DE102021108273A1 - Process for the production of a component for a motor vehicle having at least two layers of paint - Google Patents

Abstract

The present invention relates to a method for producing a component for a motor vehicle that has at least two colored layers (1, 2), the colored layers (1, 2) being applied to a thin-walled carrier structure (3) that at least partially defines the geometry of the component, wherein the carrier structure (3) consists of a transparent or translucent polymer material, the method having the following sequence of steps: coating and simultaneous masking of the first area (6) or the first areas (6) by applying the first colored layer (1) on the back ( B) the carrier structure (3) by means of a pad printing process with a pad printing element (10) which, in order to form the first ink layer (1), transfers a liquid or powder ink to the back (B) of the carrier structure (3) by means of an elastic pad (10a). , The material of the elastic tampon (10a) has a Shore A hardness according to DIN 53505 in the range of 1 to 5, preferably in the range from 2 to 4, whereby only the first area (6) or the first areas (6) are coated and masked with the first color layer (1), application of the at least one further color layer (2) at least on the unmasked second area (8) or at least on the unmasked second areas (8) on the back (B) of the carrier structure (3).

Description

The present invention relates to a method for producing a component for a motor vehicle that has at least two color layers, the color layers being applied to a thin-walled support structure that at least partially defines the geometry of the component, the support structure consisting of a transparent or translucent polymer material, the support structure has an outer side that is visible in the intended use and a rear side opposite the outer side, the at least two color layers being applied to the rear side of the carrier structure and consequently being visible or recognizable through the carrier structure on the outer side, at least in sections, the carrier structure having a first Has an area or first areas in which only a first color layer or only parts of a first color layer can be seen on the outside, and wherein the carrier structure also has a second area or it has second areas in which only the at least one additional color layer or only parts of the at least one additional color layer can be seen on the outside, the second area being determined and fixed by a recess within the support structure that is open to the rear and defines a design element, or the second areas are determined and fixed by recesses within the support structure which are open towards the back and define design elements.

In a prior art in the WO 2019/115368 A1 known methods, the color layers are applied to the carrier structures by using an inkjet printing method. Although such a method allows a very precise application of the first layer of paint, it is not always economical in the case of large quantities due to the long cycle times.

The invention therefore sets itself the task of specifying a method with the features described at the outset, which, compared to the prior art, enables faster production of a component for a motor vehicle that has at least two layers of paint.

• Verfahren zur Herstellung eines wenigstens zwei Farbschichten aufweisenden Bauteils für ein Kraftfahrzeug, wobei die Farbschichten auf einer dünnwandigen, die Geometrie des Bauteils zumindest teilweise definierenden Trägerstruktur aufgebracht werden, wobei die Trägerstruktur aus einem transparenten oder transluzenten Polymermaterial besteht, wobei die Trägerstruktur eine, in der bestimmungsgemäßen Verwendung sichtbare Außenseite und eine der Außenseite gegenüberliegende Rückseite aufweist, wobei die wenigstens zwei Farbschichten auf die Rückseite der Trägerstruktur aufgebracht werden und infolge durch die Trägerstruktur hindurch auf der Außenseite zumindest abschnittsweise sichtbar oder erkennbar sind, wobei die Trägerstruktur einen ersten Bereich oder erste Bereiche aufweist, bei denen auf der Außenseite nur eine erste Farbschicht oder nur Teile einer ersten Farbschicht erkennbar sind, und wobei die Trägerstruktur ferner einen zweiten Bereich oder zweite Bereiche aufweist bei denen auf der Außenseite nur die wenigstens eine weitere Farbschicht oder nur Teile der wenigstens einen weiteren Farbschicht erkennbar sind, wobei der zweite Bereich durch eine zur Rückseite offene, und ein Designelement definierende,
• Ausnehmung innerhalb der Trägerstruktur bestimmt und festgelegt wird oder die zweiten Bereiche durch zur Rückseite offene, und Designelemente definierende, Ausnehmungen innerhalb der Trägerstruktur bestimmt und festgelegt werden,
• wobei das Verfahren folgende Schrittreihenfolge aufweist:
  • - Beschichten und gleichzeitiges Maskieren des ersten Bereichs oder der ersten Bereiche durch das Aufbringen der ersten Farbschicht auf der Rückseite der Trägerstruktur mittels eines Tampondruckverfahrens mit einem Tampondruckelement, das zur Ausbildung der ersten Farbschicht mittels eines elastischen Tampons eine flüssige oder pulverförmige Farbe auf die Rückseite der Trägerstruktur überträgt, wobei das Material des elastischen Tampons eine Shore A Härte nach DIN 53505 im Bereich von 1 bis 5, bevorzugt im Bereich von 2 bis 4 aufweist, wodurch nur der erste Bereich oder die ersten Bereiche mit der ersten Farbschicht beschichtet und maskiert werden,
  • - Aufbringen der wenigstens einen weiteren Farbschicht zumindest auf den unmaskierten zweiten Bereich oder zumindest auf die unmaskierten zweiten Bereiche auf der Rückseite der Trägerstruktur.

According to the invention, this object is achieved by the following method:

• Method for producing a component for a motor vehicle that has at least two colored layers, the colored layers being applied to a thin-walled support structure that at least partially defines the geometry of the component, the support structure consisting of a transparent or translucent polymer material, the support structure having one, in the intended use has a visible outside and a back opposite the outside, the at least two color layers being applied to the back of the support structure and as a result being at least partially visible or recognizable through the support structure on the outside, the support structure having a first area or first areas, in which only a first color layer or only parts of a first color layer can be seen on the outside, and wherein the carrier structure also has a second area or second areas in which au f on the outside only the at least one further color layer or only parts of the at least one further color layer are recognizable, with the second area being defined by a design element which is open towards the rear
• recess is determined and fixed within the support structure or the second areas are determined and fixed by recesses within the support structure which are open towards the back and define design elements,
• the method having the following order of steps:
  • - Coating and simultaneous masking of the first area or areas by applying the first color layer to the back of the support structure using a pad printing process with a pad printing element that applies a liquid or powder color to the back of the support structure using an elastic pad to form the first color layer transferred, the material of the elastic pad having a Shore A hardness according to DIN 53505 in the range from 1 to 5, preferably in the range from 2 to 4, whereby only the first area or the first areas are coated and masked with the first color layer,
  • - Application of the at least one further color layer at least to the unmasked second area or at least to the unmasked second areas on the back of the carrier structure.

Pad printing is an indirect gravure printing process in which the ink is transferred from a printing form to the carrier structure using an elastic pad made of, for example, silicone rubber. The color is transferred to the carrier structure by pressing with suitable pressure. The color that is to be transferred can here as a possibility on a so-called Kli be applied as the printing form. The ink can be applied to the cliché using a squeegee, roller or brush. The tampon is then placed on this cliché, lifts off again, taking the ink with it, and moves to the carrier structure. There the tampon sinks, adapts to the shape of the support structure and leaves the ink on the support structure. These movements can be taken over by a traversing unit or a robot, for example.

The use of a tampon printing process with a tampon printing element and an elastic tampon for transferring the ink for the first ink layer is not unusual in the case of components for a motor vehicle. Until now, however, it was assumed that to protect the design elements from being accidentally coated with the first layer of paint, the elastic pad had to have a high Shore A hardness so that the surface of the pad did not bulge into the recesses of the design elements and transfer the paint into them . Contrary to this assumption, the applicant has found that, on the contrary, only the use of a tampon that is as soft as possible effectively prevents the coating of the design elements. One explanation is that an elastic tampon made of a material with the claimed Shore A hardness according to DIN 53505 in the range from 1 to 5, preferably in the range from 2 to 4, seals the recess (or recesses) better. The air then trapped in the recess or recesses holds the pad (and thus the ink of the first ink layer) back from the second area or areas.

The at least one additional color layer can be applied to the second area or to the second areas on the back of the support structure by transferring a liquid or powdery additional color to the back of the support structure using an additional tampon, the additional tampon having a Shore A hardness according to DIN 53505 in the range from 15 to 30, preferably in the range from 18 to 27. When using another tampon, it has been shown that here (also contrary to previous assumptions) a tampon made of a material with a relatively high degree of hardness best gets into the recess or recesses and the further color layer on the surface of these second areas can transmit.

The application of the at least one further color layer to the second area or to the second areas on the rear side of the carrier structure can alternatively take place by means of a coating process that differs from the pad printing process. Due to the fact that the first color layer applied by means of the tampon already forms the masking on the carrier structure, a coating process can be selected for the at least one further color layer which has a greater area performance (i.e. painted area per time) compared to the tampon printing process. The combination of the pad printing process for the first color layer with a coating process with a larger surface area for the second color layer makes it possible to achieve an even higher speed process.

The different coating method can include a spray painting method or a spray painting method or a brush coating or a dip coating or a roller coating or a plating method, in particular a PVD method or a CVD method, or an electroplating method.

After the step of transferring the first color layer, the first color layer can be cured and/or solidified at the same time or subsequently, with the curing and/or solidification taking place partially, partially or completely.

The curing and/or hardening of the first color layer can be enabled and/or accelerated at least partially by supplying energy. In particular, UV-curing lacquers (ie lacquers that harden with ultraviolet light) can be used.

The recess can be formed by a depression or a bead or a groove or lettering sunk into the material of the support structure or a satin finish or a nub and/or a pattern sunk into the material of the support structure, or the recesses can be formed by beads and/or grooves and /or lettering sunk into the material of the support structure and/or satin finishes and/or graining and/or patterns sunk into the material of the support structure. These design elements defined by the recesses can then be additionally highlighted visually by means of the at least one further color layer.

The first colored layer and/or the at least one further colored layer can be or can be built up by a large number of individual layers. This means that the first colored layer and/or the at least one further colored layer can in particular be made up of at least two or more individual layers.

The at least one further color layer can be a metal-containing coating, in particular a chromium-containing coating tion, to be formed. Consequently, the at least one further color layer does not necessarily mean a lacquer layer, but can also mean a coating by a metal.

The first color layer and/or the at least one further color layer can be formed by overlapping layers of the color gradually transferred from the respective pad. Consequently, the first colored layer and/or the at least one further colored layer do not necessarily have to be applied to the carrier structure in one pass, but can also be applied step by step.

The carrier structure can already have a three-dimensional geometry with at least one spatial curvature before the color layers are applied. The support structure preferably has a three-dimensional geometry with at least two spatial curvatures. The back of the support structure is preferably the inwardly curved side of the support structure.

The component can be an exterior component of a motor vehicle, in particular a bumper cladding or a radiator grille cladding or a fender cladding or an A, B, C or D pillar cladding or a spoiler outer skin or a rocker panel or an outer door cladding or a door lid outer cladding or a tailgate cladding .

The component can be part of an exterior component of a motor vehicle, in particular a part of a bumper trim or a radiator grille trim or a fender trim or an A, B, C or D pillar trim or a spoiler outer skin or a rocker panel or a door outer trim or a door flap outer trim or form a tailgate panel.

The support structure can be manufactured or manufactured by means of a generative process (e.g. 3D printing) or in an injection molding process or by thermoforming.

The transparent or translucent polymer material of the support structure can include in particular polycarbonate, polymethyl methacrylate, polystyrene (e.g. PS, ABS, ASA), thermoplastic polyester (e.g. PET, PBT) or a biopolymer (e.g. cellulose acetate, polyhydroxybutyrate, polylactic acid, polyhydroxyalkaonate).

Also part of the invention is a component that is produced using the method described above.

• 1 bis 3 den Verfahrensschritt des Beschichtens und gleichzeitigen Maskierens des ersten Bereichs durch das Aufbringen der ersten Farbschicht anhand von schematischen Querschnittsdarstellungen;
• 4 Querschnittsdarstellung der Trägerstruktur nach dem Aufbringen der ersten Farbschicht;
• 4 Aufbringung der weiteren anhand einer schematischen Querschnittsdarstellung;
• 5 Querschnittsdarstellung der Trägerstruktur nach dem Aufbringen der wenigstens einen weiteren Farbschicht.

The invention is explained below with reference to drawings that merely show exemplary embodiments. They show schematically:

• 1 until 3 the method step of coating and at the same time masking the first area by applying the first color layer on the basis of schematic cross-sectional representations;
• 4 Cross-sectional representation of the carrier structure after the application of the first color layer;
• 4 Application of the further based on a schematic cross-sectional representation;
• 5 Cross-sectional representation of the carrier structure after the application of the at least one further color layer.

Elements that are the same or have the same function are provided with the same reference symbols in the figures.

In the 1 until 5 describes a method for producing a component for a motor vehicle that has at least two color layers 1, 2. The color layers 1, 2 are applied to a thin-walled carrier structure 3 that at least partially defines the geometry of the component. The carrier structure 3 consists of a transparent or translucent polymer material and has a three-dimensional geometry with at least one spatial curvature even before the color layers 1, 2 are applied. The carrier structure 3 has an outer side A that is visible when used as intended and a rear side B that is opposite the outer side A (cf. 1 ). The at least two color layers 1, 2 are applied to the rear side B of the carrier structure 3 and are visible or recognizable through the carrier structure 3 on the outside A at least in sections as a result (due to the transparent or translucent polymer material of the carrier structure). The carrier structure 3 has a first area 6 or first areas 6, in which on the outside A only a first color layer 1 or only parts of a first color layer 1 can be seen. The carrier structure 3 also has a second area 8 or second areas 8 in which on the outside A only the at least one additional color layer 2 or only parts of the at least one additional color layer 2 can be seen.

• Beschichten und gleichzeitiges Maskieren des ersten Bereichs 6 oder der ersten Bereiche 6 durch das Aufbringen der ersten Farbschicht 1 auf der Rückseite B der Trägerstruktur 3 mittels eines Tampondruckverfahrens mit einem Tampondruckelement 10, das zur Ausbildung der ersten Farbschicht 1 mittels eines elastischen Tampons 10a eine flüssige oder pulverförmige Farbe auf die Rückseite B der Trägerstruktur 3 überträgt (vgl. 2 und 3).

The procedure has the following order of steps:

• Coating and simultaneous masking of the first area 6 or the first areas 6 by applying the first color layer 1 to the back B of the carrier structure 3 by means of a pad printing process with a pad pon printing element 10, which, in order to form the first color layer 1, transfers a liquid or powder color to the rear side B of the carrier structure 3 by means of an elastic pad 10a (cf. 2 and 3 ).

The material of the elastic pad 10a has a Shore A hardness according to DIN 53505 in the range from 1 to 5, preferably in the range from 2 to 4, whereby only the first area 6 or the first areas 6 are coated with the first color layer 1 and masked .

The at least one further color layer 2 is then applied at least to the unmasked second region 8 or at least to the unmasked second regions 8 on the rear side B of the carrier structure 3 (cf. 5 and 6 ).

The at least one additional color layer 2 is applied to the second area 8 or to the second areas 8 on the rear side B of the support structure 3 by transferring a liquid or powdered additional color to the rear side B of the support structure 3 by means of a further tampon 20a, the material of the additional tampon 20a having a Shore A hardness according to DIN 53505 in the range from 15 to 30, preferably in the range from 18 to 27.

The at least one further color layer can alternatively be applied by means of a coating method that differs from the pad printing method. The different coating method can include a spray painting method or a spray painting method or a brush coating or a dip coating or a roller coating or a plating method, in particular a PVD method or a CVD method, or an electroplating method.

After the step of transferring the first color layer 1, the first color layer 1 can be cured and/or solidified at the same time or subsequently, with the curing and/or solidification occurring partially, partially or completely. The hardening and/or hardening can at least partially be made possible and/or accelerated by supplying energy.

The recess 8a is formed by a depression or a bead or a groove or lettering sunk into the material of the support structure 3 or a satin finish or a nub and/or a pattern sunk into the material of the support structure 3, or the recesses 8a are formed by beads and/or or grooves and/or lettering sunk into the material of the support structure 3 and/or satin finishes and/or graining and/or patterns sunk into the material of the support structure 3 are formed.

The first colored layer 1 and/or the at least one further colored layer 2 can be made up of a large number of individual layers.

The at least one further color layer 2 is formed by a coating containing metal, in particular by a coating containing chromium.

The first color layer 1 is formed by overlapping layers of the color gradually transferred from the pad 10a.

The back is the inwardly curved side of the support structure 3.

The component is an exterior component of a motor vehicle, in particular a bumper trim or a radiator grille trim or a fender trim or an A, B, C or D pillar trim or a spoiler outer skin or a rocker panel or an outer door trim or a door lid outer trim or a tailgate trim , or forms part of the aforementioned components.

The carrier structure 3 can be produced or has been produced by means of a generative process (e.g. 3D printing) or in an injection molding process or by thermoforming.

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• WO 2019/115368 A1 [0002]

Claims (12)

Method for producing a component for a motor vehicle that has at least two color layers (1, 2), the color layers (1, 2) being applied to a thin-walled support structure (3) that at least partially defines the geometry of the component, the support structure (3) consists of a transparent or translucent polymer material, the carrier structure (3) having an outer side (A) that is visible when used as intended and a rear side (B) opposite the outer side (A), the at least two color layers (1, 2) on applied to the rear side (B) of the support structure (3) and as a result are at least partially visible or recognizable through the support structure (3) on the outside (A), the support structure (3) having a first region (6) or first regions ( 6) in which only a first layer of paint (1) or only parts of a first layer of paint (1) can be seen on the outside (A), and where the T The carrier structure (3) also has a second area (8) or second areas (8) in which only the at least one additional color layer (2) or only parts of the at least one additional color layer (2) can be seen on the outside (A), wherein the second area (8) is determined and fixed by a recess (8a) within the support structure (3) that is open to the rear (B) and defines a design element (D), or the second areas (8) through to the rear (B) open, and design elements (D) defining, recesses (8a) within the support structure (3) are determined and fixed, characterized in that the method has the following sequence of steps: - Coating and simultaneous masking of the first area (6) or the first areas ( 6) by applying the first color layer (1) on the back (B) of the support structure (3) by means of a pad printing process with a pad printing element (10) that is used to form the first color layer (1). using an elastic pad (10a) transfers a liquid or powdered paint to the back (B) of the carrier structure (3), the material of the elastic pad (10a) having a Shore A hardness according to DIN 53505 in the range from 1 to 5, preferably in range from 2 to 4, as a result of which only the first area (6) or the first areas (6) are coated with the first color layer (1) and masked, - applying the at least one further color layer (2) at least to the unmasked second area (8) or at least on the unmasked second areas (8) on the back (B) of the support structure (3). procedure after claim 1 , characterized in that the application of the at least one further color layer (2) to the second area (8) or to the second areas (8) on the back (B) of the carrier structure (3) by transferring a liquid or powdery further color onto the back (B) of the carrier structure (3) by means of a further tampon (20a), the material of the further tampon (20a) having a Shore A hardness according to DIN 53505 in the range from 15 to 30, preferably in the range from 18 to 27 having. procedure after claim 1 , characterized in that the at least one further color layer is applied by means of a coating process which differs from the pad printing process. procedure after claim 3 , characterized in that the different coating process comprises a spray painting process or a spray painting process or a brush coating or a dip coating or a roller coating or a plating process, in particular a PVD process or a CVD process, or a galvanic deposition process. Method according to one of the preceding claims, characterized in that after the step of transferring the first color layer (1), the first color layer (1) is cured and/or solidified at the same time or subsequently, the curing and/or solidification being partial, partial or done completely. procedure after claim 5 , characterized in that the hardening and/or hardening is made at least partially possible and/or accelerated by the supply of energy. Method according to one of the preceding claims, characterized in that the recess (8a) by a depression or a bead or a groove or in the material of the support structure (3) sunken lettering or a satin finish or a nub and / or in the material of the support structure (3) is formed by a sunk pattern, or the recesses (8a) are formed by beads and/or grooves and/or lettering and/or satin finishes and/or grainings sunk into the material of the support structure (3) and/or in the material of the support structure ( 3) buried patterns are formed. Method according to one of the preceding claims, characterized in that the first colored layer (1) and/or the at least one further colored layer (2) is built up by a large number of individual layers. Method according to one of the preceding claims, characterized in that the at least one further color layer (2) is formed by a coating containing metal, in particular by a coating containing chromium. Method according to one of the preceding claims, characterized in that the first color layer (1) is formed by overlapping layers of the color transferred in steps from the pad (10a). Method according to one of the preceding claims, characterized in that the carrier structure (3) already has a three-dimensional geometry with at least one spatial curvature before the application of the color layers (1, 2). Method according to one of the preceding claims, characterized in that the component is an exterior component of a motor vehicle, in particular a bumper cladding or a radiator grille cladding or a fender cladding or an A, B, C or D pillar cladding or a spoiler outer skin or a rocker panel or an outer door panel or an outer door panel or a tailgate panel, or forms part of the aforementioned components.

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