CN115534829A - 具有装饰性表面材料的内饰面板的照明的无缝集成 - Google Patents

具有装饰性表面材料的内饰面板的照明的无缝集成 Download PDF

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Publication number
CN115534829A
CN115534829A CN202210762921.6A CN202210762921A CN115534829A CN 115534829 A CN115534829 A CN 115534829A CN 202210762921 A CN202210762921 A CN 202210762921A CN 115534829 A CN115534829 A CN 115534829A
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CN
China
Prior art keywords
decorative
layer
light
decorative cover
panel
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Pending
Application number
CN202210762921.6A
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English (en)
Inventor
M.阿克塞尔松
M.安德烈亚松
J.A.佩尔松
E.阿莱比
H.威廉森
J.埃尔温
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Volvo Car Corp
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Volvo Car Corp
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Publication date
Application filed by Volvo Car Corp filed Critical Volvo Car Corp
Publication of CN115534829A publication Critical patent/CN115534829A/zh
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    • B32—LAYERED PRODUCTS
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
    • B60R2013/0287—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners integrating other functions or accessories
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2106/00—Interior vehicle lighting devices
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21W—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO USES OR APPLICATIONS OF LIGHTING DEVICES OR SYSTEMS
    • F21W2121/00—Use or application of lighting devices or systems for decorative purposes, not provided for in codes F21W2102/00 – F21W2107/00
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
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Abstract

一种用于车辆的背照式内饰面板的装饰性罩，所述罩是坚固的壳体结构，包括形成壳体结构的背面的透明板和包括装饰材料层的装饰性组件顶层，其形成装饰性罩的外表面，其中装饰材料层由装饰材料形成，该装饰材料是木质单板、金属层、纸、纺织品和织物组成的材料组中的一种，并且其中层压板被构造成具有预定程度的半透明度。

Description

具有装饰性表面材料的内饰面板的照明的无缝集成
技术领域
本公开涉及用于车辆的背照式内饰面板的装饰性罩，所述罩是坚固的壳体结构，包括形成壳体结构后侧的透明板和形成壳体结构前侧的装饰性组件顶层。此外，本公开涉及用于车辆的内饰面板。最后，本公开涉及制造装饰性罩的方法和制造内饰面板的方法。
背景技术
豪华车的内部越来越变成美好、温馨的环境，其提供有装饰性的环境照明。具体地，这种照明越来越多地集成在内饰面板中。
例如，一种已知的集成为装饰面板的内部氛围灯包括LED背光源和安装在LED背光源的上表面的内部显示面板。内部显示面板由IML(In-Mold Injection Molding，模内镶件注塑)制成。显示器所需的发光内容通过IML薄膜产生获得。显示内容可以是字符(诸如，欢迎、或汽车型号或品牌字样等)或各种形状或图案。这种内部氛围灯的一个缺点是，当灯打开和关闭时，光图案似乎都在显示。
提供仅在灯打开时可见的装饰性图案的一种可能方式在一种可替代的已知面板中实现了，该面板通过镶件注塑表面装饰技术(IMD技术)提供有装饰性图案，利用该技术可以在汽车内部部件的表面上形成装饰性图案，诸如金属镜、哑光表面和木质纹理，以增加装饰性。面板外表面上的图案由具有叠加效果的两个不同层组成，其中上层的图案在白天用作装饰车厢的装饰性图案。图案中另一层的高透光区域可供光线通过，作为夜间装饰的装饰性图案。
这种内部氛围灯的缺点是面朝车辆内部的材料，即用户所体验的材料，是注塑成型材料，通常是硬塑料。与具有例如由木材、金属或织物制成的不透明装饰性表面材料的装饰面板相比，这种材料通常不被认为具有豪华的外观和/或感觉。
透光的汽车内部组件的另一种已知可替代方案是，其中车体面板是不透明的，设置有中空部分，并且车体的后表面依次设置有透光层和发光层。此外，在透光层上形成凸起部分，并且凸起部分嵌入中空部分中以使车体的表面光滑。
具有带穿孔和/或半透明镶嵌物的表面的装饰的缺点是，为了产生这样的表面，需要更多的处理工序。这种材料的成本也更高，并且当表面穿孔时，材料废料增加了。
技术问题
可能需要提供具有豪华装饰性表面材料的更坚固耐用的照明内饰面板。
此外，可能需要以相对较低的成本提供具有豪华装饰性表面材料的照明内饰面板。
发明内容
根据本公开的第一方面，提供了一种用于车辆的背照式内饰面板的装饰性罩。该装饰性罩是坚固的壳结构，包括形成壳结构背面的透明板，和包括装饰材料层的装饰性组件顶层，其形成装饰性罩的外表面，其中装饰材料层由装饰材料形成，该装饰材料是由木质单板、金属层、纸、纺织品和织物组成的材料组中的一种，并且其中装饰性组件顶层被构造成具有预定程度的半透明度。
与通常采用的、这些没有背光的材料的内饰面板提供的外观和感觉相比，具有形成外表面的装饰材料的装饰性组件顶层给予装饰性罩豪华的外观和感觉。形成外表面的装饰材料应理解为在壳体结构的整个前侧上形成基本均匀的层的装饰材料。因此，当没有灯打开时，在装饰性罩面板的后面，该面板基本上与其他豪华装饰面板没有区别。
预定程度的半透明度可以作为固有的层属性来实现，例如通过使用特别薄的材料层，纬向或网格的特别紧密度。这种半透明度类似于灯罩中的半透明度，允许在装饰性罩后面直接提供的光线透过。优选地，装饰材料层的预定程度的半透明度是使得装饰性罩具有5％至15％之间的半透明度。至此，取决于材料的类型，装饰材料层的厚度相对较薄，在0.1至1.0mm之间。对于木质单板，典型的厚度在0.2毫米和0.8毫米之间。
透明板优选地由注塑成型的塑料材料制成，诸如聚碳酸酯(PC)、聚甲基丙烯酸甲酯(PMMA)或甲基丙烯酸甲酯-丙烯腈-丁二烯-苯乙烯(MABS)，这些材料在车辆的整个生命周期提供所需的透明度以及耐久性和安全性。
这允许以相对较少的制造工序制造装饰性罩。在一个实施例中，通过对装饰性组件顶层进行背面注塑来形成坚固的壳体结构，使得坚固的壳体结构是无缝的单一组件结构，并且其中装饰性组件顶层对于背部注塑的材料是不可渗透的。
装饰性罩材料作为注塑材料的屏障，允许在单个注塑成型工序中形成罩，而不需要为了在罩的外侧上具有装饰性装饰材料而进行后处理，该罩允许光以期望的图案通过。装饰性罩材料的不可渗透性防止所述注塑成型材料流过装饰材料，从而影响装饰材料的外观和感觉。这使得具有豪华外表面的面板的制造成本相对低。层压板(laminate)可以在注塑成型之前预成型为装饰性罩的期望形状。装饰性罩材料的形成以及随后的预成型和注塑工序产生相对较少的废料，使得进一步限制了制造成本。
在一个实施例中，透明板在预定部分设置有遮光装置，用于局部减少透过该板的光量。当集成在背照式内饰面板中时，罩的位于与灯直接相邻的部分将比罩的位于其他地方的部分发出更大量的光，导致不期望的不均匀照明图案。附加地或可替代地，可能期望特定的照明图案，而不必在罩下面放置大量的灯来实现所述图案。遮光装置的提供为此提供了一种解决方案。遮光装置可以是粘附在透明板内表面上的独立组件。然而，优选地，壳结构是无缝的单一组件结构。所述结构可以通过使透明板形成装饰性罩板的整个内表面来实现，在该内表面上，胶带或涂料被设置在预定部分，所述胶带或涂料是遮光装置。可替代地，遮光装置可以使用单个模具在双组件注塑处理中与透明板一体形成。遮光装置的透明度低于装饰性罩在没有提供遮光装置的区域中的透明度。遮光装置可以是不透明的装置。
在一个实施例中，装饰性组件顶层是层压板，其包括由装饰材料层组成的上层和背衬材料层。取决于为装饰性罩选择的特定装饰材料，可能需要背衬材料来确保层压板足够稳定，以允许在制造期间处理而不会使装饰材料破裂，该处理可包括在背部注塑之前成型为外壳预成型。可替代地或附加地，可能需要背衬材料来确保层压板不可渗透通过其背部注塑和/或粘附到透明板的材料。具体地，网状装饰材料，诸如多孔金属，需要背衬材料来确保装饰性组件层对于被背部注塑的材料是不可渗透的，以确保装饰材料形成装饰性罩的外表面，即装饰性罩的外表面上不存在背部注塑的材料。木质单板已经具有所需的不可渗透性，然而，为了足够坚固以允许在整个制造期间处理，需要背衬来稳定木质单板的薄层。
在一个实施例中，背衬材料层由羊毛、织物或塑料箔中的一个形成。选择作为背衬材料的具体材料可以取决于所使用的装饰材料。具体地，对于具有相对开放结构的装饰材料，诸如膨胀金属(箔)或特定织物，塑料箔是优选的背衬材料，因为羊毛或其他织物通过装饰材料的结构是可见的，可能影响面板的外观。
在一个实施例中，装饰性组件顶层的后表面设置有涂黑图案和/或遮蔽图案印痕(print)，或者其中邻近背衬材料层设置有另一塑料箔层，所述另一塑料箔设置有涂黑图案和/或遮蔽图案印痕。可以添加黑色图案印痕和/或遮蔽印痕，以提供装饰性罩的预定区域的遮掩和/或遮蔽。印痕的目的是遮光和/或阻挡某些光线强烈的区域，诸如当组装到背照式内饰面板中时，直接邻近位于装饰性罩下方的LED，和/或产生装饰性图案和/或遮光。当一些区域通过使用不透明的遮光装置被遮掩时，遮蔽印痕的使用可能是特别理想的。然后，印痕提供了从遮掩区域到光亮区域的更加渐变的变化。这些图案可以两者都提供，或者独立的提供，或者作为合并的单个图案提供。
装饰性组件顶层的背面可以由装饰材料或背衬材料层的背面形成。与在也可用作背衬材料的羊毛或织物上印刷相比，在塑料箔上印刷提供更高的印刷分辨率。因此，如果层压板中使用的背衬材料还不是塑料箔，则优选地可以添加塑料箔的附加层。
在一个实施例中，装饰材料层设置有涂层，用于保护表面免受湿气、热量和/或紫外线暴露。该涂层使得装饰性罩在更长时间内看起来像新的一样，即提高了其耐用性。取决于所选择的装饰材料，涂层可以在背部注塑透明层之后或之前施加，因为装饰性材料层的前侧不受注塑处理的影响。此外，当膨胀金属用作装饰材料时，甚至可以在其膨胀之前对金属进行涂层。
根据本公开的第二方面，提供了一种用于车辆的内饰面板，包括根据本公开第一方面的装饰性罩，还包括光源组件，该光源组件包括：载体板，其成型为形成内饰面板的后表面并具有反射表面；至少一个LED灯，安装在反射表面上；以及光板，邻近该至少一个LED灯定位在反射表面上，使得灯板在其表面区域上传递该至少一个LED灯的光，并且其中装饰性罩附着到载体板，使得内饰面板是封闭的灯单元，装饰性罩形成其前表面，并且装饰性罩和载体板一起封闭该至少一个LED灯和灯板。因此，在内饰面板中，当安装到车辆中时，装饰性组件具有完全覆盖光源组件的无缝外表面。反射载体有助于有效地迫使光穿过装饰性罩。载体的反射表面可以通过形成载体板的材料(即金属材料)固有地获得，或者作为反射层提供给载体板，例如作为箔层或涂料。光源的设计由至少一个LED灯和光板构成，该光板传输光并均匀地传播光。
根据本公开的第三方面，提供了一种制造用于包括光源组件的车辆内饰面板的装饰性罩的方法，其中该方法包括：
—提供不可渗透的装饰性组件顶层，其包括装饰材料层，该装饰材料层由装饰材料形成，该装饰材料是由木质单板、金属层、纸、纺织品和织物组成的材料组中的一种，并且该装饰材料层被构造成具有预定程度的半透明度；
—可选地，将装饰性组件顶层成型为具有用于形成装饰性罩的外表面的期望几何形状的壳体预成型件；以及
—用半透明材料背部注塑装饰性组件顶层，以形成无缝坚固的壳体结构，装饰材料形成装饰性罩的外表面，并且所述半透明塑料形成装饰性罩的内表面。
在装饰面板的几何形状相对平坦的情况下，可能不需要预形成装饰材料。在这种情况下，装饰材料(有或没有背衬)和塑料箔(如果需要)可以分别添加到背部注塑工具中，以产生“工具内层压”。
在一个实施例中，提供不可渗透的装饰性组件顶层包括通过将装饰材料层附着到背衬材料层上来形成层压板，并且可选地还包括在将所述装饰材料附着到背衬材料层上之后将装饰材料层砂磨至最小厚度，以实现预定程度的半透明度。特别是对于木质单板和纸，由于材料被层压到背衬材料上，厚度的减小可以通过在不会损害稳定性的情况下，砂磨至最小厚度来实现。砂磨是一种简单而廉价的生产工序，尤其是在平坦物体上进行时，因为层压在预成型之前。
在一个实施例中，不可渗透的装饰性组件顶层的提供包括装饰材料层的膨胀和/或拉伸，并且当装饰材料层随后附着到背衬材料层上时，背衬材料层是塑料箔。这是实现预定程度的半透明度的一种可替代方法。特别是金属、箔和织物可以被膨胀和/或拉伸。
在一个实施例中，用半透明材料对组件顶层进行背部注塑以形成坚固的壳体结构是通过双组件注塑处理来执行的，其中第一组件是半透明材料，并且其中第二组件是减少光透过的遮光材料，其中所述第二组件被注塑到来自光源的光将被遮掩的预定区域中。遮光材料用于遮掩不想光以其他方式泄漏的区域，例如罩的被所述光覆盖的LED正上方的区域，或者例如罩的边缘，其中所述罩附着到光源组件。优选地，遮光材料被选择成使得由LED直接发射的光被遮光，以基本上匹配经由光板发出的透过装饰性罩的光，从而确保在装饰性罩的整个表面上发出基本上均匀量的光。遮光的程度取决于具体的内饰面板设计，并且可以在足以使通过LED正上方的面板发出的光量与通过光板上方的面板发出的光量相似的遮光水平和100％遮光(即完全阻挡光)之间变化。
可替代地，用半透明材料对组件顶层进行背部注塑以形成坚固的壳体结构是用单组件注塑处理执行的，其中注塑半透明材料以形成装饰性罩的背面。
为了实现在装饰性罩的外表面上在使用期间基本均匀地发光，在制造罩之后和/或进一步地，在可选地将组件顶层成型为壳体预成型之前和/或在背部注塑之前，遮光材料可以作为胶带或涂料提供，在装饰材料层的背面、背衬材料层之一上设置黑色图案和/或遮蔽图案印痕，或者提供附加塑料箔层，在其上设置黑色图案和/或遮蔽图案印痕。
为了防止分层或层压翘曲，当提供塑料箔的附加层并且组件顶层被成型为壳体预成型件时，塑料箔的附加层可以独立于组件顶层被预形成，并且在背部注塑期间被附着到预成型的组件顶层，即通过向其前表面提供增粘剂并且在放置层压预成型件之后将附加箔层放置到模具中。在装饰面板的几何形状相对平坦的情况下，附加的塑料箔和组件顶层可能不需要预形成，而是可以单独添加到背部注塑模具中以产生“工具内层压”。
根据本公开的第四方面，提供了一种制造包括光源组件的车辆内饰面板的方法，包括：
—根据本公开第二方面的方法提供装饰性罩；
—提供与装饰性罩匹配的载体板，使得所述装饰性罩可以附着到载体板以形成封闭中空空间的封闭单元，其中载体板具有面向该中空空间的反射表面；
—将至少一个LED灯安装到反射表面上，以及
—将光板放置在反射表面上，邻接至少一个LED灯，使得光板在其表面区域上传输至少一个LED灯的光；和
—将装饰性罩附着到载体板，使得发光板位于载体板和装饰性罩之间。
附图说明
参照附图，将通过示例的方式描述根据本公开的内饰面板的实施例，其中：
图1示出了根据本公开的具有装饰性表面材料的内饰面板的实施例；
图2示出了图1的内饰面板的分解图；
图3示出了图1的内饰面板沿线III的剖视图；
图4示出了沿着图1的装饰性面板的线III的更详细的剖视图；和
图5A和图5B分别示出了用于如图1所示的装饰面板的遮蔽印痕和图案印痕的示例。
具体实施方式
图1示出了根据本公开的具有装饰性表面材料的内饰面板100的实施例，图2和图3分别示出了分解图和其沿着线III的剖视图。所示的面板100可以被认为是用于车辆(诸如汽车)的仪表面板的面板，其中装饰性表面材料形成仪表面板的外表面。该外表面面向车辆的内部，使得其乘坐者可以在视觉上和物理上体验装饰性表面材料。类似的面板可以例如用在隧道控制台上或门面板的内侧。装饰性表面材料是由以下材料组成的材料集合中的一种：木质单板、金属板材、箔、纸、纺织品或织物。至此，由装饰性表面材料形成的面板的外表面被称为面板100的外侧或上侧，并且内饰面板100的在安装时背朝车辆内部的对侧被称为面板100的内侧或下侧。本领域技术人员将认识到，车辆内部包括更多的面板，这些面板不限于安装在门框中，并且内饰面板的形状取决于它们在内部的安装位置以及车辆的构造和型号，使得所示的内饰面板100的具体形状可以相应地调整。
内饰面板100是由装饰性罩面板10和光源组件组成的组件，光源组件由载体板(面板)20、灯板30和LED灯40组成。载体板20成型为形成内饰面板100的内侧，并且适于附着到装饰性罩面板10，所述面板一起形成封闭空间，灯板30和LED灯40位于该封闭空间内。至此，载体板20的轮廓形状基本上与装饰性组件10的轮廓形状相匹配。LED灯安装在载体板20的面向装饰性罩面板10的表面上。在所示的光源组件中，LED灯40由两个LED元件41、42组成，这两个LED元件中的第一个41位于载体板20的第一纵向端，这两个LED元件中的第二个42位于载体板20的第二纵向端。灯板30具有与载体板20匹配的尺寸和形状，使得处于组装位置的灯板30压装在LED元件41、42之间，并且夹在载体板20和装饰性罩面板10之间。因此，LED元件41、42位于灯板30的相对的纵向端，并且载体板20和装饰性罩面板10位于灯板30的上侧和下侧。除了光板30之外，所有部件优选地都焊接在一起。然而，也可以使用诸如胶带或夹子的其他方法。
通过LED元件41、42位于两个纵向端，光板30引导和传输由LED发出的光，以基本上均匀地散布在其表面上。其上安装有LED灯40的载体板20的表面是反光的，使得发出的光被反射离开所述表面，朝向装饰性罩面板10。当LED灯40打开时，装饰性罩面板10适合于允许预定量的光穿过，同时当灯关闭时，其具有无缝且坚固的表面外观，没有可见光特征。
至此，如图3所示，装饰性罩面板10包括装饰性组件顶层1、半透明层5和遮光组件6。装饰性罩面板10形成为单个坚固的外壳，装饰性组件顶层1包括装饰性表面材料，该装饰性表面材料赋予罩面板10无缝和坚固表面外观。尽管装饰性表面材料是通常被认为是不透明材料的材料集合中的一种，但是这些材料可以调整为允许预定量的光透过，即调整为对于直接位于其后的光具有预定的半透明度，例如通常在灯罩中看到的。实现预定的半透明度的调整取决于所选择的具体材料，以及可以包括减小材料的厚度、在整个材料上膨胀或精细穿孔和/或选择具有特定经纱/纬纱紧密度的材料。为了确保装饰性罩面板10足够坚固，在装饰性组件顶层1的内侧设置相对厚的半透明层5。关于这些层以及它们如何组合的更多细节将在下面结合图4进行讨论。为了确保从内饰面板100发出的光图案平滑，装饰性罩面板10在LED灯40的位置处设置有遮光组件6。遮光组件6遮掩LED光，以防止所谓的热点直接出现在每个LED的位置。遮光组件6可以基本上完全不透明，从而遮掩LED灯40，或者包括预定的透明度，该预定的透明度小于半透明层5的透明度，并且引起LED等被遮光(shade)而不是被遮掩(mask)。这两种选择将在下面结合图4和图5进一步讨论。
图4示出了图1的装饰性罩面板10沿着线III的更详细的剖视图。装饰性罩面板10从上到下包括装饰材料层1a、背衬材料层2、可选的塑料箔层3、半透明层5和遮光组件6。
图3所示的装饰性组件顶层1由装饰材料层1a、背衬材料层2和可选的塑料箔层3形成，并且对于半透明层5的材料是不可渗透的，半透明层5是背部注塑到装饰性组件层1上的。这允许使用单个注塑成型模具以相对较少的生产工序形成装饰性罩面板10，并确保所述面板的无缝和坚固的表面外观。背部注塑之前的制造工序以及塑料箔层3的存在和背衬材料层2的材料选择取决于为装饰材料层1a选择的具体材料。如果装饰材料层1a既是足够坚固的(即不易碎，以便在生产期间可单独处理)又不可渗透半透明层5的背部注塑材料，则甚至背衬材料层2的存在也可以是可选的。典型地，装饰性组件顶层1的厚度范围在0.4毫米和3.8毫米之间，优选地在0.6毫米和1.2毫米之间，半透明层5的厚度在2毫米和3毫米之间，遮光组件的厚度大约为1毫米。取决于所使用的装饰材料，装饰性组件顶层1可以具有厚度在0.1mm和1mm之间、优选地约0.3mm的装饰材料层1a，厚度在0.1mm和0.4mm之间的背衬材料层和厚度在0.2mm和0.5mm之间的塑料箔层。对于木质单板，厚度取决于单板类型，通常在0.2-0.8毫米的范围内。
例如，当选择木质单板作为装饰材料层1a时。在砂磨至增加木材透明度所需的最小厚度之前，木质单板用稳定的半透明背衬材料2层压，例如无纺羊毛或任何类型的织物。背衬在进一步处理之前稳定木质单板，允许在砂磨至最小厚度后对其进行处理，否则会使单板太脆弱而无法进行进一步的制造工序，诸如背部注塑。然后，层压板被预成型为内饰面板100的期望几何形状，之后，层压板被背部注塑半透明材料以形成半透明层5，从而产生坚固且半透明的背光装饰性罩面板10。木质单板可以用涂层系统处理，以保护表面在背部注塑后免受湿气、热量和紫外线的影响。
木质单板的可替代方案是使用膨胀金属作为装饰材料层1a。膨胀金属对于处理来说足够稳定，但是通过膨胀，它缺乏对于将被背部注塑的材料所要求的不可渗透性。因此，膨胀金属首先被层压到塑料箔上，该塑料箔形成膨胀金属的背衬材料层2。可以在膨胀之前、层压到塑料箔上之前或层压到塑料箔上之后，执行的膨胀金属涂层处理。
半透明层5优选地在单个注塑处理中与形成遮光组件6的结构的材料一起注塑成型。这可以通过单个材料注塑成型处理来实现，其中半透明层5和遮光组件6的结构都由相同的半透明材料形成。可以在后处理工序中通过应用胶带或涂料来提供，提供用于以下的属性的材料：提供遮光组件6的期望遮光或遮掩。然而，优选地，使用单个模具通过双组件注塑处理来执行背部注塑。在该双组件注塑处理中使用的两个组件中的第一个是用于形成半透明层5的半透明材料，第二个组件是用于形成遮光组件6的阻光或遮光材料。
当完全遮掩LED时，为了实现均匀的发光，或者为了实现通过装饰材料层1a发光的预定光图案设计，可选地，可以将图案印痕添加到层压板的下侧。该图案印痕是所谓的黑色图案和/或遮蔽图案，当两者都被应用时，可以作为两个独立的图案层或作为单一的合并图案来应用。取决于所使用的装饰材料、背衬材料和光图案设计的具体要求，图案印痕可以直接印刷在装饰材料层1a的后表面、背衬材料层2中的一个上，或者印刷在附加的塑料箔层3上。将图案印刷到塑料箔上的优点是，与印刷到织物或羊毛上相比，可以获得更高分辨率的印痕。在印痕被设置在附加的可选塑料箔层3上的情况下，该层可以独立于层压板被预成型，在其顶侧提供有增粘剂，并且与层压板一起被堆叠到模具中，用于被背部注塑以形成装饰性罩面板10。图5A中描绘了用于遮掩光板30的边缘和内饰面板100的LED的黑色图案印痕的示例。图5B中描绘了同一面板的遮蔽图案印痕的示例。
对于本领域技术人员来说显而易见的是，在装饰性罩面板10的制造期间，所列出的用作装饰材料层的其它装饰材料可以类似于木质单板和/或膨胀金属进行处理。
上面已经参照附图中所示的多个示例性实施例描述了本公开。一些部分或元素的修改和可替代实施方式是可能的，并且包含在所附权利要求中限定的保护范围内。

Claims (15)

1.一种用于车辆的背照式内饰面板的装饰性罩，所述罩是坚固的壳体结构，包括形成所述壳体结构的背面的透明板和包括装饰材料层的装饰性组件顶层，其形成所述装饰性罩的外表面，其中所述装饰材料层由装饰材料形成，所述装饰材料是由木质单板、金属层、纸、纺织品和织物组成的材料组中的一种，并且其中所述装饰性组件顶层被构造成具有预定程度的半透明度。
2.根据权利要求1所述的装饰性罩，其中所述坚固的壳体结构通过对所述装饰性组件顶层进行背部注塑而形成，使得所述坚固的壳体结构是无缝的单一组件结构，并且其中所述装饰性组件顶层对于背部注塑的材料是不可渗透的。
3.根据权利要求1或2所述的装饰性罩，其中，所述透明板在预定部分设置有遮光装置，用于局部减少透过该板的光量。
4.根据前述权利要求中任一项所述的装饰性罩，其中，所述装饰性组件顶层是层压板，其包括由装饰材料层组成的上层和背衬材料层。
5.根据权利要求4所述的装饰性罩，其中，所述背衬材料层由羊毛、织物或塑料箔之一形成。
6.根据前述权利要求中任一项所述的装饰性罩，其中，所述装饰性组件顶层的后表面设置有涂黑图案和/或遮蔽图案印痕，或者其中邻近所述背衬材料层设置有另一塑料箔层，所述另一塑料箔设置有涂黑图案和/或遮蔽图案印痕。
7.根据前述权利要求中任一项所述的装饰性罩，其中，所述装饰材料层设置有涂层，用于保护所述表面免受湿气、热量和/或紫外线(UV)暴露。
8.一种用于车辆的内饰面板，包括根据权利要求1-7中任一项所述的装饰性罩，还包括光源组件，所述光源组件包括：
载体板，其成型为形成所述内饰面板的后表面并且具有反射表面，
安装在所述反射表面上的至少一个LED灯，以及
光板，邻近所述至少一个LED灯定位在所述反射表面上，使得所述光板在其表面区域上传输所述至少一个LED灯的光，并且
其中所述装饰性罩附着到所述载体板，使得所述内饰面板是封闭的灯单元，装饰性罩形成其前表面，并且装饰性罩和载体板一起围绕所述至少一个LED灯和所述光板。
9.一种制造包括光源组件的车辆内饰面板的装饰性罩的方法，包括：
提供不可渗透的装饰性组件顶层，其包括装饰材料层，所述装饰材料层由装饰材料形成，所述装饰材料是由木质单板、金属层、纸、纺织品和织物组成的材料组中的一种，并且其被构造成具有预定程度的半透明度；
可选地，将所述装饰性组件顶层成形为具有用于形成所述装饰性罩的外表面的期望几何形状的壳体预成型件；以及
用半透明材料背部注塑所述装饰性组件顶层，以形成无缝坚固的壳体结构，所述装饰材料形成所述装饰性罩的外表面，并且所述半透明塑料形成所述装饰性罩的内表面。
10.根据权利要求9所述的方法，其中，提供不可渗透的装饰性组件顶层包括通过将装饰材料层附着到背衬材料层上来形成层压板，并且可选地还包括在将所述装饰材料附着到所述背衬材料层上之后将装饰材料层砂磨至最小厚度，以实现预定程度的半透明度。
11.根据权利要求9或10所述的方法，其中，提供不可渗透的装饰性组件顶层包括膨胀和/或拉伸装饰材料层，并且其中，当装饰材料层随后附着到背衬材料层上时，所述背衬材料层是塑料箔。
12.根据权利要求9-11中任一项所述的方法，其中，用半透明材料对组件顶层进行背部注塑以形成坚固的壳体结构是通过双组件注塑处理执行的，其中第一组件是半透明材料，并且其中第二组件是减少光透过的遮光材料，其中所述第二组件被注塑到来自光源的光将被遮掩的预定区域中。
13.根据权利要求9-12中任一项所述的方法，其中，用半透明材料对组件顶层进行背部注塑以形成坚固的壳体结构是通过单组件注塑处理来执行的，其中注塑半透明材料以形成所述装饰性罩的背面。
14.根据权利要求13所述的方法，其中，在将所述组件顶层成型为外壳预成形件之前和/或在背部注塑之前，在所述装饰材料层的背面、所述背衬材料层和/或附加的塑料箔层上设置黑色图案和/或遮蔽图案印痕。
15.一种制造包括光源组件的车辆内饰面板的方法，包括：
根据权利要求9-14中任一项的方法提供装饰性罩；
提供与所述装饰性罩匹配的载体板，使得所述装饰性罩能够附着到所述载体板以形成封闭中空空间的封闭单元，其中所述载体板具有面向所述中空空间的反射表面；
将至少一个LED灯安装到所述反射表面上，
将光板放置到所述反射表面上，邻接所述至少一个LED灯，使得所述光板在其表面区域上传输所述至少一个LED灯的光；以及
将所述装饰性罩附着到所述载体板，使得所述光板在所述载体板和所述装饰性罩之间。
CN202210762921.6A 2021-06-30 2022-06-29 具有装饰性表面材料的内饰面板的照明的无缝集成 Pending CN115534829A (zh)

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EP21186243.8 2021-07-16

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DE502007001930D1 (de) * 2007-11-15 2009-12-17 Novem Car Interior Design Gmbh Leuchtendes Formteil, ausgebildet als Verkleidungsteil für den Fahrzeuginnenraum
JP6272319B2 (ja) * 2013-05-29 2018-01-31 テイ・エス テック株式会社 車両用発光部品
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