DE202014001662U1 - Vehicle trim panel with metal layer and decorative element - Google Patents

Abstract

Vehicle interior trim part (1) comprising at least one metal layer (2), a decorative element (3) being applied to the metal layer (2) and / or a decorative element (3) being introduced into the metal layer (2), characterized in that on the decorative element ( 3) a layer (4) of transparent or translucent enamel is arranged.

Description

The invention relates to a vehicle interior trim part with a metal layer and a decorative element. From the prior art it is known to equip various vehicle interior trim parts completely or partially with a metal layer as the visible side layer. Such vehicle interior trim parts with metal layers are used in particular as optional features in cars of the middle or upper class. It is furthermore known that a particularly high-quality impression can be achieved by decorative elements applied to the metal layer, for example an imprint on the metal layer.

The disadvantage is that the decorative element is usually very prone to damage from abrasion, scratches or dirt. To remedy this disadvantage, it is known from the prior art to protect the decorative element by means of a plastic coating. However, it has been found that such plastic coatings, although reduce the risk of damage, but that even with such protected decorative elements damage occurs too often. In addition, a relatively thick plastic coating is required for effective protection. With increasing thickness of the plastic coating, however, the haptic properties of the metal layer and the decorative element are increasingly distorted. The particularly high-quality impression of the impression left by metal surfaces is thus lost.

Object of the present invention is to provide a vehicle interior trim part with a metal layer and a arranged on the metal layer or introduced into the metal layer decorative element, in which the decorative element is particularly efficiently protected, at the same time the key impression of the metal layer remains as much as possible.

This object is achieved by a vehicle interior trim part according to claim 1. Advantageous developments and refinements can be found in the dependent claims.

The fact that the decorative element is coated with a layer of transparent or translucent enamel, an efficient protection of the decorative element from scratches, abrasion and dirt is achieved. Also, protection against the action of chemicals such as detergents or spilled acidic beverages is improved. For various reasons, a haptic impression is hardly distorted by the enamel:
Enamel is particularly hard, so that the key impression of the coated by the enamel coated with the decorative element metal layer is not significantly affected in terms of compliance. This is a distinct advantage over prior art solutions because plastic coatings feel soft to metal surfaces, even when relatively hard plastic is used.

The high hardness and thus the efficient protection by the enamel also makes it possible to use a relatively thin coating. The small thickness of the enamel prevents the heat transfer between the decorative element and a vehicle occupant touching the decorative element is influenced too much by the enamel. The cool feeling of a metal surface resulting from the high heat transfer is largely retained. In the known from the prior art plastic coatings on the one hand, the layer thickness is usually greater than what is required for an enamel, and on the other hand, the thermal conductivity of plastic is smaller than that of enamel.

In comparison to enamel-coated metal surfaces, the cool sense of touch is at least predominantly lost in conventional, plastic-coated metal surfaces.

If the enamel is transparent, the decorative element can furthermore be recognized, wherein a contrast between different regions of the decorative element and / or between the decorative element and the region of the metal layer surrounding the decorative element can at least predominantly be retained.

In the context of this patent application, the term "transparent" should be understood such that the enamel does not necessarily have to be almost completely transparent to light of all visible wavelengths. Conversely, the enamel may be designed to absorb certain wavelengths so that it appears colored. However, the enamel is permeable at least for some visible wavelengths. The decorative element is visible through the enamel. In one embodiment, the enamel may also be formed almost completely permeable to all visible wavelengths. As already mentioned, the enamel can be translucent, ie it can cause volume scattering. The volume scattering can be relatively weak or even so strong that the decorative element and / or the metal layer is no longer recognizable as such, but the decorative element at least still causes a visible optical effect through the enamel, ie despite the volume scattering has that Decorative element still affect the appearance of the vehicle interior trim part. The enamel is so designed that when light irradiated on the layer of enamel is at least a part of the incoming light (directly or after scattering in the layer of enamel) reaches the decorative element, there reflected back or scattered, and then leaves the vehicle interior trim part again through the layer of enamel. Although only transparent enamel is mentioned in the remainder of the description, all described features and embodiments can also be used in combination with translucent enamel and should also be regarded as disclosed in connection with translucent enamel.

The metal layer may be formed as a light metal layer. For example, the metal layer may be formed as an aluminum layer. On the one hand, aluminum is relatively light and can also be relatively easily provided with a layer of enamel. Instead of an aluminum layer, a layer of magnesium or titanium can also be enamelled.

The decorative element may be formed as a print, for example screen printing, on a region or the entire metal layer. It should be noted, however, that the colors used for printing must be chosen such that they survive all the subsequent application of the decor following process steps of a method for producing the vehicle interior trim part without damage. Likewise, the decor may be formed of a brushed portion of the metal layer. Also, the decorative element may be formed by embossing in the metal layer.

The metal layer may be curved in one direction. Likewise, a curvature in several directions is possible. The metal layer may in particular be formed as a sheet formed by bending. Before forming, the sheet may have a constant thickness apart from tolerance-related variations of, for example, less than + -10%, + -5%, + -2% or + -1%. This can be seen on the finished component in that the thickness of the sheet varies only in bent areas beyond the tolerance-related fluctuations, wherein the thickness in the bent areas depending on the bending radius due to the local stretching of the sheet due to the bending is locally reduced.

An average thickness of the metal layer may be between 0.1 mm and 5 mm, preferably between 0.2 mm and 3 mm, particularly preferably between 0.3 and 1.5 mm.

The transparent enamel may be colored, d. H. it may have pigments and / or dyes and be transparent only to a portion of the light visible to the human eye. For example, the transparent enamel may contain at least one metal oxide. For example, the enamel may contain cobalt, nickel, copper, iron, zinc, manganese, titanium, antimony, tin, vanadium, tungsten, zirconium, praseodymium, aluminum, chromium, lead, cadmium or selenium. The enamel may have mineral particles containing the metal oxide. For example, particles of spinel, rutile, zirconium, corundum, pyrochlore or sulfides can be contained in the enamel as mineral particles. By a suitable choice of pigments and enamel can be achieved, which is not transparent but translucent. For this purpose, pigments are selected which cause a volume scattering of irradiated light.

The layer of transparent enamel may for example have a thickness of between 5 μm and 200 μm. Layer thicknesses between 20 μm and 100 μm, ideally between 40 μm and 80 μm, have proved particularly suitable. With higher layer thicknesses, the risk of detachment and fragmentation of the layer in the event of an accident begins to increase. At lower layer thicknesses, a visually appealing overall impression of the vehicle interior trim part is not achieved to the same extent. Especially if an uneven surface of the enamel layer is to be provided in order to give the impression of a hand-crafted vehicle interior trim part, the layer thickness should preferably be in one of the areas indicated above.

The layer of transparent enamel may partially or completely cover a visible side of the metal layer depending on the embodiment. For example, more than 50%, 70% or 90% of the visible side of the metal layer may be enameled. If the entire visible side is enamelled, possibly optically insufficiently attractive transitions between enamelled areas and non-enamelled areas are avoided.

The metal layer can with its back, d. H. the side facing away from the enamel, communicate with a carrier. For example, the carrier may be fused to the carrier. Alternatively, the carrier may also be glued to the back of the metal layer. The carrier may for example consist partially or completely of plastic.

• a) Bereitstellen einer Metallschicht,
• b) Auf- oder Einbringen eines Dekorelements auf oder in die Metallschicht und
• c) Erzeugen einer Schicht aus transparenter Emaille auf dem Dekorelement.

The invention also relates to a method which is defined in more detail in the following aspects: According to the first aspect, the invention relates to a method for producing a vehicle interior trim part, comprising the steps:

• a) providing a metal layer,
• b) applying or introducing a decorative element on or in the metal layer and
• c) producing a layer of transparent enamel on the decorative element.

According to the second aspect, the invention relates to a method according to the first aspect, wherein the method steps a), b) and c) are carried out as separate method steps in the order specified.

According to a third aspect, the invention relates to a method according to one of the above-mentioned aspects, wherein as step b) the metal layer is printed, embossed, sprayed and / or brushed. For example, a plurality of brushed areas may be introduced into the metal layer, which differ with respect to the direction and / or strength of the brushing. It is also possible successively to apply a plurality of masks to the area to be provided with the décor, wherein each mask does not cover at least one other area. After applying each mask, the exposed area may be brushed, with the mask subsequently removed. For each mask used, it is possible to apply brushes which differ with regard to the direction of brushing and / or the strength of the brushing (i e the pressure applied during brushing). Also, the brushes used for each brush may have metal wires of different thickness. For example, three or more masks may be applied sequentially, with brushing after the application of each of the masks, the exposed area.

According to a fourth aspect, the invention relates to a method according to one of the aforementioned aspects, wherein the method additionally comprises the step d) three-dimensional forming of the metal layer. According to a fifth aspect, the invention relates to a method according to the fourth aspect, wherein step d) takes place by bending the metal layer. The metal layer can be bent in particular when cold (at a temperature of below 50 ° C). The bending can be done for example by stamping or pressing. For this purpose, for example, a plurality of pressing devices can be used successively, wherein by means of the first pressing device, a rough shape is predetermined and the other presses introduce more detailed structures in the metal layer.

According to a sixth aspect, the invention relates to a method according to the fourth or fifth aspect, wherein step d) takes place between steps b) and c).

According to a seventh aspect, the invention relates to a method according to one of the above-mentioned aspects, additionally comprising a step e): attaching a carrier to the rear side of the metal layer.

According to an eighth aspect, the invention relates to a method according to the seventh aspect, wherein step e) is carried out by adhering a carrier to the rear side of the metal layer or by injecting the rear side of the metal layer.

According to a ninth aspect, the invention relates to a method according to one of the aforementioned aspects, wherein step c) comprises sub-steps c1) applying a slurry, preferably enamel slip, to the decorative element and c2) heating the slurry to one to form the layer of transparent enamel suitable temperature.

According to a tenth aspect, the invention relates to a method according to one of the aforementioned aspects, wherein the method produces a vehicle interior trim part according to one of claims 1 to 10.

Embodiments of the invention will be explained in more detail with reference to FIGS. Show it:

1 an embodiment of a vehicle interior trim part;

2 a metal layer at the beginning of a method for producing the vehicle interior trim part 1 ;

3 the metal layer 2 during the creation of a decorative element;

4 the provided with the decorative element metal layer 3 at a subsequent forming step;

5 the formed, provided with a decorative element metal layer 4 when applying an enamel slip;

6 the metal layer 5 during the burning of the enamel slip; and

7 the enameled metal layer 6 for injection molding with a plastic-containing material.

In 1 is a vehicle interior trim part 1 shown in plan view and in cross section, wherein the vehicle interior trim part 1 a metal layer 2 having, which with a decorative element 3 is provided. The metal layer is formed in the present example as a sheet having a thickness of about 0.5 mm. The metal layer 2 is three-dimensionally shaped by bending, ie it is curved in several directions. Thus, there is no direction in which the metal layer has a cross-section which is constant over the entire extent of the metal layer in the direction (this means the shape of the cross-section and not the total size of the cross-sectional area). This means that regardless of the position of the sectional plane of a cross-section Q through the metal layer 2 at least one parallel cross-section Q 'of the metal layer may be present, which differs from the cross-section Q. The reshaped metal layer thus does not have the shape of a bar profile in the present embodiment. The metal layer is formed in the present example of an aluminum alloy.

The decorative element 3 is in the present embodiment as a print on the metal layer 2 educated. In non-illustrated embodiments, the metal layer 2 but instead a pattern of brushed and non-brushed surface areas or a pattern of surface areas brushed in different directions as a decorative element 3 on. In other embodiments, the decorative element 3 formed as embossed in the metal layer embossing. In the present embodiment, the decorative element covers 3 only a portion of the metal layer. In alternative embodiments, not shown, however, the decorative element may extend over the entire decorative layer.

The decorative element 3 is with a layer 4 covered in transparent enamel. The layer 4 has a thickness of about 60 microns. In the present example, the entire decorative layer is covered with the layer of transparent enamel. Although this is advantageous in many applications, the metal layer may also have non-enameled areas. For example, in an alternative embodiment, the metal layer may extend only over part of the surface of the vehicle interior trim part, and engage behind a plastic part forming the surface area surrounding the metal layer. In this case, it can be provided that the metal layer has no enamel in the region engaging behind the plastic part, which serves for fastening to the surrounding plastic part. The enamel is colored in the present embodiment, while still the underlying decorative element 3 through the layer 4 made of enamel. However, embodiments with undyed enamel are also possible.

With her back 5 is the metal layer 2 with a carrier 6 from a plastic-containing material, GF-PP in the present example, connected. The carrier has a thickness of about 1.5 mm and is fused directly to the metal layer, that is, the metal layer and the carrier are directly bonded to each other materially. As an alternative to a direct cohesive connection, however, an adhesive layer may also be present between the carrier 6 and the metal layer 2 be arranged.

Based on 2 to 7 hereinafter the manufacturing process of the in 1 illustrated vehicle interior trim part explained.

In a first process step, a metal layer 2 provided. This can be done, for example, by cutting an aluminum sheet or an aluminum foil. The metal layer (cf. 2 ) is used in a subsequent, based on 3 clarified process step with a decorative element 3 Mistake. In the example shown, the metal layer 2 on a pad 7 arranged and by means of an embossing stamp 8th embossed. Alternatively (or additionally), the metal layer could 2 also printed, brushed, sprayed or provided in any other way with a decorative element. It is essential, however, that the decorative element is sufficiently resistant to heat in order to survive the firing of the enamel which takes place in a later method step. The decorative element should thus be formed of a material that does not chemically change even at a maximum temperature occurring in the following process steps (for example, 500 ° C) and does not melt.

After the decorative element 3 was generated, which is the decorative element 3 having deformed metal layer (see. 4 ). The sheet is bent so. This can, for example, by deep drawing according to the Standard DIN 8584 respectively. For this purpose, a thermoforming tool 13 be used. The metal layer can also be processed in succession by means of several pressing tools. For example, a first-used pressing tool can introduce a coarse three-dimensional structure into the metal layer, whereby the further presses increasingly finer structures are introduced into the metal layer. Depending on the type of decorative element 3 Forming can already before the application of the decorative element 3 respectively.

In a subsequent process step, not shown, the metal layer 2 and the decorative element 3 pretreated. As part of the pretreatment, for example, first fats can be removed. Subsequently, the surface is passivated. Thereafter, the surface is broken (thermally or mechanically), so that the oxide layer, which forms aluminum on the surface, in the subsequent process steps Connection of the enamel to the surface is not prevented / impeded.

After pretreatment is applied to the metal layer 2 and the decorative element 3 an enamel slip 9 applied. In an alternative embodiment, a slurry for a transparent ceramic is applied. This can, for example, as in 5 represented by means of a spray gun 10 carried out, which can be operated either manually or by a robot.

The one with the enamel slip 9 provided, and with the decorative element 3 equipped metal layer 2 is subsequently placed in an oven 11 introduced and baked at a temperature of about 500 ° C. The in the oven 11 arranged metal layer 2 is in 6 shown. Thus, a uniform enamel layer is formed. However, the enamel layer can also be selectively formed irregular. For this purpose, the enamel slurry is applied in areas thicker. As a result, the finished vehicle part later gives the impression that it is made by hand. In fact, however, such an irregular application of the Enamel slip can also be achieved by a corresponding programming of a spray robot.

After at least partial cooling of the finished enamelled metal layer 2 this is in a Hinterspritzform 12 inserted and back-injected on its back with a plastic-containing material. The in the injection mold 12 arranged metal layer 2 is in 7 shown.

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 non-patent literature

• Standard DIN 8584 [0041]

Claims (10)

Vehicle interior trim part ( 1 ) comprising at least one metal layer ( 2 ), wherein on the metal layer ( 2 ) a decorative element ( 3 ) and / or in the metal layer ( 2 ) a decorative element ( 3 ) is introduced, characterized in that on the decorative element ( 3 ) a layer ( 4 ) is arranged from transparent or translucent enamel. Vehicle interior trim part ( 1 ) according to claim 1, characterized in that the metal layer ( 2 ) is formed of aluminum. Vehicle interior trim part ( 1 ) according to one of the preceding claims, characterized in that the decorative element ( 3 ) is designed as an imprint, embossing or as a chemically or mechanically modified surface area, for example a brushed surface area. Vehicle interior trim part ( 1 ) according to one of the preceding claims, characterized in that the metal layer ( 2 ) is formed curved out of a plane in at least one direction, preferably in several directions. Vehicle interior trim part ( 1 ) according to claim 4, characterized in that the metal layer ( 2 ) is formed as a sheet formed by bending. Vehicle interior trim part ( 1 ) according to one of the preceding claims, characterized in that the metal layer ( 2 ) has a thickness between 0.1 mm and 5 mm, preferably between 0.2 mm and 3 mm, particularly preferably between 0.3 mm and 1.5 mm. Vehicle interior trim part according to one of the preceding claims, characterized in that the layer ( 4 ) is colored from transparent or translucent enamel. Vehicle interior trim part according to one of the preceding claims, characterized in that the layer ( 4 ) of transparent or translucent enamel has a thickness between 10 microns and 200 microns. Vehicle interior trim part ( 1 ) according to one of the preceding claims, characterized in that the layer ( 4 ) of transparent or translucent enamel a visible side of the metal layer ( 2 ) predominantly or completely covers. Vehicle interior trim part ( 1 ) according to one of the preceding claims, comprising a carrier ( 6 ), which on the side facing away from the enamel side of the metal layer ( 2 ) and with the metal layer ( 2 ), the carrier ( 6 ) is preferably fused or glued to the metal layer.

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