DE102016221994A1 - Vehicle component and method of manufacture - Google Patents

Abstract

The present invention relates to a vehicle component (1) with at least one trim part (2) and to a method for producing such a vehicle component (1). The trim part (2) comprises a decorative element (3) and a carrier element (4) for receiving the decorative element (3). The decorative element (3) comprises a multilayer construction with a metallic decorative layer (13) and a base layer (33) and an intermediate layer (23) arranged therebetween.

Description

The present invention relates to a vehicle component having at least one trim part and a method for producing such a vehicle component. The trim part comprises at least one decorative element and at least one carrier element for receiving the decorative element.

For high-quality equipment of motor vehicles are sometimes used trim parts with metallic decorative overlays. For example, this describes DE 20 2005 010 946 U1 a trim part, which has a sheet metal part made of aluminum as decor edition. The sheet metal part is back-injected with a carrier part made of plastic.

However, a number of factors have to be taken into account in order to produce high-quality trim parts with metallic decorative overlays. In the prior art, for example, when embossing about 0.2 mm deep structures in 0.8 mm thick metal, a relatively high relief of the starting material takes place. This results in a decor-dependent different, sometimes high notch effect, combined with each reduced elongation at break of the embossed semifinished product compared to the starting material.

In addition, the material is stretched or compressed depending on the shape during further forming of the semifinished product. The respective degrees of expansion or compression lead proportionally to the change in size of the decorative overlay up to damage or failure of the structure based on microcracks in the depressions of the embossing.

Furthermore, the injection molding of the decorative cover for forming the support structure is not without problems. For example, the pressures generated in the tools in the injection molding process increase the effect of tearing the decorative cover or cause it to burst in the mold.

In addition, it should be noted that after installation of the trim part in the vehicle, the surface should be scratch-resistant and as resistant as possible to mechanical effects. For example, a keychain is placed on a center console equipped with a trim or a buckle strikes when retracting the belt to a trim part of the door trim. However, the use of correspondingly hard materials for the decorative overlay is not readily possible. Such materials can usually be reshaped bad and z. B. tear. On the other hand, softer materials generally have the disadvantage that an embossed pattern may warp during forming. The same applies to coatings such as paints or anodizing.

It is therefore the object of the present invention to provide a vehicle component and a method for producing a vehicle component, which offer particularly high quality and durable trim and which in particular meet the aforementioned requirements.

This object is achieved by a vehicle component with the features of claim 1 and by a method for manufacturing according to the features of claim 10. Preferred developments are subject of the dependent claims. Further advantages and features of the present invention will become apparent from the general description and the description of the embodiment.

The vehicle component according to the invention comprises at least one trim part. The trim part comprises at least one decorative element and at least one carrier element for receiving the decorative element. In this case, the decorative element has a multilayer structure with at least one metallic decorative layer and at least one base layer and at least one intermediate layer arranged therebetween.

The vehicle component according to the invention offers many advantages. A significant advantage of the multilayer structure of the decorative element. As a result, the metallic decorative layer can be processed or selected depending on the desired decor, without having to accept a reduced durability or stability of the entire decorative element. The metallic decorative layer is advantageously supported by the base layer as well as by the intermediate layer, both in the finished state and during production, so that overall a very high-quality and durable decorative element is available.

In the operating state, the decorative layer preferably forms the visible side of the decorative element. In this case, the decorative element and preferably the decorative layer have at least one coating.

In particular, at least three different layers are provided. Preferably, each layer comprises at least one material layer or is formed as such. In particular, the layers differ with regard to their materials and / or their strength and / or with regard to at least one mechanical property. A particular advantage of such a sandwich construction is that, despite embossing in the decorative layer, a very high stability and strength of the decorative element is achieved overall.

Particularly preferably, the base layer is formed from a metal material. Preferably, the base layer comprises at least one metal sheet or is formed as such.

In a particularly preferred embodiment, the base layer and the decorative layer are each provided by a metal sheet or each comprise at least one such. In particular, the decorative layer comprises a metal sheet suitable for deep embossing and / or embossing rolling. In particular, the base layer comprises a metal sheet, which advantageously supports the embossing process and / or a relief of the decorative layer.

It is particularly preferred that the decorative layer has a different alloy and / or a different strength and / or a different thickness than the base layer. For example, the strength of the decorative layer is selected with regard to decorability and / or scratch resistance. The base layer is selected, for example, to prevent warping and tearing of the decorative layer during embossing and / or forming.

Particularly preferably, the decorative layer is thinner and / or harder and / or more firmly formed as the base layer. By a harder and / or firmer decorative layer, the decorative element is particularly resistant and durable. A thinner decorative layer is suitable for. B. particularly good for the formation of a very precisely decorated surface structure.

Particularly preferably, the base layer is softer and / or stronger than the decorative layer. Such a configured base layer supports embossing and / or deformation of the harder or thinner decorative layer particularly well.

In particular, the thickness of the decorative layer preferably corresponds to from 80% to 10% of the thickness of the base layer. However, the thickness of the decorative layer may also correspond to less than 10% of the thickness of the base layer.

The decorative layer preferably has an at least partially and in particular completely relief surface structure. The decorative layer preferably comprises at least one embossing and in particular a deep embossed and / or embossed rolled surface structure. The decorative layer is provided, for example, by a deep-stamped metal sheet. Particularly preferably, the relief surface structure extends borderless on the decorative layer. It is also possible that the decorative layer has relief areas. It is possible that the relief surface structure comprises at least one coating.

With such a surface structure, the vehicle component according to the invention offers the advantage that the stability and, for example, the elongation at break of the embossed semifinished product compared to the starting material is not unfavorably reduced by the multilayer structure. On the other hand, this is often the case in the state of the art with single-layer or only made of sheet metal decorative coverings after embossing. In addition, such a surface structure gives the trim a particularly high quality appearance.

In a particularly advantageous and preferred embodiment, the decorative element is provided by at least one decorative shell. The decorative element is in particular three-dimensionally shaped. The decorative shell has, for example, edge regions which are raised and / or lowered at least in sections relative to the base surface. Preferably, the base layer and / or the intermediate layer are also formed like a shell. In particular, decorative layer and base layer and intermediate layer are formed together. In particular, the carrier element is at least partially received in and / or on the decorative shell. The decorative element may be curved to provide the decorative shell inwardly and / or outwardly. Such decorative shells allow particularly high-quality trim inside vehicles.

It is also possible that the decorative element has a substantially two-dimensional shape. For example, the decorative element is then formed as a decorative plate or the like.

Preferably, the intermediate layer comprises or is provided by at least one polymer layer. The polymer layer is in particular a plastic polymer. In particular, the polymer layer is suitable and designed to connect the decorative layer to the base layer. The polymer layer is preferably flexible and / or elastic in defined states. Such a polymer layer, together with the base layer, offers particularly good support for the decorative layer, in particular with regard to embossing and / or reshaping.

Particularly preferably, the decorative element is designed as a metal-polymer sandwich. In this case, the decorative layer and the base layer provide the two metallic cover layers, between which the polymer layer is arranged.

The intermediate layer, in particular the polymer layer, is preferably suitable and designed to arrange the decorative layer floating to the base layer, so that forces and / or stresses occurring during embossing and / or or reshaping the decorative element are at least partially compensated. In particular, the intermediate layer is suitable and designed to allow a relative displacement of the decorative layer to the base layer. By means of an intermediate layer designed in this way, an impairment of the decorative layer during a forming process is particularly well counteracted. The floating arrangement allows a particularly intact relief structure and a particularly minimal distortion of the decorative layer can be achieved.

Preferably, the intermediate layer is suitable and designed to prevent a relative displacement of the decorative layer to the base layer in a cured state. As a result, unwanted movements of the layers are effectively prevented each other.

A hardened state is present in particular in an operative state and preferably after embossing or deformation of the decorative element. In the cured state, a floating arrangement of decorative layer and base layer is preferably no longer provided. The intermediate layer is particularly suitable and designed to cure under targeted action. In particular, the intermediate layer is suitable and formed before curing for floating arrangement of decorative layer and base layer.

The inventive method is used to produce a vehicle component with at least one trim part with at least one decorative element and at least one support element for receiving the decorative element. In this case, the decorative element is produced with a multilayer construction. In this case, at least one metallic decorative layer is connected to at least one base layer by at least one interposed intermediate layer.

The method according to the invention offers many advantages. A particular advantage is that the metallic decorative layer is connected to the base layer via the intermediate layer. As a result, a high-quality and visually attractive decorative layer can be designed, which is supported by the base layer or the intermediate layer. This results in a very high quality and durable decorative element.

Preferably, the method is used to produce a vehicle component, which is designed like the vehicle component according to the invention described above.

In particular, the decorative layer and the base layer are provided by in each case at least one metal sheet, which are connected via an intermediate layer formed as a polymer layer.

The decorative element is preferably decorated by at least one embossing on the side of the decorative layer. Preferably, the decorative layer is thereby at least partially and in particular completely equipped with a relief surface structure. The embossing is in particular a stamping.

Particularly preferably, the decorative layer is embossed floating on the base layer. A floating arrangement is achieved, in particular, by the intermediate layer which connects the decorative layer and the base layer in a movable manner. For this purpose, the intermediate layer is preferably used in a not yet cured state. This allows a particularly precise embossing of the decorative layer.

In a preferred embodiment, the decorative element is formed into a decorative shell. In particular, the decorative layer and the base layer are pulled out differently. In particular, the base layer is pulled out more or more strongly relative to the decorative layer. Thus, an overall intact structure is achieved with minimal distortion of the decorative layer. The different separation is made possible in particular by the intermediate layer or the floating arrangement.

In an advantageous embodiment of the method, the carrier element is produced by injecting the decorative element. For this purpose, the decorative element is back-injected in particular in an injection mold. The carrier element is in particular made of a plastic material. This allows a reliable and durable connection of the decorative element to the support element. The multi-layered structure offers the advantage that the intermediate layer dampens the spray pressure compared to the decorative layer. Thus, a deterioration of the decor during the injection molding process is prevented. In particular, the arrangement of the carrier element takes place only after the embossing and / or deformation of the decorative element.

In particular, embossing and / or forming and / or injection-molding of the decorative element takes place prior to hardening of the intermediate layer. Thus, a relative movability of the decorative layer to the base layer is provided by the intermediate layer during embossing and / or forming and / or back-molding. Preferably, the intermediate layer comprises a polymer layer, which is finally crosslinked only after embossing and / or forming and / or back-molding. For example, heat and / or radiation may be provided for this purpose.

In particular, the decorative element is firmly connected to the carrier element. The carrier element is in particular made of a plastic material. The carrier element preferably comprises at least one fastening device for mounting the trim part on a vehicle part structure.

The vehicle component is intended in particular for motor vehicles and in particular for passenger vehicles.

Further advantages and features of the present invention will become apparent from the embodiment, which will be explained below with reference to the accompanying figures.

• 1 eine stark schematische Darstellung einer erfindungsgemäßen Fahrzeugkomponente in einer geschnittenen Seitenansicht;
• 2 eine stark schematisierte Darstellung der Fahrzeugkomponente während eines Verfahrenschritts;
• 3 die Fahrzeugkomponente in einem weiteren Verfahrenschritt;
• 4 die Fahrzeugkomponente in einem anderen Verfahrenschritt;
• 5 die Fahrzeugkomponente in einem Spritzgusswerkzeug; und
• 6 die Fahrzeugkomponente während eines weiteren Verfahrenschritts.

In the figures show:

• 1 a highly schematic representation of a vehicle component according to the invention in a sectional side view;
• 2 a highly schematic representation of the vehicle component during a process step;
• 3 the vehicle component in a further process step;
• 4 the vehicle component in another process step;
• 5 the vehicle component in an injection mold; and
• 6 the vehicle component during another method step.

The 1 shows a vehicle component according to the invention 1 with a decorative part 2 , The trim part 2 here consists of a decorative element 3 and a carrier element 4 for receiving the decorative element 3 , The vehicle component 1 was prepared here by the process according to the invention.

About the carrier element 4 For example, the trim part can be fastened to a vehicle part structure in an interior space or also in the exterior area of a motor vehicle. For this purpose, the support element 4 For example, suitable fasteners, which are shown here very schematically by dashed arrows.

The decorative element 3 here has a multilayer structure with a total of three different layers 13 . 23 . 33 on. The visible side or outside of the decorative element 3 here forms the decorative layer 13 , Below this is an intermediate layer 23 , On the operating bottom of the decorative element 3 here is a base layer 33 arranged here as a polymer layer 53 is trained.

The decorative layer 13 consists of a metallic material and z. B. from a metal sheet. The decorative layer 13 here is equipped with a relief surface structure. The surface structure is shown in a highly schematic manner for the purpose of illustration. Most preferably, the surface structure is uniformly provided with a repeating pattern. But also possible are irregular patterns.

The decorative element 3 is here as a decorative shell 43 educated. Such a three-dimensional structure is preferably produced by a forming process. The decorative shell 43 here extends over the carrier element 4 in that this in the proper or installed state of the trim part 2 not visible below the decorative shell 43 is arranged.

The base layer 33 is here made of a metallic material and preferably made of a metal sheet. The metal materials are selected so that the decorative layer 13 thinner and preferably harder and / or stronger than the base layer 33 is trained. In particular, the decorative layer exist 13 and the base layer 33 from sheets of different alloys.

The harder decorative layer 13 has the advantage that it is particularly scratch-resistant and resistant to mechanical effects. In addition, in a thinner or harder decorative layer 13 a particularly precise embossing pattern can be incorporated. In addition, offers a correspondingly hard decorative layer 13 the advantage that the surface structure or the pattern does not disadvantageously distort during forming.

The base layer 33 Here is stronger and softer and / or less solid than the material of the decorative layer 13 educated. As a result, the embossing and forming the decorative shell of the harder decorative layer 13 supported. In addition, the softer and / or less solid embodiment of the base layer 33 prevents cracking under mechanical stress and, for example, during forming.

The as a polymer layer 53 trained intermediate layer 23 serves here for the connection of decorative layer 13 and base layer 33 , The intermediate layer 23 allows a floating arrangement, so that a relative displacement of the two metallic layers 13,33 is possible. As a result, occurring during embossing and / or forming forces and stresses in the multi-layer structure can be compensated. This allows a very clean and differentiated shaped and at the same time hard and resistant decorative layer 13 ,

The 2 - 6 show highly schematic representations of various process steps in the manufacture of the vehicle component 1 ,

The 2 shows the decorative element 3 before embossing the surface structure and before forming the decorative shell 43 , The decorative element 3 is designed here as a metal-polymer sandwich. Thereby represent the decorative layer 13 and the base layer 33 one metal sheet each. The metal sheets are over as the polymer layer 53 trained intermediate layer 23 connected with each other. The visually arranged decorative layer 13 was here thinner and harder formed and over a relatively thick and soft base layer 33 arranged.

In the 3 is the decorative element 3 partly by a stamping process and z. B. decorated embossing rollers. Preferably, the entire intended visible side of the decorative element 3 decorated. The polymer layer 53 Supports in conjunction with the soft base layer 33 the relief of the decorative layer 13 , As a result, a clean relief is achieved and a weakening of the decorative element 3 counteracted.

The 4 shows the decorative element 3 after forming into a decorative shell 43 , The arrows shown here by dashed lines indicate the extension direction of the corresponding layers 13 . 23 . 33 at. This is the correspondingly soft base layer 33 relative to the outer decorative layer 13 more undressed. This results in an overall intact structure with minimal distortion of the decorative layer 13 achieved with its surface structure. The necessary relative movement of the layers 13 . 33 is thereby through the polymer layer 53 allows.

The 5 shows the decorative shell 43 in an injection mold 100 to the support element 4 to complete. The polymer layer 53 in the decorative bowl 43 dampens the spray pressure compared to the decorative layer 13 from. Together with the base layer 33 Thus, the danger of failure of the decorative shell 43 or a penetration of the injection molding material significantly minimized. Together with the carrier element 4 in particular results in a 4-layer overall structure of the trim part 2 , Alternatively, other layers, such as an additional adhesive film between the support element 4 and base layer 33 , possible.

The method steps described above and in particular embossing and / or forming and / or insert molding preferably take place before curing of the polymer layer 53 , This is a particularly good mobility of the two layers 13 . 23 relative to each other and a particularly good damping during back injection possible.

The 6 shows the trim part 2 with the decorative shell 43 and the carrier element arranged thereon 4 in the injection mold 100 , For optimal properties as an intermediate layer 23 to be able to offer was the polymer layer 53 not fully networked in the previous steps. In this step, additional measures are now preferably carried out to the polymer layer 53 to undergo a crosslinking reaction. For example, this can be done by the pressure occurring during injection molding. It is also possible that at least one downstream process is provided. For example, the final crosslinking of the polymer layer 53 by suitable suitable radiation 101 and / or heat 102 respectively.

The vehicle component presented here 1 offers a trim part 2 with a high quality and durable metal surface. A particular advantage lies in the multi-layer sandwich-like construction of two metal sheets with a polymer layer arranged therebetween 53 , This has significant advantages over consistently hard and also compared to consistently soft materials. For example, consistently hard materials are particularly scratch-resistant, but they are difficult to emboss and reshape and tear under mechanical stress. Continuously soft materials on the other hand have high degrees of separation, distort the pattern during forming and are easily and permanently damaged on the surface by mechanical action.

LIST OF REFERENCE NUMBERS

1

vehicle component

2

garnish

3

decorative element

4

support element

13

decorative layer

23

interlayer

33

base layer

43

decorative shell

53

polymer layer

100

injection mold

101

radiation

102

warmth

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 202005010946 U1 [0002]

Claims (16)

Vehicle component (1) having at least one decorative part (2), comprising at least one decorative element (3) and at least one carrier element (4) for receiving the decorative element (3), characterized in that the decorative element (3) has a multilayer structure with at least one metallic Decorative layer (13) and at least one base layer (33) and at least one interposed intermediate layer (23). Vehicle component (1) according to the preceding claim, wherein the base layer (33) is formed from a metal material. Vehicle component (1) according to one of the preceding claims, wherein the decorative layer (13) has a different alloy and / or a different strength and / or a different thickness than the base layer (33). Vehicle component (1) according to one of the preceding claims, wherein the decorative layer (13) is thinner and / or harder and / or stronger than the base layer (33). Vehicle component (1) according to one of the preceding claims, wherein the decorative layer (13) has an at least partially and in particular completely relief-textured surface structure. Vehicle component (1) according to one of the preceding claims, wherein the decorative element (3) is provided by at least one decorative shell (43). Vehicle component (1) according to one of the preceding claims, wherein the intermediate layer (23) comprises at least one polymer layer (53). Vehicle component (1) according to one of the preceding claims, wherein the intermediate layer (23) is suitable and designed to arrange the decorative layer (13) floating to the base layer (33), so that occurring forces and / or stresses during embossing and / or forming of the decorative element (3) are at least partially compensated. Vehicle component (1) according to one of the preceding claims, wherein the intermediate layer (23) is suitable and designed to prevent a relative displacement of the decorative layer (13) to the base layer (33) in a cured state. Method for producing a vehicle component (1) having at least one decorative part (2), comprising at least one decorative element (3) and at least one carrier element (4) for receiving the decorative element (3), characterized in that the decorative element (3) has a multi-layered construction and in that at least one metallic decorative layer (13) is connected to at least one base layer (33) by at least one intermediate layer (23) arranged therebetween. Method according to the preceding claim, wherein the decorative element (3) is decorated by at least one embossing on the side of the decorative layer (13) and that the decorative layer (13) is thereby at least partially and in particular completely equipped with a relief surface structure. Method according to the preceding claim, wherein the decorative layer (13) is embossed floating on the base layer. Method according to one of the preceding claims, wherein the decorative element (3) to a decorative shell (43) is formed and wherein the decorative layer (13) and the base layer (33) are pulled out differently. Method according to one of the preceding claims, wherein the carrier element (4) is produced by injection-molding of the decorative element (3). Method according to one of the preceding claims, wherein an embossing and / or forming and / or injection molding of the decorative element (3) prior to curing of the intermediate layer (23), so that by the intermediate layer (23) during embossing and / or forming and / or Hinterspritzens a relative mobility of the decorative layer (13) to the base layer (33) is provided. Method according to one of the preceding claims, wherein the intermediate layer (23) as a polymer layer (53) is formed, which is cured after injection molding of the decorative element (3).

Images