DE102018208717A1 - Vehicle trim element - Google Patents

Abstract

The invention relates to a vehicle cladding element, comprising: a cover layer (1) having a front side (1a) and a back side (1b), an illumination layer (4, 14, 24) on the back side of the cover layer, a transparent spacer layer ( 3, 13, 23) disposed between the illumination layer (4, 14, 24) and the cap layer, and a mask layer (2) having a pattern of through holes (2a), the mask layer having a light absorption of more than 90% in areas outside the through-holes and disposed between the cover layer (1) and the transparent spacer layer (3, 13, 23), the illumination layer (4, 14, 24) having light-guiding elements (4a), the illumination layer comprising or being a tissue fixedly is fixed to the transparent spacer layer (3, 13, 23), the mask layer (2) on the back side (1b) of the cover layer or on the side of the transparent spacer layer (3, 13, 23) adjacent to the Cover layer is adjacent, fixed, the mask layer has a thickness which is smaller than 10% of the thickness of the cover layer, and the cover layer is transparent and has a light absorption between 50% and 90%.

Description

The present invention relates to a vehicle trim element for backlighting and to a method of manufacturing such a vehicle trim element. Such trim elements are commonly used to cover a dashboard in a motor vehicle or to cover the interior surface of vehicle doors or other elements of the interior of a vehicle. More recently, covers have been developed that allow backlighting.

FR 2 920 717 A1 discloses a trim element with a backlight having a specific sequence of different layers.

US 2015/0210226 A1 discloses a vehicle trim element characterized by a panel having at least one colored mask enabling colored and textured backlighting.

One of the objects of the invention is to propose a vehicle trim element that allows backlighting, is easy to manufacture and easy to use. To achieve these objects, the invention proposes a vehicle cladding element comprising: a cover layer having a front side and a back side, an illumination layer on the back side of the cover layer, a transparent spacer layer disposed between the illumination layer and the cover layer, and a mask layer with a pattern of through holes, wherein the mask layer has a light absorption of more than 90% in areas outside the through holes and is interposed between the cover layer and the transparent spacer layer, the illumination layer having light guide elements, the illumination layer having or being a tissue fixedly attached the transparent spacer layer is fixed, the mask layer is fixed to the back side of the cover layer or the side of the transparent spacer layer which is adjacent to the cover layer, the mask layer has a thickness smaller than 10% de r is the thickness of the cover layer, and the cover layer is transparent and has a light absorption between 50% and 90%. In some embodiments, the cladding element includes a panel having the cover layer, the illumination layer, the transparent spacer layer, and the mask layer.

By combining optical fiber elements, typically optical fiber fibers for illumination in an illumination layer comprising or having a tissue and being fixedly secured to the transparent spacer layer, a mechanically very stable base layer is formed for the cladding element. By attaching the illumination layer, which has or is a fabric, to the spacer layer, this combined layer can be easily cut and sewn to other underlying elements. The illumination layer can be easily attached to the transparent spacer layer by an adhesive or by some other combination of the two layers by material engagement. For example, the fabric of the illumination layer may be brought into engagement with the transparent spacer layer when the latter is still at least partially in a liquid or molten state before it solidifies. Also, the transparent spacer layer may be molded, printed or applied to the illumination layer.

An implementation of the invention may reveal that the illumination layer comprises a flexible fabric in which a plurality of optical fibers are woven. By weaving optical fibers into a flexible fabric, a comprehensive, mechanically stable illumination layer is created. The flexible fabric may act as a light scattering medium to obtain a uniformly distributed illumination density.

Another implementation of the invention may provide that the illumination layer and the transparent spacer layer form a composite layer in which the illumination layer and the transparent spacer layer are a single layer. A respective compound layer may be formed by any of the processes discussed above and may provide homogeneous illumination of the mask layer without individual light sources being visible through the mask layer.

The invention may also be implemented by a configuration in which the top layer has on its front side a grained surface with a surface roughness between 20 and 200 microns Ra, d. h., arithmetically mean deviation from an assumed profile. This type of top layer mechanically protects the front against scratching. Also, when a scratch is generated, its optical effect is restricted, and the scratch does not catch the eye.

In an advantageous embodiment of the cladding element, the cover layer has two layers with different optical properties. These layers can be arranged one above the other. The layers on the front side of the cover layer may have the grained surface. In addition, the layer on the Rear, that is, the layer which is disposed between the grained layer and the mask layer, have a uniform thickness. The grained surface layer can exhibit high optical transmissivity with optical absorption in the visual range of the electromagnetic spectrum being less than 95%. The backside layer may have a lower optical transmission with an optical absorption in the visual range of the electromagnetic spectrum that is between 50% and 90%. An advantage of such an embodiment is that it allows the cover layer to be optimized with respect to the optical appearance and less prone to mechanical damage such as scratches.

It may also be provided that the transparent spacer layer has inhomogeneities which scatter the light. These inhomogeneities create a uniformly distributed light density from the illumination layer before the light reaches the mask layer.

This can be implemented by a configuration in which the inhomogeneities in the volume of the transparent spacer layer are distributed with a homogeneous volume density.

The inhomogeneities in the transparent spacer layer may also be implemented by a configuration in which the inhomogeneities in the volume of the transparent spacer layer are distributed with a density gradient. A density gradient of the inhomogeneities may be the result of a method of manufacturing the transparent spacer layer, and may also be advantageous in providing a particularly evenly distributed light density.

For example, it may be the case that the transparent spacer layer has a solid layer with a thickness between 0.2 and 0.5 mm. The rigidity of such a transparent spacer layer is large enough to provide a stable base for the cladding layer, and on the other hand, the bending radius of the cladding element having such a spacer layer may be, for example, about 10 mm, which is small enough Adjust the cladding element to different shaped surfaces.

In the case that the transparent spacer layer comprises a solid layer, for example of polyvinyl chloride, for example foamed PVC plastisol, it may be provided that the inhomogeneities are bubbles. These bubbles may be air bubbles or bubbles of other gas trapped in the solid material of the transparent spacer layer, the bubbles being formed by a propellant. By choosing the precise time during the manufacturing process and the temperature at which the blowing agent is supplied to the transparent spacer layer, a density gradient of the bubbles can be created.

The inhomogeneities can also be realized in the form of a two-component layer in which the two components are demixed so that one of the components forms a continuous matrix and the other component forms "bubbles" in this matrix. Preferably, both components are plastics having a different optical refractive index.

It can also be provided that the transparent spacer layer is a polyester fabric with a thickness between 1 and 3 mm. In this case, the transparent spacer layer is more flexible than a solid layer, and the bending radius of the cladding element may be less than 10 mm. The tissue of the transparent spacer layer may be interwoven with the illumination layer, or the illumination layer may be formed within the transparent spacer layer by interweaving optical fibers into the tissue of the transparent spacer layer on one side of the transparent spacer layer.

It is also to be noted that the mask layer on the back side of the cover layer or on the transparent spacer layer is preferably formed by printing a pattern with openings on one or each of the cover layer and the transparent spacer layer. The material of the ink printed as a mask layer may have a thickness of less than 50 micrometers. The mechanical properties of the ink should be appropriate, in terms of aging, adhesion and process, for the ink to be printed on the topcoat or transparent spacer layer. For example, the ink should be suitable for printing on soft PVC or on polyurethane (PU). The ink may be a water-based ink, but may also be a solvent-based ink when greater mechanical flexibility is required.

It is also to be mentioned that the cover layer can be quite soft. For example, the topcoat may have a hardness of less than 70 shore D or even less than 30 shore D.

The application further relates to a method of manufacturing the vehicle trim element discussed above or below. In this method is a Release layer having a grained, non-stick surface provided. Furthermore, a semi-finish element is prepared by: (a) applying the cover layer to the grained, non-adhesive surface, (b) applying the mask layer to the cover layer, and (c) applying the transparent spacer layer to the mask layer. In a further step, the illumination layer is fixed to the transparent spacer layer. Furthermore, the release layer is separated from the Semiverkleidungselement.

Features discussed above or below with respect to the vehicle trim element may be applied in the method of manufacturing a vehicle trim element and vice versa.

• 1 ein Verkleidungselement mit einer Deckschicht auf einer festen transparenten Abstandshalterschicht,
• 2 eine Deckschicht auf einer transparenten Abstandshalterschicht aus einem Polyestergewebe, und
• 3 ein Verkleidungselement mit einer Deckschicht auf einer transparenten Abstandshalterschicht kombiniert mit einer Beleuchtungsschicht.

Particular embodiments of the invention are shown in the accompanying drawings and discussed in detail below. In the drawings show

• 1 a cladding element having a cover layer on a solid transparent spacer layer,
• 2 a cover layer on a transparent spacer layer of a polyester fabric, and
• 3 a cladding element having a cover layer on a transparent spacer layer combined with a lighting layer.

1 shows a cross-sectional view of the trim element, which can be used to cover interior elements and surfaces in a vehicle. The cladding element has a cover layer 1 with a front side 1a and a back 1b on. The cover layer may be made of a material, for example polyurethane in a solid-shaped form or in the form of a foam. The cover layer can also comprise or consist of PVC. The cover layer can have a light absorption between 50% and 90% and can be colored through. The cover layer 1 can be a grained surface 1c have and can be elastically deformable. The grained surface area 1c the topcoat 1 can with an underlying solid layer of the same material 1d combined, wherein the underlying massive layer can have a thickness between 0 and 0.7 mm. In the case where the cover layer consists of two different layers, the grained layer on the front side of the cover layer preferably has a lower light absorption than the underlying layer which is arranged between the grained layer and the mask layer. Such a composition of the cover layer is advantageous because any mechanical damage to the surface hardly affect the visual appearance of the cladding element.

On the back of the topcoat 1 is a pattern 2 from ink areas or a full ink layer with through-holes created by printing liquid ink on the back. The thickness of the ink layer 2 may be less than 100 microns, or more preferably less than 50 microns.

The ink layer 2 or the ink areas may also be on the surface of the transparent spacer layer 3 printed, which is adjacent to the back 1b the topcoat 1 is.

The transparent spacer layer 3 can be made of transparent polyvinyl chloride (PVC). The thickness of the transparent spacer layer may be between 0.1 mm and 0.7 mm, or in particular between 0.2 mm and 0.5 mm. Inhomogeneities in the form of a grain or in the form of bubbles may occur within the transparent spacer layer 3 be distributed.

On the back side 3b the transparent spacer layer 3 opposite to the side of the transparent spacer layer attached to the cover layer 1 is adjacent, lies, is a lighting layer 4 fixed. The illumination layer 4 may comprise optical fibers interwoven with fibers of a polyester fabric. The illumination layer may be adhesively attached or adhered to the transparent spacer layer in its molten state on the transparent spacer layer 3 be fixed. The illumination layer forms together with the transparent spacer layer 3 a composite layer that provides mechanical stability to the vehicle trim element.

In 2 a similar structure of a vehicle trim element is shown, the difference with respect to the structure of 1 It is that the transparent spacer layer 13 made of a transparent fabric. The thickness of the transparent spacer layer 13 can be between 1 mm and 3 mm. The bending radius can be less than 10 mm. On the back of the transparent spacer layer 13 , Opposite the side, to the top layer 1 is adjacent, is a lighting layer 14 arranged, the light conducting wires containing and having a fabric of fibers. The illumination layer 14 may be at the transparent spacer layer 13 by an adhesive or by any other method that allows one layer of fabric to be attached to or combined with another layer of fabric. The transparent fabric can be haptic Provide properties, in particular a soft touch of the cladding element. In addition, the transparent fabric may be that of the illumination layer 14 scatter incoming light and thereby provide a more homogeneous illumination of the mask.

In 3 is shown a third version of the vehicle trim element, in which the cover layer 1 the same structure as in the 1 and 2 has, and in which the transparent spacer layer 23 again having a fabric with polyester fibers. On the back of the transparent spacer layer 23 are light-guiding elements, for example optical fibers with the tissue, from which the transparent spacer layer 23 exists, interweaves. The dash-dotted line 5 marks the boundary between the part of the transparent spacer layer 23 which has no light guiding elements and the part of the transparent spacer layer containing light guiding elements. The part of the transparent spacer layer 23 containing light guide elements is as 24 marked and acts as a lighting layer.

Under daylight conditions, the above-described vehicle trim element appears as a normal grained plastic surface with any desired color. Under conditions of less intense ambient light, and when the light in the illumination layer is turned on, light passes through the transparent spacer layer and through the through holes in the printed ink layer 2 directed. The pattern formed by the through holes is then passed through the cover layer 1 visible.

The cladding element can be produced in various ways. However, the inventors prefer the method described below. According to this method, several of the layers are stacked, for example by printing or coating. In particular, the technique of screen printing is advantageous because this technique allows the layered deposition of different types of material over one another, either as a homogeneous layer or as a pattern, for example for making a mask. In a first step, the cover layer is applied to a release layer with a grained surface. This grained non-stick surface is the reflection of the grained surface of the cladding element. The grained release layer may be grained silicon paper, but also another grained surface that allows for the release of the release layer from the cover layer in a later step may be used. As described above, the cover layer may have two layers that are stacked on top of each other. In a next step, the mask is applied to the cover layer. The ink of the mask layer is to be selected such that after drying or curing, the ink layer has an optical absorption higher than 90%. The mask layer is much thinner than the cover layer. Typically, the mask layer has a thickness that is less than one tenth of the thickness of the cover layer. In a next step, the transparent spacer layer is applied to the mask layer. Since the mask layer has through-holes, the transparent layer may protrude into the mask layer, more specifically, into the through-holes. The cover layer, the mask layer, and the transparent spacer layer together form a semi-finish element to be attached to the illumination layer. The release layer may be separated from the semi-finish element, more specifically, from the cover layer after the semi-finish element has been attached to the illumination layer or after the semivetic element has been attached to the illumination layer. The semi-finish element, more specifically, the transparent spacer layer may be attached by an adhesive applied to the transparent spacer layer, to the illumination layer, or to both the transparent spacer layer and the illumination layer.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been 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.

Cited patent literature

• FR 2920717 A1 [0002]
• US 2015/0210226 A1 [0003]

Claims (10)

Vehicle trim element comprising: a cover layer (1) having a front side (1a) and a back side (1b), a lighting layer (4, 14, 24) on the back of the cover layer, a transparent spacer layer (3, 13, 23) disposed between the illumination layer (4, 14, 24) and the cover layer, and a mask layer (2) having a pattern of through holes (2a), the mask layer having a light absorption of more than 90% in regions outside the through holes and disposed between the cover layer (1) and the transparent spacer layer (3, 13, 23) . in which the illumination layer (4, 14, 24) has light-conducting elements (4a), the illumination layer comprises or is a tissue that is firmly fixed to the transparent spacer layer (3, 13, 23), the mask layer (2) is fixed to the back surface (1b) of the cover layer or to the side of the transparent spacer layer (3, 13, 23) which is adjacent to the cover layer, the mask layer has a thickness which is less than 10% of the thickness of the cover layer, and the cover layer is transparent and has a light absorption capacity between 50% and 90%. Cladding element after Claim 1 in which the illumination layer (4, 14, 24) comprises a flexible fabric in which a plurality of optical fibers (4a) are woven. Cladding element after Claim 1 or 2 in which the cover layer has two layers with different optical properties. Cladding layer after one of Claim 1 . 2 or 3 in which the cover layer (1) has on its front side (1a) a grained surface with a surface roughness between 20 and 200 microns Ra. Cladding layer after one of Claims 1 . 2 . 3 or 4 in which the transparent spacer layer (3, 13, 23) has inhomogeneities which scatter light. Cladding layer after Claim 5 in which the inhomogeneities (3a, 3b, 3c) are distributed in the volume of the transparent spacer layer having a homogeneous volume density. Cladding layer after Claim 5 in which the inhomogeneities (3a, 3b, 3c) are distributed in the volume of the transparent spacer layer with a density gradient. Cladding layer after Claim 5 in which the inhomogeneities (3a, 3b, 3c) are bubbles. Cladding layer after one of Claims 1 . 2 . 3 . 4 or 5 in which the transparent spacer layer (3, 13, 23) is a polyester fabric having a thickness between 1 and 3 mm. A method of manufacturing a vehicle trim element according to any one of the preceding claims, comprising the steps of: Providing a release layer having a grained non-stick surface; - Producing a Semiverkleidungselements by: (a) applying the cover layer (1) to the grained non-adhesive surface, (b) applying the mask layer (2) to the cover layer (1), and (c) applying the transparent spacer layer (3, 13, 23) to the mask layer; - fixing the illumination layer (4, 14, 24) to the transparent spacer layer (3, 13, 23); and -Trennen the release layer of the Semiverkleidungselement.

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