CN110549957A

CN110549957A - Vehicle decorative element

Info

Publication number: CN110549957A
Application number: CN201910481555.5A
Authority: CN
Inventors: M·米西; S·勒琼
Original assignee: Virginia Interior Systems Co Ltd
Current assignee: Virginia Interior Systems Co Ltd; Faurecia Innenraum Systeme GmbH
Priority date: 2018-06-04
Filing date: 2019-06-04
Publication date: 2019-12-10
Also published as: DE102018208717A1

Abstract

The invention relates to a vehicle trim element comprising: a cover layer (1) having a front side (1a) and a back side (1b), an illuminating layer (4, 14, 24) on the back side of the cover layer, a translucent spacer layer (3, 13, 23) arranged between the illuminating 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 the area outside the through holes, and the mask layer being arranged between the cover layer (1) and the translucent spacer layer (3, 13, 23), wherein the illuminating layer (4, 14, 24) comprises a light guiding element (4a), the illuminating layer comprises or is a textile tightly fixed to the translucent spacer layer (3, 13, 23), the mask layer (2) is fixed to the back side (1b) of the cover layer or to the side of the translucent spacer layer (3, 13, 23) adjacent to the cover layer, the thickness of the mask layer being less than 10% of the thickness of the, and the cover layer is translucent and has a light absorption of between 50% and 90%.

Description

Vehicle decorative element

Technical Field

The invention relates to a backlit vehicle trim element and a method of manufacturing the same. The trim element is typically used to cover an instrument panel in an automotive vehicle, or to cover the interior surface of a door or other element of the vehicle interior. Recently, covers that allow backlighting have been developed.

Background

FR 2920717 a1 discloses a decorative element with a backlight comprising a specific sequence of different layers.

US 2015/0210226 a1 discloses a vehicle trim element featuring a panel with at least one colored mask, allowing colored structured backlighting.

Disclosure of Invention

One of the objects of the present invention is to propose a vehicle trim element that allows backlighting, which is easy to manufacture and easy to apply. In order to achieve these objects, the present invention proposes a vehicle trim 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 translucent spacer layer arranged between the illumination layer and the cover layer, and a mask layer having a pattern of through holes, the mask layer having a light absorption of more than 90% in an area outside the through holes and being arranged between the cover layer and the translucent spacer layer, wherein the illumination layer comprises a light guiding element, the illumination layer comprises or is a textile tightly fixed to the translucent spacer layer, the mask layer is fixed to the back side of the cover layer or to a side of the translucent spacer layer adjacent to the cover layer, the thickness of the mask layer is less than 10% of the thickness of the cover layer, and the cover layer is translucent and has a light absorption of between 50% and 90%. In some embodiments, the decorative element comprises a panel comprising a cover layer, an illumination layer, a translucent spacer layer, and a mask layer.

By incorporating the light-guiding element, typically a light-guiding fiber for illumination, in the illumination layer, which comprises or is a textile and is tightly fixed to the translucent spacer layer, a mechanically very stable base layer is formed for the decorative element. By securing the illumination layer, which comprises or is a fabric, to the spacer layer, the bonding layer can be easily cut and sewn to other underlying elements. The illuminating layer can be easily fixed to the translucent spacer layer by means of an adhesive or by another bonding of the two layers of material joint. For example, the textile of the lighting layer may be joined with the translucent spacer layer, while the translucent spacer layer is still at least partially in a liquid or molten state before becoming solid. Furthermore, the translucent spacer layer may be molded, printed or coated on the illumination layer.

The combination of the illumination layer and the spacer layer may also be formed by a plurality of light-conducting fibers that are coupled to the light source and mixed and interwoven with fibers that are not coupled to the light source.

implementations of the invention may provide: the illumination layer includes a flexible fabric in which a plurality of optical fibers are interwoven. By interweaving the optical fibres into the flexible fabric, a comprehensive, mechanically stable illumination layer is created. The flexible fabric may act as a light dispersing medium to produce a uniform distribution of illumination density.

Another implementation of the invention can provide: the illumination layer and the translucent spacer layer form a composite layer, wherein the illumination layer and the translucent spacer layer are a single layer. The various composite layers may be formed by one of the processes discussed above and may provide uniform illumination of the mask layer without requiring a single light source to be visible through the mask layer.

The invention can also be realized by a configuration in which the cover layer has a grained surface with a surface roughness of between 20 and 200 micrometers Ra on its front side, i.e. the arithmetic mean deviation of the evaluation profile. By means of this covering layer the front side is mechanically protected against scratches. Furthermore, if a scratch is generated, the optical effect thereof is limited and the scratch is not found by the eye.

In a preferred embodiment of the decorative element, the cover layer comprises two layers having different optical properties. The two layers may be arranged on top of each other. The layer covering the front side may provide a grainy surface. In addition, the layer of the back side, i.e. the layer arranged between the particle layer and the mask layer, may have a uniform thickness. The layer providing the grained surface may exhibit a high light transmission with a light absorption of less than 95% in the visible range of the electromagnetic spectrum. The back side layer may have a low light transmission with a light absorption between 50% and 90% in the visible range of the electromagnetic spectrum. An advantage of such an embodiment is that it allows the cover layer to be optimized with respect to optical appearance and is less prone to mechanical damage, such as scratches.

The front layer may have a higher or lower transmission coefficient (1% -absorbance/cm) than the back layer. Meanwhile, the front layer may have a higher or lower dielectric coefficient than the back layer. This may result in low visibility of the scratch. The front layer may also be thinner than the back layer.

It is also possible to provide the translucent spacer layer with a non-homogeneous distribution of light. By these inhomogenities, a uniformly distributed density of light from the illumination layer is produced before the light reaches the mask layer.

This can be achieved by a configuration in which the inhomogenities are distributed in the volume of the translucent spacer layer with a uniform volume density.

The inhomogeneity in the translucent spacer layer may also be achieved by a configuration wherein the inhomogeneity in the volume of the translucent spacer layer is distributed with a density gradient. The inhomogeneous density gradient may be the result of a method of manufacturing the translucent spacer layer and is advantageous for providing a particularly evenly distributed optical density.

it may be provided, for example, that the translucent spacer layer comprises a solid layer having a thickness of between 0.2 and 0.5 mm. The stiffness of the translucent spacer layer is large enough to provide a stable basis for the decorative layer, and on the other hand the bending radius of the decorative element comprising the spacer layer may be, for example, about 10mm, which is small enough to allow the decorative element to adapt to surfaces of different shapes.

In case the translucent spacer layer comprises a solid layer, for example polyvinyl chloride, for example foamed PVC plastisol, the inhomogeneity may be provided as bubbles. These bubbles may be air bubbles or bubbles of another gas encapsulated in the solid material of the translucent spacer layer, wherein the bubbles may be formed by a foaming agent. By choosing the right time during the manufacturing process and choosing the temperature at which the foaming agent is applied to the translucent spacer layer, a density gradient of the bubbles can be created.

The non-homogeneity may also be achieved in the form of a two-component layer, wherein the two components are separated such that one component forms a continuous matrix and the other component forms "bubbles" in the matrix. Preferably, both components are plastics having different optical indices of refraction.

it may also be provided that the translucent spacer layer is a polyester fabric having a thickness of between 1 and 3 mm. In this case, the translucent distance layer is more flexible than the solid layer, and the bending radius of the decorative element may be less than 10 mm. The weave of the translucent spacer layer may be interwoven with the illumination layer or the illumination layer may be formed inside the translucent spacer layer by interweaving light guiding fibres into the weave of the translucent spacer layer at one side of the translucent spacer layer.

It should also be mentioned that preferably the mask layer is formed on the backside of the cover layer or the translucent spacer layer by printing a pattern with openings on one or each of the cover layer and the translucent spacer layer. The thickness of the ink material printed as a mask layer may be less than 50 microns. For inks printed on the cover layer or translucent spacer layer, the mechanical properties of the ink should be suitable in terms of aging, adhesion and processing. For example, the ink should be suitable for printing on flexible PVC or Polyurethane (PU). The ink may be a water-based ink, but may also be a solvent-based ink when higher mechanical flexibility is required.

It should also be mentioned that the cover layer may be rather soft. For example, the hardness of the cover layer may be less than 70 shore D or even less than 30 shore D.

The following features may be applied to a mask layer, which is also shown in the figures of the present patent application, for example. The thickness of the mask layer is typically between 1 and 50 μm (micrometer), for example 10 μm. In particular, the ratio between the width of the aperture (the dimension of the aperture/pattern in the mask parallel to the layer) and the thickness of the mask layer is preferably greater than 20. Such a high ratio improves the brightness of the layer (better illumination distribution, less focus) compared to a relatively thick mask.

The advantages of a cover layer comprising a highly transparent outer layer and a less transparent lower layer can be explained as follows: the upper layer has a particle structure because it is preferred under normal (daylight) illumination of the layer, and also because of the tactile feel of such particles. However, when backlit, and therefore when the pattern becomes visible due to illumination from the back, it is not understandable to see the heterogeneity of the layers in the pattern. Correlation properties and quality transparency. Preferably, the upper layer has a transmittance of 95% or more. The refractive indices of the layers may be very similar or identical.

Preferably, the decorative element is configured such that it can be applied with a two-dimensional or three-dimensional shaped carrier. In some embodiments of the decorative element, a functional or decorative seam may be applied to the decorative element.

The lighting layer comprising light guiding elements may be a spacer textile.

the present application also relates to a method for manufacturing a vehicle trim element as described above or as described below. In the method, a release layer comprising a particulate non-tacky surface is provided. Furthermore, the semi-decorative element is made by: (a) depositing a cover layer on the grained non-stick surface, (b) depositing a mask layer on the cover layer, and (c) depositing a translucent spacer layer on the mask layer. In a further step, the illumination layer is fixed to the translucent spacer layer. Furthermore, the release layer is separated from the semi-decorative element.

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

Drawings

Specific embodiments of the present invention are shown in the drawings and are discussed in detail below. In the drawings, there is shown in the drawings,

FIG. 1 shows a decorative element with a cover layer on top of a solid translucent spacer layer;

FIG. 2 shows a cover layer on top of a translucent spacer layer made of polyester fabric; and

Fig. 3 shows a decorative element with a cover layer on top of a translucent spacer layer in combination with a lighting layer.

Detailed Description

FIG. 1 illustrates a cross-sectional view of a trim component that may be used to cover interior components and surfaces of a vehicle. The decorative element comprises a covering layer 1 having a front face 1a and a rear face 1 b. The cover layer may consist of a material such as polyurethane in the form of a block moulding or foam. The cover layer may also comprise or consist of PVC. The bulk molded form cover layer may have a light absorption between 50% and 90%, and the cover layer may be dyed through. The cover layer 1 may have a granular surface 1c and may be elastically deformable. The granular surface portions 1c of the cover layer 1 may be bonded with an underlying bulk layer 1d of the same material, which may have a thickness between 0 and 0.7 mm. If the cover layer consists of two different layers, it is preferred that the particle layer on the front side of the cover layer has a lower light absorption than the underlying layer arranged between the particle layer and the mask layer. This formation of the cover layer is advantageous because any mechanical damage on the surface hardly affects the visual appearance of the decorative element.

On the back side of the cover layer 1, a pattern 2 of ink areas or a complete ink layer with through holes is created by printing liquid ink onto the back side. The thickness of the ink layer 2 may be less than 100 microns, or in particular less than 50 microns.

the ink layer 2 or ink area may also be printed on the surface of the translucent spacer layer 3, which translucent spacer layer 3 is adjacent to the back surface 1b of the cover layer 1.

The translucent spacer layer 3 may consist of translucent polyvinyl chloride (PVC). The thickness of the translucent spacer layer 3 may be between 0.1mm and 0.7mm, or in particular between 0.2mm and 0.5 mm. Inhomogenities in the form of particles or bubbles may be distributed inside the translucent spacer layer 3.

on the back side 3b of the translucent spacer layer 3, which back side 3b is located opposite the side of the translucent spacer layer adjacent to the cover layer 1, the illuminating layer 4 is fixed. The illumination layer 4 may comprise light-conducting fibres interwoven with polyester fibres. The lighting layer may be fixed to the translucent spacer layer 3 by means of an adhesive or adhered to the translucent spacer layer 3 in the molten state of the translucent spacer layer. The illuminating layer together with the translucent spacer layer 3 forms a composite layer which provides mechanical stability to the vehicle trim element.

In fig. 2, a similar construction of a vehicle trim element is shown, differing from the construction of fig. 1 in that the translucent spacing layer 13 consists of translucent fabric. The thickness of the translucent spacer layer 13 may be between 1mm and 3 mm. The bend radius may be less than 10 mm. On the back side of the translucent spacer layer 13, opposite the side adjacent to the cover layer 1, an illumination layer 14 is arranged, which illumination layer 14 comprises light-conducting lines and comprises a fibre weave. The lighting layer 14 may be fixed to the translucent spacer layer 13 by an adhesive, or by any other method that allows one layer of fabric to be adhered or bonded and connected to another layer of fabric. The translucent fabric may provide tactile properties, in particular a soft touch to the decorative element. In addition, the translucent textile may diffuse light from the illumination layer 14, thereby providing more uniform illumination to the mask.

In fig. 3, a third version of a vehicle trim element is shown, wherein the cover layer 1 has the same structure as in fig. 1 and 2, and wherein the translucent spacer layer 23 likewise comprises a woven fabric with polyester fibers. On the back side of the translucent spacer layer 23 light guiding elements, e.g. light guiding fibers, are interwoven with the fabric constituting the translucent spacer layer 23. The dashed line 5 marks the border between the part of the translucent spacer layer 23 without light guiding elements and the part of the translucent spacer layer comprising light guiding elements. The part of the translucent spacer layer 23 comprising the light guiding element is indicated at 24 and serves as an illumination layer.

In daylight conditions, the above-described vehicle trim elements exhibit a common plastic granular surface having any desired color. Under conditions where the ambient light intensity is low, and when the light in the illumination layer is on, the light is guided through the translucent spacer layer and the through holes in the printing ink layer 2. Then, the pattern formed by the through holes becomes visible through the cover layer 1.

the decorative element can be made in several ways. However, the inventors prefer the method described below. According to this method, several layers are deposited on top of each other, for example by printing or coating. In particular, the screen printing technique is advantageous because it allows different types of materials to be deposited on top of each other in layers, as uniform layers or patterns, for example for the manufacture of masks. In a first step, a cover layer is deposited on a release layer having a grained surface. The grained non-stick surface is a mirror image of the grained surface of the decorative element. The granular release layer may be a granular silicon paper, but other granular surfaces that allow removal of the release layer from the cover layer in a subsequent step may also be applied. As mentioned above, the cover layer may comprise two layers, deposited on top of each other. In the next step, a mask is deposited on top of the cover layer. The ink of the mask layer must be chosen 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 thickness of the mask layer is less than one tenth of the thickness of the cover layer. In a next step, a translucent spacer layer is deposited on top of the mask layer. Since the mask layer comprises through holes, the translucent layer may protrude into the mask layer, more particularly into the through holes. The cover layer, the mask layer and the translucent spacer together form a semi-decorative element that has to be fixed to the illuminating layer. The release layer may be separate from the semi-decorative element, more particularly from the cover layer after the semi-decorative element has been secured to the illuminating layer or after the semi-decorative element has been secured to the illuminating layer. The semi-decorative element, more specifically the translucent spacing layer, may be fixed by an adhesive deposited on the translucent spacing layer, on the illuminating layer or on both the translucent spacing layer and the illuminating layer.

Claims

1. A vehicle trim component comprising:

A cover layer (1) having a front side (1a) and a rear side (1b),

An illuminating layer (4, 14, 24) on the back of the cover layer,

a translucent spacer layer (3, 13, 23) arranged between the lighting 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 a region outside the through holes and being arranged between the cover layer (1) and the translucent spacer layer (3, 13, 23),

wherein the content of the first and second substances,

The illumination layer (4, 14, 24) comprises a light-guiding element (4a),

The lighting layer comprises or is a textile tightly fixed to the translucent spacer layer (3, 13, 23),

The mask layer (2) being fixed to the rear side (1b) of the cover layer or to the side of the translucent spacer layer (3, 13, 23) adjacent to the cover layer,

the thickness of the mask layer is less than 10% of the thickness of the cover layer, an

the cover layer is translucent and has a light absorption of between 50% and 90%.

2. Decorative element according to claim 1, wherein said illuminating layer (4, 14, 24) comprises a flexible fabric in which a plurality of optical fibres (4a) are interwoven.

3. The decorative element of claim 1 or 2, wherein the cover layer comprises two layers having different optical properties.

4. The decorative layer according to any of claims 1, 2 or 3, wherein the overlay layer (1) has a grained surface on its front side (1a), said grained surface having a surface roughness between 20 and 200 micrometers Ra.

5. The decorative layer according to any one of claims 1, 2, 3 or 4, wherein the translucent spacer layer (3, 13, 23) has an inhomogeneous distribution of light.

6. The decorative layer according to claim 5, wherein the inhomogeneities (3a, 3b, 3c) are distributed in a volume of the translucent spacer layer with a uniform volume density.

7. The decoration layer according to claim 5, wherein the inhomogenities (3a, 3b, 3c) are distributed in the volume of the translucent spacer layer in a density gradient.

8. The decoration layer according to claim 5 wherein the inhomogenities (3a, 3b, 3c) are bubbles.

9. The decorative layer according to any one of claims 1, 2, 3, 4 or 5, wherein the translucent spacer layer (3, 13, 23) is a polyester fabric having a thickness between 1 and 3 mm.

10. A method for manufacturing a vehicle trim element according to any one of the preceding claims, comprising the steps of:

Providing a release layer comprising a particulate non-tacky surface;

The semi-decorative element is made by:

(a) Depositing the cover layer (1) on the grained non-stick surface,

(b) depositing the mask layer (2) on the cover layer (1), and

(c) -depositing said translucent spacer layer (3, 13, 23) on said mask layer (2);

-fixing the lighting layer (4, 14, 24) to the translucent spacer layer (3, 13, 23); and

Separating the release layer from the semi-decorative element.

11. The vehicle trim element according to one or more of claims 1 to 9, wherein the illuminating layer (4, 14, 24) and the spacing layer (3, 13, 23) are bonded and comprise a plurality of light guiding elements (4a), the plurality of light guiding elements (4a) being coupled to a light source and being mixed and interwoven with fibers not coupled to a light source.

12. the vehicle trim element according to one or more of claims 1 to 9 or 11, wherein the cover layer (1) comprises two layers with different optical properties, namely a front layer (1a) and a back layer (1b), wherein the front layer has a lower or higher light transmission coefficient than the back layer and/or the front layer has a lower or higher dielectric coefficient than the back layer.