DE102010034879A1 - Multilayer decorative element for use during production of lining- or trim part of motor vehicle, has plastic foil provided with multiple projections, where refractive indices of plastic foil and intermediate layer deviate from each other - Google Patents

Abstract

The element has a transparent or translucent plastic foil (2) provided with multiple projections (2a), and a continuous cover layer forming a rear side of the element. A continuous or partial color layer is formed between an inner side (12a) of the plastic foil and the cover layer. The inner side of the plastic foil points towards the cover layer, and is completely covered by a transparent or translucent intermediate layer, which forms intermediate spaces between the projections. Refractive indices of the plastic foil and the intermediate layer deviate from each other. An independent claim is also included for a method for producing a lining- or trim part for a motor vehicle.

Description

The The invention relates to a multilayer decorative element, with a transparent or translucent plastic film with an inside and an outside and with a full-surface forming the back Cover layer and with at least one color layer between the inside and the topcoat.

Such, with plastic hinterspritzbares, in particular deformable by thermoforming decorative element is for example from the EP 1 436 176 A1 known. In order to achieve a special depth effect, the film is printed on both sides with a non-covering decorative color layer, wherein the decorative color layer is printed on the inside with a covering color layer. The decorative color layers form matching patterns, wherein the decor or the pattern elements on the one side of the plastic film are slightly offset from the decor or the pattern elements on the other side of the film.

From the US 5,270,097 B a decorative element is known, which has a transparent or translucent plastic film whose inside has an embossed pattern of undulating and mutually parallel elevations. On the embossing a wood structure imitating pattern is printed, which is printed on the back over the entire surface. On the outside of the plastic film forming the base layer, a further transparent plastic layer is applied, which is also printed with a non-surface covering pattern.

The DE 44 46 255 A1 discloses a decorative film for decorating three-dimensional substrate surfaces under heating, which consists of a carrier film and a decorative layer arranged thereon, which is formed by at least one under the formation of a precisely fitting decor printed lacquer layer. The carrier film is a substantially amorphous, unstretched polyester, polyamide or polyamide copolymer film. Using this decorative film, it should be possible to perfectly decorate finely structured, three-dimensional substrate surfaces with a precisely predeterminable pattern.

From the DE 42 02 975 A1 is known a multilayer composite material having a layer structure, which as a first layer, a scratch-resistant lacquer layer with a gloss level up to 100% reflection, a second layer of a highly transparent thermoplastic, a third layer of at least one decorative color layer and a fourth layer of a thermoplastic Plastic, which may contain up to 30 weight percent of a dye.

Other decorative elements with an optical depth effect are known from the official publications US 1,150,374 A . US 2,149,171 A . US 2,951,419 A . CA 0 759 824 A . US 3,383,789 A and DE 14 46 855 A , The latter document discloses, in addition to the decorative element, a method for its lamination or bonding to a planar carrier foil or carrier layer. However, in the described lamination, the depressions in the back of the decorative film are completely filled in an adhesive or filler. Without loss of the optical effect of the decorative film, this is only possible because a back metallization prevents any passage of light into the adhesive or filler.

In front The described background arises under a first aspect the task of a decorative film of the type mentioned in such a way to implement that it is a particularly effective and outstanding Provides depth effect with a simple structure and these properties in a lamination with a substrate or the Backfilling us especially Hinterpressen or Hinterspritzen not loses. In a second aspect, the task arises Process for producing a structurally rigid trim part or decorative part with a decorative foil attached on the visible side to accomplish.

Solved The task is completed by a decorative foil with the in Claim 1 specified characteristics. The task specified below solves the present invention by a method with the specified in claim 12 steps.

The inventive selection of refractive indices of plastic film and interlayer causes the with the Embossing intended optical depth effect not lost goes. As a result, the back injection with a to the material the plastic film identical or similar material possible. For a direct order of a material with a nearly identical refractive index, however, would go lost the visual effect of the imprint.

The provided on both sides with an embossment of individual surveys Plastic film works together with the on its back applied, translucent interlayer already at a simple, only a few layers having structure of the decorative element a particularly clear and striking depth effect. It has pointed out that this effect, especially as a result of inventive construction of the decorative element, is particularly well preserved during deep drawing.

According to a preferred embodiment According to the invention, the embossed elevations on each of the two sides of the plastic film are identically designed and arranged regularly. Such embossings can be created in a simple manner in the plastic film and effect a uniform depth effect over the extent of the decorative element in the decorative element according to the invention.

The embossed surveys can be in different Shapes can be created, in particular they can be prismatic, conical, pyramidal or spherical segmental be executed. Especially with spherical section-shaped Elevations can be an excellent depth effect achieve.

The embossed surveys have in particular a height on, which is between 2 microns and 5 microns. This area provides an optimum for the achievable depth effect In such an embossing can also the outside the plastic film directly the outside of the decorative element form as optics and feel as extremely pleasant be felt.

It further simplifies the production of the plastic film when the Embossed on the inside of the plastic film with the embossing matches on the outside.

to Achieving special and on the extension of the film varying depth effects may affect the embossing on at least one of the film sides of a second embossing, for example from wells of much larger extent as the elevations, be superimposed.

Of the Depth effect and the other visual effect of the decorative element can be optimized by other layers and to different applications be adjusted. For example, on the inside and / or the outside of the plastic film at least one not surface-covering design color layer forming pattern elements, following the embossed structure. A Such, applied to the inside of the plastic film design color layer is covered by the intermediate layer.

at Another embodiment of the invention are respectively at least two design color layers, partially overlapping one another, applied, leaving free surfaces of pattern elements are, so in any case, between the pattern elements point of view the embossed foil is possible and the depth effect obtained by the embossed film. The design color layers can be translucent or opaque, so there are a lot of possibilities together with the execution of the pattern elements to a decorative element shape.

For certain applications, especially if the outside the decorative element external influences, weather conditions, it is exposed by Advantage, if the outermost layer of the decorative element formed by a transparent or translucent protective layer is, which in particular a layer thickness of 2 microns to 25 microns.

When Material for the color layer, the cover layer, the intermediate layer, the protective layer and the design color layers are preferably suitable for two-component coating systems, for example, from an acrylate / CAB paint or a saturated Polyester paint, water-based or UV-curing inks Colours.

All Layers are produced in particular by printing, in particular by screen printing, applied. When dry, the covering layer should have a layer thickness between 5 μm and 25 μm, the color layer one Layer thickness of 2 microns to 15 microns have. The Design color layers have a layer thickness between 2 μm and 10 μm.

When Material for the double-sided embossed plastic film is especially a thermoplastic material, in particular PT, PET or PA. The thickness of the plastic film is depending on the material between 0.5 mm and 1 mm.

The The invention further relates to a device according to the invention Decorative element, which is deformed by deep drawing, and a decorative element, which is back-injected with plastic.

The The invention further relates to a method for deforming a device according to the invention Decorative element by deep drawing, which process characterized is that the decorative element or its paint and color layers before the Thermoforming process are crosslinked, the mold temperature on a Value in the lower part of the softening temperature of the plastic material embossed plastic film is adjusted.

Further Features, advantages and details of the invention will now be apparent the drawing, which schematically shows an embodiment represents, described in more detail. Show

1 a cross section through an embodiment of an embossed film,

2 an oblique view of the outside of the film 1 .

3 a cross section through a further embodiment of an embossed film,

4 to 7 Cross sections through cutouts of different embodiments of layered according to the invention decorative elements and

8th a cross section through a section of a component, which from the decorative element according to 6 and a rear-injected substrate layer on the backside thereof.

A executed according to the invention decorative element 1 has a multilayer structure and has a front side, which is on the outside of a with the decorative element 1 provided on the component, and a back, on which the decorative element 1 is connected to a substrate, a substrate or the like. The central layer in the structure of the decorative element 1 is a transparent or translucent plastic film 2 . 2 ' which is marked on both sides.

1 shows a cross section through a variant of an embossed film 2 , The foil 2 indicates on both sides 12a . 12b an embossing of consistently executed, evenly arranged, in particular substantially contiguous hemispherical or spherical segment-shaped elevations 2a on. 2 schematically shows an enlarged view of the outside 12b ,

3 shows a cross section through a further embodiment of an embossed film 2 ' , Both on the inside 12'a as well as on the outside 12'b the coinage consists of a large number of surveys 2 ' , On that side, which forms the outer side in this variant, another embossment is superimposed, such that circular shallow depressions 2 B are formed in the shape or with the contour of a lens. The areas between the depressions 2 B have the original coinage with elevations 2 B on. The diameters of the example matching wells 2 B is about 6 mm, the depth t of the wells 2 B between 10 μm and 250 μm. One, also differently executed, "overlaid" coinage can on both sides 12'a . 12'b or on one of the sides 12'a . 12'b be provided.

According to another, not shown embodiments, the two-sided Embossing the film from others, especially evenly arranged and concurrently executed, prismatic elevations or elevations in the form of cones or pyramids consist. The two sides of the film can also be different have executed imprints.

The thickness d of the film 2 . 2 ' is inclusive embossing between 0.5 mm and 1 mm, the height h of the surveys 2a . 2 ' between 2 μm and 5 μm.

As material for the plastic film 2 . 2 ' a thermoplastic, in particular polycarbonate (PC), polyethylene terephthalate (PET) or polyamide (PA) is suitable. Preferred film thicknesses are in the order of 0.75 mm for a film made of PC, for a film made of PET in the order of 0.6 mm and for a film made of PA in the order of 0.55 mm.

4 to 7 show different embodiments of a layered structure of a decorative element 1 , The individual layers are shown only schematically and not to scale. The film is exemplified in 1 shown foil 2 ,

At the in 4 shown embodiment is located on the inside 12a the foil 2 a transparent or translucent, colorless or translucent (colored) intermediate layer over the entire surface 6 in a layer thickness d ₆ of 2 microns to 15 microns. The intermediate layer 6 also fills in the depressions between the elevations 2a out. On the interlayer 6 follows all over a covering color layer 3 whose layer thickness d _{3 is} between 2 μm and 15 μm.

To the color layer 3 closes a cover layer 4 as the innermost layer of the decorative element 1 which is an opaque color layer, especially the temperature recording and temperature distribution in the decorative element 1 improved during the subsequent deep drawing process. For this purpose, the cover layer 4 non-organic, metallic or non-metallic fillers. Furthermore, in the layer 4 dissolved plastic particles may be included, which provide a better bond to Hinterspritzsubstrat. The layer 4 has a layer thickness d ₄ between 5 .mu.m and 35 .mu.m.

On the outside 12b the foil 2 is a transparent or translucent, colorless or colored protective layer over the entire surface 5 - glossy or matt - applied. The protective layer 5 has a layer thickness d ₅ between 2 microns and 25 microns and fills the wells between the surveys 2a out. For certain applications, especially for low-stressed components, such as furniture fronts or housing parts for air conditioners, can on the protective layer 5 also be waived.

5 shows an embodiment in which directly on the inside 12a the embossed film 2 a design color layer 7 is applied. This, a layer thickness d ₇ from 2 microns to 10 microns having design color layer 7 follows the contour of the embossing and becomes a non-surface covering pattern of any pattern elements, for example Li nien, points, planar pattern elements, reticulated pattern elements and the like executed. To the design color layer 7 close the intermediate layer as further layers 6 , some of which are the design color layer 7 and partly directly inside 12a the foil 2 covered, the color layer 3 and the cover layer 4 as already described. The outside 12b the foil 2 is optionally with a protective layer 5 covered.

6 shows a variant in which on the inside 12a the foil 2 the layer structure according to the in 4 shown embodiment variant, therefore, are on the inside 2 the intermediate layer 6 , the color layer 3 and the cover layer 4 applied. On the outside 12b the foil 2 is directly on the embossing a design color layer 8th applied, which analogous to the design color layer 7 the in 6 In the embodiment shown, a non-surface-covering layer which forms a pattern of any desired design with pattern elements as described above and has a layer thickness d ₈ of 2 μm to 10 μm. On the design color layer 8th is the outer layer as the protective layer 5 applied.

7 shows an embodiment that differs from the embodiment according to FIG 6 this distinguishes that on the outside 12b the foil 2 two design color layers 8th and 9 are applied. The design color layers 8th . 9 can differ from one another in the selected color and / or one of the color layers can be made glazed, the other opaque. The one design color layer 8th . 9 may contain reflective pigments, the other may not contain reflective pigments. The layer thickness d _{9 of} the design color layer 9 is also between 2 microns and 10 microns. The structure of the decorative element 1 on the inside 12a the foil 2 corresponds to that according to 6 with the intermediate layer 6 , the color layer 3 and the cover layer 4 , The two on the outside 12b the foil 2 attached design color layers 8th and 9 each form a non-surface covering pattern with any pattern elements, as already described, wherein in plan view, the pattern elements of a design color layer 8th the pattern elements of the other design color layer 9 partially cover and between the pattern elements repeatedly surfaces are available, which provides a clear view of the slide 2 allow. The outermost layer in turn forms a protective layer 5 ,

The layers 3 . 4 . 5 . 6 . 7 . 8th and 9 are preferably made of a solvent-based two-component paint system, for example an acrylate / CAB paint or a saturated polyester paint. All of these layers, especially the layers 3 . 7 . 8th and 9 , Alternatively, may be made of a water-based ink or a UV-curable ink. In particular, the colors / lacquers for the layers 3 . 7 . 8th and 9 can contain metallic pigments to the layers 3 . 7 . 8th and 9 perform reflective. The design color layers 7 . 8th and 9 can be translucent or opaque. All color or lacquer layers are applied by printing, in particular by screen printing.

The selection of embossed plastic film 2 takes into account the geometry of the component to be manufactured, its field of application and location. The selection of the material of the individual layers also depends on these criteria. After each printing operation takes place in intermediate steps a defined venting of the individual layers, taking into account the evaporation rates of the optionally used solvent, the drying temperature and the layer thickness of the printing. The color or coating systems mentioned can be well deformed by deep drawing within a certain degree of crosslinking. For a continuous production process, it is important to be able to supply constantly crosslinked coating layers to the thermoforming process. It therefore becomes the decorative element 1 prior to deep-drawing, crosslinked in accordance with the structure / material of the individual layers. The essential parameters for the crosslinking, such as humidity, temperature and drying time, are largely dependent on the paint system / paint material, the melting point of the materials used and the number of paint layers. The set temperature is largely based on the glass transition temperature of the plastic material of the film 2 depending, the humidity should be between 30% and 55%. The duration of the complete paint crosslinking can be several hours. After the cross-linking, the deep-drawing process takes place. The mold temperature depends on the melting point of the plastic film 2 used plastic material. The heating of the plastic material is different depending on the layer structure and colors / paints used and their layer thicknesses and also taken into account. To the embossed structure of the plastic film 2 during the deep-drawing process, the deep-drawing process becomes in the lower part of the softening temperature of the plastic material of the film 2 carried out. It is also possible to optimize the thermoforming process by means of pre-stretching techniques.

The deep-drawn and thus shaped decorative element 1 can be back-injected to produce the desired component. According executed and formed by thermoforming decorative elements can be used in the manufacture of a variety of different components, such as furniture or automotive parts.

8th shows a cross section through a component of a hinterspritzten decorative element 1 , The at the back of the decorative element 1 Plastic material used is, for example, polyamide, optionally filled with glass fibers, polycarbonate, polymethyl methacrylate, acrylic butadiene styrene or polyethylene terephthalate. The use of other thermoplastics is also possible. The injection parameters are to be selected such that on the one hand a good connection between the decorative element 1 and the backmolding substrate 10 is guaranteed and on the other hand, the embossed structure of the plastic film 2 preserved. The setting of the reprinting after the filling of the plastic mass has proven to be significant, depending on the backmolding substrate and the type of plastic, this reprinting is comparatively low.

LIST OF REFERENCE NUMBERS

1

decorative element

2, 2 '

Plastic film with imprint

2a, 2 '

surveys

2 B

deepening

12a, 12'a

inside

12b, 12'b

outside

d

thickness the film 2, 2 '

H

height

3

coat of paint with metallic pigments

4

covering

5

protective layer

6

interlayer

7

Design color layer

8th

Design color layer

9

Design color layer

d6

layer thickness

d3

layer thickness

d4

layer thickness

d5

layer thickness

d7

layer thickness

d8

layer thickness

d9

layer thickness

10

substratum

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - EP 1436176 A1 [0002]
• - US 5270097 B [0003]
• - DE 4446255 A1 [0004]
• - DE 4202975 A1 [0005]
• - US 1150374 A [0006]
• - US 2149171 A [0006]
• - US 2951419 A [0006]
• - CA 0759824 A [0006]
• - US 3383789 A [0006]
• - DE 1446855 A [0006]

Claims (12)

Decorative element ( 1 ), comprising a transparent or translucent plastic film ( 2 . 2 ' ) with a double-sided coinage of a large number of individual surveys ( 2a . 2 ' ), a full-surface covering layer forming the rear side ( 4 ) and a full-surface or partially applied color layer ( 3 ) between the top layer ( 4 ) facing inside ( 12a . 12'a ) of the plastic film ( 2 . 2 ' ) and the cover layer ( 4 ), the inside ( 12a . 12b ) with one the spaces between the surveys ( 2a . 2 ' ) filling, transparent or translucent intermediate layer ( 6 ) is covered over the entire surface, on which the opaque color layer ( 3 ), characterized in that the refractive indices or refractive indices of the plastic film ( 2 . 2 ' ) and the intermediate layer ( 6 ) deviate from one another in order to obtain the impression of depth impressed by the embossing. Decorative element according to claim 1, characterized in that the embossed elevations ( 2a . 2 ' ) are formed identically and arranged regularly, in particular prismatic, conical, pyramidal or spherical segmental, and are preferably a height (h) which is between 2 microns and 5 microns. Decorative element according to claim 1 or 2, characterized in that the embossing on the inside ( 12a . 12'a ) of the plastic film ( 2 ) with the embossing on the outside ( 12b . 12'b ) of the plastic film ( 2 ) matches. Decorative element according to one of claims 1 to 3, characterized in that the embossing on at least one of the film sides ( 12'b ) of a second embossment, for example depressions ( 2 B ) of much larger area than the surveys ( 2 ' ), is superimposed. Decorative element according to one of claims 1 to 4, characterized in that on the inside ( 12a ) of the plastic film ( 2 . 2 ' ) at least one non-surface-covering, pattern-forming design color layer ( 7 ), the embossed structure is applied, which of the intermediate layer ( 6 ) is covered. Decorative element according to one of claims 1 to 5, characterized in that on the outside ( 12b ) of the plastic film ( 2 ) a non-surface-covering design color layer forming pattern elements ( 8th . 9 ) or two design color layers ( 8th . 9 ), which are partially applied directly to one another and leave free areas of pattern elements, are provided. Decorative element according to one of claims 1 to 6, characterized in that the design color layers ( 7 . 8th . 9 ) are translucent or opaque executed. Decorative element according to one of claims 1 to 7, characterized in that the outermost layer on the outside of a transparent or translucent protective layer ( 5 ), which has a layer thickness (d ₅ ) of 2 μm to 25 μm. Decorative element according to one of claims 1 to 8, characterized in that the color layer ( 3 ), the cover layer ( 4 ), the intermediate layer ( 6 ), the protective layer ( 3 ) and the design color layers ( 7 . 8th . 9 ) consist of a two-component paint system, for example of an acrylate / CAB paint or a saturated polyester paint, a water-based paint or a UV-curing paint. Decorative element according to one of claims 1 to 9, characterized in that the cover layer ( 4 ) has a layer thickness (d ₄ ) between 5 microns and 35 microns and / or the color layer ( 3 ) has a layer thickness (d ₃ ) of 2 μm to 15 μm and / or the design color layers ( 7 . 8th . 9 ) each have a layer thickness (d ₇ , d ₈ , d ₉ ) between 2 microns and 10 microns. Decorative element according to one of claims 1 to 10, characterized in that the double-sided embossed plastic film ( 2 ) consists of a thermoplastic material, in particular of PC, PET or PA, and a thickness (d) between 0.5 mm and 1 mm. A method of making a trim or trim part for a motor vehicle, comprising steps of a. Providing a decorative element according to one of the preceding claims; b. Deep drawing of the decorative element ( 1 ) in a shape adapted to the surface of the trim part; c. Backfilling and in particular injection-molding or back-pressing of the decorative element ( 1 ) with a plastic material; and characterized in that the paint and color layers of the decorative element ( 1 ) are crosslinked before thermoforming and the tool temperature during deep drawing to a value in the lower region of the softening temperature of the plastic material of the embossed plastic film ( 2 . 2 ' ) is set.

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