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EP-4578623-B1 - METHOD FOR PRODUCING A PARTIALLY TRANSLUCENT OUTER TRIM PART FOR A VEHICLE

EP4578623B1EP 4578623 B1EP4578623 B1EP 4578623B1EP-4578623-B1

Inventors

  • Beyerlein, Patrick
  • Friese, Dominik
  • Jäger, Christoph
  • KÄTZEL, Patrick
  • LEISTER, Christian

Dates

Publication Date
20260513
Application Date
20241216

Claims (9)

  1. Method for producing a partially light-transmissive exterior trim part for a vehicle, wherein the exterior trim part comprises a base body (1), comprising the following steps: - Providing a color film (2) which has at least one carrier film (2a) made of a plastic material that is transparent or translucent to visible light and an opaque and color-imparting layer (2b) arranged on the carrier film (2a), wherein the color-imparting layer (2b) has a plurality of cut-outs (4) in order thereby to enable partial light transmissivity of the color film (2), - Providing a design film (3) which has at least one carrier film (3a) made of a plastic material that is transparent or translucent to visible light, a transparent or translucent adhesion promoter layer (3b), and a transparent or translucent decorative layer (3c) arranged between the carrier film (3a) and the adhesion promoter layer (3b), - Inserting the color film (2) into an injection molding tool which has at least two tool mold halves (6, 7) which, in the closed state, form between them a cavity (8) defining the base body (1), wherein the color-imparting layer (2b) of the color film (2) bears against the inner wall of one of the tool mold halves (6) or lies opposite the inner wall of one of the tool mold halves (6), and inserting the design film (3) into the injection molding tool, wherein the carrier film (3a) of the design film (3) bears against the inner wall of the other tool mold half (7) or lies opposite the inner wall of the other tool mold half (7), - Injecting a plasticized plastic material forming the base body (1) into the cavity (8), wherein the plastic material consists of a plastic material that is transparent or translucent to visible light, wherein the plasticized plastic material is injected in such a manner that it back-injects the color film (2) and the design film (3) such that the base body (1) is formed between the color film (2) and the design film (3) and bonds to both films (2, 3), wherein, by the injection pressure and/or the holding pressure of the plastic material forming the base body (1), partial regions (9) of the carrier film (2a) of the color film are pressed into the cut-outs (4) of the color-imparting layer (2b), - Applying a sealing layer (10) made of a transparent or translucent plastic material, sealing the color film (2) and the partial regions (9).
  2. Method according to claim 1, characterized in that the cut-outs (4) in the color-imparting layer (2b) of the color film (2) are realized by a screen printing process or by an inkjet printing process or by a coating process with subsequent laser removal of parts of the applied coating layer.
  3. Method according to claim 1 or 2, characterized in that the plastic material of the carrier film (2a) of the color film (2) and/or the plastic material of the carrier film (3a) of the design film (3) comprises polypropylene or consists of polypropylene.
  4. Method according to one of the preceding claims, characterized in that the plastic material of the base body (1) comprises polypropylene or consists of polypropylene.
  5. Method according to claim 4, characterized in that the adhesion promoter of the adhesion promoter layer (3b) is intended to improve or enable the adhesion between the polypropylene of the base body (1) and the design film (3).
  6. Method according to one of the preceding claims, characterized in that the sealing layer (10) comprises polyurethane or consists of polyurethane.
  7. Method according to one of the preceding claims, characterized in that at least one of the two films (2, 3) has at least one heating wire or at least one antenna wire or at least one electrical circuit or at least one light-emitting diode, or that at least one additional functional film is provided which is connected to one of the films (2, 3) and/or to the base body (1), wherein the functional film has at least one heating wire or at least one antenna wire or at least one electrical circuit or at least one light-emitting diode.
  8. Method according to one of the preceding claims, characterized in that the application of the sealing layer (10) is carried out in an injection molding process or by a flooding process or by a dipping process or by a reaction injection molding process (RIM).
  9. Method according to one of the preceding claims, characterized in that the exterior trim part is a bumper cover or an outer door trim or an outer tailgate trim or a fender trim or a front panel or a radiator cover or a rocker panel trim or a spoiler, or a constituent part of a bumper cover or an outer door trim or an outer tailgate trim or a fender trim or a front panel or a radiator cover or a rocker panel trim or a spoiler.

Description

The present invention relates to a method for manufacturing a partially translucent exterior panel for a vehicle. Numerous manufacturing processes for such exterior cladding components are known. The documents are just a few examples. DE 10 2020 000 921 A1 , DE 10 2017 214 943 A1 , DE 10 2020 105 729 A1 , DE 10 2021 134 475 A1 , DE 10 2020 134 132 A1 or EP 3 632 749 A1 referred. The DE 10 2017 215126 A1 This relates to a process for manufacturing a plastic component for a vehicle. A decorative carrier is positioned in one half of an injection mold, while a film system consisting of a carrier film and a protective layer is arranged in the opposite half. A transparent plastic is injected between the decorative carrier and the film system. The protective layer bonds with the plastic layer formed by the injection molding material, while the carrier film can be removed from the finished component. The injection process can cause the decorative carrier and/or film system to be pressed into their final shape. The decorative carrier can be designed as a transparent or colored transparent plastic film and can bear an image applied by printing or a colored layer. A lighting device can be provided to illuminate the plastic layer and, if applicable, a decorative element. In the EP 3 653 358 A1 A method for manufacturing a body part is disclosed. A decorative film with a translucent and an opaque area is positioned on the wall of the mold cavity, with the opaque area in contact with the cavity wall and the translucent area positioned at a distance from it. During the injection of plastic material, the translucent area is pressed against the mold wall by the injection pressure. The decorative film comprises a translucent film and an opaque element applied to it, and may also carry a colored layer. The EP 3 632 749 A1 This describes a process for manufacturing a translucent panel. A transparent or translucent base is provided and then coated with a colored layer. Perforations are made in the coating, completely penetrating it and allowing light to pass through. A clear coat is applied over the perforated coating, sealing the coating and the perforations while simultaneously filling them. The JP S59-1236 A This relates to a process for producing a glossy pattern using a printed aluminum foil. The foil is placed with the printed side against the cavity wall, the print having recesses. During back injection molding, material is injected into the recesses. The upper surface of the foil has a coating printed with UV-curable ink. JP H01-222944 A The patent also discloses an injection molding process using a multi-layered film composite. This composite has a printing area with cutouts. Below this is a coating on a metal foil, which is bonded to a plastic film via an adhesive layer. The object of the present invention is to provide an alternative method for manufacturing to specify an exterior cladding part. This problem is solved in the present case by a method for manufacturing a partially translucent exterior trim part for a vehicle, wherein the exterior trim part has a base body, comprising the following steps: Providing a colored film comprising at least one carrier film made of a plastic material transparent or translucent to visible light and an opaque and colored layer arranged on the carrier film, wherein the colored layer has a plurality of cutouts to enable partial translucency of the colored film, Providing a design film comprising at least a carrier film made of a plastic material transparent or translucent to visible light, a transparent or translucent adhesion promoter layer, and a transparent or translucent decorative layer arranged between the carrier film and the adhesion promoter layer. Inserting the colored film into an injection mold which has at least two mold halves which, in the closed state, form a cavity between them defining the base body, wherein the color-imparting layer of the color film rests against the inner wall of one of the mold halves or is opposite the inner wall of one of the mold halves, and inserting the design film into the injection mold, wherein the carrier film of the design film rests against the inner wall of the other mold halves or is opposite the inner wall of the other mold halves, Injecting a plasticized plastic material forming the base body into the cavity, wherein the plastic material consists of a plastic material transparent or translucent to visible light, wherein the plasticized plastic material is injected in such a way that it back-injects the color film and the design film in such a way that the base body is formed between the color film and the design film and bonds with both films, wherein, by means of the injection pressure and/or the holding pressure of the plastic material forming the base body, partial areas of the carrier film of the color film are pressed into the recesses of the coloring layer. Applying a sealing layer made of a transparent or translucent pl