, particularly with high reflection. This can provide a molded part that can be used as an insulating material.

[0089] The color layer preferably consists of a combination of at least one binder and / or at least one filler, and optionally at least one additive. A color layer is preferably understood to be a special, functional layer that, in particular, creates a color impression that is perceivable by an observer.

[0090] Color is understood in particular to mean a coloring which, with regard to transparency and / or clarity or scattering power, preferably includes crystal-clear transparent coloring, scattering-transparent coloring, or even opaque coloring. The color preferably occurs as the intrinsic color of a material and / or is arranged in front of a layer as an additional colored layer in the viewing direction, wherein the underlying layer, in particular the metal layer, is modified in its colored appearance, especially for a viewer. The color preferably appears optically constant or invariable in its hue and / or color saturation and / or transparency under almost all, in particular all, viewing and / or illumination angles.It is also possible that the color itself is optically variable, with the hue and / or color saturation and / or transparency of the color changing in particular with changing viewing and / or illumination angles.

[0091] The color layer can be designed as a translucent color layer, in particular as a transparent or translucent color layer, wherein the transmittance of such a translucent, in particular transparent or translucent color layer is preferably between 25% and 99%, in particular over a partial range of the wavelength range visible to the human eye from 380 nm to 780 nm, preferably in the range from 430 nm to 690 nm.

[0092] The color layer can alternatively also be designed as an opaque, in particular as an opaque color layer, wherein the transmittance of such an opaque, in particular opaque, color layer is preferably between 0% and 25%, in particular over a partial range of the wavelength range visible to the human eye from 380 nm to 780 nm, preferably in the range from 430 nm to 690 nm.

[0093] The color layer preferably contains an additive and / or a filler that preferably absorbs light in the ultraviolet (UV) wavelength range, in particular in a wavelength range between 200 nm and 380 nm. In particular, the UV blockers exhibit no or only very low absorption in the wavelength range visible to the human eye from 380 nm to 780 nm, in order to avoid altering the color impression of the color layer.

[0094] As an alternative to transparent translucent color layers and / or translucent translucent color layers, colorless transparent layers and / or colorless translucent layers can also be used. However, a combination is also possible. Preferably, the transmittance of a colorless transparent layer and / or colorless translucent layer is preferably in a range of 25% to 99%, in particular over a sub-range of the wavelength range visible to the human eye from 380 nm to 780 nm, preferably in the range of 430 nm to 690 nm.

[0095] Binders are preferably understood to mean polymer-based systems and their mixtures, such as polyester, polyacrylate, polymethacrylate, polyurethane, polystyrene, polybutyrate, nitrocellulose, polyvinyl chloride, ethylene vinyl acetate, their copolymers or similar polymers.

[0096] Additives are preferably understood to be organic or inorganic substances that achieve a predetermined effect on the processing properties, for example, when applying a color layer in the above process, particularly in step ii), or when using the security thread or multilayer body itself. For example, a UV blocker (UV = UV radiation = ultraviolet radiation = electromagnetic radiation from the ultraviolet part of the spectrum of electromagnetic radiation or from one or more sub-ranges of the ultraviolet part of the spectrum of electromagnetic radiation) can be an additive.

[0097] Fillers are preferably understood to mean all other materials added to a system, in particular a polymer-based system, such as silica, pigments, dyes, UV blockers, tracers, in particular taggants, and / or similar materials.

[0098] Dyes and / or pigments are preferably suitable as coloring substances for the at least one color layer. Pigments are preferably practically insoluble, in particular insoluble, in the medium into which they are integrated. Dyes preferably dissolve during use and, in particular, lose their crystal and / or particle structure. Possible classes of dyes are basic dyes, fat-soluble dyes, or metal complex dyes. Possible classes of pigments are organic and inorganic pigments. Pigments are preferably composed of a single-piece material or, alternatively, have complex structures, for example as layered structures with a plurality of layers made of different materials and / or, for example, as capsules made of different materials, in particular with a core and shell.

[0099] The color layer is in particular transparent or at least translucent, with the transmittance preferably being between 25% and 99%, in particular over a sub-range of the wavelength range visible to the human eye from 380 nm to 780 nm, preferably in the range from 430 nm to 690 nm. In particular, optically variable effects of the optically variable structures arranged below the at least one color layer from the viewer's perspective, which are incorporated in particular in the at least one replication layer, can be detected.

[0100] Furthermore, it is possible for the at least one color layer to be formed and / or consist of a plurality of different colors, wherein these preferably also have regions with color mixing of the first and second colors, which are created by overlapping the color layers and / or by rasterizing the color layers. In particular, the color saturation in the color layers varies. The color layer can be produced with at least one pigment or one colorant of the color cyan, magenta, yellow or black (CMYK = cyan magenta yellow key (key = black as color depth)), in particular for generating a subtractive mixed color, or of the color red, green or blue (RGB), in particular for generating an additive mixed color.

[0101] As an alternative to mixed colours, pigments or dyes can also be used to produce a special, particularly premixed, special colour or colour from a special colour system (e.g. RAL, HKS, Pantone), for example orange or violet.

[0102] It can also be provided that the ink layer comprises a printed pattern, in particular a gradient.

[0103] In particular, it is provided that the at least one color layer has a layer thickness in the range from 0.1 pm to 30 pm, preferably in the range from 0.1 pm to 15 pm.

[0104] In particular in the case of colorless transparent and / or colorless translucent layers, it is provided that the at least one layer has a layer thickness in the range from 0.1 pm to 30 pm, preferably in the range from 0.1 pm to 15 pm.

[0105] In particular, it is provided that the decorative sheet has a total layer thickness in the range from 100 pm to 500 pm, in particular in the range from 125 pm to 300 pm. Total layer thickness is understood to mean the thickness of the substrate including the thickness of all decorative layers or the entire decorative layer. It is preferably provided that the substrate comprises polypropylene (PP) as material. It may also be possible for the substrate to comprise a material or combinations of materials selected from: polypropylene (PP), polyethylene (PE), polyolefins, polyethylene terephthalate (PET), biodegradable biopolymers, in particular polylactides (PLA). Furthermore, it is also possible to use the aforementioned materials of the substrate of the decorative sheet in combination with fillers made of organic and / or inorganic substances.For example, the fillers can be selected from: calcium carbonate, waste products from the wood industry, particularly in the form of granulated and / or powdered residues of bark or sawdust, cotton, paper particles, especially paper dust. The proportion of these substances in the substrate of the decorative sheet is preferably between 1% and 80%, particularly preferably between 20% and 50%. It is particularly advantageous if the material of the substrate matches or is at least similar to the material of the thermoplastic fiber. Preferably, both the substrate and the thermoplastic fibers are made of polypropylene.

[0106] In particular, it is possible for the substrate to be available in different colors. It may also be transparent or translucent. Furthermore, the color of the substrate may match or at least be similar to the color of the thermoplastic fibers. Alternatively, it is also possible for the color of the substrate to be different from the color of the thermoplastic fibers. It is also possible for the thermoplastic fibers to be transparent or translucent.

[0107] With a transparent or translucent substrate for the decorative sheet and a transparent or translucent decorative layer applied thereon, for example, consisting of transparent or translucent color layers and / or transparent or translucent colorless layers, the visual appearance of the fiber mat and / or of the elements or layers provided between the fiber mat and the decorative sheet can be largely retained, while simultaneously increasing the resistance of the decorated molded part or fiber mat to external influences. Thus, in particular, the visual appearance of the fiber mat is retained, but the resistance of the decorated molded part or fiber mat to damage and / or soiling is also improved.Depending on the choice of transparent or translucent decorative strip and / or the decorative layer with a coloration, the visual appearance of the fiber mat and / or of elements or layers provided between the fiber mat and the decorative strip can also be influenced by color, for example by overlaying them.

[0108] Furthermore, it is preferably provided that the substrate has a layer thickness in the range of 100 μm to 500 μm, in particular from 125 μm to 300 μm. Tests have shown that with substrates that are too thick, the feel of the natural fibers is no longer perceptible after the decoration process, and the characteristic visual appearance is no longer visible. The above layer thicknesses can thus preserve the feel of the natural fibers and their characteristic visual appearance.

[0109] In particular, it is possible that after step b) and before step c), the fiber mat is placed in a press, in particular a calibration press, and the fiber mat is calibrated without the decorative sheet. This can reduce the temperature stress on the decorative sheet.

[0110] In particular, it is possible that after calibrating the fiber mat without the decorative sheet, the fiber mat is subsequently inserted into a press, in particular a calibration press, together with the decorative sheet, and the fiber mat is recalibrated together with the decorative sheet. Furthermore, it is also possible that reinforcing materials, in particular mesh nets, are introduced or inserted in step c). These reinforcing materials provide the fiber mat or the subsequent molded part with the necessary stability. Appropriate reinforcing materials are selected depending on the intended use. These reinforcing materials are inserted, in particular, on the side of the fiber mat facing away from the visible side.

[0111] It may also be provided that a heating foil is additionally inserted in step c). This heating foil can be used to heat the molded part later, for example, for functional heating of the molded part during its normal use.

[0112] It can also be provided that, in step c), a sensor with an edge-side tail is additionally inserted. The sensor can then be connected via the edge-side tail to a corresponding processing unit, which can process the sensor data.

[0113] Step d), i.e. the pressing of the fiber mat and the decorative sheet, compacts the fiber mat and significantly reduces the strength or thickness of the fiber mat.

[0114] It is preferably possible for the press, in particular the calibration press, to have two planar, heatable plates or surface stamps in step d), by means of which the thermal heating of the fiber mat and the decorative web takes place. It can also be provided that only one of the surface stamps is heatable, for example the lower surface stamp or the upper surface stamp. It is preferably provided that the fiber mat with the decorative web is pressed for a predetermined period of time at a predetermined temperature and under a predetermined pressing force. These can also be variable parameters. For example, the temperature can be increased or reduced during pressing. It is also conceivable for the pressure or pressing force to increase or decrease gradually. Furthermore, it is possible for the pressure or pressing force to increase or decrease abruptly.Preferably, the parameters are adjusted and selected accordingly depending on the fiber mat and decorative web. It is also possible for the press's movable upper surface ram to briefly lift from the fiber mat, preferably for between 1 and 5 seconds, and then press the fiber mat again. This brief lifting can serve, in particular, to vent the calibration press. However, it is conceivable that, within this short period of time, an additional decorative web and / or an additional functional web or layer could be placed on top of the fiber mat in the calibration press and positioned preferentially.

[0115] It is preferably provided that the pressing in step d) takes place at a temperature in a range from 150°C to 250°C, in particular in a range from 170°C to 230°C, particularly preferably in a range from 180°C to 210°C.

[0116] It may also be possible for the pressing in step d) to be carried out with a pressing force in a range from 180 kN to 220 kN, in particular in a range from 185 kN to 210 kN, preferably wherein the pressing force is built up continuously or stepwise over time by closing the press or the pressing force is reached suddenly.

[0117] It is particularly advantageous if the pressing in step d) takes place for a duration ranging from 30 seconds to 180 seconds. The duration preferably depends on the thickness of the fiber mat and the thickness of the decorative sheet.

[0118] Preferably, it may be possible for the fiber mat to be deformed three-dimensionally or 2.5-dimensionally during pressing in step d).

[0119] Preferably, after pressing in step d), a deformed, in particular three-dimensionally deformed or 2.5D-deformed, decorated molded part is provided. It is also preferably possible for the decorated

[0120] The molded part is three-dimensionally or 2.5-dimensionally deformed.

[0121] It has advantageously been found that in step d) the decorative web forms a material bond with the fiber mat, in particular with the thermoplastic fibers of the fiber mat, in particular due to thermal heating.

[0122] It is preferably possible that in step d) the material of the substrate, in particular the polypropylene of the substrate, is softened and / or plasticized by the thermal heating and geometrically sinks into the fiber mat, whereby a partial decoration of the natural fibers arranged in the upper boundary region of the fiber mat takes place, so that a mottled appearance is created.

[0123] In particular, it is possible that the upper limit range is a maximum of 50%, preferably a maximum of 33%, of the total thickness of the fiber mat, in particular of the decorated molded part.

[0124] Furthermore, it may also be possible for the lower region to be a maximum of 67%, preferably a maximum of 50%, of the total thickness of the fiber mat, in particular of the decorated molded part.

[0125] The above-mentioned mottled appearance is preferably formed by the decorated natural fibers in the upper border area and by the composite of the substrate of the decorative sheet and thermoplastic fibers. The decorated natural fibers are generally lighter in appearance than the background, with the background being formed by the composite. However, the reverse is also possible, i.e., the decorated natural fibers are darker in appearance than the background, with the background being formed by the composite. Furthermore, it is also conceivable that the background formed by the composite is transparent or translucent.

[0126] It is preferably provided that in step d) the color of the substrate of the decorative web and / or the color of the thermoplastic fibers essentially represents the visible background color of the mottled appearance.

[0127] Preferably, in step d), the thermoplastic fibers are softened and / or plasticized to form a melt, so that the density of the thermoplastic fibers increases due to this melt and the melt sinks into the fiber mat, starting from the upper boundary region of the fiber mat toward the lower region of the fiber mat, causing the natural fibers, in particular those that do not melt, to partially protrude from the melt. This ensures that the haptic properties of the natural fibers can be felt or grasped in the subsequent molded part and that their characteristic visual appearance is preserved.

[0128] In particular, it is provided that in step d), as the substrate of the decorative sheet sinks into the fiber mat, the decorative layer sinks and / or infiltrates the upper boundary area of ​​the fiber mat. As a result, the natural fibers in the upper boundary area are at least partially covered by the decorative layer and thus decorated. This also promotes the mottled appearance described above.

[0129] The forming process in step e) is also commonly referred to as thermoforming. In particular, the fiber mat is deformable after step d) due to thermal heating, is deformed in step e), and then solidified into a molded part by cooling.

[0130] Preferably, immediately after pressing in step d), the still soft and deformable fiber mat is inserted into the molding tool. This is advantageously done manually. Alternatively, it can also be done using a robot, in particular a robot arm.

[0131] It is preferably provided that in step e) the mold has two mold halves, in particular wherein the two mold halves are not heated. By “not heated” is meant here that the mold halves have a temperature below the softening temperature of the thermoplastic matrix. The two mold halves are preferably three-dimensional mold halves with which the decorated fiber mat is deformed into a molded part. Because the mold halves are not heated, the plasticized or molten material of the substrate and / or the thermoplastic fibers can cool and solidify. It may also be possible for the two mold halves to be actively and / or passively tempered. If the tempering includes cooling, the cooling of the plastic mass can take place even faster and the throughput is increased.

[0132] It is preferably provided that in step e) the forming takes place at a pressing force in a range of 550 kN to 650 kN, in particular in a range of 560 kN to 640 kN.

[0133] Preferably, in step e), the molding takes place for a time in the range of 30 seconds to 60 seconds. The time is preferably selected such that the molten material of the substrate and the thermoplastic fibers cools and solidifies into a solid, particularly cohesive, composite. This ensures that the geometry of the molded part no longer changes upon or after removal of the molded part from the mold.

[0134] Preferably, in step e), the molding takes place at a maximum temperature of 80°C. In this case, the two mold halves can be temperature-controlled or have corresponding heating elements.

[0135] In particular, it is possible that in step e), the melted substrate of the decorative sheet and the melted thermoplastic fibers of the fiber mat solidify, thus causing shrinkage of the thermoplastic materials. This shrinkage causes more natural fibers to emerge from the surface of the molded part, thus improving the feel of the decorated natural fiber mat.

[0136] Furthermore, it can be provided that in step e), the mold half of the molding tool facing the visible side of the decorated fiber mat is structured, in particular, matte. This matte finish is achieved, for example, by sandblasting the mold surface to create a light-scattering surface. This allows this light-scattering structure to be at least partially molded into the surface of the decorated molded part. This is advantageous when decorated molded parts with a matte appearance are desired.

[0137] Furthermore, it can also be provided that in step e) an additional trimming takes place in the mold or that after step e) a separate trimming of the molded part takes place by means of a knife and / or laser, so that the molded part is adapted to the final shape.

[0138] Furthermore, it can be provided that after step e), the following step is carried out: f) Back-injection of the molded part with a plastic compound, preferably in the mold or in an injection molding machine, in order to attach mounting elements and / or reinforcement elements. The attachment of mounting elements or reinforcement elements makes the decorated molded part versatile and can thus be individually adapted to the predetermined area of ​​application. For example, mounting elements for attaching the molded part to a vehicle body or light guides for coupling and / or decoupling light can be provided. The plastic compound used can, for example, be polypropylene (PP), polyethylene (PE), polycarbonate (PC), polyamide (PA), acrylonitrile-butadiene-styrene copolymer (ABS), polycarbonate / acrylonitrile-butadiene-styrene copolymer (PC / ABS), polybutylene terephthalate (PBT), or polymethyl methacrylate (PMMA).Accompanying materials such as glass fiber, talc or gases for foaming, etc. can also be processed.

[0139] In particular, it is provided that the decorated fiber mat after step d) and / or the decorated molded part after step e) has a thickness in the range from 1 mm to 4 mm, in particular from 1.5 mm to 3.5 mm.

[0140] The decorated molded part is preferably a three-dimensional geometry with various curves, depressions, recesses, etc. The effect resulting from the decoration preferably varies in intensity depending on the radius of curvature and / or viewing angle. For example, if the decorative layer is metallic silver and the substrate of the decorative strip is opaque black, a bright metallic shimmer results after decoration against the "black" of the substrate. This bright shimmer varies in intensity depending on the radius of curvature and / or viewing angle, and one could also speak of a visually variable appearance.

[0141] In particular, it is provided that the decorated molded part has a mottled appearance due to the at least partial decoration of the natural fibers in the upper boundary area, in particular wherein the at least partially decorated natural fibers stand out from the background, preferably wherein the background is essentially formed by the thermoplastic composite of the fused thermoplastic fibers and the substrate of the decorative web.

[0142] Furthermore, it can be provided that the decorated molded part is decorated in a first area and is not decorated in a second area.

[0143] Preferably, the second region has the background color of the decorated molded part, which is also visible in the background of the first region.

[0144] Since, in the present method for producing a decorated molded part, the decorative sheet is preferably inserted into a press such that the decorative layer faces the fiber mat, the decorative layer itself does not need to meet any special requirements regarding durability, etc., since the surface of the decorated molded part is predominantly covered by the substrate of the decorative sheet or is formed by the substrate and the underlying fiber mat. This is preferably due to the fact that the decoration only accounts for a small portion of the surface of the decorated molded part.

[0145] Nevertheless, there are certain specifications or requirements, primarily known from the automotive industry, that such a fiber mat must ideally meet. These requirements have been confirmed by a series of tests, which are presented below.

[0146] For all subsequent tests, a decorated molded part according to the invention or a sample of a decorated molded part was used.

[0147] Among other things, the cream resistance of the decorated molded part was tested according to test method VW PV 3964. For this purpose, appropriate samples are first cut to size, which are then conditioned for seven days at room temperature, in particular in a temperature range of 18°C ​​to 28°C, or for 48 hours at 60°C in a circulating air oven. A 20-thread gauze bandage according to DIN 61631 is then placed on the samples. The test medium, in this case Test Cream Type A from Thierry GmbH or Test Cream Type B from Thierry GmbH, is applied to the gauze bandage and pressed through the gauze bandage onto the sample surface and spread. It is preferable that the spaces between the meshes of the gauze bandage are filled with the test medium.

[0148] The size of the gauze bandage and the amount of test medium should preferably be selected depending on the sample size. The prepared sample is then stored or conditioned in a convection oven at a temperature of 80°C for a period of 24 hours. The sample is then removed from the convection oven, the gauze bandage removed, and any remaining test medium is wiped off with a clean cloth. Before the sample is evaluated and subjected to further tests, it is conditioned again for a period of 4 hours at room temperature, preferably within a temperature range of 18°C ​​to 28°C.

[0149] Unless otherwise requested, a visual inspection of color and appearance is performed first. It is preferred that there be no change in appearance, i.e., no crow's feet or swelling, and no change in haptic properties, such as softening or increased stickiness, compared to the original molded part or the original sample (without test medium). An increase in gloss, for example, is permissible.

[0150] Furthermore, the cream test preferably involves a cross-cut test according to DIN EN ISO 2409, followed by abrupt adhesive tape tearing. A cross-cut characteristic value of < 1 is required. The cross-cut test is described in detail below. Furthermore, the cream test preferably also involves a cross-cut test, followed by adhesive tape tearing. A knife with a sharp, thin blade, e.g., a safety knife with a trapezoidal handle (also called a craft knife), is used to cut a cross (St. Andrew's cross) into the surface of the sample, and then an adhesive tape is applied. After the adhesive tape has been removed, no paint particles should remain on the adhesive tape.

[0151] Furthermore, the cream test is preferably also used to test scratch resistance. For samples or components with complex geometries, the scratch resistance of the sample surface is tested using an Erichsen hardness test bar at a load of up to 10 N and a Bosch test needle (0.75 mm tip). A detailed description of the scratch resistance test follows below. Cracking of the coating down to the base material is not permitted. An indentation in the substrate due to the load is permissible.

[0152] For samples with a flat surface, the cream test is preferably carried out using a grid test according to VW PV 3952.

[0153] It is preferably provided that the decorated molded part has a fastness rating of the gray scale in the range of 4 to 5 and a cross-cut characteristic value of < GT 1 according to DIN EN ISO 2409 and no change in haptics and color in a cream resistance test according to VW PV 3964 with a test cream type A and / or type B.

[0154] Furthermore, the decorated molded part was also subjected to a hydrolysis test according to test method BMWAA-0203. For this purpose, appropriate samples are first cut, which are then conditioned for seven days at room temperature or for 48 hours at 50°C in a convection oven. Conditioning for seven days at room temperature is preferable. Room temperature for storage and / or conditioning is understood to mean, in particular, the temperature range from 18°C ​​to 28°C.

[0155] The cycle described below is then performed once. The sample is conditioned in a climate chamber for a test period of 72 hours at a temperature of 90°C ± 2°C and a relative humidity of 95% ± 2%. The sample is then stored at room temperature for a period of 24 hours. After storage, adhesion tests are performed using cross-cut adhesion tests in accordance with BMWAA-0180 or BMW GS 97034-9. The evaluation is carried out according to BMWAA-0180 or BMW GS 97034-9. Surface changes, such as blistering, paint peeling, or paint softening, are not permitted. Furthermore, any change in the shape of the substrate or sample should preferably be included in the test report.

[0156] It is preferably provided that the decorated molded part does not exhibit any surface changes in a hydrolysis test according to BMWAA-0203 and has a gray scale fastness rating in the range of 4 to 5 and a cross-cut characteristic value of < GT 1 according to BMWAA-0180 and a grade 1 B in a fingernail test according to BMW GS 97034-2.

[0157] As mentioned above, cross-cut tests according to DIN EN ISO 2409, BMWAA-0180, and BMW GS 97034-9 are also performed for the evaluation of the cream test and the hydrolysis test. However, the cross-cut test can also be performed independently to provide information about the durability of the sample or the decorated molded part.

[0158] To prepare the sample, it is first stored at room temperature for seven days. In cross-cut testing, a distinction is preferably made between hard and soft substrates. Hard substrates include steel, aluminum, magnesium, thermosets, and similar materials. Soft substrates include, for example, thermoplastics, PP, EPDM, polyamides, ABS, PC, and similar materials.

[0159] In contrast to the testing according to DIN EN ISO 2409, all paint finishes tested according to BMW AA-0180 are tested as hard substrates. This means that the test is always performed with adhesive tape removal, regardless of the substrate.

[0160] Before testing, the surface of the sample or the area to be tested is thoroughly cleaned with a clean cleaning cloth soaked in isopropanol (2-propanol). It is important that any contaminants are removed completely. Furthermore, it is preferable to avoid scratches caused by cleaning by selecting suitable cleaning cloths. Testing may only be performed when the surface of the sample is visually dry and free of any propanol residue.

[0161] Next, a cross-cut is made on the surface of the sample using the appropriate cutting tool, preferably at an angle of 90°. When using a utility knife according to DIN EN ISO 2409, an angle of 30° ± 10° to the surface of the sample must be maintained. If possible, a template should be used to ensure that the cut is made at a 90° angle to the surface in the cutting direction.

[0162] Only those cross-cuts that are clearly even and continuous down to the substrate and consist of at least six individual cuts in each direction of the grid may be assessed. A magnifying glass may be used to check the continuity of the cuts down to the substrate.

[0163] Furthermore, especially with soft substrates, care should be taken to ensure that the damage to the substrate is as minimal as possible, i.e., that the cut is made close to the surface. If the damage to the substrate is too deep, the adhesion of the coating will be negatively affected by various forces. Depending on the total layer thickness and the substrate, the cutting distances listed in the following table must be observed, deviating from DIN EN ISO 2409:

[0164] The following procedure for removing the adhesive tape applies to all coatings and substrates. To do this, first remove any cutting residue from the surface using a soft brush by gently brushing back and forth. The adhesive tape is then pressed firmly and evenly onto the cut surface using the edge of the wooden back of the brush, parallel to the direction of the cross-cuts. This means that the surface of the applied adhesive tape must appear lighter in color after pressing. Avoid pressing too hard or too intensively. If the adhesive tape is pressed on too firmly, a cream-colored fabric will appear. After one minute at the most, the adhesive tape is pulled off quickly and jerkily in one movement at an angle of, if possible, 60° to the sample surface. The adhesive tape is to be used only once.Furthermore, care must be taken to ensure that the adhesive surface, which is adhered to the cross-cut, is not contaminated by fingerprints or other adhesion-reducing substances. Furthermore, the sample must be secured to a solid surface during removal, e.g., by hand, using adhesive tape, or a magnetic block.

[0165] Generally, the adhesive tape is peeled off once in the direction of the cross-cut, approximately at a 90° angle to each other, and the surface is assessed or evaluated accordingly. If the initial assessment results in a cross-cut characteristic value of GT > 1, a further adhesive tape peel cycle is performed, this time in the opposite direction to the cutting direction. In total, the tape is peeled off once in both a clockwise and counterclockwise direction. The final assessment or evaluation then follows.

[0166] The criteria for classifying cross-cut values ​​are based on DIN EN ISO 2409:2013-06 or ASTM D3359-09. These criteria are summarized in the following table:

[0167] It is preferably provided that the decorated molded part is, after a visual

[0168] Evaluation according to the test method according to DIN EN ISO 2409:2013-06 shows at least a cross-cut characteristic (GT) of 1 and / or a value of 4B according to ASTM D3359-09. This applies in particular to all tests in which the cross-cut test is used as an evaluation criterion to assess the durability of the decorated molded part.

[0169] If delamination occurs only outside the cross-cut area to be assessed, e.g. at the extension of the cuts, it is assessed using a different assessment scheme, which is briefly explained below, in deviation from DIN EN ISO 2409.

[0170] If the area removed from the grid pattern corresponds to up to 15% of the area (corresponding to a maximum of 3 squares) of the total 25 squares within the grid pattern, the grid pattern is rated GT 1. If the area removed from the grid pattern corresponds to 16% to 35% (corresponding to 4 to 8 squares), it is rated GT 2.

[0171] If the area removed from the grid pattern is between 36% and 65% (equivalent to 9 to 16 squares), it is rated GT 3. If the area removed from the grid pattern is more than 66%, it is rated GT 4 or GT 5.

[0172] If delamination occurs both inside and outside the cross-cut area to be assessed, the lower value achieved is given as the result. If a utility knife is used to perform the cross-cut, this must be marked or supplemented in the corresponding test report as a word or with a "c", e.g., "GT 1 c". Cross-cut values ​​without any addition / marking are generated using a multi-blade cutting device according to this logic. The type of cutting tool used (multi-blade cutting device or utility knife with snap-off blades) influences the test result. The results of the different cutting tools cannot be directly compared. As already mentioned above, for example, a scratch resistance test according to BMW GS 97034-9 is also carried out to evaluate the hydrolysis test according to BMW AA-0203.However, the scratch resistance test can also be carried out on its own to provide information about the durability of the sample or the decorated molded part.

[0173] When testing scratch resistance, one or more samples with a length of at least 90 mm and a width of at least 50 mm are first prepared and then conditioned for 24 hours under standard conditions according to DIN EN ISO 291-23 / 50 (Class 2). Preferably, the samples have a flat surface. Before testing, the samples are cleaned without pressure using a microfiber cloth moistened with a laboratory detergent, such as Mucasol 3% in demineralized water (= fully demineralized water or deionized water).

[0174] The preferred test specimen is an Erichsen point with a diameter of 0.75 mm. This Erichsen point is preferably made of hardened steel. The point should be examined under 30x magnification before each test. Priority should be given to checking whether the point is smooth, hemispherical, and free of scratches and contaminants. If necessary, the point may need to be replaced or cleaned.

[0175] During the test, the specified test specimen is moved relative to the surface of the sample at a constant test force and constant speed. The test speed is preferably 40 ± 5 mm / s. The test force is increased in stages (1 N, 2 N, 3 N, 5 N, 8 N, and 10 N). The surface to be tested is loaded once for each test force. To better evaluate the individual gradations, the line spacing must be shifted by 5 mm after each scratch test when the load changes. The test path is preferably between 50 mm and 100 mm.

[0176] Preferably, any test setup that allows testing within the listed parameters is suitable for carrying out the scratch resistance test.

[0177] After testing, the samples are cleaned without pressure using a microfiber cloth moistened with deionized water. Assessment is performed after a recovery period of 24 hours. Evaluation is performed according to the evaluation scheme according to BMWAA-0635.

[0178] Furthermore, a hand abrasion test is preferably performed. This test simulates, for example, the movement sequence of a finger or hand movement. Furthermore, the influence of sweat, hand cream, or other media can be taken into account by using test media. It is also possible to test continuous stress. The test method is particularly suitable for components with curved and / or structured surfaces, as well as for flat specimens, thanks to variable clamping and test travel distances.

[0179] In the hand abrasion test, one or more samples are first prepared and conditioned for a period of 24 hours under standard conditions according to DIN EN ISO 291-23 / 50 (Class 2). Before testing, the samples are cleaned without pressure using a microfiber cloth moistened with a laboratory detergent, such as Mucasol 3% in demineralized or deionized water. For sensitive surfaces, a microfiber cloth with a fine weave is preferable. The test is also carried out according to the original setup under standard conditions according to DIN EN ISO 291-23 / 50 (Class 2).

[0180] In hand abrasion tests, a test die performs a specified number of strokes with a defined test force. The geometry, material, and hardness of the test die are designed to create a flexing motion on the sample surface. The test die with the article number ABR-2061-01 Z from Innowep preferably has an outer diameter of 20 mm and a hardness of 47 ± 5 Shore A. A test fabric is placed between the sample and the test die. This fabric is either automatically advanced by a device or is attached directly to the test die. The test fabric is used to create a defined frictional load on the sample surface. Depending on the test being conducted, a test fluid can also be applied to simulate chemical stress. When using test media, the test fabric is attached to the test die and replaced after 250 double strokes.

[0181] The test stroke of the flexion movement is 40 mm, and 0.58 test cycles are performed per second. The test speed is preferably 60 ± 5 mm / s. The test force is 10 N. Depending on the component, 60 or 4000 strokes are performed. The specifications of the specimens to be tested and the test parameters to be used can be found in the standards BMW GS 97034-1 and BMW GS 97060-2.

[0182] One hour after the abrasion resistance test, the samples should be cleaned without pressure using a microfiber cloth moistened with deionized water. The samples are evaluated 24 hours after the abrasion resistance test to take into account their recovery behavior.

[0183] The tested samples are assessed visually under standard D65 light. Starting with the frontal view, the viewing angle is varied until maximum contrast is visible. The contrast or abrasion trace compared to the unexposed surface is assessed using a gray scale according to DIN EN 20105-A02 (levels 1 to 5). The assessment must be performed by at least two people experienced in assessing contrast changes using this method. For materials that cannot be meaningfully assessed using a gray scale, the assessment is performed according to the evaluation scheme listed in the following table:

[0184] For fiber mats, a BI index of 8 or better is preferred.

[0185] In particular, it is intended that the decorated molded part has a test result of at least BI 8 in a dry and / or non-grip-loaded hand abrasion test and / or in a hand abrasion test with acidic artificial sweat and / or in a hand abrasion test with alkaline artificial sweat and / or in a hand abrasion test with sunscreen and / or in a hand abrasion test with hand cream, each in accordance with the test method BMW GS 97034-1.

[0186] Furthermore, it is also specifically intended that the decorated molded part has a test result of at least BI 8 in a dry grip-loaded hand abrasion test according to test method GS 97034-1.

[0187] Furthermore, the decorated molded part was subjected to further tests, such as a fingernail test or a test to assess the color abrasion behavior.

[0188] Preferably, the decorated molded part has a grade of < 2B in a fingernail test according to the test method according to BMW GS 97034-2 with a force of 15 N.

[0189] In particular, it may be possible that the decorated molded part achieves a test result of > GM 4 in a test to assess color abrasion behavior according to test method BMW GS 97034-4 and test procedure A using glass cleaner and / or interior cleaner and / or cockpit spray and / or plastic care emulsion as the test fluid. All tests conducted, along with their test methods, requirements, and test results, are presented in a table below for an overview.

[0190]

[0191] The decorated molded part or the method for producing a decorated molded part provides a decorated molded part with the feel of a fiber mat, which can be used for a wide variety of applications. For example, such molded parts are suitable for parts of a vehicle interior. The molded part is particularly well-suited as an interior door panel, a cockpit element, a dashboard, and many more. Due to their low density and high strength, fiber composites are particularly suitable for decorative parts and / or panel parts for a vehicle interior. A key advantage of the molded part according to the invention is that paneling that is manufactured from solid plastic parts in the prior art can be replaced. This allows the use of plastics to be reduced.

[0192] The invention is explained below using several exemplary embodiments with the aid of the accompanying drawings. The exemplary embodiments shown are therefore not to be understood as limiting.

[0193] Fig. 1 shows schematically the process steps of a process for producing a decorated molded part;

[0194] Fig. 2a - 2d show schematically selected process steps of a process for producing a decorated molded part in detail;

[0195] Fig. 3 shows a microscope image of the visible side of the decorated molded part;

[0196] Fig. 4 shows a microscope image of the visible side of the decorated molded part;

[0197] Fig. 5 shows a micrograph of the visible side of the decorated molded part; Fig. 6 shows a micrograph of the visible side of the decorated molded part, with a decorated area arranged next to an undecorated area;

[0198] Fig. 7 shows a microscope image of the visible side of the decorated molded part, with a decorated area arranged next to an undecorated area;

[0199] Fig. 8 shows a partial area of ​​the visible side of a decorated

[0200] molded part with inlaid textile;

[0201] Fig. 9 shows the part of the visible side of a decorated molded part marked in Fig. 8 in detail;

[0202] Fig. 10 shows an enlarged edge area of ​​the visible side of a decorated molded part with inlaid textile;

[0203] Fig. 11 shows the part of the visible side of a decorated molded part marked in Fig. 10 in detail.

[0204] The figures show different examples of embodiments of the invention. Identical or similarly functioning components have been given the same reference symbols. Where the embodiments shown in the figures have similarities, these similarities have not been described multiple times to avoid repetition. The respective differences between the embodiments are described in relation to the respective figures. It goes without saying that a person skilled in the art can modify individual embodiments or combine individual features of these embodiments within the scope of protection of the claims. Furthermore, all figures are not drawn to scale. The proportions shown in the figures were chosen so that the individual layers of the molded part 10 can be represented sufficiently clearly.

[0205] Fig. 1 schematically shows a method for producing a decorated molded part 10, wherein the method comprises the following steps, in particular in the following order: a) Providing a decorative sheet 1, 12, wherein the decorative sheet 12 has a substrate 13 and at least one decorative layer 14 applied to the substrate 13; b) Providing a fiber mat 2, 11, wherein the fiber mat 11 has natural fibers and thermoplastic fibers; c) Inserting the fiber mat 11 and the decorative sheet 12 into a press 3, in particular into a calibration press, wherein the decorative sheet 12 is arranged on the fiber mat 11 such that the at least one decorative layer 14 of the decorative sheet 12 faces the fiber mat 11;d) Pressing the fiber mat 11 and the decorative sheet 12 under thermal heating 4, so that the substrate 13 of the decorative sheet 12 fuses with the thermoplastic fibers of the fiber mat 11 and the decorative layer 14 of the decorative sheet 12 at least partially decorates the natural fibers arranged in an upper boundary region 40 of the fiber mat 11 to provide a decorated fiber mat 11; e) Forming the decorated fiber mat 11 in a mold 5 to obtain a decorated molded part 10;

[0206] Because the decorative sheet 12 is inserted on the back, i.e. with the decorative layer 14 facing the fiber mat 11, in step c), the natural fibers can be decorated with the decorative layer 14 of the decorative sheet 12 in an upper boundary region 40 during pressing in step d) by thermal heating. This is preferably due to the fact that in step d) the material of the substrate 13 and the thermoplastic fibers are plasticized or softened by the thermal heating. As a result, the plasticized material sinks into the fiber mat 11. In the sinking direction of the material of the substrate 13, however, lies the decorative layer 14, which also disintegrates into small surface areas due to the melting of the very soft material of the substrate 13 and / or the thermoplastic fibers, in particular the polypropylene.Due to the sinking of the plasticized material of the substrate 13 and / or the thermoplastic fibers, the natural fibers now appear in the upper boundary region 40 of the fiber mat 11, to which the surface areas of the decorative layer 14 adhere and thus the natural fibers are at least partially decorated.

[0207] Furthermore, it can be provided that, in order to provide the decorative sheet 12 in step a), the following steps are carried out, in particular in the specified order:

[0208] Providing the substrate 13;

[0209] Applying the decorative layer 14 by means of printing and / or by means of transferring a transfer layer of a transfer film, in particular by means of hot stamping.

[0210] When applying the decorative layer 14 by printing, this is preferably done by means of a printing process, individually or in combination, selected from: screen printing, gravure printing, digital printing, inkjet printing, laser printing. When applying a transfer layer of a transfer film, the transfer layer of the transfer film preferably functions as the decorative layer 14. The transfer film, in particular hot stamping foil, preferably comprises a carrier and a transfer layer that can be removed from the carrier by means of a release layer. This transfer layer can have at least one layer or combinations of several layers selected from: ink layer, metal layer, replication layer, protective lacquer layer, primer, adhesive layer, primer, adhesion promoter layer, barrier layer, conductive layer, lacquer layer. The application of the decorative layer 14 can, for example, comprise the application of a transfer layer of a transfer film and a subsequent overprinting of the applied transfer layer on the substrate 13.For example, the transfer layer can have a metal layer and the transfer layer can be overprinted with one or more translucent color layers, so that the optical effect of a colored metal layer is created.

[0211] Preferably, it may be possible for the transfer layer to be transferred at least partially or over the entire surface onto the substrate 13 of the decorative web 12 by means of a hot stamping tool, in particular by means of a hot stamping stamp and / or by means of a hot stamping wheel.

[0212] It is also preferably possible for several prints and / or transfer layers of transfer films to form the decorative layer 14 of the decorative web 12.

[0213] In particular, it is provided that in step a), the decorative layer 14 is applied to the front and / or back of the substrate 13. In particular, if the decorative layer 14 is applied to both the front and back of the substrate 13, it is preferably provided that in step a), a protective lacquer layer is applied to the front of the substrate 13. This protective lacquer layer then has the task of protecting the decorative layer 14 applied to the front of the substrate 13. This is because, unlike the decorative layer applied to the back, this decorative layer 14 applied to the front is not protected by the substrate 13 of the decorative sheet 12.

[0214] It may also be possible that after step b) and before step c) the fiber mat 11 is placed in a press, in particular in a calibration press, and the fiber mat 11 is calibrated without the decorative web 12.

[0215] This allows the fiber mat 11 to be pre-pressed, and the thermoplastic fibers begin to melt before the decorative sheet 12 is placed onto the fiber mat 11 in the subsequent step c) and then pressed onto it in step d). This reduces the thermal stress on the decorative sheet.

[0216] In particular, it is possible that after calibrating the fiber mat 11 without the decorative web 12, the fiber mat 11 is then placed together with the decorative web 12 into a press, in particular a calibration press, and the fiber mat 11 is calibrated again together with the decorative web 12.

[0217] Figures 2a to 2d schematically show in detail the process steps c) to e), which have already been described above, of a process for producing a decorated molded part 10.

[0218] Figure 2a shows step c), i.e. the insertion of the fiber mat 11 and the decorative sheet 12 into a press, in particular a calibration press, wherein the decorative sheet 12 is arranged on the fiber mat 11 such that the at least one decorative layer 14 of the decorative sheet 12 faces the fiber mat 11. The embodiments shown in Figures 2a to 2d represent simplified embodiments. For example, in Figure 2a, the decorative sheet 12 is in a simple form, so that the decorative sheet 12 has a substrate 13 and a decorative layer 14. However, it may also be possible for the decorative sheet 12 to have several decorative layers 14.

[0219] The substrate 13 preferably comprises polypropylene (PP) as its material. Polypropylene is particularly suitable because it is inexpensive and easily recyclable. Thus, for example, recycled polypropylene can be used to produce the decorative sheet 12. Advantageously, the material of the substrate 13 of the decorative sheet 12 matches the material of the thermoplastic fibers of the fiber mat 11. Preferably, therefore, the thermoplastic fibers and the substrate 13 of the decorative sheet 12 are made of polypropylene. It may be possible for the decorative sheet 12 to have a total layer thickness in the range from 100 μm to 500 μm, in particular in the range from 125 μm to 300 μm. The total layer thickness includes the thickness of the substrate 13 as well as the thickness of all decorative layers 14.

[0220] In particular, it can be provided that the fiber mat 11 comprises essentially 50% natural fibers and 50% thermoplastic fibers, in particular that the fiber mat 11 comprises at least 33% natural fibers and / or at least 33% thermoplastic fibers. In a particularly preferred embodiment, the fiber mat 11 comprises approximately half natural fibers and the other half thermoplastic fibers. The thermoplastic fibers are preferably polypropylene fibers. Polypropylene fibers can be produced particularly easily and cost-effectively. Furthermore, recycled polypropylene can be used to produce the fibers.

[0221] Preferably, the natural fiber comprises a fiber type or mixture of fiber types selected from: hemp fiber, flax fiber, jute fiber, kenaf fiber, and coconut fiber. However, other natural fiber types are also conceivable.

[0222] It is preferred that the fiber mat 11, in particular the uncalibrated fiber mat 11, has a thickness in the range from 2 mm to 25 mm, in particular from 6 mm to 15 mm, in step b). This means that the fiber mat 11 shown in Figure 2a is still in the uncalibrated or unpressed state.

[0223] During the subsequent pressing in step d), which is shown in Figure 2b, the thickness of the fiber mat 11 decreases due to the pressing pressure, indicated by the two arrows, and the melting of the thermoplastic fibers due to thermal heating, indicated by the thermometer. Thus, a type of compaction takes place, which increases the stability of the fiber mat 11.

[0224] Preferably, in step d), the press, in particular the calibration press, comprises two planar, heatable plates or surface stamps, by means of which the thermal heating of the fiber mat 11 and the decorative sheet 12 takes place. The planar plates or surface stamps of the press ensure that the fiber mat 11 is pressed evenly over its entire surface.

[0225] Preferably, it may be possible for the pressing in step d) to take place at a temperature in a range from 150°C to 250°C, in particular in a range from 170°C to 230°C, particularly preferably in a range from 180°C to 210°C. The choice of temperature preferably depends on the thickness of the fiber mat 11 and the fibers used.

[0226] Furthermore, it is preferably provided that the pressing in step d) is carried out with a pressing force in a range of 180 kN to 220 kN, in particular in a range of 185 kN to 210 kN, preferably wherein the pressing force is built up continuously or gradually over time by closing the press, or the pressing force is reached suddenly. The pressing force preferably depends on the thickness of the fiber mat 11 and the fibers used.

[0227] Preferably, the pressing in step d) can be carried out for a duration ranging from 30 seconds to 180 seconds. The duration preferably depends on the material thickness of the decorative sheet 12 and the fiber mat 11.

[0228] In particular, it is possible that in step d), the decorative sheet 12 forms a material bond with the fiber mat 11, in particular with the thermoplastic fibers of the fiber mat 11, in particular due to thermal heating. As already described above, the thermal heating melts the thermoplastic matrix of the substrate 13 of the decorative sheet 12 and the thermoplastic fibers. This is followed by a sinking of the plasticized substrate 13 towards the fiber mat 11, so that the material of the substrate 13 can mix with the material of the thermoplastic fibers to form a plastic mass. During subsequent cooling, a material bond is formed.

[0229] Furthermore, it is preferably provided that in step d) the material of the substrate 13, in particular the polypropylene of the substrate 13, is softened and / or plasticized by the thermal heating and sinks from the upper boundary region 40 of the fiber mat 11 towards the lower region 41 of the fiber mat 11, whereby a partial decoration of the natural fibers arranged in the upper boundary region 40 of the fiber mat 11 occurs, resulting in a mottled appearance. The material of the substrate 13 and the thermoplastic fibers, which has been plasticized into a plastic mass, forms the background. Depending on the color of the substrate 13 or the thermoplastic fibers, the background of the fiber mat 11 or the molded part 10 is also predetermined accordingly. Black polypropylene is frequently used here. However, all other colors are also conceivable. It is also possible for the substrate 13 and / or the thermoplastic fibers to be transparent or translucent.The decorated natural fibers usually differ from the background and stand out. In particular, metallic decoration is often used on the natural fibers, giving them a grayish, slightly shiny appearance.

[0230] Appearance. However, coloring the natural fibers using a color layer as decorative layer 14 is also conceivable.

[0231] It is preferably provided that in step d) the color of the substrate 13 of the

[0232] Decorative sheet 12 and / or the color of the thermoplastic fibers essentially represents the visible background color of the mottled appearance.

[0233] In particular, it is provided that in step d) the thermoplastic fibers are softened and / or plasticized to form a melt, so that the density of the thermoplastic fibers increases due to this melt and the melt sinks into the fiber mat 11 starting from the upper boundary region 40 of the fiber mat 11 in the direction of the lower region 41 of the fiber mat 11, whereby the natural fibers, in particular those which do not melt, partially protrude from the melt.

[0234] It is furthermore also preferably possible that in step d) the decorative layer 14 sinks and / or infiltrates in the upper boundary region 40 of the fiber mat 11 due to the sinking of the substrate 13 of the decorative web 12 into the fiber mat 11.

[0235] After pressing in step d), as shown in Figure 2b, the decorated fiber mat 11 is formed in step e). Preferably, after step d) and before step e), the decorated fiber mat 11 is removed from the press and placed in a mold. The forming in step e) preferably serves to three-dimensionally deform the decorated fiber mat 11 to provide a decorated molded part 10. This can, for example, be a vehicle interior part.

[0236] As can be seen in Figure 2c, the molding tool has two mold halves 20, 21. These are preferably two mold halves 20, 21 that are not heated. "Not heated" in this case means that the mold halves have a temperature below the softening temperature of the thermoplastic matrix. However, it may also be possible for the mold halves 20, 21 to be actively or passively tempered. Preferably, in step e), molding takes place at a pressing force in a range from 550 kN to 650 kN, in particular in a range from 560 kN to 640 kN.

[0237] In particular, it is possible that in step e) the forming takes place with a time duration in a range of 30 seconds to 60 seconds.

[0238] It can also be provided that in step e) the molding takes place at a maximum temperature of 80°C. For this purpose, the mold halves 20, 21 can be heated accordingly, for example by means of heating elements.

[0239] It is preferably provided that the fiber mat 11 is deformable after step d) due to the thermal heating and is deformed in step e) and then solidified into a molded part 10 by cooling.

[0240] In particular, it can be provided that in step e), the melted substrate 13 of the decorative sheet 12 and the melted thermoplastic fibers of the fiber mat 11 solidify, thus causing the thermoplastic materials to shrink. This ensures that several natural fibers, or a larger proportion of the natural fibers, reach the surface of the molded part 10. This offers the advantage that the feel and the characteristic visual appearance of the fiber mat 11 are retained.

[0241] Furthermore, it can also be provided that in step e) an additional trimming takes place in the mold or that after step e) a separate trimming of the molded part 10 takes place by means of a knife and / or laser, so that the molded part 10 is adapted to the final shape.

[0242] It is also possible that after step e) the following step is carried out: f) back-injection of the molded part 10 with a plastic mass, preferably in the mold or in an injection molding machine, in order to attach assembly elements and / or reinforcement elements.

[0243] The attachment of mounting elements facilitates the assembly of the molded part 10 and the reinforcing elements ensure that the molded part 10 receives additional stability.

[0244] In particular, it is also possible that the decorated fiber mat 11 after step d) and / or the decorated molded part 10 after step e) has a thickness in the range from 1 mm to 4 mm, in particular from 1.5 mm to 3.5 mm.

[0245] Figure 2d schematically shows a decorated molded part 10 which has been produced according to a method according to Figure 1. The molded part 10 comprises the fiber mat 11 and the decorative sheet 12, wherein the

[0246] Decorative sheet 12 is no longer visible due to the prior plasticization of the substrate 13. Rather, the natural fibers in the upper boundary region 40, which is schematically indicated in Figure 2d, are fully decorated. However, it may also be possible for the natural fibers in the upper boundary region 40 to be only partially decorated. In particular, it is provided that the upper boundary region 40 amounts to a maximum of 50%, preferably a maximum of 33%, of the total thickness of the fiber mat 11, in particular of the decorated molded part 10.

[0247] In the embodiment according to Figure 2d, the thermoplastic fibers and the substrate 13 of the decorative sheet 12 are fused together to form a solid composite in the lower region 41. In particular, it is provided that the lower region 41 amounts to a maximum of 67%, preferably a maximum of 50%, of the total thickness of the fiber mat 11, in particular of the decorated molded part 10. It is preferably provided that the decorated molded part 10 has a thickness in the range of 1 mm to 4 mm, in particular of 1.5 mm to 3.5 mm.

[0248] Advantageously, the decorated molded part 10 has a mottled appearance due to the at least partial decoration of the natural fibers in the upper boundary region 40, in particular, wherein the at least partially decorated natural fibers stand out from the background, preferably wherein the background is essentially formed by the thermoplastic composite of the fused thermoplastic fibers and the substrate 13 of the decorative web 12. This gives the molded part 10 a visually appealing appearance and distinguishes it significantly from conventional fiber mats.

[0249] Figure 3 shows a microscope image of the visible side of the decorated molded part 10. This image was taken in incident light using illuminant type II at 50x magnification. Light-colored natural fibers can be seen in Figure 3. These are natural fibers 15 decorated with a metal layer. The dark areas represent the background, i.e., the solidified composite of substrate 13 and thermoplastic natural fibers.

[0250] Figure 4 shows another microscope image of the visible side of the decorated molded part 10. The image shown in Figure 4 is an image taken in reflected light using illuminant II at 50x magnification. In contrast to the image shown in Figure 3, which predominantly shows natural fibers 15 decorated with a metal layer, Figure 4 shows both natural fibers 15 decorated with a metal layer and natural fibers 16 coated with thermoplastic, in particular polypropylene. Here, too, the light-colored natural fibers 15 are those decorated with a metal layer. The dark natural fibers 16 are those coated with the thermoplastic or polypropylene. Figure 5 shows another microscope image of the visible side of the decorated molded part 10. The image shown in Figure 5 is an image taken in reflected light using illuminant II at 50x magnification.Similar to Figure 4, in Figure 5, the natural fibers are coated with both a metal layer and a thermoplastic, specifically polypropylene. Here, too, the light-colored natural fibers 15 are those decorated with a metal layer. The dark natural fibers 16 are those coated with the thermoplastic or polypropylene.

[0251] Figure 6 shows a microscope image of the visible side of the decorated molded part 10, wherein a first region 30, in particular the decorated region, is arranged next to a second region 31, in particular the undecorated region. The image is an image taken in reflected light using illuminant type II at a magnification of 50x. The decorated molded part 10 according to Figure 6 is the molded part 10 which is only decorated in certain regions. This means that the decoration is at least partially present in a first region 30, in particular the decorated region, and not present in a second region 31, in particular the undecorated region. In the first region 30 it is clearly visible how the natural fibers 15 have a metallic shine which is caused by the decoration of a metal layer. In the second region 31, however, this shine is not present.

[0252] Instead, the natural fibers 16 appear dark in this area because they are coated with the thermoplastic, particularly propylene. Furthermore, Figure 6 also shows the transition between the first area 30, particularly the decorated area, and the second area 31, particularly the undecorated area. To a good approximation, this can be described as a sharp-edged decoration, since the transition area is comparatively small.

[0253] Figure 7 shows a further microscope image of the visible side of the decorated molded part 10, wherein a first region 30, in particular the decorated region, is arranged next to a second region 31, in particular the undecorated region. The image is an image taken in reflected light using illuminant type II at a magnification of 15x. The statements made for Figure 6 essentially also apply to Figure 7. Figure 7 once again illustrates the visual appearance of the decorated molded part 10. At 15x magnification, it can be clearly seen that in the first region 30, in particular the decorated region, the natural fibers 15 appear light, and in the second region 31, in particular the undecorated region, the natural fibers 16 appear dark in comparison to the decorated region. This creates the mottled appearance mentioned above.The natural fibers 16 in the second area 31, in particular the undecorated area, form the background and the natural fibers 15 in the first area 30, in particular the decorated area, form the foreground. It is thus also possible to create different decorations in the form of one or more motifs. A motif can, for example, be a graphically represented outline, a figurative representation, an image, a visually recognizable design element, a symbol, a logo, a portrait, a pattern, an endless pattern, an alphanumeric character, a coding, a code pattern, a cryptographic pattern, a text, a color design and the like. The motif can also be individualized. In particular, it is provided that the decorated area forms one or more motifs.

[0254] Fig. 8 shows a partial area of ​​the visible side of a decorated molded part 10 with an inlaid textile. In the decorated molded part 10 shown in Fig. 8, at least one textile is in the upper boundary area 40 of the decorated molded part 10, in particular wherein the at least one textile is encapsulated in the fused composite of thermoplastic fibers and the substrate 13 of the decorative web 12. This means that the at least one textile is preferably materially bonded to the fiber mat 11 and correspondingly at least partially decorated with the decorative layer 14 of the decorative web 12. The decorated molded part 10 is already 3D-formed and the light reflections on the surface of the visible side reveal the through-drawing of the coarse weave of the textile used here. In order to produce such a decorated molded part 10 according to Fig.8, it is preferably provided that in step c) at least one textile or a plurality of textiles are placed into the press, in particular so that the at least one textile or the plurality of textiles are or are arranged between the decorative web 12 and the fiber mat 11. Thereafter, preferably in step d), the decorative web 12, the fiber mat 11 and the at least one textile or the plurality of textiles are pressed, in particular with thermal heating, so that the substrate 13 of the decorative web 12 fuses with the thermoplastic fibers of the fiber mat 11 and the threads of the at least one textile or the plurality of textiles, and the decorative layer 14 of the decorative web 12 at least partially decorates the threads of the at least one textile or the plurality of textiles and / or the natural fibers arranged in an upper boundary region 40 of the fiber mat 11, in order to provide a decorated fiber mat 11.Finally, this fiber mat 11 decorated with the at least one textile or the plurality of textiles is preferably formed in a molding tool 5 in step e) in order to obtain a decorated molded part 10.

[0255] The at least one textile or the plurality of textiles can change the feel and / or visual appearance of the decorated molded part 10. Appropriate textiles are selected depending on the desired haptic and / or visual effects.

[0256] Fig. 9 shows an enlarged view of the section indicated in Fig. 8. In the lower edge region of the molded part 10, it can be seen in particular that in the second region 31, in particular the undecorated region, the weave of the textile adjacent to the first region 30, in particular the decorated region, is exposed undecorated, preferably as can be seen by the black coloring. Furthermore, in addition to the undecorated region of the textile, the undecorated fiber mat 11 can also be seen. These undecorated regions of the textile and / or the fiber mat 11 are preferably subsequently trimmed. In particular, the undecorated regions, preferably the second region 31, of the textile, in comparison to the directly adjacent decorated region, preferably the first region 30, show how the textile appears visually and haptically on the visible side.

[0257] In the first region 30, in particular the decorated region, the substrate 13 of the decorative sheet 12 is fused to the thermoplastic fibers of the fiber mat 11, in particular such that the at least one textile or the plurality of textiles are encapsulated. This preferably ensures that the textile is firmly bonded to the fiber mat 11. The bond is preferably integral and in particular virtually monolithic, in particular so that this bond cannot be removed without destroying the molded part 10.

[0258] Figure 10 shows an enlarged edge region of the visible side of a decorated molded part 10 with an inlaid textile. The structure is preferably identical to the molded part 10 shown in Fig. 8. Here, based on the top view of the visible side of the decorated molded part 10 approximately in the normal direction, the decorated region, in particular first region 30, and the undecorated region, in particular second region 31, are again clearly visible. The decorated region is identified by the dark or black coloring. In the undecorated region, both a woven textile fabric exposed next to the decorated region and the exposed undecorated fiber mat are shown.

[0259] Furthermore, Figure 10 shows the composition of the textile in a larger view. Textiles or textile are understood here to mean a textile flat or three-dimensional structure. The textiles are produced in particular by meshing or weaving thread systems, as shown, for example, in Fig. 10. The threads in these textiles consist entirely of natural fibers such as cotton, linen, jute, flax, hemp, kenaf, sisal, coconut fiber or combinations of these. Furthermore, hybrid fabrics, so-called composites, made from the aforementioned natural fibers in combination with chemical fibers or inorganic fibers such as glass fibers, carbon fibers, basalt fibers are also conceivable. The threads are preferably converted into a textile by different mesh formation or weaving.

[0260] The textile is preferably manufactured either by knitting or weaving. Each textile is distinguished by its own properties and produces different appearances depending on its manufacturing method.

[0261] For example, the at least one textile or the plurality of textiles may be plain weave fabrics or woven textiles, which include, for example, viscose silk, chiffon, voile, perkai, muslin, gingham, linen, canvas, batiste and / or cretonne.

[0262] In addition to the plain weaves and their derivatives, there are also the twill weave and satin weave, which can also be called a 5-shaft weave.

[0263] Twill weaves are preferably weaves in which the threads run diagonally, in parallel lines. This stepped arrangement creates the weave points. This weave type is particularly widespread because, depending on the design, it allows for the creation of various patterns such as multi-ridge, pointed, or herringbone weaves. One example of this weave type is denim fabrics for jeans. Carbon fiber fabric looks are also created this way. The satin weave produces two-sided fabrics. This is preferably achieved by having the warp threads predominate on the upper side, thus creating very smooth surfaces like satin.

[0264] Preferably, the at least one textile or the plurality of textiles has a thickness in a range from 0.25 mm to 6 mm, preferably from 0.75 mm to 4 mm. Preferably, the thickness is measured between the outermost threads of the at least one textile or the plurality of textiles.

[0265] Fig. 11 shows an enlarged view of the section of the decorated molded part 10 with a textile shown in Fig. 10. A corresponding thread width 50 is shown as an example in Fig. 11. The thread width 50 can vary within the at least one textile and preferably depends on the manufacturing process and the parameters used there. The threads of the at least one textile or of the plurality of textiles preferably have a thickness in a range from 0.1 mm to 3 mm, preferably from 0.5 mm to 2 mm. Thickness is preferably understood to mean the thread width. The measurement of the threads should preferably be carried out in such a way that the threads are not deformed or crushed by the measuring means.

[0266] Furthermore, a mesh size 51 is also shown as an example in Fig. 11. This mesh size 51 can also vary from mesh to mesh within the at least one textile. The mesh size 51 here also preferably depends on the respective manufacturing process and the parameters therein. Furthermore, the mesh size can also change during the deformation of the at least one textile. The mesh size 51 is preferably defined as the clear distance between two adjacent warp threads or between two adjacent weft threads, measured from the two sides of the respective weft thread or warp thread which point towards one another and define the edge of the clear distance. In particular, it is provided that the mesh size 51 orThe clear distance between the warp threads or weft threads, particularly in woven fabrics or meshes, forms a mesh surface, wherein this mesh surface enables the thermoplastic substrate 13 of the decorative web 12 to fuse with the thermoplastic fibers of the fiber mat 11 within this mesh surface, in particular wherein the thermoplastic material can penetrate through this mesh surface. In other words, the mesh surface can also be referred to as the gap that forms between the threads forming the mesh.

[0267] Preferably, the mesh size 51 is in a range from 0.00 mm to 10 mm, preferably from 0.15 mm to 10 mm, particularly preferably from 0.3 mm to 5 mm.

[0268] It can also happen that two adjacent threads are directly adjacent to each other. In this case, no measurable distance is formed between the two threads. In this case, the mesh size 51 is 0.00 mm.

[0269] Depending on the density and gravimetric quantity of fibers used per square meter of the nonwoven, which is particularly achieved during the needling step in nonwoven production, the nonwoven exhibits permeability, particularly for fluids, or permeable areas through which fluids can pass through the nonwoven. This makes it possible to achieve a fusion of the thermoplastic substrate 13 of the decorative web 12 with the thermoplastic fibers of the fiber mat 11 through the intermediate nonwoven, similar to a mesh surface.

[0270] In particular, the permeability of the nonwoven is determined by its grammage. The grammage is preferably in the range of 10 g / m 2 up to 800 g / m 2 , more preferably in a range of 50 g / m 2 up to 600 g / m 2 , particularly preferably in a range of 80 g / m 2 up to 300 g / m 2This ensures that the fleece is sufficiently stable while at the same time being sufficiently permeable.

[0271]

[0272] 1 Providing a decorative strip

[0273] 2 Providing a fiber mat

[0274] 3 Inserting the fiber mat and the decorative sheet into a press

[0275] 4 Pressing of the fiber mat and the decorative sheet under thermal

[0276] warming

[0277] 5 forms of the decorated fiber mat in a mold

[0278] 10 molded part

[0279] 11 Fiber mat

[0280] 12 decorative strips

[0281] 13 Substrat

[0282] 14 decorative layer

[0283] 15 decorated natural fibers, light natural fibers

[0284] 16 thermoplastic coated natural fiber, dark natural fiber

[0285] 20 mold halves

[0286] 21 mold half

[0287] 30 first area

[0288] 31 second area

[0289] 40 upper limit range

[0290] 41 lower area

[0291] 50 thread width

[0292] 51 mesh size

Claims

Patent claims 1 . Decorated molded part (10), wherein the molded part (10) comprises a fiber mat (11) which comprises natural fibers and thermoplastic fibers, characterized in that in an upper boundary region (40) of the fiber mat (11) the natural fibers are at least partially decorated with a decorative layer (14) of a decorative web (12) and in a lower region (41) the thermoplastic fibers and a substrate (13) of the decorative web (12) are fused to form a composite.

2. Decorated molded part (10) according to claim 1, characterized in that the fiber mat (11) comprises substantially 50% natural fibers and 50% thermoplastic fibers, in particular that the fiber mat (11) comprises at least 33% natural fibers and / or at least 33% thermoplastic fibers.

3. Decorated molded part (10) according to one of the preceding claims, characterized in that the natural fiber comprises a fiber type or mixtures of fiber types selected from: hemp fiber, flax fiber, jute fiber, kenaf fiber, coconut fiber, sisal fiber.

4. Decorated molded part (10) according to one of the preceding claims, characterized in that the thermoplastic fiber comprises a material or combinations of materials selected from: polypropylene (PP), polyethylene (PE), polyolefins, polyethylene terephthalate (PET), biodegradable biopolymers, in particular polylactides (PLA).

5. Decorated molded part (10) according to one of the preceding claims, characterized in that the substrate (13) of the decorative sheet (12) comprises a material or combinations of materials selected from: polypropylene (PP), polyethylene (PE), polyolefins, polyethylene terephthalate (PET), biodegradable biopolymers, in particular polylactides (PLA).

6. Decorated molded part (10) according to one of claims 1 to 4, characterized in that the substrate (13) of the decorative sheet (12) has polypropylene (PP) as material.

7. Decorated molded part (10) according to one of the preceding claims, characterized in that the decorated molded part (10) has a thickness in the range from 1 mm to 4 mm, in particular from 1.5 mm to 3.5 mm.

8. Decorated molded part (10) according to one of the preceding claims, characterized in that the upper limit region (40) is a maximum of 50%, preferably a maximum of 33%, of the total thickness of the fiber mat (11), in particular of the decorated molded part (10).

9. Decorated molded part (10) according to one of the preceding claims, characterized in that that the lower region (41) amounts to a maximum of 67%, preferably a maximum of 50%, of the total thickness of the fiber mat (11), in particular of the decorated molded part (10).

10. Decorated molded part (10) according to one of the preceding claims, characterized in that the decorative layer (14) has at least one layer or combinations of several layers selected from: color layer, metal layer, replication layer, protective lacquer layer, primer, adhesive layer, primer, adhesion promoter layer, barrier layer, conductive layer, lacquer layer.

11. Decorated molded part (10) according to one of the preceding claims, characterized in that the decorated molded part (10) has a mottled appearance due to the at least partial decoration of the natural fibers in the upper boundary region (40), in particular wherein the at least partially decorated natural fibers stand out from the background, preferably wherein the background is essentially formed by the thermoplastic composite of the fused thermoplastic fibers and the substrate (13) of the decorative web (12).

12. Decorated molded part (10) according to one of the preceding claims, characterized in that the decorated molded part (10) is decorated in a first region (30) and is not decorated in a second region (31).

13. Decorated molded part (10) according to one of the preceding claims, characterized in that the decorated molded part (10) in a cream resistance test according to VW PV 3964 with a test cream type A and / or type B, has a fastness rating of the gray scale in the range of 4 to 5 and a Cross-cut characteristic of <GT 1 gemäß DIN EN ISO 2409 sowie keine Veränderung von Haptik und Farbe aufweist.

14. Decorated molded part (10) according to one of the preceding claims, characterized in that the decorated molded part (10) shows no surface changes in a hydrolysis test according to BMWAA-0203 and has a fastness rating of the gray scale in the range of 4 to 5 and a cross-cut characteristic value of < GT 1 according to BMW AA-0180 and a rating of 1 B in a fingernail test according to BMW GS 97034-2.

15. Decorated molded part (10) according to one of the preceding claims, characterized in that the decorated molded part (10) has a test result of at least BI 8 in a dry and / or non-grip-loaded hand abrasion test and / or in a hand abrasion test with acidic artificial sweat and / or a hand abrasion test with alkaline artificial sweat and / or a hand abrasion test with sunscreen and / or a hand abrasion test with hand cream, each according to the test method BMW GS 97034-1.

16. Decorated molded part (10) according to one of the preceding claims, characterized in that the decorated molded part (10) has a test result of at least BI 8 in a dry grip-loaded hand abrasion test according to test method BMW GS 97034-1.

17. Decorated molded part (10) according to one of the preceding claims, characterized in that that the decorated molded part (10) has a grade of < 2B in a fingernail test according to the test method according to BMW GS 97034-2 with a force of 15 N.

18. Decorated molded part (10) according to one of the preceding claims, characterized in that the decorated molded part (10) has a test result of > GM 4 in a test for assessing the paint abrasion behavior according to test method BMW GS 97034-4 and test procedure A with glass cleaner and / or interior cleaner and / or cockpit spray and / or plastic care emulsion as test liquid.

19. Decorated molded part (10) according to one of the preceding claims, characterized in that the decorated molded part (10) has at least one textile or a plurality of textiles, in particular wherein the at least one textile or the plurality of textiles is arranged in the upper boundary region (40) of the decorated molded part (10) and / or is preferably encapsulated in the fused composite of thermoplastic fibers and the substrate (13) of the decorative web (12).

20. Decorated molded part (10) according to claim 19, characterized in that the at least one textile or the plurality of textiles has a thickness in a range from 0.25 mm to 6 mm, preferably from 0.75 mm to 4 mm.

21. Decorated molded part (10) according to claim 19 or 20, characterized in that the thickness of the decorative sheet (12) is between 10% and 75%, particularly preferably between 20% and 75%, of the thickness of the at least one textile or the plurality of textiles.

22. A method for producing a decorated molded part (10), in particular according to one of claims 1 to 21, wherein the molded part (10) comprises a fiber mat (11) which has natural fibers and thermoplastic fibers, wherein the method comprises the following steps, in particular in the following order: a) providing a decorative web (1, 12), wherein the decorative web (12) has a substrate (13) and at least one decorative layer (14) applied to the substrate (13); b) providing a fiber mat (2, 11), wherein the fiber mat (11) has natural fibers and thermoplastic fibers; c) inserting the fiber mat (11) and the decorative web (12) into a press (3), in particular into a calibration press, wherein the decorative web (12) is arranged on the fiber mat (11) in such a way that the at least one decorative layer (14) of the decorative web (12) faces the fiber mat (11);d) pressing the fiber mat (11) and the decorative web (12) under thermal heating (4) such that the substrate (13) of the decorative web (12) fuses with the thermoplastic fibers of the fiber mat (11) and the decorative layer (14) of the decorative web (12) at least partially decorates the natural fibers arranged in an upper boundary region (40) of the fiber mat (11) to provide a decorated fiber mat (11); e) molding the decorated fiber mat (11) in a molding tool (5) to obtain a decorated molded part (10); 23. The method according to claim 22, characterized in that the natural fiber comprises a fiber type or mixtures of fiber types selected from: hemp fiber, flax fiber, jute fiber, kenaf fiber, coconut fiber.

24. The method according to claim 22 or 23, characterized in that the fiber mat (11), in particular the uncalibrated fiber mat (11), in step b) has a thickness in the range from 2 mm to 25 mm, in particular from 6 mm to 15 mm.

25. Method according to one of claims 22 to 24, characterized in that the decorative sheet (12) has a total layer thickness in the range from 100 pm to 500 pm, in particular in the range from 125 pm to 300 pm.

26. Method according to one of claims 22 to 25, characterized in that, in order to provide the decorative sheet (12) in step a), the following steps are carried out, in particular in the specified order: - providing the substrate (13); - applying the decorative layer (14) by means of printing and / or by means of transferring a transfer layer of a transfer film, in particular by means of hot stamping.

27. Method according to one of claims 22 to 26, characterized in that in step a) the decorative layer (14) is applied to the front side and / or to the back side of the substrate (13).

28. Method according to one of claims 22 to 27, characterized in that in step a) a protective lacquer layer is applied to the front side of the substrate (13).

29. Method according to one of claims 22 to 28, characterized in that the substrate (13) comprises a material or combination of materials selected from: polypropylene (PP), polyethylene (PE), polyolefins, polyethylene terephthalate (PET), biodegradable biopolymers, in particular polylactides (PLA).

30. Method according to one of claims 22 to 28, characterized in that the substrate (13) comprises polypropylene (PP) as material.

31. Method according to one of claims 22 to 30, characterized in that the fiber mat (11) comprises essentially 50% natural fibers and 50% thermoplastic fibers, in particular that the fiber mat (11) comprises at least 33% natural fibers and / or at least 33% thermoplastic fibers.

32. Method according to one of claims 22 to 31, characterized in that after step b) and before step c) the fiber mat (11) is placed in a press, in particular a calibration press, and the fiber mat (11) is calibrated without a decorative web (12).

33. Method according to one of claims 22 to 32, characterized in that in step c) at least one textile or several textiles are placed in the press, in particular so that the at least one textile or the several textiles are arranged between the decorative web (12) and the fiber mat (11).

34. Method according to claim 33, characterized in that in step d) the decorative web (12) and the fiber mat (11) and the at least one textile or the plurality of textiles are pressed, in particular with thermal heating, so that the substrate (13) of the decorative web (12) fuses with the thermoplastic fibers of the fiber mat (11) and the threads of the at least one textile or the plurality of textiles and the decorative layer (14) of the decorative web (12) at least partially decorates the threads of the at least one textile or the plurality of textiles and / or the natural fibers arranged in an upper boundary region (40) of the fiber mat (11) in order to provide a decorated fiber mat (11).

35. Method according to one of claims 22 to 34, characterized in that in step d) the press, in particular the calibration press, has two planar, heatable plates or surface stamps, by means of which the thermal heating of the fiber mat (11) and the decorative web (12) takes place.

36. Method according to one of claims 22 to 35, characterized in that the pressing in step d) takes place at a temperature in a range from 150°C to 250°C, in particular in a range from 170°C to 230°C, particularly preferably in a range from 180°C to 210°C.

37. Method according to one of claims 22 to 36, characterized in that the pressing in step d) is carried out with a pressing force in a range from 180 kN to 220 kN, in particular in a range from 185 kN to 210 kN, preferably wherein the pressing force is built up continuously or stepwise over time by closing the press or the pressing force is reached suddenly.

38. Method according to one of claims 22 to 37, characterized in that the pressing in step d) takes place with a duration in a range of 30 seconds to 180 seconds.

39. Method according to one of claims 22 to 38, characterized in that in step d) the decorative web (12) forms a material connection with the fiber mat (11), in particular with the thermoplastic fibers of the fiber mat (11), in particular due to thermal heating.

40. Method according to one of claims 22 to 39, characterized in that in step d) the material of the substrate (13), in particular the polypropylene of the substrate (13), is softened and / or plasticized by the thermal heating and, starting from the upper boundary region (40) of the fiber mat (11), sinks in the direction of the lower region (41) of the fiber mat (11), whereby a partial decoration of the natural fibers arranged in the upper boundary region (40) of the fiber mat (11) takes place, so that a mottled appearance is created. 41 .A method according to claim 40, characterized in that in step d) the color of the substrate (13) of the decorative web (12) and / or the color of the thermoplastic fibers essentially represents the visible background color of the mottled appearance.

42. Method according to one of claims 22 to 41, characterized in that that in step d) the thermoplastic fibers are softened and / or plasticized to form a melt, so that the density of the thermoplastic fibers increases as a result of this melt and the melt sinks into the fiber mat (11) starting from the upper boundary region (40) of the fiber mat (11) in the direction of the lower region (41) of the fiber mat (11), as a result of which the natural fibers, in particular those which do not melt, partially protrude from the melt.

43. Method according to one of claims 22 to 42, characterized in that in step d) as a result of the substrate (13) of the decorative web (12) sinking into the fiber mat (11), the decorative layer (14) sinks and / or infiltrates in the upper boundary region (40) of the fiber mat (11).

44. Method according to one of claims 22 to 43, characterized in that the upper limit region (40) is at most 50%, preferably at most 33%, of the total thickness of the fiber mat (11), in particular of the decorated molded part (10).

45. Method according to one of claims 22 to 44, characterized in that in step e) the molding tool has two mold halves (20, 21), in particular wherein the two mold halves (20, 21) are not heated.

46. ​​Method according to one of claims 22 to 45, characterized in that in step e) the forming takes place at a pressing force in a range of 550 kN to 650 kN, in particular in a range of 560 kN to 640 kN.

47. Method according to one of claims 22 to 46, characterized in that in step e) the forming takes place with a time duration in a range of 30 seconds to 60 seconds.

48. Method according to one of claims 22 to 47, characterized in that in step e) the forming takes place at a maximum temperature of 80°C.

49. Method according to one of claims 22 to 48, characterized in that the fiber mat (11) is deformable after step d) due to the thermal heating and is deformed in step e) and then solidified by cooling to form a molded part (10).

50. Method according to one of claims 22 to 49, characterized in that in step e) the melted substrate (13) of the decorative web (12) and the melted thermoplastic fibers of the fiber mat (11) solidify and thus a shrinkage of the thermoplastic materials takes place.

51. Method according to one of claims 22 to 50, characterized in that in step e) a trimming is additionally carried out in the mold or that after step e) a separate trimming of the molded part (10) is carried out by means of a knife and / or laser, so that the molded part (10) is adapted to the final shape.

52. Method according to one of claims 22 to 51, characterized in that in step e) the mold half of the molding tool facing the visible side of the decorated fiber mat is structured, in particular is matted.

53. Method according to one of claims 22 to 52, characterized in that after step e) the following step is carried out: f) back-injection of the molded part (10) with a plastic mass, preferably in the mold or in an injection molding machine, in order to attach assembly elements and / or reinforcement elements.

54. Method according to one of claims 22 to 53, characterized in that the decorated fiber mat (11) after step d) and / or the decorated molded part (10) after step e) has a thickness in the range from 1 mm to 4 mm, in particular from 1.5 mm to 3.5 mm.

Images