EP4271555A1

EP4271555A1 - Molding having a translucent surface layer and method for producing a molding having a translucent surface layer

Info

Publication number: EP4271555A1
Application number: EP21745920.5A
Authority: EP
Inventors: Mario Küfner; Roland Weissmann; Gustav GEBELEIN
Original assignee: Dr Schneider Kunststoffwerke GmbH
Current assignee: Dr Schneider Kunststoffwerke GmbH
Priority date: 2020-07-07
Filing date: 2021-07-02
Publication date: 2023-11-08
Also published as: DE102020117815A1; CN115916514A; WO2022008389A1; US20230294341A1

Abstract

The invention relates to a molding having a translucent surface layer and to a method for producing a molding that has a translucent surface layer.

Description

Shaped part with a translucent surface layer and method for producing a shaped part with a translucent surface layer

description

A molded part with a translucent textile, leather, wooden or metallic layer and a method for producing a molded part with a translucent textile, leather, wooden or metallic layer are described. Such molded parts can be found, for example, in the vehicle interior and form decorative elements, which can also have functional and display elements.

State of the art

In the interior of motor vehicles, such as cars, trucks, buses, and also in trains, ships and airplanes, visible surfaces are often provided with decorative elements in order to create an attractive and pleasant ambience. For this purpose, for example, specially treated plastics are used, which imitate the impression of high-quality surfaces. In addition, there are veneers for surfaces made of wood, leather and fabric. Especially with the latter, however, it is often difficult to implement lighting and to provide operating elements that are integrated in or under the visible surface. Difficulties exist both in the case of a planar illumination of materials and in the case of symbols that can be illuminated.

Overall, the methods and moldings known from the prior art have the disadvantage that they are many Require process steps, consist of a large number of components or also have an increased space requirement and a high weight.

EP 3573 043 A2 discloses a component and a method for producing such a component, which has a base part with a front side and a back side, with a cover layer made of a lacquer being applied to the front side thereof and forming part of a visible side of the component. An additional part that is in contact with the cover layer is completely covered all around the edge. The base part has openings which extend from the rear to the front of the base part, with the additional part forming a cover element for sealingly covering the openings, which are completely covered by the additional part.

DE 10009 304 A1 discloses a device for producing an injection molded part provided with a textile on one side, which has a shell-shaped, three-dimensional surface structure with an edge running in space, with a textile cutting unit for cutting a textile cutting to size, an actuating device for receiving the textile cutting, an injection molding unit for Injection molding of the textile blank with plastic and a processing unit for post-processing of the injection molded part. In order to reduce textile waste and production throughput times, it is proposed that the

Textile cutting unit has cutting means for a shape contour cut adapted to the surface structure and/or the edge contour of the finished injection molded part, that the processing unit is equipped with a holding device for a torsion-free and clear positioning and fixing of the injection molded part in its target geometry during the Post-processing is provided, and that the processing unit includes a trimming device for fully automatic trimming of the edge contour of the injection molded part.

task

In contrast, the object is to provide a solution for providing molded parts with textile surfaces that can be illuminated or transilluminated, with rapid, simple and inexpensive production being achieved and such a molded part being provided that is just as simple and inexpensive. Furthermore, the task is to enable illuminated structures, symbols and/or signs on textile surfaces.

solution

The above-mentioned object is achieved by a molded part with a translucent surface layer on a visible side, having at least one functional film which has at least one translucent area, a surface layer applied to the functional film on the visible side of the molded part, the surface layer being covered by a textile, leather or Imitation leather, wood veneer or laminate or formed from a metal foil, a translucent layer that is sprayed onto the back of the functional layer and serves as a diffuser for incident light, the back of the functional layer forming the side which is opposite the surface layer, and wherein a lateral foreclosure of the translucent layer by bent areas of the functional film and the surface layer is realized, with the fold formed in this way providing a light barrier that prevents light from escaping to the side, and with a light guide being arranged on the underside of the translucent layer, into which light can be introduced via a light source, so that the light guide as Diffuser trained translucent layer for illuminating the at least one illuminable area can be illuminated over the entire surface.

By using the surface layer made of a textile (e.g. fabric, woven or knitted fabric made of natural and/or synthetic materials, leather or imitation leather, wood veneer or laminate or metal foil (e.g. aluminium, copper, gold, etc.) and the functional film as a light blocker means that the number of components required to provide the molded part is kept to a minimum.

The at least one translucent area of the functional film forms the structure, the sign and/or pattern that is visible through the translucent layer.

The foil is used as a design element. Illumination takes place from below into the molded part via the translucent layer designed as a diffuser.

The structure described has a very small height and also made it possible to display symbols, characters and/or patterns on a surface layer. The above-mentioned object is also achieved by a molded part with a surface layer that can be transilluminated on a visible side, having at least one functional film that has a reflection-enabling structure and at least one illuminant, with the reflection-enabling structure radiating from the side through the at least one illuminant visible side of the molded part, which at least one light source is integrated into the functional film, a carrier layer made of plastic sprayed onto the back of the functional film, with the back of the functional film forming the side that is opposite the visible side of the molded part, a surface layer that can be transilluminated at least in sections, which is located on the visible side of the molded part, the surface layer being formed by a textile, leather or imitation leather, wood veneer or laminate or a metal foil, a translucent connecting layer, d ie is arranged between the functional film and the surface layer and is connected to both the functional film and the surface layer by a chemical and/or physical bond, and the translucent connecting layer is laterally sealed off by bent areas of the surface layer, and the The fold realized in the bent areas is held by a soft plastic component, which is injection-molded onto the bent areas on the underside of the functional film. In the case of the molded part described here, the molded part is illuminated by lighting means integrated into the functional film, such as LEDs, which are physically connected to the component by overmolding with plastic. In addition, the functional film has a reflection-enabling structure. Such a structure brings about a reflection upwards in the direction of the visible side by introducing light via at least one laterally arranged light source. In the remaining part of the functional film, the light can spread through the film without radiating in the direction of the visible side. In this way, additional area lighting of the functional film can also be achieved, which, depending on the control and the design of the illuminant, also enables area (background) lighting through the surface layer.

The bent areas of the surface layer seal off the sides, in particular the transilluminatable connection layer. The soft plastic component is applied as a (circumferential) edge on the underside of the functional film and also blocks off light. The use of a soft plastic component also makes it possible to prevent disturbing noises caused by vibrations in the vehicle, because the soft plastic component serves as a damping element. Furthermore, the bent areas are held on the underside of the carrier layer by the soft plastic component, which is sprayed onto the bent areas from below.

As stated above, only a few components are required for the molded part, the structure having a very small height, and thus the molded part can be used for various applications. The use of Surface layers made of, for example, textile, wood, leather or metallic materials as a decorative layer offer a special visual impression on the one hand and on the other hand reduce the weight of the molded part by using less material.

As textiles for the textile layers, for example, fabrics can be used which include knitted or woven fabrics. Technical textiles can also be used as textiles for the textile layers. Fibers or filaments of the textiles can be made of natural or artificial fibers or filaments. Cotton and synthetically manufactured fibers should be mentioned here, for example. In addition, threads or filaments that can be illuminated, for example made of glass or plastic fibers, can be woven in or used as (decorative) seams.

The molded parts mentioned are particularly suitable for production in an injection molding process, whereby molded parts can be produced in large quantities and inexpensively, which ensure reproducible results with regard to the position and design of the structures, patterns and symbols as well as the haptics and optics of the surface.

Several separate manufacturing steps are therefore not required for the molded parts.

The functional film can have at least one functional element for operating and/or controlling at least one component, which can be connected to the functional film and the at least one functional element via a signal connection. A functional film can, for example, in addition to illuminable structures, signs and/or symbols, control elements in the form of capacitive or inductive or have resistively effective controls. The functional film is then connected to the controllable components and/or a control unit via an interface, so that touching or pressing on the surface in the area of the control panel causes a corresponding reaction. The control panels can be displayed using the lightable areas. In addition, displays can be shown through a surface layer for the operation of the controllable components and about states, for example the controllable components and/or (environmental) parameters.

The above-mentioned object is also achieved by a method for producing a molded part with a translucent surface layer on a visible side in a one-shot process without subsequent processes, having the following method steps:

Providing a functional film and an at least partially translucent surface layer, wherein the surface layer is formed by a textile, leather or imitation leather, wood veneer or laminate or a metal foil,

Connecting the surface layer to the functional film, back-injecting the functional film with a translucent plastic in an injection molding process, with the translucent plastic being applied to the functional film and having at least one side an at least partially smaller extent than the functional film, and

Bending over the protruding part from the functional foil and surface layer.

The process steps can be carried out in an injection molding process, for which purpose the functional film in a Cavity of a mold half of an injection mold is inserted.

The surface layer can be connected to the functional film before or after the functional film is back-injected. The textile can completely cover the surface of the functional film on the visible side, so that the light barrier is formed not only by the functional film but also by the surface layer laminated on before or afterward.

For all of the designs and methods as well as molded parts described herein, the surface layers that extend completely over the bent area have the same appearance and feel on the sides as on the visible side of the molded part, so that there are no other layers when the molded parts are installed or components can be seen and/or felt.

After inserting the functional film or a combination of functional film and surface layer, the functional film is back-injected with a translucent plastic. The plastic serves as a diffuser for light introduced into the molded part from below, so that either a planar illumination is achieved or structures, patterns and/or characters are imaged, whereby the plastic can only be transilluminated in the area of the characters, symbols and/or structures. For this purpose, methods are known from the prior art for providing a masking. In further embodiments, the film can also be designed in such a way that it has cutouts in the area of the structures, characters and/or symbols. The film itself does not have to be transparent, so even with Use of a transparent plastic, only the corresponding areas can be transilluminated.

After the functional film has been back-injected, the functional film and/or the surface layer can be bent over using ejectors or slides or a handling device on the injection molding machine. In alternative versions, the injection molding tool has a further cavity for bending over the corresponding areas. For example, the back-injected component can be sucked in and/or displaced, with the areas on the wall of the mold moving and being bent over.

The above-mentioned object is also achieved by a method for producing a molded part with a translucent surface layer on a visible side in a multi-component injection molding method in a one-shot process without subsequent processes, having the following method steps:

Inserting a functional film into a cavity of a mold half of an injection molding tool, the functional film having a reflection-enabling structure and at least one light source,

Injection molding of the functional foil in the injection molding tool with a first plastic to form a carrier layer for the functional foil,

Converting the first intermediate product formed from the functional film and the carrier layer into a second cavity of the injection molding tool,

Introduction of a surface layer that can be transilluminated at least in sections into the second cavity, the surface layer having a larger surface area than the first intermediate product, the surface layer being covered by a textile, leather or imitation leather, wood veneer or laminate or formed from a metal foil,

Injecting a second plastic between the first intermediate product and the surface layer, the second plastic bonding to the surface layer and the functional film,

bending of protruding areas of the surface layer,

Converting the second intermediate product from the functional film, carrier layer, surface layer and second plastic into a further cavity,

Overmoulding the bent areas of the surface layer with a third plastic on the back of the functional film, the back being opposite the visible side of the molded part.

With this method, too, the molded part is produced in an injection molding process, with no further processing being required. This results in both large financial and time savings. Advantageously, a molded part with a very small height and a very low weight is provided.

The functional film can reproduce the reflection-generating structure by embossing, printing or similar.

The connection between the functional film and the surface layer takes place via the second plastic, which, in addition to a chemical bond and/or material connection with the functional film and the surface layer, must ensure radiation through. The surface layer and the functional film can be placed in the cavities, clamped or sucked in by vacuum.

A transparent or a translucent plastic can be used for the second plastic. Depending on the plastic used, the visibility of the corresponding signs, symbols or structures that are produced by the reflection-generating structures can thus be adjusted.

The fixation of the fold by the third plastic can be formed from a soft component. The advantages with regard to the use of a soft component for the third plastic have already been explained above.

The protruding areas of the surface layer can be bent over, analogously to the method described above, in a third cavity or via slides in the injection molding tool or a handling device on the injection molding machine. The entire production of the molded part can thus be realized in one injection molding tool.

Design elements can also be depicted in a surface layer, so that there is no need to introduce structures for this into the functional film. Furthermore, as an alternative or additional embodiment, it is also possible to perforate the surface layer, with openings being formed in the surface layer through the perforation, which allow (more) light to pass through. Depending on the surface layer, preferably in the case of wood and metal, lighting can also be suppressed down to the perforated areas. The solutions described here enable a precise representation of x-rayed elements on laminated screens/decorative screens or molded parts. In addition, the production of a transilluminated surface layer is achieved in a "one-shot" process without subsequent processes.

Special features are the soft/hard lamination in the tool. The methods presented can also be used to integrate electronics and light. For this purpose, the functional film can have corresponding electronic and/or light-emitting elements or be designed accordingly to form the structures or light-conducting fibers can be woven into a textile surface layer.

Further advantages, features and configuration options result from the following figure description of exemplary embodiments which are not to be understood as limiting.

Brief description of the drawings

In the drawings shows:

1 shows a schematic representation of a molded part in a first embodiment;

FIG. 2 different stages of the molded part according to FIG. 1 during production; FIG.

3 shows a schematic representation of a molded part in a second embodiment; and

Fig. 4 different stages of the molded part according to FIG. 3 during production. In the drawings, elements provided with the same reference numbers correspond essentially to one another, unless otherwise indicated. In addition, there is no need to show and describe components that are not essential for understanding the technical teaching disclosed herein. In the following, the reference symbols are not repeated for all elements that have already been introduced and shown, provided that the elements themselves and their function have already been described or are known to a person skilled in the art.

Detailed description of exemplary embodiments

The versions of moldings 100 and 200 shown in Figs. 1-4 are designed as decorative elements for the interior of motor vehicles and each have an IML functional film 110 or 210, which both to represent characters or symbols or structures by a Fabric layer 130 or 230 are provided as well as operating commands for controlling devices not shown in the vehicle can receive.

Depending on the design of the functional film 110 or 210 and the layers of material 130 or 230, full-area illumination and/or only illumination in certain areas can be achieved to display patterns, structures and/or characters or symbols.

The exemplary embodiments relate to the use of fabric layers 130 or 230 as surface layers, without however having a limiting effect. Other materials already mentioned can also be used as the surface layer. First embodiment

1 shows a schematic representation of a molded part 100 in a first embodiment.

The molded part 100 has a material layer 130 on the visible side 102, which is connected to a functional film 110 via a light guide layer 140 made of a transparent or translucent plastic.

The functional film 110 is connected to a carrier layer 120 made of plastic on its rear side. The layer 120 is not transilluminated and can therefore consist of non-translucent plastic. If the layer 120 is made of a light (white) plastic, this can increase the light yield in the direction of the visible side 102 through reflection. A dark plastic for the layer 120, on the other hand, leads to better light shielding at the bottom. The functional film 110 has light sources in the form of LEDs, with the actuation and the signal and power supply taking place via an electrical connection through the carrier layer 120 or on its side. For this purpose, the carrier layer 120 can have a corresponding opening for accommodating connecting lines. In alternative versions, the electrical connection is made on a side area of the carrier layer 120 towards the contacting of the corresponding interfaces of the functional film 110.

The functional film 110 has areas that are embossed or deformed in relation to the remaining area of the functional film 110 such that a defined light refraction or deflection in the direction of the visible side 102 occurs when light is introduced from the side. The lateral light input is achieved via LEDs that are integrated in the functional film 110 are. The reflection-generating structures created by the deformed areas form signs, symbols or patterns. Illumination of these by the LEDs generates a corresponding image through the layer of material 130 on the visible side 102 . For this purpose, the material layer 130 can be transilluminated.

The carrier layer 120 has a smaller areal extent than the functional film 110 and the light guide layer 140 . The material layer 130 has an even greater areal extent than the functional film 110 and the light guide layer 140 and is bent over on the sides, the bent sections on the underside of the functional film 110 being held by a peripheral edge made of a soft plastic component 150. The soft component 150 is preferably made of a black plastic, so that light is blocked off. In addition, the soft component 150 acts as a damper, so that no rattling or other disturbing noises can occur in the installed state, for example due to vibrations when the vehicle is in operation. Finally, the soft component 150 serves to hold the bent areas of the fabric layer 130 on the underside of the functional layer 110 . The soft component 150 can be materially and/or positively connected to the carrier layer 120 at least in regions. As an alternative to a soft component, a "hard component", e.g. ABS plastic, can also be used.

FIG. 2 shows various stages of the molded part 100 according to FIG. 1 during manufacture. The molded part 100 is manufactured in an injection molding process using an injection molding tool. In a first step, the functional film 110 is provided and placed in a first cavity of an injection molding tool. In addition, the functional film 110 can be sucked into it in order to assume a defined position or 2h to 3-dimensional deformation, which is retained during production (FIG. 2a).

In a next step (Fig. 2b), the back of the functional film 110, which is opposite the visible side 102 of the molded part 100, is back-injected with a plastic to form the carrier layer 120, which receptacles or connection features (clips, latching hooks, screw,

Welding domes, ...) for later assembly of the molded part, which are molded onto the carrier layer in the same process step.

The material layer 130 is then introduced into a second cavity of the injection molding tool and transparent or translucent plastic is injected between the functional film 110 and the material layer 130, with the light guide layer 140 being formed. The light guide layer 140 enters into a chemical bond and/or a positive connection with the functional film 110 and the material layer 130 .

Then, as shown in steps c) and d), the fabric layer 130 is bent over until the bent areas come into contact with the back of the functional layer 110 .

The areas of the material layer 130 are bent over in a third cavity of the injection molding tool. Alternatively, this can be done using ejectors or slides in the mold or using a handling device on the injection molding machine. A third plastic 150 is then injected onto the underside, which forms a peripheral edge that holds the bent areas against the underside of the functional film 110 . The third plastic 150 can be materially and/or positively connected to the carrier layer at least in regions. Designed as a soft component, for example a TPE, the third plastic 150 also serves to reduce disruptive noises such as rattling or creaking.

Thereafter, the manufactured molding 100 can be removed from the tool and is ready for installation in a vehicle.

Second embodiment

FIG. 3 shows a schematic representation of a molded part 200 in a second embodiment.

The molded part 200 differs from the molded part 100 in that a scattering layer 240 made of a transparent or translucent plastic is injection molded onto the back of a functional film 210, which is bent around the scattering layer 240 like a layer of material 230.

A light guide 260 is arranged on the underside of the molded part 200 and can be connected to the scattering layer 240 or arranged at a distance therefrom. In the exemplary embodiment shown, the light guide 260 is sprayed onto the underside of the scattering layer 240, even if shown differently. Light can be introduced into the light guide 260 via an LED or another light source, which light thus illuminates the scattering layer 240 over the entire surface and leads to an illumination of the areas 212 . The areas 212 of Functional foil 210 are translucent and thus cause the fabric layer 130 to be illuminated in the areas 212.

The transmissive areas 212 later image the desired translucent design through the fabric of the fabric layer 230 . Like the fabric layer 130, the cover layer or fabric layer 230 is a fabric/technical textile. The molded part 200 can be illuminated by means of a separate light guide 260 .

FIG. 4 shows various stages of the molded part 200 according to FIG. 3 during manufacture.

In the exemplary embodiment, the material layer 230 is connected to the functional film 210 in a first step (FIG. 4a). The so-called lamination can be done in different ways. It is important that the material layer 230 forms a connection with the functional film 210 .

The functional film 210 is then back-injected with a translucent or transparent plastic to form the scattering layer 240 (FIG. 4b).

In a next step, the film 210 and the laminated layer of material 230 are bent over within the tool, whereby a light barrier for the scattering layer 240 is achieved.

An optional further process step, not shown, is based on the process step from FIG Fixed areas and also has dampening and / or light-blocking properties.

Finally, in a final step, the light guide 260 is applied from below to the scattering layer 240 (FIG. 4d).

reference character list

100 molded part 102 visible side 110 functional film

120 carrier layer, first plastic 130 surface layer, material layer 140 light guide layer, second plastic 150 soft component, third plastic 200 molded part 202 visible side 210 functional film 212 area 230 surface layer, material layer 240 scattering layer

260 light guides

Claims

patent claims

1. molding (200) with a translucent

Surface layer on a visible side (202), having at least one functional film (210) which has at least one translucent area (212), one applied to the functional film (210) on the visible side (202) of the molded part (200).

Surface layer (230), wherein the surface layer is formed by a textile, leather or imitation leather, wood veneer or laminate or a metal foil, a translucent layer (240) which is sprayed onto the back of the functional layer (210) and as a diffusing screen for incident The rear side of the functional layer (210) forms the side opposite the surface layer (230), and the translucent layer (240) is laterally partitioned off by bent areas of the functional film (210) and the surface layer (230). , wherein a light barrier is provided by the fold thus formed, which prevents light from escaping to the side, and wherein a light guide (260) is arranged on the underside of the translucent layer (240), into which light can be introduced via an illuminant, so that via the Light guide (260) the translucent layer (240) designed as a diffuser for illuminating the at least one area that can be illuminated can be illuminated over the entire surface.

2. Molded part (100) with a translucent

Surface layer (130) on a visible side (102), having at least one functional film (110) which has a reflection-enabling structure and at least one illuminant, the reflection-enabling structure being emitted on the visible side (102) by laterally introduced radiation through the at least one illuminant. of the molded part (100), which at least one light source is integrated into the functional film (110), a carrier layer (120) made of plastic sprayed onto the rear of the functional film (110), the rear of the functional film (110) forming the side which opposite the visible side (102) of the molded part (100), a surface layer (130) which can be transilluminated at least in sections and which is located on the visible side (102) of the molded part (100), the surface layer (130) being covered by a textile, leather or imitation leather, wood veneer or laminate or formed from a metal foil, a translucent bonding layer (140), which is arranged between the functional film (110) and the surface layer (130) and is connected to both the functional film (110) and the surface layer (130) by a chemical bond and/or a positive connection, and wherein a lateral partitioning of the translucent connecting layer (140) is realized by bent areas of the surface layer (130), and the fold realized by the bent areas is held by a third plastic (150), which is attached to the bent Areas is injected.

3. Molded part according to claim 1 or 2, wherein the functional film (110; 210) has at least one functional element for operating and/or controlling at least one component which can be connected to the functional film (110; 210) and the at least one functional element via a signal connection .

4. A method for producing a molded part (200) according to claim 1 or 3 with a translucent surface layer (230) on a visible side (202) in a one-shot process without subsequent processes, having the following method steps:

Providing a functional film (210) and an at least partially translucent surface layer (230), wherein the

surface layer (230) is formed by a textile, leather or imitation leather, wood veneer or laminate or a metal foil,

Connecting the surface layer (230) to the functional film (210),

Back injection of the functional film (210) with a translucent plastic (240) in an injection molding process, wherein the translucent plastic (240) is applied to the functional film (210) and at least one side is at least partially smaller in extent than the functional film (210), and

Bending over the protruding part of the functional film (210).

5. The method according to claim 4, wherein the connection of the surface layer (230) to the functional film (210) takes place before or after the back-injection molding of the functional film (210).

6. The method according to claim 4 or 5, wherein the surface layer (230) completely covers the surface of the functional film (210) on the visible side (202).

7. A method for producing a molded part (100) according to claim 2 or 3 with a translucent surface layer (130) on a visible side (102) in a multi-component injection molding process in a one-shot process without subsequent processes, having the following process steps:

Insertion of a functional film (110) in a cavity of a mold half of an injection molding tool, the functional film (110) having a reflection-generating structure and at least one light source, back-injection molding of the functional film (110) in the injection molding tool with a first plastic to form a carrier layer (120) for the functional film (110),

Relocating the first intermediate product formed from the functional film (110) and the carrier layer (120) into a second cavity of the injection molding tool, introducing a surface layer (130) that can be transilluminated at least in sections into the second cavity, the surface layer (130) has a larger surface area than the first intermediate product made of functional film (110) and carrier layer (120), wherein the surface layer (130) is formed by a textile, leather or imitation leather, wood veneer or laminate or a metal foil,

Injecting a second plastic (140) between the first intermediate product and the surface layer (130), the second plastic (140) bonding to the surface layer (130) and the functional film (110),

bending over protruding areas of the surface layer (130),

Converting the second intermediate product from functional film (110), carrier layer (120), surface layer (130) and second plastic (140) into a further cavity,

Overmolding the bent areas of the surface layer (130) with a third plastic (150) on the rear of the functional film (120), the rear facing the visible side (102) of the molded part (100).

8. The method according to claim 7, wherein a transparent or translucent plastic is used for the second plastic (140).

9. The method according to claim 7 or 8, wherein the fold is fixed by the third plastic made of a soft component.

10. The method according to any one of claims 7 to 9, wherein the bending of the overhanging portions of the surface layer (130) in a third cavity or via slides in the injection mold.