DE102020111667A1 - Production of multi-layer functional bodies - Google Patents

Abstract

A method and a device for producing a multi-layer functional body (10) with a base body (11) made of a thermoplastic base material (M1), e.g. a polyolefin, PP or PE, and a functional layer (12) made of a functional material (M2), for example a polyurethane. The base material (M1) is activated on a connection surface (13), for example by ionization with an ozone plasma. The functional material (M2) is brought into connection with the base material (M1) at the activated connection surface (13) and forms an adhesive functional layer (12). The base material (M1) can be activated in particular following an extrusion of the base material (M1), while the extruded strand (14) is in a thermoplastically deformable state.

Description

The invention lies in the field of plastics technology. The disclosure relates in particular to the production of multi-layer functional plastics with a base body made of a thermoplastic base material and an additional functional layer made of a functional material.

The invention is particularly suitable for applying functional coatings to thermoplastics during the manufacturing process. A particularly interesting application of the invention is the coating of a blow-molded polyethylene (PE) or polypropylene plastic part (PP) with a polyurethane functional layer (PUR). With such a PUR functional layer, for example, high-gloss surfaces (with a “piano lacquer” look) can be produced on thermoplastics. The invention is also applicable to a variety of other material combinations and manufacturing techniques. The invention can in particular also be used for the (glue-free) connection of two materials which do not form an adhesive connection under normal conditions.

Thermoplastic plastic parts, especially polyolefins, e.g. PE or PP, are used in practice in a wide variety of areas, for example in the automotive, electronics, textile, packaging or furniture industries. The plastic part can be subject to different mechanical, chemical, optical, haptic or other requirements. Manufacturing a component from a thermoplastic has the advantage that thermoplastic manufacturing processes enable diverse component geometries at interesting material and manufacturing costs, e.g. through extrusion, injection molding or injection blow molding.

In some cases, however, the thermoplastic base material cannot meet all the requirements placed on the component. In particular, surface properties can be restricted in certain materials and / or manufacturing processes. On the other hand, the base material can be well suited as a substrate, carrier or other functional section. Multi-layer components are therefore of interest in which an additional functional layer is applied to at least part of the base material (e.g. because of their special surface properties or other functions).

The production of such a multi-layer functional body brings with it various technical and economic challenges, depending on the materials used. On the one hand, certain material combinations cannot easily be connected to one another. In addition, the manufacturing process should be able to be implemented industrially as efficiently and inexpensively as possible. The properties of the assembled functional body and the surfaces must also meet the requirements of the intended use.

For example, blow-molded PE or PP components can be manufactured inexpensively. However, the materials do not form a sufficiently aesthetically pleasing surface for all purposes. Certain plastics do not form a smooth surface, particularly when they are molded in a blow mold or casting mold. Synthetic resins such as polyurethane (PUR), on the other hand, can form shiny cast surfaces. As a base material, the thermoplastic can at the same time have a positive effect on the mechanical properties such as the toughness or temperature resistance of the functional body. In particular, the shaping of the functional body can be simplified by the base material or the base body formed therewith.

One challenge is that certain combinations of materials, e.g. PE and PUR, do not form a permanent bond under normal conditions. In addition, the possible processing methods or processing conditions of the respective materials must be taken into account.

Primarily formed plastic base bodies are often painted in a subsequent process step or glued to other components in order to form a multi-layer functional body. Such additional process steps can, however, have a disadvantageous effect on cycle times, costs, automatability and / or component properties.

Surface treatments are known from adhesive technology with which components with actually incompatible materials can be joined using additional adhesives. The use of an additional adhesive can, however, be undesirable for various reasons. Downstream process steps (e.g. by means of gluing or coating) also extend the cycle times until the finished functional body. Necessary waiting times (e.g. for the base body to cool down) between the process steps can also have a negative impact on the cycle times of the production process.

The object of the invention is to show an improved technique for producing a multi-layer functional body.

The disclosure includes a manufacturing method, a manufacturing plant and a multi-layer functional body.

A special aspect of the disclosure is the activation of a surface of the base material, to create a permanent connection between a base material and a functional material. The functional material adheres to the base material through the activation of a connection surface. The activation can take place on the shapeless base material, a preformed preform (intermediate product) or the final shaped base body.

Activation is preferably carried out by ionizing a surface of the base material. The activated connection surface can comprise the entire surface or one or more partial surfaces of the base material. Activation can be done either directly or indirectly. Different activation methods are available. The base material is preferably irradiated and / or washed with a radiating medium. A particularly suitable method is the activation of the surface with an ionized gas, in particular a plasma. Treatment with ionized ozone or argon is particularly advantageous.

During activation, a highly reactive area is preferably generated on a material surface. The material surface of the base material is preferably excited by irradiation. In particular, the formation and / or supply of free radicals on a surface can change the binding capacity of the material. When it comes into contact with the functional material, a permanent bond is created through the cross-linking of the two materials. The functional layer adheres without the addition of an additional adhesive layer. The activation of the surface has the particular advantage that no additional material residues, such as glue, remain on the functional component. In addition, the activation can be integrated particularly efficiently into the manufacturing process.

Contrary to what has been common opinion among experts, the surface of a hot thermoplastic, in particular PE or PP, can be activated in a plastically deformable state, so that a permanent connection with a functional material, in particular a synthetic resin e.g. a polyurethane, can be created.

The activation of the surface, in particular through direct or indirect ionization, creates a chemical compatibility between the materials that is not to be expected under normal conditions. In experiments, ionization by irradiation with a plasma has proven to be particularly advantageous. The plasma can in particular be directed with a nozzle onto the entire or part of the surface of the base material. Other activation agents and methods are also possible. In particular, the activation parameters can be adapted depending on the material or material combination. The activation parameters can in particular include the activation time, the activation intensity, an activation medium and ambient conditions (temperature, humidity, etc.).

The activation of the base material to produce a permanent bond to a functional material has shown an unexpected technical effect in experiments and particularly contributes to the inventive step of this disclosure.

The activation of the base material above a limit temperature or in a certain temperature range of the base material is particularly interesting for the production of multi-layer functional bodies. The limit temperature and / or the preferred temperature interval of the base body can have different values or ranges depending on the material. A particularly interesting application is the activation of a warm, thermoplastically deformable plastic, especially directly after the primary shaping (e.g. extrusion). The preferred temperature range of the base material can in particular be given by the limit temperatures of a certain state of aggregation or material structure. In tests, activation of the base material at a temperature above 50 degrees Celsius has proven to be of interest. The activation can - contrary to previous assumptions - take place in particular at over 80 degrees, for example in the range between 80 and 130 degrees Celsius. With certain materials, even higher process temperatures, e.g. in the range of around 220 degrees Celsius, can be selected.

The plastic activated in the thermoplastic state can, in particular, be brought into contact with a functional material during the subsequent processing process and processed further together. The activation and / or connection of the materials can take place "in process", i.e. during the processing of the material. The activation and connection of the materials during an original and / or forming process is particularly advantageous. In this way, particularly efficient manufacturing processes for manufacturing the functional body can be achieved. The disclosure includes in particular a process-integrated joining method.

The activation of the base material and / or the formation of the multi-layer functional body before the base material has cooled from the thermoplastic state is particularly advantageous. In contrast to known painting, coating or gluing processes, the process disclosed here can achieve advantages in terms of process efficiency and component properties.

The activation can take place as an alternative or in addition to other temperature and / or ambient conditions. For example, activation can also take place in a colder temperature range, in particular by prior cooling. Activation under negative or overpressure is also possible and can be of interest for processing certain materials.

The multi-layer functional body preferably comprises at least one base material and one functional material. The base material preferably consists of a thermoplastic plastic, in particular a polyolefin. The base material, in particular a carrier material, can in particular consist of one or a combination of the following materials or material groups or comprise these: acrylonitrile butadiene styrene (ABS), polyamide (PA), polyacrylonitrile (PAN), polybutylene terephthalate (PBTP), polycarbonate (PC), Polyethylene (PE), polyethylene terephthalate (PETP), polyimide (PI), polymethyl methacrylate (PMMA), polyoxymethylene (POM), polypropylene (PP), polyphenylene oxide (PPO), polystyrene (PS), polysulfane (PSU), polyurethane (PUR), Polyvinyl chloride (PVC), styrene acrylonitrile (SAN), styrene butadiene (SB), polytheretherketone (PEEK), polythermide (PEI), polyetherketene (PEK), polyphthalamide (PPA), polyphenylene sulfide (PPS), polyphenyl sulfone (PPSU), polyester elastomer (TEEE).

The base material preferably forms a base body which is formed by thermoplastic original and / or reshaping. Production by extrusion, injection molding and / or blow molding is particularly advantageous. The base body can be shaped in one or more manufacturing steps.

The functional material, in particular as a functional surface or as a functional coating, can comprise a thermoplastic and / or thermosetting plastic or a synthetic resin, in particular polyurethane. Alternatively or additionally, the functional material can comprise a foam or an elastomer. Resins with a suitable viscosity for application in a mold or casting tool are particularly advantageous.

Both the base material and the functional material can comprise one or more additives. In particular, dyes, hardeners, plasticizers or similar chemical or mechanical functional substances can be used.

The base body is preferably formed from a base material in a primary molding process, for example extrusion or injection molding. The base body can be molded in one or more steps (e.g. blow molding). Preferably, a preform, for example a strand, a tube, a mat or a film, is first formed from the base material. The preform can in particular be brought into the shape of the functional body together with the functional material in a further step. Alternatively or additionally, the functional material can also be applied after a shaping processing step, i.e. applied to the base material or otherwise brought into contact with it. The application of the functional material during a shaping production step, e.g. a blow molding process, is particularly advantageous, as special component geometries, short cycle times and good material distribution can be achieved. The activation of the material can in particular be integrated into manufacturing processes or inserted between manufacturing steps.

The base material is activated on at least part of the surface of the preform or the base body (e.g. by ionization with an ozone plasma). The base material is then brought into contact with the functional material on an activated surface. Depending on the manufacturing process, the functional material can be applied directly and / or indirectly to the base material. Conversely, the base material can also be applied to the functional material.

A surface of the base material and / or the functional material is preferably activated before the materials are brought into contact. Alternatively or additionally, the activation can also take place during and / or after the materials are brought into contact. For example, through continuous or additional radiation.

The time between the activation of the surface of the base material and the connection with the functional material is preferably below a maximum waiting time. The maximum waiting time depends, among other things, on the activation method, the materials and / or the ambient conditions. In certain embodiments, the base material is activated immediately before contact with the functional material. The activation effect, in particular through ionization with a plasma, lasts for a certain time. There can be a few seconds or up to 60 or 120 seconds between activation and connection of the materials. Waiting times or processing steps can also be switched between activation and joining of the layers.

With the technology disclosed here, particularly short cycle times for the production of multi-layer functional bodies can be achieved. The activation of the base material enables a particularly fast connection between the base body and the functional layer. Depending on the manufacturing technology used for the original or reshaping of the Components can achieve cycle times between 20 and 60 seconds. Compared to painting, the finished functional bodies can be manufactured much faster.

The connection between the base material and the functional material is particularly strong and durable thanks to the activation of the surface. The connection between the base body and the functional layer is in particular free of connecting means, in particular adhesive or mechanical connectors such as screws or rivets. The adhesive strength of the functional layer in particular proves to be particularly good.

In a particularly advantageous embodiment, a preform is extruded, activated with an activation medium on its surface and then placed in a molding tool that has previously been treated with the functional material. By inflating the preform, the base material is brought into contact with the functional material over a large area.

The base material can first be connected to the functional material and shaped together in one or more primary shaping and / or reshaping processes. The base material can also first be brought into an intermediate shape or final shape and then connected to the functional material.

The term functional layer in the sense of this disclosure can describe both a thin coating and an entire functional section of an assembled body (e.g. a shoe sole).

For example, components that should have a tough base material and a hard or visually appealing surface, for example visible surfaces in the cockpit of a vehicle, are conceivable. Multi-layer plastic parts can also be shoes, for example, in which the sole consists of a particularly abrasion-resistant functional material and the upper shoe has to meet other aesthetic or comfort properties.

The technology disclosed here is particularly advantageous for the production of components for the interior of vehicles. Visible surfaces with special mechanical and / or aesthetic requirements can be produced by activating the base material on a thermoplastic base body.

Further advantageous features and embodiments are described below with reference to the drawings.

Figure list

• 1: einen Ablauf einer möglichen Ausführungsform eines Verfahrens zur Herstellung eines mehrlagigen Funktionskörpers (10) sowie eine Vorrichtung mit einem Extruder (20) zur Bildung eines Stranges (14) aus einem Basismaterial (M1), einer Aktivierungsvorrichtung (30) zur Aktivierung einer Oberfläche des Basismaterials (M1) in einem Aktivierungsbereich (35), einer Handhabungsvorrichtung (40) zur Abtrennung und Handhabung eines Vorformlings (15);
• 2: eine Applikation eines Funktionsmaterials (M2) auf eine Hälfte eines Formwerkzeugs (54) mit einer Applikationsvorrichtung (50);
• 3: das Einlegen eines aktivierten Vorformlings (15) in ein Formwerkzeug (54), in das bereits das Funktionsmaterial (M2) appliziert wurde;
• 4: einen Blasform-Prozess zur Umformung des Vorformlings in einen Basiskörpers mit einer Funktionslage aus dem Funktionsmaterial;
• 5: verschiedene Varianten zur (indirekten) Applikation eines Funktionsmaterials auf oder in ein Werkzeug durch Gießen, Aufspritzen und Einspritzen;
• 6: eine Vorbehandlung (z.B. zur Kühlung) eines extrudierten Stranges in einem Vorbehandlungsbereich (65) mit einer Vorbehandlungsvorrichtung (60) sowie eine Aktivierung mehrerer Oberflächen (13', 13' und 13") mit unterschiedlicher Intensität und Kontur;
• 7: eine weitere Ausführungsform des offenbarten Verfahrens mit direkter Applikation des Funktionsmaterials (M2) auf einen extrudierten Strang (14) sowie eine Handhabungsvorrichtung (40) mit einer Einführungsvorrichtung (42) zur Einführung des Vorformlings (15) in ein Werkzeug (53) und/oder Streckung (S) des Vorformlings (15);
• 8: Beispiel eines Funktionskörpers (10) mit einer einseitigen Funktionslage (12) (z.B. einer Beschichtung) auf einem flachen Basiskörper (11);
• 9: Beispiel eines komplexeren Funktionskörper (10) in Form eines Schuhs mit einem Oberschuh (11') und einer Sohle (12), die an einer profilierten, aktivierten Verbindungsfläche (13) verbunden sind.

The invention is shown schematically and by way of example in the drawings. Show it:

• 1 : a sequence of a possible embodiment of a method for producing a multi-layer functional body ( 10 ) as well as a device with an extruder ( 20th ) to form a strand ( 14th ) from a base material ( M1 ), an activation device ( 30th ) to activate a surface of the base material ( M1 ) in an activation area ( 35 ), a handling device ( 40 ) for separating and handling a preform ( 15th );
• 2 : an application of a functional material ( M2 ) on one half of a forming tool ( 54 ) with an application device ( 50 );
• 3 : inserting an activated preform ( 15th ) into a molding tool ( 54 ), in which the functional material ( M2 ) was applied;
• 4th : a blow molding process for reshaping the preform into a base body with a functional layer made of the functional material;
• 5 : different variants for the (indirect) application of a functional material on or in a tool by pouring, spraying and injecting;
• 6th : a pretreatment (e.g. for cooling) an extruded strand in a pretreatment area ( 65 ) with a pre-treatment device ( 60 ) as well as an activation of several surfaces ( 13 ' , 13 ' and 13 " ) with different intensity and contour;
• 7th : Another embodiment of the disclosed method with direct application of the functional material ( M2 ) onto an extruded strand ( 14th ) as well as a handling device ( 40 ) with an insertion device ( 42 ) to introduce the preform ( 15th ) into a tool ( 53 ) and / or stretching (S) of the preform ( 15th );
• 8th : Example of a functional body ( 10 ) with a one-sided functional layer ( 12th ) (e.g. a coating) on a flat base body ( 11 );
• 9 : Example of a more complex functional body ( 10 ) in the form of a shoe with an upper shoe ( 11 ' ) and a sole ( 12th ), which are attached to a profiled, activated connection surface ( 13th ) are connected.

Detailed description

The features explained with reference to the drawings can be used individually or in combination in different embodiments can be used. The disclosure is not limited to the combinations shown. To facilitate the presentation, several independent aspects of the disclosure are combined in some figures, which can also be used independently of one another.

1 shows a schematic sequence of a method for producing a multi-layer functional body ( 10 ) on the basis of a possible embodiment. A base material ( M1 ) is in an extruder ( 20th ) into a strand ( 14th ) extruded. The strand ( 14th ) occurs at the extrusion nozzle ( 21 ) the end. In the embodiment shown, the strand ( 14th ) hollow, e.g. a hose or a pipe. Other strand shapes can also be formed. The extrusion nozzle ( 21 ) can in particular be designed as an annular nozzle.

The formed strand ( 14th ) is moved along the conveying direction ( F. ) promoted. The conveying movement can take place continuously or intermittently. In the case of primary forming, e.g. extrusion, the base material ( M1 ) heated up to the thermoplastic area, pressed through the extrusion nozzle and occurs in a plastically formed (intermediate) form, in particular as a strand ( 14th ) or preform ( 15th ) or as a base body ( 11 ), to the environment. A material flow that is continuous at least in sections is created. In other embodiments, e.g. in injection molding or another processing method of the base material ( M1 ), the sequence of steps or the conveying movement of the base material ( M1 ) also take place in a different way than shown.

The strand ( 14th ) or the originally formed base material ( M1 ) is in an activation area ( 35 ) activated on at least one surface. The base material ( M1 ) can be activated on at least one outer surface and / or one inner surface. The activation takes place preferably in the (direct) connection to a primary shaping step, for example at the exit from an extruder. In further embodiments, the originally formed base material ( M1 ) can also be processed or cooled in an intermediate step. The warm surface of the thermoplastic base material is preferred ( M1 ) activated. The base material is advantageously ( M1 ) to be sufficiently warm after activation and to be reshaped in a directly subsequent processing step (with or without functional layer).

The disclosure includes in particular an activation device ( 30th ). The activation device is designed to activate the surface of a base material ( M1 ) to activate, in particular to ionize and / or generate free radicals on the surface. The activation device can in particular be an irradiation device. The base material ( M1 ) is preferably carried out with an ionization medium and / or radiation ( 32 ) treated on the surface. The activated surface ( 13th ) is indicated in the drawings by jagged lines.

The activation device ( 30th ) is preferably arranged on a plastics processing machine, in particular on an extruder, a blow extrusion machine or on a forming device. The activation device ( 30th ) is preferably designed to ionize a thermoplastic material. The ionization can take place directly or indirectly. The activation device preferably comprises ( 14th ) an ionization device. For example, the activation device can comprise a device for generating and / or conveying an activation medium, in particular a plasma. The activation device can in particular have one or more nozzles ( 31 ) to control an activation medium ( 32 ) include.

The nozzle of the activation device ( 30th ) can be highly stressed, especially when using a plasma. The nozzle is advantageously made from a resistant material. The nozzle can in particular be designed to be exchangeable. The device preferably comprises a quick-change device for exchanging the nozzle.

The activated surface can be wholly or partially used as a connection surface with a functional material ( M2 ) be used. The connection of the activated base material ( M1 ) with a functional material ( M2 ) can take place during and / or after activation.

In a like in 1 The embodiment shown is made from a continuous strand ( 14th ) a preform ( 15th ) separated. For example, a piece can also be clamped off from an extruded tube. For handling and / or separating the preform ( 15th ) a handling device is preferred ( 40 ), e.g. an industrial robot with a robotic arm. The handling device ( 40 ) preferably comprises a gripper arm ( 41 ).

The base material ( M1 ), preferably the preform ( 15th ), is attached to an activated connection surface ( 13th ) with a functional material ( M2 ) brought into contact. When the surface is activated, the base material ( M1 ) and the functional material ( M2 ) a permanent bond. The connection of the two materials is preferably carried out by direct and / or indirect application of the functional material ( M2 ) on the base material ( M1 ). In 1 the application of the functional material is only indicated schematically. The disclosure encompasses various possibilities for connecting and / or processing the two materials. The materials can in particular be deformed individually or together during and / or after application. It is particularly advantageous to apply the functional material during a forming process, for example when blow-molding a preform.

The functional material ( M2 ) forms (sooner or later) a functional position ( 12th ) of the multi-layer functional body. The functional material ( M2 ) can exist in different states of aggregation during the connection with the base material, depending on the embodiment. In a preferred embodiment, the functional material ( M2 ) applied as a liquid. Alternatively or in addition, the functional material can also have a solid functional layer ( 12th ) form.

The illustrated proportions of the components of the functional body, e.g. the strand ( 14th ), the preform ( 15th ), the base body ( 11 ) or the functional situation ( 12th ), are not to be interpreted restrictively and are intended to illustrate the overarching idea.

the 2 - 4th show advantageous developments of a method for producing a multi-layer functional body, in which the functional material ( M2 ) indirectly on the base material ( M1 ) is applied.

The functional material ( M2 ) is in an advantageous embodiment in a tool ( 53 ) brought in. For example, the functional material ( M2 ), especially as a viscous liquid (e.g. synthetic resin, PUR), on one mold half ( 54 ) or poured into the tool. The tool can be, for example, a blow mold or another forming tool. The preform ( 15th ) is integrated with the functional material ( M2 ) treated molding tool. The application of the functional material is particularly advantageous ( M2 ) during a forming process of the base body ( 11 ) and / or the functional situation ( 12th ). The materials are molded and connected while at the same time. The functional material ( M2 ) at the same time on the base body ( 11 ) distributes and forms the desired functional position ( 12th ).

• ■ Urformen eines Stranges (14) aus dem Basismaterial (M1);
• ■ Aktivieren der Oberfläche des Basismaterials;
• ■ Abtrennen eines Vorformlings (15) aus dem Strang (14);
• ■ Öffnen eines Formwerkzeugs (54);
• ■ Applikation des Funktionsmaterials (M2) in ein Formwerkzeug (54);
• ■ Einbringen (z.B. Einlegen) des Vorformlings (15) in das Formwerkzeug mit dem Funktionsmaterial (M2);
• ■ Schließen der Werkzeughälften (54)
• ■ Formen (z.B. durch Aufblasen) des Vorformlings mit dem Formwerkzeug (54);
• ■ Bilden einer Funktionslage (12) auf dem Basiskörper (11);
• ■ Öffnen des Werkzeugs;
• ■ Entnahme des Funktionskörpers (10).

A particularly advantageous embodiment of the manufacturing method comprises the following steps:

• ■ archetypes of a strand ( 14th ) from the base material ( M1 );
• ■ Activation of the surface of the base material;
• ■ Cutting off a preform ( 15th ) from the strand ( 14th );
• ■ Open a forming tool ( 54 );
• ■ Application of the functional material ( M2 ) into a molding tool ( 54 );
• ■ Bringing in (e.g. inserting) the preform ( 15th ) into the mold with the functional material ( M2 );
• ■ Closing the mold halves ( 54 )
• ■ Shaping (e.g. by inflating) the preform with the molding tool ( 54 );
• ■ Formation of a functional situation ( 12th ) on the base body ( 11 );
• ■ opening the tool;
• ■ Removal of the functional body ( 10 ).

The steps can also be performed in a different order. By simultaneously shaping and applying the functional material, a particularly good surface quality and distribution of the functional layer ( 12th ) can be achieved.

The formation of the functional position ( 12th ) can, for example, by hardening the liquid functional material ( M2 ) on the base body ( 11 ) happen. The forming tool ( 54 ) is preferably kept closed for a corresponding period of time. Possibly. the formation of the functional position ( 12th ) be supported and / or controlled by suitable measures, for example by setting the curing time, the viscosity or the ambient conditions during the formation of the functional layer. For example, the temperature and / or the pressure can be adjusted to ensure the formation of the functional layer ( 12th ) to influence.

A particularly advantageous aspect of this disclosure consists in the simultaneous connection of the materials and the formation of the base body ( 11 ) and / or the functional situation ( 12th ). The invention is particularly suitable for use in the manufacture of plastic components by extrusion blow molding. On the one hand, the inflation forms the body and at the same time creates a two-dimensional connection between the base material and the functional material. The shaping of the functional body and the connection of the base material and the functional material take place at least partially at the same time.

In 5 are further options for applying the functional material to a tool ( 53 ), e.g. a molding tool ( 54 ), shown. The functional material can advantageously be applied indirectly. In the case of indirect application, the functional material is preferably applied to a tool, which is then brought into contact with the base material. It is advantageous to apply the functional material to a molding tool ( 54 ), especially a blow mold.

The functional material ( M2 ) can, for example, be placed in the tool ( 53 ) can be poured or applied to a surface. The forming device preferably comprises a suitable application device ( 50 ). In particular, the tool ( 53 ) Channels ( 56 ) to introduce the functional material ( M2 ) include. The application of the functional material can take place before and / or, for example through inlet channels, also during the forming.

The properties of the functional material ( M2 ) are preferably adapted for processing. For example, the viscosity, the curing behavior, the service life or the reaction behavior of the functional material ( M2 ), for example by adding suitable additives. In an advantageous embodiment, the functional material ( M2 ) poured into an open blow molding tool. The plastically deformable preform ( 15th ) is placed in the prepared tool, the tool is closed and the preform is inflated. The preform expands and hugs the shape of the tool. Due to the even blowing pressure, the functional material is distributed between the inflated preform ( 15th ) and the tool. A uniform functional layer is formed on the surface of the preform ( 15th ) or the simultaneously formed base body ( 11 ). The connection of the materials to the previously activated connection surface takes place during the deformation of the preform or the formation of the base body ( 11 ).

However, the disclosure is not limited to the simultaneity of the shaping of the base body and / or the functional layer and / or the connection of the materials on an activated surface. One or more steps can also be carried out upstream or downstream. The steps mentioned are advantageously carried out while the base material is still plastically deformable by the extrusion.

In further embodiments, the formation of the base body and / or the functional layer can (at least partially) also take place in a separate step. Such a connection on one or more already formed parts is explained below using the example of a shoe.

6th illustrates further possible embodiments of the invention, in particular the activation of the base material ( M1 ). The activation of the base material ( M1 ) a pretreatment, e.g. cooling ( 60 ), must be connected upstream. For example, the string ( 14th ) and / or a preform ( 15th ) through a pre-treatment area ( 65 ). The pre-treatment area ( 65 ) can be added to the activation area ( 35 ) upstream or downstream. In particular, the system can include ventilation or a fan.

As an alternative or in addition, the activation area can be specially designed. The activation device ( 30th ) can be designed in different ways. In 6th is an example of an encompassing, e.g. ring-shaped or slotted, activation device ( 30th ) indicated. Alternatively or additionally, a nozzle of the activation device ( 30th ) be profiled.

The strand ( 14th ) or a preform ( 15th ) is activated by the activation device ( 30th ) or an activation area ( 35 ) guided. For example, the activation device can comprise a ring-shaped or partially encircling nozzle. The nozzle of the activation device can in particular be designed in a profiled manner. The activation device is preferably ( 30th ) designed to activate areas on the surface of the base material in different intensities. The surface of the base material can in particular in one or more areas ( 13 ' , 13 " ) can be activated with different intensities.

For example, the radiation intensity can be aligned in a predetermined profile. The activation device can in particular be designed to be controllable. In a particular embodiment, the activation device can also be movable, in particular around a profiled surface ( 13 " ) to activate.

The activated surface or connection surface is advantageously designed in such a way that the adhesive connection between the base material and the functional material is ensured and, at the same time, the material is not treated unnecessarily.

In a particularly advantageous embodiment, the system can have a monitoring device ( 70 ), in particular with one or more sensors. Activation of the material which is adjustable or controllable on the basis of measurements is particularly advantageous.

7th shows further aspects of possible embodiments of the manufacturing technique. The application of the functional material ( M2 ) can also be before (or after) a forming process in a forming device ( 52 ) take place. In particular, the system can have one or more application devices ( 50 ) include. The application device ( 50 ) the functional material is designed for this purpose directly and / or indirectly on the base material ( M1 ) to apply.

In the case of direct application, the functional material ( M2 ) preferably directly on an activated connection surface ( 13th ) of the base material ( M1 ) applied. Application devices ( 50 ) with one or more (possibly different) application devices ( 51 ) conceivable. The functional material ( M2 ) can in particular be painted on, sprayed on and / or applied by immersion. In 7th the functional material ( M2 ) exemplarily on the strand ( 14th ) sprayed on.

Alternatively or additionally, a preform ( 15th ) on which the functional material ( M2 ) is applied. In particular, the functional material ( M2 ) directly onto a preform ( 15th ) are applied shortly before the preform ( 15th ) with the functional material ( M2 ) is transformed. It is conceivable, for example, that the preform ( 15th ) in a plunge pool with a liquid functional material ( M2 ) is immersed and then placed in a molding tool or enclosed by a molding tool.

The application device can, for example, one or more application devices ( 51 ), for example dispensers, spray devices or nozzles. The functional material can be used as in 7th indicated directly with an applicator on the base material ( M1 ), for example the strand ( 14th ), can be applied. In the example shown, the line ( 14th ) activated on the surface, then coated with the functional material.

The application device can also comprise a plunge pool and a handling device.

When inserting the preform ( 15th ) into a tool ( 53 ) the preform can in particular be preformed, for example stretched. The handling device ( 40 ), for example, an insertion device ( 42 ) include. The preform ( 15th ) can be pulled in one direction (S).

The preform ( 15th ) can in particular be held at two ends by a handling device. This is particularly advantageous for insertion into a horizontally lying tool half.

the 8th and 9 show by means of two examples how differently a functional body ( 10 ) can be formed. Both the dimensions of the base body ( 11 ) and the functional situation ( 12th ) as well as the formation of the connection surface ( 13th ) can be designed in different ways.

In a common embodiment, as in 8th shown schematically, forms the functional position ( 12th ) a layer or coating on a base body ( 13th ). A visually or haptically optimized surface of a plastic component in vehicle construction is conceivable. The functional situation ( 12th ) can all or part of the surface of the base body ( 11 ) cover. Several functional layers are also conceivable ( 12th ) on a base body ( 11 ).

In particular, the entire (outer) surface of the base material ( M1 ) are activated and a liquid functional material is distributed on the activated surface.

9 shows a possible application to the production of shoes or similar functional bodies made of two plastic materials. In the embodiment shown schematically, the functional body ( 10 ) from a shoe, which in turn is an upper shoe ( 11 ' ) as a base body and a functional sole ( 12th ) includes. The upper shoe is made from a thermoplastic base material ( M1 ) shaped. The sole ( 12th ) must meet special requirements, e.g. resistance, color fastness, abrasion properties. Accordingly, the sole can be used as a functional layer ( 12th ) made of a suitable functional material ( M2 ) can be shaped. In this or other exemplary embodiments, the size and shape relationships between the base body ( 11 ) and functional situation ( 12th ) be different from a coating.

The base body ( 11 ' ) and / or the functional situation ( 12th ) can in particular be formed before a connection surface is activated. In particular, a profiled area ( 13 ' ) of the base body - the upper shoe - can be activated as a connecting surface on which the functional layer ( 12th ) - the sole - should adhere. In this way, the described advantages over an adhesive connection can be applied to a large number of plastic parts.

List of reference symbols

10

Functional body

11

Base body

11 '

preformed strand, upper shoe

12th

Functional situation

13th

activated connection surface

13 ', 13' '

(profiled) activated connection surface

14th

strand

15th

Preform

20th

Extruder

21

Extrusion nozzle

30th

Activation device / ionizer

31

jet

32

ionization medium / radiation

35

Activation area

40

Handling device / robot

41

Gripper arm

42

Introducer

50

Application device

51

Application device

52

Forming device

53

tool

54

Forming tool

55

Application area

56

channel

60

Pre-treatment device, cooling

65

Pre-treatment area

70

Monitoring device

F.

Conveying direction

M1

Base material

M2

Functional material

Claims (25)

A method for producing a multi-layer functional body (10), comprising the following steps: - Shaping a strand (14), a preform (15) and / or a base body (11) from a thermoplastic base material (M1); - Activating a connection surface (13) on at least part of the surface of the base material (M1); - Connecting the activated connection surface (13) of the base material (M1) to a functional material (M2). - Forming a functional body (10) from a base body (11) of the base material (M1) and an adhesive functional layer (12) of the functional material (M2). Procedure according to Claim 1 , wherein the connection surface (13) is activated by ionization. Procedure according to Claim 1 or 2 wherein the connecting surface (13) is activated with an ionized gas, in particular ionized ozone or argon. Method according to one of the preceding claims, wherein the connection surface (13) is treated with a plasma for activation. Method according to one of the preceding claims, wherein the activation of the connection surface (13) takes place in a thermoplastically deformable state of the base material (M1), in particular above a thermoplastic limit temperature. A method according to any one of the preceding claims, comprising: - severing a preform (15) from an extruded strand (14); A method according to any one of the preceding claims, comprising: - applying the functional material (M2) to the base material (M1), in particular by applying, spraying, brushing and / or dipping; A method according to any one of the preceding claims, comprising: - Applying the functional material (M2) on or in a molding tool (54), in particular by applying, spraying, brushing, pouring and / or injecting; A method according to any one of the preceding claims, comprising: - Forming the base material (M1) and / or the functional material (M2) in a forming tool (54); A method according to any one of the preceding claims, comprising: - Inflating a preform (15) in a blow molding tool (54), in particular in a blow molding tool, into which the functional material (M2) has been applied; Method according to one of the preceding claims, wherein the functional body (10) is formed, in particular shaped, in one or more steps. Method according to one of the preceding claims, wherein the activation of the connecting surface (13) takes place before a deformation of the base material (M1). Method according to one of the preceding claims, wherein the connection of the activated connection surface (13) to the functional material (M2) takes place before and / or during formation of the base body. Method according to one of the preceding claims, wherein the strand (11), a preform (15) or the base body (11) is originally formed by extrusion, in particular by extrusion, hose extrusion, profile extrusion or film extrusion. Method according to one of the preceding claims, wherein the base material (M1) comprises a thermoplastic plastic, in particular a polyolefin, in particular PP and / or PE. Method according to one of the preceding claims, wherein the functional material (M2) comprises a thermosetting plastic and / or a synthetic resin, in particular a polyurethane. Method according to one of the preceding claims, wherein the base material (M1) and / or the functional material (M2) comprises one or more additives, in particular a hardener or a dye. Method according to one of the preceding claims, wherein the base material (M1) is at least partially coated with the functional material (M2). Device for producing a multi-layer functional body (10) according to a method according to one of the preceding claims, comprising: - An activation device (30) for activating a connecting surface (13) on a surface of a thermoplastic base material (M1); - An application device (50) for the direct or indirect application of a functional material (M2) to an activated connection surface (13). Device according to Claim 19 comprising an extruder (20). Device according to Claim 19 or 20th , comprising a forming device (52), in particular a blow molding tool. Device according to one of the preceding claims, wherein the activation device (30), in particular the activation area (35), is arranged at the exit of an extruder. Device according to one of the preceding claims, comprising a handling device (40), in particular a robot, for handling a preform (15). Multi-layer functional body (10) with a base body (11) and an adhesive functional layer (12), the base body (11) comprising a thermoplastically formed plastic with an activated connection surface (13) and the functional layer (12) on the activated connection surface (13) adheres. Multi-layer functional body (10) according to Claim 24 , wherein the base body (11) and the functional layer (12) are formed in a common deformation process.

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