DE102021118528A1 - Injection molded trim element for a vehicle - Google Patents

Abstract

The invention relates to a method for producing a cladding element (1) for a vehicle (3), comprising the steps: - providing (S1) a film (5) which has a carrier layer (7) made of transparent thermoplastic material and a non-transparent colored layer ( 9) includes, - application (S2) of a depth layer (11) made of transparent thermoplastic material to the carrier layer (7) of the film (5) by an injection molding process, - application (S3) of the depth layer (11) raised ornaments (13) , in particular star symbols, on the opposite side of the depth layer (11) to the film (5) by means of an injection molding process.

Description

The invention relates to a method for producing a cladding element for a vehicle, and to such a cladding element for a vehicle.

Covering elements for vehicles are known from the prior art, which have three-dimensional ornaments.

the DE 10 2020 005 896 A1 relates to a method for producing a flat paneling element for a vehicle, which has at least one ornament with a three-dimensional appearance and the edge of which is illuminated by at least one light source that can be arranged on the object side of the paneling element, with the following steps: providing an opaque layered body with a visual and an object side, which has a recess with the contour of the respective ornament at the locations of the ornaments to be formed, providing a tool mold with the shape of the visible side of the layered body, depressions being formed at the locations of the recesses, placing the layered body in the tool mold and Coating the object side of the layered body with transparent plastic, with the filling of the depressions on the visible side forming raised ornaments, each with an ornament top surface and an ornament side wall, removal of the Sc body and application of an ornamental cover layer on each of the ornamental cover surfaces with a predetermined translucency and color, application of a transparent protective layer on the visible side of the layered body.

the DE 10 2020 108 707 A1 also relates to a method for producing a trim element for a vehicle, in which at least one ornament is introduced from the object side with a three-dimensional appearance on a transparent body having a visible side and an object side, and the object side is covered with a privacy screen, the privacy screen having a black lacquer bearing support is applied to the transparent body, the black lacquer over the ornament being separated and removed during application.

However, these prior art trim elements suffer from certain deficiencies in representing the color of a vehicle evenly up to the edge of the respective trim element. In addition, attachment points on the back (the side facing the vehicle) are not easily attached by two-component injection molding, but are usually to be glued, which is more time-consuming than an injection molding process.

The object of the invention is therefore to eliminate the disadvantages mentioned above and in particular to enable a more uniform color representation when coloring a vehicle.

The invention results from the features of the independent claims. Advantageous developments and refinements are the subject matter of the dependent claims.

• - Bereitstellen einer Folie, die eine Trägerschicht aus transparentem, insbesondere thermoplastischem, Kunststoff und eine intransparente Farbschicht umfasst,
• - Aufbringen einer Tiefenschicht aus transparentem thermoplastischem Kunststoff auf die Trägerschicht der Folie durch ein Spritzgussverfahren insbesondere so, dass die Tiefenschicht eine größere Dicke als die Trägerschicht der Folie aufweist, und
• - Aufbringen von von der Tiefenschicht erhabenen Ornamenten, insbesondere Sternsymbole, auf der zur Folie gegenüberliegenden Seite der Tiefenschicht mittels des Spritzgussverfahrens.

A first aspect of the invention relates to a method for producing a cladding element for a vehicle, comprising the steps:

• - providing a film which comprises a carrier layer made of transparent, in particular thermoplastic, plastic and an opaque color layer,
• - applying a deep layer of transparent thermoplastic material to the carrier layer of the film by an injection molding process, in particular in such a way that the deep layer has a greater thickness than the carrier layer of the film, and
• - Application of raised from the deep layer ornaments, in particular star symbols, on the opposite side of the film of the deep layer by means of the injection molding process.

The cladding element can be an add-on part, spare part or, in particular, a radiator cover. The trim element has an outside facing towards the surroundings of the vehicle and is therefore visible to the surroundings, but generally also has an aerodynamic function for guiding air.

One of the following plastics is preferably used for the polymer of the depth layer: PC, PA12 or PMMA. Due to its transparency, the depth layer creates an optical depth effect, since the non-transparent color layer of the film can be viewed through the depth layer and the carrier layer. The color layer of the film, on the other hand, defines the basic color of the vehicle's cladding element, for example anthracite, cream white, red or black.

The deep layer made of a transparent, thermoplastic material is applied to the carrier layer of the film by means of injection molding. For this purpose, the film is placed in an injection mold in particular in such a way that the color layer contacts the mold. The plastic of the depth layer is applied to the carrier layer facing the interior of the injection mold. Both the plastic of the deep layer and the plastic of the carrier layer are transparent and preferably made of the same material in order to avoid optical phase transitions and thus light refraction at the interface of the two plastics.

The ornaments are forms protruding from the depth layer, in particular spatially formed star symbols.

It is an advantageous effect of the invention that the injection molding process and the general layer structure of the cladding element create a depth effect, in particular through the applied depth layer, and the color of the colored layer of the film is perceived evenly. Slight color differences to adjacent components of the vehicle are thereby concealed. In addition, by using the film using a two-component injection molding process, connection points can be applied directly to the back of the film without necessarily having to be glued there. In addition, when lofty ornaments such as stars are used and backlighting is provided by a light source, those lofty stars are directly illuminated by the light source. A uniform color design of the cladding element can be set up to the outermost edge of the cladding element by using the color layer of the film.

According to an advantageous embodiment, thermoplastically compatible, in particular identical, plastics are used for the plastic of the carrier layer and for the plastic of the deep layer. In this context, thermoplastically compatible means that the plastics bond to one another at high temperatures and can in principle be welded to one another. This advantageously avoids obtaining a prominent boundary surface and separate plastic layers from one another.

According to a further advantageous embodiment, a film is provided which has a non-transparent, in particular black, cover layer, the colored layer of the film being arranged between the carrier layer and the cover layer of the film. This advantageously brings out the color of the colored layer of the film better, reduces stray light and creates improved adhesion to attachment points that are arranged on the film by a two-component injection molding process.

• - Aufbringen einer jeweiligen metallischen Heißprägefolie, insbesondere einer Chromfolie, auf die jeweiligen Ornamente so, dass die jeweilige Heißprägefolie die Oberfläche des jeweiligen der Ornamente vollständig bedeckt.

According to a further advantageous embodiment, the method also has the step:

• - Application of a respective metallic hot stamping foil, in particular a chrome foil, to the respective ornaments in such a way that the respective hot stamping foil completely covers the surface of the respective ornaments.

The metallic hot stamping foil is preferably a metallic foil, in particular a chrome foil, which means that a metal layer is used at least on the top side of the hot stamping foil that is visible from the outside, in order to obtain a special appearance of the ornaments through the metallic sheen.

According to a further advantageous embodiment, the application of the deep layer and the application of the ornaments are carried out in a single, coherent injection molding process step. Advantageously, therefore, only a single injection molding process step is necessary to provide the foil with both the depth layer and the ornaments. This advantageously leads to a very quick production of the cladding element and a seamless transition of the ornaments to the deep layer.

According to a further advantageous embodiment, the application of the deep layer and the application of the ornaments are carried out as a respective injection molding step of a two-component injection molding process. A two-component injection molding process for applying the ornaments is only necessary if the ornaments should have certain properties, for example should be made of a different material or should have a different color than the depth layer.

• - Aufbringen mindestens eines Anbindungspunkts aus thermoplastischem Kunststoff durch ein Zweikomponenten-Spritzgussverfahren auf die Außenfläche der Folie, die der Tiefenschicht gegenüberliegt, wobei der mindestens eine Anbindungspunkt zum Anbinden des Verkleidungselements an das Fahrzeug dient. Bevorzugt wird auch der mindestens eine Anbindungspunkt aus einem thermoplastischen Polymer durch ein Zweikomponenten-Spritzgussverfahren auf der Folie an der Farbschicht, bzw. wenn verwendet, der Deckschicht, aufgetragen, wobei bevorzugt als Polymer wiederum eines aus PC, PA12, PC/ABS oder PMMA verwendet wird und weiterhin bevorzugt zumindest ein Anbindungspunkt nahe einem Rand der Folie angeordnet wird.

According to a further advantageous embodiment, the method also has the step:

• - Application of at least one connection point made of thermoplastic material by a two-component injection molding process on the outer surface of the film, which is opposite the deep layer, wherein the at least one connection point is used to connect the covering element to the vehicle. The at least one connection point made of a thermoplastic polymer is also preferably applied to the film on the color layer or, if used, the top layer by a two-component injection molding process, with a polymer made of PC, PA12, PC/ABS or PMMA again being preferably used and more preferably at least one attachment point is arranged near an edge of the film.

• - Entfernen, insbesondere durch Aufbringen eines Laserstrahls, aller Schichten bis auf die Trägerschicht der Folie in der Projektionsfläche der Ornamente auf die Folie, sodass Licht im Bereich der Ornamente durch die Folie zu den Ornamenten gelangen kann. Insbesondere wird hierbei die Farbschicht der Folie entfernt und, wenn verwendet, auch die Deckschicht der Folie. Die Folie besteht in diesen Bereichen der Projektion der Ornamente auf die Folie daher lediglich aus der Trägerschicht, welche transparent ist.

According to a further advantageous embodiment, the method also has the step:

• - Removal, in particular by applying a laser beam, of all layers except for the carrier layer of the foil in the projection area of the ornaments onto the foil, so that light in the area of the ornaments can reach the ornaments through the foil. In particular, the color layer of the film is removed here and, if used, also the top layer of the film. In these areas where the ornaments are projected onto the film, the film therefore consists only of the carrier layer, which is transparent.

Another aspect of the invention relates to a trim element for a vehicle, comprising a film with a carrier layer made of transparent, in particular thermoplastic, plastic and with a non-transparent color layer, and comprising a deep layer made of transparent thermoplastic plastic, the deep layer having a greater layer thickness than the carrier layer of the film and the depth layer has raised ornaments, in particular star symbols, on the side of the depth layer opposite the film, with at least one attachment point made of thermoplastic material being arranged on the outer surface of the film, which is opposite the depth layer, which is used to attach the trim element to the vehicle serves. This cladding element is preferably obtained by a production method described above or below.

According to a further advantageous embodiment, the cladding element also comprises a respective metallic hot stamping foil, in particular a chrome foil, on the respective ornaments, with the respective hot stamping foil completely covering the surface of the respective ornament, and comprising at least one light source on the side of the assembly opposite the ornaments Deep layer and foil, wherein all layers of the foil except for the carrier layer are removed in a projection surface of the ornaments onto the foil, so that light from the at least one light source passes through the foil in the area of the ornaments through the transparent carrier layer and the transparent deep layer to the ornaments. This cladding element is preferably obtained by a production method described above or below.

Advantages and preferred developments of the proposed cladding element result from an analogous and analogous transfer of the statements made above in connection with the proposed method.

Further advantages, features and details result from the following description, in which at least one exemplary embodiment is described in detail-if necessary with reference to the drawing. Identical, similar and/or functionally identical parts are provided with the same reference symbols.

• 1: Ein Verfahren zum Herstellen eines Verkleidungselements gemäß einem Ausführungsbeispiel der Erfindung.
• 2: Ein Verkleidungselement gemäß einem Ausführungsbeispiel der Erfindung.
• 3: Ein weiteres Verkleidungselement gemäß einem Ausführungsbeispiel der Erfindung.
• 4: Ein weiteres Verkleidungselement gemäß einem Ausführungsbeispiel der Erfindung.
• 5: Eine Fahrzeugfront mit einem Verkleidungselement gemäß einem Ausführungsbeispiel der Erfindung.

Show it:

• 1 : A method for producing a cladding element according to an embodiment of the invention.
• 2 : A covering element according to an embodiment of the invention.
• 3 : Another trim element according to an embodiment of the invention.
• 4 : Another trim element according to an embodiment of the invention.
• 5 : A vehicle front with a cladding element according to an embodiment of the invention.

The representations in the figures are schematic and not to scale.

• - Bereitstellen S1 einer Folie 5, die eine Trägerschicht 7 aus transparentem thermoplastischem PC-Kunststoff (Polycarbonat) und eine intransparente schwarze Farbschicht 9 umfasst,
• - Aufbringen S2 einer Tiefenschicht 11 aus transparentem thermoplastischem PC-Kunststoff auf die Trägerschicht 7 der Folie 5 durch ein Spritzgussverfahren so, dass die Tiefenschicht 11 eine größere Dicke als die Trägerschicht 7 der Folie 5 aufweist, und
• - Aufbringen S3 von von der Tiefenschicht 11 erhabenen sternförmigen Ornamenten 13 auf der zur Folie 5 gegenüberliegenden Seite der Tiefenschicht 11 mittels Spritzgussverfahren,
• - Aufbringen S4 einer jeweiligen metallischen Heißprägefolie 17, insbesondere einer Chromfolie, auf die jeweiligen Ornamente 13 so, dass die jeweilige Heißprägefolie 17 die Oberfläche des jeweiligen der Ornamente 13 vollständig bedeckt, wobei das Aufbringen der Tiefenschicht 11 und das Aufbringen der Ornamente 13 in einem einzigen, zusammenhängenden Spritzgussverfahrensschritt ausgeführt wird,
• - Aufbringen S5 mindestens eines Anbindungspunkts 19 aus thermoplastischem Kunststoff durch ein Zweikomponenten-Spritzgussverfahren auf die Außenfläche der Folie 5, die der Tiefenschicht 11 gegenüberliegt, wobei der mindestens eine Anbindungspunkt 19 zum Anbinden des Verkleidungselements 1 an das Fahrzeug 3 dient, und
• - Entfernen S6, insbesondere durch Aufbringen eines Laserstrahls, aller Schichten bis auf die Trägerschicht 7 der Folie 5 in der Projektionsfläche der Ornamente 13 auf die Folie 5, sodass Licht im Bereich der Ornamente 13 durch die Folie 5 zu den Ornamenten 13 gelangen kann.

1 shows a method for producing a cladding element 1 for a vehicle 3, comprising the steps:

• - Providing S1 a film 5, which comprises a carrier layer 7 made of transparent thermoplastic PC plastic (polycarbonate) and a non-transparent black color layer 9,
• - Application S2 of a deep layer 11 made of transparent thermoplastic PC plastic onto the carrier layer 7 of the film 5 by an injection molding process in such a way that the deep layer 11 has a greater thickness than the carrier layer 7 of the film 5, and
• - Application S3 of raised from the deep layer 11 star-shaped ornaments 13 on the opposite side of the film 5 of the deep layer 11 by injection molding,
• - Application S4 of a respective metallic hot stamping foil 17, in particular a chrome foil, to the respective ornaments 13 in such a way that the respective hot stamping foil 17 completely covers the surface of the respective ornaments 13, the application of the deep layer 11 and the application of the ornaments 13 being carried out in a single , coherent injection molding process step is carried out,
• - Application S5 of at least one connection point 19 made of thermoplastic material by a two-component injection molding process on the outer surface of the film 5, which is opposite the deep layer 11, wherein the at least one attachment point 19 is used to attach the cladding element 1 to the vehicle 3, and
• - Removal S6, in particular by applying a laser beam, of all layers except for the carrier layer 7 of the foil 5 in the projection surface of the ornaments 13 on the foil 5, so that light in the area of the ornaments 13 can pass through the foil 5 to the ornaments 13.

The reference numerals used in the above method steps, which refer to components, can also be used in the following 2 until 4 be read. In particular, the result of step S6 is more accurate based on the 4 explained.

2 shows a cladding element 1 for a vehicle 3 in a cross-sectional view. A film 5 of the cladding element 1 has a carrier layer 7 made of transparent thermoplastic PC plastic and an opaque colored layer 9 . A deep layer 11 also made of transparent thermoplastic PC plastic was as in step S2 with respect to 1 applied to the foil 5 in the injection molding process together with the above ornaments 13. Furthermore, the deep layer 11 has a greater layer thickness than the carrier layer 7 of the film 5 . Raised star-shaped ornaments 13 are arranged on the deep layer 11 that is visible to the area surrounding the vehicle 3 and 5 are shown in more detail from a plan view. Furthermore, a left and a right connection point 19 made of thermoplastic PC plastic was arranged on the outer surface of the film 5, which is opposite the deep layer 11, using a two-component injection molding process. A respective metallic hot stamping foil 17 was applied to the respective ornaments 13 by means of pressure and heat to completely cover the respective surface of each of the ornaments 13 .

3 shows a modification of the covering element 1 of FIG 2 . In contrast to the in 2 cladding element 1 shown, this cladding element 1 has a different film 5 . An opaque, black cover layer 15 is arranged on an inside of the covering element 1 facing the interior of the vehicle in such a way that the colored layer 9 of the film 5 is located between the carrier layer 7 and the cover layer 15 of the film 5 .

4 shows a further modification of the cladding element 1. In contrast to that in 2 The cladding element 1 shown has this cladding element 1 a light source 21 on the side of the composite of depth layer 11 and film 5 opposite the ornaments 13 . Furthermore, in a projection surface of the ornaments 13 on the film 5, all layers of the film 5 have been removed except for the carrier layer 7, so that the light from the light source 21 passes through the film 5 in the area of the ornaments 13 through the transparent carrier layer 7 and the transparent depth layer 11 reaches the ornaments 13 and illuminates them from below. The likewise star-shaped recess in the film 5 is designed to be larger than the exact projection surface of the ornaments 13 on the film 5, in order to be able to better illuminate the ornaments 13, namely also with a component on the side of the ornaments 13.

5 shows a vehicle 3 with a paneling element 1 from its flat upper side, only the ornaments 13 being shown because of the sketchy representation. The ornaments 13 are star-shaped, with one of the stars being enlarged in order to emphasize the depth effect compared to the color layer 9 .

Although the invention has been illustrated and explained in more detail by means of preferred exemplary embodiments, the invention is not restricted by the disclosed examples and other variations can be derived therefrom by a person skilled in the art without departing from the protective scope of the invention. It is therefore clear that a large number of possible variations exist. It is also understood that the embodiments given as examples are really only examples and should not be construed as limiting in any way the scope, applications or configuration of the invention. Rather, the preceding description and the description of the figures enable the person skilled in the art to concretely implement the exemplary embodiments, whereby the person skilled in the art, knowing the disclosed inventive idea, can make a variety of changes, for example with regard to the function or the arrangement of individual elements mentioned in an exemplary embodiment. without departing from the scope of protection defined by the claims and their legal equivalents, such as further explanations in the description.

Reference List

1

paneling element

3

vehicle

5

foil

7

backing layer

9

paint layer

11

deep layer

13

ornaments

15

top layer

17

hot stamping foil

19

connection point

21

light source

S1

Provide

S2

apply

S3

apply

S4

apply

S5

apply

S6

Removed

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was 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.

Patent Literature Cited

• DE 102020005896 A1 [0003]
• DE 102020108707 A1 [0004]

Claims (10)

Method for producing a cladding element (1) for a vehicle (3), comprising the steps: - Providing (S1) a film (5) comprising a carrier layer (7) made of transparent, in particular thermoplastic, plastic and an opaque color layer (9), - Application (S2) of a deep layer (11) made of transparent thermoplastic material to the carrier layer (7) of the film (5) by an injection molding process, in particular in such a way that the deep layer (11) has a greater thickness than the carrier layer (7) of the film (5 ) has, and - Application (S3) of the deep layer (11) raised ornaments (13), in particular star symbols, on the film (5) opposite side of the deep layer (11) by injection molding. procedure after claim 1 , wherein for the plastic of the carrier layer (7) and for the plastic of the deep layer (11) thermoplastically compatible, in particular the same, plastics are used. Method according to one of the preceding claims, in which a film (5) is provided which has a non-transparent, in particular black, cover layer (15), the color layer (9) of the film (5) between the carrier layer (7) and the cover layer ( 15) of the film (5) is arranged. Method according to one of the preceding claims, further comprising the step: - Application (S4) of a respective metallic hot stamping foil (17), in particular a chrome foil, to the respective ornaments (13) in such a way that the respective hot stamping foil (17) completely covers the surface of the respective ornaments (13). Procedure according to one of Claims 1 until 4 , wherein the application of the depth layer (11) and the application of the ornaments (13) is carried out in a single, coherent injection molding process step. Procedure according to one of Claims 1 until 4 , wherein the application of the depth layer (11) and the application of the ornaments (13) is carried out as a respective injection molding step of a two-component injection molding process. Method according to one of the preceding claims, further comprising the step: - Applying (S5) at least one attachment point (19) made of thermoplastic material to the outer surface of the film (5) by a two-component injection molding process, which is opposite the deep layer (11), the at least one attachment point (19) for attaching the cladding element (1 ) to the vehicle (3) is used. Method according to one of the preceding claims, further comprising the step: - Removal (S6), in particular by applying a laser beam, of all layers except for the carrier layer (7) of the foil (5) in the projection surface of the ornaments (13) on the foil (5), so that light in the area of the ornaments (13) can get through the film (5) to the ornaments (13). Covering element (1) for a vehicle (3), comprising a film (5) with a carrier layer (7) made of transparent, in particular thermoplastic, plastic and with an opaque colored layer (9), and comprising a deep layer (11) made of transparent thermoplastic plastic , wherein the deep layer (11) has a greater layer thickness than the carrier layer (7) of the film (5) and the deep layer (11) has raised ornaments (13), in particular star symbols, on the side of the deep layer (11 ), wherein at least one connection point (19) made of thermoplastic material is arranged on the outer surface of the film (5), which is opposite the depth layer (11), which is used to connect the covering element (1) to the vehicle (3). Paneling element (1) after claim 9 , further comprising a respective metallic hot stamping foil (17), in particular a chrome foil (5), on the respective ornaments (13), the respective hot stamping foil (17) completely covering the surface of the respective ornament (13), and comprising at least one light source (21) on the opposite side of the composite of depth layer (11) and foil (5) from the ornaments (13), wherein in a projection surface of the ornaments (13) onto the foil (5) all layers of the foil (5) except for the carrier layer (7) are removed, so that light from the at least one light source (21) passes through the film (5) in the area of the ornaments (13) through the transparent carrier layer (7) and the transparent depth layer (11) to the ornaments (13). .

Images