DE102015220573A1 - Process for producing a decorative layer with integrated composite film - Google Patents

Abstract

The present invention relates to a method for producing a decorative layer (1) in which a composite film (2) on a visible side (3) of a cover material (4) is positioned, the composite film (2) with the reference material (4) by means of a first seam (5) and then its envelope (6) is formed by the cover material (4) covering the first seam (5). Subsequently, the composite film (2) with the envelope (6) through a second seam (8) is connected. Furthermore, the present invention comprises a decorative layer (1), which is composed of such a composite film (2) or such a reference material (4), wherein the composite film (2) and the cover material (4) together form a visible surface of the decorative layer.

Description

Technical area

The present invention relates to a method for producing a decorative layer, in which a composite film is sewn to a cover material.

State of the art

In motor vehicles, especially passenger cars of the middle class and upper class, high-quality decors and decorative layers are often used to make the surface of the interior fittings as appealing as possible. Especially with instrument panels can be large areas that are equipped with a homogeneous decor of a material. This is mainly due to the fact that interior fittings and in particular the decors laminated on the interior fittings are exposed to high temperature and humidity loads. Furthermore, the decors are usually heavily loaded when laminating on the interior trim part.

The use of a homogeneous decoration is intended to ensure that the surface quality of the decor remains as long as possible despite the strong influences. A disadvantage of such decors, however, that the laminated with a decor surfaces of an interior trim part are usually designed very homogeneous and have no creative variety.

Description of the invention

It is therefore an object of the present invention to provide a method which makes it possible to produce a decorative layer of a plurality of different materials, without the lifetime or the handling of the decorative layer is limited. Furthermore, the object according to the invention relates to the provision of such a decorative layer.

The object of the invention is achieved by means of a method and a decorative layer according to the features of the main claims. Further advantageous embodiments of the present invention can be taken from the subclaims, the description and from the drawings.

An inventive method for producing a decorative layer comprises at least the step of positioning a composite film on a visible side of a cover material. When positioning the composite film is thus placed on the reference material. In this context, the visible side of the cover material can be understood to mean a side of the cover material which faces the vehicle occupant when the decorative layer is arranged on an interior trim part in the vehicle. For this purpose, both the composite film and the cover material can already be cut into a shape as desired on the interior trim part. For reasons of material savings, it may be advantageous in this case if the composite film is applied with an outer edge to an outer edge of the cover material.

In this context, the reference material can be understood as meaning a form-flexible layer which has a small thickness but a length and width which are many times greater than the thickness. The cover material may for example consist of leather or a leather-like material.

Furthermore, the method according to the invention comprises the step of connecting the covering material to the composite foil by means of a first seam. It is preferred here that this step takes place after the positioning step. For this purpose, the composite foil and the covering material can be carried out by a sewing machine which introduces a seam into both layers and thus connects the two layers to one another. If the composite film is applied with an outer edge to an outer edge of the cover material, it is advantageous if the seam is introduced as parallel as possible and at a small distance of, for example, 0.5 to 2 cm to the outer edges.

After the composite film is joined to the cover material via the seam, the step of folding the cover material over the first seam follows. By flipping an envelope is formed on the composite film, which partially covers a part of one side of the composite film. The first seam is thus covered by the envelope at least on this side of the composite film. However, another part of this page remains free and is not covered by the reference material. It is preferred if the further part of the side which remains free of the cover material forms part of the visible side of the later decorative layer and thus the cover can also be on the later visible side of the decorative layer.

After transfer, the step of introducing a second seam into the composite film and into the envelope takes place. The seam therefore runs through at least two layers of the cover material and through the composite film, so that the composite film is connected to the cover material via at least one first seam and at least one second seam. With the help of the second seam, on the one hand, the envelope is fixed in its position, so that this For example, even under heavy mechanical loads during a laminating process has a form faithfulness. At the same time, a second connecting line between the composite film and the cover material is created, which additionally stabilizes the connection of the two materials.

Under an envelope can be understood in this context, a doubling of the cover material to form an edge. The cover material can therefore be made in two layers in the area of the envelope. In order to fix the envelope in an easier way in its shape before the introduction of the second seam, an adhesive can be introduced into the envelope.

By the manufacturing method according to the invention, a decorative layer can be formed, the visible side can be formed both of a composite film and of a reference material. As a result of the formation of the envelope, the first seam is covered by the covering material at least on one side. If the decorative layer is arranged on an interior fitting part such that the cover is on the visible side of the decorative layer, then the first seam is separated by the cover from an interior of the vehicle. The seam is therefore not directly exposed to the strong fluctuations in humidity and temperature that usually prevail in a vehicle. This has the advantage that the life of the seam and thus the connection between the cover material and the composite film can be increased.

Furthermore, the envelope creates a defined edge between the cover material and the composite film, which additionally protects the outer edge of the cover material. It can thus be ruled out that the temperature and moisture influences, for example, the reference material on the outer edge frayed. It may be advantageous if an adhesive is introduced between the cover material and the composite foil. The introduction can for example already take place during the positioning step, which further improves the connection between the covering material and the composite foil. Alternatively or additionally, a sealant can also be introduced between the cover or cover material and the composite film, so that the connection point becomes impermeable to liquids, for example. This allows, for example, a process-reliable backfoaming of the decorative layer according to the invention. However, the sealing effect can also be realized with an adhesive.

In order to ensure that no thickening occurs in the decorative layer due to the cover of the cover material and the associated partial layering of the cover material, the cover material can be thinned or thinned in a region which forms the cover after the folding step. This can be done for example by simple material removal. If, for example, the cover material is a leather, this would be possible, for example, via gaps, sharpening or sharpness gaps. The thickness reduction can in this case have a uniform depth. Alternatively, the thickness reduction can also have sections with greater depth and sections with less depth, so that, for example, flowing changes in thickness in the cover material can be realized with the aid of the thickness reduction. This allows the appearance of transitions using the thickness reduction.

The step of positioning may be preceded by a step of arranging a functional layer between a base layer and a cover layer to form the composite film. For example, these layers can be connected to one another in a material-bonded manner, in particular by bonding or welding. In this context, a functional layer can be understood as meaning a layer which serves not only optical or haptic purposes, but also functions such as, for example, the emission of light in that the functional layer comprises, for example, an OLED film or a film display. However, the functional layer can also convert incident light into electrical current by the functional layer comprising, for example, a photovoltaic element. Other functions, such as the dissipation of heat when an electric current is applied to the functional layer, are also feasible. Furthermore, the recording of light may be realized by generating current or emitting heat radiation through the functional layer. It is therefore advantageous if the cover layer consists of a transparent material, so that the functionality of the functional layer is as far as possible not impaired by the cover layer.

With the help of such a composite film, it is possible that not only a decorative layer can be produced, which has a greater variety of design, but also additional functions can be integrated into the decorative layer.

By arranging the functional layer between the base layer and the cover layer, it is possible to ensure that the functional layer is protected against mechanical and thermodynamic influences both during the production and processing of the decorative layer and in the vehicle.

It is advantageous if the functional layer during the step of arranging Media density is trapped between the decorative layer and the base layer. In this context, "media-tight" can be understood as meaning that no outside air and in particular no moisture can reach the functional layer. In this way, even in extreme climatic conditions in the vehicle can be ensured that the functionality of the functional layer is not affected by external influences.

Before or after the arranging step, a recess can be introduced into the base layer. By means of the recess, it is possible to provide the functional layer, for example with at least one contact element. In this case, the contact element is preferably introduced into the recess in such a way that, after introducing the contacting, the functional layer is introduced between the base layer and the cover layer in a media-tight manner. If power is required to operate the functional layer, the functional layer can be connected via the contact element to a corresponding electric circuit.

The largest surfaces of the base layer and the cover layer can be selected to be larger than the largest surface of the functional layer. This makes it possible, during the step of arranging, to produce a peripheral region in the composite film which surrounds the functional layer. It is advantageous in this case if the base layer, the cover layer and the functional layer are arranged with their largest surfaces parallel to one another. In particular on the outer edges, the strongest mechanical forces act during processing of the composite foil. The edge region ensures that these acting forces exclude at least damage to the functional layer.

It is also advantageous if the first and / or second seam are introduced into the edge region of the composite film. In this way it can be avoided that the seams damage the functional layer or limit the functionality of the functional layer.

It has been shown that it is advantageous if the first seam is introduced at a distance of 1 to 8 mm, more preferably 2.5 to 5.5 mm to a side edge of the functional layer in the edge region. The first seam may run parallel to the side edge of the functional layer. The edge region therefore preferably has a width of 0.5 to 20 mm. At this distance, the cover material can be sewn particularly close to the functional layer, so that a subsequently formed envelope directly adjacent to the functional layer. The edge region can thus be completely covered by the reference material. At the same time, however, the seam is still far enough away from the functional layer to avoid damage to the functional layer, which can occur during sewing.

It is advantageous if the second seam is introduced at a greater distance from the side edge of the functional layer in the edge region than the first seam. The second seam can run parallel to the first seam or alternatively also describe a pattern. However, it is preferred that the second seam does not intersect with the first seam.

In order to produce a particularly even transition between composite film and cover material on at least one side, which in particular has no height differences between cover material and composite film, a step or ramp can be introduced into the composite film at least in the edge region of the composite film prior to the positioning step. This step or ramp can be introduced, for example, by embossing or pressing in the composite film. By the step or ramp, a height difference between the edge region and the functional layer is generated. With the help of the height difference, for example, a thickness difference between the reference material and the composite film can be compensated so that, for example, the envelope can be brought to a height with the composite film in the region of the functional layer with the aid of the step or ramp. The step acts together with a reduction in the thickness of the cover material in the area of the envelope.

A particularly uniform transition can be created if the cover of the cover material is laid in such a way that the edge formed by the cover directly adjoins the functional layer or covers it slightly. On the finished decor so the edge area for the occupant is no longer visible.

In addition to the inventive method for producing a decorative layer, the present invention comprises a decorative layer for an interior trim part of a motor vehicle. This decorative layer comprises a cover material and a composite film. The cover material is connected to the composite film via a first seam. Further, the cover material forms an envelope along the first seam which partially covers a portion of one side of the composite sheet. However, another part of this page remains free from this reference material. A second seam further secures the envelope to the composite foil and the cover material forms a visible surface of the decorative layer with the composite foil.

In this context, a visible surface can be understood as meaning a side of the decorative layer that is visible to a viewer, if the decorative layer is laminated, for example, on an interior trim part. The visible surface of the decorative layer is therefore preferably facing away from the interior trim part and facing the viewer.

It is hereby preferred that the envelope is also arranged on the visible side of the decorative layer, since thus a defined visible edge between the reference material and the composite film can be formed.

It is advantageous if the cover material is reduced in thickness in the area of the cover by at least half the total thickness of the cover material. This excludes the fact that the envelope creates a survey on the composite film by the reference material.

The composite layer may be composed of a, in particular transparent top layer and a base layer, wherein a functional layer is arranged between the base layer and top layer. In this case, the cover layer and the base layer can be larger in their largest areas than the largest area of the functional layer, so that an edge region is formed which surrounds the functional layer. The composite film can be sewn in this edge region with the cover material or the envelope over the first and second seam.

The cover layer may be structured and / or matted on a side facing away from the functional layer. If the decorative layer according to the invention is used, for example, in an instrument panel of a motor vehicle, it can be ensured by means of the structuring or matting that the cover layer does not reflect in the vehicle window even in the case of strong solar radiation and, for example, affects the field of vision of the vehicle occupants. Thus, the composite film does not affect the field of view of the vehicle occupant. Alternatively or in addition to structuring or matting, the cover can also be dyed and / or printed in order to avoid light reflections on the cover layer.

The functional layer may comprise a photovoltaic element, an infrared element or a screen element. Thus, the composite foil can either be used to produce electricity, produce and deliver heat or, for example, form a screen that is integrated directly into the decorative layer.

It has been shown that it is advantageous if the cover layer and / or the base layer consist of a thermoplastic, in particular polyethylene. These plastics have proven to be particularly resistant to environmental influences typically expected in vehicles.

In addition, it has been found that a cover layer and / or base layer with a thickness of 70 to 150 .mu.m are particularly suitable for use in a composite film according to the invention. At this thickness, the layers are sturdy enough to protect the functional layer from any impact and at the same time thin enough to be still flexible and resilient enough to process the decorative layer.

The invention has been described with reference to a method for producing a decorative layer and to a decorative layer. Unless stated otherwise, the comments on the method are analogously applicable to the decorative layer. The same naturally applies in the reverse direction, so that the refinements of the decorative layer also find their way into the process.

In addition, other advantages and features of the present invention will become apparent from the following description of preferred embodiments. The features described there and above may be implemented alone or in combination insofar as the features do not contradict each other. The description of the preferred embodiments is made with reference to the accompanying drawings.

Show it:

1 to 6 an inventive manufacturing method of a decorative layer in a schematic representation,

7 a composite layer according to the invention in a plan view.

1 shows the step of arranging a functional layer 9 between a transparent cover layer 11 and a base layer 10 , In the present embodiment, the cover layer is 11 around a transparent, 90 μm thick polyethylene layer, which is a structuring 15 having. The base layer 10 , which also consists of a polyethylene, is colored and has a thickness of 100 microns. The intervening functional layer 9 comprises an organic photovoltaic module (OPV) with a thickness of 100 μm. The cover layer 11 and the base layer 10 are chosen larger in area than the functional layer 9 so that the functional layer 9 surrounding border area 12 can be generated.

In 2 is the functional layer 9 between the cover layer 11 and the base layer 10 laminated. The base layer 10 was here in a production step, not shown, in the edge region 12 with the topcoat 11 pressed and welded. Alternatively, however, it is also possible to join the layers with an adhesive. Due to the welding is the functional layer 9 between cover layer 11 and base layer 10 media-tight included.

The functional layer 9 , the base layer 10 and the topcoat 11 together form a composite film 2 with a the functional layer 9 circumferential edge area 12 out. After production of the composite film 2 gets into the edge area 12 with the help of a process step, not shown, a stage 14 imprinted. A composite foil 2 with embossed step 14 is for example in 3 shown. The embossing also adds to the structuring 15 the topcoat 11 at the edge 12 balanced.

After the embossing of the stage 14 becomes a reference material 4 in the present embodiment is made of genuine leather, as in 4 shown with his visual side 3 on the topcoat 11 arranged and in the edge area 12 with the composite foil 2 with the help of a first seam 5 sutured. The reference material 4 was previously in an area where the cover material 4 with the composite foil 2 is sewn, reduced in a process step, not shown in its thickness.

After insertion of the first seam 5 The leather is folded down, leaving an envelope 6 is formed. Subsequently, by the envelope 6 a second seam 8th introduced, which is also the composite film 2 penetrates. By the thickness reduction 16 increases the thickness of the cover material 4 despite the formation of the envelope 6 Not. The described training of the envelope 6 and introduced second seam 8th is in 5 shown. For both seams polyester multifilament yarn was used. A polyamide multifilament yarn is also for both seams 3 . 8th or just one of the seams 3 . 8th suitable.

After the first cover material 4 has been attached to the edge portion is at the opposite edge portion 12 a second cover material 4 in the same process to the composite film 2 sewn. The composite foil 2 with two attached cover materials 4 is in 6 shown. In this way, a decorative layer 1 formed, in which a composite film 2 is integrated, without having these interruptions or contour jumps. The resulting decorative layer can be laminated with conventional laminating on an interior trim part. In this context, the decorative layer can be laminated directly onto a support of the interior trim part as well as together with a spacer knit or a comparable haptic material on the interior trim part. If the haptic material is a foam, the decorative layer of such a foam can also be backfoamed during the lamination process. To ensure that in a Presskaschierprozess the decorative layer 1 or the composite film 2 not damaged, a depositor can on the composite film 2 be placed so that during the press laminating the composite film 2 not damaged.

7 shows a plan view of a composite film according to the invention 2 , To the functional layer 9 around is the edge area using the cover layer and the base layer 12 educated. Furthermore, the border area 12 in the places where the functional layer 9 sharp radii has wider running. This simplifies the processing or sewing of the composite film with the reference material 4 additionally. Here with additional seams or additional envelopes a clean transition between functional layer 9 or composite film 2 and cover material 4 will be realized.

LIST OF REFERENCE NUMBERS

 1

decorative layer

 2

composite film

 3

Visible side (cover material)

 4

reference material

 5

First seam

 6

envelope

 7

page

 8th

Second seam

 9

functional layer

10

base layer

11

topcoat

12

border area

13

side edge

14

step

15

structuring

16

thickness reduction

Claims (21)

Method for producing a decorative layer ( 1 ), comprising the following steps: - positioning a composite film ( 2 ) on a visible side ( 3 ) of a reference material ( 4 ); - connecting the cover material ( 4 ) with the composite film ( 2 ) using a first seam ( 5 ); - transfer of the cover material ( 4 ) over the first seam ( 5 ), so that with the reference material ( 4 ) on the composite foil ( 2 ) an envelope ( 6 ) forming part of a page ( 7 ) of the composite film ( 2 ) is partially covered, with another part of the page ( 7 ) free of the reference material ( 4 ) remains; - introducing a second seam ( 8th ) in the composite film ( 2 ) and the envelope ( 6 ). Method according to the preceding claim, wherein the reference material ( 4 ) is thinness reduced in at least a portion prior to the step of joining, which after the folding step, the envelope ( 6 ) trains. Method according to one of the preceding claims, wherein before the step of positioning, the step of arranging a functional layer ( 9 ) between a base layer ( 10 ) and a transparent cover layer ( 11 ) for forming the composite film ( 2 ) he follows. Method according to the preceding claim, wherein the functional layer ( 9 ) during the step of arranging media-tight between the cover layer ( 11 ) and the base layer ( 10 ) is included. Method according to one of claims 3 to 4, wherein before or after the step of arranging at least one recess in the base layer ( 10 ) is introduced, in which a contact element for contacting the functional layer ( 9 ) is introduced. Method according to one of claims 3 to 5, wherein the largest areas of the base layer ( 10 ) and the cover layer ( 11 ) are larger than the largest surface of the functional layer ( 9 ), so that during the step of arranging the functional layer ( 9 ) peripheral edge area ( 12 ) in the composite film ( 2 ) is formed. Method according to the preceding claim, wherein the first and / or the second seam ( 5 . 8th ) in the edge region at a distance to a side edge ( 13 ) the functional layer ( 9 ) are introduced. Method according to the preceding claim, wherein the first seam ( 5 ) at a distance of 1 to 8 mm, more preferably 2.5 to 5.5 mm, to the side edge ( 13 ) is introduced. Method according to one of claims 7 or 8, wherein the second seam ( 8th ) at a greater distance to the side edge ( 13 ) is arranged as the first seam ( 5 ). Method according to one of claims 6 to 9, wherein before the step of positioning at least in the edge region ( 12 ) a step ( 14 ) or ramp into the composite foil ( 2 ) is introduced. Method according to one of claims 6 to 10, wherein the envelope ( 6 ) is arranged during the folding step such that the envelope ( 5 ) the edge area ( 12 ) and to the functional layer ( 9 ) adjoins. Method according to one of the preceding claims, wherein the second seam ( 8th ) parallel to the first seam ( 5 ) is introduced. Decorative layer ( 1 ) for an interior trim part of a motor vehicle, comprising: - a cover material ( 4 ), and - a composite film ( 2 ), the reference material ( 4 ) with the composite film ( 2 ) over a first seam ( 5 ), the cover material ( 4 ) along the first seam ( 5 ) an envelope ( 6 ) that forms part of a page ( 7 ) of the composite film ( 2 ) is partially covered, with another part of the page ( 7 ) free of the reference material ( 4 ), a second seam ( 8th ) the envelope ( 6 ) on the composite foil ( 2 ), and the reference material ( 4 ) with the composite film ( 2 ) forms a visible surface of the decorative layer. Decorative layer ( 1 ) according to the preceding claim, wherein the reference material ( 4 ) in the envelope ( 6 ), preferably by half, is reduced in thickness. Decorative layer ( 1 ) according to one of claims 13 or 14, wherein the composite foil ( 2 ) a transparent cover layer ( 11 ), a base layer ( 10 ) and one between base layer ( 10 ) and cover layer ( 11 ) functional layer ( 9 ). Decorative layer ( 1 ) according to the preceding claim, wherein the largest areas of the base layer ( 10 ) and the cover layer ( 11 ) are larger than the largest surface of the functional layer ( 9 ), so that the top layer ( 11 ) and the base layer ( 10 ) one the functional layer ( 9 ) peripheral edge region ( 12 ) in which the composite film ( 2 ) with the reference material ( 4 ) is sewn. Decorative layer ( 1 ) according to one of claims 15 to 16, wherein the cover layer ( 11 ) on one of the functional layers ( 9 ) facing away from structured and / or frosted. Decorative layer ( 1 ) according to one of claims 15 to 17, wherein the functional layer ( 9 ) comprises a photovoltaic element or an infrared element or a screen element. Decorative layer ( 1 ) according to one of claims 15 to 18, wherein the cover layer ( 11 ) and / or the base layer ( 10 ) consist of a thermoplastic material, in particular polyethylene. Decorative layer ( 1 ) according to one of claims 15 to 19, wherein the cover layer ( 11 ) and / or the base layer ( 10 ) have a thickness of 70 to 150 microns. Interior fitting for a motor vehicle with a decorative layer ( 1 ) according to claims 13 to 20.

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