DE102022109515A1 - METHOD FOR PRODUCING A DECOR COMPOSITE AND DECORATIVE COMPOSITE FOR A MOTOR VEHICLE - Google Patents

Abstract

The invention relates to a decorative composite (1) and a method for producing a decorative composite (1), wherein a coating side (6) of a decorative blank (2) in a coating area (4) is coated with a coating material (11) which has a predetermined connection contour (5) is characterized; the decorative blank (2) is placed with the coating side (6) on a lining element (8) which is reversibly elastically compressible, whereby a layer arrangement (15) is formed, which is then pressed by means of a pressing element (19) shaped according to the connecting contour (5). is compressed along the connecting contour (5) by pressing with the pressing element (19) onto a surface area (20) of a decorative side (7) of the decorative blank (2) corresponding to the predetermined connecting contour (5), the lining element (8) being pushed along the connection contour (5) is compressed; the decorative blank (2) and the lining element (8) are connected to one another with the connecting contour (5) pressed in and along which, whereby a cushion structure (9) is created on the decorative side (7).

Description

Technical area

The present invention relates to a method for producing a decorative composite which has a cushion-like surface structure on its visible or decorative surface. The invention also relates to a decorative composite for a motor vehicle.

State of the art

The decorative composite with the cushion-like surface structure or cushion structure is intended in particular for use in the automotive sector, for example as a decoration or part of a decoration in an interior of a motor vehicle, in particular a passenger car and/or truck. Possible applications of such a decorative composite are, for example - in particular illuminated/illuminable or backlit/backlit - symbols (warning symbols, status indicators, etc.), emblems (coats of arms, manufacturer symbols, logos, vehicle model and/or series designations, etc.), functional decors (interior or ambient lighting, button and/or switch surfaces, etc.), seams, seam imitations (e.g. decorative seams, functional seams, cross seams, etc.). In addition, the decorative composite can serve as a cladding element for a loudspeaker. For this purpose, a decorative cut of the decorative composite or the entire decorative composite has, for example, one or more through openings that can be transilluminated or backlit and/or are permeable to air or sound (“sound permeable”). Individual cushions of the cushion-like surface structure are usually separated from one another by connecting seams, which are created in particular by sewing or stitching, so that the individual cushions rise between the connecting seams from a plane of the connecting seams. So that the cushion structure can be formed particularly uniformly, a flexible decorative blank is used for a conventional decorative composite. However, it is currently problematic to produce a particularly high-quality cushion structure when a flexible decorative blank is completely coated on its flesh side with a coating material, for example a polymer, etc., since the decorative blank is solidified by the coating material, which is why it is difficult to fit into it desired gentle, even, organic-looking cushion shape can be achieved. Therefore, nowadays it is particularly difficult to produce a decorative composite with a cushion structure of high quality.

Description of the invention

It is the object of the invention to create a solution for a particularly simple and/or low-cost production of a decorative composite with a cushion-like decorative surface.

This task is solved by the subject matter of the independent patent claims. Further possible embodiments of the invention are disclosed in the subclaims, the description and the figures. Features, advantages and possible configurations set out in the description for one of the subject matter of the independent claims are at least analogous to the features, advantages and possible embodiments of the respective subject matter of the other independent claims and any possible combination of the subject matter of the independent claims, if applicable in conjunction with one or more of the subclaims.

According to a first aspect of the invention, a method for producing a decorative composite is proposed. In a second aspect of the invention, a decorative composite is proposed which was produced using the method. The method according to the invention is therefore used to produce the decorative composite. In other words, the decorative composite according to the invention is a product that was/is produced using the method according to the invention. The method for producing the decorative composite has the steps explained in more detail below, which can take place in a different order than the description. Furthermore, the steps can at least partially overlap each other in time or at least partially begin, run and/or end at the same time. In other words: First, the individual steps involved in the process are explained; Their order is determined in connection with the description, in particular by the description of the possible configurations of the process. If necessary, the order of the steps differs from possible embodiment to possible embodiment.

The decorative composite has a decorative side or decorative side which faces into the interior when the decorative composite is installed in the intended position, that is, when the decorative composite has been installed as intended in a vehicle, in particular a motor vehicle. On the other hand, the decorative composite has a back that faces away from the interior when installed in the intended position. The decorative composite can, for example, be attached to a dimensionally stable support, for example laminated onto the support. “Stable in shape” means that the shape of the wearer itself is load-bearing or inherently stable; This means that as long as a sufficiently strong deformation force does not act on the carrier, the decorative carrier will not be deformed. The decorative carrier can, for example, have wood, glass, metal or another rigid or dimensionally stable material as the material. In particular, the carrier can have or be formed from plastic, for example ABS (acrylonitrile butadiene styrene), PMMA (polymethyl methacrylate), PP (polypropylene), PC (polycarbonate), PU (polyurethane), ABS-PC (blend), etc It is conceivable that the plastic is used as a matrix for reinforcing fibers, such as natural, metal or carbon fibers, so materials such as PP-GF, PU-GF, NF-PP etc. are also conceivable for the carrier. In addition, the carrier can be translucent, transparent or opaque.

The decorative composite has a decorative blank which has a decorative side which forms the decorative side of the decorative composite in the finished decorative composite. The decorative blank also has a coating side which is spaced from the decorative side by a thickness of the decorative blank. The coating side can be processed using a smoothing process. The decorative cut extends predominantly two-dimensionally between the decorative side and the coating side. The respective decorative cut is therefore in particular a plan product made of a textile, a textile-like material, leather and/or artificial leather. Furthermore, film structures made of these or other materials are conceivable, such as TPO (thermoplastic polyolefins) etc. Natural, renewable and/or synthetic leather substitutes (apple leather, mushroom leather, eucalyptus leather, pineapple leather, etc.), hot-stamped or not, are also used as materials for the respective decorative cut hot-stamped textiles come into question. Other options include Alcantara ® or Dinamica O. In addition, a material structure made of a mixed material is conceivable, which, for example, has one or more of the aforementioned materials. In addition, the decorative blank can be designed in multiple layers, for example from a leather or artificial leather layer and a textile or fleece layer. If two or more decorative cuts are used, they can be made of the same or different material. The respective material can be transparent or non-transparent and/or permeable or non-permeable to acoustic waves. The decorative blank can be completely or partially pre-coated with a polymer on its coating side, the polymer being in particular transparent. The pre-coating is used, for example, to bind fibers and can contain additives (waxes, oils, color pigments, etc.). In addition, the pre-coating gives the decorative cut improved trimability. Furthermore, cavities in the decorative blank can be filled. An example of an application is partially embedding the textile backing of an artificial leather.

In the method for producing the decorative composite, the coating side of the decorative blank is coated with a coating material in a coating area, the coating area being characterized or predetermined by the predetermined connection contour. Thus, the coating side of the decorative blank is only coated with the coating material in exactly the area that is specified by the predetermined connection contour. In particular, the coating area is specified or characterized by the connection contour in that the coating area lies outside the connection contour. The connecting contour reproduces a pattern on the finished decorative composite, according to which, for example, individual cushions of a cushion structure of the decorative composite are separated from one another and arranged relative to one another. This pattern can be regular or irregular. The coating material can in particular only be formed in a predetermined portion of the coating area, for example in a symbol area, of the cushion structure or a (respective) individual cushion of the cushion structure. A symbol arranged or formed in the symbol area can (but does not have to) be formed by means of a perforation or have such a perforation. The coating follows, for example, the contour of the perforation or openings (for example line-like gaps). In addition to the contour of the openings, the coating can be seamless.

The decorative blank is then placed with the coating side partially coated with the coating material on a lining element which is reversibly elastically compressible along its thickness direction. In this way, in particular, a layer arrangement is formed which has the decorative blank and the lining element. The underlining element has at least one reversibly elastically compressible layer. The underlining element can be constructed in multiple layers, with the individual layers being connected to one another, for example, by means of a light-transparent and/or UV-stable adhesive. It can also, in particular, have a carrier layer which is connected to the reversibly elastically compressible layer. In addition, the underlining element can have a cover layer, so that the reversibly elastically compressible layer is arranged between the carrier layer and the cover layer. According to a further development of the method, the reversibly elastically compressible layer of the lining element is, for example, a textile structure, foam structure, sponge forms, cotton wool structures, etc. A textile structure is understood to mean, among other things, a woven fabric, a knitted fabric, in particular a spacer fabric, a knitted fabric, a braid, a sewn-knit fabric, a fleece, etc. Furthermore, a composite of one or more of the aforementioned components is conceivable. Threads or fibers of the lining element are in particular plastic fibers. Layers of the layer arrangement, i.e. at least the decorative blank and the lining element, can lie loosely on top of one another or can be fixed relative to one another in a non-positive, positive and/or material fit.

The decorative cut and the lining element are then connected to each other. When connecting the decorative blank to the lining element, the connecting contour is compressed, for example by means of a pressing element. The compression can alternatively or additionally be carried out using a connecting means used to connect the decorative blank and the lining element, such as a thread, a rivet, etc. The connection contour can be compressed before or during connection by means of the connection tool, in particular by means of a sewing foot of a sewing machine, etc. After connecting, the underlining element is permanently held in a compressed state along the connecting contour, with the underlining element being at least substantially relaxed outside the connecting contour. In this way, the cushion-like structure of the decorative composite, which has individual cushions, is created, which, measured on the individual cushions, is thicker/stronger than away from the individual cushions. This means that measured against the connecting contour, the decorative composite is thinner than the individual cushions. In this respect, the respective individual cushion can be viewed as a mountain of the decorative composite, whereby the connecting contour between the individual cushions or mountains can be viewed as a valley.

In particular, a pressing element is used to compress the underlining element. The layer arrangement is then compressed along the predetermined connection contour by means of the pressing element, which is shaped according to the connecting contour, for example a press stamp, a press roller, etc., by pressing with the pressing element onto a surface area of a decorative side of the decorative blank that corresponds to the predetermined connecting contour, whereby the lining element is compressed along its thickness direction and along the connecting contour. The pressing element therefore has a pressing relief corresponding to the predetermined connection contour, which is pressed into the decorative blank and consequently into the layer arrangement. The press relief of the pressing element displaces the material of the layers or the decorative blank and the lining element, so that the layer arrangement is pressed in by means of the pressing element or by means of its press reliefs. If at this point in the process the pressing element is completely lifted off the layer arrangement, that is to say from the decorative blank, the lining element, for example, automatically completely returns to its original shape. Depending on the material of the underlining element, it can happen that the underlining element is at least partially plastically deformed by means of the pressing element. In this case, the lining element partially relaxes again along its thickness direction and remains partially plastically deformed.

In any case, coating areas of the coating side away from the connection contour and, as a result, undesirable solidification or stiffening of the decorative blank are advantageously avoided. As a result, the decorative cut largely retains its flexibility, which means that the decorative cut fits particularly closely to the lining element. The individual cushions are desirably given a particularly even shape. In addition, the cushion structure can be produced particularly easily and with little effort, since the decorative blank has no resistance to deformation caused by the coating material. The decorative cut can be placed particularly efficiently on the lining element.

According to a further possible embodiment, in order to coat the coating area of the coating side, a masking template shaped according to the connection contour and the coating side of the decorative blank are fixed to one another in a non-positive, positive and/or material fit, for example glued. The coating area remains uncovered due to the shape of the masking template. The coating side of the decorative blank is coated with the coating material in the uncovered area by coating, for example rolling, the masking template and the decorative blank together with the coating material. The masking template therefore has one or more material-free areas that correspond to the predetermined connection structure, with one or more material areas of the masking template covering the area of the coating side that is to be kept free of coating material. Accordingly, producing the decorative composite is even easier, since coating a large contiguous area is easier than partially coating individual areas.

The masking stencil is, for example, a plate, an adhesive pad, an adhesive tape, an adhesive film, etc. The masking stencil can be smooth or surface-structured be carried out. In particular, the masking template is coated in an adhesive and/or sealing manner on the side that rests on the coating side of the decorative blank during/for coating. The other surfaces of the masking template can be coated without adhesive, for example with silicone, PTFE (polytetrafluoroethylene, Teflon®), etc. and/or surface-structured. The masking stencil has at least one layer, but can also be multi-layered. Furthermore, the masking template can be elastically compressible. The masking template can be used to compensate for any unevenness or unevenness on the coating side of the decorative blank. For example, island-like or spot-like elevations can be pressed into the material of the masking stencil, so that the masking stencil nestles particularly closely to the coating side. This means there is no air gap between the masking stencil and the coating side. This ensures an optimal seal. When coating the decorative blank, no coating material runs between the masking template and the decorative blank.

When forming the layer arrangement, the masking template can remain between the decorative blank and the lining element, so that the masking template is incorporated into the decorative composite as a component. Alternatively and as provided in a further development of the method, the masking template is removed from the decorative blank before the layer arrangement is formed. In particular, the entire masking template or, if appropriate, at least one of the individual layers of the masking template can be used multiple times. Before removing the masking stencil, the coating material is tempered to a predetermined target temperature. The target temperature is specified or selected so that the coating material, when it has the target temperature, is too brittle to pull unwanted coating material threads when the masking template is removed from the coating material film. As a result, the decorative cut and the workers and machines involved in removing the masking template are not unnecessarily contaminated.

In order to make the removal of the masking template from the decorative blank even more efficient, according to a further embodiment it is provided to cut the coating material along a contour of the masking template before removing the masking template, for example by means of punching, laser cutting, water jet cutting, compressed air cutting, etc.

To ensure a particularly high-quality or clean transition between areas coated with coating material and areas of the coating side of the decorative blank free of coating material, another possible embodiment provides - especially after removing the masking template - to press or press a contour or edge of the area coated with coating material. to contour press. For this purpose, in particular a pressing tool or contour pressing tool is used, which is optionally non-stick coated and/or tempered (i.e. heated and/or cooled). The pressing tool can advantageously be tempered in such a way that the achievement of the target temperature of the coating material is supported or promoted.

Depending on the processing or post-processing of the edges of the area coated with coating material, sharp or soft (stepless) transitions can be created between the areas coated with the coating material and adjacent areas free of coating material. Such hard and soft transitions make it possible, for example, to create visible bends that correspond to a desired surface design of the decorative side.

According to a further possible embodiment, a transfer tool that is shaped according to the connection contour, in particular a transfer roller and/or a transfer stamp, is used to coat the coating area of the coating side. This means that the transfer tool has, for example, a transfer relief that is wetted with the coating material in order to transfer the coating material from the transfer relief to the coating side. The transfer relief corresponds to the predetermined connection contour, so that the coating material is applied to the coating side only along the connection contour using the transfer tool. Both the masking template and the transfer tool can be used in the process (simultaneously or one after the other). The use of the transfer tool is advantageous in that a repeatable application of the coating material along the predetermined connection contour to the coating side is possible.

In a further possible embodiment, the decorative blank and the lining element are fixed to one another to form the layer arrangement. For example, it can be provided that the layers of the layer arrangement, i.e. the decorative blank and the lining element, are clamped or tensioned together by means of a clamping or tensioning device. Anyway, there is one Undesirable relative movement of the decorative blank and the lining element is avoided by the fixation, which contributes to a particularly high quality of the cushion structure, i.e. to a particularly high quality of the decorative composite. The decorative blank and the lining element can be fixed in relation to one another in particular by fixing the layer arrangement in a processing machine, for example a sewing machine, etc.

A possible further development provides for the decorative blank and the lining element to be thermally connected to one another along the connecting contour. The decorative blank and the lining element can, for example, be welded together (in particular high-frequency, ultrasonic, laser, friction welded, etc.), hot stamped and/or fused together along the predetermined connection contour. In this way, the decorative cut and the lining element are connected or joined to one another in a materially bonded manner and are therefore particularly reliable. In addition, the underlining element is thermally treated, in particular melted, by the thermal joining/connecting along the connection contour, so that the underlining element, at least its reversibly elastic layer, no longer changes into the initial shape by itself after subsequent cooling.

Alternatively or in addition to thermally connecting the decorative blank and the lining element to one another, the decorative blank and the lining element can be sewn together along the connecting contour in a further possible embodiment. The resulting seam can be designed as a design element, for example due to the seam being designed as a decorative seam, and/or further strengthen the particularly strong and reliable connection between the decorative cut and the lining element.

When thermally connecting and/or sewing the decorative blank and the lining element together, the surface area can be pressed in along the connecting contour by means of a connecting machine that is set up or is used to connect the decorative blank and the lining element to one another. For example, a sewing machine can have a hold-down device or press-down device, which acts as the pressing element when/for sewing the decorative blank to the lining element. In particular, a sewing foot of the sewing machine can be set up - that is, designed and arranged - in order to be able to function as the pressing element as intended. It is also conceivable that a thermal joining machine, for example an ultrasonic, laser or friction welding machine, has such a hold-down device that functions as the pressing element.

The decorative composite can be used in a particularly versatile manner if - as provided in a further embodiment - a light-conducting thread is used to sew the decorative blank to the lining element. Light can then be coupled into this on the back of the decorative composite, which shines through the thread into the interior. This makes it possible to have a particularly inconspicuous lighting device integrated into an interior, such as ambient lighting, etc. In this case, a translucent lining material and/or a translucent, dimensionally stable carrier is preferred. In other words, the lining material and/or the material of the dimensionally stable carrier are/is completely or partially transparent.

According to a further possible embodiment, the decorative blank is provided with an opening arrangement that has one or more through openings. The respective through openings penetrate the decorative blank completely between its decorative side and its coating side, with the respective through opening opening into an environment of the decorative blank on the one hand on the decorative side and on the other hand on the coating side. As a result, the decorative composite can be used in a particularly versatile or flexible manner, for example as a functional decor with lighting, button and/or switch functionality and/or as a cladding element for a motor vehicle loudspeaker. The loudspeaker is in particular covered by one or more individual cushions. In addition, the dimensionally stable carrier is provided with through openings or perforated to ensure sound permeability. For this purpose, one, some or all through openings of the opening arrangement (or possibly the carrier) can be transilluminated or backlit and/or air or sound permeable (“sound permeable”). Alternatively, it is conceivable that the depression area is designed to seal off or limit sound waves. A respective opening contour of the respective through opening can be oval, in particular circular, or polygonal, for example three-, four-, five-, six-, seven-, octagonal, etc., whereby one or more of the corners can be rounded. Furthermore, it is conceivable that the opening contour has at least one oval section and at least one polygonal section. The respective through opening has a hollow cylindrical, hollow prismatic or hollow conical shape. In addition, the term “opening” or “through opening” can also mean a material-free space, which is already due to the structure of the corresponding body with the opening. For example, the term “opening” is also used herein for a material-free space between stitches/threads/fibers of textile structures. Furthermore, the respective opening can be a so-called decorative opening, for example in the form of a pattern, an image, etc. In this case, for example, line-like or gap-shaped line courses of the openings or decorative openings can overlap and/or cross each other. A respective overlap region formed thereby can itself form an opening or have one or more further openings which are filled with the coating material or are free of the coating material. The coating can, for example, follow the line of the light shape. The secondary areas are not coated.

If the decorative blank has the opening arrangement, i.e. one or more through openings, it is provided according to a possible development that when the coating side of the decorative blank is coated, one or more of the through openings is completely or partially filled with the coating material. If the masking template is used, it has further material-free areas that correspond to the through openings, so that the coating material can enter the corresponding through opening. If the transfer tool is used alternatively or additionally, its transfer relief has transfer relief components corresponding to the through openings, by means of which the coating material is transferred into the corresponding through opening. By means of the pressing tool, which is also used to press the edge of the uncovered area coated with coating material, the coating material arranged in the (respective) through opening can be further compacted.

In general, the coating material is in particular a polymer, a hot melt, a dispersion, etc. The coating material can react into a fully reacted or hardened state in which it is at least partially translucent or at least partially transparent, in particular image-true transparent. The coating material can, for example, have a milky appearance, similar to frosted glass. As a result, when the coating material located in one of the through openings is illuminated, a diffusely distributed light emerges in the desired manner, which emerges from the coating material or from the corresponding through opening. In order to fill the respective through-opening and to coat the adhesive side of the decorative blank with the coating material, it is also provided in particular that the coating material is provided in an at least pasty, in particular liquid, state, so that when filling or during the filling of the through-opening(s) and during the coating of the specified coating area between the decorative blank and the coating material a cohesive connection is established. In general, in the process or in the decorative composite it can be provided that the coating material has at least the adhesive properties of an adhesive. Accordingly, an adhesive, for example, can be used as the coating material. The adhesive, i.e. cohesive connection between the coating material and the decorative blank results in a particularly stable structure of the decorative element. The through openings are stabilized in terms of their final 3D contour position and in terms of their haptic base by the filling or coating.

In order to prevent coating material from getting through the opening arrangement onto the decorative side of the decorative blank or decorative composite and causing damage or contamination there, a sealing element is provided in a further possible embodiment. To coat the coating side and/or to fill the through opening(s), the decorative side of the decorative blank and the sealing element are fixed to one another, so that one or more of the through openings of the opening arrangement are fluidically sealed on the decorative side. This means that the coating material cannot emerge from the opening arrangement on the decorative side. It is irrelevant whether the coating material entered the through opening in a desired or undesired manner.

The sealing element can be, for example, a sealing film. Furthermore, it is conceivable that the sealing element is a component of a processing machine by means of which the decorative blank, the layer arrangement or the decorative composite is processed. The desired sealing functionality can be produced, for example, by gluing the sealing element onto the decorative side of the decorative blank in a non-destructively removable manner. A vacuum suction of the decorative blank onto the sealing element is also conceivable.

In a further possible embodiment, it is provided that one or more of the through openings of the opening arrangement is kept free of the coating material when the coating side is coated. Alternatively or additionally, one or more of the through openings is freed from the coating material after coating the coating side or after filling. This allows one Inner circumferential surface of the through opening can be sealed with the coating material and still ensure sound permeability. In particular if the coating material is designed to be light-conducting, a cross section of the corresponding through opening can first be completely filled with the coating material and then - for example by means of drilling, lasering, water and / or compressed air cutting, etc. - a part with a smaller diameter than that of the through opening to free the cross section from the coating material. This creates a hollow cylindrical or hollow prismatic coating material structure in the passage opening, which, when illuminated from the back of the decorative composite, emits ring-shaped light and at the same time is permeable to air, that is, permeable to sound waves. Alternatively or additionally, further openings can be subsequently formed which penetrate the decorative composite to ensure sound or sound wave permeability.

According to a further possible embodiment, a material that is UV-stable, translucent and/or air-permeable is used for the decorative cut, the coating material and/or the lining element. If - alternatively or in addition to the coating material - a (further) adhesive is used, as can generally be intended for the decorative composite, this is also UV-stable, translucent and / or air-permeable. A non-UV-stable adhesive that is arranged under/behind the UV-stable coating material can lead to an unacceptable color shift when backlit. Because the decorative blank, the coating material and/or the lining element are designed to be particularly resistant to UV radiation, i.e. ultraviolet radiation, no UV radiation-induced damage occurs to the corresponding element of the decorative composite, i.e. no discoloration, for example. Brittleness, reduction in strength, loss of adhesive strength, etc. This means that the corresponding UV-stable element is even more durable and resistant. It is also possible to use UV cleaning devices to destroy germs, which is an advantage for a rental car company, bus company, etc., for example. Furthermore, a long-lasting use of the corresponding element is conceivable in places that are often exposed to direct sunlight, for example in convertibles etc. The UV stability can be given to the element in question, for example, by coating it with a UV protective layer and/or by When producing the corresponding element, at least one additive is added to the material, which creates or enhances the UV stability. The light and/or air permeability of the element in question again favors the use of the decorative composite in a light and/or sound application. The coating material is therefore designed, at least in this embodiment, such that it is translucent, at least in a fully reacted state.

Further advantages, features and details of the invention can be found in the following description of possible exemplary embodiments and in the drawing. The features and combinations of features mentioned above in the description as well as the features and combinations of features shown below in the description of the figures and/or in the figures alone can be used not only in the combination specified in each case, but also in other combinations or on their own, without the scope of the invention to leave.

Short character description

• 1 eine schematische Ansicht eines Dekorzuschnitts für einen Dekorverbund, der eine Öffnungsanordnung aufweist und bei dem ein Beschichtungsbereich dargestellt ist, der durch eine vorgegebene Verbindungskontur charakterisiert ist;
• 2 eine schematische und geschnittene Ansicht des Dekorzuschnitts, an den ein Abdichtelement angebracht ist;
• 3 eine schematische und geschnittene Ansicht einer Lagenanordnung, die den Dekorzuschnitt und ein Unterfutterelement aufweist, wobei mit einem Presselement auf einen mit der vorgegebenen Verbindungskontur korrespondierenden Bereich einer Dekorseite des Dekorzuschnitts gedrückt wird;
• 4 eine schematische und geschnittene Ansicht der Lagenanordnung, wobei der Dekorzuschnitt und das Unterfutterelement miteinander verbunden sind;
• 5 eine schematische Ansicht einer Maskierungsschablone bzw. eines Transferwerkzeugs, die/das gemäß der vorgegebenen Verbindungskontur geformt ist; und
• 6 eine perspektivische Ansicht des Dekorverbunds, der eine Kissenstruktur an einer Dekorseite aufweist.

The drawing shows in:

• 1 a schematic view of a decorative blank for a decorative composite, which has an opening arrangement and in which a coating area is shown which is characterized by a predetermined connection contour;
• 2 a schematic and sectional view of the decorative blank to which a sealing element is attached;
• 3 a schematic and sectional view of a layer arrangement which has the decorative blank and a lining element, with a pressing element being pressed onto an area of a decorative side of the decorative blank which corresponds to the predetermined connecting contour;
• 4 a schematic and sectional view of the layer arrangement, with the decorative blank and the lining element being connected to one another;
• 5 a schematic view of a masking template or transfer tool shaped according to the predetermined connection contour; and
• 6 a perspective view of the decorative composite, which has a cushion structure on one decorative side.

The following describes a method for producing a decorative composite 1 (for the first time in 4 shown) and the decorative composite 1 itself presented in a joint description. The same and functionally identical elements in the figures are given the same reference numerals.

1 shows a schematic view of a decorative blank 2 for the decorative composite 1, which has an opening arrangement 3 and in which coating areas 4 are shown, which are characterized by a predetermined connection contour 5. The coating area 4 is provided on a coating side 6 of the decorative blank 2, which is spaced from a visible or decorative side 7 of the decorative blank by a thickness/thickness of the decorative blank 2. The coating area 4 is specified by the connection contour 5 being defined. At/in the predetermined connecting contour 5, the decorative cut is made with a lining element 8 (for the first time in 3 shown) connected, whereby, for example, a cushion structure 9 (see 6 ), as will be described in more detail below. The shape or pattern of the connecting contour 5 and therefore also the shape or pattern of the coating area 4 is in 1 only shown as an example. All possible other courses for the connection contour 5 or for the coating area 4 are conceivable.

The opening arrangement 3 has at least one through opening 10, in the present case a plurality of through openings 10, wherein the through openings 10 can be designed the same or different. How out 1 As can be seen, one or more of the through openings 10 can be oval, in particular circular, while at the same time one or more of the through openings 10 can be polygonal. In addition, the decorative blank can have two or more opening arrangements 3 and/or only partially penetrated by through openings 10.

The decorative blank 2 is superficially coated on its coating side 6 with a coating material 11, only or mainly in the respective coating area 4. Furthermore - as provided in the present example - one or more of the through openings 10 are completely or partially coated with the coating material 11 filled. In any case, the decorative blank 2 has a surface area 12 or surface areas 12 on its coating side 6, the respective surface area 12 having significantly less coating material 11 after the coating and/or filling process compared to the coating area 4, in particular being free of coating material 11. In the 1 The surface areas 12 shown are here arranged outside the connection contour. The coating side 6 of the decorative blank 2 is therefore not completely, but only partially, coated with the coating material 11. In addition, it is provided here that one or more of the through openings 10 of the opening arrangement 3 or opening arrangements 3 is/are kept free of the coating material 11 during the coating of the coating side 6 and/or is/are freed of at least part of the coating material 11 after coating. This means that the decorative composite 1, in particular its decorative blank 2, can have both through openings 10 that are completely or partially filled with coating material 11, as well as through openings 10 that are completely or partially free of coating material 11.

In order to prevent the coating material 11 from getting onto the decorative side 7 of the decorative blank 2 in an undesirable manner, it is also provided here that the opening arrangement(s) 3 on the decorative side 7 is sealed against the escape of coating material 11 by means of a sealing element 13. become. This is in 2 shown, which shows a schematic and sectional view of the decorative blank 2 to which the sealing element 13 is attached.

After the coating side 6 has been partially, that is mainly in the coating area 4, coated with the filling material 11, the decorative blank 2 is placed with its coating side 6 on the lining element 8, whereby a layer arrangement 15 is formed, which in 3 is shown in a schematic and sectional view. The layer arrangement 15 has the decorative blank 2 and the lining element 8. In the present example, the decorative blank 2 and the lining element 8 are fixed to one another to form the layer arrangement 15. Preferably, a light-transparent adhesive or more light-transparent adhesives is/are used between the decorative blank 2 (in its coated or non-coated areas) and the lining element 8 for cohesive joining. The (respective) adhesive is also UV-stable.

The lining element 8 is reversibly elastically compressible along its thickness direction 14. The underlining element 8 has at least one reversibly elastically compressible layer 16. In addition, the underlining element 8 here also has a cover layer 17 and a carrier layer 18, both of which are connected to the reversibly elastically compressible layer 16, which is arranged between the cover layer 17 and the carrier layer 18. The cover layer 17 and the carrier layer 18 are both optional and, for example, designed as a cover or carrier fleece etc. in order, for example, to simplify connecting the lining element 8 to another element/component. The layers 17, 18 can, for example, be denser than the reversibly compressible layer 16 and/or have a higher resistance to compression. Than the reversible Elastically compressible layer 16 can be a textile structure, a foam structure, a sponge structure, a cotton structure or another reversibly elastically compressible structure.

As in 3 Furthermore, it can be seen that the layer arrangement 15 is compressed along the predetermined connection contour 5 by means of a pressing element 19 shaped according to the connecting contour 5. The pressing element 19 can be a press die, a press roller, etc. The pressing element 19 is used to press onto a surface area 20 of the decorative side 7 of the decorative blank 2 corresponding to the predetermined connecting contour 5, with the underlining element 8, in particular its reversibly elastically compressible layer 16, being compressed along the thickness direction 14 and along the connecting contour 5. The pressing element 19 displaces and compresses the material of the layer arrangement 15 non-destructively by means of its pressing reliefs 21. The pressing of the surface area 20 or the compression of the lining element 8 preferably takes place at a time when the coating material is still soft/elastic or pasty enough that it does not break due to the use of the pressing element 19.

4 shows a schematic and sectional view of the layer arrangement 15 or the decorative composite 1, wherein the decorative blank 2 and the lining element 8 are or are connected to one another. When producing the decorative composite 1, the decorative blank 2 and the lining element 8 are connected to one another with the connecting contour 5 pressed in and along it, whereby the lining element 8 is permanently held in a compressed state along the connecting contour 5 and outside the connecting contour 5, for example on the surface areas 12. is more relaxed than in the connecting contour 5.

In 4 It can also be seen that the decorative blank 2 and the lining element 8 are thermally connected to one another along the connecting contour 5, for example ultrasonically or laser welded, fused, hot-stamped, etc 4 a thermal connection 22 is indicated, in which the materials involved in the thermal connection 22 merge into one another in a cohesive manner. Alternatively or in addition to the thermal connection 22, the decorative blank 2 and the lining element 8 can be connected to one another along the connection contour 5 by sewing. For this purpose, a seam 24 is formed from one or more threads 23. In order to sew the decorative blank 2 to the lining element 8, a light-conducting thread 23 is used in the present case, and the seam 24 is designed as a double seam. Of course, other seam shapes or seam imitations are conceivable. The seam 24 is preferably designed as a decorative seam. Through the sewing process, the composite of decorative blank 2 and lining element 8 is pulled together or compressed or pressed down. When viewed in section, for example, a convex lens optic is created. If vertical or perpendicular holes are formed in the previously flat (uncompressed) decorative blank 2 and/or in the previously flat (uncompressed) underlining element 8, these will change in shape and course due to the contraction of the composite 15, which results in a Light emission angle when the holes are illuminated changes. The light emission angles can be influenced in a defined manner by additionally introduced bending areas on the cushion structure 9. The light emission angles of the opening arrangement 3 or the through openings 10 can also change when the cushion structure 9 is loaded and reset.

5 shows a schematic view of a masking template 25, which is shaped according to the predetermined connection contour 5 or according to the coating area 4 or the coating areas 4. To coat the respective coating area 4 of the coating side 6, the masking template 25 shaped according to the connecting contour 5 and the coating side 6 of the decorative blank 2 are fixed to one another. The respective coating area 4 remains uncovered due to the shape of the masking template 25. When coating the coating side 6 with the coating material 11, it is only coated with the coating material 11 in the uncovered coating area 4 by coating the masking template 25 and the decorative blank 2 together with the coating material 11. The masking template 25 has, for example, material recesses 26 that match the course and size of the connecting contour 5.

5 shows, in an alternative view, a schematic view of a transfer tool 28 having an outer surface 27, which is shaped according to the predetermined connection contour 5 or according to the coating area 4. The transfer tool 28 can be used for coating the coating area 4 of the coating side 6 and can be designed, for example, as a transfer roller (the outer surface of the transfer roller is in 5 shown unrolled) or as a transfer stamp. In any case, a transfer relief 29 protrudes from the outer surface 27 and is wetted with the coating material 11 in order to transfer the coating material 11 from the transfer relief 29 to the coating side 6. The transfer relief 29 corresponds to the specified connection contour 5, so that the coating material 11 is applied by means of the transfer tool 28 only along the connecting contour 5, that is only in the coating area 4 of the coating side 6.

The masking template 25 can remain between the decorative blank 2 and the lining element 8 or can be removed from the decorative blank 2 before the layer arrangement 15 is formed. In the present case, for a particularly simple removal of the masking template 25 from the decorative blank 2, the coating material 11 is first tempered to a predetermined target temperature, which is specified or selected so that the coating material 11 tempered to the target temperature, that is to say cooled or heated, when the masking template is removed 25 does not pull unwanted coating material threads out of the coating material film. In addition, the coating material 11 is cut along a contour of the masking template 25 or along an outer edge of the predetermined coating area 5, for example by means of punching, laser cutting, water jet cutting, compressed air cutting, etc.

After removing the masking template 25, a contour or edge of the uncovered or unmasked coating area 4 coated with coating material 11 is pressed, in particular contour-pressed. For this purpose, in particular a pressing tool (not shown) is used, which is optionally non-stick coated and/or tempered (i.e. heated and/or cooled). The pressing tool is tempered in such a way that the reaching of the target temperature of the coating material 11 is supported or favored. By contour pressing, filling material 11 arranged in corresponding through openings 10 is also recompacted.

6 shows a perspective view of the decorative composite 1, which has the cushion structure 9 on a decorative side 7 of the decorative blank 2 or the decorative composite 1 due to the method described above. As a purely exemplary shape or arrangement of the cushion structure 9, several individual cushions 30 can be seen, which are surrounded by a respective seam 24, in this case a double seam, and are thereby separated from one another. In addition, opening arrangements 3 can be seen, each of which has a large number of through openings 10. Since in the present example at least the underlining element 8 and the coating material 11 are translucent, the respective through opening 10 can be a light or lighting opening from which light emerges, which is coupled into the decorative composite on the part of the underlining element 8. Furthermore, it is conceivable that a flat light source or a flat light guide is inserted between the underlining element 8 and the decorative blank, which shines through the through-openings 10 free of coating material or through the through-openings 10 filled with the translucent coating material 11. The light source can also be formed by the underlining element 8 or embedded in the underlining element 8. The light source is, for example, a flexible matrix light, an arrangement of a large number of LEDs and/or OLEDs, etc.

In order to make the decorative composite 1 translucent or permeable to sound waves, the decorative blank, the coating material and/or the lining element are designed to be permeable to air. The decorative blank, the coating material and/or the lining element are/is also designed to be UV-stable in order to make the decorative composite 1 particularly resistant to sunlight.

The decorative composite 1 can be laminated onto a dimensionally stable support (not shown). For this purpose, a light-transparent adhesive or more light-transparent adhesives are used between the lining element 8 and the carrier for cohesive joining. The (respective) adhesive is also UV-stable. The advantage here is that the connection area 5, in which, for example, the seam 24 runs, adheres completely to the carrier or a carrier textile. This results in visually straight seams that are perceived by a viewer as correct and of high quality. Bends between an individual cushion 30 and the connecting contour 5 are advantageously particularly striking. Alternatively, it is possible for the decorative composite 1 to be laminated or glued on to form material-free spaces or air spaces between the carrier and the decorative composite 1. The light optics and sound wave propagation vary depending on the application.

The decorative composite 1 and the method for producing it show a respective solution as to how particularly easy and/or low-cost a decorative composite with a high-quality cushion-like decorative surface can be produced. Because automobile manufacturers currently have a demand for such a decorative composite 1, which can be used, for example, as a bulging decorative quilting, a bulging decorative hot pressing, a bulging decorative bonding (for example leather, artificial leather or textile, combined with a textile/textile composite or with a foam/foam composite), a sewn, multi-layer, bulging decorative composite (especially made of leather with haptic, air-permeable, backlit backing material or materials such as spacer materials, spacer fabrics, foam, etc.). In addition, the decorative composite 1 should be designed in particular for backlighting or for sound penetration (as a loudspeaker cladding element). By filling openings and/or coating a decorative blank, the decorative composite becomes too stiff for subsequent processes, for example sewing or hot pressing, as well as for a haptic function in the required or requested stomach/pillow representation. Forming tummies/pillows is now difficult. This problem is solved by creating a flexible 3D light and/or sound decoration that is/is partially depressed. The corresponding decorative blank, for example the decorative blank 2, is filled or coated like an island (“micro/macro perforation light sealing”), for example using a grid-like or structured or stencil-like masking of areas/zones that are not to be coated retain their elasticity or flexibility due to the non-coating/filling.

REFERENCE SYMBOL LIST

1

Decorative composite

2

Decorative cutting

3

Opening arrangement

4

Coating area

5

specified connection contour

6

Coating side

7

Decor page

8th

Underlining element

9

Cushion structure

10

Passage opening

11

Coating material

12

surface area

13

Sealing element

14

Thickness direction

15

Layer arrangement

16

reversibly elastically compressible layer

17

top layer

18

Backing layer

19

Pressing element

20

surface area

21

Press relief

22

thermal connection

23

thread

24

seam

25

masking stencil

26

material recess

27

external surface

28

Transfer tool

29

Transfer relief

30

Single pillow

Claims (17)

Method for producing a decorative composite (1), wherein - a coating side (6) of a decorative blank (2) is coated in a coating area (4) with a coating material (11), which is characterized by a predetermined connection contour (5); - the decorative blank (2) with the coating side (6) partially coated with the coating material (11) is placed on a lining element (8) which is reversibly elastically compressible along its thickness direction (14); - for connecting the decorative blank (2) and the lining element (8), the connecting contour (5) is compressed, the decorative blank (2) and the lining element (8) being connected to one another along the connecting contour (5), whereby after connecting Underlining element (8) is permanently held in a compressed state along the connecting contour (5) and is relaxed outside the connecting contour (5). Procedure according to Claim 1 , characterized in that for coating the coating area (4), a masking template (25) shaped according to the connecting contour (5) and the coating side (6) of the decorative blank (2) are fixed to one another, the coating area (4) due to the shape of the masking template (25) remains uncovered, and the adhesive side (6) of the decorative blank (2) in the uncovered coating area (4) is coated with the coating material (11) by the masking template (25) and the decorative blank (2) together with the coating material ( 11) be coated. Procedure according to Claim 2 , characterized in that before removing the masking template (25), the coating material (11) is tempered to a predetermined target temperature. Procedure according to Claim 2 or 3 , characterized in that before removing the masking template (25), the coating material material (11) is cut along a contour of the masking template (25). Method according to one of the preceding claims, characterized in that an edge of the coating area (4) coated with coating material (11) is pressed. Method according to one of the preceding claims, characterized in that for coating the coating area (4), a transfer tool (28) is used which is shaped according to the connecting contour (5), in particular a transfer roller and/or a transfer stamp. Method according to one of the preceding claims, characterized in that the decorative blank (2) and the lining element (8) are fixed to one another before they are connected to one another. Method according to one of the preceding claims, characterized in that the decorative blank (2) and the lining element (8) are thermally connected to one another along the connecting contour (5). Method according to one of the preceding claims, characterized in that the decorative blank (2) and the lining element (8) are sewn together along the connecting contour (5). Procedure according to Claim 9 , characterized in that a light-conducting thread (23) is used to sew the decorative blank (2) to the lining element (8). Method according to one of the preceding claims, characterized in that the decorative blank (2) is provided with an opening arrangement (3) which has one or more through openings (10). Procedure according to Claim 11 , characterized in that by coating the coating side (6), one or more of the through openings (10) of the opening arrangement (3) is filled with the coating material (11). Procedure according to Claim 11 or 12 , characterized in that for coating the coating side (6), the decorative side (7) of the decorative blank (2) and a sealing element (13) are fixed to one another, so that one or more of the through openings (10) on the decorative side (7) are fluidically sealed . Procedure according to one Claims 11 until 13 , characterized in that one or more of the through openings (10) of the opening arrangement (3) is kept free of the coating material (11) during the coating of the coating side (6) and/or is freed of the coating material (11) after coating. Method according to one of the preceding claims, characterized in that one or more of the following structures is used as a reversibly elastically compressible layer (16) of the underlining element (8): - a textile structure, - a foam structure, - a sponge structure, - a cotton structure. Method according to one of the preceding claims, characterized in that a material is used for the decorative blank (2), the coating material (11) and/or the lining element (8) and in particular for adhesives of the decorative composite (1) which is UV-stable , - translucent and/or - permeable to air. Decorative composite (1), which is produced by means of a method designed according to one of the preceding claims.

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