EP3600909A1

EP3600909A1 - Selectively illuminable metallic looking trims and their methods of manufacture

Info

Publication number: EP3600909A1
Application number: EP18740643.4A
Authority: EP
Inventors: Fernando Colon; Sergio PILES; Raul Martinez
Original assignee: SRG Global Liria SL
Current assignee: SRG Global Liria SL
Priority date: 2017-06-09
Filing date: 2018-06-08
Publication date: 2020-02-05
Also published as: ES2706652R1; CN111065527A; JP2023071725A; ES2693388A1; JP2020525326A; KR20230125098A; KR20200036842A; ES2706652A2

Abstract

Metallic looking object trims include a transparent or translucent substrate defining top and bottom surfaces, an opaque layer applied to one of the top and bottom surfaces of the substrate, the opaque layer defining one or more apertures through which light can pass, and one or more translucent metallic-effect layers applied to a top surface of the opaque layer when the opaque layer is applied to the substrate's top surface or to the top surface of the substrate when the opaque layer is applied to the substrate's bottom surface. The one or more metallic-effect layers include one or more metallic effect paints or one or more layers of digitally printed metallic material. A light source is arranged beneath the bottom surface of the substrate and generates light that passes through the substrate, the one or more apertures, and the one or more metallic-effect layers.

Description

SELECTIVELY ILLUMINABLE METALLIC LOOKING TRIMS AND THEIR

METHODS OF MANUFACTURE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a PCT International Application that claims the benefit of Spanish Application No. P201730785, filed on June 9, 2017, and Spanish Application No. P201830556, filed on June 7, 2018. The disclosures of the above applications are incorporated herein by reference in their entirety.

FIELD

[0002] The present application generally relates to decorative trims and, more particularly, to selectively illuminable metallic looking trims and their methods of manufacture.

BACKGROUND

[0003] Decorative trims are applied to accent or enhance the visual appearance of an object. For example, vehicle interior and exterior components often have decorative trims. To further enhance visual appearance, light sources can be incorporated into decorative trims to generate a lighting effect. Chrome plating is one example of a decorative trim that is often utilized due to its high gloss appearance. Chrome plating, however, can have a negative environmental impact, e.g., due to the use of hexavalent chromium baths. Chrome plating is also formed of one or more opaque metallic layers that do not allow light to pass through and thus it cannot be used in connection with back-lit lighting effects. Accordingly, while such decorative trims work well for their intended purpose, there remains a need for improvement in the relevant art.

SUMMARY

[0004] According to one aspect of the present disclosure, a trim for an object is presented. In one exemplary embodiment, the trim comprises: a transparent or translucent substrate defining a top surface, an opaque layer applied to the top surface of the substrate, the opaque layer defining one or more apertures through which light can pass, and one or more translucent metallic-effect layers applied to a top surface of the opaque layer.

[0005] In some embodiments, the one or more metallic-effect layers comprise one or more metallic-effect paint layers. In other embodiments, the one or more metallic-effect layers comprise one or more digitally printed metallic-effect material layers.

[0006] In some embodiments, the one or more metallic-effect layers comprise only one or more base coat layers of metallic-effect paint. In other embodiments, the one or more metallic-effect layers comprise (i) a translucent primer layer applied to the top surface of the opaque layer and portions of the substrate corresponding to the one or more apertures and (ii) one or more translucent base coat paint layers of metallic-effect paint applied to a top surface of the primer layer. In some embodiments, the one or more metallic-effect layers further comprise a transparent or translucent top coat layer applied to a top surface of the one or more base coat paint layers, wherein the top coat layer protects and enhances a metallic-effect of the one or more metallic-effect layers.

[0007] In some embodiments, at least one of the primer layer and the top coat layer comprises metallic particles to further enhance the metallic-effect of the one or more metallic-effect layers. In some embodiments, the top coat layer is at least one of tinted and colored to further enhance the metallic-effect of the one or more metallic-effect layers.

[0008] In some embodiments, the trim is a selectively illuminable trim that further comprises a light source arranged beneath a bottom surface of the substrate, the light source being configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic-effect layers. In some embodiments, the trim further comprises a light guide arranged between the light source and the bottom surface of the substrate, the light guide being configured to distribute the light output from the light source.

[0009] According to another aspect of the present disclosure, a trim for an object is presented. In one exemplary embodiment, the trim comprises: a transparent or translucent substrate defining a top surface and a bottom surface, an opaque layer applied to the bottom surface of the substrate, the opaque layer defining one or more apertures through which light can pass, and one or more translucent metallic-effect layers applied to the top surface of the substrate.

[0010] In some embodiments, the one or more metallic-effect layers comprise one or more metallic-effect paint layers. In other embodiments, the one or more metallic-effect layers comprise one or more digitally printed metallic-effect material layers.

[0011] In some embodiments, the one or more metallic-effect layers comprise only one or more base coat layers of metallic-effect paint. In other embodiments, the one or more metallic-effect layers comprise (i) a translucent primer layer applied to the top surface of the substrate and (ii) one or more translucent base coat paint layers of metallic-effect paint applied to a top surface of the primer layer. In some embodiments, the one or more metallic-effect layers further comprise a transparent or translucent top coat layer applied to a top surface of the one or more base coat paint layers, wherein the top coat layer protects and enhances a metallic-effect of the one or more metallic-effect layers.

[0012] In some embodiments, at least one of the primer layer and the top coat layer comprises metallic particles to further enhance the metallic-effect of the one or more metallic-effect layers. In some embodiments, the top coat layer is at least one of tinted and colored to further enhance the metallic-effect of the one or more metallic-effect layers.

[0013] In some embodiments, the trim is a selectively illuminable trim that further comprises a light source arranged beneath a bottom surface of the substrate, the light source being configured to output light through the one or more apertures defined by the opaque layer, the substrate, and the one or more metallic-effect layers. In some embodiments, the trim further comprises a light guide arranged between (i) the light source and (ii) the bottom surface of the substrate and the opaque layer, the light guide being configured to distribute the light output from the light source.

[0014] According to another aspect of the present disclosure, a method of manufacturing a trim for an object is presented. In one exemplary implementation, the method comprises: providing a transparent or translucent substrate defining a top surface and a bottom surface, applying an opaque layer to one of the top surface of the substrate and the bottom surface of the substrate, the opaque layer defining one or more apertures through which light can pass, and applying one or more translucent metallic-effect layers to one of (i) a top surface of the opaque layer when the opaque layer is applied to the top surface of the substrate and (ii) the top surface of the substrate when the opaque layer is applied to the bottom surface of the substrate.

[0015] In some embodiments, applying the one or more metallic-effect layers comprises applying one or more layers of metallic-effect paint. In other embodiments, applying the one or more metallic-effect layers comprises digitally printing one or more layers of a metallic-effect material. In some embodiments, the one or more metallic-effect layers comprise only one or more base coat layers of metallic-effect paint.

[0016] In some embodiments, applying the one or more metallic-effect layers comprises (i) applying a translucent primer layer applied to the top surface of the opaque layer and portions of the substrate corresponding to the one or more apertures and (ii) applying one or more translucent base coat paint layers of metallic-effect paint applied to a top surface of the primer layer. In some embodiments, the method further comprises applying a transparent or translucent top coat layer to a top surface of the one or more base coat paint layers, wherein the top coat layer protects and enhances a metallic-effect of the one or more metallic-effect layers.

[0017] In some embodiments, applying the opaque layer further comprises: applying an initial opaque layer that does not define the one or more apertures, and removing portions of the initial opaque layer corresponding to the one or more apertures and obtain the opaque layer. In some embodiments, applying the initial opaque layer comprises spraying an opaque primer and curing the sprayed opaque primer to obtain the initial opaque layer, and wherein removing portions of the initial opaque layer comprises laser etching the initial opaque layer.

[0018] In some embodiments, applying the opaque layer further comprises: applying a temporary mask layer to the one of the top surface and the bottom surface of the substrate, applying an initial opaque layer by spraying an opaque primer over the one of the top surface and the bottom surface of the substrate and the temporary mask layer, and removing the temporary mask layer and portions of the initial opaque layer associated therewith to obtain the opaque layer. In other embodiments, applying the opaque layer comprises digitally printing an opaque material to portions of the top surface of the substrate.

[0019] In some embodiments, the method further comprises injection or compression molding, thermoforming, or additive manufacturing a plastic material to form the substrate. In some embodiments, the trim is a selectively illuminable trim and the method further comprises: arranging a light source beneath the bottom surface of the substrate, the light source being configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic-effect layers, and packaging the light source and the selectively illuminable trim into a single integrated module.

[0020] According to another aspect of the present disclosure, a method of manufacturing a trim for an object is presented. In one exemplary embodiment, the method comprises: providing a transparent or translucent substrate defining a top surface, applying an opaque layer to the top surface of the substrate, the opaque layer defining one or more apertures through which light can pass, and applying one or more translucent metallic-effect layers to a top surface of the opaque layer.

[0021] In some embodiments, applying the one or more metallic-effect layers comprises applying one or more layers of metallic-effect paint. In other embodiments, applying the one or more metallic-effect layers comprises digitally printing one or more layers of a metallic-effect material.

[0022] In some embodiments, the one or more metallic-effect layers comprise only one or more base coat layers of metallic-effect paint. In other embodiments, applying the one or more metallic-effect layers comprises (i) applying a translucent primer layer applied to the top surface of the opaque layer and portions of the substrate corresponding to the one or more apertures and (ii) applying one or more translucent base coat paint layers of metallic-effect paint applied to a top surface of the primer layer. In some embodiments, the method further comprises applying a transparent or translucent top coat layer to a top surface of the one or more base coat paint layers, wherein the top coat layer protects and enhances a metallic-effect of the one or more metallic-effect layers.

[0023] In some embodiments, applying the opaque layer further comprises: applying an initial opaque layer that does not define the one or more apertures, and removing portions of the initial opaque layer corresponding to the one or more apertures and obtain the opaque layer. In some embodiments, applying the initial opaque layer comprises spraying an opaque primer and curing the sprayed opaque primer to obtain the initial opaque layer. In some embodiments, removing portions of the initial opaque layer comprises laser etching the initial opaque layer. In other embodiments, applying the opaque layer further comprises: applying a temporary mask layer to the top surface of the substrate, applying an initial opaque layer by spraying an opaque primer over the top surface of the substrate and the temporary mask layer, and removing the temporary mask layer and portions of the initial opaque layer associated therewith to obtain the opaque layer. In still other embodiments, applying the opaque layer comprises digitally printing an opaque material to portions of the top surface of the substrate.

[0024] In some embodiments, the method further comprises injection or compression molding, thermoforming, or additive manufacturing a plastic material to form the substrate.

[0025] In some embodiments, the trim is a selectively illuminable trim and the method further comprises arranging a light source beneath a bottom surface of the substrate, the light source being configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic-effect layers. In some embodiments, the method further comprises arranging a light guide between the light source and the bottom surface of the substrate, the light guide being configured to distribute the light output from the light source. In some embodiments, the method further comprises packaging the light source and the selectively illuminable trim into a single integrated module.

[0026] According to another aspect of the present disclosure, a method of manufacturing a trim for an object is presented. In one exemplary embodiment, the method comprises: providing a transparent or translucent substrate defining a top surface and a bottom surface, applying an opaque layer to the bottom surface of the substrate, the opaque layer defining one or more apertures through which light can pass, and applying one or more translucent metallic-effect layers to the top surface of the substrate.

[0027] In some embodiments, applying the one or more metallic-effect layers comprises applying one or more layers of metallic-effect paint. In other embodiments, applying the one or more metallic-effect layers comprises digitally printing one or more layers of a metallic-effect material.

[0028] In some embodiments, the one or more metallic-effect layers comprise only one or more base coat layers of metallic-effect paint. In other embodiments, applying the one or more metallic-effect layers comprises (i) applying a translucent primer layer applied to the top surface of the substrate and (ii) applying one or more translucent base coat paint layers of metallic-effect paint applied to a top surface of the primer layer. In some embodiments, the method further comprises applying a transparent or translucent top coat layer to a top surface of the one or more base coat paint layers, wherein the top coat layer protects and enhances a metallic-effect of the one or more metallic-effect layers.

[0029] In some embodiments, applying the opaque layer further comprises: applying an initial opaque layer that does not define the one or more apertures, and removing portions of the initial opaque layer corresponding to the one or more apertures and obtain the opaque layer. In some embodiments, applying the initial opaque layer comprises spraying an opaque primer and curing the sprayed opaque primer to obtain the initial opaque layer. In some embodiments, removing portions of the initial opaque layer comprises laser etching the initial opaque layer. In other embodiments, applying the opaque layer further comprises: applying a temporary mask layer to the bottom surface of the substrate, applying an initial opaque layer by spraying an opaque primer over the bottom surface of the substrate and the temporary mask layer, and removing the temporary mask layer and portions of the initial opaque layer associated therewith to obtain the opaque layer. In still other embodiments, applying the opaque layer comprises digitally printing an opaque material to portions of the top surface of the substrate.

[0030] In some embodiments, the method further comprises injection or compression molding, thermoforming, or additive manufacturing a plastic material to form the substrate.

[0031] In some embodiments, the trim is a selectively illuminable trim and the method further comprises arranging a light source beneath a bottom surface of the substrate, the light source being configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic-effect layers. In some embodiments, the method further comprises arranging a light guide between the light source and the bottom surface of the substrate, the light guide being configured to distribute the light output from the light source. In some embodiments, the method further comprises packaging the light source and the selectively illuminable trim into a single integrated module.

[0032] Further areas of applicability of the teachings of the present disclosure will become apparent from the detailed description, claims and the drawings provided hereinafter, wherein like reference numerals refer to like features throughout the several views of the drawings. It should be understood that the detailed description, including disclosed embodiments and drawings referenced therein, are merely exemplary in nature intended for purposes of illustration only and are not intended to limit the scope of the present disclosure, its application or uses. Thus, variations that do not depart from the substance of the present disclosure are intended to be within the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] FIGS. 1 A-1 B are cross-sectional views of a first embodiment of a selectively illuminable trim according to the principles of the present disclosure for two different user viewing angles;

[0034] FIG. 2 is a flow diagram of a method of manufacturing the first embodiment of the selectively illuminable trim according to the principles of the present disclosure; [0035] FIGS. 3A-3B are cross-sectional views of a second embodiment of a selectively illuminable trim according to the principles of the present disclosure for two different user viewing angles;

[0036] FIGS. 4A-4B are cross-sectional views of alternate first and second embodiments of a selectively illuminable trim according to the principles of the present disclosure; and

[0037] FIG. 5 is a flow diagram of a method of manufacturing the second embodiment of the selectively illuminable trim according to the principles of the present disclosure.

DETAILED DESCRIPTION

[0038] As discussed above, chrome plating is formed of one or more opaque metallic layers that do not allow light to pass through, which makes it unusable for decorative trim having back-lit lighting effects. Chrome plating also attenuates radar transmission. Accordingly, improved selectively illuminable metallic looking trims and their methods of manufacture are presented. In other aspects of the present disclosure, metallic looking trims comprising multiple stacked layers along with a light source and an optional light guide are packaged together to form single integrated modules. In some embodiments, these trims utilize a metallic-effect paint and an opaque back layer to achieve a metallic looking component that is aesthetically pleasing as chrome plating. In other embodiments, these trims utilize digital printing to deposit or apply a metallic-effect layer instead of the metallic-effect paint. In further embodiments, a non-metallic effect paint can be utilized in lieu of a metallic-effect paint. For example, a matte finished paint can be utilized. Traditional painting techniques (e.g. roll, brush, or spay) can be used to apply the metallic or non-metallic effect paint. Moreover, vacuum deposition or electro-static (e.g. powder coating) can be used to apply the metallic or non-metallic paint. In each embodiment, multiple application techniques can be used. For example, the opaque back layer can be applied with spraying.

[0039] In a first embodiment, an opaque layer is deposited on a top surface of a substrate, thereby positioning it nearer to a viewing user's eyes and creating a crisper image with less distortion, such as when viewed at an angle. In a second embodiment, the opaque layer is deposited on a bottom surface of the substrate, thereby positioning it further from the viewing user's eyes and creating a potentially less crisp image with greater distortion, such as when viewed at an angle. This second embodiment, however, has advantages from a processing standpoint because the opaque layer needs only to have a necessary level of adherence with the bottom surface of the substrate. These processing advantages can result in decreased costs, which could more than offset any potential distortion when viewing. In addition, the amount of distortion depends on the thickness of the substrate and the type of light source. Different levels of distortion may be deemed acceptable for different applications.

[0040] Referring now to FIGS. 1A-1 B, cross-sectional views of the first embodiment of the single integrated module 100 is illustrated. The module 100 comprises a metallic looking trim stack 104 formed of multiple stacked layers. A transparent or translucent substrate 108 forms a base of the trim 104. Details of the formation of the substrate 108 are described in detail below in reference to FIG. 2. Non-limiting examples of the substrate 108 include plastic or polymer materials, such as polycarbonates (PC), polymethyl methacrylates (PMMA), acrylonitrile butadiene styrenes (ABS), styrene acrylics, styrene acrylonitrile polymers, polyamides, and combinations thereof. For vehicle trim applications, the substrate 108 could be an interior component (a dash assembly, a center console assembly, a multimedia or infotainment unit assembly, a door trim panel, etc.) or an exterior body component (front or side grille assemblies, bumper or fender accents, head or taillight accents, a trunk lid finisher, etc.). It will be appreciated that the systems and methods described herein are not limited to automotive applications and could be applicable to decorative trims for non-automotive applications (appliances and consumer goods, railway, motorbikes, aerospace, etc.).

[0041] An opaque layer 1 12 is applied to a top surface of the substrate 108. Details of the application of the opaque layer 1 12 are described in detail below with reference to FIG. 2. The opaque layer 1 12, while illustrated as a black primer layer, could have any suitable color or composition that prevents or substantially mitigates light transmission therethrough. Non-limiting examples of the opaque layer 1 12 comprise epoxy-based, polyurethane-based, and acrylic-based curable wet paints having opaque color pigments and combinations thereof. The opaque layer 1 12 could alternatively be digitally printed. The opaque layer 1 12 defines one or more gaps or apertures 1 16 through which light is able to pass. The one or more apertures 1 16 correspond to a designed lighting accent effect, such as, for example, an accent, logo, indicia, icon, motif, pattern, button, or other similar accent for the object associated with the trim. A translucent primer layer 120 is optionally applied to a top surface of the opaque layer 1 12 as well as to the top surface of the substrate 108 in areas corresponding to the one or more apertures 1 16. Details of the application of the primer layer 120 are described in detail below with reference to FIG. 2. Non-limiting examples of the primer layer 120 include epoxy-based, polyurethane-based, and acrylic-based curable wet paints that are transparent or translucent and combinations thereof.

[0042] One or more translucent metallic-effect layers 124 are applied to a top surface of the base coat layer 120 (or to the opaque layer 1 12 and portions of the substrate 108 in areas corresponding to the one or more apertures 1 16 when no primer layer 120 is applied). For example, two or more paint layers could achieve the optimal aesthetics (base coat layer 120 + single metallic-effect paint layer 124, single primer layer 120 + two metallic-effect paint layers 124, two metallic-effect paint layers 124 and no primer layer 120, etc.). Alternatively, the metallic-effect layers(s) 124 could be applied via digital printing. Details of the application of the metallic-effect layer 124 are described in detail below with reference to FIG. 2. The metallic-effect layer 124 is translucent because it is formed of a paint or printed material comprising elements that are translucent (i.e., at least partially light- transmissive) such as, but not limited to, transition metals, post-transition metals, metalloids, and combinations thereof (e.g., alloys, such as oxides and oxide alloys). For example, the metallic-effect paint could be a paint solution comprising flakes of one or more of the elements described above. It will be appreciated that metallic flakes or similar materials could also be included in the primer layer 120 to further enhance the metallic-effect.

[0043] The thickness of the metallic-effect paint layer 124 should be such that it remains at least translucent when illuminated by back-lighting while also looking metallic when not illuminated. The transluceny of a metallic layer could also be affected by the chemical composition of the layer and dispersion of elements as reflected. The metallic-effect paint layer 124 could also comprise multiple layers of a single metallic-effect paint or different metallic-effect paints applied in various stages to achieve the desired appearance and translucency (i.e., desired optical properties). For example, FIG. 4A illustrates one configuration 400 of the trim stack 104 that only requires a single metallic-effect layer 124 of one or more base coat layers of metallic-effect paint (and no primer layer 120), along with optional top coat layer 128 to achieve the optimal aesthetics, thereby saving costs and reducing complexity. As discussed above, digital printing may be utilized as an alternative to metallic-effect paint. Specifically, one or more metallic-effect layers can be digitally printed onto the substrate 108, thereby eliminating the need for the primer layer 120.

[0044] The optional top coat layer 128 could be applied to a top surface of the metallic-effect layer 124. Details of the application of the optional top coat layer 128 are described in detail below with reference to FIG. 2. Non-limiting examples of the top coat layer 128 include epoxy-based, polyurethane-based, and acrylic-based curable wet paints that are transparent or translucent and combinations thereof. The optional top coat layer 128 could be applied to both protect the metallic-effect layer 124 (e.g., from chipping, stripping, or scratching) and/or to further enhance the appearance of the metallic-effect layer 124 (e.g., by enhancing its glossy appearance). It will be appreciated that the top coat layer 128 could include metallic flakes or similar materials to further enhance the metallic- effect. It will also be appreciated that the top coat layer 128 could be tinted and/or colored to further enhance the metallic-effect. Non-limiting examples of this include a blue metallic-effect, a copper metallic-effect, and a bronze metallic-effect, but any tinting and/or coloring combinations could be utilized.

[0045] While the various upper layers 1 12, 120, 124, and 128 are shown to have approximately the same thickness, it will be appreciated that their actual thicknesses could widely vary and, in most cases, will be substantially less than the thickness of the substrate 108. In one exemplary implementation, the primer layer 120 could have a thickness of 15 microns, the metallic-effect layer 124 could have a thickness of 1 -3 microns, and the top coat layer 128 could have a thickness of 20- 22 microns. This is much thinner compared to a standard paint process, where a primer layer has a thickness of 20-25 microns, a base coat paint layer has a thickness of 12-16 microns, and a top coat layer has a thickness of 30-35 microns. In another exemplary implementation, the primer layer 120 could have a thickness of 3-30 microns, the metallic-effect layer 124 could have a thickness of 1 -6 microns, and the top coat layer 128 could have a thickness of 10-50 microns. In this example, the metallic-effect paint layer 124 still has a thickness that is substantially thinner than conventional paint processes.

[0046] The single integrated module 100 further comprises a light source 132 (e.g., a light-emitting diode (LED), organic LED (OLED), optical fiber, electroluminescent, or a similar device, such as a laser light source) and an optional light guide 136 for directing, focusing, or distributing the light generated from the light source 132 through the substrate 108 and the one or more apertures 1 16 to form a visible field 140. Reference 144 represents a focal or viewing angle of a viewing user. As shown in FIG. 1A, from a straight-on viewing angle, there is no distortion of the visible field 140. In other words, the perceived width 148 of the viewing user 144 is equal to or approximately equal to the actual width of the visible field 140. As shown in FIG. 1 B, from an offset or angled viewing angle, there is very minor distortion of the visible field 140. As can be seen, the perceived width 152 of the viewing user 144 is only slightly larger than the actual width of the visible field 140. The viewing user 144, therefore, should still see a crisp, clear image as intended when back-lit by the light source 132 and should see a glossy, metal looking layer when not back-lit by the light source 132.

[0047] Referring now to FIG. 2, a flow diagram of a method 200 of manufacturing the first embodiment of the single integrated module 100 of FIGS. 1A-1 B is illustrated. At 204, the transparent or translucent substrate is obtained. The substrate 108 could be formed, for example, using any suitable plastic or polymer processing technique including, but not limited to, injection molding, extrusion, compression molding, thermoforming, and additive manufacturing (e.g., three-dimensional (3D) printing). As previously mentioned, non-limiting examples of the substrate 108 include plastic or polymer materials, such as PC, PMMA, ABS, styrene acrylics, styrene acrylonitrile polymers, polyamides, and combinations thereof. In one exemplary implementation, the substrate is a plastic interior component or exterior body component of a vehicle as previously described herein.

[0048] At 208, the opaque layer 1 12 is applied to the top surface of the substrate 108. In one exemplary embodiment, the opaque layer 1 12 is applied spraying an opaque primer, which is then cured to form an initial opaque layer. Portions of the initial opaque layer corresponding to the one or more apertures are then removed (e.g., stripped away) to obtain the opaque layer. For example, laser etching could be utilized to remove the portions of the initial opaque layer. In another exemplary embodiment, a temporary mask layer is initially applied to the top surface of the substrate 108. The temporary mask layer corresponds to the one or more apertures 1 16 defined by the opaque layer 1 12. This temporary mask layer could be a tape or another adhesive or a rigid mask device. Once the temporary mask layer has been applied, an opaque primer is sprayed over the substrate 108 and the temporary mask layer to form an initial opaque layer. The temporary mask layer is then removed, thereby removing portions of the initial opaque layer corresponding to the one or more apertures 1 16 to obtain the opaque layer 1 12. As previously mentioned, non-limiting examples of the opaque layer 1 12 comprise epoxy-based, polyurethane-based, and acrylic-based curable wet paints having opaque color pigments and combinations thereof. In another exemplary embodiment, the opaque layer 1 12 is an opaque paint that is deposited using a digital printing process, thereby avoiding the need of using (i) a posterior laser etching process to define the one or more apertures 1 16 or (ii) using a mask to avoid the deposition of the opaque layer 1 12 and form the one or more apertures 1 16. [0049] At optional 212, the translucent primer layer 120 is applied to a top surface of the opaque layer 1 12 and to the substrate 108 in areas corresponding to the one or more apertures 1 16 defined by the opaque layer 1 12. The application of the primer layer 120 is such that it defines a substantially flat or planar top surface (e.g., flush), while also having an uneven thickness (i.e., thicker in regions corresponding to the one or more apertures 1 16 and less thick in other regions). In one exemplary embodiment, the primer layer 120 is applied by spraying a translucent coat, which is then cured to form the primer layer 120. As previously mentioned, non-limiting examples of the primer layer 120 include epoxy-based, polyurethane-based, and acrylic-based curable wet paints that are transparent or translucent and combinations thereof.

[0050] At 216, the translucent metallic-effect layer 124 is applied to the top surface of the base coat layer 120. The metallic-effect layer 124 is applied using any suitable painting or printing processes such as, but not limited to, spraying, brushing, rolling, and digital printing, as well as vacuum processes such as physical vapor deposition (PVD) and chemical vapor deposition (CVD) or electro-static deposition (e.g. powder coating). As previously mentioned, the paint solution comprises elements that are translucent (i.e., at least partially light-transmissive) such as, but not limited to, transition metals, post-transition metals, metalloids, and combinations thereof (e.g., alloys, such as oxides and oxide alloys). For example, a metallic-effect paint solution could comprise flakes of one or more of the elements described above. As previously mentioned, the thickness of a metallic-effect paint layer 124 should be such that it remains at least translucent when illuminated by back-lighting while also looking metallic when not illuminated. It will also be appreciated that multiple layers of a single metallic-effect paint or multiple layers of different metallic effect paints could be applied in different stages to form a metallic- effect paint layer 124.

[0051] At optional 220, the optional transparent or translucent top coat layer 128 is applied to a top surface of the metallic-effect layer 124. Similar to the primer layer 120, in one exemplary embodiment, the top coat layer 128 is applied by spraying a transparent or translucent coat, which is then cured to form the top coat layer 128. As previously mentioned, non-limiting examples of the top coat layer 128 include epoxy-based, polyurethane-based, and acrylic-based curable wet paints that are transparent or translucent and combinations thereof. Potential benefits of providing the top coat layer 128 include protecting the metallic-effect layer 124 from weathering or damage (chipping, scratching, etc.) and/or enhancing the appearance (e.g., glossiness) of the metallic-effect layer 124. At optional 224, the light source 132 and the optional light guide 136 are arranged beneath the bottom surface of the substrate 108. At optional 228, the trim stack 104 and the light source 132 (and optionally, the light guide 136) are assembled or packaged into the single integrated module 100. The method 200 then ends.

[0052] Referring now to FIGS. 3A-3B, cross-sectional diagrams of a second embodiment of a single integrated module 300 are illustrated. The module 300 comprises a metallic looking trim stack 304 formed of multiple stacked layers. The trim stack 304 comprises a transparent or translucent substrate 308 having an opaque layer 312 applied to a bottom surface of the substrate 308, with the opaque layer 312 defining one or more apertures 316. The trim stack 304 further comprises an optional translucent primer layer 320, a translucent metallic-effect layer 324, and an optional transparent or translucent top coat layer 328 applied sequentially to a top surface of the substrate 308. For example, FIG. 4B illustrates one configuration 450 of the trim stack 304 that only requires a single metallic-effect layer 324 (and no primer layer 320), along with optional top coat layer 328 to achieve the optimal aesthetics, thereby saving costs and reducing complexity. It will be appreciated that these layers 308-328 can be applied or formed from the same or similar materials and using the same or similar methods as previously described referencing the layers 108-128 of FIGS. 1A-1 B. The same goes for the light source 332 and optional light guide 336 and the related description of light source 132 and optional light guide 136.

[0053] While the various upper layers 312, 320, 324, and 328 are shown to have approximately the same thickness, it will be appreciated that their actual thicknesses could widely vary and, in most cases, will be substantially less than the thickness of the substrate 308. In one exemplary implementation, the primer layer 320 could have a thickness of 15 microns, the metallic-effect layer 324 could have a thickness of 1 -3 microns, and the top coat layer 328 could have a thickness of 20- 22 microns. This is much thinner compared to a standard paint process, where a primer layer has a thickness of 20-25 microns, a base coat paint layer has a thickness of 12-16 microns, and a top coat layer has a thickness of 30-35 microns. In another exemplary implementation, the primer layer 320 could have a thickness of 3-30 microns, the metallic-effect layer 324 could have a thickness of 1 -6 microns, and the top coat layer 328 could have a thickness of 10-50 microns. In this example, the metallic-effect paint layer 324 still has a thickness that is substantially thinner than conventional paint processes. As discussed above, digital printing may be utilized as an alternative to metallic-effect paint. Specifically, one or more metallic- effect layers can be digitally printed onto the substrate 308, thereby eliminating the need for the primer layer 320.

[0054] The primary difference between modules 100 and 300 is that the opaque layer 312 is applied to the bottom surface of the substrate 308 in module 300. There could also an optional transparent or translucent bottom coat layer 318 applied to the bottom surface of the substrate 308 in the regions corresponding to the one or more apertures 316 such that the bottom surface (B-side) of the trim stack 304 is flush. This bottom coat layer 318 could be the same or similar material as optional primer layer 320 and/or optional top coat layer 328 and could be applied using the same or similar processes (e.g., masking). As shown in FIG. 3A, from a straight-on viewing angle (see reference 344, representing a viewing user 344), there is no distortion of a visible field 340. In other words, the perceived width 348 of the viewing user 344 is equal to or approximately equal to the actual width of the visible field 340.

[0055] As shown in FIG. 3B, however, from an offset or angled viewing angle, there is a very large distortion of the visible field 340. As can be seen, the perceived width 352 of the viewing user 344 is substantially larger than the actual width of the visible field 340. The viewing user 144, therefore, will see a less crisp (i.e., slightly distorted) image when back-lit by the light source 332, while still seeing a glossy, metal looking layer when not back-lit by the light source 332. One benefit of the configuration of module 300, however, is easier processing or formation. More specifically, the opaque layer 312 only has to be designed or selected for adherence to the substrate 308 and not to both the substrate 308 and the primer layer 320 (as is required for opaque layer 1 12 with respect to the substrate 108 and base coat layer 120 in FIGS. 1A-1 B).

[0056] Referring now to FIG. 5, a flow diagram of a method 500 of manufacturing the second embodiment of the single integrated module 300 is illustrated. Again, it will be appreciated that the same or similar processes or methods described above with respect to FIGS. 1A-1 B, FIG. 2, and FIG. 4A could be utilized in the formation of the module 300 of FIGS. 3A-3B, FIG. 4B, and method 500. At 504, the transparent or translucent substrate 308 is obtained. At 508, the opaque layer 312 defining the one or more apertures 316 is applied to the back surface of the substrate 308. While described and shown as being a second processing step after obtaining the substrate 308, it will be appreciated that the opaque layer 312 could be applied after the application of the optional translucent primer layer 320, the translucent metallic-effect layer 324, and the optional transparent or translucent top coat layer 328, or somewhere in between the application of these layers 320-328, but before steps 528 and 532.

[0057] At optional 512, the primer layer 320 is applied to the top surface of the substrate 308. At 516, the metallic-effect layer 324 is applied to the top surface of the primer layer 320 using conventional means (e.g. spraying, brushing, rolling, and digital printing), as well as vacuum processes such as physical vapor deposition (PVD) and chemical vapor deposition (CVD) or electro-static deposition (e.g. powder coating). At optional 520, the top coat layer 328 is applied to the top surface of the metallic-effect layer 324. At optional 524, the light source 332 and the optional light guide 336 are arranged beneath the bottom surface of the trim stack 304. At optional 428, the trim stack 304 and the light source 332 (and optionally, the light guide 336) are assembled or packaged into the single integrated module 300. The method 500 then ends.

[0058] Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known procedures, well-known device structures, and well-known technologies are not described in detail.

[0059] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The term "and/or" includes any and all combinations of one or more of the associated listed items. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0060] Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0061] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

[0062] It should be understood that the mixing and matching of features, elements, methodologies and/or functions between various examples may be expressly contemplated herein so that one skilled in the art would appreciate from the present teachings that features, elements and/or functions of one example may be incorporated into another example as appropriate, unless described otherwise above.

Claims

CLAIMS What is claimed is:

1. A trim for an object, the trim comprising:

a transparent or translucent substrate defining a top surface;

an opaque layer applied to the top surface of the substrate, the opaque layer defining one or more apertures through which light can pass; and

one or more translucent metallic-effect layers applied to a top surface of the opaque layer.

2. The trim of claim 1 , wherein the one or more metallic-effect layers comprise one or more metallic-effect paint layers.

3. The trim of claim 1 , wherein the one or more metallic-effect layers comprise one or more digitally printed metallic-effect material layers.

4. The trim of claim 2, wherein the one or more metallic-effect layers comprise only one or more base coat layers of metallic-effect paint.

5. The trim of claim 2, wherein the one or more metallic-effect layers comprise (i) a translucent primer layer applied to the top surface of the opaque layer and portions of the substrate corresponding to the one or more apertures and (ii) one or more translucent base coat paint layers of metallic-effect paint applied to a top surface of the primer layer.

6. The trim of claims 4 or 5, wherein the one or more metallic-effect layers further comprise a transparent or translucent top coat layer applied to a top surface of the one or more base coat paint layers, wherein the top coat layer protects and enhances a metallic-effect of the one or more metallic-effect layers.

7. The trim of claim 6, wherein at least one of the primer layer and the top coat layer at least one of (i) comprises metallic particles to further enhance the metallic-effect of the one or more metallic-effect layers and (ii) is at least one of tinted and colored to further enhance the metallic-effect of the one or more metallic- effect layers.

8. The trim of any preceding claim, wherein the trim is a selectively illuminable trim that further comprises a light source arranged beneath a bottom surface of the substrate, the light source being configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic-effect layers.

9. The trim of claim 8, further comprising a light guide arranged between the light source and the bottom surface of the substrate, the light guide being configured to distribute the light output from the light source.

10. A trim for an object, the trim comprising:

a transparent or translucent substrate defining a top surface and a bottom surface;

an opaque layer applied to the bottom surface of the substrate, the opaque layer defining one or more apertures through which light can pass; and

one or more translucent metallic-effect layers applied to the top surface of the substrate.

1 1. The trim of claim 10, wherein the one or more metallic-effect layers comprise one or more metallic-effect paint layers.

12. The trim of claim 10, wherein the one or more metallic-effect layers comprise one or more digitally printed metallic-effect material layers.

13. The trim of claim 1 1 , wherein the one or more metallic-effect layers comprise only one or more base coat layers of metallic-effect paint.

14. The trim of claim 13, wherein the one or more metallic-effect layers comprise (i) a translucent primer layer applied to the top surface of the substrate and (ii) one or more translucent base coat paint layers of metallic-effect paint applied to a top surface of the primer layer.

15. The trim of claims 13 or 14, wherein the one or more metallic-effect layers further comprise a transparent or translucent top coat layer applied to a top surface of the one or more base coat paint layers, wherein the top coat layer protects and enhances a metallic-effect of the one or more metallic-effect layers.

16. The trim of claim 15, wherein at least one of the primer layer and the top coat layer at least one of (i) comprises metallic particles to further enhance the metallic-effect of the one or more metallic-effect layers and (ii) is at least one of tinted and colored to further enhance the metallic-effect of the one or more metallic- effect layers.

17. The trim of any of claims 10-16, wherein the trim is a selectively illuminable trim that further comprises a light source arranged beneath a bottom surface of the substrate, the light source being configured to output light through the one or more apertures defined by the opaque layer, the substrate, and the one or more metallic-effect layers.

18. The trim of claim 17, further comprising a light guide arranged between (i) the light source and (ii) the bottom surface of the substrate and the opaque layer, the light guide being configured to distribute the light output from the light source.

19. A method of manufacturing a trim for an object, the method comprising: providing a transparent or translucent substrate defining a top surface and a bottom surface;

applying an opaque layer to one of the top surface of the substrate and the bottom surface of the substrate, the opaque layer defining one or more apertures through which light can pass; and

applying one or more translucent metallic-effect layers to one of (i) a top surface of the opaque layer when the opaque layer is applied to the top surface of the substrate and (ii) the top surface of the substrate when the opaque layer is applied to the bottom surface of the substrate.

20. The method of claim 19, wherein applying the one or more metallic- effect layers comprises applying one or more layers of metallic-effect paint.

21. The method of claim 19, wherein applying the one or more metallic- effect layers comprises digitally printing one or more layers of a metallic-effect material.

22. The method of claim 21 , wherein the one or more metallic-effect layers comprise only one or more base coat layers of metallic-effect paint.

23. The method of claim 22, wherein applying the one or more metallic- effect layers comprises (i) applying a translucent primer layer applied to the top surface of the opaque layer and portions of the substrate corresponding to the one or more apertures and (ii) applying one or more translucent base coat paint layers of metallic-effect paint applied to a top surface of the primer layer.

24. The method of claims 22 or 23, further comprising applying a transparent or translucent top coat layer to a top surface of the one or more base coat paint layers, wherein the top coat layer protects and enhances a metallic-effect of the one or more metallic-effect layers.

25. The method of any of claims 19-24, wherein applying the opaque layer further comprises:

applying an initial opaque layer that does not define the one or more apertures; and

removing portions of the initial opaque layer corresponding to the one or more apertures and obtain the opaque layer.

26. The method of claim 25, wherein applying the initial opaque layer comprises spraying an opaque primer and curing the sprayed opaque primer to obtain the initial opaque layer, and wherein removing portions of the initial opaque layer comprises laser etching the initial opaque layer.

27. The method of any of claims 19-24, wherein applying the opaque layer further comprises: applying a temporary mask layer to the one of the top surface and the bottom surface of the substrate;

applying an initial opaque layer by spraying an opaque primer over the one of the top surface and the bottom surface of the substrate and the temporary mask layer; and

removing the temporary mask layer and portions of the initial opaque layer associated therewith to obtain the opaque layer.

28. The method of any of claims 19-24, wherein applying the opaque layer comprises digitally printing an opaque material to portions of the top surface of the substrate.

29. The method of any of claims 19-28, further comprising injection or compression molding, thermoforming, or additive manufacturing a plastic material to form the substrate.

30. The method of any of claims 19-29, wherein the trim is a selectively illuminable trim and the method further comprises:

arranging a light source beneath the bottom surface of the substrate, the light source being configured to output light through the substrate, the one or more apertures defined by the opaque layer, and the one or more metallic-effect layers; and packaging the light source and the selectively illuminable trim into a single integrated module.