EP2266810A1 - Method and production of a printed three-dimensional curved plastic panel - Google Patents

Method and production of a printed three-dimensional curved plastic panel Download PDF

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Publication number
EP2266810A1
EP2266810A1 EP10006117A EP10006117A EP2266810A1 EP 2266810 A1 EP2266810 A1 EP 2266810A1 EP 10006117 A EP10006117 A EP 10006117A EP 10006117 A EP10006117 A EP 10006117A EP 2266810 A1 EP2266810 A1 EP 2266810A1
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EP
European Patent Office
Prior art keywords
disc
printing
flat
printed
plastic
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP10006117A
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German (de)
French (fr)
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EP2266810B1 (en
Inventor
Manfred Nawroth
Peter Capellen
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Bayer Intellectual Property GmbH
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Bayer MaterialScience AG
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M1/00—Inking and printing with a printer's forme
    • B41M1/40—Printing on bodies of particular shapes, e.g. golf balls, candles, wine corks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M3/00—Printing processes to produce particular kinds of printed work, e.g. patterns
    • B41M3/006—Patterns of chemical products used for a specific purpose, e.g. pesticides, perfumes, adhesive patterns; use of microencapsulated material; Printing on smoking articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00—Duplicating or marking methods; Sheet materials for use therein
    • B41M5/0011—Pre-treatment or treatment during printing of the recording material, e.g. heating, irradiating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01Q—ANTENNAS, i.e. RADIO AERIALS
    • H01Q1/00—Details of, or arrangements associated with, antennas
    • H01Q1/12—Supports; Mounting means
    • H01Q1/1271—Supports; Mounting means for mounting on windscreens
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M1/00—Inking and printing with a printer's forme
    • B41M1/12—Stencil printing; Silk-screen printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41P—INDEXING SCHEME RELATING TO PRINTING, LINING MACHINES, TYPEWRITERS, AND TO STAMPS
    • B41P2200/00—Printing processes
    • B41P2200/40—Screen printing

Definitions

  • the invention relates to a method for the production of three-dimensional curved plastic discs, which are provided with printed electrical conductors.
  • the US-A 2006/045120 describes a method and a vehicle window made of plastic, in which an electrically conductive material is applied by means of a nozzle directly on the already shaped disc.
  • the nozzle is attached to a robot and travels the desired structure along the curved surface, the position / distance of the nozzle is determined by sensors exactly.
  • existing patterns show that the optical quality can not compete with existing systems.
  • the applied material forms an unsightly bead and there is a spray around the applied structure - both can not be avoided up to now. Furthermore, this process is very time consuming, the nozzle must drive off the complete structure along the surface.
  • Core element of the method according to the invention is to deform the three-dimensional curved plastic disc for the duration of the printing process by the exercise of pressure or train so that it is flat or approximately flat.
  • the plastic disc can be produced by injection molding or thermoforming.
  • this three-dimensionally curved plastic disk is then coated over the entire surface / part of the area. The coating ensures the scratch resistance and the weather resistance of the plastic disc.
  • step b) the plastic disk, which was optionally previously coated in step a), deformed:
  • the three-dimensionally curved plastic disk circumferentially by means of a frame-shaped element on a flat surface, such as a flat work table, pressed.
  • a frame-shaped element on a flat surface, such as a flat work table, pressed.
  • a partial surface can be pressed.
  • step c The plastic disk now lying flat on a plane is printed in step c), e.g. by screen printing process.
  • the printing inks are preferably electrically conductive screen printing inks, whereby printed circuit traces are printed, which can be used, for example, as heating elements or antennas.
  • step d) the disc is relieved by removing the pressure or the suction and curing the screen printing pattern.
  • step b), c) and d) can be repeated as often as desired in order to print other (screen) printing patterns and / or to print with other (screen) printing inks.
  • a frame-shaped screen print pattern can still be printed around the printed strip conductors, or pressure can still be applied to cover and protect the electrical strip conductors.
  • step a), the coating of the plastic disk, is carried out only after the printing as described in b) - d).
  • the component can be coated over the entire surface or partial area after printing.
  • the plastic disc is made of a thermoplastic material.
  • transparent or translucent thermoplastics can be used.
  • Suitable thermoplastics are, for example, polycarbonates or copolycarbonates based on diphenols, poly- or copolyacrylates and poly- or copolymers of copolymethacrylate, preferably polymethylmethacrylate, poly- or copolymers with styrene, preferably transparent polystyrene or polystyrene-acrylonitrile (SAN), transparent thermoplastic polyurethanes, and also polyolefins.
  • polypropylene types preferably transparent polypropylene types, or polyolefins based on cyclic olefins (for example, TOPAS ®, Ticona), poly- or copolycondensates of terephthalic acid, preferably poly- or copolyethylene terephthalate (PET or CoPET) or glycol-modified PET (PETG).
  • Particularly preferred materials are bisphenol A polycarbonate, copolycarbonates of bisphenol A and 1,1-bis (4-hydroxyphenyl) -3,3,5-trimethylcyclohexane, and poly- and methacrylates, in particular polymethyl methacrylate (PMMA).
  • PMMA polymethyl methacrylate
  • the wall thickness of the plastic disc is between 1 and 10 mm, in particular 2-7 mm.
  • the plastic disk may be both a one-component (1K) and a two-component (2K) component in which the transparent component is partially back-injected with a second plastic.
  • the first component is preferably made from a transparent thermoplastic, in particular from a polycarbonate or polymethyl methacrylate, and the second component is preferably made from a polycarbonate blend.
  • the coating has the task to protect the plastic disc both from environmental influences, such as UV radiation and other weathering caused by weathering, as well as against mechanical stress, for example against abrasion or scratches.
  • Glass-like surfaces for example plasma coatings, or commercially available scratch-resistant coatings, for example based on siloxane, polyurethane or acrylate, or combinations of these paints may be mentioned here.
  • the coatings are systems based on polysiloxane varnish, which can be both single-layered and multilayered (with a merely adhesion-promoting primer layer between substrate and polysiloxane topcoat). These are among others in US-A 4,278,804 . US-A 4,373,061 . US-A 4,410,594 .
  • the marginal fiber elongation determined in accordance with the DIN EN ISO 178 or ASTM-D 790-003 standards, should not exceed 2% in the component, preferably 1% and particularly preferably 0.5%.
  • the printing can be done for example with electrically conductive screen printing inks. These preferably have a sheet resistance that is less than 100 mOhm / sq / mil (determined by the four-point method). Providers of such colors are for example the company DuPont or the company Acheson.
  • the advantages of the method according to the invention are that it is very easy to perform, that no high investment costs for the system are necessary, and that the printing can be done at any time after production and before installation of the plastic disc. This makes the process simple, flexible, fast and cost-effective.
  • Areas of application are also generally in the area of curved 1K or 2K injection molded parts and thermoformed injection molded and extruded parts, e.g. in headlight and lamp covers and architectural glazing.
  • the method was tested on a three-dimensionally curved specimen measuring 1100 mm x 650 mm.
  • the component had a uniform wall thickness of 4.5 mm.
  • test specimen was produced from Makrolon AG2677 from Bayer MaterialScience AG by injection-compression molding and then coated on both sides with a paint system from the company Momentive Performance Materials (primer SHP 401 / paint AS4000).
  • a screen printing machine from the company Europa-Siebdruckmaschinen-Centrum, type ESC-AT-P semi-automatic for lithographic printing, was modified.
  • a frame-shaped steel element was attached to the motor-driven sieve frame lift.
  • the dimensions of the frame-shaped element were adapted to the size of the component, so that during the actual printing process, the specimen was pressed by the frame-shaped element circumferentially flat on the printing table. In this embodiment resulted by holding down an edge fiber elongation of 0.3%.
  • the three-dimensional specimen was placed with the curvature up on the printing table and positioned. Subsequently, the Siebrahmenhebung was moved vertically down and pressed the component by the attached frame-shaped element flat on the printing table. At the same time, vacuum holes in the printing table ensured that the component rests almost level. This was followed by the well-known from the prior art screen printing step. The screen frame elevation with the frame-shaped element was moved vertically after completion of the screen printing and the now free component could be removed. Finally, the component goes through a drying process to dry the screen printing ink.
  • the component was printed with a conductive screen printing ink from DuPont.
  • the printed image corresponded to a standard heating field of vehicle rear windows.
  • the layer thickness of the screen printing in order to increase the layer thickness of the screen printing and to improve the conductivity, printed on the same components in an analogous manner, and the printing step - sometimes even several times - repeated. For some of these samples, the intervening drying step was even omitted, so that the screen printing ink was printed "wet in wet” and finally dried.
  • the layer thicknesses of the screen printing ink could be applied with different thicknesses. In any case, a print sample of very good quality could be easily produced.

Abstract

The method involves deforming the sheets such that at the time of printing the sheets are flat or nearly flat, and full or partial surface coating of the three-dimensional curved plastic sheet of thermoplastic. The flat lying plastic sheet is printed by screen printing method.

Description

Die Erfindung betrifft ein Verfahren zur Herstellung von dreidimensional gekrümmten Kunststoffscheiben, welche mit aufgedruckten elektrischen Leitern versehen sind.The invention relates to a method for the production of three-dimensional curved plastic discs, which are provided with printed electrical conductors.

Um im Automobilbau das Karosseriegewicht zu reduzieren, werden z.B. Glasscheiben durch transparente Kunststoffscheiben ersetzt. Insbesondere sucht man dabei nach Lösungen, um Glasscheiben mit integrierten Heiz- und/oder Antennenelementen durch leichtere Kunststoffscheiben mit gleicher Funktion zu ersetzen.In order to reduce body weight in the automotive industry, e.g. Glass panes replaced by transparent plastic panes. In particular, they are looking for solutions to replace glass panes with integrated heating and / or antenna elements by lighter plastic discs with the same function.

Aus dem Stand der Technik sind Verfahren zur Herstellung von Kunststoffscheiben bekannt, in die elektrische Leiterstrukturen eingebettet werden.From the prior art methods for the production of plastic discs are known, are embedded in the electrical conductor structures.

So ist aus DE-A 101 47 537 ein Verfahren bekannt, bei dem elektrische Leiter einer Oberfläche einer Kunststofffolie zugeordnet werden, die anschließend mit einer weiteren Kunststoffschicht hinterspritzt oder hinterprägt wird, um einen Scheibenkörper zu bilden. Zum Verlegen der Drähte werden aus dem Stand der Technik bekannte Verfahren verwendet. Beispielsweise wird ein Verlegekopf über die Folienfläche geführt, der die Drähte unter leichtem Druck und mittels Wärme kontinuierlich in die Folienoberfläche eindrückt oder einsteppt. Der Nachteil dieses Verfahrens liegt darin, dass es vergleichsweise zeitaufwändig ist. Ein verbessertes Verfahren zur Einarbeitung der elektrischen Drähte wird in der WO 2006/105887 A beschrieben.That's how it is DE-A 101 47 537 a method is known in which electrical conductors are assigned to a surface of a plastic film, which is then back-injected with a further plastic layer or embossed to form a disk body. For laying the wires known methods are used from the prior art. For example, a laying head is guided over the surface of the film, which presses or presses the wires continuously under light pressure and by means of heat into the surface of the film. The disadvantage of this method is that it is relatively time consuming. An improved method of incorporating the electrical wires is disclosed in US Pat WO 2006/105887 A described.

In der US-A 5,525,401 wird ein Verfahren zur Herstellung eines Fahrzeugfensters aus Kunststoff offenbart, bei dessen Herstellung auf eine Oberfläche einer zunächst ebenen dünnen Kunststofffolie eine elektrisch leitfähige Struktur durch Siebdruck aufgebracht wird. Nach dem Aushärten des Siebdruckmusters, das auch einen opaken rahmenförmigen Randstreifen umfassen kann, wird die bedruckte Folie in eine Spritzgießform eingelegt, in der sie eine gekrümmte Raumform annehmen kann. Dann wird ihre bedruckte Seite mit einem Kunststoffsubstrat verbunden, das in die Form eingespritzt wird.In the US-A 5,525,401 discloses a method for producing a vehicle window made of plastic, in the production of which an electrically conductive structure is applied by screen printing to a surface of a first flat thin plastic film. After curing of the screen printing pattern, which may also include an opaque frame-shaped edge strip, the printed film is placed in an injection mold in which it can assume a curved spatial form. Then its printed side is bonded to a plastic substrate which is injected into the mold.

Durch diese Verfahren werden Produkte erhalten, deren leitfähige Strukturen zwischen Folie und dem Scheibenkörper eingekapselt und dadurch gegen Beschädigung gesichert sind, jedoch sind diese mehrstufigen Verfahren umfassend die Schritte Bedrucken oder Belegen von Folien und anschließendes Hinterspritzen relativ aufwändig. Auch steigen durch die Verwendung von Folien die Produktkosten, was für den Einsatz in der Automobil-Serienproduktion einen deutlichen Nachteil darstellt.By these methods, products are obtained whose conductive structures are encapsulated between the film and the disk body and thereby secured against damage, however, these multi-stage processes comprising the steps of printing on or covering of films and subsequent back molding are relatively complicated. Also increase by the use of films, the product cost, which represents a significant disadvantage for use in the automotive mass production.

Die US-A 2006/045120 beschreibt ein Verfahren und ein Fahrzeugfenster aus Kunststoff, bei dem ein elektrisch leitendes Material mittels einer Düse direkt auf die bereits geformte Scheibe aufgebracht wird. Die Düse ist an einem Roboter befestigt und fährt die gewünschten Struktur entlang der gekrümmten Oberfläche ab, die Position / der Abstand der Düse wird durch Sensoren exakt bestimmt. Der Einsatz einer Düse, die leitfähiges Material direkt auf die Scheibe aufbringt, ist zwar zielgerichtet, vorliegende Muster zeigen aber, dass die optische Qualität nicht zu bestehenden Systemen konkurrieren kann. Das aufgebrachte Material bildet eine unschöne Wulst und um die aufgebrachte Struktur befindet sich ein Sprühnebel - beides lässt sich bis zum jetzigen Zeitpunkt verfahrenstechnisch nicht vermeiden. Weiterhin ist dieses Verfahren sehr zeitaufwändig, die Düse muss die komplette Struktur entlang der Oberfläche abfahren.The US-A 2006/045120 describes a method and a vehicle window made of plastic, in which an electrically conductive material is applied by means of a nozzle directly on the already shaped disc. The nozzle is attached to a robot and travels the desired structure along the curved surface, the position / distance of the nozzle is determined by sensors exactly. Although the use of a nozzle, which applies conductive material directly to the pane, is purposeful, existing patterns show that the optical quality can not compete with existing systems. The applied material forms an unsightly bead and there is a spray around the applied structure - both can not be avoided up to now. Furthermore, this process is very time consuming, the nozzle must drive off the complete structure along the surface.

Aus dem Stand der Technik ergibt sich die Notwendigkeit, ein vereinfachtes und kostengünstiges Verfahren zur Herstellung einer bedruckten, dreidimensional gekrümmten Kunststoffscheibe bereitzustellen. Insbesondere soll ein Verfahren bereitgestellt werden, mit dem sich elektrisch leitende Heiz- und/oder Antennenelementen auf einfachste Weise aufdrucken lassen.From the prior art, there is a need to provide a simplified and inexpensive method for producing a printed, three-dimensionally curved plastic disc. In particular, a method is to be provided with which electrically conductive heating and / or antenna elements can be imprinted in the simplest manner.

Kernelement des erfindungsgemäßen Verfahrens ist es, die dreidimensional gekrümmte Kunststoffscheibe für die Dauer des Druckverfahrens durch die Ausübung von Druck oder Zug so zu verformen, dass sie eben oder annähernd eben ist.Core element of the method according to the invention is to deform the three-dimensional curved plastic disc for the duration of the printing process by the exercise of pressure or train so that it is flat or approximately flat.

In einer Ausführungsform umfasst das erfmdungsgemäße, vereinfachte Verfahren zur Herstellung einer bedruckten dreidimensional gekrümmten Kunststoffscheibe die folgenden Schritte:

  1. a) Vollflächige oder teilflächige Beschichtung einer dreidimensional gekrümmten Kunststoffscheibe aus thermoplastischem Kunststoff
  2. b) Verformen der kompletten Fläche der dreidimensional gekrümmten Kunststoffscheibe oder einer Teilfläche der Scheibe, so dass diese eine ebene oder nahezu ebene Fläche bildet
  3. c) Bedrucken der flach liegenden Kunststoffscheibe mittels Siebdruckverfahren
  4. d) Entlasten der Scheibe und Aushärten des Siebdruckmusters
In one embodiment, the simplified method according to the invention for producing a printed three-dimensionally curved plastic disk comprises the following steps:
  1. a) Full-surface or partial coating of a three-dimensionally curved plastic disc made of thermoplastic material
  2. b) deforming the entire surface of the three-dimensionally curved plastic disc or a partial surface of the disc, so that it forms a flat or nearly flat surface
  3. c) printing the flat plastic disc by screen printing
  4. d) Relieving the disc and curing the screen printing pattern

Die Kunststoffscheibe kann im Spritzgieß- oder im Thermoformverfahren hergestellt werden. In Schritt a) wird diese dreidimensional gekrümmte Kunststoffscheibe dann vollflächig / teilflächig beschichtet. Die Beschichtung gewährleistet die Kratzfestigkeit und die Witterungsstabilität der Kunststoffscheibe.The plastic disc can be produced by injection molding or thermoforming. In step a), this three-dimensionally curved plastic disk is then coated over the entire surface / part of the area. The coating ensures the scratch resistance and the weather resistance of the plastic disc.

In Schritt b) wird die Kunststoffscheibe, die optional vorhergehend im Schritt a) beschichtet wurde, verformt: Dazu wird beispielsweise die dreidimensional gekrümmte Kunststoffscheibe umlaufend mittels eines rahmenförmigen Elements auf eine ebene Fläche, beispielsweise einen ebenen Arbeitstisch, gedrückt. Ebenso ist es möglich, die Scheibe durch Ansaugen mit Vakuum auf der zum Druck rückwärtigen Seite der Scheibe zu verformen, wodurch die Notwendigkeit des Drückens mit dem rahmenförmigen Element entfällt. Statt der kompletten Scheibe kann auch nur eine Teilfläche angedrückt werden.In step b), the plastic disk, which was optionally previously coated in step a), deformed: For this purpose, for example, the three-dimensionally curved plastic disk circumferentially by means of a frame-shaped element on a flat surface, such as a flat work table, pressed. Likewise, it is possible to deform the disc by suction with vacuum on the rearward to the pressure side of the disc, whereby the need for pressing with the frame-shaped element is eliminated. Instead of the complete disc, only a partial surface can be pressed.

Die nun auf einer Ebene flach anliegende Kunststoffscheibe wird im Schritt c) bedruckt, z.B. mittels Siebdruckverfahren.The plastic disk now lying flat on a plane is printed in step c), e.g. by screen printing process.

Vorzugsweise handelt es sich bei den Druckfarben um elektrisch leitende Siebdruckfarben, wodurch Leiterbahnen aufgedruckt werden, die beispielsweise als Heizelemente oder Antennen genutzt werden können.The printing inks are preferably electrically conductive screen printing inks, whereby printed circuit traces are printed, which can be used, for example, as heating elements or antennas.

Im Schritt d) lässt man die Scheibe durch Entfernen des Drucks bzw. des Sogs entlasten und das Siebdruckmuster aushärten.In step d), the disc is relieved by removing the pressure or the suction and curing the screen printing pattern.

Gegebenfalls können die in Schritt b), c) und d) beschriebenen Prozessschritte beliebig oft wiederholt werden, um andere (Sieb)druckmuster zu drucken und/oder mit anderen (Sieb)druckfarben zu bedrucken. Beispielsweise kann um die aufgedruckten Leiterbahnen noch ein rahmenförmiges Siebdruckmuster aufgedruckt werden, oder es kann noch Druck aufgebracht werden, um die elektrischen Leiterbahnen abzudecken und zu schützen. Es ist natürlich auch möglich, vor dem eigentlichen Bedrucken oder auch anstatt des Bedruckens mit den elektrisch leitfähigen Siebdruckfarben das Bauteil auf die gleiche Weise mit anderen Farben oder Strukturen bedrucken, beispielsweise zu Dekorzwecken.Optionally, the process steps described in step b), c) and d) can be repeated as often as desired in order to print other (screen) printing patterns and / or to print with other (screen) printing inks. For example, a frame-shaped screen print pattern can still be printed around the printed strip conductors, or pressure can still be applied to cover and protect the electrical strip conductors. Of course, it is also possible to print the component in the same way with other colors or structures, for example for decorative purposes, before the actual printing or also instead of printing with the electrically conductive screen printing inks.

In einer weiteren Ausführungsform wird Schritt a), die Beschichtung der Kunststoffscheibe, erst im Anschluss an das Bedrucken wie in b) - d) beschrieben, durchgeführt. Das Bauteil kann nach der Bedruckung vollflächig oder teilflächig beschichtet werden.In a further embodiment, step a), the coating of the plastic disk, is carried out only after the printing as described in b) - d). The component can be coated over the entire surface or partial area after printing.

Die Kunststoffscheibe wird aus einem thermoplastischen Kunststoff gefertigt. Je nach Anforderung können transparente oder transluzente Thermoplaste eingesetzt werden. Als Thermoplasten eignen sich z.B. Polycarbonate oder Copolycarbonate auf Basis von Diphenolen, der Poly- oder Copolyacrylate und Poly- oder Copolymethacrylate, vorzugsweise Polymethylmethacrylat, Poly- oder Copolymere mit Styrol, vorzugsweise transparentes Polystyrol oder Polystyrolacrylnitril (SAN), transparente thermoplastische Polyurethane, sowie Polyolefine, vorzugsweise transparente Polypropylentypen, oder Polyolefine auf der Basis von cyclischen Olefinen (z.B. TOPAS®, Ticona), Poly- oder Copolykondensate der Terephthalsäure, vorzugsweise Poly- oder Copolyethylenterephthalat (PET oder CoPET) oder glycol-modifiziertes PET (PETG). Besonders bevorzugte Materialien sind Bisphenol-A-polycarbonat, Copolycarbonate aus Bisphenol-A und 1,1-Bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexan, sowie Poly- und Comethylmethacrylate, insbesondere Polymethylmethacrylat (PMMA).The plastic disc is made of a thermoplastic material. Depending on the requirements, transparent or translucent thermoplastics can be used. Suitable thermoplastics are, for example, polycarbonates or copolycarbonates based on diphenols, poly- or copolyacrylates and poly- or copolymers of copolymethacrylate, preferably polymethylmethacrylate, poly- or copolymers with styrene, preferably transparent polystyrene or polystyrene-acrylonitrile (SAN), transparent thermoplastic polyurethanes, and also polyolefins. preferably transparent polypropylene types, or polyolefins based on cyclic olefins (for example, TOPAS ®, Ticona), poly- or copolycondensates of terephthalic acid, preferably poly- or copolyethylene terephthalate (PET or CoPET) or glycol-modified PET (PETG). Particularly preferred materials are bisphenol A polycarbonate, copolycarbonates of bisphenol A and 1,1-bis (4-hydroxyphenyl) -3,3,5-trimethylcyclohexane, and poly- and methacrylates, in particular polymethyl methacrylate (PMMA).

Die Wanddicke der Kunststoffscheibe liegt zwischen 1 und 10 mm, insbesondere 2 - 7 mm. Bei der Kunststoffscheibe kann es sich sowohl um ein Einkomponenten (1K) - als auch um ein Zweikomponenten (2K) - Bauteil handeln, bei dem die transparente Komponente teilweise mit einem zweiten Kunststoff hinterspritzt ist.The wall thickness of the plastic disc is between 1 and 10 mm, in particular 2-7 mm. The plastic disk may be both a one-component (1K) and a two-component (2K) component in which the transparent component is partially back-injected with a second plastic.

Handelt es sich bei der Kunststoffscheibe um ein 2K - Bauteil, so ist die erste Komponente bevorzugt aus einem transparenten Thermoplasten, insbesondere aus einem Polycarbonat oder Polymethylmethacrylat, und die zweite Komponente bevorzugt aus einem Polycarbonat - Blend.If the plastic disk is a 2K component, the first component is preferably made from a transparent thermoplastic, in particular from a polycarbonate or polymethyl methacrylate, and the second component is preferably made from a polycarbonate blend.

Die Beschichtung hat die Aufgabe, die Kunststoffscheibe sowohl vor Umwelteinflüssen, wie z.B. UV-Einstrahlung und andere durch Bewitterung hervorgerufene Belastungen, als auch gegen mechanische Belastungen, z.B. gegen Abrieb oder Kratzer, zu schützen. Hier sind beispielsweise glasähnliche Oberflächen, z.B. Plasmabeschichtungen, oder handelsübliche Kratzfestlacke, z.B. auf Siloxan-, Polyurethan- oder Acrylatbasis, oder Kombinationen dieser Lacke zu nennen. In einer bevorzugten Ausführungsform handelt es sich bei den Beschichtungen um Systeme auf Basis Polysiloxanlack, die sowohl einschichtig als auch mehrschichtig (mit einer lediglich haftvermittelnden Primerschicht zwischen Substrat und Polysiloxandecklack) sein können. Diese sind u. a. in US-A 4,278,804 , US-A 4,373,061 , US-A 4,410,594 , US-A 5,041,313 und EP-A-1 087 001 beschrieben. Beispielhaft sind hier die kommerziell erhältlichen Systeme der Momentive Performance Materials Inc. Wilton, CT USA wie PHC 587; PHC 587B, PHC 587C; SHP 401 (Primer) / AS 4000 (Topcoat) oder auch SHP 401 (Primer) / AS 4002 (Topcoat) erwähnt sowie KASI Flex® oder Sun Flex®, beide von KRD Coatings, Geesthacht, Deutschland, oder Silvue® MP 100, SDC Coatings, Deutschland, oder Sicralan® MRL von GFO, Schwäbisch Gmünd, Deutschland.The coating has the task to protect the plastic disc both from environmental influences, such as UV radiation and other weathering caused by weathering, as well as against mechanical stress, for example against abrasion or scratches. Glass-like surfaces, for example plasma coatings, or commercially available scratch-resistant coatings, for example based on siloxane, polyurethane or acrylate, or combinations of these paints may be mentioned here. In a preferred embodiment, the coatings are systems based on polysiloxane varnish, which can be both single-layered and multilayered (with a merely adhesion-promoting primer layer between substrate and polysiloxane topcoat). These are among others in US-A 4,278,804 . US-A 4,373,061 . US-A 4,410,594 . US-A 5,041,313 and EP-A-1 087 001 described. Exemplary here are the commercially available systems of Momentive Performance Materials Inc. Wilton, CT USA as PHC 587; PHC 587B, PHC 587C; SHP 401 (primer) / AS 4000 (topcoat) or SHP 401 (primer) / AS 4002 (topcoat) mentioned and KASI Flex ® or Sun Flex ®, both ® from KRD Coatings, Geesthacht, Germany, or Silvue MP 100, SDC Coatings, Germany, or Sicralan ® MRL from GFO, Schwabisch Gmund, Germany.

Während des Niederhaltens der Scheibe sollte die Randfaserdehnung, nach den Normen DIN EN ISO 178 bzw. ASTM-D 790-003 bestimmt, im Bauteil im Höchstfall 2%, bevorzugt 1 % und besonders bevorzugt 0,5% nicht überschreiten.During hold-down of the pane, the marginal fiber elongation, determined in accordance with the DIN EN ISO 178 or ASTM-D 790-003 standards, should not exceed 2% in the component, preferably 1% and particularly preferably 0.5%.

Die Bedruckung kann beispielsweise mit elektrisch leitenden Siebdruckfarben erfolgen. Diese haben vorzugsweise einen Flächenwiderstand, der geringer ist als 100 mOhm/sq/mil (bestimmt mittels der Vier-Punkt-Methode). Anbieter solcher Farben sind zum Beispiel die Fa. DuPont oder die Fa. Acheson.The printing can be done for example with electrically conductive screen printing inks. These preferably have a sheet resistance that is less than 100 mOhm / sq / mil (determined by the four-point method). Providers of such colors are for example the company DuPont or the company Acheson.

Die Vorteile des erfindungsgemäßen Verfahrens bestehen darin, dass es sehr einfach durchzuführen ist, dass keine hohen Investitionskosten für die Anlage notwendig sind, und dass das Bedrucken zu einer beliebigen Zeit nach Herstellung und vor Einbau der Kunststoffscheibe erfolgen kann. Dadurch ist das Verfahren einfach, flexibel, schnell und kostengünstig.The advantages of the method according to the invention are that it is very easy to perform, that no high investment costs for the system are necessary, and that the printing can be done at any time after production and before installation of the plastic disc. This makes the process simple, flexible, fast and cost-effective.

Für die so hergestellten, bedruckten und dreidimensional gekrümmten Kunststoffscheiben ist eine Vielzahl von Anwendungen denkbar. Die Vorteile des Verfahrens können natürlich besonders gut bei Automobilverscheibungen ausgenutzt werden, insbesondere Heckverscheibungen und Fahrzeugscheinwerferabdeckungen, bei denen die aufgedruckten elektrisch leitfähigen Strukturen Defroster- / Heizelemente oder Antennen darstellen. Die elektrischen Leiter als Heizeinrichtung sind zweckmäßigerweise mit geeigneten Sensoren und einer geeigneten Regelungselektronik verknüpft, um die Leistungsaufnahme der Heizeinrichtung automatisch zu regeln und mit dem jeweiligen Belastungszustand des Bordnetzes abzustimmen.For the thus produced, printed and three-dimensionally curved plastic discs a variety of applications is conceivable. Of course, the advantages of the method can be exploited particularly well in automobile glazing, in particular rear glazing and vehicle headlight covers, in which the printed electrically conductive structures represent defroster / heating elements or antennas. The electrical conductors as a heater are expediently associated with suitable sensors and a suitable control electronics to automatically regulate the power consumption of the heater and vote with the respective load condition of the electrical system.

Anwendungsbereiche fmden sich auch insgesamt im Bereich von gekrümmten 1K- bzw. 2K-Spritzgussteilen und thermogeformten Spritzguss- und Extrusionsbauteilen, wie z.B. in Scheinwerfer- und Lampenabdeckscheiben und Architekturverscheibungen.Areas of application are also generally in the area of curved 1K or 2K injection molded parts and thermoformed injection molded and extruded parts, e.g. in headlight and lamp covers and architectural glazing.

Ausführungsbeispieleembodiments

Das Verfahren wurde an einem dreidimensional gekrümmten Probekörper mit den Abmessungen 1100 mm x 650 mm erprobt. Die Krümmungsradius der Bauteilfläche betrug in Längsrichtung R1 = 14900 mm und in Querrichtung R2 = 5800 mm, es handelte sich somit um eine gewölbte Bauteilfläche. Das Bauteil hatte eine gleichmäßige Wanddicke von 4,5 mm.The method was tested on a three-dimensionally curved specimen measuring 1100 mm x 650 mm. The radius of curvature of the component surface was in the longitudinal direction R 1 = 14900 mm and in the transverse direction R 2 = 5800 mm, thus it was a curved component surface. The component had a uniform wall thickness of 4.5 mm.

Der Probekörper wurde aus Makrolon AG2677 der Fa. Bayer MaterialScience AG im Spritzprägeverfahren hergestellt und anschließend mit einem Lacksystem der Fa. Momentive Perfomance Materials (Primer SHP 401 / Lack AS4000) beidseitig beschichtet.The test specimen was produced from Makrolon AG2677 from Bayer MaterialScience AG by injection-compression molding and then coated on both sides with a paint system from the company Momentive Performance Materials (primer SHP 401 / paint AS4000).

Um den Siebdruck auf den dreidimensional gekrümmten Probekörper aufzubringen, wurde eine Siebdruckmaschine der Firma Europa-Siebdruckmaschinen-Centrum, Typ ESC-AT-P Halbautomat für den Flachdruck, modifiziert. Ergänzend zur bestehenden Maschine wurde ein rahmenförmiges Element aus Stahl an die motorisch angetriebene Siebrahmenhebung befestigt. Die Dimensionen des rahmenförmigen Elements wurden an die Größe des Bauteils angepasst, so dass während des eigentlichen Druckvorgangs der Probekörper durch das rahmenförmige Element umlaufend flach auf den Drucktisch gepresst wurde. Bei diesem Ausführungsbeispiel ergab sich durch das Niederhalten eine Randfaserdehnung von 0,3 %.In order to apply the screen printing to the three-dimensionally curved test specimen, a screen printing machine from the company Europa-Siebdruckmaschinen-Centrum, type ESC-AT-P semi-automatic for lithographic printing, was modified. In addition to the existing machine, a frame-shaped steel element was attached to the motor-driven sieve frame lift. The dimensions of the frame-shaped element were adapted to the size of the component, so that during the actual printing process, the specimen was pressed by the frame-shaped element circumferentially flat on the printing table. In this embodiment resulted by holding down an edge fiber elongation of 0.3%.

Beim eigentlichen Druckvorgang wurde der dreidimensionale Probekörper mit der Wölbung nach oben auf den Drucktisch gelegt und positioniert. Anschließend wurde die Siebrahmenhebung vertikal nach unten gefahren und das Bauteil durch das daran befestigte rahmenförmige Element flach auf den Drucktisch gedrückt. Parallel sorgten im Drucktisch befindliche Vakuumbohrungen dafür, dass das Bauteil nahezu eben aufliegt. Anschließend erfolgte der aus dem Stand der Technik hinlänglich bekannte Siebdruckschritt. Die Siebrahmenhebung mit dem rahmenförmigen Element wurde nach Abschluss des Siebdrucks vertikal nach oben gefahren und das nun freie Bauteil konnte entnommen werden. Abschließend durchläuft das Bauteil einen Trocknungsprozess, um die Siebdruckfarbe zu trocknen.During the actual printing process, the three-dimensional specimen was placed with the curvature up on the printing table and positioned. Subsequently, the Siebrahmenhebung was moved vertically down and pressed the component by the attached frame-shaped element flat on the printing table. At the same time, vacuum holes in the printing table ensured that the component rests almost level. This was followed by the well-known from the prior art screen printing step. The screen frame elevation with the frame-shaped element was moved vertically after completion of the screen printing and the now free component could be removed. Finally, the component goes through a drying process to dry the screen printing ink.

Im beschriebenen Falle wurde das Bauteil mit einer leitfähigen Siebdruckfarbe der Fa. DuPont bedruckt. Das Druckbild entsprach einem Standard-Heizfeld von Fahrzeugheckscheiben.In the case described, the component was printed with a conductive screen printing ink from DuPont. The printed image corresponded to a standard heating field of vehicle rear windows.

In weiteren Ausführungsbeispielen wurden, um die Schichtdicke des Siebdrucks zu erhöhen und die Leitfähigkeit zu verbessern, an gleichen Bauteilen auf analoge Weise bedruckt, und der Druckschritt - teilweise sogar mehrfach - wiederholt. Bei einigen dieser so erstellten Muster, wurde auf den dazwischen liegenden Trocknungsschritt sogar verzichtet, so dass die Siebdruckfarbe "wet in wet" gedruckt und erst abschließend getrocknet wurde. Je nach Kombination der Druck- und Trocknungsschritte konnten die Schichtdicken der Siebdruckfarbe unterschiedlich dick aufgetragen werden. In jedem Fall konnte auf einfache Weise ein Druckmuster sehr guter Qualität hergestellt werden.In further embodiments, in order to increase the layer thickness of the screen printing and to improve the conductivity, printed on the same components in an analogous manner, and the printing step - sometimes even several times - repeated. For some of these samples, the intervening drying step was even omitted, so that the screen printing ink was printed "wet in wet" and finally dried. Depending on the combination of the printing and drying steps, the layer thicknesses of the screen printing ink could be applied with different thicknesses. In any case, a print sample of very good quality could be easily produced.

Claims (15)

Verfahren zur Herstellung einer bedruckten dreidimensional gekrümmten Kunststoffscheibe aus thermoplastischem Kunststoff, dadurch gekennzeichnet, dass während der Dauer der Bedruckung die Scheibe so verformt wird, dass sie eben oder annähernd eben ist.A process for producing a printed three-dimensionally curved plastic disc made of thermoplastic material, characterized in that during the printing period, the disc is deformed so that it is flat or approximately flat. Verfahren gemäß Anspruch 1, umfassend die folgenden Schritte: a) Vollflächige oder teilflächige Beschichtung einer dreidimensional gekrümmten Kunststoffscheibe aus thermoplastischem Kunststoff b) Verformen der kompletten Fläche der dreidimensional gekrümmten Kunststoffscheibe oder einer Teilfläche der Scheibe, so dass diese eine ebene oder nahezu ebene Fläche bildet c) Bedrucken der flach liegenden Kunststoffscheibe mittels Siebdruckverfahren d) Entlasten der Scheibe und Aushärten des Siebdruckmusters Method according to claim 1, comprising the following steps: a) Full-surface or partial coating of a three-dimensionally curved plastic disc made of thermoplastic material b) deforming the entire surface of the three-dimensionally curved plastic disc or a partial surface of the disc, so that it forms a flat or nearly flat surface c) printing the flat plastic disc by screen printing d) Relieving the disc and curing the screen printing pattern Verfahren gemäß Anspruch 2, dadurch gekennzeichnet, dass die Schritte b - d) mehrfach wiederholt werden.A method according to claim 2, characterized in that the steps b - d) are repeated several times. Verfahren gemäß Anspruch 2 oder 3, dadurch gekennzeichnet, dass Schritt a) erst nach den Schritten b - d) oder einer mehrfachen Wiederholung der Schritte b - d) durchgeführt wird.Method according to claim 2 or 3, characterized in that step a) is carried out only after the steps b-d) or a repeated repetition of the steps b-d). Verfahren gemäß einem der Ansprüche 2-4, dadurch gekennzeichnet, dass die Verformung durch Drücken auf eine ebene Fläche mit einem rahmenförmigen Element erfolgt.Method according to one of claims 2-4, characterized in that the deformation takes place by pressing on a flat surface with a frame-shaped element. Verfahren gemäß einem der Ansprüche 2 - 4, dadurch gekennzeichnet, dass die Verformung der Scheibe durch Ansaugen mit Vakuum auf der zum Druck rückwärtigen Seite der Scheibe erfolgt.A method according to any one of claims 2-4, characterized in that the deformation of the disc takes place by suction with vacuum on the pressure to the rear side of the disc. Verfahren gemäß einem der Ansprüche 2 - 4, dadurch gekennzeichnet, dass die Verformung der Scheibe durch Ansaugen mit Vakuum auf der zum Druck rückwärtigen Seite der Scheibe und durch Drücken auf eine ebene Fläche mit einem rahmenförmigen Element erfolgt.A method according to any one of claims 2-4, characterized in that the deformation of the disc takes place by suction with vacuum on the rearward to the pressure side of the disc and by pressing on a flat surface with a frame-shaped element. Verfahren gemäß einem der Ansprüche 1 - 7, dadurch gekennzeichnet, dass die die Bedruckung zum Aufdrucken von elektrischen Leiterbahnen und / oder Dekorzwecken erfolgt.Method according to one of claims 1-7, characterized in that the printing takes place for printing on electrical conductor tracks and / or decorative purposes. Verfahren nach einem der Ansprüche 1 und 2, dadurch gekennzeichnet, dass die Kunststoffscheibe durch Spritzgießen, Spritzprägen oder Thermoformen hergestellt wurde.Method according to one of claims 1 and 2, characterized in that the plastic disc was produced by injection molding, injection compression molding or thermoforming. Verfahren nach Anspruch 9, dadurch gekennzeichnet, dass die thermoplastische Kunststoffscheibe aus einem transparenten Thermoplasten, insbesondere aus einem Polycarbonat oder Polymethylmethacrylat ist.A method according to claim 9, characterized in that the thermoplastic resin disc is made of a transparent thermoplastic, in particular of a polycarbonate or polymethylmethacrylate. Verfahren nach Anspruch 9, dadurch gekennzeichnet, dass die Kunststoffscheibe im Zweikomponentenspritzguss hergestellt wurde.A method according to claim 9, characterized in that the plastic disc was produced by two-component injection molding. Verfahren nach Anspruch 11, dadurch gekennzeichnet, dass die thermoplastische Kunststoffscheibe aus einem transparenten Thermoplasten, insbesondere aus einem Polycarbonat oder Polymethylmethacrylat ist und die zweite Komponente ein Polycarbonat-Blend ist.A method according to claim 11, characterized in that the thermoplastic resin disc is made of a transparent thermoplastic, in particular of a polycarbonate or polymethylmethacrylate and the second component is a polycarbonate blend. Verfahren nach Anspruch 9, dadurch gekennzeichnet, dass die Kunststoffscheibe 1 - 10 mm, insbesondere 2 - 7 mm dick ist.A method according to claim 9, characterized in that the plastic disc is 1 - 10 mm, in particular 2 - 7 mm thick. Bedruckte, dreidimensional gekrümmte thermoplastische Kunststoffscheiben, hergestellt durch das Verfahren gemäß Anspruch 1 oder 2.Printed, three-dimensionally curved thermoplastic sheet produced by the method according to claim 1 or 2. Automobilverscheibungen, Architekturverscheibungen, Scheinwerferabdeckscheiben enthaltend eine bedruckte, dreidimensional gekrümmte thermoplastische Kunststoffscheibe gemäß Anspruch 14.Automobile glazings, architectural glazings, headlight cover panes containing a printed, three-dimensionally curved thermoplastic resin pane according to claim 14.
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